US3843594A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermoset molding powders employing glycidyl methacrylate-functional prepolymers and diphenol-expoxy resin adducts and molding thereof
Assignee: Ford Motor Co
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Filing: 1974-02-15
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Granted: 1974-10-22
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Expires: 1994-02-15
Abstract
Abstract Novel thermosetting resin powders which can be molded to form products characterized, in flexural measurement, by high elongation-to-break, high strength and modulus and by a high glass transition temperature are prepared from a mixture of an epoxy-functional prepolymer consisting essentially of acrylic monomers and a hydroxy-terminated crosslinking agent prepared by reacting a diphenol with an epoxy resin to form an adduct having molecular weight in the range of about 700 to about 4,000.
Inventors
- 👤 S Labana
- 👤 A Theodore
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 23:48
CPC Classifications
C; C08; C08G; C08G59/00; C08G59/18; C08G59/182; C08G59/20; C08G59/32; C08G59/3209
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
15 words
A DIPLHENOL HAVING MOLECULAR WEIGHT IN THE RANGE OF ABOUT 110 TO LABOUT 500 AND
Claim 2
Dependent Claim
15 words
A DIPLHENOL HAVING MOLECULAR WEIGHT IN THE RANGE OF ABOUT 110 TO LABOUT 500 AND
Claim 3
Dependent Claim
18 words
A MOLDING POWDER WHICH COMPRISES A PARTICULATE , INTIMATE MIXTURE OF: A. AN EPOXY-FUNCTIONAL COPOLYMER OF ACRYLIC MONOMERS
Claim 4
Dependent Claim
18 words
A MOLDING POWDER WHICH COMPRISES A PARTICULATE , INTIMATE MIXTURE OF: A. AN EPOXY-FUNCTIONAL COPOLYMER OF ACRYLIC MONOMERS
Claim 5
Dependent Claim
28 words
CONSISTING OF ABOUT 15 TO ABOUT 40 WEIGHT PERCENT GLYCIDYL METHACRYLATE, ABOUT 10 TO ABOUT 30 WEIGHT PERCENT METHACRYLONITRILE, AND A REMAINDER CONSISTING ESSENTIALLY OF METHYL METHACRYLATE, AND
Claim 6
Dependent Claim
28 words
CONSISTING OF ABOUT 15 TO ABOUT 40 WEIGHT PERCENT GLYCIDYL METHACRYLATE, ABOUT 10 TO ABOUT 30 WEIGHT PERCENT METHACRYLONITRILE, AND A REMAINDER CONSISTING ESSENTIALLY OF METHYL METHACRYLATE, AND
Claim 7
Dependent Claim
76 words
HAVING AN AVERAGE MOLECULAR WEIGHT IN THE RANGE OF ABOUT 1,500 TO ABOUT 16,000, WITH LESS THAN 5 PERCENT OF THE MOLECULAR OF SAID COPOLYMER HAVING A MOLECULAR WEIGHT BELOW 1,000, A SOFTENING POINT ABOVE 25*C, AND EPOXIDE GROUPS IN ITS MELECULAR STRUCTURE RESULTANT OF INCLUSION OF SAID GLYCIDYL MELTHACRYLATE AS A CONSTITUENT MONOMER THEREOF, AND B. A HYDROXY-TERMINATED ADDUCT OR ADDUCT-BLEND FORMED BY HEATING TOGETHER A MIXTURE WHICH ON A CATALYST-FREE BASIS CONSISTING ESSENTIALLY OF
Claim 8
Dependent Claim
76 words
HAVING AN AVERAGE MOLECULAR WEIGHT IN THE RANGE OF ABOUT 1,500 TO ABOUT 16,000, WITH LESS THAN 5 PERCENT OF THE MOLECULAR OF SAID COPOLYMER HAVING A MOLECULAR WEIGHT BELOW 1,000, A SOFTENING POINT ABOVE 25*C, AND EPOXIDE GROUPS IN ITS MELECULAR STRUCTURE RESULTANT OF INCLUSION OF SAID GLYCIDYL MELTHACRYLATE AS A CONSTITUENT MONOMER THEREOF, AND B. A HYDROXY-TERMINATED ADDUCT OR ADDUCT-BLEND FORMED BY HEATING TOGETHER A MIXTURE WHICH ON A CATALYST-FREE BASIS CONSISTING ESSENTIALLY OF
Claim 9
Dependent Claim
101 words
