One-Pot Curing Agent Synthesis for Low-Emission Epoxy Resins
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Solution Overview
Problem
Existing processes for preparing curing agents for epoxy resins using a combination of adduct amines and alkylated amines are complex and inefficient, requiring separate preparation and purification of amines, which increases energy expenditure and reduces product yield.
Innovation Solution
A simplified process involving a one-pot reaction of a parent amine and an alkylated amine with a glycidyl ether to form a curing agent, eliminating the need for separate purification and excess amine removal, thereby simplifying the preparation and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate preparation and purification of adduct amines and alkylated amines are performed individually, then the curing agent can be obtained with desired properties, but the process complexity increases and energy expenditure rises
Solution Approach 1:
The patent combines the separate preparation processes of adduct amines and alkylated amines into a single one-pot reaction system. The parent amine, alkylating agent, and glycidyl ether are reacted together in one vessel, eliminating the need for separate preparation and purification steps while maintaining the desired curing agent properties through controlled reaction conditions and stoichiometry
Solution Approach 2:
The one-pot reaction system serves multiple functions simultaneously: it performs alkylation of the parent amine, adduction of the glycidyl ether, and self-purification by controlling the distribution of amine components. This multi-functional approach replaces multiple dedicated unit operations with a single integrated process
2Manufacturing precision
If excess parent amine is used in separate preparations, then complete reaction can be achieved, but additional purification steps are required to remove excess amine
Solution Approach 1:
The reaction system performs self-purification through controlled stoichiometry and reaction conditions. The excess parent amine reacts in situ to form the desired adduct amine and alkylated amine components, eliminating the need for separate purification steps. The system automatically adjusts the composition to achieve complete reaction without requiring additional removal operations
3Quantity of substance
If multiple separate preparation steps are performed, then the curing agent can be produced, but the production time and energy consumption increase
Solution Approach 1:
The one-pot reaction enables continuous useful action by maintaining reaction conditions that simultaneously perform alkylation and adduction. The reaction proceeds in a single continuous operation without interruption for purification or intermediate handling, maximizing productivity while maintaining high product yield through optimized reaction stoichiometry and conditions
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 process results in a curing agent that enables low-odor, low-toxicity, low-viscosity epoxy resin products with rapid curing and high-quality coatings, maintaining properties similar to those produced by conventional methods while reducing energy consumption and increasing yield.
Implementation Method 1
an amine mixture comprising at least one parent amine of the formula (I) and at least one alkylated amine of the formula (II) is reacted with at least one glycidyl ether of the formula (III)
Data Source
AI summary
A process for preparing a curing agent for epoxy resins, in which an amine mixture including at least one parent amine of the formula (I) and at least one alkylated amine of the formula (II) is reacted or adducted with at least one glycidyl ether of the formula (III). The amine mixture is especially a reaction mixture from the partial alkylation of the amine of the formula (I). The process described enables, with low energy expenditure and high space-time yield, curing agents of low odor, low toxicity, low viscosity and high reactivity for epoxy resins and epoxy resin products that cure rapidly at ambient temperatures and especially also under cold conditions and at the same time enable high-quality coatings having an even, shiny surface.