Corrosion resistant structural foam
AssigneeHenkel Corporation
InventorsBradley L. Hilborn, Bruce Lee Harrison
Life of this patent
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Abstract
Titanates and zirconates bearing organic substituents can act as corrosion inhibitors when added to foamable compositions based on thermosettable synthetic resins such as epoxy resins. Combinations of organometallates containing certain specific types of substituents provide synergistic improvements in the properties of structural reinforcement foams obtained by heating and curing the foamable compositions.
Claims17
A method of producing a foam comprising heating and curing a foamable composition comprising
- a) one or more epoxy resins;
- b) one or more curatives;
- c) one or more blowing agents;
- and
- d) one or more organanometallate compounds selected from the group consisting of organic titanates and organic zirconates in an amount effective to reduce corrosion when said foam is in contact with a metal surface as compared to an analogous foamable composition not containing any of said organometallate compounds.
A method of inhibiting corrosion of a metal surface in contact with a foam obtained by heating a foamable composition comprised of one or more thermosettable synthetic resins, one or more blowing agents, and one or more curatives, said method comprising incorporating into the foamable composition one or more organometallate compounds selected from the group consisting of organic titanates and organic zirconates in an amount effective to reduce corrosion of said metal surface.
A method of producing a structural reinforcement foam comprising heating a foamable dough comprising:
- a) from about 35 weight % to about 85 weight % of one or more epoxy resins, wherein at least one of said epoxy resins is a glycidyl ether of a polyhydric phenol;
- b) from about 0.5 weight % to about 10 weight % of one or more chemical blowing agents;
- c) from about 0.1 weight % to about 15 weight % of one or more curatives, wherein at least one of said curatives is a nitrogen-containing compound;
- d) one or more fillers, wherein from about 5 weight % to about 50 weight % of the foamable dough is comprised of hollow glass microspheres;
- and
- e) from about 0.1 weight % to about 2 weight % total of at least two different organometallate compounds selected from the group consisting of:
- (i) amine adducts of tetrasubstituted titanates
- (ii) organic titanates containing at least one phosphato or pyrophosphato substituent bonded to titanium;
- (iii) organic titanates containing at least one neoalkoxy substituent bonded to titanium;
- (iv) phosphite adducts of tetrasubstituted titanates;
- (v) organic zirconates containing at least one neoalkoxy substituent bonded to zirconium;
- and
- (vi) organic zirconates containing at least one benzoate substituent or derivative thereof bonded to zirconium;
- at a temperature of at least about 150.degree. C. for a time effective to foam and cure said foamable dough.
A method of inhibiting corrosion of a surface of a ferrous article in contact with a structural reinforcement foam obtained by heating and curing a foamable dough comprised of:
- a) from about 35 weight % to about 85 weight % of one or more epoxy resins, wherein at least one of said epoxy resins is a glycidyl ether of a polyhydric phenol;
- b) from about 0.5 weight % to about 10 weight % of one or more chemical blowing agents;
- c) from about 0.1 weight % to about 15 weight % of one or more curatives, wherein at least one of said curatives is a nitrogen-containing compound;
- d) one or more fillers, wherein from about 5 weight % to about 50 weight % of the foamable dough is comprised of hollow glass microspheres;
- said method comprising incorporating into the foamable dough a total of from about 0.1 weight % to about 2 weight % of at least two different organometallate compounds selected from the group consisting of:
- (i) amine adducts of tetrasubstituted titanates;
- (ii) organic titanates containing at least one phosphate or pyrophosphato substituent bonded to titanium;
- (iii) organic titanates containing at least one neoalkoxy substituent bonded to titanium;
- (iv) phosphite adducts of tetrasubstituted titanates;
- (v) organic zirconates containing at least one neoalkoxy substituent bonded to zirconium;
- and
- (vi) organic zirconates containing at least one benzoate substituent or derivative thereof bonded to zirconium.
Dependencies are inferred from the claim text.