Encapsulated reactive components for activatable materials

Abstract

A material comprising an encapsulated component within a housing, a rupture initiator associated with the encapsulated component, and a polymeric matrix material, wherein the encapsulation is adapted to fail upon activation of the rupture initiator, thereby allowing release of the encapsulated component to initiate a reaction or increase the reactivity of the material.

Description

Technical Field

[0001] The present teachings generally relate to reactive components encapsulated for activatable materials, and the manufacture and use of such materials. Background Art

[0002] Activable materials such as adhesives, sealants, and reinforcing materials are commonly used in various industries. When producing materials (activable materials) that undergo a transformation due to heat exposure or other stimuli, these materials may react prematurely before use. Premature reaction occurs because the reactive components are intimately mixed with the reactant components, often referred to as one-component materials. Premature reaction results in an undesirably short shelf life. However, there are many obstacles to extending the shelf life of these "one-component" materials.

[0003] To avoid these challenges, these activable materials can be manufactured and stored as "two-part" compositions such that the reactive components are separated from the reactant components. Generally, such materials (when combined) react at room temperature or ambient temperature without the addition of heat or other additional stimuli. However, the manufacture, storage, and ultimate handling of combining such two-part materials can result in additional cost and effort.

[0004] In one-component materials, the curing agent and / or curing agent accelerator react slowly but are generally not inert. There have also been attempts to encapsulate portions of these materials to prevent premature curing of the one-component materials. However, incomplete encapsulation, undesired rupture of the capsules during compounding or secondary processing, and poor delivery of the reactive components to the remaining material have presented substantial challenges. Accordingly, the present invention aims to provide an improved activable material that includes one or more encapsulated components for extending the shelf life of the material, or providing the ability to more aggressively compound or form formulations during compounding. Summary of the Invention

[0005] The teachings herein provide a material that includes an encapsulated component within a housing, a rupture initiator associated with the encapsulated component, and a polymeric matrix material. The encapsulation is adapted to fail upon activation of the rupture initiator, thereby allowing the encapsulated component to be released to initiate a reaction or increase the reactivity of the material.

[0006] The teachings herein also relate to a method of forming an industrial material that includes encapsulating an encapsulated component within an encapsulating housing, positioning a rupture initiator within the encapsulating housing or within the housing surface, mixing the encapsulated component with a polymeric matrix material, and activating the rupture initiator to allow the encapsulated component to be released to initiate a reaction or increase the reactivity of the material.

[0007] Failure of the housing can be initiated by having a rupture component triggered by heat. The rupture component can be part of the polymeric housing or located inside the housing with the reactive component.

[0008] The rupture initiator can be within a shell having an encapsulated component. The rupture initiator can be formed as part of the shell surrounding the encapsulated component. The rupture initiator can include a foaming agent. The encapsulated component can include a plurality of particles to improve dispersion after release of the encapsulated component. The shell can include a polyester material. The rupture initiator can include a chemical or physical foaming agent. The encapsulated component can be selected from a curing agent, a curing agent accelerator, a foaming agent, a foaming agent activator, a moisture scavenger, an acid, a monomer, an odor scavenger, or any combination thereof. The rupture initiator can be activated in response to a stimulus. The rupture initiator can be activated in response to a stimulus selected from pressure, heat, ultraviolet light, moisture, or any combination thereof.

[0009] The encapsulated component can be a curing agent. The encapsulated component can be a curing agent accelerator. The encapsulated component can be a liquid at room temperature (20 °C - 22 °C). The encapsulated component can be a solid at room temperature (20 °C - 22 °C). The encapsulated component can be dicyandiamide or a urea-based reagent. The encapsulated component can be selected from amines, imidazoles, thiols, or combinations thereof. The encapsulated component can accelerate the reaction of the material.

[0010] The shell can include polyester, gelatin, polyformaldehyde urea formaldehyde, melamine formaldehyde, polyurethane, silica, or some combination thereof. The shell can be formed by submerged nozzle extrusion, rotary disk coating, interfacial polymerization, microfluidics, coacervation, spray drying, fluidized bed coating, or some combination thereof. When the rupture initiator expands from within the shell, the shell may rupture. Encapsulation may fail due to pressure on the shell surface, a chemical reaction with the shell surface or its contents, a stimulus affecting the shell surface or its contents, or some combination thereof.

