Unsaturated Polyester Resin with Itaconic Acid for Low VOC Curing

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Solution Overview

Problem

Unsaturated polyester resin compositions face challenges with VOC emissions, surface cure issues, and mechanical properties, particularly in open mould applications, where they often require complex production processes and may not meet requirements for low odour, low emissions, and adequate mechanical performance.

Innovation Solution

A curable unsaturated polyester resin composition comprising a (meth)acrylate compound and a polyester formed from itaconic acid, maleic acid, dicyclopentadiene, and a di- or poly-functional alcohol, with a weight ratio that optimizes surface cure, mechanical properties, and low VOC emissions, allowing for single-reactor production and improved processing characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If styrene is used as reactive diluent, then processing performance and cure speed are improved, but VOC emissions and carcinogenicity increase

Engineering Contradiction:

Improvecure speedVSAvoidVOC emissions and carcinogenicity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical parameters by replacing styrene with non-volatile reactive diluents (glycidyl methacrylate, glycidyl acrylate, gamma-methacryloxypropyltrimethoxysilane) that have different volatility and toxicity profiles, maintaining cure speed while eliminating VOC emissions and carcinogenicity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses readily available commercial reactive diluents (glycidyl methacrylate, glycidyl acrylate, gamma-methacryloxypropyltrimethoxysilane) that can be procured off-the-shelf, avoiding the need for complex custom synthesis while achieving the desired low-VOC, non-carcinogenic properties

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-affected harmful factors

If non-volatile reactive diluents are used, then VOC emissions are reduced, but surface cure quality deteriorates

Engineering Contradiction:

ImproveVOC emissionsVSAvoidsurface cure quality

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent creates a composite resin system combining unsaturated polyester resin with multiple non-volatile reactive diluents (glycidyl methacrylate, glycidyl acrylate, gamma-methacryloxypropyltrimethoxysilane) that work synergistically to achieve both low VOC emissions and adequate surface cure quality

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent addresses surface cure quality by selecting reactive diluents with appropriate reactivity and molecular weight characteristics that enable adequate polymerization at the resin-air interface, compensating for oxygen inhibition while maintaining low volatility

Inventive Principle:

Principle #3Local quality

3Reliability

If complex multi-reactor production process is used, then resin performance is improved, but production complexity and cost increase

Engineering Contradiction:

Improveresin performanceVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the production process into a single reactor by directly combining unsaturated polyester resin with non-volatile reactive diluents and initiators, eliminating the need for separate synthesis reactors and intermediate handling steps while maintaining resin performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a universal production approach where a single reactor can produce the final resin composition by simply mixing commercially available components (unsaturated polyester resin, reactive diluents, initiators), making the process adaptable and eliminating dedicated equipment requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 achieves efficient surface curing, enhanced mechanical properties, and reduced VOC emissions, enabling faster demoulding and improved heat distortion temperature, while avoiding carcinogenic and mutagenic reactive diluents, thus addressing the limitations of existing resin compositions.

Implementation Method 1

Unsaturated polyester resin compositions are cured through radical polymerisations

Methodology Applied

Scientific EffectRadical polymerisation: Photopolymerisation

Data Source

PatentEP4110839B1Unsaturated polyester resin compositions and methods for preparation thereof

Publication Date: 2023.11.22 ACR III

AI summary

The invention relates to an unsaturated polyester resin composition comprising: - a (meth)acrylate compound; and, - a polyester formed from at least: - reagent a) comprising itaconic acid and/or itaconic anhydride; - reagent b) comprising maleic acid, maleic anhydride, and/or fumaric acid; - reagent c) comprising dicyclopentadiene (DCPD); and, - reagent d) comprising at least one di- or poly-functional alcohol, preferably at least one diol; wherein the combined weight of reagent a) (i.e. the combined weight of itaconic acid and/or itaconic anhydride) is at least 10 wt.%, preferably at least 20 wt.%, of the total weight of di-acids and anhydrides used in the unsaturated polyester resin composition. The invention further relates to use of said unsaturated polyester resin for structural parts and for gel-coats. The invention also provides methods for preparing said unsaturated polyester resin composition.