Bio-Based (Meth)acrylate Cross-Linkers for Vinyl Ester Resins
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Solution Overview
Problem
Current vinyl ester resin systems rely on petroleum-derived monomers, which are volatile and environmentally costly, and require hazardous reactive diluents like styrene to reduce viscosity, compromising toughness and processability.
Innovation Solution
A one-pot, two-step synthesis method using bio-based (meth)acrylate monomers derived from non-petroleum celluloses or carbohydrates with isosorbide as a core scaffold, reducing the need for reactive diluents by producing low viscosity curable resins with enhanced toughness and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If petroleum-based vinyl ester resins are used, then the resin system provides good mechanical properties and processability, but it requires hazardous reactive diluents like styrene to reduce viscosity, which compromises environmental safety and toughness
Solution Approach 1:
The patent changes the chemical composition parameters by using bio-based (meth)acrylate monomers with specific molecular structures (derived from celluloses or carbohydrates with isosorbide core scaffold) to inherently achieve low viscosity without requiring hazardous diluents like styrene
Solution Approach 2:
The patent replaces expensive and hazardous petroleum-based monomers with cheaper, environmentally friendly bio-based monomers that are derived from renewable resources, eliminating the need for toxic reactive diluents
2Strength
If petroleum-derived monomers are used, then the resin system achieves desired mechanical properties, but it increases dependency on volatile petroleum products with high environmental costs
Solution Approach 1:
The patent converts the potential weakness of bio-based monomers into a strength by carefully selecting and optimizing the molecular structure of (meth)acrylate monomers derived from celluloses or carbohydrates with isosorbide core scaffold, achieving mechanical properties comparable to petroleum-based systems while providing environmental benefits
Solution Approach 2:
The patent creates a composite resin system by blending bio-based (meth)acrylate monomers with vinyl ester resins, combining the advantages of both material systems to achieve both environmental sustainability and mechanical performance
3Strength
If high molecular weight vinyl ester resins are used, then the resin provides good mechanical strength, but it results in extremely high viscosity that complicates processing
Solution Approach 1:
The patent segments the resin system into multiple components: low molecular weight bio-based (meth)acrylate monomers for low viscosity and ease of processing, and vinyl ester resin for mechanical strength, combining them to achieve both properties simultaneously
Solution Approach 2:
The patent uses bio-based (meth)acrylate monomers as intermediary substances that act as both reactive diluents and cross-linking agents, reducing viscosity while maintaining or enhancing mechanical properties through controlled cross-linking
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 method produces vinyl ester resins with improved viscosity and toughness, reducing dependency on petroleum-based materials and hazardous diluents, while maintaining mechanical properties comparable to petroleum-based systems.
Implementation Method 1
reacting an organic compound having at least one hydroxy group with a (meth)acrylate to produce a reaction product containing a (meth)acrylic ester and (meth)acrylic acid
Implementation Method 2
reacting said reaction product from step i) with at least one organic compound containing at least one epoxy group to form a reaction product
Data Source
AI summary
This invention outlines a method for synthesizing a blended resin system in a one pot reaction that may utilize, for example, bio-based anhydrosugars such as isosorbide as a principle component to produce isosorbide dimethacrylate and other monomeric materials for thermosetting applications. This invention establishes a one-pot procedure for reacting a hydroxy group containing compound with methacrylic anhydride in the first step and using the by-product methacrylic acid to react with glycidyl ethers to form additional methacrylate compounds in the second step. This methodology can be formulated to produce a wide array of resin systems that have controlled ratios of hydroxy group containing compound/cross-linker/reactive diluent. Additionally, the novel resin systems may be partially to fully bio-based, promoting global sustainability and reducing costs, and when free radically polymerized have properties that meet or exceed their petroleum derived counterparts.