Epoxy Encapsulant Composition for Narrow-Gap Adhesion Stability

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Solution Overview

Problem

Existing epoxy resin compositions, particularly two-component systems, face challenges with storage and handling due to the need for separate storage and mixing of epoxy resin and curing agent, leading to inefficiencies and reduced adhesion in narrow gap sites.

Innovation Solution

An epoxy resin composition is developed with a heteroatom-containing curing agent having a molecular weight between 200 and 1200 and a specific ratio of molecular weight to the number of heteroatoms, which improves adhesion and storage stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a solid aromatic amine compound is used as a curing agent, then curability is improved, but penetration into narrow gaps deteriorates

Engineering Contradiction:

ImprovecurabilityVSAvoidpenetration depth

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The patent changes the physical state parameter of the curing agent from solid to liquid by selecting specific aromatic amine compounds with molecular weights in the range of 80-200 and specific structural features (such as cresyl glycidyl ether, phenyl glycidyl ether). This parameter change enables the curing agent to penetrate narrow gaps effectively while maintaining curability, resolving the contradiction between solid-state curability and liquid-state penetration.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If a liquid aromatic amine compound is used as a curing agent, then penetration into narrow gaps is improved, but storage stability deteriorates

Engineering Contradiction:

Improvepenetration depthVSAvoidstorage stability

Core Design Contradiction:

Length of moving objectVSStability of the object's composition

Solution Approach 1:

The patent optimizes the molecular weight parameter of the liquid aromatic amine compound to a specific range (80-200) and controls the heteroatom content to achieve a balance between penetration ability and storage stability. By selecting compounds within this parameter range, the formulation achieves both good penetration into narrow gaps and acceptable storage stability without requiring additional stabilizing additives.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite epoxy resin composition by combining the liquid aromatic amine compound with epoxy resin in specific ratios. This composite formulation synergistically combines the penetration ability of the liquid curing agent with the structural integrity of the epoxy resin, achieving both narrow gap penetration and storage stability.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a two-component epoxy resin composition is used, then curability is improved, but handling complexity increases

Engineering Contradiction:

ImprovecurabilityVSAvoidhandling ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent merges the epoxy resin and curing agent into a single-component pre-mixed composition. The liquid aromatic amine compound is pre-combined with the epoxy resin in optimal ratios, eliminating the need for separate storage and mixing operations. This merging maintains curability while dramatically improving handling ease and operational simplicity.

Inventive Principle:

Principle #5Merging (Combining)

4Length of moving object

If the molecular weight of the curing agent is reduced to improve penetration, then adhesion to dense fibers deteriorates

Engineering Contradiction:

Improvepenetration depthVSAvoidadhesion strength

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The patent identifies an optimal molecular weight range (80-200) for the aromatic amine compound that balances penetration and adhesion. Within this range, the curing agent has sufficiently low molecular weight to penetrate narrow gaps and dense fiber structures, while maintaining adequate molecular complexity to form strong adhesive bonds with the substrate.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite system where the liquid aromatic amine compound works synergistically with the epoxy resin. The epoxy resin provides the primary adhesion mechanism to dense fibers, while the liquid curing agent ensures complete penetration and cross-linking. This composite approach allows the use of lower molecular weight curing agents without compromising adhesion strength.

Inventive Principle:

Principle #40Composite materials

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 proposed epoxy resin composition achieves favorable adhesion, improved storage stability, and enhanced penetration into narrow gaps, addressing the limitations of existing compositions.

Implementation Method 1

epoxy resin composition containing (A) epoxy resin, and (B) a heteroatom-containing curing agent

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS20250034319A1Epoxy resin composition, cured product, encapsulant and adhesive

Publication Date: 2025.01.30 ASAHI KASEI KOGYO KABUSHIKI KAISHA

AI summary

Provided is an epoxy resin composition containing (A) epoxy resin, and (B) a heteroatom-containing curing agent, wherein molecular weight α of the heteroatom-containing curing agent (B) is 200≤α≤1200, and ratio α/β of the molecular weight α to number β of heteroatoms in a structure of the heteroatom-containing curing agent (B) is 30≤α/β≤95.