Thermoplastic/thermoset hybrid foams and methods for making same
OwnerMario Alberto Perez, Robert Dennis Waid +3inventors
InventorsMario Alberto Perez, Robert Dennis Waid, John Ekrem Gozum, Cheryl Lee Senger Elsbernd, Mark David Gehlsen
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Abstract
Foams comprising blends of thermoplastic and thermoset materials wherein the thermoset forms a discontinuous phase in a continuous thermoplastic phase are described. Foams comprising an uncured thermoset and unreacted radiation-activatable curing agent in a thermoplastic matrix are also described. Additionally described are batch and continuous methods for making the foams. Particular uses for the foams, such as flexographic mounting tapes, are also described.
Claims30
A material comprising a foam comprising a discontinuous phase of at least one cationically-curable thermoset material in a continuous phase of at least one thermoplastic material, and at least one unactivated radiation-activatable curing agent for the thermoset material.
A material comprising a foam comprising a discontinuous phase of at least one cationically-curable thermoset material in a continuous phase of at least one thermoplastic material, wherein the thermoset material is selectively cured after the foam is formed.
A foamable composition comprising a discontinuous phase of 10 to 25 weight % of at least one cationically-curable thermoset material in a continuous phase of at least one thermoplastic material, at least one blowing agent, and at least one unactivated radiation-activatable curing agent for the thermoset material.
A foamable composition comprising a discontinuous phase of at least one cationically-curable thermoset material in a continuous phase of at least one thermoplastic material, at least one blowing agent, and at least one light activatable curing agent for the thermoset material.
A method for making a hybrid thermoplastic/thermoset foam comprising:
- mixing at least one thermoplastic material with at least one cationically curable thermoset material and at least one blowing agent at a temperature and pressure sufficient to form and maintain a uniformly dispersed mixture such that the thermoset forms a discontinuous phase in a continuous thermoplastic phase,
- shaping the mixture, and
- exposing the mixture to a reduced pressure to cause nucleation and cell formation;
- wherein said at least one thermoset material remains substantially uncured.
Dependencies are inferred from the claim text.