MXPA99010642A - Epoxy-containing foaming compositions and use thereof - Google Patents

Abstract

Se describen una composición espumosa y los precursores de lo mismo. El precursor espumoso comprende;(a) un epoxi, un material modificador, y un agente de soplado;y (b) un portador y una fuenteácida.

Description

FOAMY COMPOSITIONS CONTAINING EPOXY AND USES OF THEM.

FIELD OF THE INVENTION The present invention relates to compositions, precursors thereof and methods for using the precursors to make foams and foam-containing articles.

BACKGROUND OF THE INVENTION Foams are used in a wide range of commercial applications including automotive, construction, among other applications that require thermal or acoustic insulation. In the automotive industry, foams are typically formed in situ, and can be used to fill cavities such as pillars and oscillating panels, and to decrease sound transmission. Foaming in situ has typically been done using a polyurethane foam based on isocyanate chemistry. It is believed that certain components of the polyurethane foam and the products thereof have an undesirable environmental impact. Consequently, there is a need in REF .: 32107 for this technique of a low temperature foam which is economically and substantially free of undesirable materials.

BRIEF DESCRIPTION OF THE INVENTION The present invention solves the problems associated with conventional foaming formulations by providing foaming compositions and precursors thereof which are not based on polyurethane or isocyanate chemistry. The inventive compositions and precursors thereof reduce, if not eliminate, the presence of conventional undesirable compounds and products thereof while providing the benefits associated with conventional foams, for example, the decrease in sound. The inventive compositions may be free of polyurethane and / or isocyanate. The term "free" means that the inventive compositions before or after being foamed contain less than about 10% by weight of polyurethane and / or isocyanurates, isocyanate, and in most cases 0% by weight. While the presence of such compounds does not adversely affect the reaction described in greater detail below, these materials can be avoided by employing the inventive formulations. Therefore, the present invention provides a foam that can be used with or in exchange for urethane / isocyanate-based foams and foaming or foaming systems.

One aspect of the invention relates to a method of contacting and in turn reacting the precursors of the composition at ambient conditions to produce a foam. This reaction produces a relatively large heat release. The exothermic or heat released by the contact reaction is found to be sufficient to handle an endothermic blowing agent, thus creating a foam virtually instantaneously. In addition, the exothermic reaction can trap a blowing agent, for example, thermoplastic powders, in order to thereby expand a foam.

Another aspect of the invention relates to a method for containing the foam during expansion by expanding the foam within a control or containment means. The control means confines the expansion of the foam and determines the direction of the expansion. While any appropriate control means may be used, a polymer bag or sack is desirable. The polymer bag can be manufactured from a virtually unlimited array of materials and configured in any desirable way.

The inventive foam can be used in a wide array of end uses. Examples of such uses include thermal insulation such as cooling, rigid wall insulation spray, marine foams, water heaters, for automotive sound reduction, among others.

CROSS REFERENCE OF PATENT APPLICATIONS RELATED The subject matter of the present invention relates to an International Publication of PCT No. WO 98/53008, filed with the same date herein in the name of Jeffrey Pachl et al., And entitled "Curable Sealant Composition". The description of this non-provisional patent application is incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a graphic representation of the temperature and velocity of the foamy reaction as a function of the acid percentage. Figures 2A and 2B are schematic drawings of the assemblies which can be used to dispense the inventive foam within a defined cavity or area.

DETAILED DESCRIPTION The inventive foaming composition is obtained from foaming precursors. The precursors comprise at least one epoxy functional compound, at least one carrier, for example, a polyol, at least one hydrogen donor or an acid, for example, phosphoric acid or a catalyst such as a photoinitiator, optionally at least one material modifier such as a thermoplastic, and at least one blowing or blowing agent, among other components. The precursor (s) may comprise a two-component system (a so-called side A and B) that are contacted to produce a foam, or a single-phase system that is activated in response to a source of energy, for example, heat, UV light, among other energy sources. When a two component system is used, the epoxy and the acid source are separated. An exothermic reaction between the epoxy and the hydrogen or acid donor activates the blowing or expanding agent whereby a foam is produced.

The epoxy functional compound comprises from about 30 to about 50% by weight of the precursor. Examples of suitable epoxy functional compounds comprise at least one member selected from the group consisting of bisphenol A epoxy, modified epoxy elastomers, epoxy modified polybutene, epoxy modified polybutadiene, modified ethylene-propylene rubber (EPDM), cycloaliphatic epoxy. , mixtures thereof, among others. When a two component system is employed, the epoxy functional compound is located on the A side, or otherwise the reaction with the acid is prevented, for example, the epoxy is separated from an acid source.