[0011] The encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 250 °C, below 200 °C, below 180 °C, or even below 150 °C. The material can be a cured thermosetting material. The material can be a thermoplastic material. The material can be a foamable material. The polymer matrix material can be an epoxy-based material. The polymer matrix material can include ethylene materials. The polymer matrix material can include methacrylate materials. The polymer matrix material can include urethane-based materials.

[0012] The encapsulating material can surround the encapsulated component and can be combined with a shell rupture initiator that is also within the encapsulation shell. The rupture initiator is capable of generating pressure to expose the reactive encapsulating material to the polymer matrix material.

[0013] The teachings herein also provide for the use of the materials described herein for sealing vehicle cavities. The teachings herein also provide for the use of the materials described herein as a structural adhesive to adhere two or more structural members together. The teachings herein contemplate methods of adhering and applying the materials to a structural support member or cavity.

[0014] The materials and methods described herein allow for the use of encapsulated materials within a polymer matrix that includes a rupture initiator to expose the encapsulated materials to the polymer matrix material. Detailed Description

[0015] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. The specific embodiments of the teachings set forth are not intended to be exhaustive or to limit the teachings. The scope of the teachings should be determined with reference to the appended claims and the full scope of equivalents to which those claims are entitled. The disclosures of all articles and references (including patent applications and publications) are incorporated herein by reference for all purposes. Other combinations are possible as will be gathered from the appended claims, which are also incorporated by reference into this written description. Percentages herein are by weight unless otherwise indicated.

[0016] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 62 / 856,700, filed on June 3, 2019, the content of which is incorporated herein by reference for all purposes.

[0017] The potential reactive materials described herein are typically activated to react upon exposure to a stimulus. However, a stimulus may not be required. Stimuli such as heat, moisture, pressure, ultraviolet light, etc. may be used. It is considered an advantage if one or more reactive components of the material are kept separate from one or more additional components in the polymer matrix by encapsulation. In a one-component material, the internal pressure generated by a rupture medium (e.g., a rupture initiator) may cause failure of the shell of the encapsulated reactive component. A preferred method is to have a rupture initiator that causes the shell to rupture, thereby delivering the reactive component to the polymer matrix material. The rupture initiator may be part of the polymer encapsulation shell or located inside the shell with the encapsulated component. Poor delivery of the active component is a problem in the prior art. The rupture initiator provides a solution because it allows the reactive component to be closer to the polymer matrix material.

[0018] Typically, although not required, the polymeric matrix material remains separated from the reactive material by encapsulating the reactive material, which can be a curing agent and / or a curing agent accelerator. Then, upon application of an activating stimulus, a chemical reaction, or some combination thereof, the encapsulation will typically fail (e.g., rupture), thereby exposing the polymeric matrix material to the reactive material. In one specific embodiment, the curing agent accelerator can be encapsulated within a material (including the curing agent), and upon failure of the encapsulation surface, the curing agent accelerator can be used to react with the curing agent in the polymeric matrix material.

[0019] A variety of types of encapsulation techniques can be employed to form the desired encapsulating material. For example but not limited to, techniques such as submerged nozzle extrusion, rotary disk coating, interfacial polymerization, microfluidics, coacervation, spray drying, fluidized bed coating, combinations thereof, etc. can be used. Suitable methods for encapsulation are also disclosed in U.S. Application Publication No. 2018 / 0008948, which is incorporated herein by reference for all purposes. The particular technique used and the type of encapsulation formed can depend on the material to be encapsulated and the state of that material (e.g., liquid, solid, gas, or a combination thereof). Exemplary materials for forming the encapsulation can include solid curing agents and / or (solid) curing agent accelerators and / or liquid curing agents and / or (liquid) curing agent accelerators.

[0020] The rupture of the encapsulating shell can be customized by selecting various melting temperatures of the shell, by crosslinking the polymeric shell, and by selecting different rupture components.

[0021] Typically, in order to produce a one-component material containing the encapsulated components, it is preferred that one or more curing agents can cause the polymeric compound to react at a temperature below about 250 °C, more typically below about 200 °C, more typically below about 180 °C, or even below 150 °C. The rupture initiator can avoid any activation of the material at the temperatures that will be encountered during compounding and secondary processing (e.g., injection molding, extrusion, etc.). Thus, it may be beneficial for the rupture agent not to activate at temperatures below 120 °C. For example, the rupture agent can activate at a temperature of 140 °C or higher.

