Abstract: A composition which cures and foams at room temperature contains a acid-catalyzed, polymerizable resin, an acid and a filler which liberates gas in an endothermic reaction with the acid. The acid serves the dual purpose of catalyzing the polymerization reaction and generating the foaming gas.

Abstract: Polymeric foams with novel chemical compositions are prepared by the condensation of specially-synthesized precursors, which contain (in addition to carbon and hydrogen) one or more of the following elements: oxygen, fluorine, nitrogen (in structures with stable chemical bonds), silicon, boron, phosphorus (in high oxidation states), and certain metals (and/or their oxides and hydroxides). Upon mixing in the proper proportions and/or heating these precursors react rapidly to generate polymeric networks, consisting of heterocyclic crosslink centers, connected with heterochain segments; hydrogen is largely eliminated or replaced by fluorine. These structures possess inherent nonflammability and high thermoxidative stability. Foaming is effected by the gaseous by-products of the condensation reactions, as well as by the addition of foaming agents. The resulting foam products can be formulated to have a wide range of densities and flexibilities.

Abstract: A method for production of a crosslinked, foamed vinyl chloride containing polymer, by adding a blowing agent to a copolymer produced by a copolymerisation of a monomer composition comprising vinyl chloride and glycidyl containing monomer, and optionally other monomers, foaming the copolymer, where the decomposition products of the blowing agent or decomposition products of reaction produces from the blowing agent, are chemically reactive with epoxy groups of the copolymer or its reaction products, and crosslinking the copolymer when the blowing agent or the reaction product of the blowing agent is decomposed.

Abstract: Supercritical drying has distinct advantages in generating microcellular materials. The dimensional stability of the polymer is not affected on drying because the supercritical process does not go through the two phase path and therefore the effect of capillary forces is absent. This helps in maintaining the morphology of the final polymer structure and better control over cell size.Organic microcellular foams were prepared by polymerizing directly in a near-critical fluid and pursuing the supercritical drying in the same reactor. The critical variables are the choice of a diluent with a strong enough solvent power to stabilize the polymer matrix, but with a low enough critical temperature to permit critical point drying without damage to the polymer matrix.

Abstract: Improved hydrophilic materials, such as foams and films, are provided. These material find use in a wide variety of fluid absorbent products, especially those relating to the absorption of bodily fluids. The soft, absorbent, and resilient foams of this invention exhibit greater wet and dry mechanical strength when compared with those known in the art, as well as improved fluid wicking capacity and lower density. These improved properties are believed attributable to the incorporation into the foams of at least one polyfunctional aliphatic amine.The provided hydrophilic materials comprise the polymeric reaction product of a mixture which comprises at least one epoxy resin, at least one amine-terminated poly(alkylene oxide), and at least one polyfunctional aliphatic amine. Methods for preparing foams and other hydrophilic materials are also provided.

Abstract: A normally liquid epoxy resin obtainable by reaction of a bisphenol based oligocarbonate having terminal phenolic hydroxyl groups with an epihalohydrin, followed by dehydrohalogenation. The epoxy resin is capable of forming a tough cured product having improved flexural strength and flexural modulus. A process for the production of an epoxy resin foam in which a polyepoxy compound is crosslinked and simultaneously foamed by the aid of carbonate oligomers having terminal phenolic hydroxyl groups. The product is highly flexible against compression, bending and warp.

Abstract: An improved method of using polymer compositions to produce foamed plastics, wherein a major, auxiliary source of blowing agent for the foam is the decomposition of dialkyl dicarbonates. The dialkyl dicarbonates can be decomposed over temperatures ranging from about 10.degree. C. to about 45.degree. C. when used in combination with particular tertiary amine decomposition catalysts. Enhanced production of carbon dioxide is obtained by the addition of water.

Abstract: Supercritical drying has distinct advantages in generating microcellular materials. The dimensional stability of the polymer is not affected on drying because the supercritical process does not go through the two phase path and therefore the effect of capillary forces is absent. This helps in maintaining the morphology of the final polymer structure and better control over cell size.Organic microcellular foams were prepared by polymerizing directly in a near-critical fluid and pursuing the supercritical drying in the same reactor. The critical variables are the choice of a diluent with a strong enough solvent power to stabilize the polymer matrix, but with a low enough critical temperature to permit critical point drying without damage to the polymer matrix.

