Polyether-Epoxy Polymer Composition for Flexible Coatings
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Solution Overview
Problem
Epoxy-based products face challenges in achieving desirable flexibility at a low cost while maintaining other important properties, such as high glass-transition temperatures and low ultimate elongations, and often rely on environmentally challenging polyamine curatives and isocyanates.
Innovation Solution
A polyether-epoxide polymer composition is developed, comprising a reaction product of a polyepoxide compound and a polyether polyol with specific hydroxyl functionality ranges, allowing for adjustable glass-transition temperatures and improved elongation, impact resistance, and abrasion resistance without using polyamines or polyisocyanates, using a low-temperature or elevated-temperature process with catalysts like Lewis acids or bases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional epoxy-based products use polyamines or isocyanates for curing, then crosslinking density and mechanical strength are improved, but environmental harm and cost increase
Solution Approach 1:
The invention extracts and removes the harmful polyamine curatives and isocyanates from the epoxy-based product formulation. By using polyether polyols instead of these traditional hardeners, the system eliminates the environmental and health concerns associated with polyamines while maintaining the crosslinking mechanism through hydroxyl-epoxide reactions.
Solution Approach 2:
The invention changes the chemical parameters of the curing system by substituting polyamines with polyether polyols having specific hydroxyl functionalities (3.5 to 8.0). This parameter change in the curative chemistry enables the formation of crosslinked networks with desirable flexibility, lower glass-transition temperatures, and improved elongation while avoiding harmful substances.
2Strength
If epoxy-based products use conventional hardeners to achieve high crosslinking density, then mechanical strength is improved, but flexibility and elongation deteriorate
Solution Approach 1:
The invention changes the chemical structure parameters of the crosslinking agent from rigid polyamines to flexible polyether polyols with high hydroxyl functionalities. This structural parameter change in the curative produces crosslinked networks that maintain strength while incorporating flexible ether linkages, resulting in lower glass-transition temperatures and improved elongation properties.
3Ease of operation
If polyether polyols with high hydroxyl functionalities are used to cure epoxy resins, then elongation and flexibility are improved, but reaction speed may decrease
Solution Approach 1:
The invention incorporates preliminary action by using polyether polyols that are pre-synthesized with high hydroxyl functionalities (3.5 to 8.0). These polyols are prepared in advance with the appropriate molecular structure and functionality to ensure both fast reaction with epoxy groups and the desired flexible network formation, eliminating the need for post-reaction adjustments.
4Temperature
If conventional epoxy formulations are used to achieve low glass-transition temperature, then flexibility is improved, but cost and environmental impact increase
Solution Approach 1:
The invention extracts the harmful polyamine curatives that are traditionally used to achieve low glass-transition temperatures in epoxy systems. By replacing these environmentally harmful hardeners with polyether polyols, the system achieves the same low Tg effect through the flexible ether linkages in the polyol structure without the associated environmental and health concerns.
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 polyether-epoxide polymer compositions offer increased elongation, improved impact and abrasion resistance, and tunable glass-transition temperatures, meeting industry needs for flexible and durable coatings, elastomers, and adhesives while avoiding environmentally harmful reactants.
Implementation Method 1
a polyether-epoxide polymer composition that comprises a reaction product of a polyepoxide compound and a polyol composition
Implementation Method 2
using a low-temperature or elevated-temperature process with catalysts like Lewis acids or bases
Data Source
AI summary
Polyether-epoxide polymer compositions are disclosed. The compositions comprise a reaction product of a polyepoxide compound and a polyol composition comprising a polyether polyol. The ratio of epoxy equivalents to hydroxyl equivalents is within the range of 0.5:1 to 3:1. The polyether-epoxide composition has a Tg within the range of −40° C. to 60° C. The polyether polyol has a hydroxyl value within the range of 150 to 800 mg KOH/g and an average hydroxyl functionality within the range of 3.5 to 8.0. In some aspects, the polyol composition further comprises a polyester polyol. Low- and elevated-temperature processes catalyzed by bases or Lewis acids for making the polyether-epoxide compositions are also disclosed. In a simple yet innovative approach, a new class of polymers useful for coatings, elastomers, adhesives, sealants, and other valuable products is assembled from readily available starting materials without reliance on polyamines or polyisocyanates.