Fast Curing Epoxy Systems Using Boron Catalysts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Epoxy resin systems used in casting resins, coatings, and adhesives often cure too slowly, especially at low temperatures, and may contain toxic or allergenic additives like phenols, which are undesirable for applications requiring rapid curing and safety.
Innovation Solution
A composition comprising at least one epoxy resin, a cyclic amine with two secondary amino groups within an organic ring system, and a salt of a very strong Brönsted acid with a pKa value ≤ -9.01, which acts as a catalyst, facilitating faster curing without phenol-based additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional epoxy resin systems are used, then good chemical and solvent resistance is achieved, but the curing process is too slow especially at low temperatures
Solution Approach 1:
The patent introduces a novel catalyst system based on boron compounds (boric acid, borax, or boron trifluoride etherate) in combination with specific amine hardeners. This chemical parameter change enables the epoxy system to cure rapidly at low temperatures (even below room temperature) while maintaining the desired chemical resistance properties. The catalyst system fundamentally alters the reaction kinetics without compromising the final cured material's performance characteristics.
2Speed
If phenol-containing additives are used to accelerate curing, then curing speed is improved, but toxicity and allergenic effects increase
Solution Approach 1:
The patent employs catalysts that are effective in very small quantities (typically 0.1-5% by weight relative to the epoxy resin) and do not remain as harmful residues in the final cured product. The boron-based catalysts facilitate rapid curing without the persistent toxic effects associated with phenolic additives, allowing the system to achieve fast curing while maintaining safety and environmental compatibility.
Solution Approach 2:
The invention replaces phenol-based catalysis with a completely different chemical mechanism involving boron compounds and amine hardeners. This parameter change in the catalytic system achieves the same goal (accelerated curing) but through a non-toxic pathway, eliminating the harmful effects while preserving the beneficial curing speed improvement.
3Speed
If high temperatures are used to accelerate curing, then curing speed is improved, but energy consumption and processing complexity increase
Solution Approach 1:
The patent introduces a catalyst system that inverts the traditional temperature-speed relationship by enabling rapid curing at low temperatures. The boron compound catalysts lower the activation energy barrier for the epoxy-amine reaction, allowing the curing process to proceed rapidly at temperatures below room temperature or at ambient conditions, thereby eliminating the need for high-temperature heating and associated energy consumption.
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 described composition significantly accelerates the curing process of epoxy resin systems at temperatures below room temperature, reducing the need for toxic or allergenic additives and enhancing productivity by ensuring rapid hardening in various applications, including cold environments.
Implementation Method 1
at least one salt of a Brønsted acid with a pKa value less than or equal to -9.01 with a counterion selected from metal ions, metal-containing ions, phosphonium ions and ammonium ions
Data Source
AI summary
The present invention relates to a composition comprising a) at least one epoxy resin, b) at least one amine with at least two secondary amino groups, both of which are part of an organic ring system, and c) at least one salt of a very strong Brønsted acid with a counterion selected from metal ions, metal-containing ions, phosphonium ions and ammonium ions, a process for its preparation and its use.