Abstract: Disclosed is a process of producing microcellular from which comprises the steps of:(a) selecting a multifunctional epoxy oligomer resin;(b) mixing said epoxy resin with a non-reactive diluent to form a resin-diluent mixture;(c) forming a diluent containing cross-linked epoxy gel from said resin-diluent mixture;(d) replacing said diluent with a solvent therefore;(e) replacing said solvent with liquid carbon dioxide; and(f) vaporizing off said liquid carbon dioxide under supercritical conditions, whereby a foam having a density in the range of 35-150 mg/cc and cell diameters less than about 1 .mu.m is produced.Also disclosed are the foams produced by the process.

Abstract: Disclosed is an intumescent curable composition which contains as a resinous binder a flexible polyepoxide resin. The polyepoxide is cured with an appropriate curing agent adapted for the particular resin. An additive component is present which contains a mixture of materials which provide a source of(i) zinc,(ii) boron,(iii) phosphorus, and(iv) an expansion gas upon thermal decomposition. The composition is capable of forming a carbonaceous char upon exposure to heat or flame, with the proviso that the cured, unburned composition has sufficient flexibility that is passes at least 10 continuous cycles of a cold cycle test without cracking. The cold cycle test involves the following steps: the composition is applied at a thickness of 0.5 inch (12.7 millimeters) to a 10 inch (0.0254 meter) section of a 4W13 I-beam having two thermocouples attached to the surface, allowed to cure at ambient temperature for 16 hours, force cured for 5 days at about 60.degree. C. and subjected to the cold cycle test.

Abstract: A method of using blowing agent compositions to produce foamed plastics such as polyurethanes, polyesters and the like, wherein a major auxiliary source of blowing agent for the foam is the decomposition of dialkyl dicarbonates. The dialkyl dicarbonates can be decomposed over temperatures ranging from about 10.degree. C. to about 45.degree. C. when used in combination with particular tertiary amine decomposition catalysts.

Abstract: Disclosed is an intumescent curable composition which contains as a resinous binder a flexible polyepoxide resin. The polyepoxide is cured with an appropriate curing agent adapted for the particular resin. An additive component is present which contains a mixture of materials which provide a source of(i) zinc,(ii) boron,(iii) phosphorus, and(iv) an expansion gas upon thermal decomposition. The composition is capable of forming a carbonaceous char upon exposure to heat or flame, with the proviso that the cured, unburned composition has sufficient flexibility that it passes at least 10 continuous cycles of a cold cycle test without cracking. The cold cycle test involves the following steps; the composition is applied at a thickness of 0.5 inch (12.7 millimeters) to a 10 inch (0.254 meter) section of a 4W13 I-beam having two thermocouples attached to the surface, allowed to cure at ambient temperature for 16 hours, force cured for 5 days at about 60.degree. C. an subjected to the cold cycle test.

Abstract: Disclosed is a process of producing microcellular foam which comprises the steps of:(a) selecting a multifunctional epoxy oligomer resin;(b) mixing said epoxy resin with a non-reactive diluent to form a resin-diluent mixture;(c) forming a diluent containing cross-linked epoxy gel from said resin-diluent mixture;(d) replacing said diluent with a solvent therefore;(e) replacing said solvent with liquid carbon dioxide; and(f) vaporizing off said liquid carbon dioxide under supercritical conditions, whereby a foam having a density in the range of 35-150 mg/cc and cell diameters less than about 1 .mu.m is produced.Also disclosed are the foams produced by the process.

Abstract: An improved lightweight, ablative coating that may be spray applied and cured without the development of appreciable shrinkage cracks. The ablative mixture consists essentially of phenolic microballoons, hollow glass spheres, glass fibers, ground cork, a flexibilized resin binder, and an activated colloidal clay.

Abstract: A fire-retardant coating material includes a fluid intumescent material and conductive particles of various sizes dispersed or suspended therein for particular applications. The fluid intumescent material includes a foaming agent, a blowing agent gas source, a carbonific or charring agent, a film-forming binder, a solvent and, in some cases, a pigment or filler. The conductive particles are formed of a substrate and a conductive coating.

Abstract: An expandable polymer concrete or mortar composition, and process for producing it, which allows the use of low temperature cure resins by incorporating a substituted mineral which is able to expand in the polymer concrete mix so that the dilation of the mineral will counteract the shrinking effect of the curing resin. The substituted mineral may be selected from the montmorillonite group and is produced by substituting its water of hydration with a higher volatility composition such as ammonia.

Abstract: A two-part system for reinforcing a hollow structural member and its method of use are provided. Part A of the two-part system is formed by adding a filler and unexpanded, thermally-expandable microspheres to a liquid thermosetting resin, such as an epoxy resin, in a quantity sufficient to produce a dough-like mass which can be readily kneaded. Part B is formed by adding a filler and a colorant, such as carbon black, to a liquid curing agent, again forming a dough-like mass. The curing agent is compatible with the thermosetting resin to promote cross-linking of the thermosetting resin upon contact with the curing agent.A hollow structural member is cleared of debris of the like and may be preheated to enhance the rate at which the thermosetting resin cross-links. The two parts are blended together until a reactive third dough of substantially uniform mixture is formed.

