Catalyst and solvent free epoxy materials

Claim 1

A process for preparing an amine-hardened epoxy material based on epichlorohydrin/bisphenol A comprising the steps of: mixing together by weight approximately 10% of an ester, approximately 79% of a first resin, approximately 6% of a plasticizer, and approximately 5% of a second resin to form a resin material, mixing said resin material with a filler selected from the group of cured rubber alone and in combination with silica flour and mixtures thereof in predetermined proportions by weight, respectively, to form a resin material mixture, if cured rubber is used as the filler the proportion is approximately 60%:40% by weight and if silica is used as the filler the proportion is approximately 27%:72%, respectively, by weight with 1% by weight of a coloring agent added, said silica flour comprising equal parts by weight of 140 mesh, 200 mesh and 325 mesh material mixing together by weight approximately 80% of a coreactant and approximately 20% of a phenol mixture to form a hardener material, and mixing said resin material mixture with said hardener material in a proportion of approximately 50%:50% by weight, said ester comprising a high boiling glycidyl ester of tertiary, saturated carbon-chain substituted, carboxylic acid, having an epoxide equivalent weight of 240 to 250, said first resin comprising an epochlorohydrin/bisphenol A liquid resin having an epoxide equivalent weight in the range 182 to 194, said plasticizer comprising a mixture of the monoglycidyl ether derivatives of the C 15 -alkyl phenols obtained from cashew nut liquid, having an epoxide equivalent weight of about 490, said second resin comprising an epichlorohydrin/bisphenol A liquid or solid resin having an epoxide equivalent weight of about 390 to 500, and said co-reactant comprising a very low viscosity, resinous amidoamine adduct having an amine value of about 450.