[0022] In addition to curing, the adhesive material can optionally be activated to foam and can therefore include a foaming agent, or alternatively, the reaction of the polymeric component (which can include one of the curing agent or the curing agent accelerator) with the curing agent and / or the curing agent accelerator can release a gas for foaming or expanding the adhesive material. If used, the foaming or expansion of the adhesive material can contribute to the wetting and / or adhesion of the adhesive material to the members of the structure.

[0023] The encapsulated materials described herein can be used in epoxy-based systems, urethane-based systems, acrylate-based systems, or systems that utilize monomeric or oligomeric reactive compounds to produce polymers. The materials can be adhesives, sealants, reinforcement materials, tapes, or some combination thereof. The materials can be pumpable or batch dispensable (e.g., a paste product suitable for dispensing via a pump). Generally, for polyurethane systems (e.g., systems having isocyanates and isocyanate-reactive compounds), various different combinations of components can provide systems that only react or systems that expand or foam and cure. For other systems (e.g., epoxy / amine, acrylate / amine, acrylate / peroxide, or other systems), and even for polyurethane systems, additional blowing agents (e.g., physical or chemical blowing agents) may be required or desired for foaming or expansion. Exemplary blowing agents can include one or more nitrogen-containing groups (e.g., amides, amines, etc.), carbonates, or can be a thermoplastic encapsulating solvent or other chemicals.

[0024] It is possible that the encapsulated component is a curing agent accelerator. The curing agent accelerator can be a urea-based curing agent accelerator. The curing agent accelerator can be encapsulated due to its tendency to increase viscosity over time due to accelerated reaction upon mixing with the remaining components of the material. While the curing agent may have a viscosity-reducing effect on the material. The urea-based curing agent accelerator can be a solid material at room temperature. When the encapsulating material is exposed to heat, the encapsulated curing agent accelerator can be exposed to the remaining components. It is possible that the curing agent used in combination with the urea-based curing agent accelerator includes dicyandiamide (examples include Amicure CG1200G or DDA10). By encapsulating the curing agent accelerator, the reactivity can be reduced when used in an extruder, injection molding machine, or other melt processing equipment. Additionally, the shelf life of the material can be extended by two months, three months, four months, five months, or even six months.

[0025] The encapsulated component can also be a low-temperature curing agent. For example, the encapsulated component can be selected from amines, imidazoles, thiols, or combinations thereof to prepare a low-temperature reaction product. These curing agents can be liquid curing agents. These curing agents can be solid curing agents. In a preferred embodiment, the encapsulating material is a liquid material that effectively remains in a fully encapsulated form through compounding and secondary processing until exposed to sufficient heat.

[0026] The encapsulating material can protect or isolate the encapsulated component from initiating reactions with the remaining components within the material and will release some or all of the encapsulated component upon exposure to or application of a physical or chemical modification. The encapsulating material (e.g., an encapsulating shell) can include a polymeric material, which can be a crosslinked polymeric material. The encapsulating material can include polyester, gelatin, polyformaldehyde urea formaldehyde, melamine formaldehyde, polyurethane, or silica.

[0027] The material to be encapsulated can be selected such that a large number of particles are included within the shell in an effort to disperse the particles throughout the polymeric matrix material. Reactive materials of large particle size may not be selected because the distribution of the reactive material within the polymeric matrix may become challenging when the number of particles is limited.

[0028] The formation of the materials described herein can be accomplished according to various new or known techniques. Preferably, the binder material is formed into a material of substantially uniform composition. However, it is contemplated that various combination techniques can be used to increase or decrease the concentration of certain components in certain locations of the material.

[0029] The binder material can be formed by supplying the components of the material in solid form (e.g., pellets, blocks, capsules, etc.), in liquid form, or a combination thereof. The components are typically combined in one or more containers such as large bins or other containers. Preferably, the containers can be used to mix the components by rotating or otherwise moving the container or the materials therein. Thereafter, heat, pressure, or a combination thereof can be applied to soften or liquefy the components such that the components can be mixed into a single, uniform composition by stirring or otherwise. When used, this heat and / or pressure is typically relatively low so as not to damage or rupture any encapsulation. Thus, it may be desirable for the unencapsulated components of the material to have a relatively low viscosity to allow mixing at lower pressures and lower heat conditions. Accordingly, the components used for encapsulation can be selected to avoid an undesirable increase in viscosity.

