Novolac-epoxy resin foam, foamable composition for making novolac-epoxy resin foam and method of making novolac-epoxy resin foam
AssigneeAmerican Foam Technologies, Inc.
InventorSamuel L. Rader
Life of this patent
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Abstract
Provided is a foamable composition adapted to form a cross-linked novolac-epoxy resin foam. The foamable composition is formulated from a composition comprising at least one novolac resin, at least one epoxy resin, and at least one blowing agent.
Claims28
A foamable composition adapted to form a cross-linkednovolac-epoxy resin foam, said foamable composition being formulated from a composition comprising:
- at least one novolac resin;
- at least one epoxy resin;
- and
- at least one blowing agent.
A foamable composition adapted to form a novolac-epoxy resin foam, said foamable composition being formulated from a composition comprising:
- at least one novolac resin having a viscosity of from about 100 to about 3000 centipoise at 25° C. and a number average molecular weight of about 100 to about 400;
- at least one epoxy resin having at least about 2 epoxide groups on average and a number average molecular weight of about 100 to about 1000;
- at least one amine catalyst;
- at least one hydrogen active silicone blowing agent, which is capable of reacting with an amine group present in said catalyst to form hydrogen gas;
- and
- at least one surfactant.
A closed-cell foam comprising:
- a cross-linked polymeric matrix formulated from at least one epoxy resin and at least one novolac resin, and at least 80% of the cells are closed.
A flame-retardant, foamable, novolac-epoxy resin composition, said foamable composition being formulated from a composition comprising:
- at least one novolac resin;
- at least one epoxy resin;
- at least one blowing agent;
- and
- at least one flame retardant.
Method of formulating a novolac-epoxy foam comprising:
- reacting at least one epoxy resin with at least one novolac resin in presence of a blowing agent to form a foam, wherein the ratio between said novolac resin and said epoxy resin is selected to provide a desired flexibility in said foam.
A rigid novolac-epoxy resin foam formulated from more epoxy resin than novolac resin.
A flexible novolac-epoxy foam formulated from more novolac resin than epoxy resin.
A sprayable, foamable novolac-epoxy resin composition comprising:
- at least one novolac resin;
- at least one epoxy resin;
- a gas-generating compound which generates a gas during a curing reaction of said novolac and epoxy resins, wherein said composition has a viscosity suitable for spraying.
A method of making a novolac-epoxy resin foam layer on a surface comprising the steps of:
- spraying a foam-forming, novolac-epoxy resin composition comprising at least one novolac resin;
- at least one epoxy resin;
- and a gas-generating compound which generates a gas during a curing reaction of said novolac and epoxy resins, whereby said novolac and epoxy resins are cured and blown forming a foam layer.
A sprayed novolac-epoxy resin foam comprising a cured novolac-epoxy resin composition which has been blown by a gas generated from a gas-generating compound which generates a gas during a curing reaction of said novolac-epoxy resin composition.
An article having a sprayed-on novolac-epoxy resin foam comprising a cured novolac-epoxy resin composition which has been blown by a gas generated from a gas-generating compound which generates a gas during a curing reaction of said novolac-epoxy resin composition.
Dependencies are inferred from the claim text.