Polyvinyl Butyral Epoxy Composite for High Modulus and Strain
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Solution Overview
Problem
Existing materials for acoustic attenuation, adhesion, and reinforcement in automotive vehicles face challenges in achieving a balance between high tensile modulus, strain to failure, and adhesion durability, as these properties often have an inverse relationship.
Innovation Solution
A material comprising at least 10% by weight polyvinyl butyral and a thermoplastic epoxy, with a ratio of polyvinyl butyral to thermoplastic epoxy ranging from 1:10 to 1:4, and at least 2% but less than 15% by weight adducted carboxyl-terminated polymer, which exhibits a strain to failure of greater than 2% and a modulus of at least 700 MPa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tensile modulus materials are used, then structural strength is improved, but strain to failure decreases
Solution Approach 1:
The invention uses a composite material system comprising epoxy resin combined with specific elastomers (carboxyl-terminated polybutadiene and/or carboxyl-terminated polysulfide) to achieve both high tensile modulus and high strain to failure. The composite formulation creates a synergistic effect where the epoxy provides structural strength while the elastomers provide ductility and strain capability, resolving the contradiction between strength and reliability.
2Reliability
If adhesion durability is improved, then bonding strength is increased, but tensile modulus decreases
Solution Approach 1:
The invention changes the chemical composition parameters of the adhesive system by incorporating specific ratios of carboxyl-terminated polybutadiene (2-15 wt%) and carboxyl-terminated polysulfide (2-15 wt%) with epoxy resin. This parameter optimization allows the material to simultaneously achieve high adhesion durability through improved chemical bonding and high tensile modulus through the structural properties of the epoxy matrix, eliminating the inverse relationship between these properties.
Data Source
AI summary
A material comprising at least about 10% by weight polyvinyl butyral, a thermoplastic epoxy, wherein the ratio of polyvinyl butyral to thermoplastic epoxy is about 1 to 10 to about 1 to 4, and at least 2% but less than 15% by weight adducted carboxyl-terminated polymer, wherein the material has a strain to failure of greater than 2% and a modulus of at least 700 MPa.