Epoxy resin-based material, polycarbonate and catalyst, structural adhesive and its uses.

Abstract

A material adapted for curing and / or foaming comprising (i) one or more epoxy resins, (ii) at least one polycarbonate, and (iii) at least one catalyst, preferably transesterification catalyst for catalyzing reaction of the polycarbonate.

Description

1 / 36 Epoxy resin-based material, polycarbonate and catalyst, structural adhesive and its uses. PRIORITY CLAIM

[001] This application claims the benefit of the priority date of U.S. Provisional Application No. 63 / 453,311, filed March 20, 2023, the contents of which application are incorporated herein by reference in their entirety and for all purposes. FIELD OF THE INVENTION

[002] These teachings generally refer to adhesives, preferably structural adhesives, cured by transesterification reaction of polycarbonate. BACKGROUND OF THE INVENTION

[003] Structural adhesives have been widely used in various industries, including automotive, aerospace, wind energy, marine, and other industrial sectors. These adhesives offer alternatives to mechanical fastening, allowing for more flexible product design and the use of new materials for lightness and sustainability. One-component heat-activated adhesives contain latent curing agents and are heat-activated to initiate polymer advancement and subsequent polymerization or crosslinking. Common latent curing agents include dicyandiamide, urea, hydrazide, boron trifluoride amine complex, acid anhydrides, and other related compounds. Nitrogen-containing curing agents often generate ammonia or amine byproducts with Petition 870250080834, dated 09 / 09 / 2025, page 9 / 71 2 / 36 strong odor when the adhesive is being cured at high temperatures.

[004] The United Nations Economic Commission for Europe has been promoting its guidelines on indoor air quality standards for vehicles, with the aim of reducing interior odor. Other organizations are also interested in addressing the odor problem, particularly in Asia, where complaints about unpleasant odors or harmful emissions inside vehicles appear to be especially prevalent. As indoor air quality regulations for vehicles have been adopted by an increasing number of automotive manufacturers in Europe and Asia, there is a demand for materials that meet this requirement, with specific difficulties associated with reactive chemical systems such as adhesives and sealants.

[005] In the automotive industry, heat-activated foam sealants with reduced odor created during the reaction process have been developed by introducing foaming agents that create minimal ammonia byproducts. Similarly, structural adhesives with nitrogen-containing curing agents face the same challenge and may require replacements to meet automotive indoor air quality regulations. Thus, a different curing mechanism, without odor-generating byproducts, is desirable.

[006] It has been discovered that polycarbonate (PC) reacts with other materials, including epoxide and hydroxyl / phenol, via the transesterification mechanism. The present teachings, therefore, Petition 870250080834, dated 09 / 09 / 2025, page 10 / 71 3 / 36 seek to provide structural adhesives cured by presumed transesterification of polycarbonate in the absence of common heat-activated curing agents, including dicyandiamide, hydrazide, acid anhydride, and boron trifluoride amine complex. Furthermore, the PC transesterification curing mechanism may lead to properties unattainable by traditional curing reactions. SUMMARY OF THE INVENTION

[007] The teachings presented here are directed to a material comprising one or more epoxy resins, at least one polycarbonate, and at least one catalyst for the reaction between one or more epoxy resins and at least one polycarbonate. The material is an adhesive, preferably a one-component adhesive.

[008] The adhesive may contain polyol and / or phenols.

[009] The adhesive may contain a moisture eliminator, flexibilizers and / or core and shell polymer particles.

[010] The adhesive may exhibit an expansion (volume expansion) of 0% to 100% when cured at 140-200 °C for at least 30 minutes.

[011] The adhesive may be in the form of pumpable materials, tapes and / or injection moldable adhesives.

[012] It is possible to produce products with a wide range of desirable physical properties using polycarbonate transesterification curing.

[013] A high-modulus adhesive can be produced with an overlap shear strength greater than 30 MPa, when determined according to ASTM D5868, with a tensile speed. Petition 870250080834, dated 09 / 09 / 2025, page 11 / 71 4 / 36 50.4 mm / min and a glue line of 0.25 mm, and a tensile strength modulus greater than 1100 MPa, determined according to ASTM D638, with a tensile speed of 5 mm / min, when cured at 162.8 °C for 30 minutes.

[014] An elastomeric adhesive can be produced with a strain-to-failure rate greater than 50% (determined according to ASTM D638, with a speed of 5 mm / min on the crosshead) when cured at 162.8 °C for 30 minutes.

[015] A non-expanding adhesive can be produced with a T-Peel strength of at least 5 N / mm when determined with a tensile speed of 254 mm / min and a glue line of 0.25 mm, and an adhesive joint shear strength of at least 30 MPa when determined according to ASTM D5868 with a tensile speed of 50.4 mm / min and a glue line of 0.25 mm, when cured at 162.8 °C for 30 minutes.

[016] An expandable adhesive may be produced with a T-Peel strength of at least 4 N / mm when determined with a tensile speed of 254 mm / min and a glue line of 0.25 mm, and an adhesive joint shear strength of at least 14 MPa when determined in accordance with ASTM D5868 with a tensile speed of 50.4 mm / min and a glue line of 0.25 mm, when cured at 140-200 °C for at least 30 minutes.

[017] The adhesive may comprise polycarbonate in the range of about 5% to about 60% by weight relative to the total weight of the adhesive. Petition 870250080834, dated 09 / 09 / 2025, page 12 / 71 5 / 36

[018] The adhesive may comprise a catalyst in the range of about 0.01% to about 10% by weight relative to the total weight of the adhesive.

[019] The adhesive may comprise a moisture eliminator in the range of about 0% to about 40% by weight relative to the total weight of the adhesive.

[020] The adhesive may comprise a flexibilizer in the range of about 0% to about 40% by weight relative to the total weight of the adhesive.

[021] The adhesive may comprise a polymeric particle in the range of about 0% to about 30% by weight relative to the total weight of the adhesive.

[022] Polycarbonate resins can have a melting index ranging from about 2 to about 60 g / 10 min (300 °C, 1.2 kg load) and a molecular weight of about 5,000 to about 300,000 Daltons.

[023] Polyol can be aliphatic or aromatic polyester, polyether or polycarbonate.

[024] Phenols may include hydroquinone, resorcinol, catechol, various diphenols, including bisphenol A, bisphenol F, bisphenol E, bisphenol AP, bisphenol Z, bisphenol M, bisphenol P, bisphenol G, bisphenol BP, novolac phenols or any combination thereof.

[025] The catalyst for the reaction between one or more epoxy resins and at least one polycarbonate may include quaternary ammonium salts, quaternary phosphonium salts, Lewis acids, metal oxides, phosphines, strong solid acids, or any combination thereof. The moisture eliminator may include calcium oxide, Petition 870250080834, dated 09 / 09 / 2025, page 13 / 71 6 / 36 molecular sieves, vinyltrimethoxysilane, zeolite, oxazolidines, or any combination thereof.

[026] The flexibilizer (or flexibilizer in an adduct with epoxy) may be selected from phenol-terminated urethane, fatty acid dimer / epoxy adduct, polyetheramine (Jeffamine® products available from Huntsman, for example) / epoxy adduct, Epoxonic 328 (e.g., a dicarboxyl functional modifier) ​​(available from Epoxonic GmbH) or any combination thereof.

