Epoxy hardener compositions incorporating naphthol and naphthol derivatives

Abstract

The present invention relates to an epoxy curing agent composition comprising a combination of naphthol and naphthol derivatives and at least one polyamine having three or more active amine hydrogens, and the use of the curing agent as a toughening agent for epoxy resins. The curing agent composition can be used to cure, toughen and / or crosslink epoxy resins.

Description

[Technical field]

[0001] Epoxy hardeners are used in a variety of industrial applications. These applications include industrial coatings and composites. The cured epoxy resin system provides the final product with excellent adhesion, chemical resistance, good mechanical and electrical insulating properties, and in some cases heat resistance. Cured epoxy resin systems are particularly useful for protecting metal and concrete surfaces, cementitious and ceramic substrates.

[0002] To convert epoxy resins into a rigid, permeable, thermosetting network, a crosslinker must be used. These crosslinkers, tougheners or hardeners are widely known and promote the crosslinking or curing of epoxy resins. Epoxy resins have epoxy groups that react with amines, carboxylic acids and mercaptans to effect the cure. Curing can occur by homopolymerization initiated by catalytic hardeners or by polyaddition / copolymerization reactions with multifunctional hardeners.

[0003] Many industrial applications of epoxy coatings require fast recovery to improve productivity. There is a market demand for improved reactivity and performance at low temperatures, e.g. 5°C and even 0°C. Current epoxy curing systems used at these temperatures do not provide adequate coating performance. Curing is too slow, and as a result, the coating has defects such as whitening, carbamate formation, and water spots. This is due to unreacted amine-based curing agents migrating to the coating surface and reacting with moisture and carbon dioxide in the air to form an oily white film (carbamate formation). In addition, the slow cure results in a longer time for the coating to dry or harden, which in turn results in a longer time before the next coating can be applied.

[0004] To increase the cure rate of epoxy coatings at low temperatures, painters have traditionally used epoxy accelerators. These accelerators include tertiary amines, phenols, phenol derivatives such as Mannich bases, and acids such as salicylic acid, p-toluenesulfonic acid, and sulfuric acid. These accelerators can only be used at low levels and have several drawbacks, including brittleness of the coating due to homopolymerization initiation of the epoxy resin. There are also growing health and safety concerns associated with phenol and substituted phenols, including toxicity and mutagenicity of this class of compounds. Indeed, there is growing regulatory pressure from professional organizations and consumers against the use of phenol and phenol derivatives in coating materials.

[0005] There is a need in the art for hardener compositions for epoxy resins that can enhance the cure rate at sub-ambient temperatures (e.g., 5° C.) and provide a safer alternative to currently used materials. We now disclose naphthol and naphthol derivative compositions that provide excellent cure rates while exhibiting greater safety for health and the environment.

[0006] Summary of the Invention The present invention relates to an epoxy curing agent composition comprising a combination of naphthol and naphthol derivatives and at least one polyamine having three or more active amine hydrogens, and the use of said curing agent as a toughening agent for epoxy resins. The curing agent composition can be used to cure, toughen and / or crosslink epoxy resins. In addition, these inventive compositions can provide a dry cure of epoxy coatings at room temperature (23°C) or 5°C at a much higher rate than the prior art fast-curing epoxy systems containing phenol or phenol-derived Mannich bases and phenalkamines.

[0007] The fast-curing epoxy curing system of the present invention offers the advantage of lower carbamate tendency and shorter drying time of the coating compared to conventional epoxy accelerators such as phenol Mannich base and salicylic acid. Furthermore, the naphthol or naphthol derivative in the coating composition acts as a plasticizer to enhance the degree of cure without reducing the flexibility of the coating.

[0008] One aspect of the present invention is (a) a structure (I) below: [ka] [Where, R 1 and R 2 are, independently of each other, OH, H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , HSO 3 , or X(CH 2 ) NHY, where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 aryl, or polyamine; X is Ph or C 1 ~C 4 R is alkyl; 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 ;R 1 or R 2 one of which is OH] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; The present invention relates to a hardener composition comprising:

[0009] Preferably, in one embodiment, at least one naphthol or naphthol derivative has the following structures (II)-(V): [ka] [Where, R 2 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 is] [ka] [Where, R 1 and R 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 is] [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C 1 ~C 4 is alkyl] and [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C 1 ~C 4 is alkyl] It is expressed as:

[0010] Compounds of structures (II) and (III) can be synthesized by conventional methods or purchased from commercial sources, while naphthol derivatives of structures (IV) and (V) can be obtained by the Mannich reaction in which 1-naphthol (α-naphthol) or 2-naphthol (β-naphthol) is reacted with an aldehyde and an amine to form a Mannich base.

[0011] Preferably, the polyamine compound used for the reaction with 1-naphthol or 2-naphthol is an alkylene polyamine, such as ethylene diamine, a polyalkylene polyamine, such as diethylene triamine, triethylene tetramine, tetraethylene pentamine, N 1-(3-dimethylaminopropyl)propylenediamine (DMAPAP), dimethylaminopropylamine (DMAPA), an arylalkylpolyamine, such as m-xylylenediamine, a cycloaliphatic polyamine, such as 4,4'-methylenedicyclohexylamine (PACM), or a polyetherpolyamine, such as Jeffamine D230.

[0012] Another aspect of the invention relates to compositions comprising a combination of naphthol and naphthol derivatives, at least one polyamine having three or more active amine hydrogens, and a multifunctional epoxy resin.

[0013] In preparing the compositions of the present invention, the naphthol or naphthol derivative can be dissolved in the polyamine prior to contacting with the epoxy resin component, or the naphthol or derivative can be dissolved in the resin and the mixture then treated with the polyamine.

[0014] Preferably, in one embodiment, the hardener composition of the present disclosure has an amine hydrogen equivalent weight (AHEW) of 50 to 500 based on 100% solids. In another aspect, the present disclosure provides an amine-epoxy composition and a cured product made therefrom. For example, an amine-epoxy composition according to the present disclosure includes a reaction product of a hardener composition comprising a novel composition comprising at least one naphthol or naphthol derivative and having at least two active amine hydrogen atoms, and an epoxy composition comprising at least one multifunctional epoxy resin. Preferably, in one embodiment, the naphthol or naphthol derivative is 0.5 to 50 wt % based on the amine in the hardener composition.

[0015] The present disclosure also provides the use of a curing agent composition comprising a naphthol or naphthol derivative represented by Structures (I)-(V) and at least one polyamine having three or more active amine hydrogens as a toughening agent for epoxy resins.

[0016] The amine-epoxy compositions disclosed herein produce articles of manufacture including, but not limited to, coatings, primers, sealants, curable compounds, building products, flooring products, and composite products. Furthermore, such coatings, primers, sealants, or curable compounds can be applied to metal or cementitious substrates. The mixture of the hardener and epoxy resin component often does not require a "maturity time" to obtain a contact product with high gloss and transparency. Maturation time or incubation time is defined as the time from mixing the epoxy resin component and the amine to applying the product to the target substrate. It can also be defined as the time required for the mixture to become transparent. Furthermore, the novel hardener composition also provides a higher amine-epoxy reaction rate. These unique properties provide the advantages of lower carbamate tendency and faster drying time of the coating compared to conventional epoxy accelerator products derived from alkylene polyamines and phenols such as ethylenediamine and diethylenetriamine.