[0030] The material can be formed by heating one or more components (e.g., polymer-based materials) that are typically more easily softened or liquefied to bring these components into a mixable state. Thereafter, the remaining components can then be mixed with the softened components.

[0031] The teachings herein are based on providing improved materials (e.g., curable materials) and articles including such materials. The material can contribute to providing structural reinforcement, adhesion, barrier, sound absorption, vibration damping properties, or combinations thereof, within a cavity of a structure or on a surface of a structure or to one or more structural members of an article. The material can include any material that can be activated by environmental conditions or another condition to melt, flow, cure (e.g., thermosetting), expand, foam, or combinations thereof. For example, upon exposure to conditions such as heat, pressure, chemical exposure, combinations thereof, etc., the material can expand, foam, flow, melt, cure, combinations thereof, etc. Under similar conditions, the encapsulating material may fail and release any material included therein.

[0032] The material may include an elastomer-based compound. The elastomer compound may be a thermosetting elastomer, but it is not necessary. Exemplary elastomers include, but are not limited to, natural rubber, styrene-butadiene rubber, polyisoprene, polyisobutylene, polybutadiene, isoprene-butadiene copolymer, neoprene, nitrile rubber (e.g., nitrile, such as carboxyl-terminated nitrile), butyl rubber, polysulfide elastomer, acrylic elastomer, acrylonitrile elastomer, silicone rubber, polyester rubber, diisocyanate-linked condensation elastomer, EPDM (ethylene-propylene-diene rubber), etc.

[0033] Generally, the activatable material preferably includes at least one type of polymer particle. Such polymer particles can be used to improve fracture toughness (G 1C ), peel resistance, and impact resistance. As used herein, like any other component of the present teachings, the term "polymer particle" can include one or more polymer particles.

[0034] The material may include polymers or other additives for increasing strength, failure strain, and / or swelling properties. Compared with the material without additives, the additives can allow the material to have an improved balance between Young's modulus (measured by ASTM D638) and failure strain. For example, contrary to the material without additives, the additives can allow the modulus and failure strain not to increase simultaneously. After curing, the material may exhibit a tensile modulus of at least about 100 MPa, more typically at least about 200 MPa, and even more typically at least about 500 MPa. After curing, the material may exhibit a tensile modulus of about 1500 MPa or less, more typically about 1200 MPa or less, and even about 1000 MPa or less.

[0035] The material may include a toughening agent. The use of the term toughening agent may involve a single toughening agent or a combination of multiple different toughening agents. Although other toughening agents may be used, preferred toughening agents include amine-modified, epoxy-modified, or both polymers. These polymers may include thermoplastics, thermosets, or elastomers, combinations thereof, etc. These polymers may be modified with aromatic or non-aromatic epoxy resins and / or may be modified with bisphenol-F type, bisphenol-A type, combinations thereof, or other types of epoxy resins. Examples of preferred toughening agents are epoxidized polysulfides sold under the trade names EPS-350 and EPS-80 and commercially available from Akzo Nobel.

[0036] Phenol-containing molecules such as the toughening agent Rez-Cure EP 1820 (available from Innovative Resin Systems) are a possible material that can be used. Another example of a preferred toughening agent is an epoxy-dimer acid elastomer sold under the trade name HYPOX DA 323 and commercially available from CVC Specialty Chemicals. Other examples of preferred toughening agents are polyurethane-modified epoxy resins sold under the trade names GME-3210 and GME-3220 and commercially available from GNS Technologies. Without being bound by theory, it is believed that when a polyurethane-modified epoxy toughening agent is included, the activatable material can substantially maintain impact strength (e.g., impact resistance) at low temperatures while minimizing the decrease in glass transition temperature (Tg) (e.g., compared to other toughening agents). Other examples of preferred toughening agents are amine- or epoxy-terminated polyethers such as JEFFAMINE D-2000 commercially available from Huntsman and DER 732 commercially available from Dow Chemical Company. Toughening agents based on cashew nut shell liquid such as epoxidized liquids Cardolite NC-514 and Cardolite Lite 2513HP are also useful toughening agents. Unless otherwise stated, all of the individual toughening agents discussed herein can be used alone or in combination with each other in the materials of the present invention.