[027] The polymer particle may include polybutadiene core modifiers, styrene-butadiene rubber or a combination thereof. The polymer particle may include core / shell rubber particles with an average size of about 100-200 nm and may be free of agglomerated particles.

[028] The adhesive may include one or more particulate and / or fibrous components, which may be selected from silica, diatomaceous earth, glass, clay (for example, including nanoclay), glass spheres or microspheres, glass, carbon or ceramic fibers, nylon, aramid or polyamide fibers (for example, Kevlar), pyrophyllite, sauconite, saponite, nontronite, wollastonite, montmorillonite or any combination thereof.

[029] The adhesive may include a silica and / or calcium-based reinforcing component. The adhesive may include a silica-based rheology modifier comprising fumed silica. BRIEF DESCRIPTION OF THE DRAWINGS Petition 870250080834, dated 09 / 09 / 2025, page 14 / 71 7 / 36

[030] Figure 1 shows the characterization of polycarbonate transesterification by measuring the carbonate peak shift in an FTIR spectrum. DETAILED DESCRIPTION

[031] The explanations and illustrations presented here are intended to familiarize others skilled in the art with the present teachings, their principles, and their practical application. The specific embodiments of the present teachings, as presented, are not intended to be exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, together with the full scope of equivalents to which such claims are entitled. Disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible, as will be inferred from the following claims, which are also incorporated by reference into this written description.

[032] The percentages presented here refer to the percentage by weight, unless otherwise indicated.

[033] Unless otherwise indicated, the terms material and adhesive are used interchangeably. Thus, the material according to the invention is the adhesive according to the invention.

[034] Unless otherwise indicated, the terms epoxy resin and epoxy are used interchangeably.

[035] Unless otherwise indicated, the terms polycarbonate resin and polycarbonate are used interchangeably. Petition 870250080834, dated 09 / 09 / 2025, page 15 / 71 8 / 36

[036] Unless otherwise indicated, the molecular weight of polymeric species is preferably expressed as weight-average molecular weight (Mw), preferably determined by GPC.

[037] Unless otherwise indicated, all references to standards such as ASTM refer preferably to the version officially valid as of January 1, 2024.

[038] The melting index is preferably determined in accordance with ASTM D1238.

[039] T-peel resistance is preferably determined in accordance with ASTM D1876.

[040] The material of these teachings can be applied to various manufactured articles to add structural integrity to parts or components of the articles. Examples of such manufactured articles include, without limitation, household or industrial appliances, furniture, storage containers, buildings, structures, or the like. The material can be applied to parts of transportation vehicles, including boats, trucks, trains, airplanes, motor vehicles, or the like. The material can be used in a motor vehicle, such as in body or chassis components (for example, a chassis rail) of the motor vehicle.

[041] The present teachings are directed to the use of a transesterification reaction process to cure heat-activated compositions, including structural adhesives, in the absence of common nitrogen-containing curing agents such as dicyandiamide, hydrazide, and boron trifluoride amine complex. The exclusion of these agents Petition 870250080834, dated 09 / 09 / 2025, page 16 / 71 9 / 36 curing mentioned above allows the creation of structural adhesives with minimal odor before, during, and after curing. Examples of transesterification include the heat-activated reaction of polycarbonate with epoxide and / or hydroxyl / phenol in the presence of a catalyst, which may be a transesterification catalyst.

[042] Polycarbonates (e.g., polycarbonate resins) are a family of thermoplastic polymers characterized by high deformation to failure, combined with high strength, stiffness, and impact resistance. They have not traditionally been used in thermoset compositions. They contain carbonate groups in their chemical structure, which are known to react with epoxies, polyols, and phenols via transesterification reactions. Such transesterification can be catalyzed by suitable catalysts.

[043] The present teachings aim to demonstrate the use of these reactions as crosslinking mechanisms for epoxy-based heat-activated structural adhesives, which may be one-component epoxy-based heat-activated structural adhesives. The present teachings also aim to reveal the main factors that alter the adhesive properties (i.e., adhesive joint shear strength, pull-off strength, deformation strength to rupture, and percentage of foaming (if any)) with polycarbonates as curing agents.

[044] The material may include at least one type of polycarbonate resin with a melting index ranging from about 3 to about 35 g / 10 min (300 °C, 1.2 kg load) Petition 870250080834, dated 09 / 09 / 2025, page 17 / 71 10 / 36 and molecular weight of approximately 10,000 to approximately 100,000 Daltons. Non-limiting examples of polycarbonate resins that can be used are Lexan™ from Sabic, Hylex™ from Ravago Manufacturing Americas, CALIBRE™ from Trinseo, and TRIREX™ from Samyang Corporation. Polycarbonate can be included in a percentage of up to approximately 50% by weight relative to the total weight of the material.

[045] The polycarbonate resin content may be approximately at least about 2% by weight, more typically at least about 10% by weight, more typically at least about 20% by weight relative to the total weight of the material. It may be approximately about 50% or less by weight, more typically about 40% or less by weight, more typically about 30% or less by weight, and even more typically 25% or less by weight relative to the total weight of the material. To improve the adhesive composition, it is preferable that the polycarbonate resin be combined with other constituents of the composition as a solution. Although any solvent may be used to lower the incorporation temperature during mixing, it is particularly preferable to use a low molecular weight epoxy resin as the solvent so that the solvent can react in the adhesive composition after activation.

[046] The material described herein may include an epoxy resin, to react with polycarbonate by transesterification, forming the polymeric matrix of the adhesive. Liquid and solid epoxy resins may be used in combination to adjust the viscosity of the material. Exemplary epoxy resins may be Olin DER 331. Petition 870250080834, dated 09 / 09 / 2025, page 18 / 71 11 / 36 Corporation, Epotec™ YDF 172LV (DGEBF), available from Aditya Birla, and DER 664 from Olin Corporation. An epoxy resin can also be added to the material to increase its adhesive properties and flexibility. A silane-modified epoxy resin can aid in the adhesion of the material to non-ferrous metals, such as aluminum, and improve adhesion after environmental exposure (e.g., humidity, salt spray). The silane-modified epoxy resin can be a reaction product between at least one epoxy resin and a silane compound. An example of a suitable silane-modified epoxy resin is Epokukdo™ KSR-177 (bifunctional silane-modified epoxy resin), available from Kukdo Chemical. Suitable flexible epoxy resins include Epiol™ DE202 from Kukdo Finechem Co., Ltd. and DER 732 from Olin Corporation. Various mixtures of different epoxy resins can be used to obtain the desired properties for the intended purpose.

[047] The epoxy resin content may be approximately at least 20% by weight, more typically at least 30% by weight, more typically at least 40% by weight relative to the total weight of the material. It may be approximately 80% or less by weight, more typically about 70% or less by weight, more typically about 60% or less by weight and even more typically 50% or less by weight relative to the total weight of the material.