[0017] Detailed Description of the Invention In preparing the compositions of the present invention, the naphthol or naphthol derivative can be dissolved in the polyamine prior to contacting with the epoxy resin component, or the naphthol or naphthol derivative can be dissolved in the resin and the mixture then treated with the polyamine.

[0018] One aspect of the present invention is (a) a structure (I) below: [ka] [Where, R 1 and R 2 are, independently of each other, OH, H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH2 , Cl, Br, I, NO 2 , HSO 3 , or X(CH 2 ) NHY, where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 aryl or polyamine, X is Ph or C 1 ~C 4 R is alkyl; 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 ;R 1 or R 2 one of which is OH] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; The present invention relates to a hardener composition comprising:

[0019] Preferably, in one embodiment, at least one naphthol or naphthol derivative has the following structures (II)-(V): [ka] [Where, R 2 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO2 , or HSO 3 is] [ka] [Where, R 1 and R 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 is] [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C 1 ~C 4 is alkyl] and [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1-(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C 1 ~C 4 is alkyl] It is expressed as:

[0020] The naphthol compounds of structures (II) and (III) can be synthesized by methods known in the art or purchased from commercial sources.Preferred examples of these compounds include 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol, 1-naphthol-4-sulfonic acid, and the like. Preferably, in one embodiment, the at least one naphthol compound is selected from the group consisting of 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol and 1-naphthol-4-sulfonic acid.

[0021] Preferably, the naphthol derivatives of structures (IV) and (V) are obtained by the Mannich reaction in which 1-naphthol (α-naphthol) or 2-naphthol (β-naphthol) is reacted with an aldehyde and an amine to form a Mannich base. Preferably, in one embodiment, the molar ratio of amine to naphthol is in the range of 1:1 to 1:3. Preferably, in another embodiment, the molar ratio of amine to naphthol is in the range of 1:1 to 1:2. Preferably, in one embodiment, the molar ratio of amine to aldehyde is in the range of 1:1 to 1:6. Preferably, in another embodiment, the molar ratio of naphthol to aldehyde is in the range of 1:1 to 1:3.

[0022] Preferably, the reaction is carried out in a single step by mixing naphthol and amine and treating the mixture with aldehyde at the desired reaction temperature. Alternatively, the aldehyde can be mixed with amine and treated with naphthol at the reaction temperature. Preferably, the reaction can be carried out at 40°C to 150°C. In another embodiment, the reaction can be carried out at 80°C to 120°C. After completion of the reaction, the product is obtained by distilling water.

[0023] Preferably, the aldehyde compound used has the formula RCOH, where R is H, C 1 ~C 10 Alkyl, Ph, C 5 ~C 6 The aldehyde is preferably a cycloaliphatic group or a mixture thereof.Suitable aldehydes are formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, pentanal, hexanal, octanal, heptanal, decanal, benzaldehyde, cyclopentanecarboxaldehyde, cyclohexanecarboxaldehyde.Preferred aldehydes are formaldehyde and acetaldehyde.Preferably, formaldehyde can be used as an aqueous solution or as p-formaldehyde in polymeric form.

[0024] Preferably, the amine compound used in the reaction with 1-naphthol or 2-naphthol is an alkylene polyamine, such as ethylenediamine, a polyalkylene polyamine, such as diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine (DMAPAPA), dimethylaminopropylamine (DMAPA), or an arylalkylpolyamine, such as m-xylylenediamine, or an alicyclic polyamine, such as 4,4'-methylenedicyclohexylamine (PACM), or a polyetherpolyamine, such as Jeffamine D230.

[0025] In another embodiment, the hardener composition further comprises another epoxy accelerator in addition to naphthol or naphthol derivative.Preferably, in this further embodiment, the hardener composition further comprises at least one compound selected from the group consisting of boron trifluoride amine complex, substituted phenol such as 2,4,6-tri(dimethylaminomethyl)phenol, tertiary amine such as benzyldimethylamine, or imidazole, calcium nitrate, carboxylic acid, salicylic acid and sulfuric acid.

[0026] The present disclosure also provides the use of a curing agent composition comprising a naphthol or naphthol derivative represented by Structures (I)-(V) and at least one polyamine having three or more active amine hydrogens as a toughening agent for epoxy resins.

[0027] The present disclosure is also directed to a method of making a composition, the method comprising: (a) dissolving at least one naphthol or naphthol derivative in at least one polyamine to form a mixture; and (b) reacting the mixture with an epoxy resin component. Preferably, the at least one naphthol or naphthol derivative is represented by Structure (I). Preferably, the at least one naphthol or naphthol derivative is represented by Structures (II)-(V). Preferably, the at least one naphthol is selected from the group consisting of 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol, and 1-naphthol-4-sulfonic acid. Preferably, at least one naphthol derivative is obtained by the Mannich reaction in which 1-naphthol or 2-naphthol is reacted with an aldehyde and an amine to form a Mannich base.

[0028] The present disclosure is also directed to a method for preparing a composition, the method comprising: (a) dissolving at least one naphthol or naphthol derivative in an epoxy resin component to form a mixture; and (b) reacting the mixture with at least one polyamine. Preferably, the at least one naphthol or naphthol derivative is represented by Structure (I). Preferably, the at least one naphthol or naphthol derivative is represented by Structures (II)-(V). Preferably, the at least one naphthol is selected from the group consisting of 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol, and 1-naphthol-4-sulfonic acid. Preferably, at least one naphthol derivative is obtained by the Mannich reaction in which 1-naphthol or 2-naphthol is reacted with an aldehyde and an amine to form a Mannich base.

[0029] The present disclosure also provides amine-epoxy compositions and cured products made therefrom. Another aspect of the present invention is (a) a structure (I) below: [ka] [Where, R 1 and R 2 are, independently of each other, OH, H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , HSO 3 , or X(CH 2 ) NHY, where Y is C 1 ~C 10 Alkyl, C 1~C 10 aryl or polyamine, X is Ph or C 1 ~C 4 R is alkyl; 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 ;R 1 or R 2 one of which is OH] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; (c) an epoxy resin component comprising at least one multifunctional epoxy resin; The present invention relates to a composition comprising the reaction product of

[0030] In a preferred embodiment, the composition comprises: (a) at least one naphthol or naphthol derivative, the at least one naphthol or naphthol derivative having the following structures (II)-(V): [ka] [Where, R 2 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 is] [ka] [Where, R 1 and R 3 ~R 8 , H, C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, C 1 ~C 10 Alkyl ether or C 1 ~C 10 Aryl ether, NH 2 , Cl, Br, I, NO 2 , or HSO 3 is] [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C 1 ~C 4 is alkyl] and [ka] [where Y is C 1 ~C 10 Alkyl, C 1 ~C 10 Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N 1 -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine and 4,4'-methylenedicyclohexylamine, and X is Ph or C1 ~C 4 is alkyl] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; (c) an epoxy resin component comprising at least one multifunctional epoxy resin; This includes reaction products of:

