Curable Resin for Ablative Composites
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Solution Overview
Problem
Phenolic resins used in ablative materials for aerospace applications are toxic and pose environmental concerns due to their precursors, and they can produce porous materials with volatile compounds leading to harmful degassing, necessitating the development of non-toxic alternatives with similar properties.
Innovation Solution
A curable resin composed of propargylated aromatic or heteroaromatic compounds with thiol groups, derived from biomass, which forms a prepolymer suitable for ablative composite materials with a high coke rate and low viscosity, eliminating the need for organic solvents and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic resins are used in ablative materials, then high coke rate and thermal stability are achieved, but toxicity and environmental harm increase due to phenol and formaldehyde precursors
Solution Approach 1:
The patent changes the chemical parameters of the resin system by replacing phenolic monomers with alternative monomers (such as vinyl-containing monomers, epoxies, or isocyanates) that do not rely on toxic phenol and formaldehyde precursors, while maintaining the essential performance parameters like coke rate and thermal stability through formulation optimization
Solution Approach 2:
The patent employs readily available, non-toxic monomers and curing agents that can be easily synthesized or sourced, replacing the need for hazardous phenolic resins while achieving comparable or superior performance in ablative applications
2Reliability
If phenolic resins are used in ablative materials, then high coke rate is achieved, but porous material formation and volatile compound emission occur leading to harmful degassing
Solution Approach 1:
The patent modifies the chemical composition and curing characteristics of the resin system by selecting monomers and crosslinking agents that produce denser, less porous carbon structures upon pyrolysis, thereby reducing volatile compound formation and degassing while maintaining high coke rate
Solution Approach 2:
The patent develops composite resin formulations combining multiple polymer systems (e.g., vinyl-epoxy-isocyanate combinations) that synergistically improve carbon structure density and reduce porosity during pyrolysis, eliminating the need for phenolic resins while achieving low degassing
3Ease of manufacture
If traditional curable resins are used, then adequate viscosity is achieved, but organic solvents are required which increase environmental impact
Solution Approach 1:
The patent adjusts the molecular weight, functional group density, and crosslinking characteristics of the resin components to achieve optimal viscosity for impregnation processes without requiring organic solvents, using only water or no solvent at all
Solution Approach 2:
The patent employs water-based or solvent-free resin formulations that are easy to apply and process, eliminating the need for harmful organic solvents while maintaining manufacturability and impregnation performance
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 resin achieves properties comparable to phenolic resins, such as high coke rate and glass transition temperature, while being derived from non-toxic biomass sources, ensuring thermal stability and environmental sustainability.
Implementation Method 1
a curable resin which comprises: at least one prepolymer resulting from the prepolymerization of a compound A comprising one or more aromatic or heteroaromatic cycles, a first group —O—CH2—C≡CH and at least one second group selected from the groups —O—CH2—C≡CH and —CH2—CH═CH2
Implementation Method 2
The coke rate is greater than 50% and may even exceed 60% for the best organic polymers with ablative potential. This is the case of the coke rate of certain phenolic resins
Implementation Method 3
a compound B comprising at least two thiol groups (—SH)
Data Source
AI summary
The invention relates to a curable resin that represents an excellent substitute for phenolic resins and is therefore able to replace phenolic resins in all applications in which they are used. Said resin is characterised in that it comprises: (1) at least one prepolymer resulting from the prepolymerisation of a compound A comprising at least one aromatic or heteroaromatic ring, a first group —O—CH2-C≡CH and at least one second group selected from the groups —O—CH2-C≡CH2 and —CH2-CH═CH2, said groups being carried by the at least one aromatic or heteroaromatic ring; and (2) a compound B comprising at least two thiol groups (—SH). The invention also relates to a material obtained by curing said curable resin, and in particular to an ablative composite material. The invention further relates to a material obtained by curing said curable resin.