Foam curable by heat

Patent metadata

Field	Value
Publication number	US-9139682-B2
Application number	US-68994110-A
Country	US
Kind code	B2
Filing date	Jan 19, 2010
Priority date	Jul 16, 2007
Publication date	Sep 22, 2015
Grant date	Sep 22, 2015

Abstract

A foam is disclosed that can be cured by heat having, for example, 10 to 80 vol. % of at least one gas and a compound that can be cured by heat. The foam can include at least one polyurethane polymer and at least one curing agent that can be activated by increased temperature. Foams that can be cured are suitable as flues, sealing compounds, or for the production of coatings, and can be cured by heat for structural adhesive bonds and for lining in vehicle construction.

First claim

What is claimed is:

1. A heat curing foam, comprising:
a) from 10 to 80% by volume of at least one gas; and
b) a heat curing composition Z containing:
b1) at least one polyurethane polymer of formula (I) in an amount of 10 to 35% by weight, based on a total weight of the foam:

where
R 1 is a polyurethane polymer PU1 terminated by n1+n2+n3 isocyanate groups after removal of all terminal isocyanate groups;
each radical R 2 , independently of other R 2 radicals, is at least one of a blocking group which is eliminated at a temperature above 100° C., and a group of formula (II):

each radical R 3 , independently of other R 3 radicals, is at least one of a blocking group which is eliminated at a temperature above 100° C., and a group of formula (II′):

where each R 4 and R 4′ are at least one of an aliphatic, a cycloaliphatic, an aromatic, and an arylaliphatic (p+1), respectively (f+1)-valent hydrocarbon radical, where:
p=1, 2 or 3 and f=1, 2 or 3;
n1 and n2 are each in a range from 0 to 7, n3 is 0, with 2≦(n1+n2+n3)≦8, provided that at least one of n1 and n2 is not 0; and

b2) at least one hardener B which is activated by elevated temperature,

wherein the heat curing composition Z further comprises: at least one liquid epoxy resin A which has formula (VII):

wherein R′″ and R″″ are each, independently of one another, H or CH 3 , and r is from 0 to 1.

2. The heat curing foam as claimed in claim 1 , wherein the heat curing composition Z is free of chemical blowing agents.

3. The heat curing foam as claimed in claim 1 , wherein the gas is enclosed in cells which are homogeneously distributed in the foam.

4. The heat curing foam as claimed in claim 1 , wherein at least one of an R 2 and R 3 in the blocked polyurethane polymer of the formula (I) is a radical selected from the group consisting of:

where
R 5 , R 6 , R 7 and R 8 are each, independently of any other R 5 , R 6 , R 7 and R 8 , at least one of an alkyl group, a cycloalkyl group, an aryl group, an arylalkyl group, an alkylaryl group; or at least one of R 5 together with R 6 , and R 7 together with R 8 , form part of a substituted 4- to 7-membered ring;
R 9 , R 9′ and R 10 are each, independently of any other R 9 , R 9′ and R 10 , at least one of an alkyl group, an aryl group, an arylalkyl group, an alkylaryl group, an alkoxy group, an aryloxy group and an arylalkyloxy group; R 11 is an alkyl group;
R 12 , R 13 and R 14 are each, independently of any other R′ 2 , R 13 and R 14 , at least one of an alkylene group having from 2 to 5 carbon atoms, a phenylene group, and a hydrogenated phenylene group;
R 15 , R 16 and R 17 are each, independently of any other R 15 , R 16 and R 17 , at least one of H, an alkyl group, an aryl group and an arylalkyl group; and
R 18 is at least one of an arylalkyl group or a monocyclic or polycyclic substituted or unsubstituted aromatic group.

5. The heat curing foam as claimed in claim 1 , wherein the polyurethane polymer PU1 is prepared from at least one polyisocyanate and at least one polymer Q having at least one of a terminal amino group, a thiol group and a hydroxyl group and/or a substituted or unsubstituted phenol.

6. The heat curing foam as claimed in claim 1 , wherein R 2 is a radical of the formula (II); and R 3 is a radical of the formula (II′).

7. The heat curing foam as claimed in claim 1 , wherein a proportion of the epoxy resin A is from 2 to 80% by weight, based on the total weight of the foam.

8. The heat curing foam as claimed in claim 1 , wherein a proportion of the polyurethane polymer of the formula (I) is from 15 to 35% by weight, based on the total weight of the foam.

9. The heat curing foam as claimed in claim 1 , wherein a proportion of the hardener B is from 0.5 to 8% by weight, based on the total weight of the foam.

10. The heat curing foam as claimed in claim 1 , wherein the hardener B is a catalyst with a proportion from 0.05 to 2% by weight, based on the total weight of the foam.

11. The heat curing foam as claimed in claim 1 , wherein the gas is selected from the group consisting of nitrogen (N 2 ), carbon dioxide (CO 2 ), hydrogen (H 2 ), carbon monoxide (CO), nitrous oxide (N 2 O), a noble gas, any mixtures of these gases, air and air mixtures.

12. The heat curing foam as claimed in claim 1 , wherein the foam comprises:
at least one filler, in an amount of from 1 to 50% by weight, based on the total weight of the foam.

13. The heat curing foam of claim 1 , further comprising:
a substrate.

14. The heat curing foam of claim 1 , wherein the polyurethane polymer of formula (I) is obtained by reaction of isophorone diisocyanate (IPDI) and a polymer Q PM having thiol, amine or hydroxyl groups.

15. The heat curing foam of claim 1 , wherein the polyurethane polymer of formula (I) is obtained by reaction of a polyisocyanate and a polyol, wherein the polyol comprises a polyoxyalkylene polyol, a polyhydrocarbon polyol or a mixture thereof, wherein the polyoxyalkylene polyol is a polymerization product of tetrahydrofuran, and the polyhydrocarbon polyol is a hydroxyl-terminated polybutadiene.

16. The heat curing foam of claim 1 , further comprising silica in an amount of 3 to 35% by weight, based on the total weight of the foam.

17. The heat curing foam of claim 1 , further comprising a reactive diluent in an amount of 1 to 8% by weight, based on the total weight of the foam.

18. A process for producing a heat curing foam, comprising:
forming
a heat curing composition Z containing:
b1) at least one polyurethane polymer of formula (I) in an amount of 10 to 35% by weight, based on a total weight of the foam:

where
R 1 is a polyurethane polymer PU1 terminated by n1+n2+n3 isocyanate groups after removal of all terminal isocyanate groups;
each radical R 2 , independently of other R 2 radicals, is at least one of a blocking group which is eliminated at a temperature above 100° C., and a group of formula (II):

each radical R 3 , independently of other R 3 radicals, is at least one of a blocking group which is eliminated at a temperature above 100° C., and a group of formula (II′):

where each R 4 and R 4′ are at least one of an aliphatic, a cycloaliphatic, an aromatic, and an arylaliphatic (p+1), respectively (f+1)-valent hydrocarbon radical, where:

Assignees

• Linnenbrink Martin
• Schulenburg Jan Olaf
• Gutgsell Michael
• Sika Technology Ag

Inventors

• Linnenbrink Martin
• Schulenburg Jan Olaf
• Gutgsell Michael

Classifications

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title

• C08G18/10 Primary

  Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step · CPC title

• C08G63/00

  Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule (polyester-amides C08G69/44; polyester-imides C08G73/16) · CPC title

• C08L2666/22

  Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20 · CPC title

• Y10T428/249984

  Adhesive or bonding component contains voids · CPC title