The density, moisture and temperature resistance among other physical properties of the final foam product can be modified or adapted by adding a thermoplastic, a plastic or resinous material to the functional epoxy compound. All materials include carriers, fillers, viscosity control agents, etc., which are incorporated within the function of the final foaming composition as a modification material. While any modification material may be employed, examples of such materials comprise at least one member selected from the group consisting of ethylene-vinyl acetate copolymer, propylene / polyethylene rubber, phenoxy resins, phenolic resins, powdered wax, a compound functional powdered epoxy, among others. About 1 to about 10% by weight of the modifying material can be added to the epoxy, for example, about 2% by weight of the precursor. The modifier material typically comprises a powder having a particle size of less than about 20 microns and a melting point from about 200 to about 270 ° C. The modifying agent becomes fluid and normally melts when exposed to the exothermic reaction temperature. When a two component precursor system is used, these materials are usually combined with the epoxy or A side functional compound.

The carrier usually comprises from about 20 to about 40% by weight of the precursor, for example, usually about 30% by weight. The carrier serves to release an acid, an expansion agent, a catalyst, mixtures thereof, among others to make contact with the epoxy functional compound. A carrier further functions as a modifying material by virtue of which the carrier is incorporated into the final foam and modifies the physical properties of the foam. Examples of suitable carriers comprise at least one member selected from a group consisting of polyester polyols, polyvinyl alcohol, water, among other carriers that are preferably miscible with the epoxy functional compound and mixtures thereof. When a two-component precursor system is employed, these carrier materials are added to the acid side or component of the "B" side of the foaming precursors. Depending on the relative concentration of the precursor components, polyvinyl alcohol, hygroscopic polypropylene, (as well as other suitable materials) can be used to absorb steam or water generated by the exothermic reaction.

The hydrogen donor, for example an acid or photoinitiator, provides a source of H + that participates in an exothermic reaction with an epoxy functional compound. The hydrogen or acid donor usually comprises from about 20 to about 30% by weight of the precursor, for example, from about 5 to about 20% by weight of the precursor of part B. Examples of suitable donors may include acids Lewis such as at least one member selected from the group consisting of sulfonic acids, phosphoric acid, citric acid, carboxylic acid, oxalic and tannic acids, mixtures thereof, among others. Particularly desirable results have been achieved using sulfonic and / or phosphoric acids. When a two-component precursor system is employed, the acid responds to the B side of the foaming precursors. If desired, the acid may comprise an acid functionally equivalent to the hydrogen donor released by a UV photoinitiator, for example, by replacing a portion of the photoinitiator with its corresponding acid. That is, a photoinitiator is a precursor of a hydrogen donor by virtue of which the photoinitiator provides H + when activated.

In one aspect of the invention, the hydrogen donor comprises a photoinitiator that becomes active when exposed to an energy source. While any photoinitiator / hydrogen donor can be employed, an example of a suitable photoinitiator comprises a catalyst such as UVI 6974 (Union Carbide) which is described in greater detail in the aforementioned co-pending and commonly assigned International Publication of the PCT No. WO 98/53008. When such a hydrogen donor is employed, the foaming precursors can be used in a single phase system. For example, such a single-phase system can be partitioned, exposed to a UV light source which causes the UV catalyst to generate an acid thereby allowing a reaction based on the functional epoxy to be present. In turn, the heat released by the exothermic epoxy reaction activates a blowing or expanding agent, for example, a hydrocarbon encapsulated within a thermoplastic, whereby a foam is produced. While any suitable two-phase or single-phase system can be employed, a single-phase system typically produces a foam that is thin relative to a two-phase system.

In another aspect of the invention, the modifying material comprises a thermoplastic. The thermoplastic modifier material of the foamed precursor may comprise at least one member selected from the group consisting of polyacrylonitrile, polyethylene, phenolic resins, wax, EVA, polypropylene, GMA, modified acid polyethylene, polybutadiene, modified polyethylene combinations (such as Bynel® supplied by DuPont Company), SIS block copolymers (such as Katron® supplied by Envoltura Chemical), among other thermoplastic materials that can be dispersed in a foamed precursor and have a melting point less than about the exothermic reaction referred to and mixtures Of the same. Typically, the thermoplastic modifier material of the precursor comprises about 10% up to about 15% by weight of the precursor. The thermoplastic may possess any desirable configuration or particle size. In some cases, the thermoplastic can form a film or skin on an outer surface of the foam thereby improving the resistance of the foam to fluids, for example, water, gasoline, among other fluids.

