Water-Soluble Acrylic-Modified Phenolic-Epoxy Resin Viscosity Control
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Solution Overview
Problem
Existing methods for making water-soluble epoxy resins face challenges in achieving low viscosity, high solid content, and high chemical resistance, which are essential for effective coating applications, particularly in the context of environmental concerns related to volatile organic compounds (VOCs).
Innovation Solution
A method involving the copolymerization of (meth)acrylic acid monomers, alkyl (meth)acrylate monomers, and styrenic monomers to create an acrylic resin, followed by ring-opening reaction with a bisphenol A-type epoxy resin and subsequent esterification with a phenolic compound, and finally neutralizing the resulting acryl-modified phenolic-modified epoxy resin to enhance water solubility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If epoxy resin is modified with acrylic monomers to improve water solubility, then water solubility is improved, but viscosity increases and chemical resistance decreases
Solution Approach 1:
The patent changes the chemical parameters of the epoxy resin by introducing specific functional groups (carboxyl groups from acrylic monomers) and controlling the degree of substitution. This allows the resin to achieve water solubility through neutralization while maintaining appropriate viscosity by optimizing the monomer composition and reaction conditions
Solution Approach 2:
The patent creates a composite structure by combining epoxy resin with acrylic monomers (such as acrylic acid, methacrylic acid, or their esters) to form a graft copolymer or modified resin. This composite approach allows the hydrophobic epoxy backbone to provide chemical resistance while the hydrophilic acrylic side chains provide water solubility, thus resolving the contradiction between these two properties
2Object-affected harmful factors
If epoxy resin is emulsified externally to improve water solubility, then water solubility is improved, but the process becomes complicated and viscosity increases
Solution Approach 1:
The patent enables the epoxy resin to emulsify itself by incorporating emulsifying functional groups (carboxyl groups from acrylic monomers) directly into the resin molecule. This self-emulsification capability eliminates the need for separate emulsifier additives and complex emulsification processes, thereby simplifying the overall formulation process while maintaining water solubility
Solution Approach 2:
The acrylic monomers act as intermediaries that bridge the hydrophobic epoxy resin and hydrophilic water environment. These monomers contain both hydrophobic segments (attached to epoxy) and hydrophilic segments (carboxyl groups), facilitating spontaneous emulsification without requiring external emulsifiers or complex processing
3Object-affected harmful factors
If epoxy resin is simply dispersed in water to improve water solubility, then water solubility is improved, but storage stability deteriorates and precipitation occurs
Solution Approach 1:
The patent modifies the epoxy resin to possess self-stabilizing properties through the introduction of carboxyl groups from acrylic monomers. These groups can be neutralized to form ionic structures that provide electrostatic repulsion between molecules, preventing aggregation and precipitation during storage. The resin essentially stabilizes itself without requiring additional stabilizing additives
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach results in a water-soluble acryl-modified phenolic-modified epoxy resin with improved viscosity, solid content, and chemical resistance, suitable for various applications including coatings and can lid surfaces, offering excellent post-forming processibility and thermal stability.
Implementation Method 1
copolymerization of (meth)acrylic acid monomers, alkyl (meth)acrylate monomers, and styrenic monomers to create an acrylic resin
Implementation Method 2
ring-opening reaction with a bisphenol A-type epoxy resin
Implementation Method 3
subsequent esterification with a phenolic compound
Implementation Method 4
finally neutralizing the resulting acryl-modified phenolic-modified epoxy resin to enhance water solubility
Data Source
AI summary
According to the present invention, there are provided a preparation method of a water-soluble acryl-modified phenolic-modified epoxy resin including preparing an acrylic copolymer resin containing a carboxylic acid group; preparing a phenolic-modified epoxy resin by reacting an epoxy resin with a phenolic compound; preparing an acryl-modified phenolic-modified epoxy resin by ester-reacting the acrylic copolymer resin with the phenolic-modified epoxy resin; and preparing a water-soluble acryl-modified phenolic-modified epoxy resin by neutralizing the acryl-modified phenolic-modified epoxy resin, a water-soluble acryl-modified phenolic-modified epoxy resin prepared thereby, and an aqueous paint composition including the same. According to the present invention, the water-soluble acryl-modified phenolic-modified epoxy resin and the aqueous coating composition including the same may be applied to most of conventional uses in which the epoxy resin is used due to excellent various physical properties. In addition, the formed coating film may be usefully applied as an aqueous coating composition for the inner surface of a two-piece can lid and the inner and outer surfaces of EOE due to excellent post-forming processibility, chemical stability in contents, and thermal stability at a high temperature.