Oxidoreductase-Catalyzed Curing of Unsaturated Polyester Resins
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Solution Overview
Problem
Current accelerators used in the curing of unsaturated polyester resins, such as cobalt salts, are hazardous to the environment and non-biodegradable, and existing enzyme-based methods are limited to aqueous coating compositions, necessitating the development of non-carcinogenic, biodegradable alternatives for non-aqueous thermosetting resins.
Innovation Solution
A composition comprising a curable resin with ethylenically unsaturated polymerizable groups, an ethylenically unsaturated polymerizable monomer, an oxidoreductase, and at least one of an organic peroxide or hydrogen peroxide, with a water content of 0.0 to 20.0% by weight, which utilizes enzymes like horseradish peroxidase to initiate radical polymerization, providing a biobased acceleration mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cobalt salts are used as accelerators for curing unsaturated polyester resins, then curing efficiency is improved, but environmental harm increases due to carcinogenicity and non-biodegradability
Solution Approach 1:
The patent changes the chemical nature of the accelerator from inorganic cobalt salts to biological enzymes (oxidoreductases). This parameter change maintains the catalytic function for polymerization while eliminating the harmful properties of cobalt. The enzyme catalysts operate through different mechanistic parameters (oxidoreduction reactions) compared to traditional metal salts, achieving curing without environmental harm.
Solution Approach 2:
The patent replaces the chemical mechanism of metal salt acceleration with a biological mechanism. Instead of using cobalt salts that initiate polymerization through single-electron transfer, the invention employs oxidoreductase enzymes that catalyze the reaction through enzymatic oxidation-reduction processes. This substitution maintains curing functionality while removing toxicological concerns.
2Object-affected harmful factors
If enzyme-based accelerators are used for curing polymers, then environmental friendliness is improved, but applicability is limited to aqueous coating compositions
Solution Approach 1:
The patent makes the enzyme-based acceleration system universal by demonstrating its effectiveness across multiple substrate types and formulation environments. The oxidoreductase catalysts can function in aqueous coating compositions, non-aqueous thermosetting resins, and other diverse systems. This multi-functionality is achieved by selecting enzymes with broad substrate specificity and optimizing their performance across different chemical environments.
Solution Approach 2:
The patent introduces water-soluble mediators or co-factors that enable the enzyme-based acceleration system to operate effectively in non-aqueous systems. These intermediaries facilitate the transfer of electrons or reactive species between the enzyme active site and the polymerizable groups in non-aqueous environments, bridging the gap between enzymatic catalysis and diverse application media.
3Reliability
If traditional peroxide initiators are used for polymerization, then curing is achieved, but the process lacks environmental sustainability
Solution Approach 1:
The patent employs oxidoreductase enzymes that can be easily separated from the polymerization system and recovered for reuse. Unlike metal salts that remain in the cured product and pose environmental risks, the enzymatic catalysts can be removed through filtration or centrifugation and potentially reused. This approach eliminates the need to discard harmful substances while maintaining reliable curing through the enzyme's catalytic activity.
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
This solution enables efficient curing of thermosetting resins while being environmentally friendly, as it uses biodegradable enzymes and reduces the environmental impact associated with traditional accelerators, and is applicable in both aqueous and non-aqueous systems, offering a broader range of applications.
Implementation Method 1
The radical initiator, usually a peroxide, decomposes into highly reactive peroxide radicals that start the radical polymerisation of the unsaturated polyesters with the vinyl functional monomers
Implementation Method 2
certain enzymes can act as biobased accelerators for the crosslinking of certain kinds of polymers
Implementation Method 3
The radical initiator, usually a peroxide, decomposes into highly reactive peroxide radicals
Implementation Method 4
a composition comprising a curable resin or prepolymer component having ethylenically unsaturated polymerizable groups, an ethylenically unsaturated polymerizable monomer, an oxidoreductase, and at least one of an organic peroxide or hydrogen peroxide
Data Source
AI summary
A composition comprising a) a curable resin or prepolymer component having ethylenically unsaturated polymerizable groups, b) an ethylenically unsaturated polymerizable monomer, c) an oxidoreductase and d) at least one of an organic peroxide and hydrogen peroxide, wherein the composition comprises between 0.0 and 20.0 % by weight of water, calculated on the total weight of the composition.