Premix and method for producing a thermally expandable and curable epoxy-based compound

Patent metadata

Field	Value
Publication number	US-9464153-B2
Application number	US-201213456707-A
Country	US
Kind code	B2
Filing date	Apr 26, 2012
Priority date	Oct 29, 2009
Publication date	Oct 11, 2016
Grant date	Oct 11, 2016

Abstract

A two-component premix for preparing a heat-expandable and heat-curable epoxy-based material, comprises an isocyanate, a diol or polyol, an epoxy prepolymer, a heat-activatable hardener for epoxy prepolymers, and a heat-activatable blowing agent.

First claim

The invention claimed is:

1. A method for preparing a heat-expandable and heat-curable epoxy-based material, wherein a component A and a component B are mixed together at a temperature in the range from 20 to 100° C., the mixture is introduced into a mold and is allowed to pre-cure in the mold at a temperature in the range from 20 to 100° C. to form a material that is dimensionally stable up to 40° C., wherein component A contains at least one isocyanate and component B contains at least one diol or polyol selected from the group consisting of aliphatic diols, polyether polyols, polyester polyols and combinations thereof, at least one of components A or B contains at least one epoxy prepolymer, at least one of components A or B contains a heat-activatable hardener for epoxy prepolymers, and at least one of components A and B contains a heat-activatable blowing agent, and wherein the constituents of each of component A and component B are chosen such that component A and component B each have a viscosity such that each of component A and component B is pumpable at a temperature of at most 100° C.

2. The method according to claim 1 , wherein:
component A contains at least one difunctional isocyanate, and
component B contains at least one epoxy prepolymer.

3. The method according to claim 1 , wherein component A additionally contains one or more of the following constituents, relative to the entire component A:
i) 2 to 10 wt. %, of heat-activatable blowing agent,
ii) 5 to 20 wt. %, of lightweight filler,
iii) 1 to 5 wt. %, of water-binding agent,
iv) 1 to 4 wt. %, of curing accelerator for epoxies,
v) 5 to 20 wt. %, of toughener.

4. The method of claim 1 , wherein component A contains at least one isocyanate, component B contains at least one epoxy prepolymer and at least one diol or polyol, at least one of components A or B contains a heat-activatable hardener for epoxy prepolymers, and at least one of components A or B contains a heat-activatable blowing agent.

5. The method of claim 1 , wherein component A is free from epoxy resins.

6. The method of claim 1 , wherein one or both of the following conditions applies to the composition of component B:
the percentage by weight of epoxy prepolymer, relative to the entire component B, is 35 to 80 wt. %;
the percentage by weight of diol or polyol, relative to the entire component B, is 2.5 to 35 wt. %.

7. The method of claim 1 , wherein at least one of components A and B contains an epoxy prepolymer that is liquid at 22° C.

8. The method of claim 1 , wherein component A and component B are mixed in a weight ratio of 4:1 to 1:4.

9. The method of claim 1 , wherein component B additionally contains one or more of the following constituents, relative to the entire component B:
i) 0.5 to 5 wt. %, of heat-activatable blowing agent,
ii) 0 to 30 wt. %, of lightweight filler,
iii) 0.5 to 6 wt. %, of water-binding agent,
iv) 0.5 to 15 wt. %, of heat-activatable hardener for epoxies,
v) 0.005 to 0.5 wt. %, of curing accelerator for isocyanates,
vi) 0 to 10 wt. %, of curing accelerator for epoxies, and
vii) 0 to 50 wt. %, of toughener.

10. The method according to claim 7 , wherein at least one of components A and B additionally contains an epoxy prepolymer that is solid or semi-solid at 22° C.

11. The method of claim 1 , wherein the at least one diol or polyol is 1,4-butanediol, a trifunctional polyethylene polyether polyol or a combination thereof.

12. The method of claim 1 , wherein the percentage by weight of diol or polyol, relative to the entire component B, is 4 to 25 wt. %.

13. The method of claim 1 , wherein component B contains at least one epoxy prepolymer and the percentage by weight of epoxy prepolymer, relative to the entire component B, is 50 to 65 wt. %.

14. The method of claim 1 , wherein component A additionally contains filler and water-binding agent.

Assignees

• Hornung Martin
• Barriau Emilie
• Renkel Martin
• Henkel Ag & Co Kgaa

Inventors

• Hornung Martin
• Barriau Emilie
• Renkel Martin

Classifications

• C08G18/58

  Epoxy resins {(C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003)} · CPC title

• C08K7/28

  Glass · CPC title

• C08G2101/00

  Manufacture of cellular products · CPC title

• C08J9/32

  from compositions containing microballoons, e.g. syntactic foams · CPC title

• C08J2203/22

  Expandable microspheres, e.g. Expancel® · CPC title