Epoxidized Vegetable Oil Binder Compositions for Low Toxicity
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Solution Overview
Problem
Existing thermoset and thermoplastic compositions, particularly unsaturated polyesters, face issues such as high toxicity, volatility, flammability, and limited impact resistance due to brittleness, and there is a need for compositions with low toxicity, volatility, and improved processability 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 ranges from 50 to 500, allowing for dual/hybrid polymerization and improved mechanical and chemical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unsaturated polyesters are used in thermoset compositions, then the compositions provide useful structural properties, but they exhibit high toxicity, high volatility, high flammability, and high shrinkage during processing
Solution Approach 1:
The patent changes the chemical composition parameters by replacing conventional unsaturated polyester resins with epoxidized vegetable oils (such as epoxidized soybean oil, epoxidized linseed oil) combined with carboxyl-functionalized resins. This substitution fundamentally alters the chemical properties, eliminating the harmful characteristics (toxicity, volatility, flammability) while maintaining structural performance through the epoxy-carboxyl crosslinking reaction system.
Solution Approach 2:
The invention creates a composite binder system by combining epoxidized vegetable oils with carboxyl-functionalized resins (such as carboxyl-terminated polyester resins or carboxyl-functionalized acrylic resins). This composite approach leverages the advantages of both components: the bio-based epoxy provides structural integrity and low toxicity, while the carboxyl resin enables crosslinking and enhances mechanical properties, resulting in a material that overcomes the limitations of conventional unsaturated polyesters.
2Ease of manufacture
If conventional thermoset compositions are used, then processing is straightforward, but the compositions exhibit high shrinkage and warpage during processing
Solution Approach 1:
The patent modifies the chemical composition to use epoxidized vegetable oils with carboxyl-functionalized resins, which undergo a different curing mechanism compared to conventional unsaturated polyesters. The epoxy-carboxyl crosslinking reaction exhibits lower shrinkage characteristics, directly addressing the manufacturing precision issue while maintaining ease of processing through straightforward mixing and curing procedures.
3Strength
If polymerized resin matrices are used to provide structural integrity, then the compositions gain strength, but they exhibit limited impact resistance due to brittleness
Solution Approach 1:
The invention creates a composite crosslinked network by combining epoxidized vegetable oils with carboxyl-functionalized resins. This composite structure provides both structural integrity and improved impact resistance. The carboxyl-functionalized resin component introduces flexibility and toughness to the crosslinked matrix, reducing brittleness while maintaining strength through the epoxy-carboxyl crosslinking bonds.
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 non-volatile, with enhanced processability at lower temperatures, addressing the limitations of previous formulations.
Implementation Method 1
binder composition comprising an epoxidized vegetable oil or a derivative thereof, a carboxyl-functionalized resin, and a liquid reactive diluent
Implementation Method 2
a liquid reactive diluent; wherein a combined acid value of the carboxyl-functionalized resin and the liquid reactive diluent is 50 to 500
Implementation Method 3
a carboxyl-functionalized resin having an acid value of greater than or equal to 50
Implementation Method 4
a transesterification reaction product of an epoxidized fatty acid methyl ester and a vinyl compound having pendant hydroxyl groups
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.