Thermosetting Resin Composition for Long-Pot-Life Composite Prepregs
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Solution Overview
Problem
Existing thermosetting resin compositions for prepregs fail to achieve a balance of high glass transition temperature, high elongation percentage, and long pot life, which are essential for manufacturing lightweight, high-pressure gas containers.
Innovation Solution
A thermosetting resin composition comprising an epoxy resin, a (meth)acrylate compound, an epoxy resin curing agent, and a thermal radical polymerization initiator, specifically using poly(butadiene-CO-acrylonitrile) and a boron amine complex, to enhance the properties of the cured product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermosetting resin composition is designed to achieve high glass transition temperature and high elongation percentage, then the heat resistance and toughness of the cured product are improved, but the pot life of the resin composition becomes short
Solution Approach 1:
The patent divides the curing process into two separate stages by using two different curing agents: a first curing agent that reacts with epoxy groups at lower temperatures to extend pot life, and a second curing agent that completes the curing at higher temperatures to achieve the desired glass transition temperature and elongation properties. This segmentation allows the resin to remain workable longer while still achieving the target performance characteristics.
Solution Approach 2:
The patent employs parameter changes by selecting curing agents with different reactivity levels and temperature dependencies. The first curing agent has lower reactivity to maintain long pot life at room temperature, while the second curing agent has higher reactivity to achieve complete curing and desired thermal-mechanical properties at elevated temperatures. This controlled parameter variation resolves the contradiction between extended working time and final performance.
2Duration of action of stationary object
If the resin composition is formulated for long pot life, then the shelf life of prepreg is extended, but the glass transition temperature and elongation percentage of the cured product decrease
Solution Approach 1:
The dual curing agent system segments the curing function: the first curing agent contributes to extended shelf life and initial curing, while the second curing agent ensures the final cured product achieves the required glass transition temperature and elongation percentage. This functional segmentation allows each component to optimize for its specific purpose without compromising the other.
Solution Approach 2:
The patent creates a composite curing system by combining two different curing agents with complementary properties. This composite approach allows the resin composition to exhibit both long pot life (from the first curing agent's slow reaction) and high performance (from the second curing agent's complete curing capability), effectively resolving the contradiction between storage stability and final material properties.
3Ease of manufacture
If conventional epoxy resin compositions are used, then the manufacturing process is simple, but the balance of heat resistance, toughness, and pot life cannot be achieved
Solution Approach 1:
The patent enhances the universality of the epoxy resin composition by incorporating a first curing agent that provides multiple benefits: extending pot life, enabling long-term storage stability, and contributing to the overall curing process. This multi-functional additive allows a single resin system to achieve extended shelf life, high heat resistance, and good toughness simultaneously, maintaining ease of manufacture while improving overall performance.
Solution Approach 2:
The first curing agent acts as an intermediary that facilitates the extended pot life and stable storage conditions, allowing the second curing agent to subsequently achieve the high glass transition temperature and elongation properties. This intermediary component mediates between the conflicting requirements of long working time and high final performance, enabling both to be achieved without complicating the manufacturing process.
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 composition provides a cured product with high glass transition temperature, high elongation percentage, and a long pot life, suitable for manufacturing fiber-reinforced composite materials and high-pressure gas containers.
Implementation Method 1
a thermal radical polymerization initiator
Implementation Method 2
the component (C) includes a boron amine complex
Data Source
AI summary
A thermosetting resin composition containing a component (A) that is an epoxy resin, a component (B) that is a (meth)acrylate compound, a component (C) that is an epoxy resin curing agent, and a component (D) that is a thermal radical polymerization initiator, wherein the component (B) contains a component (B1) that is a poly(butadiene-CO-acrylonitrile) having an acryloyloxy group each at both termini and a component (B2) that is a polyfunctional (meth)acrylate other than the component (B1), and the component (C) contains a boron amine complex; a cured product of the thermosetting resin composition; a prepreg; a fiber-reinforced composite material; and a high-pressure gas container containing the fiber-reinforced composite material.