# US 10,119,004 B2 · Foam, composition, and method

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- Number: US 10,119,004 B2
- Document ID: US10119004B2
- Status: Granted
- Kind: B2
- Application number: 15/466,571
- Filed: 2017-03-22
- Published: 2017-07-06
- Granted: 2018-11-06
- Earliest claimed: 2011-12-29
- Assignees: CertainTeed Corporation
- Applicants: CertainTeed Corporation
- Inventors: Zoran S. Petrovic; Ivan J. Javni; Mihail Ionescu; Ivana Cvetkovic; Alisa Zlatanic; Nikola Bilic; Kwangjin Song; DooPyo Hong; John J. Bozek; Murray S. Toas
- Web page: https://patentgrep.com/patent/US10119004B2

## CPC

- C08J 9/146: {only fluorine as halogen atoms}
- B05D 7/24: for applying particular liquids or other fluent materials
- B29C 44/02: for articles of definite length, i.e. discrete articles
- B29C 44/1271: {the preformed parts being partially covered}
- B29C 44/18: Filling preformed cavities {(B29C44/1204 takes precedence)}
- B29C 67/20: for porous or cellular articles, e.g. of foam plastics, coarse-pored {(chemical aspects of working up macro-molecular substances to porous or cellular articles C08J9/00)}
- C08G 59/68: characterised by the catalysts used
- C08J 9/0023: {containing oxygen}
- C08J 9/0038: {containing phosphorus}
- C08J 9/04: using blowing gases generated by a previously added blowing agent
- C08L 63/00: Compositions of epoxy resins; Compositions of derivatives of epoxy resins
- C09D 163/00: Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
- B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material
- B29K 2105/04: cellular or porous
- B29K 2105/20: Inserts
- B29L 2031/10: Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)}
- C08J 2203/142: Halogenated saturated hydrocarbons, e.g. H3C-CF3
- C08J 2203/144: Perhalogenated saturated hydrocarbons, e.g. F3C-CF3
- C08J 2207/04: Aerosol, e.g. polyurethane foam spray
- C08J 2363/00: Characterised by the use of epoxy resins; Derivatives of epoxy resins
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## 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/ft3 to about 5.0 lbs/ft3 as measured by ASTM D1622. Further disclosed are the foam and a method for installing the foam.

## Claims

### Claim 1

A foam composition consisting of a resin matrix, wherein the resin matrix consists of an epoxy-containing compound; a cationic catalyst consisting of a superacid, a BF3 complex, a phosphoric acid derivative, or combination thereof; an optional blowing agent; and at least one additive; wherein the composition is free of an isocyanate compound, the foam having a density from about 0.3 lbs/ft3 to about 5.0 lbs/ft3 as measured by ASTM D1622.

### Claim 2 (depends on 1)

The foam of claim 1, wherein the epoxy-containing compound is bio-based, petrochemical based, or combination thereof.

### Claim 3 (depends on 2)

The foam of claim 2, wherein the bio-based epoxy compound is derived from linseed oil, corn oil, soybean oil, sunflower oil, safflower oil, canola oil, rapeseed oil, palm oil, camelina oil, fish oil, tall oil, algae oil, or combinations thereof.

### Claim 4 (depends on 2)

The foam of claim 2, wherein the petrochemical based epoxy-containing compound consists of a cycloaliphatic epoxy compound and an aromatic epoxy compound.

### Claim 5 (depends on 1)

The foam of claim 1, wherein the superacid is HBF4, CF3SO3H (triflic acid), HSbF6, HPF6, FSO3H, HClO4, CF3(CF2)x-SO3H, FSO3H—SbF5 (magic acid) or combinations thereof.

### Claim 6 (depends on 5)

The foam of claim 5, wherein the superacid has a pKa of about −8 to about −25.

### Claim 7 (depends on 1)

The foam of claim 1, wherein the additive consists of a surfactant.

### Claim 8 (depends on 1)

The foam of claim 1, wherein the additive consists of a fire retardant.

### Claim 9 (depends on 1)

The foam of claim 1, wherein the additive consists of a co-reactant including a diol, a glycerin, or a combination thereof.

### Claim 10 (depends on 1)

The foam of claim 1, wherein the additive consists of a catalyst carrier.

### Claim 11 (depends on 10)

The foam of claim 10, wherein the catalyst carrier consists of a polyhydroxyl compound.

### Claim 12 (depends on 1)

The foam of claim 1, wherein the cationic catalyst is present at an amount of about 0.05 wt. % to about 5.0 wt. %, based on the total composition.

### Claim 13 (depends on 1)

The foam of claim 1, wherein the blowing agent is present at an amount of about 5.0 wt. % to about 30.0 wt. %, based on the total composition.

### Claim 14 (depends on 1)

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

### Claim 15 (depends on 14)

The foam of claim 14, wherein the cationic catalyst provides a gel time of about 10 seconds to about 50 seconds.

### Claim 16 (depends on 1)

A building cavity comprising the foam of claim 1.

### Claim 17

A method of installing a foam in a building cavity comprising:
mixing a composition consisting of a resin matrix, wherein the resin matrix consists of an epoxy-containing compound, a cationic catalyst consisting of a superacid, a BF3 dihydrate complex, or combination thereof, an optional blowing agent and at least one additive to form an epoxy matrix foam composition; and
spraying the foam composition to the building cavity, wherein the foam is isocyanate free and has a density from about 0.3 lbs/ft3 to about 5.0 lbs/ft3 as measured by ASTM D1622.

### Claim 18 (depends on 17)

The method of claim 17, wherein the cationic catalyst provides a gel time of about 5 seconds to about 180 seconds.

### Claim 19 (depends on 17)

The method of claim 17, wherein the sprayed foam composition hardens in about 30 seconds to about 5 minutes.

### Claim 20 (depends on 17)

The method of claim 17, wherein the superacid has a pKa of about −8 to about −25.