Abstract: A fire-retardant coating material includes a fluid intumescent material and refractory fibers of various sizes dispersed or suspended therein for particular applications. The fluid intumescent material includes a foaming agent, a blowing agent gas source, a carbonific or charring agent, a film-forming binder, a solvent and, in some cases, a pigment or filler. The refractory fibers consist of aluminum oxide, silicon dioxide, and one or more other metal oxides.

Abstract: Thermosetting fluoropolymer foams are made by mixing fluid form thermosetting fluoropolymer components having a substantial fluorine content, placing the mixture in a pressure tight chamber, filling the chamber with a gas, at relatively low pressure, that is unreactive with the fluoropolymer components, allowing the mixture to gel, removing the gelled fluoropolymer from the chamber and thereafter heating the fluoropolymer at a relatively low temperature to simultaneously cure and foam the fluoropolymer. The resulting fluoropolymer product is closed celled with the cells storing the gas employed for foaming. The fluoropolymer resins employed may be any thermosetting fluoropolymer including fluoroepoxies, fluoropolyurethanes and fluoroacrylates.

Abstract: A method of producing a porous material having open pores comprises the steps of preparing an emulsion slurry by vigorously agitating a mixture comprising (i) a glycidyl type epoxy resin, (ii) a first hardener selected from the group consisting of modified polyamine hardeners each being prepared by modifying a polyamine hardener with a modifier, amine hardeners and mixtures thereof, (iii) a second hardener selected from the group consisting of polyamide hardeners, (iv) a filler and (v) water, casting said slurry in a water-impermeable mold, and hardening said slurry while it contains water. A large size molded product having a complicated contour and having open pores whose average pore diameter ranges from 0.2 to 10 microns can be produced with high dimensional accuracy.

Abstract: Process for the preparation of polycarbonates by reacting at least one epoxy compound with carbon dioxide at 40.degree. to 200.degree. C. and 2 to 40 bar in the presence of a catalytic amount of a double metal cyanide complex and(a) one or more salts composed of at least bivalent metal ions and metal-free anions having a solubility in water of at least 1 g/100 ml at 25.degree. C., and/or(b) one or more no-metal containing acids of which a 0.1 N solution in water at 25.degree. C. has a pH not exceeding 3.

Abstract: A method of producing a porous material having open pores comprises the steps of preparing an emulsion slurry by vigorously agitating a mixture comprising a main ingredient, a polyamide hardener, a filler and water, casting said emulsion slurry in a water-impermeable mold, hardening said slurry while it contains the water. The main ingredient is a bisphenol-type epoxy resin added with one or more reactive diluents each having one or more epoxy rings per molecule and added in an amount of 18 to 50 wt %, based on 100 wt % of said bisphenol-type epoxy resin. A large size molded product having a high wet bending strength and a complicated contour can be produced.

Abstract: Epihalohydrin compounds will react chemically with alkali oxidated silicon compounds in the presence of a peroxide to produce a self-standing cellular or solid epoxy silicate product which may be utilized for thermal and sound insulation, as a cavity filler and as a coating agent.

Abstract: The first invention relates to a novel manufacturing process of mold containing continuous holes and used for filter materials, gas dispersive materials, and mold materials. By this invention, the epoxy resin mixture including an epoxy compound having one or more epoxy groups in each molecule, a hardener which reacts with and hardens the epoxy compound, emulsifiers, water or water-surface active agent, and fillers respectively is used as the molding material. As the emulsifier, at least two kinds of three different kinds of nonionic emulsifiers of 4-8, 8-17, and 11-15.6 HLB respectively are used together. This is the primary feature of the invention and no molding materials including such emulsifiers are known so far. The molding material is cured to a desired shape to prepare a mold containing continuous holes and for molding, conventional methods such as hardening after casting, for example, are adopted.The second invention relates to a novel casting mold suitable be for slip discharge casting.

Abstract: A trowelable ablative coating composition is disclosed. The composition comprises an epoxy resin, an amide curing agent, glass microspheres and ground cork. A method for protecting a substrate is also disclosed. The method comprises applying the trowelable ablative coating discussed above to a substrate and curing the coating composition.

