Epoxy Resin Composition for Abrasive Binders
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Solution Overview
Problem
Conventional thermosetting resins used in abrasive articles, such as resol type phenolic resins, contain formaldehyde, which is harmful to human health and the environment, and emit formaldehyde during manufacturing and usage, violating increasingly stringent regulations.
Innovation Solution
A thermally curable liquid resin composition comprising at least one epoxy resin with two epoxy groups and a reactive diluent, with a viscosity of less than 7000 mPa·s at 25°C, is developed to replace resols and aqueous epoxy resins, featuring a higher epoxy resin content and specific reactive diluents like furfuryl alcohol and gamma-butyrolactone to reduce formaldehyde content and improve mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resol type phenolic resins are used in abrasive articles, then the binder provides strong binding and thermal resistance, but formaldehyde is emitted during manufacturing and usage, violating environmental regulations
Solution Approach 1:
The patent changes the chemical composition parameters by replacing resol type phenolic resins with epoxy resins having specific molecular weights (150-500 g/mol) and epoxy equivalent weights (100-300 mg KOH/g). This parameter change eliminates formaldehyde emission while maintaining the required binding strength and thermal resistance properties of the abrasive article binder.
Solution Approach 2:
The patent creates a composite binder system combining epoxy resin with specific crosslinking agents and fillers to achieve both environmental compliance (no formaldehyde) and performance requirements (binding strength, thermal resistance). The composite approach allows optimization of both harmful factor reduction and functional performance.
2Object-generated harmful factors
If epoxy resin content is increased to reduce formaldehyde, then environmental compliance is improved, but viscosity increases and processing becomes difficult
Solution Approach 1:
The patent optimizes the viscosity parameter by selecting epoxy resins with specific molecular weights (150-500 g/mol) and epoxy equivalent weights (100-300 mg KOH/g), ensuring the composition remains processable. Additional parameters including water content (0.1-5%) and solid content (40-80%) are controlled to maintain ease of application while achieving low formaldehyde levels through high epoxy resin content.
3Ease of operation
If reactive diluents are added to reduce viscosity, then processing ease is improved, but the composition complexity increases
Solution Approach 1:
The patent controls composition complexity by limiting reactive diluents to specific compounds (furfuryl alcohol, gamma-butyrolactone, or their mixtures) in controlled amounts (5-50 parts per 100 parts epoxy resin). This parameter control simplifies the formulation while achieving the desired viscosity reduction for easy processing during application.
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 new resin composition effectively reduces formaldehyde content and water usage in abrasive products, enhancing mechanical properties and compliance with environmental regulations while maintaining performance under high mechanical stresses and thermal resistance.
Implementation Method 1
A thermally curable liquid resin composition comprising at least one epoxy resin with two epoxy groups and a reactive diluent
Implementation Method 2
effectively reduces formaldehyde content and water usage in abrasive products
Data Source
AI summary
The present invention relates to a thermally curable liquid resin composition capable of being used in the manufacture of abrasive articles, and to the resulting abrasive articles.