Solvent-Free Ionic Epoxy Resin for Low-VOC High-Strength Polymers
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Solution Overview
Problem
Traditional epoxy systems emit significant volatile organic compounds (VOCs) during manufacturing, leading to environmental and health hazards, and increased operational costs, despite providing desirable properties such as high strength and chemical resistance.
Innovation Solution
A solvent-free ionic epoxy system comprising a hardener compound and an epoxy compound with specific molecular structures that form a secondary ionic liquid upon polymerization, reducing VOC emissions and enabling self-healing properties through stable electrical charges in the polymeric chains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional epoxy systems are used to achieve high strength and chemical resistance, then desirable mechanical properties are obtained, but significant VOC emissions occur causing environmental and health hazards
Solution Approach 1:
The patent changes the chemical composition parameters of the epoxy system by incorporating ionic liquid components with specific molecular structures (Y1 and Z1) that maintain the crosslinking chemistry needed for strength while eliminating volatile organic solvents. This parameter change transforms the system from VOC-emitting to solvent-free, resolving the contradiction between mechanical performance and environmental safety
Solution Approach 2:
The patent creates a composite epoxy system combining traditional epoxy compounds with ionic liquid hardeners and additives. This composite approach maintains the desirable mechanical properties of conventional epoxies while introducing ionic liquid components that eliminate VOC emissions, thus resolving the contradiction between strength and harmful emissions
2Ease of operation
If traditional epoxy systems with solvents are used to improve processability, then viscosity is reduced and handling is easier, but operational costs increase due to VOC capture requirements
Solution Approach 1:
The patent modifies the viscosity parameters through selective removal of volatile solvents while retaining ionic liquid components that provide adequate flow characteristics. This parameter change improves processability without requiring expensive VOC capture infrastructure, thereby reducing operational costs while maintaining ease of operation
Solution Approach 2:
The patent extracts and removes the volatile organic solvent components from the epoxy system, keeping only the non-volatile ionic liquid portions. This extraction eliminates the need for VOC capture systems and associated operational costs, while the remaining ionic liquid components continue to provide processability benefits
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 solvent-free ionic epoxy system significantly reduces VOC emissions, lowers processing costs, and mitigates health hazards while maintaining the desirable properties of traditional epoxy systems, with the added benefit of self-healing capabilities and versatile applications in materials like filtration membranes and electronic components.
Implementation Method 1
the presence of stable electrical charges along to the polymeric chains that drive the healing process through electrostatic attraction
Data Source
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AI summary
Solvent free epoxy system that includes: a hardener compound H comprising: a molecular structure (Y1-R1-Y2), wherein R1 is an ionic moiety Y1 is a nucleophilic group and Y2 nucleophilic group; and an ionic moiety A acting as a counter ion to R1; and an epoxy compound E comprising: a molecular structure (Z1R2-Z2), wherein R1 is an ionic moiety, Z1 comprises an epoxide group, and Z2 comprises an epoxide group; and an ionic moiety B acting as a counter ion to R2. In embodiments, the epoxy compound E and/or the hardener H is comprised in a solvent-less ionic liquid. The systems can further include accelerators, crossiinkers, plasticizers, inhibitors, ionic hydrophobic and/or super-hydrophobic compounds, ionic hydrophilic compounds, ionic transitional hydrophobic/hydrophilic compounds, biological active compounds, and/or plasticizer compounds. Polymers made from the disclosed epoxy systems and their methods of used.