[048] The material may include a bifunctional or multifunctional polyol or phenol, which reacts with both epoxy resins and polycarbonate at high temperatures in the presence of the catalyst, which may be a transesterification reaction. Petition 870250080834, dated 09 / 09 / 2025, page 19 / 71 12 / 36

[049] Bifunctional phenols act as chain extenders for epoxy resins, resulting in a longer chain length and therefore a greater possibility of obtaining a composition capable of plastic deformation. They have been considered useful for improving adhesive peel resistance, since longer chain oligomers reduce crosslink density. Although polyols and phenols are not required to produce crosslinkable epoxy resins, they can be used as bridging molecules to link epoxy to polycarbonate due to reactivity with both materials, consequently resulting in higher crosslink density and glass transition temperature. Examples of polyols include aliphatic and aromatic polyester, polyether, and polycarbonate polyols, such as Bakelike™ Resonance aliphatic and aromatic polyols and UBE Industries Ltd. Eternacoll™ polyols.Examples of phenols include hydroquinone, resorcinol, catechol, bisphenol A, bisphenol F, bisphenol E, bisphenol AP, bisphenol Z, bisphenol M, bisphenol P, bisphenol G, bisphenol BP, and other related compounds. Polyphenols with functionality greater than two can also be used to improve crosslinking density for high-temperature performance. Exemplary polyphenols include tannin, ellagic acid, theaflavin 3-gallate, and phenolic resin.

[050] The content of polyols and phenols may be approximately at least 1% by weight, more typically at least 5% by weight, more typically at least 10% by weight relative to the total weight of the material. It may be approximately 30% or less by weight, more typically Petition 870250080834, dated 09 / 09 / 2025, p. 20 / 71 13 / 36 approximately 25% or less by weight, more typically approximately 20% or less by weight, and even more typically 15% or less by weight relative to the total weight of the material.

[051] A catalyst can be used to activate the transesterification of polycarbonate to assist in sufficient crosslinking. The reaction partners in the transesterification reaction with polycarbonate can be one or more epoxy resins and / or one or more polyols and / or phenols, optionally present. Quaternary ammonium salts, quaternary phosphonium salts, phosphines, Lewis acids, metal oxides and strong solid acids can be suitable catalysts for this reaction.

[052] Examples of quaternary ammonium and phosphonium salts may include tetraethylammonium bromide, tetrabutylammonium bromide, tetramethylammonium chloride, tetraethylphosphonium chloride, tetrabutylphosphonium chloride, and other related compounds. The catalyst may also consist of quaternary ammonium functionalized fillers, such as BYK's Garamite-treated nanoclay products, and quaternary ammonium functionalized ion exchange resins, such as the Dowex™ strong base resin, available from DuPont. The catalyst may also be phosphines, such as triphenylphosphine, trinaphtylphosphine, or tritolylphosphine. Examples of Lewis acid catalysts include SnCl4, Si(OEt)3(CH2)2SnCl3, TiCl4, TiCl3, Ti(O-isopropyl)4, Cp2TiCl2, SmI2, VOCl3, AlCl3, dimethyltin dithioglycolate, dibutyltin dilaurate, dioctyltin dithioglycolate, and related materials. Metal oxides that can be used include TiO2, TiO2 / SiO2, PbO, Petition 870250080834, dated 09 / 09 / 2025, page 21 / 71 14 / 36 PbO / MgO, PbO / SiO2, PbO-r-Al2O3, PbO / TiO2, MoO3, MoO3 / Al2O3, MoO3 / CaO, MgO, Mg6Fe(OH)i6CO3, Mg-Al-hydrotalcite and / or SnO2. Strong solid acids that may be included are sulfonated inorganic fillers or ion exchange resins, including Amberlyst™ and Amberlite™ materials, available from DuPont, and Dowex™ products from Lenntech.

[053] The catalyst may be present in an amount of approximately at least 0.02% by weight, more typically at least 0.1% by weight, more typically at least 0.2% by weight relative to the total weight of the material. It may be approximately 10% or less by weight, more typically about 5% or less by weight and even more typically about 2% or less by weight relative to the total weight of the material.

[054] The described material may also include a moisture scavenger. In addition to improving moisture resistance in the green (uncured) state, the moisture scavengers in the present teachings prevent moisture from participating in the decomposition pathway of polycarbonate by thermal hydrolysis and / or aminolysis. Due to the absence of primary and secondary amines in the materials of the present teachings, which are known initiators of polycarbonate decomposition, it is predicted that the polycarbonate will decompose primarily by thermal hydrolysis. Carbon dioxide is one of the products of this decomposition reaction, which can cause the material to foam after heat activation. For applications where foam formation is undesirable, moisture scavengers may be added to minimize foam formation or material porosity. Examples of moisture scavengers Petition 870250080834, dated 09 / 09 / 2025, page 22 / 71 Suitable 15 / 36 materials include calcium oxide, molecular sieves, vinyltrimethoxysilane, zeolites, and oxazolidines.

[055] To minimize foaming, moisture scavengers may be included in an amount of approximately at least 1% by weight, more typically at least 7% by weight, more typically at least 15% by weight relative to the total weight of the material. It may be approximately about 30% or less by weight, more typically about 25% or less by weight, more typically about 20% or less by weight, and even more typically 15% or less by weight relative to the total weight of the material. For applications where expansion of a gap is important, moisture scavengers may be omitted to ensure high volume expansion, since the presence of water in the composition will act as a blowing agent to increase volume expansion.

[056] A flexibilizer may be included in the material to improve properties such as resistance to deformation until failure and pull-out resistance. The use of the term flexibilizer may refer to a single flexibilizer or a combination of several different flexibilizers. Although other flexibilizers may be employed, preferred flexibilizers include epoxy-modified polymers, urethane, or any combination thereof. It is believed that when a polyurethane flexibilizer is included, the material can reduce stiffness, increase resistance to deformation until failure, and substantially maintain impact strength (e.g., impact resistance) at low temperatures, while minimizing the reduction of Petition 870250080834, dated 09 / 09 / 2025, p. 23 / 71 16 / 36 glass transition temperature (Tg) (e.g., compared to other flexibilizers). Examples of a preferred flexibilizer might be a phenol-terminated urethane-based flexibilizer, Rez-Cure® EP 1820 (available from Innovative Resin Systems) and Huntsman's DY965.

[057] Examples of other preferred flexibilizers are epoxy-terminated polyethers or amine precursors to produce epoxy-terminated polyethers, such as the JEFFAMINE™ M or SD series, commercially available from Huntsman (polyetheramine / epoxy adducts). Cashew nut shell liquid-based flexibilizers, such as the Cardolite™ NC-514 epoxidized liquids and Cardolite™ Lite 2513 HP are also useful flexibilizers. Another example of a flexibilizer is the Epoxonic™ 328 adduct (e.g., a dicarboxylic functional modifier) ​​with epoxy. All the individual flexibilizers discussed herein can be used separately or in combination with each other in the material of the present invention, unless otherwise indicated. Other examples of a preferred flexibilizer are HyPox™ DA323 (DGEBA and fatty acid dimer adduct) available from Emerald Performance Materials and Epokukdo™ YD-172 from Kukdo Chemical Co., Ltd.

[058] Typically, the content of the flexibilizer is less than 50%, more typically less than 35% and even possibly less than 20% by weight relative to the total weight of the material, although higher and lower values ​​may also be possible, unless otherwise indicated.

[059] Generally, it is preferable that the material include at least one type of polymeric particle. Such Petition 870250080834, dated 09 / 09 / 2025, page 24 / 71 17 / 36 Polymeric particles can be used to improve fracture toughness (G1C), pull-out resistance, and impact resistance. As used herein, the term “polymeric particle” is defined as a particle comprising a polymeric material. As with any other ingredients of the present teachings, the term polymeric particle may include one or more polymeric particles. Various polymeric particles may be employed in the practice of the present teachings and frequently include one or more elastomers.