In a particularly useful aspect of the invention, a blowing agent is combined with or encapsulated within a thermoplastic particle or powder, for example, a hydrocarbon encapsulated within an acrylonitrile shell known as Expancel® which is supplied by the Nobel company Industries. When a two-component precursor system is used, the wraps are normally combined on the B side together with the carrier. These casings can, however, be combined with the A side or in a single phase system while the composition of the casings is not substantially affected by the epoxy, for example, the acrylonitrile casings can be. soluble within the epoxy. For example, wraps can be made of nylon, EVA, among other materials not soluble in the epoxy functional compound, and mixtures thereof can be present in the epoxy compound of a two-phase precursor system. Polyethylene and polypropylene can function as a shell for the encapsulation of a blowing agent as well as a modifying material. That is, the encapsulated blowing agent is incorporated into the foam and the characteristics of the casing encapsulate the blowing agent as well as the blowing agent can modify the properties of the final foam. When sides A and B are contacted (or in the case of a single-phase system exposed to an energy source), the epoxy functional compound reacts with the hydrogen donor or acid with which heat is released which causes the expanding agent inside the wrappers to become foamy. The foam can be characterized by a compound wherein the product of the epoxy functional reaction (including the above-mentioned modifying materials) forms a matrix that embeds the expanded shells. Depending on the physical characteristics desired in the foam, the wrappers can be open or closed wrappers.

The aforementioned blowing agent may comprise at least one member selected from the group consisting of hydrazide, diphenyloxide-4,4-disulfohydrazide, carbonamide, azocarbonamide, hexamethylenediamine carbamate, sodium bicarbonate, carbon dioxide, hydrofluorocarbons such as difluoroethane, tetrafluoroethane , among others; hydrocarbons such as butane, propane; mixtures thereof, among others. Water can function as a carrier as well as a blowing agent. That is, the water can be used to carry or release the hydrogen donor and if the exothermic reaction releases sufficient heat, the water can be converted into vapor that expands, thereby producing a foam. Typically, the blowing or expanding agent comprises about 5 to about 40% by weight of the foam precursors.

The foamy characteristic can also be adapted by adding one or more filling materials. Conventionally used filling materials comprise at least one of talc, mica, magnesium silicate, mixtures thereof and, if desired, calcium carbonate can be added to the foaming precursor to increase the hardness and density of the resulting foam. . When included, the filler comprises about 5 to about 35% by weight of the foaming precursors.

An example of a combined side A and B precursor composition is set forth in the following table.

TABLE Name Brand% by weight Registered Chemical supplier Equivalent Epoxy Salaromer Cycloaliphatic Uvacure 1500 UCB Radcure 30 - 50 SARCAT K126 Polyester Tone 0301 Union Carbide 20 - 30 polyol Phos. Acid J.T. Baker 5 - 15 commodity Phosphoric Thermoplastic Expancel Nobel Industries 5 - 15 H.M. Royal Microspheres The precursors can be combined using any suitable apparatus that imparts a sufficient amount of cut to obtain a substantially homogeneous precursor. Examples of suitable apparatus include hand mixing, static tube mixing, the described structures illustrated in FIGS. 2A and 2B (described below in greater detail), among other conventional apparatuses. Typically, the samples are mixed from about 2 to about 10 seconds depending on the composition and mixing environment, for example, a composition A: B 1: 1 can be mixed for about 5 seconds in a static tube mixer.

The inventive foam can be formed by contacting the precursors under conditions sufficient to cause the aforementioned exothermic reaction which causes the blowing agent to expand and in turn foam to foam. Before contacting them, the precursors can be previously combined and stored in separate containers. That is, a Part A or first precursor mixture is typically obtained by combining the epoxy and the modifying material, for example, polyvinyl alcohol and the polypropylene, and a part B or second precursor mixture can be obtained by combining the carrier, for example, a polyol. , a hydrogen / acid donor and a blowing agent, for example, an encapsulated blowing agent within a thermoplastic shell. A part A and part B can be combined to obtain a foam using conventional foam making equipment. For example, a part A and a part B can be contacted as two high pressure streams within a mixing chamber of an external mixing head. While heat can be added to the precursors, the reaction between "A" and "B" can occur under environmental conditions. The ratio of "A" to "B" is usually within the range of about 1: 1 to about 5: 1.

The pH of the A side (or epoxy) is usually around 6 to about 8. The pH of the B side of the foaming precursor comprising an acid and a carrier is usually from about 0.5 to about 4, for example, the pH of the phosphoric acid when mixed with a polyol. Usually, the pH before the reaction with part A is around 1.6. The composition and concentration of the foaming precursors can be modified to obtain a predetermined reaction rate, for example by modifying the concentration of the acid. The effects of the pH or acid concentration of the B side are better understood with reference to Figure 1 which illustrates the effects on the composition shown in Example 9. Refer now to Figure 1, Figure 1 is a graphical representation of the% acid in the precursor versus the time of the foamy reaction and the temperature. Figure 1 illustrates that as the acid concentration increases the reaction temperature increases and the reaction time decreases. Figure 1 also illustrates that the precursor can be selected at a predetermined reaction temperature / time. For example, by selecting a high reaction temperature (high acid concentration) a broader range of modifying materials can be employed while selecting a lower reaction time (lower acid concentration) the foam has more easily manageable characteristics.

