Epoxy Functional Surfactants for Aqueous Dispersion Stability

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Solution Overview

Problem

Aqueous dispersions of epoxy resins face inferior performance compared to solvent-borne counterparts due to surfactant migration affecting film quality, and suffer from reduced storage stability and increased particle size with higher surfactant levels, necessitating improved surfactants for better handling and dispersion properties.

Innovation Solution

Development of improved epoxy functional surfactants through the reaction of an epoxy composition with an amidoamine composition formed from a blend of acid-terminated polyoxyalkylene polyols, specifically using a blend of polyoxyalkylene polyols with varying molecular weights and oxidized carboxyl groups to create a polyamidoamine functionalized surfactant that can emulsify epoxy and amine polymers effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional surfactants (nonylphenol ethoxylates, alkylphenol initiated poly(oxyethylene) ethanols) are used to render epoxy emulsifiable, then the epoxy component becomes dispersible in water, but the surfactants migrate to surface interfaces and deleteriously affect film performance

Engineering Contradiction:

Improveemulsifiability of epoxyVSAvoidfilm performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention changes the chemical structure parameters of the surfactant by using oxidized polyoxyalkylene polyols with controlled oxidation levels (50-100% carboxylic end groups) and specific molecular weight distributions (polydispersity ≥1.1), which alters the surfactant's molecular properties to prevent migration while maintaining emulsification capability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite surfactant system by reacting epoxy compounds with amidoamine compositions formed from blends of oxidized polyoxyalkylene polyols, producing an integrated molecular structure that combines the emulsification properties of polyoxyalkylene chains with the stability of amidoamine linkages and epoxy functional groups

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If larger amounts of surfactant are used to decrease particle size and disperse solids in water, then dispersion effectiveness improves, but pH increases and storage stability reduces

Engineering Contradiction:

Improveparticle size controlVSAvoidstorage stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The invention optimizes the surfactant's molecular weight distribution (polydispersity ≥1.1) and oxidation level (50-100% carboxylic end groups), which enhances the surfactant's efficiency per unit mass, allowing effective particle size control at lower concentrations that maintain storage stability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates surfactant molecules with differentiated functional regions - hydrophilic oxidized polyoxyalkylene chains for water interaction, amidoamine linkages for structural stability, and epoxy-functional groups for resin compatibility - allowing each region to perform its specific function optimally

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If surfactant levels are decreased to control pH, then storage stability improves, but particle size increases

Engineering Contradiction:

ImprovepH control and storage stabilityVSAvoidparticle size

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The invention modifies the surfactant's chemical parameters by controlling the oxidation degree (50-100% carboxylic end groups) and polydispersity (≥1.1) of the polyoxyalkylene polyol, which increases the surfactant's efficiency and allows effective particle size control at lower concentrations

Inventive Principle:

Principle #35Parameter changes

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 surfactants achieve reduced particle size, improved shelf life, and enhanced non-volatile content with lower viscosity, addressing the stability and dispersion issues in aqueous epoxy resin dispersions.

Implementation Method 1

the two or more acid terminated polyoxyalkylene polyol compounds have from 50% to 100% of carboxylic end groups oxidized from hydroxyl end groups

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

improved epoxy functional surfactants prepared by reaction of an epoxy composition and an amidoamine composition

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Data Source

PatentEP2652039B1Improved epoxy systems and amine polymer systems and methods for making the same

Publication Date: 2019.10.30 HEXION RESEARCH BELGIUM SA

Figure 1

AI summary

Compositions and methods for forming surfactants, aqueous dispersions, and curing agents are provided. In one aspect, the invention relates to improved epoxy functional surfactants prepared by reaction of an epoxy composition and an amidoamine composition formed from a blend of acid-terminated polyoxyalkylene polyols. The improved epoxy functional surfactants may be reacted with an excess of epoxy composition and water to result in an aqueous dispersion. The amidoamone composition may be a reaction mixture of a diamine compound and an acid terminated polyoxyalkylene composition formed from two or more polyoxyalkylene polyol compounds. The epoxy functional surfactant may be reacted with amine compounds to form a compound suitable as a curing agent.