Ionic Liquid Catalyst for Low-Temperature Epoxy Curing
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Solution Overview
Problem
Conventional epoxy resin compositions face challenges with high curing temperatures, long curing times, and poor operability due to the need for mixing main ingredients and curing agents, leading to impracticality and reliability issues.
Innovation Solution
A resin composition combining a compound with at least two epoxy and/or thiirane groups with a specific ionic liquid, featuring cations like ammonium or phosphonium and anions such as acidic or neutral amino acid ions, along with a polythiol compound and/or acid anhydride, to achieve balanced curing capability and storage stability at ambient temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional curing agents are used for epoxy resin, then curing capability is achieved, but curing temperature becomes excessively high and curing time becomes excessively long
Solution Approach 1:
The patent changes the chemical parameters of the curing system by introducing a novel catalyst composition comprising a specific ionic liquid and organic metal compound. This catalyst system operates at much lower temperatures (ambient to 100°C) compared to conventional curing agents that require 150-200°C, thereby resolving the contradiction between achieving reliable curing and maintaining acceptable curing temperature.
Solution Approach 2:
The patent employs a composite catalyst system combining ionic liquid and organic metal compound rather than using a single curing agent. This composite approach synergistically enhances curing capability while enabling low-temperature operation, thus achieving both reliable curing and low curing temperature simultaneously.
2Reliability
If conventional curing agents are used for epoxy resin, then curing capability is achieved, but curing time becomes excessively long
Solution Approach 1:
The patent introduces a highly active catalyst system that dramatically accelerates the epoxy curing reaction. The ionic liquid-organic metal compound catalyst enables complete curing within minutes to hours at low temperatures, compared to the excessively long curing times required by conventional agents, thus resolving the contradiction between curing reliability and curing speed.
Solution Approach 2:
The patent replaces thermal activation (conventional high-temperature curing) with catalytic activation (low-temperature catalyst-driven curing). This substitution of the curing mechanism enables rapid curing at ambient temperatures, eliminating the need for prolonged high-temperature exposure.
3Productivity
If solid dispersion-type curing accelerators are used, then curing speed is improved, but material availability becomes difficult and operability becomes troublesome
Solution Approach 1:
The patent transforms the physical state and chemical composition of the catalyst system to achieve both rapid curing and ease of use. The ionic liquid-organic metal compound catalyst provides high curing speed while maintaining liquid or easily handleable form at ambient temperature, eliminating the need for complex solid dispersion preparations and improving operability.
Solution Approach 2:
The catalyst system is designed to be self-active at ambient conditions without requiring complex preparation steps. The ionic liquid and organic metal compound can be directly applied to epoxy substrates and immediately initiate rapid curing, making the process as simple as conventional treatments while achieving superior curing speed.
4Ease of operation
If one-component epoxy resin composition is used, then operability is improved, but storage stability becomes poor
Solution Approach 1:
The patent carefully controls the chemical parameters of the catalyst system to achieve a delicate balance between stability and reactivity. The ionic liquid-organic metal compound catalyst remains dormant during storage but activates rapidly under curing conditions, enabling the one-component system to maintain both excellent storage stability and high curing performance.
Solution Approach 2:
The patent introduces a stable intermediate catalyst system that can be stored without premature reaction. The ionic liquid-organic metal compound combination acts as a stable precursor that only becomes active when applied to the epoxy substrate, serving as an intermediary between storage stability and curing reactivity in the one-component system.
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 a practicable, one-component resin with rapid curing and excellent storage stability, suitable for applications requiring narrow adhesion and impregnation, offering improved operability and reliability.
Implementation Method 1
a resin composition comprising a compound having at least two epoxy and/or thiirane groups in the molecule (ingredient (1)) and an ionic liquid (ingredient (2))... a practicable resin composition can be obtained, which comprises constitutive elements of easily available materials and which has well-balanced suitable curing capability and storage stability
Implementation Method 2
The resin composition of any one of [1] to [5], which further comprises a polythiol compound having at least two thiol groups in the molecule (ingredient (3))
Implementation Method 3
The resin composition of any one of [1] to [7], which further comprises an acid anhydride (ingredient (5))
Data Source
Figure 1
AI summary
A resin composition contains a compound having at least two epoxy and/or thiirane groups in the molecule (ingredient (1)) and a specific ionic liquid (ingredient (2)). The ionic liquid (ingredient (2)) comprises a combination of an ammonium cation or phosphonium cation and a carboxylate anion. The resulting resin composition has a desirable balance of properties being both storage stable and conveniently curable.