The viscosity of a foaming precursor can be adapted to increase the resulting foaming characteristics. The viscosity of the "A" side or the epoxy functional component of the foaming precursor is normally controlled, for example, such that a modifying material, eg, a plastic powder, becomes or remains dispersed in the "A" side precursor. While any viscosity control agent can be employed, desirable results can be obtained by using a solid polymer (in particulate form) to produce a foaming precursor gel. Examples of suitable solid polymers comprise at least one member selected from the group consisting of EVOH, fluoropolymers and dispersions thereof such as polytetrafluoroethylene (supplied as Teflon® by the DuPont Company), among others. Certain modifying materials such as wax and polyethylene, and carriers such as PVOH can also function as viscosity control agents. That is, the viscosity control agents are incorporated into the final foam and modify the properties of the foam. The viscosity control agent may be within the range of particle size from about 20 to 50 microns, for example, less than 325 mesh. An example of a controlled viscosity composition comprises from about 5 to about 10% by weight of solid epoxy, from about 5 to about 15% by weight, powdered polyethylene and from about 25 to about 30% by weight of blowing agent. In addition to the viscosity, the characteristics of the foam can be adapted by varying the temperature, pressure, pH of the foam, density of the foam, among other parameters known to those skilled in this art. In addition, the "A" side of the system can be thickened in a gel by the addition of a surfactant such as any commercially available liquid detergent or titanate such as Kenrich KRTTS, eg, from about 0.5 to about 3% by weight of surfactant (referring to example 9B). This allows a more complete rheological control, ensuring the homogeneity of the included system.

In one aspect of the invention, the foam comprises a single phase system, for example, only a mixture of the "A" side. An example of such a system comprises an epoxy functional compound, a polyol, ther oplastic spheres that encapsulate a blowing agent, materials such as phenoxy, polypropylene, mixtures thereof, among other components. This system can be activated by heat. In other words, the system expands when exposed to high temperatures, for example, around 125 ° C. If desired, the single-phase foaming system can be initiated using a hydrogen donor comprising a photoinitiator instead of or in conjunction with an elevated temperature. Examples of such initiators comprise at least one member selected from the group consisting of Union Carbide UVI 6974 among others. Normally, the amount of such initiator corresponds from 5 to about 15% by weight of the foaming precursor. More details than with respect to photoinitiators can be found in the document "Photopolymerization Behavior of Several Cationic Photoinitiators in Cationically Cured Resin Systems" by Edward Jurezak; which is incorporated herein for reference purposes. This single-phase system is especially useful when applied to a substrate by spraying. For example, the single-phase system can be sprayed on a prior automotive assembly for reducing the amount of sound transmission to the interior of the automobile. In a further example, the single-phase system can be sprayed onto a first component, for example, a plastic strip, exposed to UV rays to cause foam and applied to a second component, for example, a metal support member, where the function of the foam is to reduce the vibrations between the components.

A foamed structure composition can be obtained in accordance with the present invention. A structural modifier such as fibers, particles, rods, tubes, powders, mixtures thereof, among others, can be incorporated as components of the foaming precursor. The structural modifier can be used to adapt the physical and / or chemical properties of the resulting foam. Examples of suitable structural modifiers, usually as staple fibers or powders, may comprise at least one of nylon, carbon, carbonates, graphite, Kevlar®, Dyneon®, ceramics, glass fiber, metals, among other materials. Certain thermoplastic modifying materials such as polyethylene and polypropylene, and fillers such as mica and polytetrafluoroethylene can also function as structural modifiers. The amount of such structural modifiers usually comprises about 1 to about 30% by weight of the uncured foaming precursor.

Any suitable commercially available equipment may be employed to produce foam, to mix and dispense the inventive foam precursors to obtain the inventive foam. An example of such equipment comprises the ECONO-MIX supplied by Kirkco Corporation, Monroe, N.C. Another example involves using a DO-PAG pump in combination with an Albeon static mixing head. If desired, the inventive foam can be expanded with a cavity, e.g., a automotive A-pillar, employing a dispensing apparatus having a replaceable / disposable mixing head. That is, the static mixing head can comprise a replaceable plastic tube having a centerpiece with a helix or vortex configuration, which is connected to a discharge flange of a pump and inserted into the cavity for the foaming precursors. Another static mixing head design has a valve type arrangement that is illustrated in Figures 2A and 2B. Referring now to Figure 2A, Figure 2A illustrates has a one-way valve type arrangement where the foam or precursors thereof are introduced or injected via a 1-way valve (commonly known as a zerk) that it is placed inside a cap 2. Valve 1 can also include a secondary or flap valve LA that prevents foam from escaping through a reverse flow through valve 1. The cap 2 seals or defines one end of a cavity to be filled with the foam. The cap 2 may include securing hooks or tabs 3 for securing the position of the cap 2j_ for example, within a so-called pillar A of an automobile whereby the foam is allowed to dispense into the car's cavity in a controlled manner . Normally, one end of the valve 5 1 is connected to a mixing zone 4 so that the aforementioned static mixers have helical vanes 5. After travel through the valve 1 and the static mixer 4, the foam is released inside " of the cavity to be filled with the foam The area 0 and direction within which the foam expands can be controlled and / or defined using a containment means such as a polymer bag 6, (the containment means are described with more detail below.}.,. * 5 Referring now to Figure 2B, this type of arrangement provides a longer mixing time for the foamy precursors before the foam is released into the cavity to be filled. 0 illustrated in Figure 2B can also be used as a cap 10 to seal or define an end of the cavity to be sealed.After providing the foaming precursors, a mixing head 11 or the valves in advance described (4 and 5_ of Figure 2A). 5 Foamy precursors travel through the TI mixing head and are released at the opening defined at 12 as a foam. The opening _12 may also be within the aforementioned containment means. The caps 1 and 1_0 may remain associated with the foamy product within the cavity. Using such a replaceable mixing head, any of the problems associated with clogged mixing heads are avoided. Two pressure streams can also be used to converge in a mixing chamber or cavity for foaming and the mixing action is presented without the use of an additional mixing apparatus. In addition to the foregoing, the inventive foamed composition can be injected, extruded, formed, sprayed, molded, among other conventional processes in order to obtain a desirable foamable article.

