US4605570A
Expired / Lapsed
US
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Epoxy-phosphate ceramic compositions and methods of preparation
Assignee: Armstrong World Industries Inc
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Filing: 1985-08-09
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Granted: 1986-08-12
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Expires: 2005-08-09
Abstract
Abstract The present invention relates to novel compositions comprising epoxy resins and phosphate ceramic compositions derived from wollastonite, a metal oxide, and phosphoric acid. In addition to providing a curing component for the inorganic constituents of the composition, the phosphoric acid also serves as an acid catalyst for the epoxy resin. As a result, a system is obtained which can be highly filled with inert material, yet which provides superior resistance to traffic and other wear conditions. In one preferred embodiment, the above composition comprises latent curing additives which provide an accelerated cure to the system.
Inventors
- 👤 Richard E. Felter
- 👤 Dean A. Markley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 12:08
CPC Classifications
C; C08; C08K; C08K3/00; C08K3/32; C08K3/34
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
32 words
A curable material comprising an epoxy resin, and a composition which is suitable to provide a rigid, water-resistant phosphate ceramic material, said composition comprising phosphoric acid, a metal oxide and calcium silicate.
Claim 2
Dependent Claim
32 words
A curable material comprising an epoxy resin, and a composition which is suitable to provide a rigid, water-resistant phosphate ceramic material, said composition comprising phosphoric acid, a metal oxide and calcium silicate.
Claim 3
Dependent Claim
48 words
The curable material as set forth in claim 1 hereof wherein said material comprises for every 100 parts by weight of said resin and phosphate composition from about 5 to about 95 parts of said resin and from about 95 to about 5 parts of said phosphate composition.
Claim 4
Dependent Claim
33 words
The curable material as set forth in claim 2 hereof comprising from about 50 to about 95 parts of said resin and from about 50 to about 5 parts of said phosphate composition.
Claim 5
Dependent Claim
32 words
The curable material as set forth in claim 3 hereof wherein said composition comprises a metal oxide selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide.
Claim 6
Dependent Claim
22 words
The curable material as set forth in claim 3 hereof wherein said composition comprises an organic acid to facilitate the epoxy cure.
Claim 7
Dependent Claim
19 words
The curable material as set forth in claim 3 hereof wherein said composition comprises a masked Lewis Acid catalyst.
Claim 8
Dependent Claim
19 words
The curable material as set forth in claim 6 hereof wherein said masked catalyst is a boron trifluoride derivative.
Claim 9
Dependent Claim
33 words
The curable material as set forth in claim 7 hereof wherein said catalyst is boron trifluoride monoethylamine, said catalyst being present at a level of from about 0.5 to about 3% by weight.
Claim 10
Dependent Claim
18 words
The curable material as set forth in claim 3 hereof wherein said composition comprises a viscosity reducing agent.
Claim 11
Dependent Claim
20 words
The curable material as set forth in claim 9 hereof wherein said agent is furfuryl alcohol or a derivative thereof.
Claim 12
Dependent Claim
15 words
The curable material as set forth in claim 3 hereof wherein said composition comprises fillers.
Claim 13
Dependent Claim
18 words
The curable material as set forth in claim 3 hereof wherein said epoxy resins are liquid epoxy resins.
Claim 14
Dependent Claim
53 words
A process for preparing a curable composition, said process comprising the steps of selecting an epoxy resin and components suitable to provide a rigid, water-resistant phosphate ceramic material, said components comprising phosphoric acid, a metal oxide and calcium silicate; and intermixing said resin and said components to provide a substantially uniform curable composition.
Claim 15
Dependent Claim
53 words
A process for preparing a curable composition, said process comprising the steps of selecting an epoxy resin and components suitable to provide a rigid, water-resistant phosphate ceramic material, said components comprising phosphoric acid, a metal oxide and calcium silicate; and intermixing said resin and said components to provide a substantially uniform curable composition.
Claim 16
Dependent Claim
42 words
The process as set forth in claim 13 hereof comprising from about 5 to about 95 parts of said resin and from about 95 to about 5 parts of said components based on 100 total parts of said resin and said components.
Claim 17
Dependent Claim
31 words
The process as set forth in claim 14 hereof comprising from about 50 to about 95 parts of said resin and from about 50 to about 5 parts of said components.
Claim 18
Dependent Claim
31 words
The process as set forth in claim 15 hereof wherein said components comprise a metal oxide selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide.