[060] It is generally preferable that the polymer particles represent at least 2%, more typically at least 3%, even more typically at least 6%, even more typically at least 10% and even more typically at least 20% by weight of the material, and it is also preferable that the polymer particle represent less than 90%, more typically less than 40% and even more typically less than 30% by weight of the material, although larger or smaller amounts may be used in certain embodiments.

[061] Examples of useful polymeric particles include, among others, those sold under the trade name Kane Ace™, commercially available from Kaneka Americas Holding, Inc., Clearstrength™ from Arkema and Paraloid™ from Dow. Particularly preferred grades of Kane Ace™ are sold under the designations MX-134 and MX-267. The polymeric particles may have an average size of not less than 50 nm and not more than 300 nm.

[062] The epoxy-functionalized elastomer may be present in the range of about 1% to about 40% by weight relative to the total weight of the material. The elastomer is Petition 870250080834, dated 09 / 09 / 2025, page 25 / 71 18 / 36 is frequently a product of epoxy resins and elastomers selected from among carboxyl-terminated butadiene-acrylonitrile (CTBN), amine-terminated butadiene-acrylonitrile (ATBN), carboxylated nitrile rubber (XNBR) and polysulfide, or any combination thereof.

[063] The material may include one or more constituents that are distinct from the remaining polymer matrix and do not melt in normal compounding or processing (e.g., discrete constituents). Discrete constituents are organic or inorganic additives that differ from the polymer matrix to improve adhesive properties, alter thixotropic properties, improve moisture resistance, and / or reduce costs. These may include: silicates, such as those sold under the trade names Garamite™ and Satintone™ clays, mica, talc, clays, wollastonite under the trade names Nyglos™, Vansil™, and Wollastocoat™, calcium carbonate, calcium oxide, calcium sulfate, fumed silica under the trade names Aerosil™ and Cab-o-sil™, hollow glass and polymer spheres, carbon black, barium sulfate, and graphite.

[064] Other additives, agents or performance modifiers may also be included in the material as desired, including, but not limited to, a UV resistant agent, a flame retardant, a heat stabilizer, a colorant, a processing aid, a lubricant or the like.

[065] It is anticipated that almost any chemicals, materials or other additives may be added to the material, provided they are suitable for the Petition 870250080834, dated 09 / 09 / 2025, page 26 / 71 19 / 36 material and for a chosen application, and do not compromise the latency of single-component materials.

[066] It is possible that the specific combination and relative quantities of one or more materials described herein may assist in providing enhanced values ​​for one or more of the following strengths: T-peel strength or adhesive joint shear strength. As an example, the combination of a polyetheramine / epoxy adduct, core-shell particles, and urethane flexibilizer is useful for high T-peel strength. With optimal ratios of these three ingredients, it is possible to achieve a T-peel strength of approximately 9 N / mm when determined with a tensile speed of 254 mm / min and a glue line of 0.25 mm. The synergistic effects of these ingredients can be explained by the combination of phase separation toughening, matrix flexibilization, local plastic deformation capacity, and reduction of internal strength.For example, core-shell particles and urethane flexibilizer can form phase separation domains or separation domains for toughening, while the polyetheramine / epoxy adduct improves the flexibility and local deformation of the adhesive matrix.

[067] Certain adhesive materials formed in accordance with the present teachings exhibited deformation to failure greater than about 2%, greater than about 10%, and even possibly greater than about 100% when determined according to the ASTM D638 Type IV test method with a tensile speed of 5 mm / min. The deformation to failure was measured using a Petition 870250080834, dated 09 / 09 / 2025, page 27 / 71 A 20 / 36 strain gauge is used to record the strain, which is then used to calculate the strain of the material.

[068] Certain adhesive materials formed in accordance with the present teachings exhibited adhesive joint shear strength greater than about 10 MPa, greater than about 30 MPa, and even possibly greater than 40 MPa when determined in accordance with ASTM D58 68 with a pull-through speed of 50.4 mm / min and a glue line of 0.25 mm.

[069] Certain materials formed in accordance with the present teachings exhibited T-peel strength greater than about 5 N / mm, greater than about 7 N / mm, and even possibly greater than 8.5 N / mm when determined with a tensile speed of 254 mm / min and a glue line of 0.25 mm.

[070] Certain adhesive materials formed according to the present teachings exhibited glass transition temperatures (Tg) greater than 20 degrees Celsius, greater than 70 degrees Celsius, and even greater than 90 degrees Celsius, when determined by the ASTM D7028-07 standard. The glass transition temperature determined by this test method (referred to as Dynamic Mechanical Analysis Tg or DMA Tg) may not be the same as that reported by other measurement techniques (i.e., tan delta peak) in the same specimen. The test method is commonly used to determine the maximum service temperature for composite materials.

[071] For example purposes, Table A is presented below to illustrate six exemplary formulations for the formation of adhesives activated by Petition 870250080834, dated 09 / 09 / 2025, page 28 / 71 21 / 36 heat of a component cured by a transesterification curing mechanism.

[072] Table A #1 #2 #3 #4 #5 #6 Calcium oxide 9.65 7.46 11.8 11.16 13.84 Fatty dimer acid adduct 5.79 Core and shell particles 6.69 4.1 6.49 6.14 7.72 4.43 Urethane flexibilizer 3 6.22 9.84 9.3 11.7 6.72 Jeffamine™ / epoxy adduct 12.44 9.3 11.7 13.44 Polycarbonate 14.55 21.45 14.75 13.95 6.14 23.18 Bisphenol A type liquid epoxy resin 17.78 Bisphenol F type liquid epoxy resin 23.23 34.55 37.77 35.72 30.97 37.33 Hexanediol Diglycidyl Ether 4.65 5.85 Bisphenol A type solid epoxy resin 15.92 7.25 4.92 7.84 Bisphenol A 6.22 13.94 9.3 11.7 6.72 Epoxonic 328 Additive 2.9 Tetraethylammonium Bromide 0.49 0.21 0.33 0.32 0.23 Tetrabutylphosphonium Bromide 0.19 Pigment 0.10 0.10 0.16 0.16 0.19 0.11 Total weight 100 100 100 100 100 100 Propra Expansion (%) 0 0 0 0 0 94 T-peel resistance1 (N / mm) 5.4 8.6 5.0 8.8 12.4 4.2 Adhesive joint shear strength2 (MPa) 34.1 44.4 43.3 37.4 22.1 14.7 Petition 870250080834, dated 09 / 09 / 2025, page 29 / 71 22 / 36 Tensile strength modulus³ (MPa) 1934 1656 2097 1185 202 172 Peak stress³ (MPa) 28.2 26.3 39.5 18.8 12.2 3.5 Strain to failure³ (%) 2.9 3.0 2.9 14.3 290 3.3 Tg⁴ (°C) 49.7 70.6 79.6 50.2 37.5 73.9 Tg per peak of tan delta (°C) 65.2 90.0 98.9 70.2 50.9 93.8 1. 0.030 EG60, test speed: 254 mm / min, glue line 0.25 mm. 2. 0.060 EG60, test speed: 50.4 mm / min, glue line 0.25 mm. 3. Test method ASTM D638 Type IV with a tensile speed of 5 mm / min. 4. ASTM D7028-07. Curing schedule: 162.8 °C for 30 min