While the foregoing description emphasizes particular foaming compositions, the inventive compositions (and precursors thereof) may include additives such as dyes, surfactants, pigments, core forming agents, among other conventionally foamed additives. If desired, a pH indicator can be added to the precursor in order to provide visual detection means for a reaction product. An example of an appropriate pH indicator comprises at least one member selected from the group consisting of methyl red, methyl blue, chlorophenol red, bromothymol blue. That is, as the foaming precursor reacts, for example, epoxy-acid, the acid is consumed thereby changing the pH which causes the pH indicator to change color.

If desired, the inventive composition can be laminated or bonded with other articles, for example, laminated on a metal sheet, sheet, etc. The inventive composition may also be expanded within a bag control or containment means having a predetermined shape whereby a foamed article that replicates the bag is formed, for example, with reference to US Patent No. 4,269,890 (Breitling), 4, 232, 788 (Roth), 4,390,333 (Dubois); the description of each of them is incorporated herein for reference purposes. When the foam is expanded within a bag, the valves previously described illustrated in Figures 2A and 2B, those marketed by Inflatable Packaging as part No. IP04, or any other appropriate supply means may be employed in the opening in order to control the introduction of the foam inside the bag. For example, a bag replicates a cavity such as a car's cavity or any other desirable configuration unwinds or expands within the cavity as foam that is introduced into the bag via the valve. If desired, the bag may comprise or be coated with a heat sensitive adhesive where the heat generated by the exothermic foaming reaction activates the adhesive. The adhesive can permanently adhere the foam contained in the bag to any desirable location. The bag may also include predetermined areas having weakened seams or perforations that are designed to rupture when the foam expands whereby the expansion of the foam is directed. Similarly, the composition of the bag can be selected so that the bag melts when exposed to the foam. The casting bag can direct the expansion of the foam, form a coating on the foam, have the function of an adhesive, among other utilities. In addition, a plurality of bags can be used where one bag is surrounded by another bag. The internal and / or external bag may possess the predetermined properties mentioned above. In addition, the bag may comprise areas having different physical and / or chemical properties, for example, a bag comprising a polyethylene sheet heat sealed around its periphery to a sheet comprising polybutadiene. At least a portion of the bag can be manufactured from one or more members selected from the group consisting of polyethylene, polyester, vinyl, nylon, Surlyn®, ethylene-vinyl acetate, styrene-isoprene-styrene, styrene-butadiene- styrene or other block copolymers, polybutadiene, among other plastic materials with melting points corresponding to the range of reaction temperatures, polyamide, modifications of EVA, modified polyethylene, modified polybutadiene, GMA, SBR, among other plastic materials suitable for bags or construction of sewing capacity bag. In some cases, the aforementioned thermoplastic modifying materials can also be used to fabricate a containment means. The bag or containment means can be used with a wide range of foaming compositions in addition to the epoxy-containing foams previously described. Examples of foams that can be expanded within the bags or containment means previously described comprise at least one amine of epoxy, acrylics, phenolics, among others.

The following examples are provided to illustrate but do not limit the scope of the invention as defined in the appended claims. Unless otherwise indicated, commercially available materials and apparatus were used in these examples.

EXAMPLE 1 A foaming product was produced using a two part system (part A and part B) by a conventional foam making apparatus comprising a static mixer manufactured by the Albion company (Model No. 535-1 or equivalent). The constituents of the foam were kept in two separate supplies of materials, Part A and Part B.

Part A comprises a combination of the epoxy and the thermoplastic spheres (a blowing agent) in a proportion of 30 to 15 parts (a total of 100 parts). Part B comprises a combination of the phosphoric acid and the polyol in a proportion of 30 to 50 parts (also 100 parts). The feed ratio of part A to part B with the mixer is 1: 1. The pH of part B is about 1.6 before the reaction with part A.

