TOUGHENED POLYMERIC MATERIAL AND METHOD OF FORMING AND USING SAME

1 . A toughened polymeric material, comprising:

a thermoplastic material formed of polymeric chains wherein the thermoplastic material includes a polyetheramine; and

at least one toughener toughening the thermoplastic material, the at least one toughener selected from a tougher thermoplastic polymer, an elastomer or a combination thereof, wherein either:

i. the at least one toughener is grafted onto ends of the polymeric chains;

ii. the at least one toughener is disposed along the polymeric chains as pendant group or within the polymeric chains; or

iii. the at least one toughener is non-reactively blended with the polymer chains.

2 . A polymeric material as in claim 1 wherein the at least one toughener includes an elastomer that is incorporated within the polymeric chains.

3 . A polymeric material as in claim 1 wherein the at least one toughener includes an elastomer that is a pendant group of the polymeric chains of the thermoplastic material.

4 . A polymeric material as in claim 1 wherein the polymeric material is part of a powder coating covering the surface of a substrate.

5 . A polymeric material as in claim 1 further comprising a curing agent, a blowing agent or both, the polymeric material being activatable to expand, cure or both and adhere to a structure.

6 . A polymeric material as in claim 1 wherein the polymeric material is formed by reactively blending the at least one toughener with the thermoplastic material wherein the at least one toughener includes an elastomer that is epoxidized or includes maleic anhydride.

7 . A polymeric material as in claim 1 wherein the thermoplastic material, once toughened, exhibits an impact strength that is at least 3× relative to thermoplastic material prior to toughening.

8 . A polymeric material as in claim 1 wherein the thermoplastic material, once toughened, exhibits a notched izod impact strength of at least about 20 Joules/meter.

9 . A polymeric material as in claim 1 wherein the thermoplastic material, once toughened, exhibits a notched izod impact strength of at least about 50 Joules/meter.

10 . A toughened polymeric material, comprising:

a thermoplastic material formed of polymeric chains wherein the thermoplastic material includes a polyetheramine; and

at least one toughener toughening the thermoplastic material, the at least one toughener selected from a tougher thermoplastic polymer, an elastomer or a combination thereof, the at least one toughener including a butyl group or an ethylene group, wherein either:

i. the at least one toughener is grafted onto ends of the polymeric chains; or

ii. the at least one toughener is disposed along the polymeric chains as pendant group or within the polymeric chains.

11 . A polymeric material as in claim 10 wherein the at least one toughener includes an epoxy/elastomer adduct that is incorporated within the polymeric chains.

12 . A polymeric material as in claim 10 wherein the at least one toughener includes an elastomer that is a pendant group of the polymeric chains of the thermoplastic material.

13 . A polymeric material as in claim 10 wherein the polymeric material is part of a powder coating covering the surface of a substrate.

14 . A polymeric material as in claim 10 further comprising a curing agent, a blowing agent or both, the polymeric material being activatable to expand, cure or both and adhere to a structure.

15 . A polymeric material as in claim 10 wherein the polymeric material is formed by reactively blending the at least one toughener with the thermoplastic material wherein the at least one toughener includes an elastomer that is epoxidized or includes maleic anhydride.

16 . A polymeric material as in claim 1 wherein the thermoplastic material, once toughened, exhibits an impact strength that is at least 10× relative to thermoplastic material prior to toughening.

17 . A polymeric material as in claim 1 wherein the thermoplastic material, once toughened, exhibits a notched izod impact strength of at least about 50 Joules/meter.

18 . A toughened polymeric material, comprising:

a thermoplastic material formed of polymeric chains wherein the thermoplastic material includes a polyetheramine; and

at least one toughener toughening the thermoplastic material, the at least one toughener that includes an elastomer, the at least one toughener including a butyl group or an ethylene group, wherein either:

i. the at least one toughener is grafted onto ends of the polymeric chains; or

ii. the at least one toughener is disposed along the polymeric chains as pendant group or within the polymeric chains; and

wherein:

i. the elastomer has a relatively low mooney viscosity that is between about 10 and about 50;

ii. the polymeric material exhibits a notched izod impact strength of at least 50 Joules/meter.

19 . A polymeric material as in claim 28 wherein the thermoplastic material, once toughened, exhibits an impact strength that is at least 10× relative to thermoplastic material prior to toughening.

20 . A polymeric material as in claim 19 wherein the at least one tougher include an acetate, an acrylate or a butyl rubber.