Peroxide Dispersion in Reactive Epoxy Carrier
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Solution Overview
Problem
The existing polyester resin compositions face challenges in achieving a consistent mix ratio between resin and catalyst, leading to issues like loss of adhesion, cracking, and discoloration due to improper catalysis, especially when using non-reactive carriers like phthalates which can disrupt the curing process at higher concentrations.
Innovation Solution
A two-part polyester resin system is introduced, utilizing a reactive carrier such as epoxy resin for the peroxide catalyst, allowing for a more stable and controlled curing process with a mix ratio of 1:10 to 1:1, eliminating the need for guesswork in catalyst application and enhancing the product's value by ensuring accurate measurement and integral cure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If non-reactive carriers like phthalates are used for peroxide catalyst, then the catalyst can be dispersed in the resin system, but the cure process is disrupted at higher concentrations (above 5 parts per hundred)
Solution Approach 1:
The patent changes the chemical nature of the carrier from non-reactive (phthalates) to reactive (epoxy resin), fundamentally altering the system's behavior. This parameter change allows the catalyst to be dispersed at much higher concentrations (up to 100 parts per hundred resin weight) without disrupting the cure process, as the reactive carrier becomes part of the curing reaction itself
Solution Approach 2:
The invention creates a composite hardener composition by combining peroxide catalyst with epoxy resin carrier. This composite material integrates the catalytic function with the structural polymer matrix, allowing the catalyst to be dispersed and stabilized within the epoxy resin structure, enabling higher concentrations without compromising cure reliability
2Ease of operation
If variable amounts of resin are dispensed into a cup, then flexibility in application is achieved, but the mix ratio with catalyst becomes inconsistent leading to improper catalyzation
Solution Approach 1:
The patent segments the hardener into a pre-formulated composition where the peroxide catalyst is already dispersed in the epoxy resin carrier at controlled concentrations. This segmentation allows the hardener to be applied as a unified component, maintaining consistent catalyst-to-resin ratios even when variable amounts are used, eliminating the guesswork in catalyst application
Solution Approach 2:
The epoxy resin carrier acts as an intermediary between the peroxide catalyst and the unsaturated polyester resin. It provides a stable medium that maintains consistent catalyst distribution and enables reliable mixing ratios, transforming the application process from guesswork to controlled chemistry
3Quantity of substance
If small tube packaging for peroxide catalyst is used, then the catalyst can be stored separately, but the small amount of catalyst required (1-3 parts per hundred) makes accurate measurement difficult
Solution Approach 1:
The patent merges the peroxide catalyst with the epoxy resin carrier into a single hardener composition. This combining allows the catalyst to be supplied in larger, more manageable quantities while maintaining precise catalyst-to-resin ratios through the pre-formulated composition, eliminating the measurement difficulties associated with small catalyst tubes
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 use of a reactive epoxy resin carrier stabilizes the peroxide catalyst, allowing for a broader range of catalyst dispersion levels up to 100 parts per hundred resin weight, reducing common problems associated with unsaturated polyester repair products and improving the reliability of surface repairs.
Implementation Method 1
a peroxide catalyst
Implementation Method 2
a reactive carrier comprising an epoxy resin
Data Source
AI summary
A hardener composition useful in a two part resin system. The hardener composition includes a reactive carrier, and a peroxide catalyst. The hardener composition can have a shelf life of over six months. A two-part polyester resin system and a method of making a polyester resin composition are also disclosed.