A pressurized flow through the mixing chamber produces a polymer that expands rapidly and releases an amount of exothermic heat sufficient to produce a foam.

EXAMPLE 2 The process of Example 1 is repeated with the exception that the ratio of the epoxy to the thermoplastic spheres in Part A is 2: 1, and the ratio of the phosphoric acid to the polyol in Part B is 3: 5. The feed ratio of Part A to Part B with the mixing head is 3: 1.

EXAMPLE 3 The process of Example 1 is repeated with the exception that the components of Part A and the Part B are mixed together by hand (instead of using a static mixer). spheres) . Part A is shaken by hand until it has an even consistency.

Part B is composed of polyol (Tone 301) and phosphoric acid (10%) by weight). The acid is combined within the polyol. Part A and Part B of 1: 1 are contacted in a static tube mixer (a commercially available tube having internal vanes that mix any material passing through the tube) and a foam is produced. The ratio of A to B can be from 1: 1 to 4: 1 depending on the concentration of the acid.

EXAMPLE 6 A two-phase system is used to produce a foam. Part A comprises an epoxy (Radcure 1500). Part B comprises a polyol (50% by weight - Tone 301), phosphoric acid diluted with water (approximately 50% acid in a commercially available solution) at 20%, and 30% microspheres. The mixtures are stirred by hand in a polyol until they have an even consistency. The acid mixture is combined by hand mixing in the polyol-spherical mixture. Part A to Part B with a 1: 1 ratio is contacted in a static tube mixer and a foam is produced. The ratio of A to B can be from 1: 1 to 4: 1 depending on the acid concentration.

EXAMPLE 7 A two-phase system is used to produce a foam. Part A comprises an epoxy (Radcure 1500) Part B comprising a polyol (Tone 301), a combination of polyvinyl alcohol and water (combination PV0H: H20 3: 1 corresponding to 20% of the polyol) and 30% of microspheres per The weight of the polyol and the acid can be 10% of the total of the "B" mixture. The spheres are shaken by hand inside the polyol until they have an even consistency. The PVOH and water are stirred - by hand. The temperature of the PVOH / water solution is 140 ° C. The PVOH combination is added to the polyol by shaking by hand. The acid is stirred by hand into the spheres-PVOH-polyol mixture. The proportion of Part A and Part B of 1: 1 is brought into contact in a static tube mixer and a foam is produced. The ratio of A to B can be from 1: 1 to 4: 1 depending on the concentration of the acid.

EXAMPLE 8 A two-phase system is used to produce a foam. Part A comprises an epoxy (Radcure 1500) and a phenoxy resin (Paphen 200 corresponding to 25% of Part A, the epoxy is 75% of Part A). Part B comprises 45% polyol (Tone 301), 23.5% polyvinyl alcohol (Air Products 203S) and 23.5% microspheres. The phosphoric acid is 10% of Part B. The spheres are shaken by hand into the polyol until they are even. The PVOH, the microspheres, and the polyol are combined by shaking them by hand. The phosphoric acid is stirred by hand into the PVOH-polyol spheres mixture. The ratio of Part A to Part B is 1: 1 is brought into contact in a static tube mixer to produce a foam. The ratio of A to B can be within the range from 1: 1 to 4: 1 depending on the acid concentration.

EXAMPLE 9A A two-phase system, ie Part A and Part B, is used to produce a foam. Part A comprises an epoxy (Radcure 1500) 60% by weight, polypropylene powder (Equistar FP 800-00) 20% by weight, polyvinyl alcohol (Air Products 203S) 20% by weight. Part B comprises polyol (Tone 301) 60% by weight and 30% microspheres. The phosphoric acid is 10%. The spheres are shaken by hand inside the polyol until an even consistency is obtained. The microspheres and the polyol are combined by shaking them by hand. The phosphoric acid is stirred by hand into the mixture of the microspheres and the polyol. The ratio of Part A to Part B of 1: 1 is used and brought into contact in a static tube mixer to produce a foam. The ratio of A to B can, however, be within the range from 1: 1 to 4: 1 depending on the concentration of the acid.

EXAMPLE 9B In this example, a two-phase system was used where Part A comprises a gel. A two-phase system, namely a Part A and a Part B, is used to produce a foam. Part A comprises an epoxy (Radcure 1500) 59% by weight, polypropylene powder (Equistar FP 800-00) 20% by weight, polyvinyl alcohol (Air Products 203S) 20% by weight and a surfactant (gelling agent) in 1%. % by weight. The Part B comprises polyol (Tone 301) 60% by weight, and a % of microspheres. The phosphoric acid is 10%. The spheres were shaken with the polyol until an even consistency was obtained. The microspheres and the polyol are combined by shaking them by hand. The phosphoric acid is stirred by hand into the mixture of the polyol and the microspheres. A ratio of Part A to Part B of 1: 1 is used and contacted in a static tube mixer to produce a foam. The ratio of A to B can, however, be within the range from 1: 1 to 4: 1 depending on the acid concentration.