[073] The materials shown in Table A are one-component heat-activated adhesives with a wide range of properties. Sample 1 is an example of a high-strength structural adhesive cured by transesterification between polycarbonate and epoxy resins. The shear strength at overlap of sample 1 is greater than 30 MPa and the T-peel strength is greater than 5 N / mm. Samples 2 to 6 demonstrate how to adjust adhesive properties by incorporating other ingredients or manipulating the ratio of these ingredients. For example, the Jeffamine™ / epoxy adduct can increase the T-peel strength (> 8 N / mm) and deformation to failure (> 14%) for samples 2 and 4, respectively. Increasing the amount of bisphenol A helps achieve a higher Tg (i.e., 80 °C) for sample 3. Reducing the ratio of polycarbonate to epoxy leads to an elastomeric adhesive (i.e., sample 5) with a deformation to failure above 290%.Sample 6, without moisture scavenger (CaO), is a foamed adhesive with volume expansion around 100%. These results demonstrate the viability of transesterification as a curing mechanism for various structural adhesives. Petition 870250080834, dated 09 / 09 / 2025, page 30 / 71 23 / 36

[074] Notably, sample 5 exhibited a combination of tensile strength modulus above 200 MPa and strain to failure of 290%. The modulus of this adhesive is significantly higher compared to a typical dicyandiamide-cured adhesive with the same strain to failure. It is typical that, to obtain an epoxy adhesive with 290% strain to failure, the tensile strength modulus is less than 5 MPa. Strain to failure and tensile strength modulus generally have an inverse relationship, where an increase in one corresponds to a decrease in the other. Therefore, it is a significant challenge to simultaneously provide high strain to failure and high modulus of elasticity. This result reveals a significant benefit of using PC transesterification curing for adhesives that produce high strain to failure, relatively high modulus, and consequently, superior toughness.

[075] Different ingredients have been found to play important roles in influencing the adhesive and mechanical properties. The comparative examples shown below demonstrate the change in physical properties based on the inclusion / removal of certain components in the material disclosed here.

[076] Table B #2 #7 #8 #9 #10 #11 #6 Calcium oxide 7.20 7.20 7.20 7.20 7.20 7.20 Core and shell particles 3.96 3.96 3.96 3.96 3.96 3.96 Urethane flexibilizer 6.00 6.00 6.00 6.00 6.00 6.00 6.00 Petition 870250080834, dated 09 / 09 / 2025, page 31 / 71 24 / 36 Jeffamine™ / epoxy adduct 12.00 12.00 12.00 12.00 12.00 12.00 Polycarbonate 20.7 20.7 20.7 20.7 20.7 20.7 Liquid epoxy resin type bisphenol F 33.34 33.34 33.34 33.34 33.34 33.34 33.34 Solid epoxy resin type bisphenol A 7.00 7.00 7.00 7.00 7.00 7.00 7.00 Bisphenol A 6.00 6.00 6.00 6.00 6.00 6.00 Tetraethylammonium bromide 0.2 0.2 0.2 0.2 0.2 0.2 0.2 Pigment 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Total weight 96.5 75.8 90.5 84.5 90.5 92.54 89.3 Properties Expansion (%) 0 0 0 0 0 0 94 Tpeel1 Strength (N / mm) 8.6 3.5 4.6 3.7 2.3 3.9 4.2 Adhesive joint shear strength2 (MPa) 44.4 2.3 25.5 45.6 39.5 28.5 14.7 Tensile modulus3 (MPa) 1656 13 544 2251 2793 1766 172 Stress peak3 (MPa) 26.3 0.05 13.7 43.5 50.1 30.9 3.5 Strain to failure3 (%) 3.0 16 28.4 2.7 2.3 2.3 3.3 Tg4 (°C) 70.6 4.7 40.2 93.2 89.6 82.6 73.9 Tg per peak of tan delta (°C) 90.0 32.5 56.7 108.9 104.6 101.4 93.8 1. 0.030 EG60, test speed: 254 mm / min, glue line 0.25 mm. 2. 0.060 EG60, test speed: 50.4 mm / min, glue line 0.25 mm. 3. ASTM D638 Type IV test method with a tensile speed of 5 mm / min. 4. ASTM D7028-07. Curing schedule: 162.8 °C for 30 min.

[077] Sample 2 is used as a control to show how the exclusion of each ingredient affects the Petition 870250080834, dated 09 / 09 / 2025, page 32 / 71 25 / 36 properties of the respective compositions. Comparison of sample 7 with sample 2 demonstrates that polycarbonate is the key constituent necessary to produce a highly cross-linked network. Excluding polycarbonate from sample 2 causes the adhesive joint shear strength to drop from over 40 MPa to 2.3 MPa in sample 7. In essence, removing the polycarbonate renders the composition no longer a structural adhesive. Inspection of the T-Peel strength results of samples 8 to 11 reveals the synergistic effect of the core-shell particles, urethane flexibilizer, Jeffamine™ / epoxy adduct, and bisphenol A on the material's pull-off resistance. Excluding any of these ingredients from sample 2 leads to a reduction in T-Peel strength, although they can still be considered adhesives.This can be explained by the synergy of the adhesive's plastic nature, phase separation hardeners, and matrix flexibility in the toughness of structural adhesives. Since polycarbonate decomposes by thermal hydrolysis in the presence of a catalyst to generate carbon dioxide, sample 6, without the moisture scavenger CaO, foams at 94%, which explains the reduction in adhesive joint shear strength and T-peel resistance. For high-strength applications, moisture scavengers are preferable to minimize foaming. However, when covering a gap between substrates, foaming is desirable. CaO can be omitted or reduced to promote foaming and create a high-performance foamed adhesive.

[078] Table C Petition 870250080834, dated 09 / 09 / 2025, page 33 / 71 26 / 36 #2 #12 #13 #14 Calcium oxide 7.20 7.20 7.20 7.10 Core and shell particles 3.96 3.96 3.96 3.96 Urethane flexibilizer 6.00 6.00 6.00 6.00 Jeffamine™ / epoxy adduct 12.00 12.00 12.00 6.00 Polycarbonate 20.7 20.7 20.7 3.15 Liquid epoxy resin type Bisphenol F 33.34 33.34 33.34 15.89 Solid epoxy resin type Bisphenol A 7.00 7.00 7.00 3.00 Bisphenol A 6.00 6.00 6.00 PM92-500 Resonance 6.00 Tetraethylammonium bromide 0.2 0.2 Tetraethylphosphonium bromide 0.20 Triphenylphosphine 0.10 Pigment 0.10 0.10 0.10 0.10 Total weight 96.5 96.5 96.5 51.2 Properties Expansion (%) 0 0 0 0 T-peel resistance1 (N / mm) 8.6 4.2 4.6 11.0±0.6 Adhesive joint shear strength2 (MPa) 44.4 44.0 17.4+0.8 42.9 Tensile modulus3 (MPa) 1656 2418 2427 4 6 + 1 6 Peak stress3 (MPa) 26.3 42.8 41.7 6.9±1.6 Deformation to failure3 (%) 3.0 2.3 2.4 439131 Tg4 (°C) 70.6 77.7 98.3 27.7 Tg per peak of tan delta (°C) 90.0 99.1 117.3 45.9 1. 0.030 EG60, test speed: 254 mm / min, glue line 0.25 mm. 2. 0.060 EG60, test speed: 50.4 mm / min, glue line 0.25 mm. 3. ASTM D638 Type IV test method with a tensile speed of 5 mm / min. 4. ASTM D7028-07. Curing schedule: 162.8 °C for 30 min Petition 870250080834, dated 09 / 09 / 2025, p. 34 / 71 27 / 36

[079] Different types of phenols and catalysts have been used as alternatives to bisphenol A and quaternary ammonium salts for the preparation of transesterification-cured polycarbonate adhesives. Quaternary phosphonium salts and phosphine have proven effective in catalyzing the transesterification reaction. PM92-500 resonance, a highly functional phenol (i.e., f = 2.6), further improves the Tg to approximately 100 °C compared to the use of bisphenol A, corroborating the hypothesis that phenol contributes to network crosslinking.

