Hydroxy Urethane Epoxy Composition Without Isocyanate Accelerators
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Solution Overview
Problem
Existing epoxy resin compositions are highly reactive, exothermic, and rigid, leading to safety and environmental concerns due to the use of accelerators like isocyanates and endocrine disruptors such as bisphenol A or F, with limited flexibility and hardness range.
Innovation Solution
A two-part epoxy resin composition is developed using a modified hydroxy alkyl urethane formed by reacting a (meth)acrylate monomer or oligomer with a hydroxy alkyl urethane, eliminating isocyanates and incorporating a less reactive Michael addition reaction to achieve flexibility and hardness between Shore A 20 to Shore D 85.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional epoxy resin compositions use accelerators like isocyanates and hardeners, then the reaction speed and curing efficiency are improved, but the toxicity, environmental harm, and safety risks increase
Solution Approach 1:
The patent removes harmful accelerators (isocyanates, boron trifluoride, salicylic acid, paratoluene sulfonic acid) from the epoxy resin composition entirely. The curing process relies on the inherent reactivity between epoxy groups and amine hardeners without requiring additional accelerators, thereby eliminating the toxic and environmentally harmful components while maintaining curing functionality
Solution Approach 2:
The patent modifies the chemical composition parameters by replacing traditional accelerator systems with a simplified two-component system (epoxy resin + amine hardener). This parameter change shifts the curing mechanism from accelerator-dependent to direct amine-epoxy reaction, reducing toxicity while preserving curing efficiency through proper selection of amine hardener types and ratios
2Strength
If epoxy resin compositions use bisphenol A or F containing resins, then the mechanical strength and rigidity are improved, but the endocrine disruption risks and health concerns increase
Solution Approach 1:
The patent eliminates bisphenol A and bisphenol F containing epoxy resins from the composition. Instead, it uses alternative epoxy resin types that do not contain these endocrine-disrupting compounds, thereby removing the harmful substances while maintaining the necessary mechanical strength through proper resin selection and formulation
Solution Approach 2:
The patent creates a composite formulation combining alternative epoxy resins (free from bisphenol A/F) with amine hardeners and optional safe additives. This composite material approach achieves the required mechanical strength and rigidity without relying on harmful bisphenol-based resins, providing a safe alternative that meets performance requirements
3Speed
If the epoxy amine acrylate reaction is used, then the reaction speed is improved, but the exothermicity and three-dimensional networking rigidity increase excessively
Solution Approach 1:
The patent avoids using acrylate modifiers that create highly crosslinked rigid networks. Instead, it employs a simpler amine-epoxy reaction system that provides adequate curing speed without the excessive exothermicity and rigidity associated with acrylate-based highly crosslinked systems
Solution Approach 2:
The patent adjusts the reaction parameters by selecting amine hardeners with appropriate functionality and molecular weight to control the crosslinking density. This parameter optimization achieves a balance between curing speed and exothermicity, preventing excessive temperature rise while maintaining adequate reaction rate for practical applications
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 composition provides improved chemical and mechanical properties, such as abrasion resistance, while being safer and compliant with REACH regulations, offering reduced risk to users and avoiding the use of harmful substances.
Implementation Method 1
The modified hydroxy alkyl urethane is formed by a reaction between a (meth)acrylate monomer or oligomer and a hydroxy alkyl urethane... The composition undergoes a Michael addition when mixed with an unsaturated polyester resin
Implementation Method 2
epoxy resins react with amines as hardeners, forming a three-dimensional network according to the following reaction scheme
Data Source
AI summary
A two-part epoxy resin composition is provided comprising: a first resin part comprising a modified hydroxy alkyl urethane and an epoxy component; and a second resin part comprising an amine component; wherein the modified hydroxy alkyl urethane is formed by a reaction between a (meth)acrylate monomer or oligomer and a hydroxy alkyl urethane having the formula: (Formula (I)); where: R1 is an amine residue; and R2 and R3 are the same or different and are selected from the group consisting of H, alkyl, and hydroxyalkyl.