Core-Shell Graft Copolymer Dispersion in Epoxy Resin
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Solution Overview
Problem
Conventional methods for dispersing graft copolymers in epoxy resins face challenges with high viscosity and environmental concerns, particularly in the particulate phase dispersion method, which affects the processing cost and performance of curable resin compositions.
Innovation Solution
A core-shell type graft copolymer with a rubbery polymer core and a graft monomer shell, comprising conjugated diene-based and alkyl (meth)acrylate units, is developed, optimizing the weight ratio and thickness of the shell to enhance dispersibility and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the liquid phase dispersion method is used to disperse graft copolymer in epoxy resin, then homogeneous dispersion is achieved, but storage problems and environmental pollution occur due to water and solvent discharge
Solution Approach 1:
The patent changes the physical state parameter of the graft copolymer from liquid (latex) to solid (particulate) form, enabling direct dispersion in epoxy resin without water or organic solvents. This parameter change eliminates the environmental pollution associated with solvent discharge while maintaining dispersion effectiveness.
Solution Approach 2:
The patent extracts and removes the water and solvent components from the dispersion system by using pre-formed particulate graft copolymer. This extraction eliminates the harmful environmental factors while preserving the core functional components (graft copolymer particles) for effective dispersion in the epoxy resin.
2Ease of manufacture
If particulate phase dispersion method is used to disperse graft copolymer in epoxy resin, then process cost is reduced, but dispersion becomes very difficult or impossible due to high viscosity
Solution Approach 1:
The patent optimizes critical parameters of the particulate graft copolymer including particle size distribution, shell thickness (3-50 nm), and core-shell structure composition. These parameter changes reduce the viscosity of the particulate material and improve its flow characteristics, making dispersion in epoxy resin feasible while maintaining the cost advantages of the particulate phase method.
Solution Approach 2:
The patent employs a core-shell composite structure where the core provides the rubbery polymer functionality and the shell provides dispersibility and compatibility with the epoxy resin. This composite structure enables the particulate material to disperse easily in the resin matrix while maintaining the desired mechanical properties, thus resolving the dispersion difficulty without sacrificing cost efficiency.
3Strength
If graft copolymer is used as toughening agent in epoxy resin, then impact resistance and adhesive strength are improved, but glass transition temperature changes and performance deterioration occur
Solution Approach 1:
The patent applies the local quality principle by creating a core-shell structure where different regions have different properties: the core provides rubbery elasticity for impact resistance, while the shell provides compatibility and controlled interaction with the epoxy resin. This localized property distribution allows improvement of impact resistance while minimizing adverse effects on glass transition temperature and overall performance stability.
Solution Approach 2:
The patent optimizes parameters including the weight ratio of core to shell, shell thickness (3-50 nm), and graft monomer composition to control the interaction between the graft copolymer and epoxy resin. By carefully adjusting these parameters, the patent achieves improved impact resistance while maintaining stable glass transition temperature and preventing performance deterioration.
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 graft copolymer exhibits excellent particulate dispersibility in epoxy resins, improving impact resistance and adhesive strength, while maintaining low viscosity and environmental sustainability.
Implementation Method 1
the graft copolymer exhibits excellent particulate dispersibility in epoxy resins
Data Source
AI summary
The present invention relates to a graft copolymer, and to a core-shell type graft copolymer comprising a core comprising a rubbery polymer; and a shell formed by graft polymerizing a graft monomer to the rubbery polymer, wherein the rubbery polymer comprises a conjugated diene-based monomer unit, the graft copolymer comprises the core in 75 wt % to 83 wt %, and a thickness of the shell is 3 nm to 25 nm, a curable resin composition comprising same, and an adhesive composition.