[080] Table D #2 #15 #16 #6 Calcium oxide 7.20 3.50 1.50 0.00 Core and shell particles 3.96 3.96 3.96 3.96 Urethane flexibilizer 6.00 6.00 6.00 6.00 Jeffamine™ / epoxy adduct 12.00 12.00 12.00 12.00 Polycarbonate 20.7 20.7 20.7 20.7 Bisphenol F type epoxy resin 33.34 33.34 33.34 33.34 Bisphenol A type epoxy resin 7.00 7.00 7.00 7.00 Bisphenol A 6.00 6.00 6.00 6.00 Tetraethylammonium bromide 0.2 0.2 0.2 0.2 Orange powder E6580 0.10 0.10 0.10 0.10 Total 96.5 93.0 90.5 89.50 Petition 870250080834, dated 09 / 09 / 2025, p. 35 / 71 28 / 36 Properties Expansion (%) 0 8 23 94 T-peel resistance1 (N / mm) 8.6 7.9 7.3 4.2 Adhesive joint shear strength2 (MPa) 44.4 35.8 34.5 14.7 Tensile modulus3 (MPa) 1656 1244 469 172 Peak stress3 (MPa) 26.3 19.2 9.2 3.5 Deformation to failure3 (%) 3.0 2.6 2.9 3.3 Tg4 (°C) 70.6 79.1 61.2 73.9 Tg per peak of tan delta (°C) 90.0 98.8 82.5 93.8 1. 0.030 EG60, test speed: 254 mm / min, glue line 0.25 mm. 2. 0.060 EG60, test speed: 50.4 mm / min, glue line 0.25 mm. 3. ASTM D638 Type IV test method with a tensile speed of 5 mm / min. 4. ASTM D7028-07. Curing schedule: 162.8 °C for 30 min

[081] The examples shown in Table D demonstrate how the volumetric expansion of the material can be adjusted by altering the percentage of moisture scavenger. Samples 16 and 6, with low or no percentage of CaO, exhibit adequate expansion for gap jumping applications. Sample 16 is a low-expansion adhesive (i.e., 23% expansion) that exhibits typical properties of a high-performance structural adhesive (i.e., an adhesive joint shear strength of 34.5 MPa and a T-peel strength of 7.3 N / mm). Sample 6 is a high-expansion adhesive (i.e., 94% expansion) that exhibits an adhesive joint shear strength of 14.7 MPa, higher than that considered a structural adhesive (i.e., 7 MPa). These results demonstrated the feasibility of preparing adhesives. Petition 870250080834, dated 09 / 09 / 2025, page 36 / 71 29 / 36 expandable structural components using polycarbonate transesterification as a curing mechanism.

[082] CaO is an excellent moisture scavenger due to its reactivity with water, producing calcium hydroxide. Thus, CaO can lose its antifoaming function as it transforms into calcium hydroxide and loses reactivity to moisture. To determine if foam formation occurs with exposure to moisture, sample 2 is exposed to 85% humidity at 25 °C. The adhesive did not expand for up to 5 months under this condition.

[083] For any latent dressing, it is important to have high reactivity at the adhesive's curing temperature and low reactivity at room temperature for storage and transport. Polycarbonate transesterification only occurs in the presence of suitable catalysts. Catalytic reactivity at 160 °C and at room temperature (i.e., 23 °C and 43 °C) determines the curing and aging of polycarbonate transesterification-cured adhesives. Ideal catalysts are expected to activate transesterification at 160 °C for curing but not exhibit catalytic activity at 23 and 43 °C to maintain adequate shelf life. As shown in Figure 1, polycarbonate transesterification can be characterized by the shift of the carbonate peak in an FTIR spectrum. Transesterification for epoxy causes the carbonate peak to shift to a higher wavenumber due to the chemical structural change from aromatic to aliphatic carbonates.Thus, the catalyst's reactivity at 160 °C can be scaled from 0 to 2, according to the extent of the carbonate peak shift. Petition 870250080834, dated 09 / 09 / 2025, page 37 / 71 30 / 36 In contrast, the catalyst's reactivity at room temperature is measured by the increase in adhesive viscosity, which is a more sensitive response to a smaller extent of reaction than the infrared peak shift.

[084] Table E Catalyst Reactivity Scale Viscosity increase after 3 days at 43 °C Viscosity increase after 1 month at 23 °C TEABr 0.2 phr 1 30% 29% TEABr 0.4 phr 1 122% 76% TBPBr 0.1 phr 2 143% 11% TBPBr 0.2 phr 2 370% 222% lATPPBr 0.1 phr 1 75% 58% lATPPBr 0.2 phr 1 180% 97% TpTP 0.1 phr 1 182% 138% TpTP 0.2 phr 1 332% 228% TEABr, Tetraethylammonium bromide; TBPBr, Tetrabutylphosphonium bromide; lATPPBr, Isoamyltriphenylphosphonium bromide; TpTP, Tri(p-tolyl)phosphine

[085] Adhesive formulations composed of 15% polycarbonate, 85% YDF-170 (i.e., bis-F epoxy resin) and various catalysts were used to investigate the reactivity of these catalysts. The adhesives were cured at 160 °C for 30 min. The aging study of the uncured adhesives was performed at 23 and 43 °C. As shown in Table E, the catalyst reactivity at 160 °C decreases in the order of TBPBr (high), TEABr and lATPPBr (medium), and TpTP (low). Surprisingly, TpTP also leads to the most significant aging at both 23 and 43 °C. While low concentrations (i.e., 0.1 phr) of TBPBr show minimal aging at only 23 °C, 0.2 phr of TEABr and 0.1 phr of lATPPBr result in Petition 870250080834, dated 09 / 09 / 2025, pp. 38 / 71 31 / 36 Minimum aging at 23 and 43 °C. For DICY-cured adhesives, a viscosity increase of 70 to 100% is typical after aging at 43 °C for 3 days. Analysis of the results in Table E reveals comparable or reduced aging of polycarbonate transesterification-cured adhesives when 0.2 phr of TEABr and 0.1 phr of lATPPBr are used as catalysts.