Claim 19
Dependent Claim
22 words
The process as set forth in claim 15 hereof wherein said curable composition comprises an organic acid to facilitate the epoxy cure.
Claim 20
Dependent Claim
19 words
The process as set forth in claim 15 hereof wherein said curable composition comprises a masked Lewis Acid catalyst.
Claim 21
Dependent Claim
18 words
The process as set forth in claim 18 hereof wherein said masked catalyst is a boron trifluoride derivative.
Claim 22
Dependent Claim
32 words
The process as set forth in claim 19 hereof wherein said catalyst is boron trifluoride monoethylamine, said catalyst being present at a level of from about 0.5 to about 3% by weight.
Claim 23
Dependent Claim
18 words
The process as set forth in claim 15 hereof wherein said curable composition comprises a viscosity reducing agent.
Claim 24
Dependent Claim
19 words
The process as set forth in claim 21 hereof wherein said agent is furfuryl alcohol or a derivative thereof.
Claim 25
Dependent Claim
15 words
The composition as set forth in claim 15 hereof wherein said curable composition comprises fillers.
Claim 26
Dependent Claim
17 words
The process as set forth in claim 15 hereof wherein said epoxy resins are liquid epoxy resins.
Claim 27
Dependent Claim
81 words
A process for preparing a coated substrate, said process comprising the steps of selecting an epoxy resin and components suitable to provide a rigid, water-resistant phosphate ceramic material, said components comprising phosphoric acid, a metal oxide and calcium silicate; intermixing said resin and said components to provide a substantially uniform coating composition; disposing said composition on a substrate to be coated; permitting said composition to self-cure on said substrate; and optionally, applying a post-cure heat treatment to completely cure said composition.
Claim 28
Dependent Claim
81 words
A process for preparing a coated substrate, said process comprising the steps of selecting an epoxy resin and components suitable to provide a rigid, water-resistant phosphate ceramic material, said components comprising phosphoric acid, a metal oxide and calcium silicate; intermixing said resin and said components to provide a substantially uniform coating composition; disposing said composition on a substrate to be coated; permitting said composition to self-cure on said substrate; and optionally, applying a post-cure heat treatment to completely cure said composition.
Claim 29
Dependent Claim
42 words
The process as set forth in claim 25 hereof comprising from about 5 to about 95 parts of said resin and from about 95 to about 5 parts of said components based on 100 total parts of said resin and said components.
Claim 30
Dependent Claim
31 words
The process as set forth in claim 26 hereof comprising from about 50 to about 95 parts of said resin and from about 50 to about 5 parts of said components.
Claim 31
Dependent Claim
32 words
The process as set forth in claim 27 hereof wherein said coating composition comprises a metal oxide selected from the group consisting of aluminum oxide, magnesium oxide, calcium oxide and zinc oxide.
Claim 32
Dependent Claim
27 words
The process as set forth in claim 27 hereof wherein said coating composition comprises an organic acid to faciliate the epoxy cure. set forth in claim 27
Claim 33
Dependent Claim
19 words
The process as set forth in claim 27 hereof wherein said coating composition comprises a masked Lewis Acid catalyst.
Claim 34
Dependent Claim
18 words
The process as set forth in claim 30 hereof wherein said masked catalyst is a boron trifluoride derivative.
Claim 35
Dependent Claim
32 words
The process as set forth in claim 31 hereof wherein said catalyst is boron trifluoride monoethylamine, said catalyst being present at a level of from about 0.5 to about 3% by weight.
Claim 36
Dependent Claim
18 words
The process as set forth in claim 27 hereof wherein said coating composition comprises a viscosity reducing agent.
Claim 37
Dependent Claim
19 words
The process as set forth in claim 33 hereof wherein said agent is furfuryl alcohol or a derivative thereof.
Claim 38
Dependent Claim
14 words
The process as set forth in claim 27 hereof wherein coating composition comprises fillers.
Claim 39
Dependent Claim
17 words
The process as set forth in claim 27 hereof wherein said epoxy resins are liquid epoxy resins.
References Cited (Backward Citations)
US4548959A
Cited
US4375516A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1989-08-11 | 1990-02-10 | 1990-08-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-08-11 | 1994-02-10 | 1994-08-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-08-11 | 1998-02-10 | 1998-08-12 | $7700.00 | Window Closed / Lapsed |