EXAMPLE 10 From a high density polyethylene film an approximately 8x8 inch bag or containment medium having a one-way valve located at one end of the bag was constructed. The seams of the bag were designed to break into specific locations, which directs the expansion of the foam within the area of the cavity adjacent to the weak seams. The sheets are put together by heating in a sealing device of the TEW Electric Heating Company). The seams were selectively reinforced by double sealing or reinforcement to provide multiple points of direction of the foam from the same bag. The foaming composition demonstrated in Example 9 is introduced into this bag. As the foam expands, the foam escapes from the bag through the relatively weak seams.

EXAMPLE 11 A bag or bag each composed of polyethylene, ethylene-vinyl acetate, polybutadiene was made using the apparatus described in Example 10. The foam of Example 9 was introduced into these bags. The bags, which have a melting point lower than the exothermic reaction temperature of the foam, failed and released the foam.

EXAMPLE 12 Using the apparatus of Example 10, a bag or bag each made of modified EVA (Bynel®), modified polyethylene, (Primcor® supplied by the Dow Chemical Company), modified butadiene, glycidyl methacrylate (GMA) was manufactured. The foam of example 9 was introduced into these bags. The heat released by the exothermic reaction of the foam causes the bags to melt. The molten bag material adheres to the foam thereby modifying the surface of the foam. The casting bag also adheres the foam to any surrounding surface or items.

EXAMPLE 13 Using the apparatus of Example 10, a bag or bag composed of polypropylene, polyethylene, nylon braided mesh, aluminized fiberglass mesh was manufactured. Each of the bags was also processed to possess multiple perforations (25-100 holes / inch). The foam of example 9 was introduced into each of these bags. The perforations allowed the foam to escape in controlled quantities while also maintaining the shape of the bag.

EXAMPLE 14 Using the apparatus of Example 10, two bags or sacks were made, ie an inner bag and an outer bag. The inner bag comprises modified butadiene and the outer bag comprises high density polyethylene. The inner bag is placed inside the outer bag and the outer bag is sealed. The foam of Example 9 was introduced into the inner bag. The inner bag or sac melt during the foaming reaction. The inner bag is of sufficient size to contain the required amount of mixed foam precursors to fill the outer bag. The construction of the outer bag is of material and size to contain the reaction within the cavity.

EXAMPLE 15 The characteristics of sound reduction or insertion loss of the foam produced according to example 9A was tested in accordance with the Society of Automotive Engineers (SAE) J 1400. The sample size was 3x3x10 inches and placed within a channel Coated metallic E. An increase in insertion loss corresponds to an increase in noise reduction properties which in turn correspond to less noise within the passenger compartment of a car.

FREQUENCY (Hz) LOSS OF INSERTION (dB) 125 IZ5 160 10.6 200 11.4 250 12.0 315 24.5 400 35.4 500 46.8 630 38.4 doo 40.1 1000 45.7 1250 45 1 1600 49.6 2000 49.2 2500 50.1 3150 50.9 4000 55.5 5000 58.7 6300 59.2 8000 64.2 These data illustrate the desirable sound absorption characteristics of the inventive foaming compositions.

A person skilled in this technique should understand that these exemplary processes can be modified by manipulating the process variables such as the time and temperature of each of the above mixing steps, mixing speed (RPM), time under vacuum, exposure to lightning UV, and vacuum level (Hg mm) as well as the continuous process of operation. While previous examples illustrate a process a person skilled in the art after reviewing and understanding the present invention will be able to manipulate the above process variables to adapt the present composition for a virtually unlimited array of product applications.

It is noted that in relation to this date, the best method known to the applicant, to practice the following invention, is that which is clear from the present description of the invention.

Having described the invention as above, property is claimed as contained in the following:

Claims (31)

1. A foaming precursor characterized in that it comprises: an A side comprising at least one epoxy functional compound, and; a side B comprising at least one carrier that is miscible with said at least one epoxy functional compound, and at least a sufficient amount of hydrogen donor to cause an exothermic reaction between said epoxy and said hydrogen donor, wherein at least one one of said sides A or B comprises an encapsulated blowing agent and said exothermic reaction is sufficient to expand the blowing agent when said sides A and B are contacted.

2. A foaming precursor characterized in that it comprises: at least one epoxy functional compound, at least one carrier that is miscible with the at least one epoxy functional compound; at least one blowing agent and a hydrogen donor comprising at least one photoinitiated.

3. The foaming precursor of claim 1, characterized in that said side A comprises a cycloaliphatic epoxy; at least one member selected from the group consisting of polypropylene, polyethylene, polyvinyl alcohol; and wherein said encapsulated blowing agent comprises butane.

