High-Functionality Epoxy Resins from Polyol Esters
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Solution Overview
Problem
The limited reactivity of internal epoxy groups in seed oil epoxides restricts their extensive use in coatings, and there is a need for improved processes to broaden their applications, particularly in achieving higher crosslink density and functionality for enhanced performance in coatings.
Innovation Solution
Highly functional epoxy resins are synthesized from the epoxidation of vegetable or seed oil esters of polyols with 4 or more hydroxyl groups, which can be cured using UV photoinitiators to form hard coatings and incorporated into formulations with oxetanes and cycloaliphatic epoxides, leading to increased photopolymerization rates and improved crosslink density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If epoxidized seed oils are used as coating materials, then renewable resource utilization is improved, but the reactivity of internal epoxy groups is insufficient leading to low crosslink density
Solution Approach 1:
The patent changes the chemical structure parameter by using polyols with 4 or more hydroxyl groups instead of conventional triglycerides, which increases the number of epoxy groups per molecule from typically 3-6 to 8 or more. This structural parameter change directly increases the crosslink density while maintaining renewable resource utilization.
Solution Approach 2:
The patent creates composite epoxy resins by combining polyol esters of fatty acids with photoinitiators and optional reactive diluents. This composite approach enables UV-curable coatings with high crosslink density while incorporating renewable seed oil components.
2Device complexity
If conventional epoxidized vegetable oils are used, then the coating formulation is simple, but the photopolymerization rate is slow and coating hardness is insufficient
Solution Approach 1:
The patent changes the functionality parameter of the epoxy resin from conventional values to high functionality (8 or more epoxy groups per molecule). This parameter change accelerates the photopolymerization rate and improves coating hardness, while the formulation remains relatively simple by using direct epoxidation of polyol esters.
3Reliability
If internal epoxy groups in seed oil epoxides are used, then the material is derived from renewable sources, but the reactivity is limited restricting extensive applications
Solution Approach 1:
The patent changes the molecular architecture parameter by selecting polyols with 4 or more hydroxyl groups as starting materials. This structural modification increases the number of epoxy groups per molecule and enhances reactivity, thereby expanding the range of applicable coatings and applications while maintaining renewable source derivation.
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 resins provide higher crosslink density and functionality, resulting in harder and more durable coatings with enhanced mechanical properties compared to conventional epoxidized vegetable or seed oils.
Implementation Method 1
which can be cured using UV photoinitiators to form hard coatings
Data Source
AI summary
The invention provides highly functional epoxy resins that may be used themselves in coating formulations and applications but which may be further functionalized via ring-opening reactions of the epoxy groups yielding derivative resins with other useful functionalities. The highly functional epoxy resins are synthesized from the epoxidation of vegetable or seed oil esters of polyols having 4 or more hydroxyl groups/molecule. In one embodiment, the polyol is sucrose and the vegetable or seed oil is selected from corn oil, castor oil, soybean oil, safflower oil, sunflower oil, linseed oil, tall oil fatty acid, tung oil, vernonia oil, and mixtures thereof. Methods of making of the epoxy resin and each of its derivative resins are disclosed as are coating compositions and coated objects using each of the resins.