Di(4-tert-butylcyclohexyl) Peroxydicarbonate Phlegmatization

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Solution Overview

Problem

Di(4-tert-butylcyclohexyl) peroxydicarbonate formulations are unstable and pose fire safety risks due to high classification, and existing pastes are difficult to handle and incompatible with styrene, necessitating a stable, Class II-rated solution that dissolves in styrene without segregating.

Innovation Solution

A powder formulation blending 20-75 wt% di(4-tert-butylcyclohexyl) peroxydicarbonate with 25-80 wt% ethylene glycol dibenzoate, with milling to achieve specific particle sizes and optional anti-caking agents, allowing for higher peroxide concentrations and stable non-segregating mixtures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If di(4-tert-butylcyclohexyl) peroxydicarbonate is formulated as neat powder or paste, then high peroxide concentration is achieved, but fire safety classification deteriorates to Class I or Class III with higher burning rates

Engineering Contradiction:

Improveperoxide concentrationVSAvoidfire safety classification

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

Ethylene glycol dibenzoate serves as an intermediary substance that mediates between the peroxide and the environment. It phlegmatizes the peroxide by forming a stable mixture that reduces the burning rate from Class I (>300 kg/min) to Class II (60-300 kg/min), while maintaining high peroxide concentration through efficient blending.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If paste formulations with glycols and dispersants are used, then fire safety classification improves to Class III, but ease of operation deteriorates due to difficulty in pumping and incompatibility with styrene

Engineering Contradiction:

Improvefire safety classificationVSAvoidpumpability and compatibility

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The formulation changes the physical parameters of the peroxide by blending with ethylene glycol dibenzoate to achieve optimal viscosity and flow characteristics. This enables the formulation to be pumped easily like a liquid while maintaining stability, and ensures compatibility with styrene for dissolution in curable resin compositions.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If solutions in inert phlegmatizing solvents are prepared, then ease of operation improves with better pumpability, but stability deteriorates due to formulation instability

Engineering Contradiction:

ImprovepumpabilityVSAvoidformulation stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The invention creates a composite material system combining di(4-tert-butylcyclohexyl) peroxydicarbonate with ethylene glycol dibenzoate in specific ratios (20-75 wt% peroxide, 25-80 wt% EGDB). This composite maintains the stability of solid peroxide while achieving the pumpability of liquid formulations, eliminating the instability problems of conventional solvent solutions.

Inventive Principle:

Principle #40Composite materials

4Object-affected harmful factors

If dilauroyl peroxide and glycerol tribenzoate are used as phlegmatizers, then fire safety classification improves, but ease of manufacture deteriorates due to dissolution difficulties requiring co-solvents or heating

Engineering Contradiction:

Improveburning rate reductionVSAvoiddissolution process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The invention replaces complex phlegmatizer systems requiring co-solvents or heating with a simpler blend of peroxide and ethylene glycol dibenzoate. This simplified formulation achieves the same fire safety benefits without the manufacturing complexity, eliminating the need for additional processing steps or auxiliary substances.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 formulation achieves a reduced burning rate, stability during storage, and efficient dissolution in styrene, maintaining compatibility with resin curing processes while meeting Class II fire safety standards, enabling safer and more efficient handling and use in polymer modification and curing processes.

Implementation Method 1

WO 2017/089375 discloses di(4-tert-butylcyclohexyl) peroxydicarbonate formulations with reduced burning rate. As phlegmatizers, this document discloses, amongst others, glycerol tribenzoate and dilauroyl peroxide.

Methodology Applied

Scientific EffectPhlegmatization:

Implementation Method 2

The formulation according to the present invention allows for efficient dissolution in styrene

Methodology Applied

Scientific EffectSolvation: Solvation

Data Source

PatentUS10689337B2Formulation of di(4-tert-butylcyclohexyl) peroxydicarbonate

Publication Date: 2020.06.23 AKZO NOBEL CHEMICALS INTERNATIONAL BV

AI summary

Powder formulation comprising 20-75 wt % of di(4-tert-butylcyclohexyl) peroxydicarbonate and 25-80 wt % of ethylene glycol dibenzoate.