[0031] Preferred polyamines having three or more active amine hydrogens include diethylenetriamine (DETA), triethylenetetramine (TETA), tetraethylenepentamine (TEPA), pentaethylenehexamine (PEHA), hexamethylenediamine (HMDA), 1,3-pentanediamine (DYTEK™ EP), 2-methyl-1,5-pentanediamine (DYTEK™ A), triaminononane, N-(2-aminoethyl)-1,3-propanediamine (N-3-amine), N,N'-1,2-ethanediylbis-1,3-propanediamine (N 4-amines), or dipropylenetriamine; arylaliphatic polyamines, such as m-xylylenediamine (mXDA), p-xylylenediamine; alicyclic polyamines, such as 1,3-bis(aminomethyl)cyclohexylamine (1,3-BAC), isophoronediamine (IPDA), 4,4'-methylenebiscyclohexanamine, 1,2-diaminocyclohexylamine (DCHA), aminopropylcyclohexylamine (APCHA), methylene bridged poly(alicyclic-aromatic)amines, such as MPCA, aromatic polyamines, such as m-phenylenediamine, diaminodiphenylmethane (DDM), or diaminodiphenylsulfone (DDS); heterocyclic polyamines, such as N-aminoethene, tylpiperazine (NAEP), or 3,9-bis(3-aminopropyl)2,4,8,10-tetraoxaspiro(5,5)undecane; polyalkoxypolyamines in which the alkoxy groups may be oxyethylene, oxypropylene, oxy-1,2-butylene, oxy-1,4-butylene, or copolymers thereof, such as 4,7-dioxadecane-1,10-diamine, 1-propanamine, 3,3'-(oxybis(2,1-ethanediyloxy))bis(diaminopropylated diethylene glycol ANCAMINE 1922A), poly(oxy(methyl-1,2-ethanediyl)), α-(2-aminomethylethyl)ω-(2-aminomethylethoxy) (JEFFAMINE D 230, D-400), triethylene glycol diamine and oligomers (JEFFAMIN EXTJ-504, JEFFAMINE XTJ-512), poly(oxy(methyl-1,2-ethanediyl)), α,α'-(oxydi-2,1-ethanediyl)bis(ω-(aminomethylethoxy)) (JEFFAMINE XTJ-511), bis(3-aminopropyl)polytetrahydrofuran 350, bis(3-aminopropyl)polytetrahydrofuran 750, poly(oxy(methyl-1,2-ethanediyl)), α-hydro-ω-(2-aminomethylethoxy)ether and 2-ethyl-2-(hydroxymethyl)-1,3-propanediol (3:1) (JEFFAMINE T-403), and diaminopropyl diaminopropyl dipropylene glycol.

[0032] Other preferred polyamine co-curing agents include amidoamines and polyamides. Polyamides consist of the reaction product of dimerized fatty acids (dimer acids) with polyethyleneamines, usually with some amount of monomeric fatty acids to help control molecular weight and viscosity. "Dimerized" or "dimer" or "polymerized" fatty acids refer to polymerized acids derived from unsaturated fatty acids. These are more fully described in TE Breuer, "Dimer Acids", JI Kroschwitz (ed.), Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed., Wiley, New York, 1993,Vol. 8, pp. 223-237. Common monofunctional unsaturated C-6 to C-20 fatty acids that are also used in the manufacture of polyamides include tall oil fatty acid (TOFA) or soybean fatty acid.

[0033] More preferred polyamine co-curing agents include phenalkamines and Mannich bases of phenolic compounds, polyamines and formaldehyde.

[0034] Preferably, in one embodiment, the weight ratio of naphthol or naphthol-derived Mannich base to polyamine co-curing agent is 1:1 to 1:0.05. In another preferred embodiment, the weight ratio of naphthol or naphthol-derived Mannich base to polyamine co-curing agent is 1:0.75 to 1:0.25.

[0035] Preferably, in one embodiment, the amine-epoxy composition of the present disclosure has a stoichiometric ratio of epoxy groups in the epoxy resin component to amine hydrogens in the hardener composition in the range of 1.5:1 to 0.7:1. Preferably, in one embodiment, such amine-epoxy composition can have a stoichiometric ratio of 1.5:1, 1.4:1, 1.3:1, 1.2:1, 1.1:1, 1:1, 0.9:1, 0.8:1, or 0.7:1. In another preferred embodiment, the stoichiometric ratio is in the range of 1.3:1 to 0.7:1, or 1.2:1 to 0.8:1, or 1.1:1 to 0.9:1.

[0036] Preferably, in one embodiment, the hardener composition of the present disclosure has an amine hydrogen equivalent weight (AHEW) of 50 to 500 based on 100% solids. In another aspect, the present disclosure provides an amine-epoxy composition and a cured product made therefrom. For example, an amine-epoxy composition according to the present disclosure includes a reaction product of a hardener composition comprising a novel composition comprising at least one naphthol or naphthol derivative and having at least two active amine hydrogen atoms, and an epoxy resin component comprising at least one multifunctional epoxy resin.

[0037] Preferably, in one embodiment, naphthol or naphthol derivative is 0.5-50% by weight relative to the amine in the curing agent composition. In a preferred embodiment, 5-30% by weight relative to the amine can be used. In another preferred embodiment, the ratio of naphthol or naphthol derivative to the amine is 10-30% by weight.

[0038] Preferred naphthol compounds are naphthol Mannich bases, 1-naphthol (α-naphthol) and 2-naphthol (β-naphthol).

[0039] The present disclosure also includes the use of the above-mentioned curing agent and at least one epoxy resin component to produce a reinforced article of manufacture. Preferably, such articles may include, but are not limited to, coatings, primers, sealants, curable compounds, building products, flooring products, composite products, laminates, potting compounds, grouts, fillers, cementitious grouts, or self-leveling flooring. Additional components or additives may be used with the compositions of the present disclosure to produce an article of manufacture. Furthermore, such coatings, primers, sealants, curable compounds, or grouts may be applied to metal or cementitious substrates. Preferably, the article is a coating. Preferably, in one embodiment, the coating is a flexible epoxy coating. Preferably, in one embodiment, the coating is produced at ambient temperature. Preferably, in another embodiment, the coating is produced below ambient temperature, down to 0°C.

[0040] Encapsulation of epoxy hardeners with solid naphthols, e.g., 2-naphthol, also provides a useful technique for one-part (1K) epoxy hardeners. Such applications are known for the combination of phenol-formaldehyde resins and epoxy amine hardeners. Encapsulation of the amine with solid naphthol compounds allows 1K epoxy systems to cure faster / at lower temperatures.

[0041] The relative amounts of the epoxy resin component and the hardener composition selected may vary, for example, depending on the end-use article, its desired properties, and the manufacturing method and conditions used to produce the end-use article. For example, in coating applications using a particular amine-epoxy composition, the incorporation of more epoxy resin relative to the amount of hardener composition may result in a coating with increased drying time but increased hardness and improved appearance as measured by gloss. The amine-epoxy compositions of the present disclosure have a stoichiometric ratio of epoxy groups in the epoxy resin component to amine hydrogens in the hardener composition ranging from 1.5:1 to 0.7:1. For example, such amine-epoxy compositions may have a stoichiometric ratio of 1.5:1, 1.4:1, 1.3:1, 1.2:1, 1.1:1, 1:1, 0.9:1, 0.8:1, or 0.7:1. In other embodiments, the stoichiometric ratio ranges from 1.3:1 to 0.7:1, or from 1.2:1 to 0.8:1, or from 1.1:1 to 0.9:1.

