Room temperature crosslinked foam

Abstract

Foams for filling cavities and crevasses and for forming foamed products are provided. The latex foam may include an A-side containing a functionalized latex and a B-side that contains a crosslinking agent and optionally a non-functionalized latex. The A- and/or B-side contain a blowing agent package or components forming the blowing agent package. The blowing agent package may be the combination of two or more chemicals that when mixed together form a gas or a chemical compound that, when activated by heat or light, forms a gas. In an alternate embodiment, the latex foam includes a functionalized latex, an acid, and an encapsulated crosslinking agent and base. Alternatively, the spray latex foam may include a functionalized latex, a crosslinking agent, and an encapsulated dry acid and dry base. The encapsulating agent may be a protective, non-reactive shell that can be broken or melted at the time of application.

1 . A method of forming a foam comprising:
 delivering a first component including one or more functionalized resins selected from a functionalized water-dispersible resin and a functionalized water-soluble resin through a first delivery line to an application device;   delivering a second component including a crosslinking agent that crosslinks at or about room temperature, said first and second component further including a member selected from an acid and a base; wherein said first component includes said base when said second component includes said acid, and wherein said first component includes said acid when said second component includes said base;   mixing said first and second components within said application device to form a reaction mixture; and   permitting said crosslinking agent and said one or more functionalized resins to chemically react while simultaneously reacting said acid and said base to form a gas to initiate a foaming reaction and form a foam.   
     
     
         2 . The method of  claim 1 , wherein said functionalized resin comprises one or more members selected from a functionalized latex and an acrylic solution. 
     
     
         3 . The method of  claim 1 , wherein said second component further comprises a non-functionalized latex. 
     
     
         4 . The method of  claim 1 , wherein at least one of said first component and second component further includes an alcohol co-solvent. 
     
     
         5 . The method of  claim 1 , wherein said crosslinking agent is selected from aziridines, multifunctional carbodiimides, polyfunctional aziridines, melamine formaldehyde, polysiloxanes and multifunctional epoxies. 
     
     
         6 . The method of  claim 1 , further comprising:
 permitting said foam to harden, said permitting step occurring in about two minutes or less.   
     
     
         7 . The method of  claim 1 , further comprising:
 spraying said foam to a desired location, said desired location being selected from an open cavity, a closed cavity, a crevasse and a crack.   
     
     
         8 . A method of forming a foam comprising:
 delivering a first component including at least one functionalized resin selected from a functionalized water-dispersible resin and a functionalized water-soluble resin through a first delivery line to an application device;   delivering a second component including a crosslinking agent that crosslinks at or about room temperature through a second delivery line to said application device, wherein one of said first component and said second component includes a blowing agent selected from a chemical compound that generates a gas upon heating, irradiation, or photo initiation;   mixing said first and second components within said application device to form a reaction mixture; and   permitting said crosslinking agent and said at least one functionalized resin to chemically react while said blowing agent simultaneously degrades to generate a gas to initiate a foaming reaction and form a foam.   
     
     
         9 . The method of  claim 8 , wherein said functionalized resin comprises one or more members selected from a functionalized latex and an acrylic solution. 
     
     
         10 . The method of  claim 8 , further comprising:
 spraying said foam to a desired location, said desired location being an open cavity, a closed cavity, a crevasse, or a crack.   
     
     
         11 . The method of  claim 10 , further comprising:
 permitting said foam to harden, said permitting step occurring in about two minutes or less.   
     
     
         12 . The method of  claim 8 , wherein at least one of said first component and second component further includes an alcohol co-solvent. 
     
     
         13 . The method of  claim 8 , wherein said second component further comprises a non-functionalized latex. 
     
     
         14 . A method of making a foam comprising:
 placing at least one functionalized resin selected from a functionalized water-dispersible resin and a functionalized water-soluble resin, a crosslinking agent that crosslinks at or about room temperature, and a phase change blowing agent under pressure;   releasing said at least one functionalized resin, said crosslinking agent, and said phase change blowing agent from said pressure to initiate a phase change of said blowing agent from a liquid to a gas; and   permitting said crosslinking agent and said at least one functionalized resin to chemically react while said blowing agent forms a gas to form a foam.   
     
     
         15 . The method of  claim 14 , wherein said functionalized resin comprises one or more members selected from a functionalized latex and an acrylic solution. 
     
     
         16 . The method of  claim 14 , wherein said phase change blowing agent is selected from low boiling point hydrocarbons and inert gases. 
     
     
         17 . The method of  claim 14 , further comprising:
 permitting said foam to harden, said permitting step occurring in about two minutes or less.   
     
     
         18 . A method of forming a molded foamed product comprising:
 mixing a first component including at least one functionalized resin selected from a functionalized water-dispersible resin and a functionalized water-soluble resin and a second component including a crosslinking agent that crosslinks at or about room temperature to form a reaction mixture, wherein one or both of said first component and said second component includes a blowing agent;   adding said reaction mixture to a mold; and   permitting said crosslinking agent and at least one functionalized resin selected from a functionalized water-dispersible resin and a functionalized water-soluble resin to chemically react while said blowing agent simultaneously degrades to foam a gas to initiate a foaming reaction and form a molded foamed product having a desired shape.   
     
     
         19 . The method of  claim 18 , wherein said functionalized resin comprises one or more members selected from a functionalized latex and an acrylic solution. 
     
     
         20 . The method of  claim 18 , wherein said blowing agent package is selected from a chemical compound that generates a gas upon heating, irradiation, or photo initiation, alkylsiloxanes and an acid and a base. 
     
     
         21 . The method of  claim 18 , further comprising:
 permitting said foam to harden, said permitting step occurring in about two minutes or less.   
     
     
         22 . The method of  claim 18 , wherein at least one of said first and second component further includes an alcohol co-solvent. 
     
     
         23 . The method of  claim 18 , wherein said at least one of said functionalized resin, said crosslinking agent, and said blowing agent are encapsulated in one or more encapsulating shells.