Epoxy Adhesive Composition with Core-Shell Rubber for Low-Temperature Impact Strength
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Solution Overview
Problem
Epoxy resin-based adhesives used in the automotive industry lack sufficient impact-resistant strength at low temperatures, such as -40°C, and do not maintain consistent adhesion and impact-resistant properties across a wide temperature range.
Innovation Solution
An adhesive composition comprising epoxy resins, core-shell rubbers in primary and secondary forms, and epoxy curing agents, which provides excellent adhesion, impact-resistant, and shear strength from -40°C to 80°C, by optimizing the epoxy resin equivalent, core-shell rubber particle size distribution, and curing agent content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin-based adhesives are used to achieve high adhesion strength and heat resistance, then adhesion strength and heat resistance are improved, but impact-resistant strength at low temperatures deteriorates
Solution Approach 1:
The patent combines epoxy resin with core-shell rubber particles to create a composite adhesive material. The core-shell rubber particles (with rubber cores and shell polymers) are dispersed in the epoxy resin matrix, creating a multi-phase composite structure that provides both the adhesion strength of epoxy and the impact resistance of rubber, particularly at low temperatures.
Solution Approach 2:
The patent optimizes specific parameters including the epoxy equivalent weight (200-650), core-shell rubber particle size distribution (D10-D90 ratio of 1.2-3.0), and curing agent content (1-10 parts by weight per 100 parts epoxy resin). These parameter optimizations ensure the adhesive maintains proper viscosity, curing characteristics, and mechanical properties across the temperature range -40°C to 80°C.
2Strength
If epoxy resin-based adhesives are formulated for high strength, then adhesion strength is improved, but consistency across wide temperature range deteriorates
Solution Approach 1:
The patent systematically optimizes multiple parameters including epoxy equivalent weight (200-650), core-shell rubber particle size distribution (D10-D90 ratio of 1.2-3.0), and curing agent content (1-10 parts by weight per 100 parts epoxy resin). These parameter optimizations ensure the adhesive maintains proper viscosity, curing characteristics, and mechanical properties across the temperature range -40°C to 80°C.
Solution Approach 2:
The core-shell rubber particles provide localized reinforcement within the epoxy matrix. The shell polymer layer creates a transition zone that accommodates thermal expansion differences between the rubber core and epoxy matrix, providing local stress relief and maintaining overall structural consistency across temperature variations.
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 adhesive composition ensures uniform and enhanced adhesion and impact-resistant strength across a wide temperature range, effectively addressing the limitations of existing epoxy resin-based adhesives.
Implementation Method 1
core-shell rubber in the form of primary particles, core-shell rubber in the form of secondary particles
Implementation Method 2
impact-resistant strength
Implementation Method 3
epoxy-based resin, epoxy curing agents
Implementation Method 4
adhesive composition comprising an epoxy-based resin and a curing agent for the epoxy-based resin
Implementation Method 5
excellent adhesion strength, impact-resistant strength and shear strength uniformly from a low temperature such as -40° C. to a high temperature such as 80° C.
Data Source
AI summary
An epoxy-based adhesive composition and methods for manufacturing the same are provided. The adhesive composition provides excellent adhesive strength and impact strength uniformly over a wide temperature range.