[0042] The amine-epoxy composition of the present disclosure comprises the reaction product of a hardener composition and an epoxy resin component comprising at least one multifunctional epoxy resin. As used herein, multifunctional epoxy resin refers to a compound containing two or more 1,2-epoxy groups per molecule. Preferably, the epoxy resin component is selected from the group consisting of aromatic epoxy resins, cycloaliphatic epoxy resins, aliphatic epoxy resins, glycidyl ester resins, thioglycidyl ether resins, N-glycidyl ether resins, and combinations thereof.

[0043] Preferred aromatic epoxy resins suitable for use in the present disclosure include glycidyl ethers of polyhydric phenols, including glycidyl ethers of dihydric phenols. More preferred are glycidyl ethers of resorcinol, hydroquinone, bis-(4-hydroxy-3,5-difluorophenyl)-methane, 1,1-bis-(4-hydroxyphenyl)-ethane, 2,2-bis-(4-hydroxy-3-methylphenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dichlorophenyl)propane, 2,2-bis-(4-hydroxyphenyl)-propane (commercially known as bisphenol A), bis-(4-hydroxyphenyl)-methane (commercially known as bisphenol F, which may contain various amounts of 2-hydroxyphenyl isomers), and the like, or any combination thereof. In addition, the following structures are included: [ka] Also useful in the present disclosure are highly dihydric phenols of the formula: where R' is a divalent hydrocarbon radical of a dihydric phenol, such as those listed above, and p is an average value between 0 and 7. Materials according to this formula can be made by polymerizing a mixture of a dihydric phenol and epichlorohydrin, or by polymorphizing a mixture of a diglycidyl ether of a dihydric phenol and a dihydric phenol. While the value of p is an integer in any given molecule, the material is necessarily a mixture, and the mixture is characterized in that the average value of p is not necessarily an integer. In one embodiment of the present disclosure, polymeric materials can be used in which the average value of p is between 0 and 7.

[0044] In one embodiment of the present disclosure, the at least one multifunctional epoxy resin is preferably a diglycidyl ether of bisphenol-A (DGEBA), a higher order or higher molecular weight version of DGEBA, a diglycidyl ether of bisphenol-F, a diglycidyl ether of a novolac resin, or any combination thereof. Higher molecular weight versions or derivatives of DGEBA are produced by a higher order process in which excess DGEBA is reacted with bisphenol-A to obtain an epoxy-terminated product. The epoxy equivalent weight (EEW) of such products ranges from 450 to over 3000. These products are solid at room temperature and are therefore often referred to as solid epoxy resins.

[0045] In a preferred embodiment, the at least one multifunctional epoxy resin has the following structure: [ka] [wherein R'' is H or CH 3 where p is an average value from 0 to 7. DGEBA is a diglycidyl ether of bisphenol-F or bisphenol-A, represented by the structure above, where R'' is CH 3 and p is 0]. DGEBA or higher-ordered DGEBA resins are often used in coating formulations due to their combination of low cost and high performance properties. Commercial grades of DGEBA are readily available with EEWs ranging from 174 to 250, more commonly 185 to 195. At these low molecular weights, the epoxy resins are liquid and are often referred to as liquid epoxy resins. Those skilled in the art will appreciate that pure DGEBA has an EEW of 174, so most grades of liquid epoxy resins are slightly higher molecular weight. Resins with EEWs of 250 to 450 and produced by the proposed method are referred to as semi-solid epoxy resins because they are a mixture of solids and liquids at room temperature. Multifunctional resins with EEWs based on solids of 160 to 750 are useful in the present disclosure. In another embodiment, the multifunctional epoxy resins have an EEW ranging from 170 to 250.

[0046] Examples of cycloaliphatic epoxy compounds include, but are not limited to, polyglycidyl ethers of polyols having at least one cycloaliphatic ring, or compounds containing cyclohexene oxide or cyclopentene oxide obtained by epoxidizing a compound containing a cyclohexene ring or a cyclopentene ring with an oxidizing agent. Some specific examples include, but are not limited to, hydrogenated bisphenol A diglycidyl ether; 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexyl carboxylate; 3,4-epoxy-1-methylcyclohexyl-3,4-epoxy-1-methylhexane carboxylate; 6-methyl-3,4-epoxycyclohexylmethyl-6-methyl-3,4-epoxycyclohexane carboxylate; 3,4-epoxy-3-methylcyclohexylmethyl-3,4-epoxy-3-methylcyclohexane carboxylate; 3,4-epoxy-5-methylcyclohexylmethyl-3,4-epoxy-5-methylcyclohexanecarboxylate; bis(3,4-epoxycyclohexylmethyl)adipate; methylene bis(3,4-epoxycyclohexane); 2,2-bis(3,4-epoxycyclohexyl)propane; dicyclopentadiene dipoxide; ethylene-bis(3,4-epoxycyclohexanecarboxylate); dioctyl epoxy hexahydrophthalate; and di-2-ethylhexyl epoxy hexahydrophthalate.

[0047] Examples of aliphatic epoxy compounds include, but are not limited to, polyglycidyl ethers of aliphatic polyols or their alkylene oxide adducts, polyglycidyl esters of aliphatic long-chain polybasic acids, homopolymers synthesized by vinyl polymerization of glycidyl acrylate or glycidyl methacrylate, and copolymers synthesized by vinyl polymerization of glycidyl acrylate or glycidyl methacrylate with other vinyl monomers. Specific examples include, but are not limited to, glycidyl ethers of polyols, such as 1,4-butanediol diglycidyl ether; 1,6-hexanediol diglycidyl ether; triglycidyl ether of glycerin; triglycidyl ether of trimethylolpropane; tetraglycidyl ether of sorbitol; hexaglycidyl ether of dipentaerythritol; diglycidyl ether of polyethylene glycol; and diglycidyl ether of polypropylene glycol; and polyglycidyl ethers of polyether polyols obtained by adding one or more types of alkylene oxide to an aliphatic polyol such as ethylene glycol, propylene glycol, trimethylolpropane, or glycerin.

[0048] The glycidyl ester resin is obtained by reacting a polycarboxylic acid compound having at least two carboxylic acid groups in the molecule with epichlorohydrin. Examples of such polycarboxylic acids include aliphatic, alicyclic, and aromatic polycarboxylic acids. Examples of aliphatic polycarboxylic acids include oxalic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, sebacic acid, suberic acid, azelaic acid, or dimerized or trimerized linoleic acid. Examples of alicyclic polycarboxylic acids include tetrahydrophthalic acid, 4-methyltetrahydrophthalic acid, hexahydrophthalic acid, or 4-methylhexahydrophthalic acid, and examples of aromatic polycarboxylic acids include phthalic acid, isophthalic acid, or terephthalic acid.

