Epoxy Imbibed Polymer Particles Stabilization
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Solution Overview
Problem
Current polymer latex systems face challenges in incorporating high concentrations of thermosettable compounds while maintaining particle stability, especially during heat-age stability testing, due to reactivity issues with carboxylate salts and limited incorporation levels of epoxy resins.
Innovation Solution
A stable aqueous dispersion of thermoplastic polymer particles imbibed with a thermosettable compound having at least two oxirane groups, characterized by sufficient anti-agglomerating functional groups, which are non-reactive and hydrophilic, allowing for high concentrations of thermosettable compounds without a hardener, and are heat-age stable at 60°C for 10 days.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If carboxylate salts are used to stabilize latex particles, then particle stability is improved, but reactivity with thermosettable compounds causes particle instability
Solution Approach 1:
The patent introduces anti-agglomerating functional groups as intermediary stabilizing agents that mediate between the thermosettable compound and the polymer matrix. These functional groups prevent agglomeration without reacting with the oxirane groups, thus resolving the conflict between stabilization and reactivity.
Solution Approach 2:
The patent modifies the chemical parameters of the polymer by incorporating specific anti-agglomerating functional groups (such as carboxylic acid groups with controlled concentration and reactivity) to change the interaction characteristics with thermosettable compounds, enabling stable incorporation at high concentrations.
2Strength
If epoxy resin is incorporated into latex particles, then handling performance and wet/chemical strength are improved, but particle stability deteriorates due to reactivity with carboxylate salts
Solution Approach 1:
Anti-agglomerating functional groups serve as intermediaries that enable epoxy resin incorporation without direct harmful interaction. These groups maintain particle stability while allowing the thermosettable compound to provide enhanced mechanical and chemical properties.
Solution Approach 2:
The patent applies local quality modification by incorporating anti-agglomerating functional groups at specific concentrations and locations within the polymer structure, creating zones of stability that allow high levels of thermosettable compound incorporation without global instability.
3Quantity of substance
If high concentrations of thermosettable compound are incorporated into polymer particles, then coating performance is improved, but particle stability deteriorates during heat-age testing
Solution Approach 1:
The patent changes the chemical parameters of the polymer system by incorporating anti-agglomerating functional groups at optimized concentrations, enabling high levels of thermosettable compound (up to 60% by weight) to be incorporated while maintaining heat-age stability through controlled reactivity and steric effects.
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
This approach enables the formation of a heat-age stable polymer latex that can be used for coatings, adhesives, sealants, and fillers, with high solids content and reduced VOCs, allowing for high levels of thermosettable compound incorporation without particle instability.
Implementation Method 1
a stable aqueous dispersion of thermoplastic polymer particles imbibed with a thermosettable compound having at least two oxirane groups
Implementation Method 2
which polymer particles are characterized by having a sufficient concentration of anti-agglomerating functional groups to stabilize the latex against agglomeration
Implementation Method 3
contacting the composition of any of Claims 1 to 7 with a hardener to form a curable composition
Data Source
AI summary
The present invention relates to a stable aqueous dispersion of thermoplastic polymer particles imbibed with a thermosettable compound. The polymer particles are characterized by having a sufficient concentration of anti-agglomerating functional groups to stabilize the latex against agglomeration. The dispersion is useful as one part of a two-pack formulation.