[086] As shown in Table A, epoxy-based structural adhesives are often composed of several ingredients that positively affect properties, including toughness, resistance to environmental exposure, and elongation. To ensure minimal adhesive aging, it is also important to incorporate ingredients compatible with polycarbonate curing, so that they do not activate the polycarbonate transesterification reaction until the reaction is desired to occur. Table F shows the viscosity increase of 15% polycarbonate and 85% YDF-170 caused by different ingredients. It is evident that none of these ingredients activates polycarbonate transesterification, as indicated by the absence of a perceptible increase in viscosity.

[087] Table F #17 #18 #19 #20 #21 #22 #23 PC (polycarbonate) 15 15 15 15 15 15 15 Epokukdo™ YDF170 epoxy resin 85 85 85 85 85 85 85 Urethane hardener 6 Petition 870250080834, dated 09 / 09 / 2025, pp. 39 / 71 32 / 36 CaO 7 Aliphatic diacid / epoxy adduct 5 CTBN adduct 10 Nucleus-shell particle dispersion in bisphenol-A epoxy resin 30 Jeffamine™ / epoxy adduct 5 Nucleus-shell particle dispersion in bisphenol-F epoxy resin 30 Pyrogenic silica 1 1 1 1 1 1 1 Viscosity increase after three-dimensional aging at 43 °C 0 0 0 0 0 0 0 Viscosity increase after 1 month at 23 °C 0 0 0 0 0 0 0

[088] Table G #24 #25 #26 Calcium oxide 7.1 7.1 7.1 Pyrogenic silica 1.0 Core and shell particles Urethane flexibilizer 6.00 6.00 6.00 Jeffamine™ / epoxy adduct 6.00 CTBN adduct 6.00 6.00 Polycarbonate 3.15 3.15 3.15 Petition 870250080834, dated 09 / 09 / 2025, pp. 40 / 71 33 / 36 Liquid epoxy resin type bisphenol F 19.85 19.85 19.85 Hexanediol Diglycidyl Ether 3.00 3.00 Bisphenol A 6.00 6.00 6.00 Tetrabutylphosphonium Bromide 0.10 0.10 0.10 Pigment 0.10 0.10 0.10 Total weight 51.30 51.30 49.30 Properties Expansion (%) 0 0 0 T-peel strength1 (N / mm) 9.0 11.3 7.9 Adhesive joint shear strength2 (MPa) 11.2 15.9 27.5 Tensile modulus3 (MPa) 22 44 1523 Peak stress3 (MPa) 5.2 6.9 18.0 Deformation to failure3 (%) 352 358 46 Tg4 (°C) 26.2 26.8 46.8 Tg per tan delta peak (°C) 43.9 43.4 62.5 Viscosity increase after 3 days at 43 °C 25% 0% 137% Viscosity increase after 1 month at 23 °C 25% 5% 417% 1. 0.030 EG60, test speed: 254 mm / min, glue line 0.25 mm. 2. 0.060 EG60, test speed: 50.4 mm / min, glue line 0.25 mm. 3. ASTM D638 Type IV test method with a tensile speed of 5 mm / min. 4. ASTM D7028-07. Curing schedule: 162.8 °C for 30 min

[089] Table G shows the properties and aging of polycarbonate transesterification-cured formulated adhesives. Samples 24 and 25 exhibit minimal aging. The increase in viscosity is equal to or less than 25% after 3 days at 43 °C and 1 month at 23 °C. Compared to sample 25, sample 26 is an example excluding hexanediol glycidyl ether, which showed a more significant increase in viscosity at both 23 and 43 °C. This may be a result of the higher polycarbonate to epoxide ratio. In fact, there is a correlation. Petition 870250080834, dated 09 / 09 / 2025, pp. 41 / 71 34 / 36 positive relationship between adhesive aging and curing concentration. The examples shown in Table G demonstrate the feasibility of using polycarbonate transesterification to cure adhesives with minimal aging. It has been proven that the catalyst concentration plays an important role in maintaining aging comparable to that of adhesives cured with dicyandiamide.

[090] As used herein, unless otherwise indicated, the teachings provide that any member of a genus (list) may be excluded from the genus; and / or any member of a Markush group may be excluded from the group.

[091] Unless otherwise indicated, any numerical values ​​mentioned here include all values ​​from the lower to the higher value in increments of one unit, provided there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the quantity of a component, a property or a value of a process variable, such as temperature, pressure, time and the like, is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate values, such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.), are within the scope of this descriptive report. Similarly, individual intermediate values ​​are also within the scope of this descriptive report. For values ​​less than one, a unit is considered 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are just... Petition 870250080834, dated 09 / 09 / 2025, page 42 / 71 35 / 36 examples of what is specifically intended, and all possible combinations of numerical values ​​between the smallest and largest enumerated values ​​should be considered expressly stated in this application in a similar manner. As can be observed, the indication of quantities expressed in parts by weight here also contemplates the same ranges expressed in terms of percentage by weight. Thus, an expression in the form of a range in terms of 'x' parts by weight of the resulting polymer mixture composition also contemplates an indication of ranges of the same mentioned quantity of x in percentage by weight of the resulting polymer mixture composition.

[092] Unless otherwise indicated, all ranges include both endpoints and all numbers between the endpoints. The use of about or approximately in connection with a range applies to both ends of the range. Thus, about 20 to 30 is intended to cover about 20 to about 30, including at least the specified endpoints.

[093] Disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and any other elements, ingredients, components or steps that do not materially affect the basic and innovative characteristics of the combination. The use of the terms comprising or including to describe combinations of elements, ingredients, components or steps herein also contemplates Petition 870250080834, dated 09 / 09 / 2025, page 43 / 71 36 / 36 modalities that consist of, or essentially consist of, elements, ingredients, components or steps.

[094] Multiple elements, ingredients, components, or steps may be provided by a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step may be divided into separate multiple elements, ingredients, components, or steps. Disclosure of one or two or more to describe an element, ingredient, component, or step is not intended to exclude additional elements, ingredients, components, or steps.

[095] Naturally, the above description is intended to be illustrative and not restrictive. Many embodiments, as well as many applications, beyond the examples provided, will be evident to those skilled in the art after reading the above description. The scope of the invention must therefore be determined not with reference to the above description, but rather with reference to the appended claims together with the full scope of equivalents to which such claims are entitled. Disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission, in the following claims, of any aspect of the subject matter disclosed herein does not constitute a disclaimer of liability with respect to such subject matter, nor should it be considered that the inventors did not consider such subject matter as part of the disclosed inventive object. Petition 870250080834, dated 09 / 09 / 2025, p. 44 / 71

Claims

1 / 8 CLAIMS 1. Material, characterized by comprising: (i) one or more epoxy resins; (ii) at least one polycarbonate; (iii) at least one catalyst, preferably a transesterification catalyst.

2. Material according to claim 1, characterized by including one or more polyols and / or phenols.

3. Material according to claim 2, characterized in that the catalyst is capable of catalyzing reactions of at least one polycarbonate with one or more epoxy resins and / or one or more polyols and / or phenols.

4. Material, according to any of the preceding claims, characterized by including one or more flexibilizers.

5. Material, according to any of the preceding claims, characterized by including one or more polymeric core and shell particles.

6. Material, according to any of the preceding claims, characterized by exhibiting a volumetric expansion of about 0% to about 100% when cured at 162.8 °C for 30 minutes.

