Room temperature crosslinked foam

Patent metadata

Field	Value
Publication number	US-9868836-B2
Application number	US-89347407-A
Country	US
Kind code	B2
Filing date	Aug 16, 2007
Priority date	Dec 29, 2006
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

Foams for filling cavities and crevasses and for forming foamed products are provided. The latex foam may include an A-side containing a functionalized latex and a B-side that contains a crosslinking agent and optionally a non-functionalized latex. The A- and/or B-side contain a blowing agent package or components forming the blowing agent package. The blowing agent package may be the combination of two or more chemicals that when mixed together form a gas or a chemical compound that, when activated by heat or light, forms a gas. In an alternate embodiment, the latex foam includes a functionalized latex, an acid, and an encapsulated crosslinking agent and base. Alternatively, the spray latex foam may include a functionalized latex, a crosslinking agent, and an encapsulated dry acid and dry base. The encapsulating agent may be a protective, non-reactive shell that can be broken or melted at the time of application.

First claim

Having thus described the invention, what is claimed is:

1. A two-part foamable spray composition for forming an insulative foam, the composition comprising:
a first component including: (1) a carboxylated acrylic latex, with or without an acrylic solution, the carboxylated acrylic latex present in an amount of 90 to 95% by weight of the first component, and (2) an acid of an acid-base blowing agent package; and
a second component including: (1) a base of the acid-base blowing agent package, (2) a plasticizer, and (3) a polyfunctional aziridine that crosslinks at or about room temperature, the polyfunctional aziridine present in an amount of 2.7% to 30% by weight of the second component;
wherein the polyfunctional aziridine is the only crosslinking agent in the composition;
wherein a molar ratio of carboxy functional groups of the carboxylated acrylic latex to aziridine functional groups of the polyfunctional aziridine is 0.5:1 to 2:1;
wherein upon mixing the first component with the second component a reaction of the acid and the base is operable to generate a gas simultaneously with crosslinking of the first component and the polyfunctional aziridine crosslinking agent to form the insulative foam, the insulative foam hardening to achieve an R-value of 3.5° Fft 2 h/BTU per inch to 8° Fft 2 h/BTU per inch within two minutes after the first component is contacted with the second component, and
wherein the insulative foam has a density of 0.5 to 5 pounds per cubic foot.

2. The two-part foamable spray composition of claim 1 , wherein the foam is able to withstand the force of gravity when applied to a vertical surface.

3. The two-part foamable spray composition of claim 1 , wherein the second component further comprises a non-functionalized latex.

4. The two-part foamable spray composition of claim 1 , wherein at least one of the first component and the second component further includes an alcohol co-solvent.

5. The two-part foamable spray composition of claim 1 , wherein the carboxylated acrylic latex contains from about 1.0 to about 50.0 wt % the carboxy functional groups based on the total weight of the carboxylated acrylic latex.

6. The two-part foamable spray composition of claim 1 , wherein at least one of the first component and the second component further comprises at least one of a surfactant and a thickening agent.

7. The two-part foamable spray composition of claim 1 , wherein the two-part foamable composition forms a non-structural foam.

8. The two-part foamable spray composition of claim 1 , wherein the first component includes acrylic acid.

9. The two-part foamable spray composition of claim 1 , wherein the acid is selected from the group consisting of: citric acid, oxalic acid, tartaric acid, succinic acid, fumaric acid, adipic acid, maleic acid, malonic acid, glutaric acid, phthalic acid, metaphosphoric acid, and salts that are convertible into these acids.

10. The two-part foamable spray composition of claim 1 , wherein the base is selected from the group consisting of: calcium carbonate, magnesium carbonate, lithium carbonate, sodium carbonate, potassium carbonate, calcium hydrogen carbonate, magnesium hydrogen carbonate, lithium hydrogen carbonate, sodium hydrogen carbonate (sodium bicarbonate), potassium hydrogen carbonate (potassium bicarbonate) and combinations thereof.

11. The two-part foamable spray of claim 1 , wherein the acid is a dry acid powder.

Assignees

• Korwin-Edson Michelle L
• O'Leary Robert J
• Quinn Robert E
• Olang Fatemeh
• Owens Corning Intellectual Capital Llc

Inventors

• Korwin-Edson Michelle L
• O'Leary Robert J
• Quinn Robert E
• Olang Fatemeh

Classifications

• C08L53/02

  of vinyl-aromatic monomers and conjugated dienes · CPC title

• C08J2351/00

  Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers · CPC title

• C08L2666/04

  Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof · CPC title

• C08J9/08 Primary

  developing carbon dioxide · CPC title

• C08L2666/02

  Organic macromolecular compounds, natural resins, waxes or and bituminous materials · CPC title