Epoxy Coating with Cyclic Diamine and Elastomeric Particles for Aluminum Bonding
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Solution Overview
Problem
Current coating compositions, including sealants and adhesives, face challenges in achieving high lap shear strength and displacement on aluminum substrates, particularly in providing a strong and durable bond that withstands mechanical stress.
Innovation Solution
The development of a composition comprising an epoxy-containing compound, a diamine or polyamine with a cyclic ring, and elastomeric particles, where at least 50% of the elastomeric particles have a styrene butadiene core, which chemically react to form a strong adhesive bond with a lap shear displacement of at least 2.5 mm and a lap shear strength of at least 30 MPa when applied to 2024-T3 aluminum substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coating compositions are used, then the coating can be applied to aluminum substrates, but the lap shear strength and displacement are insufficient
Solution Approach 1:
The patent employs a composite coating composition integrating epoxy-containing compounds, cyclic diamine/polyamine curing agents, and elastomeric particles (minimum 50% styrene butadiene core). This multi-component composite system achieves lap shear strength ≥30 MPa and displacement ≥2.5 mm on aluminum substrates, resolving the contradiction between strength and bond durability by combining the high strength of epoxy with the flexibility of elastomeric particles.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the coating composition by specifying precise compositional requirements: epoxy-containing compounds with specific functional groups, cyclic diamine/polyamine curing agents with defined structural characteristics, and elastomeric particles with minimum 50% styrene butadiene core content. These parameter changes enable the coating to achieve both high lap shear strength and reliable bond durability on aluminum substrates.
2Strength
If high lap shear strength is achieved, then the bond strength increases, but the displacement at failure may be limited
Solution Approach 1:
The patent applies local quality by incorporating elastomeric particles (minimum 50% styrene butadiene core) into the epoxy-based coating matrix. These elastomeric particles provide localized flexibility and shock absorption within the rigid epoxy structure, enabling the coating to achieve both high lap shear strength (≥30 MPa) and adequate displacement at failure (≥2.5 mm) on aluminum substrates.
Solution Approach 2:
The patent changes the physical and chemical parameters of the coating by integrating elastomeric particles with specific compositional requirements into the epoxy-curing agent system. This parameter modification creates a dual-phase structure that simultaneously delivers high strength and acceptable displacement characteristics, resolving the contradiction between strength and stability.
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 achieves enhanced lap shear strength and displacement, ensuring a robust and durable bond on aluminum substrates, as measured by ASTM D1002-10 standards, using an INSTRON 5567 machine, thereby addressing the limitations of existing technologies.
Implementation Method 1
a second component that chemically reacts with the epoxy-containing compound, the second component comprising a diamine comprising a cyclic ring and/or a polyamine comprising a cyclic ring
Implementation Method 2
elastomeric particles, wherein at least 50% by weight of the elastomeric particles comprise a styrene butadiene core based on total weight of the elastomeric particles
Data Source
AI summary
The present invention is directed to compositions comprising a first component, a second component, and elastomeric particles. The first component comprises an epoxy-containing compound. The second component comprises a diamine comprising a cyclic ring and/or a polyamine comprising a cyclic ring. The diamine may chemically react with the epoxy-containing compound. Optionally, the cyclic ring of the diamine and/or the polyamine has at least one carbon positioned between the amino functional groups and the cyclic ring structure. Optionally, at least 50% by weight of the elastomeric particles comprise a styrene butadiene core based on total weight of the elastomeric particles. The present invention is also directed to methods of making the compositions, methods of coating a substrate, and coated substrates.