[0049] Thioglycidyl ether resins are derived from dithiols such as, for example, ethane-1,2-dithiol and bis(4-mercaptomethylphenyl) ether.

[0050] N-glycidyl resins are obtained by dechlorination of the reaction products of epichlorohydrin with amines containing at least two amine hydrogen atoms. Such amines are, for example, aniline, n-butylamine, bis(4-aminophenyl)methane, m-xylylenediamine or bis(4-methylaminophenyl)methane. However, N-glycidyl resins also include triglycidyl isocyanurate, N,N'-diglycidyl derivatives of cycloalkylene ureas, such as ethylene urea or 1,3-propylene urea, and diglycidyl derivatives of hydantoin, such as 5,5-dimethylhydantoin.

[0051] For one or more embodiments, the resin component further comprises a reactive diluent. A reactive diluent is a compound that participates in a chemical reaction with the toughening agent component during the curing process and is incorporated into the cured composition, and is a monofunctional epoxide. Reactive diluents can also be used to change the viscosity and / or curing properties of the curable composition in various applications. In some applications, reactive diluents can impart a lower viscosity to affect the flow properties of the curable composition, extend pot life, and / or improve adhesion properties. For example, lowering the viscosity can increase the level of pigment in the formulation or composition while allowing for easier application and also allows for the use of higher molecular weight epoxy resins. Thus, it is within the scope of the present disclosure for an epoxy component that includes at least one multifunctional epoxy resin to further comprise a monofunctional epoxide. Examples of monoepoxides include, but are not limited to, styrene oxide, cyclohexene oxide, and glycidyl ethers of phenol, cresol, tert-butylphenol, other alkylphenols, butanol, 2-ethylhexanol, C4-C14 alcohols, and the like, or combinations thereof. The multifunctional epoxy resin can also be present in a solution or emulsion, where the diluent is water, an organic solvent, or a mixture thereof. The amount of multifunctional epoxy resin can range from 50% to 100%, 50% to 90%, 60% to 90%, 70% to 90%, and in some cases 80% to 90% by weight of the epoxy component. In one or more embodiments, the reactive diluent is less than 60% by weight of the total weight of the resin component.

[0052] Particularly suitable polyfunctional epoxy compounds are the diglycidyl ethers of bisphenol-A and bisphenol-F, the higher diglycidyl ethers of bisphenol-A and bisphenol-F, and epoxy novolac resins. The epoxy resin may be a single resin or a mixture of mutually compatible epoxy resins.

[0053] The compositions of the present disclosure can be used to manufacture various articles of manufacture. Various additives can be used in the formulations and compositions to adjust specific properties during the manufacture of the article or as required for the end use. These additives include, but are not limited to, solvents (including water), accelerators, plasticizers, fillers, fibers such as glass or carbon fibers, pigments, pigment dispersants, rheology modifiers, thixotropic agents, flow or leveling aids, surfactants, defoamers, biocides, or any combination thereof. It is understood that the compositions or formulations may include other mixtures or materials known in the art and are within the scope of the present disclosure.

[0054] The present disclosure is also directed to an article of manufacture comprising the composition disclosed herein. For example, the article can comprise an amine-epoxy composition comprising the reaction product of a hardener composition and an epoxy composition. The hardener composition can comprise naphthol or a naphthol-derived Mannich base. The epoxy resin component can comprise at least one multifunctional epoxy resin. Optionally, various additives can be present in the composition or formulation used to manufacture the article to be made, depending on the desired properties. These additives include, but are not limited to, solvents (including water), accelerators, plasticizers, fillers, fibers, such as glass or carbon fibers, pigments, pigment dispersants, rheology modifiers, thixotropic agents, flow or leveling aids, surfactants, defoamers, biocides, or any combination thereof. The choice and amount of these additives is at the discretion of the formulator.

[0055] In another embodiment, the naphthol or naphthol-derived Mannich base accelerator curing composition can be combined with other epoxy curing accelerators.Preferably, representative accelerators that can be used include boron trifluoride amine complexes, substituted phenols such as 2,4,6-tri(dimethylaminomethyl)phenol, tertiary amines such as benzyldimethylamine and imidazole.Calcium nitrate, carboxylic acids, salicylic acid, sulfuric acid, etc.

[0056] Articles according to the present disclosure include, but are not limited to, coatings, primers, sealants, curable compounds, building products, flooring products, composite products, laminates, potting compounds, grouts, fillers, cementitious grouts, or self-leveling flooring. Coatings based on these amine-epoxy compositions can include diluents such as water or organic solvents as needed for the particular application. Coatings can include various types and levels of pigments for use in paint or primer applications. Amine-epoxy coating compositions include layers having thicknesses ranging from 40 to 400 μm (micrometers), preferably 80 to 300 μm, and more preferably 100 to 250 μm, for use in protective coatings applied over metal substrates. Additionally, for use in flooring or building products, coating compositions include layers having thicknesses ranging from 50 to 10,000 μm, depending on the type of product and the final properties desired. Coating products offering limited mechanical and chemical resistance comprise layers with a thickness in the range of 50-500 μm, preferably 100-300 μm, whereas coating products offering high mechanical and chemical resistance, such as self-levelling flooring, comprise layers with a thickness in the range of 1,000-10,000 μm, preferably 1,500-5,000 μm.

[0057] As is well known to those skilled in the art, a variety of substrates are suitable for application of the coatings of the present invention, provided that the substrate is properly surface-treated. Such substrates include, but are not limited to, concrete, various types of metals and alloys, such as steel and aluminum. The coatings of the present disclosure are suitable for painting or coating large metal objects or cementitious substrates, including marine vessels, bridges, industrial plants and equipment, and flooring.

[0058] The coatings of the present invention can be applied by any number of techniques, including spray, brush, roller, paint mitt, etc. To apply the very high solids or 100% solids coatings of the present invention, a multi-component spray application device can be used, where the amine and epoxy components are mixed in the line leading to the spray gun, in the spray gun itself, or by mixing the two components together as they exit the spray gun. This technique can be used to alleviate limitations on the pot life of the formulation, which typically decreases as both amine reactivity and solids content increase. A heated multi-component device can be used to reduce the viscosity of each component, thereby improving ease of application.

[0059] Building and flooring applications include compositions comprising the disclosed amine-epoxy compositions in combination with concrete or other materials commonly used in the building industry. Applications of the disclosed compositions include, but are not limited to, use as primers, deep penetration primers, coatings, curing compounds and / or sealants for new or old concrete, as referenced in ASTM C309-97, which is incorporated herein by reference. As a primer or sealant, the disclosed amine-epoxy compositions can be applied to a surface to improve adhesive bonding before applying a coating. As it relates to concrete and cementitious applications, a coating is an agent used to apply to a surface to form a protective or decorative layer or coating. Crack injection agents and crack fillers can also be made from the disclosed compositions. The disclosed amine-epoxy compositions can be mixed with cementitious materials, such as concrete mixes, to form polymer cements or modified cements, tile grouts, and the like. Non-limiting examples of composite products or articles comprising the amine-epoxy compositions disclosed herein include tennis racquets, skis, bicycle frames, aircraft wings, fiberglass reinforced composites, and other molded articles.

