Composition comprising a light-weight filler

Patent metadata

Field	Value
Publication number	US-12215246-B2
Application number	US-201916693637-A
Country	US
Kind code	B2
Filing date	Nov 25, 2019
Priority date	Jun 28, 2017
Publication date	Feb 4, 2025
Grant date	Feb 4, 2025

Abstract

The present invention relates to compositions containing at least one reactive binder, at least one curing agent and/or accelerator, at least one thermally activatable blowing agent and at least one light-weight filler, wherein at least one expanded particle of at least one glass-rich volcanic rock with a closed outer shell is contained as a light-weight filler. The invention also relates to a method for stiffening and/or reinforcing components with thin-walled structures with a corresponding composition as well as to correspondingly produced components.

First claim

What is claimed is:

1. A composition comprising:
a) at least one reactive binder;
b) at least one curing agent and/or accelerator;
c) at least one thermally activatable blowing agent, the at least one thermally activatable blowing agent releasing gas after being heated to a temperature ranging from 120° C. to 220° C. for 10 to 150 minutes and being selected from solid polycarboxylic acids, salts of said solid polycarboxylic acids, and mixtures thereof; and
d) at least one lightweight filler, wherein the at least one lightweight filler includes at least one expanded particle of at least one glass-rich volcanic rock, the glass-rich volcanic rock forms a closed outer shell, wherein the expanded particles have a bulk density of 100 kg/m 3 to 500 kg/m 3 ; and

the composition is free of hollow glass spheres and free of polymer balloons, is foamable, has a density of 0.9 g/cm 3 to 2 g/cm 3 , and is pumpable and stable at a temperature below 70° C. and at a pump pressure of up to 360 bar.

2. The composition according to claim 1 , wherein the at least one reactive binder is selected from epoxides, rubbers, peroxidically crosslinkable polymers or triglyceride fractions comprising unsaturated fatty acids.

3. The composition according to claim 1 , wherein the at least one reactive binder comprises 5-50 wt. % of at least one polyene.

4. The composition according to claim 3 , wherein the at least one polyene is a liquid polybutadiene having a molecular weight Mw below 20,000.

5. The composition according to claim 1 , wherein the at least one reactive binder comprises 5-50 wt. % of at least one triglyceride fraction of which the fatty acid distribution has a proportion of at least 5 wt. % of one or more 2-3 fatty acids and/or one or more Ω-6 fatty acids.

6. The composition according to claim 1 , wherein the at least one curing agent and/or accelerator is present in an amount of from 0.25 to 15 wt. % of the composition.

7. The composition according to claim 1 , wherein the at least one chemical blowing agent is present in an amount of from 0.1 to 15 wt. % of the composition.

8. The composition according to claim 1 , wherein the at least one expanded particle of at least one glass-rich volcanic rock is present in an amount of from 1 to 35 wt. % of the composition.

9. The composition according to claim 8 , wherein the at least one expanded particle of at least one glass-rich volcanic rock comprises at least one expanded perlite.

10. The composition according to claim 1 including a plurality of the expanded particles of at least one glass-rich volcanic rock, wherein the expanded particles of at least one glass-rich volcanic rock have a maximum particle size of less than 1,000 μm, and/or a weight-average particle size d50 of less than 500 μm.

11. The composition according to claim 1 , wherein the at least one expanded particle of at least one glass-rich volcanic rock, acting as a lightweight filler, has a bulk density of from 200 kg/m 3 to 500 kg/m 3 .

12. A method for stiffening and/or reinforcing components which have thin-walled structures, wherein a composition according to claim 1 is applied to a surface of the structure to be reinforced at a temperature below 70° C., at a pump pressure of greater than 3 bar, and said composition is cured at a later point in time at temperature(s) above 130° C.

13. The stiffening and/or reinforcing method according to claim 12 , wherein the composition is applied in a temperature range of from 40° C. to 60° C. at an application pressure of from 6 bar to 180 bar.

14. A component stiffened and/or reinforced with the composition according to claim 1 .

15. A component stiffened and/or reinforced with the composition produced according to the method of claim 12 .

16. An article of manufacture comprising a thin-walled structure, having a hollow cavity, and a composition according to claim 1 cured in or on the thin-walled structure whereby the thin-walled structure is stiffened and/or reinforced.

17. A composition comprising:
a) at least one reactive binder;
b) at least one curing agent and/or accelerator;
c) at least one thermally activatable blowing agent, the at least one thermally activatable blowing agent releasing gas after being heated to a temperature ranging from 120° C. to 220° C. for 10 to 150 minutes and being selected from solid polycarboxylic acids, salts of said solid polycarboxylic acids, and mixtures thereof; and
d) at least one lightweight filler, wherein the at least one lightweight filler includes at least one expanded particle of at least one glass-rich volcanic rock comprising perlite, said at least one expanded particle having a closed outer shell, a maximum particle size of less than 1,000 micron, a bulk density of 200 to 500 kg/m 3 ; and exhibiting pressure stability such that the composition can be pumped at pump pressure of up to 360 bar without damage to the lightweight filler; wherein the composition is foamable, has a density of 0.9 g/cm 3 to 1.2 g/cm 3 , and is pumpable and stable at a temperature below 70° C. and at a pump pressure of up to 360 bar.

18. The composition according to claim 17 , wherein the at least one reactive binder is selected from epoxides, rubbers, peroxidically crosslinkable polymers or triglyceride fractions comprising unsaturated fatty acids.

19. The composition according to claim 17 , wherein the at least one reactive binder comprises 5-50 wt. % of at least one polyene.

20. A composition comprising:
a) 5 to 50 wt. % of at least one reactive binder comprising:
1) a triglyceride fraction or oil containing the triglyceride fraction,
2) a liquid polybutadiene; and
3) a functionalized polybutadiene;

b) at least one curing agent and at least one organic curing accelerator;
c) 0.1 to 15 wt. % of at least one thermally activatable blowing agent;
d) 1 to 35 wt. % of at least one lightweight filler, wherein the at least one lightweight filler includes expanded perlite particles having a closed outer shell, a maximum particle size of less than 1,000 micron and a bulk density of 200 to 500 kg/m 3 ; and
e) a combination of three or more inorganic fillers different from d), the combination comprising:
1) 21 to 30 wt. % calcium carbonate,
2) 2 wt. % to 15 wt. % of at least one sheet-like inorganic filler selected from graphite;
3) 0.1 to 4 wt. % of at least one rheology additive inorganic filler selected from silicon dioxide;

wherein the composition is foamable, has a density of 0.9 g/cm 3 to 1.2 g/cm 3 , and is pumpable and stable at a temperature below 70° C. and at a pump pressure of up to 360 bar without damage to d).

Assignees

• Henkel Ag & Co Kgaa

Inventors

• Sauer Ralf
• Klotz Michael
• Zahn Thomas
• Born Peter

Classifications

• C09D5/02

  Emulsion paints {including aerosols} · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L2203/14

  used for foams · CPC title

• C09D7/70

  characterised by shape, e.g. fibres, flakes or microspheres · CPC title

• C09D7/61

  inorganic · CPC title