Liquid Epoxy Resin Composition With Low Crystallinity Stability
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Solution Overview
Problem
Existing epoxy resin compositions used in making polymers, such as those derived from bisphenol A (BPA) and bisphenol F (BPF), often suffer from storage instability at ambient conditions due to excessive crystallinity, necessitating costly and complex process steps to maintain usability, which affects manufacturing efficiency and cost.
Innovation Solution
A liquid epoxy resin composition derived from epihalohydrin and ortho-substituted diphenols, particularly tetramethyl bisphenol F (TMBPF), is formulated with controlled ratios of n=0 and n=1 diepoxide resins to ensure stability, minimizing crystallinity and maintaining a liquid state for extended periods, thereby simplifying manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional epoxy resin compositions (e.g., from BPA or BPF) are used to make polymers, then polymer production can proceed, but the epoxy resin composition suffers from storage instability at ambient conditions due to excessive crystallinity
Solution Approach 1:
The patent changes the chemical parameters of the epoxy resin composition by using ortho-substituted diphenols (specifically TMBPF) instead of conventional BPA or BPF, and by controlling the ratio of n=0 to n=1 diepoxide resins to be less than 80:20. This parameter change prevents excessive crystallinity and maintains storage stability at ambient conditions for at least one month without requiring special process steps
Solution Approach 2:
The patent creates a composite epoxy resin composition that combines TMBPF-derived diepoxide resins with specific molecular weight distributions (n=0 and n=1 units). This composite structure, where n=0 units represent unextended chains and n=1 units represent extended chains, provides both processability and storage stability by balancing crystallinity suppression with polymerization performance
2Productivity
If epoxy resin compositions with excessive crystallinity are used, then polymer production can proceed, but costly and complex process steps are required to maintain usability
Solution Approach 1:
By changing the chemical composition parameters to use TMBPF-based diepoxide resins with controlled n=0/n=1 ratios, the patent eliminates the need for complex process steps such as heating, cooling, or stirring that would otherwise be required to manage crystallinity. This simplifies the manufacturing process while maintaining productivity
Solution Approach 2:
The patent extracts and eliminates the problematic crystallinity issue by removing conventional BPA/BPF-based epoxy resins from the composition and replacing them with TMBPF-based resins that inherently resist excessive crystallization, thereby simplifying the manufacturing process
3Productivity
If conventional epoxy resin compositions are used, then polymer production can proceed, but manufacturing cost increases due to special process steps
Solution Approach 1:
The patent changes the compositional parameters to TMBPF-based diepoxide resins with specific n=0/n=1 ratios, which eliminates the need for energy-intensive special process steps. This reduces manufacturing costs while maintaining production efficiency
Data Source
AI summary
A liquid epoxy resin composition is provided. In preferred embodiments, the liquid epoxy resin composition is free of bisphenol A, bisphenol F, and bisphenol S, including epoxides thereof, and is useful in preparing a polyether polymer having utility in coating compositions, including, e.g., coating compositions for use on food or beverage containers.