[0060] In the specific use of the hardener composition of the present disclosure, coatings can be applied to various substrates such as concrete and metal surfaces at low temperatures with high cure speed and good coating appearance. This is particularly important in the application of topcoats where good aesthetics are desired, and provides a solution to a long-standing problem in the industry that has yet to be overcome: rapid low-temperature cure with good coating appearance. High cure speeds at low temperatures can reduce operation and equipment downtime, and in the case of outdoor applications, can extend the working season in cold climates.

[0061] Fast-curing epoxy hardeners allow amine-cured epoxy coatings to be highly cured in a short time. The cure rate of the coating is monitored by the coating setting time (TFST), which measures the time it takes for the coating to dry. Coating setting times are classified into four stages: stage 1, set to touch; stage 2, tack-free; stage 3, dry-hard; stage 4, dry-through. The drying time of the third stage indicates how quickly the coating cures and dries. For fast-curing ambient temperature curing coatings, the drying time of the third stage is less than 4 hours or less than 3 hours, or preferably less than 2 hours. Low temperature or below ambient temperature curing usually refers to curing temperatures below ambient temperature, 10°C or 5°C, or sometimes 0°C. For fast-curing low temperature curing, the third stage drying time at 5°C is less than 6 hours, which provides a significant productivity advantage over values ​​with a third stage drying time of less than 4 hours, preferably less than 3 hours.

[0062] The extent to which a coating has cured is measured by the degree of cure. The degree of cure is often measured using DSC (Differential Scanning Calorimetry) techniques well known to those skilled in the art. A fully cured coating has a degree of cure of at least 85%, or at least 90%, or at least 95% after 7 days at room temperature (25° C.). A fully cured coating has a degree of cure of at least 80%, or at least 85%, or at least 90% after 7 days at 5° C.

[0063] Many fast-curing low-temperature epoxy curing agents can rapidly cure epoxy resins. However, due to low compatibility between epoxy resins and curing agents, especially at low temperatures of 10°C or 5°C, phase separation occurs between the resin and the curing agent, and the curing agent migrates to the coating surface, resulting in poor appearance as manifested by stickiness and cloudiness of the coating. Good compatibility between epoxy resins and curing agents results in a transparent glossy coating film with good carbamate resistance and good coating appearance. The curing agent composition of the present disclosure provides a combination of high cure speed, good compatibility, and high cure degree. EXAMPLES

[0064] The various aspects of the invention can be used alone or in combination. Certain aspects of the invention are illustrated by the following examples, which do not limit the scope of the appended claims.

[0065] Example 1 Synthesis of 2-naphthol Mannich bases from formaldehyde and triethylenetetramine (TETA) N 2 A three-necked 1 L round bottom flask equipped with an inlet, an addition funnel and a temperature probe was charged with 2-naphthol (1.0 mol) and triethylenetetramine (g, 1.0 mol). The mixture was heated to 80°C. A 37% solution of formaldehyde (81 g, 37% by weight, 30 g, 1.0 mol) was added to maintain the reaction temperature at 80-90°C. After addition, the mixture was held at 90-95°C for 1 hour. Water was distilled at 120°C to obtain the product as a light brown liquid. The product was cooled to room temperature and tested for epoxy cure performance.

[0066] Performance Testing Unless otherwise specified, hardener mixtures were prepared by mixing each of the components listed in the examples above with the epoxy component of a standard bisphenol-A based epoxy resin (Epon 828, type DER 331), EEW 190. These were then mixed at a stoichiometric level of 1:1 (amine:epoxy equivalents).

[0067] Coating setting time Dry time or film setting time (TFST) was measured using a Beck-Koller recorder according to ASTM D5895. Amine-epoxy coatings were produced on standard glass panels with a wet film thickness of 150 μm WFT (wet film thickness) using a Bird applicator to obtain a dry film thickness of ±100 μm. The coatings were cured in a Lunaire (TPS) environmental chamber at 23° C. and 5° C. and 60% relative humidity (RH).

[0068] Differential scanning calorimetry Thermal studies were carried out using DSC to understand the curing kinetics, reactivity and Tg of 1–2 mg samples.

[0069] Viscosity cure profile To generate viscosity cure profiles, latency experiments were performed using a Brookfield viscometer and Wingather software.

[0070] [Table 1]

[0071] Example 2 Control hardener: A1-Control A 3-neck round bottom flask equipped with a nitrogen inlet, an addition funnel and a temperature probe was charged with 50 grams of nonylphenol and 50 grams of 2-aminomethylpiperazine. The mixture was heated to 40 C and stirred until a homogenous mixture was obtained.

[0072] Mixed hardener: A1-test specimen N 2 A 3-neck 1 / 2 L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 50 grams of 2-naphthol and 50 grams of aminoethylpiperazine. The mixture was heated to 40C and stirred until the 2-naphthol dissolved in the aminoethylpiperazine. Control Hardener A-1 - A comparison of the performance properties of the control and compounded hardener A-1 specimens is shown in Table 2.

[0073] Example 3 Control hardener-A2-Control A three-necked round bottom flask equipped with a nitrogen inlet, an addition funnel and a temperature probe was charged with 26.3 grams of M-xylylenediamine, 5 grams of nonylphenol, 25.3 grams of trimethylhexamethylenediamine and 43.4 grams of p-tert-butylphenol The mixture was heated and stirred until the p-tert-butylphenol was completely dissolved.

[0074] Mixed hardener-A2-test specimen N 2 A 3-neck 1 / 2 L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 35 grams of 2-naphthol and isophorone diamine, and 25.3 grams of trimethylhexamethylene diamine. The mixture was heated to 40C and stirred until the 2-naphthol was completely dissolved in the amine mixture. Control Hardener A-2 A comparison of the performance properties of the control and blended hardener A-2 specimens is shown in Table 2.

[0075] Example 4 Control hardener - A2 - Comparison A three-necked round bottom flask equipped with a nitrogen inlet, an addition funnel and a temperature probe was charged with 26.3 grams of M-xylylenediamine, 5 grams of nonylphenol, 25.3 grams of trimethylhexamethylenediamine and 43.4 grams of p-tert-butylphenol The mixture was heated and stirred until the p-tert-butylphenol was completely dissolved.

[0076] Mixed hardener-A3-test specimen N 2 A 3-neck 1 / 2 L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 43.4 grams (0.34 moles) of 2-naphthol, 0.23 moles of m-xylylenediamine, and 25.3 grams (0.16 moles) of trimethylhexamethylenediamine. The mixture was heated to 40C and stirred until the 2-naphthol was completely dissolved in the amine mixture. A comparison of the performance properties of the Control Hardener A-2 control and the Blended Hardener A-3 specimens is shown in Table 2.

[0077] Example 5 Mixed hardener-A4-test specimen N 2A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 65 grams of Sunmide CX-1151, a phenalkamine hardener commercially available from Evonik Corporation, and 35 grams of 2-naphthol was added and heated to 40C with stirring until the 2-naphthol was completely dissolved in the phenalkamine hardener. A comparison of the performance properties of the hardener formulated in Example 5 compared to Sunmide CX1151 hardener is shown in Table 3.