[0037] One or more foaming agents can be added to the material to create an open and / or closed cell structure within the material. In this way, the density of the article made from the material can be varied according to the needs of a particular application.

[0038] The foaming agent can include one or more nitrogen-containing groups such as amides, amines, etc. Examples of suitable foaming agents include azodicarbonamide, dinitrosopentamethylenetetramine, 4,4 i -oxybis-(benzenesulfonylhydrazide), trihydrazinotriazine, and N,N i -dimethyl-N,N i -dinitroterephthalamide. The material can include physical foaming agents that include but are not limited to reagents such as Expancel available from AkzoNobel.

[0039] A promoter for the foaming agent can also be provided in the activatable material. Various promoters can be used to increase the rate at which the foaming agent forms inert gas. One preferred foaming agent promoter is a metal salt or an oxide, such as a metal oxide like zinc oxide. Other preferred promoters include modified and unmodified thiazoles, ureas, and imidazoles.

[0040] The present teachings also contemplate omitting the blowing agent. However, preferably, the materials, blowing agent, or both of the present teachings are heat-activated. Alternatively, other reagents may be employed to effect activation in other ways, such as moisture, radiation, or other means.

[0041] The material may include one or more additional polymers or copolymers, which may include a variety of different polymers such as thermoplastics, elastomers, plastomers, combinations thereof, and the like. By way of example and not limitation, polymers that may be suitably incorporated include halogenated polymers, polycarbonates, polyketones, urethanes, polyesters, silanes, sulfones, allyls, olefins, styrenes, acrylates, methacrylates, epoxy resins, silicones, phenolic resins, rubbers, polyphenylene ethers, terephthalates, acetates (such as EVA), acrylates, methacrylates (such as ethylene methyl acrylate polymers), or mixtures thereof. Other potential polymeric materials may be or may include, but are not limited to, polyolefins (such as polyethylene, polypropylene), polystyrene, polyacrylates, poly(ethylene oxide), poly(ethylene imine), polyesters, polyurethanes, polysiloxanes, polyethers, polyphosphazines, polyamides, polyimides, polyisobutylene, polyvinyl butyral, polyacrylonitrile, acrylonitrile butadiene styrene, poly(vinyl chloride), poly(methyl methacrylate), poly(vinyl acetate), poly(vinylidene chloride), polytetrafluoroethylene, polyisoprene, polyacrylamide, polyacrylic acid, polymethacrylates.

[0042] In certain embodiments, it may be desirable to include a thermoplastic polyether in the activatable material. However, as with other materials, more or less thermoplastic polyether may be used depending on the intended use of the activatable material. Thermoplastic polyethers generally include pendant hydroxyl moieties. Thermoplastic polyethers may also include aromatic ether / amine repeat units in their backbone. For a sample weighing 2.16 kg at a temperature of about 190 °C, the thermoplastic polyethers of the present teachings preferably have a melt index of about 5 to about 300 grams per 10 minutes, more preferably about 30 to about 250 grams per 10 minutes. Of course, the thermoplastic polyethers may have higher or lower melt indices depending on their intended applications. Preferred thermoplastic polyethers include, but are not limited to, polyetheramines, poly(amino ethers), copolymers of monoethanolamine and diglycidyl ether, combinations thereof, and the like.

[0043] According to one embodiment, a thermoplastic polyether is formed by reacting a primary amine, a bis(secondary) diamine, a cyclic diamine, combinations thereof, etc. (e.g., monoethanolamine) with a diglycidyl ether or by reacting an amine with an epoxy-functionalized poly(alkylene oxide) to form a poly(amino ether). According to another embodiment, a thermoplastic polyether is prepared by reacting a bifunctional amine with a diglycidyl ether or a diepoxy-functionalized poly(alkylene oxide) under conditions sufficient to react the amine moiety with the epoxy moiety to form a polymer backbone having amine bonds, ether bonds, and pendant hydroxyl moieties. Optionally, the polymer can be treated with a monofunctional nucleophile, which can be or can be not a primary or secondary amine.

[0044] In addition, amines having one reactive group (e.g., one reactive hydrogen), such as cyclic amines, are expected to be used to form thermoplastic polyethers. Advantageously, such amines can help control the molecular weight of the thermoplastic ether formed.

