Foam, composition, and method

Patent metadata

Field	Value
Publication number	US-9617412-B2
Application number	US-201514721595-A
Country	US
Kind code	B2
Filing date	May 26, 2015
Priority date	Dec 29, 2011
Publication date	Apr 11, 2017
Grant date	Apr 11, 2017

Abstract

A method of producing a foam is disclosed. The method includes providing an epoxy-containing compound, a cationic catalyst, an optional blowing agent, and at least one additive. The method further includes combining the epoxy-containing compound with the cationic catalyst, the optional blowing agent, and the at least one additive, wherein the epoxy-containing compound and the cationic catalyst react to polymerize the epoxy-containing compound to provide the foam having a density from about 0.3 lbs/ft 3 to about 5.0 lbs/ft 3 as measured by ASTM D1622. Further disclosed are the foam and a method for installing the foam.

First claim

What is claimed is:

1. A method of producing a foam comprising providing a composition consisting of an epoxy-containing compound, a cationic catalyst consisting of a superacid, a BF 3 dihydrate complex, a phosphoric acid derivative, or combination thereof, an optional blowing agent, and least one of a surfactant, a flame retardant, a catalyst carrier, or a co-reactant consisting of a diol, a glycerin, or a combination thereof, and combining the epoxy containing compound with the cationic catalyst, the optional blowing agent, and the least one of a surfactant, a flame retardant, a catalyst carrier, or a co-reactant consisting of a diol, a glycerin, or a combination thereof, wherein the epoxy-containing compound and the cationic catalyst react to polymerize the epoxy-containing compound to provide an epoxy matrix and an isocyanate free foam; the foam having a density from about 0.3 lbs/ft 3 to about 5.0 lbs/ft 3 as measured by ASTM D1622.

2. The method of claim 1 , wherein the cationic catalyst is a superacid, the superacid comprising HBF 4 , CF 3 SO 3 H (triflic acid), HSbF 6 , HPF 6 , FSO 3 H, HClO 4 , CF 3 (CF 2 ) x —SO 3 H, FSO 3 H—SbF 5 (magic acid), or combinations thereof.

3. The method of claim 1 , wherein the foam is a substantially closed cell foam.

4. The method of claim 1 , wherein the cationic catalyst provides a gel time of about 5 seconds to about 180 seconds.

5. The method of claim 1 , wherein the catalyst carrier consists of a polyhydroxyl compound.

6. A method of installing a foam comprising:
mixing a composition consisting of an epoxy-containing resin with a cationic catalyst consisting of a superacid, a BF 3 dihydrate complex, a phosphoric acid derivative, or combination thereof, a surfactant, an optional blowing agent, and at least one of a flame retardant, a catalyst carrier, or a co-reactant consisting of a diol, a glycerin, or a combination thereof to form an epoxy matrix foam composition; and
spraying the foam composition to a material to form the foam, wherein the foam is isocyanate free and has a density from about 0.3 lbs/ft 3 to about 5.0 lbs/ft 3 as measured by ASTM D1622.

7. The method of claim 6 , wherein the superacid is HBF 4 , CF 3 SO 3 H (triflic acid), HSbF 6 , HPF 6 , FSO 3 H, HClO 4 , CF 3 (CF 2 ) x —SO 3 H, FSO 3 H—SbF 5 (magic acid) or combinations thereof.

8. The method of claim 6 , wherein the foam is a substantially closed cell foam.

9. The method of claim 6 , wherein the sprayed foam composition hardens in about 30 seconds to about 5 minutes.

10. The method of claim 6 , wherein the material is a structure for a building, a furniture article, or an automotive article.

11. The method of claim 6 , wherein the catalyst carrier consists of a polyhydroxyl compound.

12. A method of installing a foam comprising:
mixing a composition consisting of a bio-based epoxy compound, a petrochemical-based epoxy compound, or combination thereof with a cationic catalyst consisting of a superacid, a BF 3 dihydrate complex, a phosphoric acid derivative, or combination thereof, a surfactant, a blowing agent, a flame retardant, and at least one of a catalyst carrier or a co-reactant consisting of a diol, a glycerin, or a combination thereof to form an epoxy matrix and an isocyanate free foam composition; and
spraying the foam composition on a material to form the foam.

Assignees

• Certain Teed Corp

Inventors

• Petrovic Zoran S
• Javni Ivan J
• Ionescu Mihail
• Cvetkovic Ivana
• Zlatanic Alisa
• Bilic Nikola
• Song Kwangjin
• Hong Doopyo
• Bozek John J
• Toas Murray S

Classifications

• C08G59/68

  characterised by the catalysts used · CPC title

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title

• C08J2203/144

  Perhalogenated saturated hydrocarbons, e.g. F3C-CF3 · CPC title

• C08J9/146 Primary

  only fluorine as halogen atoms · CPC title

• B29L2031/10

  Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)} · CPC title