[0078] Example 6 Mixed hardener-A5-test specimen N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 65 grams of Ancamide 350A, a triethylenetetramine-based polyamide curing agent commercially available from Evonik Corporation, and 33.4 grams of 2-naphthol was added and heated to 40 C with stirring until the 2-naphthol was completely dissolved in the polyamide. The performance properties of the formulated curing agent A5 were compared to Ancamide 350A and are shown in Table 3.

[0079] Example 7 Mixed hardener-A6-test specimen N 2 A 3-neck 1 / 2 L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 65 grams of Sunmide CX105, a commercial ethylenediamine based phenalkamine hardener available from Evonik Corporation, 30 grams of 2-naphthol, heated to 40C and stirred until the 2-naphthol was completely dissolved in the phenalkamine. The performance properties of the compounded hardener A-6-specimen were compared to Sunmide CX105 phenalkamine hardener and are shown in Table 3.

[0080] Example 8 Mixed hardener-A7-test specimen N 2A 3-neck ½ L round bottom flask equipped with an inlet, an addition funnel and a temperature probe was charged with 70 grams of Ancamine 2280 cycloaliphatic hardener available from Evonik Corporation, 30 grams of composition 040-141 (A2) was added and heated to 40 C with stirring until the 2-naphthol was completely dissolved in the cycloaliphatic hardener. The performance properties of compounded hardener A-7 of Example 8 are compared to Ancamine A2280 and are shown in Table 3.

[0081] Application examples and performance tests Performance Testing Unless otherwise specified, hardener mixtures were prepared by mixing each of the components listed in the examples above with the epoxy component of a standard bisphenol-A based epoxy resin (Epon 828, type DER 331), EEW 190. These were then mixed at a stoichiometric level of 1:1 (amine:epoxy equivalents).

[0082] The following application tests were carried out for the compounded hardener examples A1 to A9, and the results are shown in Tables 2 and 3. Coating Setting Time - ASTM D 5895 Gel Time - ASTM D 2471 Persoz hardness - ASTM D 4366 Shore D hardness ASTM-D2240

[0083] [Table 2]

[0084] The compounded hardeners A-1 through A-3 specimens provide increased gel time and film setting time compared to the control. The compounded hardeners show improved MEK double rub resistance indicating that the extent of reaction of the compounded hardener with the epoxy resin is much higher compared to the control. Persoz hardness data also supports the higher extent of reaction of the compounded hardeners.

[0085] [Table 3]

[0086] The test specimens A4 to A7 have a very short coating setting time compared to the specimens that do not contain 2-naphthol.

[0087] Example 9 The following examples demonstrate the addition of 2-naphthol to the epoxy resin side instead of to the amine side.

[0088] Preparation of Base Resin - (DER 354 Test Specimen) (Comparison of Compounds Containing Naphthol) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 75 grams of bisphenol F diglycidyl ether epoxy resin with an epoxy equivalent weight of 228. 25 grams of 2-naphthol was added and heated to 40C with stirring until the 2-naphthol was completely dissolved in the resin. The DER 354 specimen resin described in this example is then added to the DER 354 bisphenol resin shown in Table 1. The total weight percent of 2-naphthol and the epoxy equivalent weight for resin formulation numbers B1 through B5 are shown in Table 4.

[0089] [Table 4]

[0090] Application and performance test of compounded resins - Samples B1 to B5 DER 354 (test resin) was mixed with standard bisphenol F diglycidyl ether epoxy resins listed in Table 4 and then cured with (1) a cycloaliphatic hardener (Ancamine 2791), (2) an aliphatic epoxy hardener (Ancamine 2739), and (3) a polyamide epoxy hardener (Ancamide 2769). The film setting times of DER 354 test resin when cured at room and low temperatures with (1) a cycloaliphatic hardener (A 2791), (2) an aliphatic hardener (A 2739), and (3) a polyamide hardener (A 2769) are shown in Table 5.

[0091] [Table 5]

[0092] The addition of 2-naphthol to the resin side significantly reduces the film setting time when cured with a different amine-based hardener compared to the film setting time of the neat resin cured with the same hardener.

[0093] The following examples demonstrate the addition of 2-naphthol in flexible epoxy coatings.

[0094] (Example 10 (blended hardener) (C1) (data comparison with K-54 alone)) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 60 grams of Ancamide 910 polyamide curing agent, 10 grams of Ancamine 2716 modified polyamine curing agent, 15 grams of Ancamine 2914UF, 10 grams of Ancamine K54, and 5 grams of 2-naphthol and heated to 40C with stirring until the 2-naphthol was completely dissolved in the curing agent blend.

[0095] (Example 11 (blended hardener) (C2) (comparison with K-54 alone)) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 70 grams of Ancamide 910 polyamide curing agent, 10 grams of Ancamine 2716 modified polyamine curing agent, 10 grams of Ancamine K54, and 10 grams of 2-naphthol and heated to 40 C with stirring until the 2-naphthol was completely dissolved in the curing agent blend.

[0096] (Example 12 (blended hardener) (C3)) N 2A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 70 grams of Ancamide 910 polyamide curing agent, 10 grams of Priamine 1071 (Croda) curing agent, 10 grams of Ancamine 2914UF, and 10 grams of 2-naphthol and heated to 40° C. with stirring until the 2-naphthol was completely dissolved in the curing agent blend.

[0097] (Example 13 (blended hardener) (C4)) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 65 grams of Ancamide 910 polyamide hardener, 20 grams of Ancamine 2914UF hardener, 10 grams of Ancamine K54, and 5 grams of 2-naphthol and heated to 40 C with stirring until the 2-naphthol was completely dissolved in the hardener blend.

[0098] (Example 14 (blended hardener) (C5)) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 60 grams of Ancamide 910 polyamide hardener, 10 grams of a hardener consisting of an adduct of diethylenetriamine and cresyl glycidyl ether (Epodil 742), 10 grams of Ancamine 2914UF, and 20 grams of 2-naphthol and heated to 40° C. with stirring until the 2-naphthol was completely dissolved in the hardener blend.

[0099] (Example 15 (blended hardener) (C6) (comparison with and without naphthol)) N 2 A 3-neck ½ L round bottom flask equipped with an inlet, addition funnel and temperature probe was charged with 70 grams of Ancamide 910 polyamide hardener, 10 grams of Tomamine PA-14, 10 grams of Ancamine K54, and 10 grams of 2-naphthol and heated to 40 C with stirring until the 2-naphthol was completely dissolved in the hardener blend.

[0100] Application and performance testing Unless otherwise specified, hardener mixtures were prepared by mixing each of the components listed in the examples above in a 90:10 weight ratio blend with a standard bisphenol-A based epoxy resin (Epon 828, type DER 331), the epoxy component of EEW 190. These were then mixed at a stoichiometric level of 1:1 (amine:epoxy equivalents).