7. Material, according to any of the preceding claims, characterized in being a structural material with an adhesive joint shear strength greater than 30 MPa (determined in accordance with ASTM D5868) and a tensile modulus greater than 1100 MPa (determined in accordance with ASTM D638 with a tensile rate of 5 mm / min), when cured at 162.8 °C for 30 minutes. Petition 870250080834, dated 09 / 09 / 2025, p. 45 / 71 2 / 8 8. Material, according to any of the preceding claims, characterized by being an elastomeric material with a strain to failure greater than 50% (determined in accordance with ASTM D638 with a tensile rate of 5 mm / min), when cured at 162.8 °C for 30 minutes.

9. Material, according to any of the preceding claims, characterized in that it is a non-expandable material and has a T-peel strength of at least 5 N / mm² (determined in accordance with ISO 11339) and an adhesive joint shear strength of at least 30 MPa (determined in accordance with ASTM D5868), when cured at 162.8 °C for 30 minutes.

10. Material, according to any of the preceding claims, characterized by being an expandable material and having a T-peel strength of at least 4 N / mm (determined in accordance with ISO 11339) and an adhesive joint shear strength of at least 14 MPa (determined in accordance with ASTM D5868), when cured at 162.8 °C for 30 minutes.

11. Material, according to any of the preceding claims, characterized in that polycarbonate is present in an amount of about 5% to about 60% by weight relative to the total weight of the material.

12. Material, according to any of the preceding claims, characterized in that at least one catalyst is present in an amount of about 0.01% to about 10% by weight relative to the total weight of the material. Petition 870250080834, dated 09 / 09 / 2025, p. 46 / 71 3 / 8 13. Material, according to any of the preceding claims, characterized by comprising one or more moisture eliminators in an amount of about 0% to about 40% by weight relative to the total weight of the material.

14. Material, according to any of the preceding claims, characterized by comprising one or more flexibilizers in an amount of about 2% to about 40% by weight relative to the total weight of the material.

15. Material, according to any of the preceding claims, characterized by comprising one or more polymeric particles in an amount of about 2% to about 30% by weight relative to the total weight of the material.

16. Material, according to any of the preceding claims, characterized in that at least one polycarbonate has a melting point ranging from about 2 to about 60 g / 10 min (300 °C, 1.2 kg load) and a molecular weight of about 5,000 to about 300,000 Daltons.

17. Material, according to any of the preceding claims, characterized by including one or more polyols that are aliphatic or aromatic polyester or polyether or polycarbonate polyol.

18. Material, according to any of the preceding claims, characterized by including one or more phenols selected from hydroquinone, resorcinol, catechol, bisphenol A, bisphenol F, bisphenol E, bisphenol AP, bisphenol Z, bisphenol M, bisphenol P, bisphenol G, bisphenol BP and any combination thereof. Petition 870250080834, dated 09 / 09 / 2025, p. 47 / 71 4 / 8 19. Material, according to any of the preceding claims, characterized in that at least one catalyst is selected from quaternary ammonium salts, quaternary phosphonium salts, phosphines, Lewis acids, metal oxides, phosphines, solid strong acids and any combination thereof.

20. Material, according to any of the preceding claims, characterized by including one or more moisture scavengers selected from calcium oxide, molecular sieves, vinyltrimethoxysilane, zeolite, oxazolidines and any combination thereof.

21. Material, according to any of the preceding claims, characterized by including one or more flexibilizers or flexibilizers in an adduct with epoxy selected from phenol-terminated urethane, fatty acid dimer / epoxy adduct, polyetheramine / epoxy adduct, a dicarboxyl functional modifier or any combination thereof.

22. Material, according to any of the preceding claims, characterized by including one or more polymeric particles selected from polybutadiene core modifiers, styrene-butadiene rubber, or any combination thereof.

23. Material, according to any of the preceding claims, characterized by including one or more polymeric particles comprising core / shell rubber particles having an average size of about 100 to about 200 nm.

24. Material, according to any of the preceding claims, characterized by including one or more polymeric particles that are substantially free of agglomerated particles.

25. Material, according to any of the preceding claims, characterized by including one or more discrete constituents.

26. Material according to claim 25, characterized in that one or more discrete constituents are selected from silica, diatomaceous earth, glass, clay (for example, including nanoclay), glass spheres or microspheres, glass, carbon or ceramic fibers, nylon, aramid or polyamide fibers (for example, Kevlar), pyrophyllite, sauconite, saponite, nontronite, wollastonite, montmorillonite or any combination thereof.

27. Material, according to any of the preceding claims, characterized by including discrete silica- and / or calcium-based constituents.

28. Material, according to any of the preceding claims, characterized by including discrete silica-based constituents comprising fumed silica.

29. Material, according to any of the preceding claims, characterized by being substantially free of a curing agent other than polycarbonate.

30. Material, according to any of the preceding claims, characterized by being substantially free of a blowing agent other than polycarbonate. Petition 870250080834, dated 09 / 09 / 2025, p. 49 / 71 6 / 8 31. Material, according to any of the preceding claims, characterized by being substantially free of any dicyandiamide.

32. Material, according to any of the preceding claims, characterized by having a tensile strength modulus greater than 200 MPa (determined in accordance with ASTM D638 with a tensile rate of 5 mm / min) and a deformation to failure of at least 275% (determined in accordance with ASTM D638 with a tensile rate of 5 mm / min).

33. Material, according to any of the preceding claims, characterized by including one or more moisture eliminators.

34. Material, according to any of the preceding claims, characterized in that it is an adhesive, preferably a structural adhesive, more preferably a one-component adhesive.

35. Adhesive, characterized by comprising at least (i) one or more epoxy resins; and (ii) at least one polycarbonate; wherein the adhesive has a tensile strength modulus greater than 200 MPa (determined in accordance with ASTM D638 at a tensile rate of 5 mm / min) and a deformation to failure of at least 275% (determined in accordance with ASTM D638 at a tensile rate of 5 mm / min).

36. Adhesive, according to claim 35, characterized by including a catalyst for reacting with at least one polycarbonate, preferably a transesterification catalyst. Petition 870250080834, dated 09 / 09 / 2025, p. 50 / 71 7 / 8 37. Adhesive, according to claim 35 or 36, characterized by including: i) one or more of the following polyols and / or phenols; ii) one or more moisture scavengers; iii) one or more flexibilizers; iv) one or more polymeric particles; e) one or more discrete constituents; or any combination thereof.

38. Adhesive, according to any one of claims 35 to 37, characterized in that the catalyst is capable of catalyzing reactions of polycarbonate with one or more epoxy resins and / or one or more polyols and / or phenols.

39. Adhesive, according to any one of claims 35 to 38, characterized in that it is substantially free of any curing agent other than polycarbonate.

40. Adhesive, according to any one of claims 35 to 39, characterized in that it is substantially free of any blowing agent other than polycarbonate.

41. Use of the material or adhesive, as defined in any of the preceding claims, characterized in that it is for filling a cavity in a transport vehicle.

42. Use of the material or adhesive, as defined in any of the preceding claims, characterized by being for the reinforcement of a cavity in a transport vehicle. Petition 870250080834, dated 09 / 09 / 2025, pp. 51 / 71 8 / 8 43. Use of the material or adhesive, as defined in any of the preceding claims, characterized by being for application in civil construction. Petition 870250080834, dated 09 / 09 / 2025, pp. 52 / 71

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