Abstract: A foam-fiber composite, useful as an absorbent for sanitary napkins is disclosed. It is a resilient, absorbent structure made from large particles of an amino-ether hydrophilic foam (and optionally a superabsorbent and wood pulp), which by use of a carding machine is uniformly distributed in, and heat bonded to a fibrous matrix, which matrix is preferably made from two different kinds of fibers, one of which is low melting at the bonding temperatures used in the oven, e.g., polyethylene and the other high melting, e.g., polyester.

Abstract: Azo compounds such as 2-ethyl-6-methyl-phenylazo-t-butane which contain an aromatic moiety bridged to one or more alkyl moieties by azo groups are useful blowing agents in a novel process for foaming compositions of polymers such as polycarbonates.

Abstract: Epihalohydrin compounds will react chemically with alkali oxidated silicon compounds in the presence of a peroxide to produce a self-standing cellular or solid epoxy silicate product which may be utilized for thermal and sound insulation, as a cavity filler and as a coating agent.

Abstract: Syntactic foam with improved processing characteristics is disclosed wherein a blend of coupling agents and alkylphenol alkoxylates are used to improve processibility and reduce cure time of the syntactic foam system.

Abstract: Surface coating methods and compositions are disclosed which eliminate many of the disadvantages associated with known coating processes from pollution, equipment, materials, energy, labor and cost standpoints. According to techniques described, thermosetting liquid compositions containing film-forming solids are formulated, then conveyed in the foam state toward a surface, and upon foam disintegration, form a film of solids on the surface. The foamable thermosetting resin compositions contain a curable resin having a free hydroxyl or carboxyl group, a curing agent consisting of a lower (C.sub.1 -C.sub.4) alkoxylated amine for reaction with the resin hydroxyl or carboxyl group and a liquid blowing agent consisting of a C.sub.1 -C.sub.4 alkanol which is also a by-product of the thermosetting reaction.

Abstract: Syntactic foam with improved processing characteristics is disclosed wherein a blend of aminosilane and aminated alkylphenol alkoxylates are used to improve processibility and reduce cure time of the syntactic foam system.

Abstract: A pressure-resistant buoyancy material, comprising pressure-resistant hollow elements, a syntactic foam, and an empty space intervening between the pressure-resistant hollow elements and the syntactic foam, communicating with the outside of the buoyancy material. The pressure-resistant hollow elements are retained in a freely movable state in the empty space.

Abstract: Fiber-reinforced syntactic foam composites having a low specific gravity and a coefficient of thermal expansion of about 9.0.times.10.sup.-6 in/in/.degree.F. (16.2.times.10.sup.-6 cm/cm/.degree.C.) or less are prepared from a mixture of: a heat curable thermosetting resin comprising an uncured polyglycidyl aromatic amine, a polycarboxylic acid anhydride curing agent, and a chosen curing accelerator; hollow microspheres having a diameter of about 5 to 200 micrometers; and fibers having a length less than or equal to 250 micrometers. These composites are useful for forming lightweight structures for space applications.

Abstract: An absorbent, flexible, resilient, cellular polymer is provided which comprises the reaction product of at least one epoxy resin and amine terminated poly(alkylene oxide).

Abstract: An epoxy foam product is presented which is produced by frothing in an intensive mixer an epoxy functional reactant stream and a curing agent stream in the presence of a surfactant and gaseous frothing agent. The epoxy foam product is characterized as a strong, rigid low-density foam having a fine, uniform cell size.

Abstract: An absorbent cellular polymeric material is provided which exhibits enhanced water retentivity and may also exhibit enhanced compressibility. Such a material is provided by foaming the reaction product of a poly(aminoether) and an epoxy resin and quaternizing the resulting reaction product with, for example, an acid. The foam is particularly usable in products for absorbing body fluids.

Abstract: Disclosed is a method of producing a porous material having open pores, comprising the steps of preparing a slurry from a mixture comprising a bisphenol-type epoxy resin, a specific mixture amide compound as a hardener, a filler and water, casting the slurry in a water-impermeable mold, hardening the slurry while it contains the water and dehydrating the hardened body.

Abstract: Disclosure is made of a method of curing the polyepoxide resin binder component of polyepoxide based syntactic foams. Ketones are employed to reversably block primary amine groups on polyamine curing agents during the initial curing. As the cure progresses, the block is removed to complete the cure. The result is a moderation of peak exotherms generally associated with the cure, inhibiting degradation of the product foam.

Abstract: Disclosure is made of a method of curing the polyepoxide resin binder component of polyepoxide based syntactic foams of high density. Ketones are employed to reversably block primary amine groups on polyamine curing agents during the initial curing. As the cure progresses, the block is removed to complete the cure. The result is a moderation of peak exotherms generally associated with the cure, inhibiting degradation of the product foam.

