Anhydride-Cured Epoxy Composite for Signal Transmitter Protection

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Solution Overview

Problem

Existing fiber reinforced epoxy composites used for protecting signal transmitters/receivers face challenges with dielectric constant, dielectric loss tangent, and water absorption, particularly due to the negative effects of curing agents, necessitating improved materials with reduced curing agent content and enhanced performance.

Innovation Solution

A composite structure featuring a cured epoxy composition with a high percentage of ether crosslinkage, reduced amine and hydroxyl crosslinkage, and a blend of epoxy resin and polyphenylene oxide, using less than stoichiometric amounts of anhydride curing agents and imidazole-based catalysts to promote ether/ester crosslinkage, resulting in improved dielectric constant, water absorption, and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional curing agents are used in fiber reinforced epoxy composites, then the composite achieves full cure and structural integrity, but the dielectric constant deteriorates and signal transmission properties worsen

Engineering Contradiction:

Improvestructural integrityVSAvoiddielectric constant

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes traditional amine-based curing agents from the epoxy composite system and replaces them with anhydride curing agents. This extraction of the harmful curing agent component eliminates the negative impact on dielectric constant while maintaining full cure through alternative chemistry (using catalysts like imidazole or DMAP to achieve complete curing with anhydrides).

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical parameters of the curing system by switching from amine-based to anhydride-based curing agents and adjusting the curing conditions (temperature, catalyst selection). This parameter change transforms the crosslinking chemistry to produce a cured network with superior dielectric properties while maintaining mechanical integrity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If more curing agent is added to ensure full cure, then the composite achieves complete curing, but water absorption increases and dielectric loss tangent worsens

Engineering Contradiction:

Improvecure completenessVSAvoidwater absorption

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the problematic amine-based curing agents that cause high water absorption and dielectric loss, replacing them with anhydride-based curing agents that produce a cured network with lower hygroscopy and better dielectric performance, while achieving full cure through catalyst-assisted chemistry.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates a composite curing system combining anhydride curing agents with specific catalysts (imidazole, DMAP) to achieve synergistic effects. This composite approach enables complete curing with reduced curing agent quantities while minimizing water absorption and optimizing dielectric properties.

Inventive Principle:

Principle #40Composite materials

3Strength

If fiber reinforced epoxy composite is used for protective covers, then mechanical strength and weight reduction are achieved, but the composite fails to meet dielectric and water absorption requirements

Engineering Contradiction:

Improvemechanical strengthVSAvoiddielectric loss tangent

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the epoxy matrix by using anhydride curing agents with catalysts, which transforms the crosslinked network structure to achieve simultaneously high mechanical strength and superior dielectric properties with low water absorption.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent develops a multi-component composite system combining fiber reinforcement with a specially formulated anhydride-cured epoxy matrix. This composite material integrates structural strength with optimized dielectric performance, meeting both mechanical and electromagnetic requirements.

Inventive Principle:

Principle #40Composite materials

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 solution achieves synergistic improvements in dielectric constant, water absorption, and mechanical strength, providing enhanced protection for signal transmitters/receivers while minimizing the use of curing agents, thus overcoming the limitations of existing composites.

Implementation Method 1

using less than stoichiometric amounts of anhydride curing agents and imidazole-based catalysts to promote ether/ester crosslinkage

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10662304B2Composites for protecting signal transmitters/receivers

Publication Date: 2020.05.26 SAINT GOBAIN PERFORMANCE PLASTICS CORP

AI summary

Embodiments of the present disclosure are directed to a composition and composite for protecting a transmission/reception device. The composite can include a reinforcing material and a cured epoxy composition impregnating the reinforcing material. The cured epoxy composition can contain reaction constituents including less than 50% stoichiometric amount of an anhydride curing agent to an epoxy resin. The composite can exhibit synergistic improvements in mechanical strength, weatherability, and signal transmission properties.