Graft Copolymer Core-Shell Structure for Epoxy Resin Dispersion
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Solution Overview
Problem
The existing methods for improving the impact resistance of epoxy resins, such as using graft copolymers as impact reinforcing agents, face challenges with particulate dispersibility, particularly in the particulate phase dispersion method, which affects processing costs and environmental sustainability.
Innovation Solution
A graft copolymer composition with a core-shell structure, comprising a rubbery polymer core and a shell formed by graft polymerizing an alkyl (meth)acrylate-based monomer, is developed, with specific weight percentages and particle diameter distributions to enhance dispersibility in epoxy resins, allowing for effective particulate phase dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the liquid phase dispersion method is used to disperse graft copolymer in epoxy resin, then homogeneous dispersion is achieved, but storage problems and environmental pollution occur due to water and solvent discharge
Solution Approach 1:
The invention extracts and removes the harmful water and solvent components from the dispersion process by using a melt dispersion method that directly processes the graft copolymer in its solid state, eliminating the need for liquid phases that cause environmental pollution while maintaining dispersion effectiveness
Solution Approach 2:
The invention changes the physical state parameter of the graft copolymer from liquid/latex phase to solid particulate phase, and changes the dispersion medium from water/solvent to epoxy resin melt, thereby eliminating environmental pollution while achieving homogeneous dispersion through controlled melting and mixing
2Ease of manufacture
If the particulate phase dispersion method is used to directly disperse agglomerated dry powder graft copolymer in epoxy resin, then processing cost is reduced, but dispersion becomes very difficult or impossible due to high viscosity
Solution Approach 1:
The invention performs preliminary action by pre-processing the graft copolymer latex to control its particle size distribution and morphology before drying into particulate form, ensuring that the subsequent melt dispersion process can proceed smoothly without excessive viscosity issues while maintaining cost effectiveness
Solution Approach 2:
The invention changes the temperature parameter to melt state, transforming the high-viscosity solid particulate graft copolymer into a lower-viscosity melt that can be easily dispersed in epoxy resin, thereby solving the dispersion difficulty while maintaining the cost advantages of particulate phase processing
3Strength
If graft copolymer with high core content (75-90 wt%) is used to improve impact resistance, then mechanical properties are enhanced, but particulate dispersibility becomes challenging
Solution Approach 1:
The invention segments the graft copolymer particles into specific size ranges (0.1-10 μm) with controlled size distribution, creating smaller discrete units that can disperse more easily in the epoxy resin while maintaining the high core content necessary for impact resistance, thus resolving the contradiction between strength and dispersibility
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 graft copolymer composition achieves excellent particulate dispersibility and mechanical properties, including improved impact resistance, while reducing viscosity and ensuring environmental benefits through optimized particle distribution and core-shell structure.
Implementation Method 1
a core comprising a rubbery polymer
Implementation Method 2
the improvement of the particulate dispersibility of a graft copolymer particulate material
Data Source
AI summary
A graft copolymer, and a graft copolymer composition having excellent particulate dispersibility in a curable resin such as an epoxy resin and is applicable as a particulate impact reinforcing agent, a curable resin composition including same, and methods of preparing them.