AN EPOXY RESIN THAT CONVERTS FROM A SOLID TO A LIQUID AT A TEMPERATURE BELOW ABOUT 140*C, HAS AT LEAST TWO EPOXY GROUPS PER MOLECULE, AND HAS MOLECULAR WEIGHT IN THE RANGE OF ABOUT 200 TO ABOUT, 3,000 AT A TEMPERATURE AT LEAST 20*C ABOVE THE MELTING POINT OF SAID EPOXY RESIN UNTIL AT LEAST ABOUT 10 PERCENT OF SAID EPOXY RESIN IS REACTED WITH SAID DIPHENOL, THE COMPONENTS OF SAID MOLDING POWDER BEING EMPLOYED IN SUCH RELATIVE PROPORTIONS THAT THE RATIO OF FREE PHENOLIC HYDROXYL GROUPS TO FREE EPOXY GROUPS IN SAID MOLDING POWDER IS ABOUT 0.8 TO ABOUT 1.2.
Claim 10
Dependent Claim
101 words
AN EPOXY RESIN THAT CONVERTS FROM A SOLID TO A LIQUID AT A TEMPERATURE BELOW ABOUT 140*C, HAS AT LEAST TWO EPOXY GROUPS PER MOLECULE, AND HAS MOLECULAR WEIGHT IN THE RANGE OF ABOUT 200 TO ABOUT, 3,000 AT A TEMPERATURE AT LEAST 20*C ABOVE THE MELTING POINT OF SAID EPOXY RESIN UNTIL AT LEAST ABOUT 10 PERCENT OF SAID EPOXY RESIN IS REACTED WITH SAID DIPHENOL, THE COMPONENTS OF SAID MOLDING POWDER BEING EMPLOYED IN SUCH RELATIVE PROPORTIONS THAT THE RATIO OF FREE PHENOLIC HYDROXYL GROUPS TO FREE EPOXY GROUPS IN SAID MOLDING POWDER IS ABOUT 0.8 TO ABOUT 1.2.
Claim 11
Dependent Claim
77 words
having an average molecular weight in the range of about 1, 500 to about 16,000, with less than 5 percent of the molecules of said copolymer having a molecular weight below 1,000, a softening point above 25*C, and epoxide groups in its molecular structure resultant of inclusion of said glycidyl methacrylate as a constituent monomer thereof, and B. a hydroxy-terminated adduct or adduct-blend formed by heating together a mixture which on a catalyst-free basis consists essentially of
Claim 12
Dependent Claim
77 words
having an average molecular weight in the range of about 1, 500 to about 16,000, with less than 5 percent of the molecules of said copolymer having a molecular weight below 1,000, a softening point above 25*C, and epoxide groups in its molecular structure resultant of inclusion of said glycidyl methacrylate as a constituent monomer thereof, and B. a hydroxy-terminated adduct or adduct-blend formed by heating together a mixture which on a catalyst-free basis consists essentially of
Claim 13
Dependent Claim
101 words
an epoxy resin that converts from a solid to a liquid at a temperature below about 140*C, has at least two epoxy groups per molecule, and has molecular weight in the range of about 200 to about 3,000 at a temperataure at least 20*C above the melting point of said epoxy resin until at least about 10 percent of said epoxy resin is reacted with said diphenol, the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 14
Dependent Claim
101 words
an epoxy resin that converts from a solid to a liquid at a temperature below about 140*C, has at least two epoxy groups per molecule, and has molecular weight in the range of about 200 to about 3,000 at a temperataure at least 20*C above the melting point of said epoxy resin until at least about 10 percent of said epoxy resin is reacted with said diphenol, the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 15
Dependent Claim
25 words
A molding powder in accordance with claim 1 wherein said copolymer has an average molecular weight in the range of about 2,000 to about 10,000.