4. The foaming precursor of claim 1, characterized in that said side B comprises a polyester polyol and the hydrogen donor comprises at least one of phosphoric acid or a photoinitiator.

5. The foaming precursor of claim 1, characterized in that said encapsulated blowing agent comprises a blowing agent encapsulated within a thermoplastic shell.

6. The foaming precursor of claim 1, characterized in that said side A comprises an epoxy functional compound, polyvinyl alcohol, a thermoplastic plastic powder, and an encapsulated blowing agent.

7. The foaming precursor of claim 1, characterized in that said side B comprises a polyol and the hydrogen donor comprises an acid source.

8. The sparkling precursor of the claim 1 or 2, characterized in that it also comprises a member selected from the group consisting of nylon, carbon, polytetrafluoroethylene, carbonates and graphite.

9. The sparkling precursor of the claim 1, characterized in that the hydrogen donor comprises an effective amount of at least one photoinitiator.

10. The sparkling precursor of the claim 1 or 2, characterized in that it also comprises a surfactant.

11. The foaming precursor of claim 1, characterized in that said side A has a pH of 6 to 8.

12. The sparkling precursor of the claim 1 or 2, characterized in that said epoxy functional compound comprises at least one member selected from the group consisting of bisphenol A epoxy, epoxy modified elastomers, epoxy modified polybutene, epoxy modified polybutadiene, epoxy and epoxy-modified propyldiene-ethylene rubber cycloaliphatic

13. The foaming precursor of claim 1, characterized in that said hydrogen donor comprises an acid source comprising at least one member selected from the group consisting of sulfonic acids, phosphoric acid, citric acid, carboxylic acid, tannic acid and oxalic acid.

14. The foaming precursor of claim 13, characterized in that said acid source comprises phosphoric acid.

15. The foamy precursor of claim 5, characterized in that said thermoplastic shell comprises at least one member selected from the group consisting of acrylonitrile, polyethylene, nylon, EVA and polypropylene.

16. The foaming precursor of any of claims 1 or 2, characterized in that said blowing agent comprises at least one member selected from the group consisting of water, hydrazide, diphenyloxide-4, 4-disulfohydrazide, carbonamide, azocarbonamide, hexamethylenediamine carbamate, bicarbonate of sodium, carbon dioxide, difluoroethane, tetrafluoroethane, butane, and propane.

17. The foaming precursor of claim 1, characterized in that side B has a pH from 0.5 to 4.

18. The foaming precursor of any of claims 1 or 2, further characterized in that said at least one member selected from the group consisting of acrylonitrile, ethylene-vinyl acetate, polypropylene, polyethylene, rubber, phenoxy resin and wax powder.

19. The foaming precursor of claim 2, characterized in that said blowing agent comprises an encapsulated blowing agent.

20. The foamy precursor of any one of claims 1 or 2, further characterized in that it comprises at least one member selected from the group consisting of glass fiber, mica, calcium carbonate, magnesium silicate, metal, and ceramic.

21. The foaming precursor of any of claims 1 or 2, characterized in that said blowing agent comprises a hydrocarbon.

22. The foamy precursor of any of claims 1 6 2, characterized in that carrier comprises at least one member selected from the group consisting of water, polyols and polyvinyl alcohol.

23. A foam was obtained from the precursors of claim 1 or 2.

24. The foam of claim 23 characterized in that said foam comprises at least one of fibers, particles, rods, tubes and powders.

25. A foam comprising the foam of claim 23, characterized in that said foam is at least partially in contact with at least one member selected from the group consisting of polyethylene, polyester, vinyl, ethylene-vinyl acetate, nylon, styrene-isoprene. styrene, styrene-butadiene-styrene or other block copolymers, polybutadiene, polyamide, modifications of EVA, modified polyethylene, modified polybutadiene, GMA, SBR and mixtures thereof.

26. The foam of claim 25, characterized in that said at least one member comprises a containment means.

27. A method for making a foam, characterized in that it comprises: (a) combining an A side comprising at least one epoxy functional compound with a B side comprising at least one hydrogen donor while in the presence of a hydrogenating agent; blown encapsulated under conditions sufficient to provide an exothermic reaction; and (b) using heat from the exothermic reaction in order to expand the combined components to form a foam.

28. A method for producing a foam characterized in that it comprises: (a) providing a foaming precursor characterized in that it comprises (i) at least one epoxy functional compound, (ii) at least one photoinitiator, and (iii) at least one blowing agent, ( b) exposing the foaming precursors to a sufficient radiation source to activate the photoinitiator and cause an exothermic reaction, and use the heat of the exothermic reaction in order to cause the blowing agent to expand.

29. The method according to any of claims 27 or 28, characterized in that it further comprises: c) recovering the foam.

30. The method according to claim 28, characterized in that the blowing agent comprises an encapsulated blowing agent.

31. The method according to any of claims 27 or 28, characterized in that step (a) is presented at least in part within a containment device.