Patent GB-919779-A (GB)
Title: An improved process for the production of epoxy resin foams
IPC: C08J9/14
Filed: 1960-07-12
Abstract: Epoxy resin foam is produced by releasing into a space maintained at substantially atmospheric pressure a mixture under superatmospheric pressure of (1) a liquid mass comprising (a) one or more polyepoxides having an epoxy equivalent greater than one, (b) one or more relatively slow-acting epoxy curing agents, (c) one or more thixotropic agents with (2) one or more fluids, at least one of which has a boiling point below -20 DEG C., which are gaseous at atmospheric pressure at the operating temperature. Normally liquid glycidyl ethers of polyhydric phenols and alcohols are the preferred polyepoxides and these are preferably used in conjunction with epoxy esters of which many are specified; numerous types of polyepoxides in general are specified.  While many types of epoxy curing agents are specified, those particularly useful are aliphatic amines, e.g. N-aminoethyl-piperazine, and polyalkylene polyamines, e.g. diethylene triamine and N-hydroxyethyl-diethylene triamine, and their adducts, e.g. addition compounds with unsaturated nitriles or with epoxides; polyamine salts such as the 2-ethylhexoate of 2,4,5-tri(dimethylaminoethyl)-phenol; the adduct of a monoepoxide and a polyamine, such as a phenyl glycidyl ether-metaphenylene diamine adduct; acid anhydrides such as tetrahydrophthalic anhydride, pyromellitic anhydride and chlorendic anhydride; phosphoric acid and esters; boron trifluoride complexes, e.g. with water; and salts of inorganic acids such as salts of fluoboric acid.  Thixotropic agents mentioned include asbestos floc, silicate clays, micas, colloidal silica, organic complexes of bentonite, attapulgite, metallic soap powders, metallic leafing powders and finely divided solidified vegetable oil derivatives.  Blowing agents specified include nitrogen, propane, various chlorofluoroalkanes and alkenes, air, helium, methane, ethane and carbon dioxide.  Optional additives are surface active agents such as those known under the Registered Trade Marks "Span" and "Tween" as well as polyoxyglycols fluidizing solvents such as acetone, methyl ethyl ketone, toluene, xylene, ethyl acetate, butyl acetate, chloroform and trichloropropane.  The examples describe the preparation of a polyether from bis-phenol and epichlorohydrin and the polyepoxide prepared by reacting this polyether with the polyglycidyl ester of a mixture of dimer and trimer fatty acids; and the preparation of epoxy foams from these polyepoxides.ALSO:Epoxy resin foam is produced by releasing into a space maintained at substantially atmospheric pressure a mixture under super-atmospheric pressure of (1) a liquid mass comprising (a) one or more polyepoxides having an epoxy equivalent greater than one (b) one or more relatively slow-acting epoxy curing agents (c) one or more thixotropic agents with (2) one or more fluids, at least one of which has a boiling point below -20 DEG C., which are gaseous at atmospheric pressure at the operating temperature. Normally liquid glycidyl ethers of polyhydric phenols and alcohols are the preferred polyepoxides and these are preferably used in conjunction with epoxy esters of which many are specified; numerous types of polyepoxides in general are specified.  While many types of epoxy curing agents are mentioned, those particularly useful are aliphatic amines, e.g. N-aminoethyl-piperazine, and polyalkylene polyamines, e.g. diethylene triamine a-dN-hydroxyethyl-diethylene triamine, and their adducts, e.g. addition compounds with unsaturated nitriles or with epoxides; polyamine salts such as the 2-ethylhexoate of 2, 4, 5 tri-(dimethylaminoethyl)-phenol; the adduct of a monoepoxide and a polyamine, such as a phenylglycidyl ether-metaphenylene diamine adduct; acid anhydrides such as tetrahydrophthalic anhydride, pyromellitic anhydride and chlorendic anhydride; phosphoric acid and esters; boron trifluoride complexes, e.g. with water; and salts of inorganic acids such as salts of fluoboric acid.  Thixotropic agents mentioned include asbestos floc, silicate clays, micas, colloidal silica, organic complexes of bentonite, a thapalgite, metallic soap powders, metallic leafing powders and finely divided solidified vegetable oil derivatives.  Blowing agents specified include nitrogen, propane, various chloro fluoroalkanes and alkenes, air, helium, methane, ethane and carbon dioxide. Optional additives are surface-active agents such as those known under the Registered Trade Marks "Span" and "Tween" as well as polyoxyglycols: fluidising solvents such as acetone, methyl ethyl ketone, toluene, xylene, ethyl acetate, butyl acetate, chloroform and trichloropropane.  The examples describe the preparation of a polyether from bis-phenol and epichlorohydrin and the polyepoxide prepared by reacting this polyether with the polyglycidyl ester of a mixture of dimer and trimer fatty acids; and the preparation of epoxy foams from these polyepoxides.