Claim 16
Dependent Claim
102 words
an epoxy resin that converts from a solid to a liquid at a temperature below about 140*C, has at least two epoxy groups per molecule, and has a molecular weight in the range of about 200 to about 3,000 at a temperature at least 20*C above the melting point of said epoxy resin until at least above 10 percent of said epoxy resin is reacted with said diphenol the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 17
Dependent Claim
102 words
an epoxy resin that converts from a solid to a liquid at a temperature below about 140*C, has at least two epoxy groups per molecule, and has a molecular weight in the range of about 200 to about 3,000 at a temperature at least 20*C above the melting point of said epoxy resin until at least above 10 percent of said epoxy resin is reacted with said diphenol the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 18
Dependent Claim
102 words
a diepoxide that converts from a solid to a liquid at a temperature below about 140*C and has a molecular weight in the range of about 200 to about 3,000 at a temperature in the range of about 110*C to about 180*C and at least 20*C above the melting point of said epoxy resin until at least about 25 percent of said diepoxide is reacted with said diphenol, the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 19
Dependent Claim
102 words
a diepoxide that converts from a solid to a liquid at a temperature below about 140*C and has a molecular weight in the range of about 200 to about 3,000 at a temperature in the range of about 110*C to about 180*C and at least 20*C above the melting point of said epoxy resin until at least about 25 percent of said diepoxide is reacted with said diphenol, the components of said molding powder being employed in such relative proportions that the ratio of free phenolic hydroxyl groups to free epoxy groups in said molding powder is about 0.8 to about 1.2.
Claim 20
Dependent Claim
75 words
having average molecular weight in the range of about 2,000 to about 10,000, with less than 5 percent of the molecules of said copolymer having a molecular weight below 1,000, a softening point above 25*C, and epoxide groups in its molecular structure resultant of inclusion of said glycidyl methacrylate as a constituent monomer thereof, and B. a hydroxy-terminated adduct or adduct-blend formed by heating together a mixture which on a catalyst-free basis consists essentially of
Claim 21
Dependent Claim
75 words
having average molecular weight in the range of about 2,000 to about 10,000, with less than 5 percent of the molecules of said copolymer having a molecular weight below 1,000, a softening point above 25*C, and epoxide groups in its molecular structure resultant of inclusion of said glycidyl methacrylate as a constituent monomer thereof, and B. a hydroxy-terminated adduct or adduct-blend formed by heating together a mixture which on a catalyst-free basis consists essentially of
Claim 22
Dependent Claim
25 words
A molding powder in accordance with claim 1 wherein said copolymer has an average molecular weight in the range of about 3,500 to about 8,000.
Claim 23
Dependent Claim
54 words
A molding powder in accordance with claim 1 wherein at least a minor portion but not more than one-third of said methyl methacrylate is replaced with a monomer selected from the group consisting of styrene, alpha-methyl styrene, vinyl acetate and an ester of acrylic or methacrylic acid and a monohydric alcohol other than methanol.
Claim 24
Dependent Claim
22 words
A molding powder in accordance with claim 1 wherein said epoxy resin is a diepoxide consisting essentially of carbon, hydrogen and oxygen.
Claim 25
Dependent Claim
32 words
A molding powder in accordance with claim 1 wherein said temperature is maintained between about 110*C and about 180*C until at least 25 percent of said diepoxide is reacted with said diphenol.
Claim 26
Dependent Claim
43 words
A molding powder in accordance with claim 1 wherein said epoxy-functional copolymer of acrylic monomers consists essentially of about 20 to about 35 weight percent glycidyl methacrylate, about 10 to about 25 weight percent methacrylonitrile and a remainder consisting essentially of methyl methacrylate.
Claim 27
Dependent Claim
25 words
A molding powder in accordance with claim 1 wherein particulate reinfOrcing filler is intimately dispersed with said copolymer and said hydroxy-terminated adduct or adduct blend.
