Epoxy and Silicone Curing Modifiers for Rapid Crosslinking
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Solution Overview
Problem
The curing process of curable compositions, such as sealants and coatings, is often the bottleneck in manufacturing, taking up to a day and limiting production rates and increasing costs.
Innovation Solution
Incorporating a curing rate modifier, such as nanostructured graphene-based materials or hydrophilic polymers, into curable prepolymers to accelerate crosslinking reactions, which can be induced by heat or water exposure, without the need for additional hardeners or catalysts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional curable compositions are used without curing rate modifiers, then the composition remains stable and does not cure prematurely, but the curing process takes up to a day and limits production rates
Solution Approach 1:
The patent introduces curing rate modifiers that change the kinetic parameters of the crosslinking reaction. These modifiers (such as metal oxides, metal hydroxides, or organic compounds) alter the reaction rate constant, enabling the curing process to proceed much faster than conventional compositions while maintaining control over the curing timeline.
Solution Approach 2:
The curing rate modifiers act as intermediaries between the curable prepolymers and the curing process. These modifiers facilitate the crosslinking reaction by providing alternative reaction pathways or catalytic surfaces, thereby accelerating the formation of the crosslinked network without requiring additional hardeners or catalysts.
2Productivity
If curing rate modifiers are added to accelerate crosslinking, then curing time is reduced and production rate increases, but the composition complexity increases
Solution Approach 1:
The curing rate modifiers are used in small amounts and are consumed during the curing process. They serve their purpose of accelerating the reaction and then become part of the cured network or decompose, eliminating the need for complex recovery or separation processes.
Solution Approach 2:
The curing rate modifiers serve multiple functions: they accelerate the crosslinking reaction, can influence the morphology of the cured network, and in some cases provide additional functional properties to the final product. This multi-functionality justifies the added composition complexity.
3Productivity
If curing rate modifiers are used to increase crosslinking rate, then curing time is reduced, but manufacturing costs increase
Solution Approach 1:
By changing the kinetic parameters of the curing reaction through the addition of modifiers, the process time is significantly reduced. Although the modifiers add some cost, the productivity gain from reduced curing time and increased production rate typically outweighs the additional material cost.
Solution Approach 2:
The curing rate modifiers are used in relatively small amounts (partial action) to achieve the desired acceleration effect. This partial addition minimizes the cost increase while still providing significant productivity benefits, avoiding the need for excessive modifier concentrations that would dramatically increase cost.
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 curing rate is significantly increased, allowing for faster conversion to a cured, crosslinked state, reducing curing times and lowering manufacturing costs.
Implementation Method 1
a curing rate modifier that increases a rate of crosslinking reactions between the curable prepolymers
Implementation Method 2
the curing rate modifier forms covalent bonds with a hardener present in the curable composition or with the curable prepolymers
Implementation Method 3
the curing rate modifier forms non-covalent bonds with the curable prepolymers, wherein the non-covalent bonds are hydrogen bonds
Implementation Method 4
the curing rate modifier increases a diffusion rate of water molecules in a vicinity of the curing rate modifier
Data Source
AI summary
Curable compositions are provided. In embodiments, a curable composition comprises curable prepolymers selected from the group consisting of epoxy prepolymers and silicone prepolymers, and a curing rate modifier that increases a rate of crosslinking reactions between the curable prepolymers as compared to a comparative curable composition without the curing rate modifier, wherein the curing rate modifier does not cure the curable composition in the absence of a hardener present in the curable composition, a catalyst present in the curable composition, water, or a combination thereof. Methods of using the curable compositions are also provided.