Curable Epoxy Resin Composition with Solid Filler for Thermal Stability
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Solution Overview
Problem
Current curable compositions and cured products suffer from brittleness and inconsistent behavior across various temperature and environmental conditions, limiting their practical applications.
Innovation Solution
A curable composition comprising a liquid epoxy resin, a curative component, and a curable resin filler, where at least a portion of the filler is solid at 25°C, is developed. This composition includes a method of curing by increasing temperature and potentially altering pressure, which allows for the formation of a non-brittle film with improved thermal performance and uniform glass transition temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solid curable resin filler is added to liquid epoxy resin, then thermal performance is improved, but brittleness increases
Solution Approach 1:
The patent uses a composite material system combining liquid epoxy resin with solid curable resin filler particles. The liquid resin matrix embeds the solid filler particles, creating a composite that achieves high thermal performance while maintaining flexibility and adhesion through the continuous liquid phase that prevents brittleness.
Solution Approach 2:
The patent creates local quality differentiation by having solid curable resin filler particles distributed within the liquid epoxy resin matrix. The solid particles provide thermal performance in localized regions, while the liquid matrix maintains overall flexibility and adhesion, allowing each component to fulfill its specific function without compromising the other.
2Ease of operation
If solid curable resin filler is added to liquid epoxy resin, then handling characteristics are improved, but uniform behavior across temperatures deteriorates
Solution Approach 1:
The patent utilizes parameter changes by controlling the dispersion of solid curable resin filler particles within the liquid epoxy resin at different temperatures. The composition maintains uniform behavior across temperatures through proper parameter control of filler distribution and resin viscosity, ensuring consistent handling characteristics from room temperature through curing temperature ranges.
3Ease of operation
If large amount of thermoplastic resin is added to liquid epoxy resin, then tackiness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functional components into a single integrated composition: liquid epoxy resin provides the base matrix, solid curable resin filler enhances thermal performance, and thermoplastic resin additive improves tackiness. This merging of functions into one composition simplifies manufacturing by eliminating the need for separate application steps for each functional component.
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 results in a curable film with enhanced tackiness, handling characteristics, and thermal performance, maintaining form and adhesion across a wide temperature and environmental spectrum, with Wet and Dry Glass Transition Temperatures being substantially equal.
Implementation Method 1
curing the curable composition
Implementation Method 2
Wet and Dry Glass Transition Temperatures being substantially the same
Data Source
AI summary
The present disclosure provides a curable composition. The curable composition includes a liquid epoxy resin component a curative component, and a curable resin filler component. At least a portion of curable resin filler is dispersed in the liquid epoxy resin and solid at about 25° C. According to various examples, the curable composition can produce a film having good tackiness and improved handling characteristics. Additionally, according to some examples, a cured product of the curable composition can have a Wet Glass Transition Temperature and a Dry Glass Transition Temperature that are substantially the same.