Bio-based Binder Composition for Low Toxicity Thermosets
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Solution Overview
Problem
Existing thermoset compositions, particularly unsaturated polyesters, face issues such as high toxicity, volatility, flammability, and brittleness, leading to limited impact resistance and poor processability, with a need for compositions that are non-toxic, low in volatility, and derived from bio-based sources.
Innovation Solution
A binder composition comprising epoxidized vegetable oil or its derivative with an epoxy group content of 1 to 12 weight percent, a carboxyl-functionalized resin with an acid value of greater than or equal to 50, and a liquid reactive diluent, where the combined acid value of the resin and diluent is 50 to 500, allowing for dual/hybrid polymerization and improved mechanical and chemical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional unsaturated polyester formulations are used, then the composition achieves basic thermoset properties, but the composition exhibits high toxicity, high volatility, high flammability, and high shrinkage during processing
Solution Approach 1:
The patent changes the chemical composition parameters by using epoxidized vegetable oils (1-12 wt% epoxy group content) combined with carboxyl-functionalized resins (acid value ≥50) and liquid reactive diluents (combined acid value 50-500). This parameter change transforms the harmful properties: the epoxidized oils provide bio-based content with lower toxicity and volatility compared to conventional polyesters, while the specific acid value ranges ensure proper curing and reduce shrinkage during processing
Solution Approach 2:
The patent creates a composite binder system combining three distinct components: epoxidized vegetable oil or derivatives, carboxyl-functionalized resin, and liquid reactive diluent. This composite approach allows each component to contribute specific properties - the epoxidized oil provides bio-based content and reduced harmful factors, the carboxyl-functionalized resin provides structural integrity and crosslinking capability, and the liquid reactive diluent ensures processability and reduced shrinkage
2Strength
If conventional thermoset compositions are used, then the composition achieves basic structural properties, but the composition exhibits brittleness and limited impact resistance
Solution Approach 1:
The patent modifies the compositional parameters by incorporating epoxidized vegetable oils with specific epoxy group contents (1-12 wt%) and combining them with carboxyl-functionalized resins having acid values of ≥50. This parameter change introduces flexibility into the polymer matrix through the vegetable oil components, reducing brittleness while maintaining structural strength and improving impact resistance
Solution Approach 2:
The patent employs a composite binder system where epoxidized vegetable oil components provide flexibility and toughness, while carboxyl-functionalized resins provide structural strength. The synergistic combination creates a matrix that resists both brittleness and impact, solving the contradiction between strength and stability
3Ease of manufacture
If conventional unsaturated polyesters are used, then the composition achieves basic curing properties, but the composition exhibits high shrinkage and poor processability
Solution Approach 1:
The patent changes the chemical parameters by using epoxidized vegetable oils combined with carboxyl-functionalized resins having specific acid values (≥50) and liquid reactive diluents with controlled combined acid values (50-500). This parameter change reduces shrinkage during curing while improving processability, as the specific acid value ranges ensure optimal crosslinking density and reduced volumetric contraction
Solution Approach 2:
The liquid reactive diluent acts as an intermediary component that facilitates processing while controlling shrinkage. By selecting diluents with specific acid values and molecular weights (650 g/mol or less), the system achieves reduced shrinkage and improved processability without sacrificing the curing properties of the epoxidized oil and carboxyl-functionalized resin combination
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 composition provides improved mechanical and chemical properties, including high Barcol hardness, impact resistance, low water absorption, UV resistance, and high gloss, while being non-toxic and processable at lower temperatures, reducing shrinkage and volatility.
Implementation Method 1
a binder composition comprising: an epoxidized vegetable oil or a derivative thereof having an epoxy group content of 1 to 12 weight percent... and a carboxyl-functionalized resin having an acid value of greater than or equal to 50
Implementation Method 2
Another aspect of the present disclosure is a composition comprising a cured product derived from the binder composition
Data Source
AI summary
A binder composition includes an epoxidized vegetable oil or a derivative thereof having an epoxy group content of 1 to 12 weight percent, based on the total weight of the epoxidized vegetable oil; a carboxyl-functionalized resin; and a liquid reactive diluent. A combined acid value of the carboxyl-functionalized resin and the liquid reactive diluent is 50 to 500. Uses of the binder composition, for example in composites, coatings, elastomer formulations, and adhesives are also disclosed.