Claim 28
Dependent Claim
17 words
A molding powder which comprises a particulate, intimate mixture of: A. an epoxy-functional copolymer of acrylic monomers
Claim 29
Dependent Claim
17 words
A molding powder which comprises a particulate, intimate mixture of: A. an epoxy-functional copolymer of acrylic monomers
Claim 30
Dependent Claim
23 words
A molding powder in accordance with claim 9 wherein said copolymer has an average molecular weight in the range of 3,500 to 8,000.
Claim 31
Dependent Claim
55 words
A molding powder in accordance with claim 9 wherein at least a minor portion but not more than one-third of said methyl methacrylate is replaced with a monomer selected from the group consisting essentially of styrene, alpha-methyl styrene, vinyl acetate and an ester of acrylic or methacrylic acid and a monohydric alcohol other than methanol.
Claim 32
Dependent Claim
35 words
A molding powder in accordance with claim 9 wherein said temperature in the range of about 110*C to about 180*C is maintained until 50 to 100 percent of said diepoxide is reacted with said diphenol.
Claim 33
Dependent Claim
25 words
A molding powder in accordance with claim 9 wherein particulate reinforcing filler is intimately dispersed with said copolymer and said hydroxy-terminated adduct or adduct blend.
Claim 34
Dependent Claim
49 words
A molded article having a glass transition temperature above 90*C, flexural strength above about 15,000 psi, flexural modulus above about 1.2 X 106 psi and elongation-to-break above 1 percent and formed from a molding powder which comprises a particulate, intimate mixture of: A. an epoxy-functional copolymer of acrylic monomers
Claim 35
Dependent Claim
49 words
A molded article having a glass transition temperature above 90*C, flexural strength above about 15,000 psi, flexural modulus above about 1.2 X 106 psi and elongation-to-break above 1 percent and formed from a molding powder which comprises a particulate, intimate mixture of: A. an epoxy-functional copolymer of acrylic monomers
Claim 36
Dependent Claim
25 words
A molded article in accordance with claim 14 wherein said copolymer has an average molecular weight in the range of about 2,000 to about 10,000.
Claim 37
Dependent Claim
25 words
A molded article in accordance with claim 14 wherein said copolymer has an average molecular weight in the range of about 3,500 to about 8,000.
Claim 38
Dependent Claim
54 words
A molded article in accordance with claim 14 wherein at least a minor portion but not more than one-third of said methyl methacrylate is replaced with a monomer selected from the group consisting of styrene, alpha-methyl styrene, vinyl acetate and an ester of acrylic or methacrylic acid and a monohydric alcohol other than methanol.
Claim 39
Dependent Claim
22 words
A molded article in accordance with claim 14 wherein said epoxy resin is a diepoxide consisting essentially of carbon, hydrogen and oxygen.
Claim 40
Dependent Claim
32 words
A molded article in accordance with claim 14 wherein said temperature is maintained between about 110*C and about 180*C until at least 25 percent of said diepoxide is reacted with said diphenol.
Claim 41
Dependent Claim
43 words
A molded article in accordance with claim 14 wherein said epoxy-functional copolymer of acrylic monomers consists essentially of about 20 to about 35 weight percent glycidyl methacrylate, about 10 to about 25 weight percent methacrylonitrile and a remainder consisting essentially of methyl methacrylate.
Claim 42
Dependent Claim
29 words
A molded article in accordance with claim 14 wherein said article contains particulate reinforcing filler which is intimately dispersed with said copolymer and said hydroxy-terminated adduct or adduct blend.
Claim 43
Dependent Claim
28 words
A molded article in accordance with claim 14 wherein said article contains glass fibers which are intimately dispersed with said copolymer and said hydroxy-terminated adduct or adduct blend.
References Cited (Backward Citations)
No citation records indexed.
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-10-21 | 1978-04-22 | 1978-10-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-10-21 | 1982-04-22 | 1982-10-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-10-21 | 1986-04-22 | 1986-10-22 | $7700.00 | Window Closed / Lapsed |