Epoxy Phosphate Ester Resin Water Dispersion Stability
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Solution Overview
Problem
Existing epoxy phosphate ester resins face challenges with water dispersion stability, high VOC content, and limited applicability due to high viscosity and gelation issues, which hinder their use in environmentally friendly coating solutions with superior corrosion resistance and film properties.
Innovation Solution
A process involving the reaction of epoxy resins with phosphoric acid to form epoxy phosphate ester resins, using a combination of different grades and types of epoxy resins, with controlled phosphoric acid addition and neutralization, to create a water-thinnable and stable coating composition with reduced VOC levels and improved corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If epoxy phosphate ester resins are made water-dispersible by balancing hydrophobic and hydrophilic portions, then environmental friendliness and low VOC are improved, but water dispersion stability and coating properties deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the acid value of epoxy phosphate ester resin within 25-45 mg KOH/g and the phosphoric acid to oxirane group ratio within 0.5-2.0:1. These parameter optimizations enable the resin to achieve both water dispersibility and stability, resolving the contradiction between environmental friendliness and performance.
Solution Approach 2:
The patent uses composite materials by combining epoxy resins with phosphoric acid to create epoxy phosphate ester resins that integrate both hydrophobic epoxy portions and hydrophilic phosphate ester portions. This composite structure enables the resin to be water-dispersible while maintaining coating performance and stability.
2Strength
If high molecular weight epoxy phosphate ester resins are used to improve coating properties, then corrosion resistance and film strength are improved, but water dispersibility and aqueous stability deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the acid value within 25-45 mg KOH/g and molecular weight parameters, which enables high molecular weight epoxy phosphate ester resins to maintain both film strength and aqueous stability. This resolves the contradiction between coating performance and water dispersibility.
3Stability of the object's composition
If unreacted phosphoric acid is present in the resin product to maintain water dispersibility, then water solubility is improved, but coating defects such as blushing occur
Solution Approach 1:
The patent applies parameter changes by precisely controlling the phosphoric acid to oxirane group ratio within 0.5-2.0:1 and acid value within 25-45 mg KOH/g. This optimization ensures sufficient water solubility while preventing excessive unreacted phosphoric acid that causes coating defects like blushing.
4Object-affected harmful factors
If high solid content solution of high molecular weight epoxies is used to reduce VOC, then environmental compliance is improved, but viscosity becomes unmeasurably high preventing handling and application
Solution Approach 1:
The patent applies parameter changes by optimizing the balance between hydrophobic and hydrophilic portions through controlled phosphoric acid addition ratio and acid value, which reduces viscosity to measurable and manageable levels while maintaining high solid content and low VOC content.
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 resulting epoxy phosphate ester resins provide stable, water-borne coatings with superior physical properties, corrosion resistance, and reduced VOC content, suitable for various substrates and meeting environmental standards, while maintaining excellent film thickness and protective properties.
Implementation Method 1
reacting an epoxy resin having an average of greater than one vicinal epoxy group with phosphoric acid to produce an epoxy resin adduct
Implementation Method 2
When an epoxy phosphate ester resin has been neutralized and dispersed into water, the resultant product is the well-known emulsion type
Data Source
AI summary
The present invention relates to novel compositions uniquely comprising combinations of different grades and/or type of epoxy resins and phosphoric acid into stable, water dispersion, epoxy phosphate ester copolymers. Aqueous thermosetting coating compositions, based on the novel epoxy phosphate ester resins, have the ability to reduce the requirements of curing temperature and time. The resultant coating films have superior protective properties, film properties, and wider applications than the conventional epoxy phosphate ester resins.