[0101] The following application tests were carried out for the compounded hardener examples C1 to C5, and the results are shown in Table 6. 1. Viscosity was measured using a Brookfield viscometer (ASTM D-2196) with a stand-alone Thermosel accessory. 2. Coating setting time was measured at 6 mil thickness using ASTM D-5895. 3. Gel time was measured using ASTM D-2471. 4. Shore D hardness was measured using ASTM D-2240. 5. Die C tear strength was measured using ASTM D-624. 6. Trouser tear strength was measured using ASTM D-1938. 7. Adhesion to dry and wet concrete was measured using ASTM D-7234. · Wet concrete was prepared by immersing concrete blocks halfway in water for 24 hours before application. 8. Tensile properties were measured using ASTM D-638.

[0102] [Table 6-1]

[0103] [Table 6-2]

[0104] Application and performance testing Unless otherwise specified, hardener mixtures were prepared by blending and mixing each of the components shown in Example C6 with a standard bisphenol-F based epoxy resin (DER 354 type resin), the epoxy component of EEW 175 (R1), Epodil 748 (R2), Ancarez 2364 (R3), and a combination of Ancarez 2364 and Epodil 748 (R4) in a 90:10 weight ratio, which were then mixed using the specified stoichiometric levels (amine:epoxy equivalents).

[0105] The following application tests were carried out for compounded hardener example C6 and resins R1 to R4, and the results are shown in Table 7. 1. Viscosity was measured using a Brookfield viscometer (ASTM D-2196) with a stand-alone Thermosel accessory. 2. Coating setting time was measured at 6 mil thickness using ASTM D-5895. 3. Gel time was measured using ASTM D-2471. 4. Shore D hardness was measured using ASTM D-2240. 5. Water Spot Test - Internal Test 6. Carbamate Test - Internal Test 7. Pore Resistance – Electrical Impedance Spectroscopy Measurements on S412 Panels 8. Impact test - on S412 panel; direct impact test ASTM-G14 and reverse impact test ASTM D2794 9. Abrasion resistance - ASTM D4060 CS 17 wheel, 1Kg 10. Tensile properties were measured using ASTM D-412C. 11. Dolly Peel Test on 1 / 4" Hot Rolled Steel Sandblasted Substrate - ASTM D4541

[0106] [Table 7-1] [Table 7-2]

Claims

1. (a) a molecule having the following structure (I): 【Chemical 1】 [where R １ and R ２ are independently OH, H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , HSO ３ , or X(CH ２ ) NHY, where Y is C １ ~C １０ Alkyl, C １ ~C １０ aryl, or polyamine; X is Ph or C １ ~C ４ alkyl; R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ and R １ or R ２ one of which is OH] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; A hardener composition comprising:

2. The at least one naphthol or naphthol derivative has the following structures (II) to (V): 【Chemistry 2】 [where R ２ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 3】 [where R １ and R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 4】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] and 【Chemistry 5】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] The composition according to claim 1, wherein

3. 2. The composition of claim 1, wherein the at least one naphthol or naphthol derivative is selected from the group consisting of 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol, and 1-naphthol-4-sulfonic acid.

4. 2. The composition of claim 1, wherein the at least one naphthol derivative is obtained by the Mannich reaction in which 1-naphthol or 2-naphthol is reacted with an aldehyde and an amine to form a Mannich base.

5. 10. The composition of claim 1, further comprising at least one compound selected from the group consisting of boron trifluoride amine complex, 2,4,6-tri(dimethylaminomethyl)phenol, benzyldimethylamine, imidazole, calcium nitrate, carboxylic acid, salicylic acid, and sulfuric acid.

6. 6. Use of the hardener composition according to any one of claims 1 to 5 as a toughening agent for epoxy resins.

7. 1. A method for preparing a composition, comprising the steps of: (a) dissolving at least one naphthol or naphthol derivative in at least one polyamine to form a mixture; and (b) reacting the mixture with an epoxy resin component.

8. 1. A method for preparing a composition, the method comprising the steps of: (a) dissolving at least one naphthol or naphthol derivative in an epoxy resin component to form a mixture; and (b) reacting the mixture with at least one polyamine.

9. The at least one naphthol or naphthol derivative has the following structure (I): 【Chemistry 6】 [where R １ and R ２ are independently OH, H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , HSO ３ , or X(CH ２ ) NHY, where Y is C １ ~C １０ Alkyl, C １ ~C １０ aryl, or polyamine; X is Ph or C １ ~C ４ alkyl; R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ and R １ or R ２ one of which is OH] The method according to claim 7 or 8, wherein

10. The at least one naphthol or naphthol derivative has the following structures (II) to (V): 【Chemistry 7】 [where R ２ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 8】 [where R １ and R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 9】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] and 【Chemistry 10】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] The method of claim 9, wherein

11. 10. The method of claim 9, wherein the at least one naphthol or naphthol derivative is selected from the group consisting of 4-methyl-1-naphthol, 2-methyl-1-naphthol, 4-amino-3-methyl-1-naphthol, 4-methoxy-1-naphthol, 3-methoxy-2-naphthol, 5-methoxy-1-naphthol, 4-chloro-1-naphthol, 1-chloro-2-naphthol, 1-bromo-2-naphthol, and 1-naphthol-4-sulfonic acid.

12. 10. The method of claim 9, wherein the at least one naphthol derivative is obtained by the Mannich reaction in which 1-naphthol or 2-naphthol is reacted with an aldehyde and an amine to form a Mannich base.

13. 6. Use of the hardener composition of any one of claims 1 to 5 and at least one epoxy resin component to produce a reinforced article of manufacture.

14. 14. The use according to claim 13, wherein the article is a coating, a building product, a flooring product or a composite product.

15. The use according to claim 14, wherein the article is a coating.

16. 16. The use according to claim 15, wherein the coating is produced at ambient temperature.

17. 16. The use according to claim 15, wherein the coating is produced at sub-ambient temperatures up to 0°C.

18. 16. The use according to claim 15, wherein the coating is a flexible epoxy coating.

19. (a) a molecule having the following structure (I): 【Chemistry 11】 [where R １ and R ２ are independently OH, H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , HSO ３ , or X(CH ２ ) NHY, where Y is C １ ~C １０ Alkyl, C １ ~C １０ aryl, or polyamine; X is Ph or C １ ~C ４ alkyl; R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ and R １ or R ２ one of which is OH] and at least one naphthol or naphthol derivative represented by (b) at least one polyamine having three or more active amine hydrogens; (c) an epoxy resin component comprising at least one multifunctional epoxy resin; A composition comprising the reaction product of

20. The at least one naphthol or naphthol derivative has the following structures (II) to (V): 【Chemistry 12】 [where R ２ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 13】 [where R １ and R ３ ~R ８ is H, C １ ~C １０ Alkyl, C １ ~C １０ Aryl, C １ ~C １０ Alkyl ether or C １ ~C １０ Aryl ether, NH ２ ,Cl,Br,I,NO ２ , or HSO ３ is] 【Chemistry 14】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] and 【Chemistry 15】 [wherein Y is C １ ~C １０ Alkyl, C １ ~C １０ Aryl, or ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, N １ -(3-dimethylaminopropyl)propylenediamine, dimethylaminopropylamine, m-xylenediamine, and 4,4'-methylenedicyclohexylamine, and X is a polyamine selected from the group consisting of Ph or C １ ~C ４ alkyl] The composition of claim 19, wherein

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