Epoxy Adhesive Flame Retardancy and Curing Speed
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Solution Overview
Problem
Current epoxy adhesives in the aerospace industry fail to meet Federal Aviation Regulations for flammability and have long set-up times, requiring extensive tooling and increasing project duration and equipment costs.
Innovation Solution
A two-component adhesive composition comprising an epoxy component with a flame retardant and a curing component including an amine and a polymer salt adhesion promoter, which meets Federal Aviation Regulations for flammability and has a set-up time of less than 2 hours, reducing the need for custom fixtures and equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional epoxy adhesives are used to achieve light weight and high strength, then structural bonding strength is improved, but the adhesive fails to meet Federal Aviation Regulations for flammability
Solution Approach 1:
The patent applies composite materials by combining epoxy resin with specific flame retardant additives (such as aluminum hydroxide, magnesium hydroxide, or phosphorus-based compounds) to create an adhesive composition that maintains the base epoxy's high strength and light weight properties while incorporating flame retardant mechanisms. This composite approach allows the adhesive to simultaneously achieve structural bonding strength and meet Federal Aviation Regulations flammability requirements
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition parameters of the epoxy adhesive through controlled addition of flame retardant compounds. By adjusting the concentration and type of flame retardant additives, the adhesive's flammability resistance is enhanced while maintaining acceptable strength properties. The patent specifies particular ranges of flame retardant content to optimize both flammability resistance and bonding strength
2Strength
If epoxy adhesives with long set-up times are used to ensure proper curing, then adhesive strength is improved, but project duration and equipment costs increase due to extensive tooling requirements
Solution Approach 1:
The patent applies parameter changes by modifying the curing kinetics parameters of the epoxy adhesive through selection of specific curing agents and additives. This enables control over the set-up time and curing rate, allowing optimization of both adhesive strength development and production efficiency. The patent describes formulations that achieve adequate strength within reduced timeframes compared to conventional epoxies
Solution Approach 2:
The patent applies preliminary action by incorporating pre-formulated curing agents and catalysts in optimized ratios within the two-component adhesive system. This pre-preparation of the chemical composition enables faster initiation and progression of the curing reaction, reducing the time required to achieve handling strength while ensuring proper curing. The components are designed to react rapidly upon mixing, accelerating the overall process
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 meets the 60-second Ignition Vertical Bunsen Burner Test, achieves high lap shear strength, and significantly reduces project duration by shortening set-up times while maintaining the necessary strength and flammability standards for aerospace applications.
Implementation Method 1
a curing component which includes an adhesion promoter
Implementation Method 2
an epoxy component comprising: an epoxy resin greater than or equal to about 10% or less than or equal to about 50% of the total material composition weight, a flame retardant greater than or equal to about 2% to less than or equal to about 10% of the total material composition weight
Implementation Method 3
an adhesive is formed when the epoxy component is combined with the curing component
Data Source
AI summary
An adhesive material which comprises an epoxy component including a first flame retardant and a curing component which includes an adhesion promoter and a second flame retardant The epoxy component and curing component are present in a ratio of about 1:1 and the adhesive is formed when the epoxy component is combined with the curing component.