Abstract: High temperature-resistant thermobarriers have a filler therein. The filler can be an opaque thermobarrier material, a fabric or cloth such that a laminated thermobarrier is formed, or preformed bubbles of glass, ceramic or plastic such that a syntactic foam thermobarrier is formed. The thermobarrier contains a boroxine compound therein as well as epoxy resins and various phosphorus compounds and/or aromatic alcohols. Generally, the syntactic foam thermobarriers give the best heat protection.

Abstract: For forming synthetic cellular materials, gas is generated by the reaction of an isocyanate and a hydroperioxide. The reactants produce a novel polymeric amine oxide foam. When the reactants are introduced to a base resin, cellular foam products (densities throughout the 50 to 2 lbs/ft.sup.3 range), extended resin products of even higher densities, and non-shrink resinous solids (with microcellular distribution of gas) can be obtained. When employed in resins curable with hydroperoxide, a small fraction of the hydroperoxide interacts with a promoter and serves to cure the resin while the larger fraction reacts earlier with the isocyanate to evolve gas before the gellation state of the base resin is reached. The foaming agent can be made commercially available as a premixture of isocyanate and appropriate surfactant for the hydroperoxide reaction. By mixing with low hydroxyl and carboxyl base resin, long pot life is obtainable.

Abstract: Epoxy compounds will react chemically with an amine to produce an epoxy prepolymer that will produce a self-standing cellular solid product upon heating.

Abstract: Linear polypropylene ether glycols of high molecular weight are made by reacting a linear polypropylene ether glycol of lower molecular weight first with an alkaline agent such as sodium hydroxide or other suitable base to form an alcoholate, and then coupling the alcoholate with a suitable difunctional coupling agent, such as the benzene-sulfonic acid diester of ethylene glycol or with some other suitable arylsulfonic acid diester of a C.sub.2 to C.sub.6 alcohol, thereby obtaining a 100 percent linear polypropylene ether glycol of a desirably higher molecular weight. Materials so produced find use in an aqueous medium as defoaming agents, thickeners, or emulsifiers, and use as protective colloids to improve the low-temperature stability of polyurethane and other latices.

Abstract: The invention provides inorganic fibers based on calcium sulfate dihydrate or calcium sulfate aluminate hydrate (or their dehydration products), wherein the ratio of average length to diameter of the fibers is more than 100:1 and the length of the fibers is at least 0.2 mm; preferably the ratio of average length to diameter is 300-800:1, and the length is 0.5-6 mm.

Abstract: Curable organic resin compositions, such as epoxy resins, are provided, based on the use of dialkyl hydroxy arylsulfonium salts in combination with certain orgainc oxidants such as iodosoaromatic esters, or the use of certain amines or transition metals in combination with organic peroxides. The curable compositions can provide flexible or rigid organic resin foam when used with a volatile organic solvent as a result of exothermic heat of cure.

Abstract: A fine granular silica is reacted chemically with a polyhydroxy alcohol by using an alkali catalyst and heating the mixture, thereby producing an organic hydroxy silicate compound which will react chemically with polycarboxylic acids, polycarboxylic anhydrides, vinyl monomers and polyisocyanates to produce resinous products.

Abstract: Phosphoric acid is reacted with mono- or polyfunctional epoxides containing methyol or alkoxymethyl groups, to provide resins which are curable simply by heating and contain as much as about 30 weight percent of phosphoric acid. Improved flame retardancy and water resistance are imparted to structural foams by impregnating them with these resins and curing in-situ.

Abstract: Mixtures of approximately equivalent amounts of (a) a glycidylated hydantoin and (b) a mononuclear phenol with 2 or 3 phenolic hydroxyl groups, at least one of the components (a) or (b) being trifunctional. They additionally contain a curing accelerator and on heating form mechanically good and flexible plastics which are stable to hydrolysis and can be used as building materials and foams, for the finishing and coating of textile material and for the preparation of water-permeable membranes.

Abstract: Low temperature curable organic resin compositions, for example, epoxy resins are provided, which can be either exothermically cured or cured in several minutes or less at relatively low temperatures. Certain diaryliodonium salts have been found to spontaneously release strong protonic acids when used in combination with a copper salt and a reducing agent.

Abstract: Diaryliodonium salts have been found to be effective thermal initiators for the polymerization of a variety of cationically polymerizable materials including epoxides, cyclic ethers, phenol formaldehyde resins, etc., when used in combination with various cocatalysts. Among the cocatalysts which have been found to be effective are, for example, copper chelates and mixtures of such copper chelates with various reducing agents such as ascorbic acid, tin.sup.+2 salts, etc.