[0045] Examples of preferred thermoplastic polyethers and methods for their formation are disclosed in U.S. Patent Nos. 5,275,853; 5,464,924 and 5,962,093, which are incorporated herein by reference for all purposes. Advantageously, the thermoplastic polyethers can provide various desired properties to the activatable material, such as desired physical and chemical properties for various applications, as further described herein.

[0046] Although not required, the material can include one or more ethylene polymers or copolymers, such as ethylene acrylate, ethylene acetate, etc. Ethylene methacrylate and ethylene vinyl acetate are two preferred ethylene copolymers. The material can also be free of any ethylene polymers or copolymers.

[0047] It may also be desirable to include a reactive polyethylene resin modified with one or more reactive groups such as glycidyl methacrylate or maleic anhydride. Examples of such polyethylene resins are sold under the trade name LOTA (e.g., LOTADER AX 8900) and are commercially available from Arkema Group.

[0048] The activatable material can also include one or more reinforcing components. Preferably, the reinforcing components include materials that generally do not react with other components present in the activatable material. It is contemplated that the reinforcing components can also impart properties such as strength and impact resistance to the activatable material.

[0049] Examples of reinforcing components include wollastonite, silica, diatomaceous earth, glass, clays (e.g., including nanoclays), glass beads or bubbles, glass, carbon or ceramic fibers, nylon, aramid or polyamide fibers, etc. One or more reinforcing components can be selected from mineral reinforcements such as diatomaceous earth, clays (e.g., including nanoclays), pyrophyllite, sauconite, soapstone, nontronite, wollastonite or montmorillonite. The reinforcing component can include silica and / or calcium mineral reinforcements. The reinforcing component can include glass, glass beads or bubbles, carbon or ceramic fibers, nylon, aramid or polyamide fibers (e.g., Kevlar). The reinforcing component can be wollastonite. The reinforcing component can be a fiber having an aspect ratio of from about 20:1 to about 3:1. The reinforcing component can be a fiber having an aspect ratio of from about 15:1 to about 10:1. The reinforcing component can be a fiber having an aspect ratio of about 12:1. The reinforcing component can improve the first physical property while substantially avoiding any significant adverse effect on the second physical property. As an example, the selected reinforcing component can improve the total modulus of the material while still having a minimal adverse effect on the failure strain. The material can also include one or more fillers including pigments or colorants, calcium carbonate, talc, silicate minerals, vermiculite, mica, etc.

[0050] It is contemplated that most almost any additional chemical, material or other substance can be added to the activatable material, provided they are suitable for the activatable material and for the selected application of the activatable material.

[0051] Other additives, reagents or property modifiers can also be included in the activatable material as needed, including but not limited to UV resistant agents, flame retardants, polymer particles, heat stabilizers, colorants, processing aids, lubricants, etc.

[0052] As used herein, unless otherwise specified, this teaching contemplates that any member of a genus (list) can be excluded from the subgenus; and / or any member of a Markush grouping can be excluded from the grouping.

[0053] Unless otherwise indicated, any numerical values recited herein include all values from the lower value to the higher value in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if the value of a component amount, property, or process variable (such as temperature, pressure, time, etc.) is stated to be, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, then the intermediate range values (such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc.) are intended to be within the teachings of this specification. Similarly, each intermediate value is also within this teaching. For values less than 1, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are merely examples of specific intentions, and all possible combinations of numerical values between the recited lowest and highest values are considered to be expressly stated in this application in a similar manner. It can be seen that the teachings of amounts expressed herein as "parts by weight" also contemplate the same ranges expressed as weight percentages. Thus, the expression in the range of "x parts by weight" of the resulting polymer blend composition also contemplates the teachings of the same recited amounts of "x" in terms of weight percentages of the resulting polymer blend composition.

[0054] 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.

[0055] The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The term "consisting essentially of" used to describe a combination shall include the identified elements, ingredients, components, or steps, as well as such other elements, ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the term "comprising" or "includes" herein to describe an element, ingredient, component, or step also contemplates embodiments consisting of or consisting essentially of the element, ingredient, component, or step.

[0056] A plurality of 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. The disclosure of "a" or "an" in connection with an element, ingredient, component, or step is not intended to exclude additional elements, ingredients, components, or steps.

