Peroxide Composition for Low VOC Composite Curing
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Solution Overview
Problem
Unsaturated polyester and vinyl ester composite materials used in automotive parts face challenges in reducing volatile organic compound (VOC) emissions, which are necessary to comply with stringent environmental regulations, while maintaining good surface quality and mechanical properties.
Innovation Solution
A peroxide composition comprising an organic monoperoxycarbonate and a polyalkylene polyol as a phlegmatizer is used, which significantly reduces VOC emissions without compromising the surface quality or mechanical properties of the molded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If commonly used peroxide initiators like t-butylperoxybenzoate are replaced with organic monoperoxycarbonates to reduce VOC emissions, then VOC emissions are reduced, but the explosive nature of the peroxide requires additional phlegmatization steps
Solution Approach 1:
The patent combines the peroxide initiator and phlegmatizer into a single pre-mixed composition. The organic monoperoxycarbonate is already diluted in the phlegmatizing agent before use, eliminating the need for separate mixing steps and reducing processing complexity while maintaining safety and VOC reduction benefits
Solution Approach 2:
The phlegmatizing agent serves as an intermediary substance that both reduces the explosive hazard of the peroxide and acts as a carrier for delivery to the reaction system. This intermediary approach allows safe handling and dosing of the peroxide while maintaining its effectiveness as an initiator
2Reliability
If standard diluents like odorless mineral spirit are used to dilute peroxide initiators, then handling safety is improved, but VOC emissions increase
Solution Approach 1:
The patent changes the chemical parameters of the diluent from conventional options like odorless mineral spirit to specific phlegmatizing agents with appropriate flash points and chemical compatibility. This parameter change allows the diluent to serve dual functions: maintaining safety through appropriate volatility characteristics while reducing VOC emissions through lower evaporative potential
Solution Approach 2:
The patent creates a composite initiator system combining the peroxide with a specifically selected phlegmatizing agent. This composite approach allows optimization of both safety and environmental characteristics by selecting agents with appropriate balances of flash point, chemical compatibility, and volatility
3Object-generated harmful factors
If conventional peroxide/phlegmatizer combinations are used to reduce VOC emissions, then VOC emissions are reduced, but surface quality and mechanical properties are negatively affected
Solution Approach 1:
The patent optimizes parameters including the type of organic monoperoxycarbonate, the specific phlegmatizing agent selection, and the concentration ratio to achieve a balance where VOC emissions are reduced while the curing characteristics remain appropriate for producing high-quality surfaces and maintaining mechanical properties
Solution Approach 2:
The patent applies the peroxide/phlegmatizer composition with locally optimized characteristics - the phlegmatizing agent is selected to provide appropriate volatility and reactivity profiles for the specific application, allowing surface quality and mechanical properties to be maintained while still achieving VOC reduction
4Object-generated harmful factors
If conventional peroxide/phlegmatizer combinations are used to reduce VOC emissions, then VOC emissions are reduced, but mechanical properties such as flexural strength and impact strength are compromised
Solution Approach 1:
The patent adjusts critical parameters including peroxide concentration, phlegmatizing agent selection, and molecular weight characteristics to ensure adequate initiator activity remains. This allows the system to achieve VOC reduction through phlegmatization while maintaining sufficient peroxide content and reactivity to produce composites with required mechanical strength properties
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 combination of organic monoperoxycarbonate and polyalkylene polyol in the peroxide composition achieves low VOC emissions, excellent surface quality, and good mechanical properties, including flexural strength and impact resistance, while minimizing short and long-term waviness and surface defects.
Implementation Method 1
a significant reduction of the VOC-emissions of in particular unsaturated polyester or vinyl ester based composite materials such as SMC and BMC parts can be achieved by using an organic monoperoxycarbonate
Implementation Method 2
in view of the explosive nature of these peroxides, it is preferred to prepare or at least dilute such peroxide prior to its use in a phlegmatizer
Data Source
AI summary
The present invention relates to a peroxide composition comprising an organic peroxide, wherein the peroxide is an organic monoperoxycarbonate R-O-CO-O-O-tertiar butyl where R is a C1-C6 alkyl and the peroxide composition further comprises a polyalkylene polyol.