[0057] It should be understood that the above description is intended to be illustrative and not restrictive. After reading the above description, many embodiments and many applications other than the examples provided will be apparent to those skilled in the art. Therefore, the scope of the present invention should not be determined with reference to the above description, but should be determined with reference to the appended claims and the full scope of the equivalents thereto. The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The omission of any aspect of the subject matter disclosed herein from the appended claims is not a waiver of such subject matter, nor should it be considered that the inventors do not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

1. A material, comprising: i) an encapsulated component within a housing, the encapsulated component comprising a curing agent that is liquid at room temperature; ii) a rupture initiator associated with the encapsulated component, the rupture initiator being formed as part of the housing; iii) a polymer matrix material; wherein the encapsulation is adapted to fail upon activation of the rupture initiator, thereby allowing the encapsulated component to be released to initiate a reaction or increase the reactivity of the material; wherein the rupture initiator comprises a chemical or physical foaming agent, and the rupture initiator is activated in response to a stimulus selected from heat, ultraviolet light, moisture, or any combination thereof.

2. The material according to claim 1, wherein the encapsulated component comprises a plurality of particles to improve the dispersion after release of the encapsulated component.

3. The material according to claim 1 or 2, wherein the encapsulated component is dicyandiamide or a urea-based reagent.

4. The material according to claim 1 or 2, wherein the encapsulated component is selected from amines, imidazoles, thiols, or combinations thereof.

5. The material according to claim 1 or 2, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 250 °C.

6. The material according to claim 1 or 2, wherein the material is a thermosetting material after curing.

7. The material according to claim 1 or 2, wherein the material is a thermoplastic material.

8. The material according to claim 1 or 2, wherein the material is a foamable material.

9. The material according to claim 1 or 2, wherein the polymer matrix material is an epoxy-based material.

10. The material according to claim 1 or 2, wherein the polymer matrix material comprises an ethylene material.

11. The material according to claim 1 or 2, wherein the polymer matrix material comprises a methacrylate material.

12. The material according to claim 1 or 2, wherein the polymer matrix material comprises a urethane-based material.

13. A method for forming an industrial material, comprising: encapsulating an encapsulated component in an encapsulating housing, the encapsulated component comprising a curing agent that is liquid at room temperature; forming a rupture initiator as part of the encapsulating housing; mixing the encapsulated component with a polymer matrix material; activating the rupture initiator to allow the encapsulated component to be released to initiate a reaction or increase the reactivity of the material; wherein the rupture initiator comprises a chemical or physical foaming agent, and the rupture initiator is activated in response to a stimulus selected from heat, ultraviolet light, moisture, or any combination thereof.

14. The method according to claim 13, wherein the encapsulated component comprises a plurality of particles to improve the dispersion after release of the encapsulated component.

15. The method according to claim 13 or 14, wherein the encapsulated component is dicyandiamide or a urea-based reagent.

16. The method according to claim 13 or 14, wherein the encapsulated component is selected from amines, imidazoles, thiols, or combinations thereof.

17. The method according to claim 13 or 14, wherein the housing ruptures when the rupture initiator expands from within the housing.

18. The method according to claim 13 or 14, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 250 °C.

19. The method according to claim 13 or 14, wherein the material is a thermosetting material after curing.

20. The method according to claim 13 or 14, wherein The material is a thermoplastic material.

21. The method according to claim 13 or 14, wherein, The material is a foamable material.

22. The method according to claim 13 or 14, wherein the polymer matrix material is an epoxy-based material.

23. The method according to claim 13 or 14, wherein the polymer matrix material comprises an ethylene-based material.

24. The method according to claim 13 or 14, wherein the polymer matrix material comprises a methacrylate-based material.

25. The method according to claim 13 or 14, wherein, The polymer matrix material comprises a urethane-based material.

26. Use of the material according to any one of claims 1 to 12 for sealing a cavity.

27. Use of the material according to any one of claims 1 to 12 as a structural adhesive for bonding together two or more structural members.

28. A method comprising applying the material according to any one of claims 1 to 12 to a structural support member or a cavity.

29. The material according to claim 5, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 190 °C.

30. The material according to claim 29, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 140 °C.

31. The method according to claim 18, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 200 °C.

32. The method according to claim 31, wherein the encapsulated component is a curing agent that causes the polymer matrix to react at a temperature below 170 °C.