Ring-Opened Benzoxazine Thermoplastic for Moldable Curing
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Solution Overview
Problem
Thermoset resins have limited shelf life and require complex cure cycles, while thermoplastics are costly and challenging to mold, lacking the combination of properties needed for advanced composite applications.
Innovation Solution
Development of crosslinkable thermoplastic resin compositions formed from bis-benzoxazine monomers and bifunctional comonomers, allowing for crosslinking at elevated temperatures to achieve thermoset properties and moldability below those temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset resins are used to achieve high modulus and superior creep resistance, then mechanical strength is improved, but shelf life is limited and cure cycle complexity increases
Solution Approach 1:
The patent applies a dynamic approach by using a thermoplastic resin that can transition from a moldable state at processing temperature to a crosslinked rigid state during service. The resin starts as a thermoplastic for easy processing, then undergoes in-situ crosslinking to achieve thermoset-like performance, creating a dynamic material system that adapts its properties through temperature and time
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature to trigger crosslinking of the thermoplastic resin. Below a specific temperature, the resin remains thermoplastic and moldable; above this temperature, crosslinking occurs to provide high modulus and creep resistance. This temperature-dependent parameter change resolves the contradiction between processability and mechanical performance
2Strength
If thermoset resins are used to achieve high modulus and superior creep resistance, then mechanical strength is improved, but cure cycle complexity increases
Solution Approach 1:
The patent extracts the crosslinking step from a separate, complex cure cycle and integrates it into the molding process itself. The thermoplastic resin crosslinks in-situ during molding, eliminating the need for separate curing operations and complex temperature profiling, thereby simplifying the overall manufacturing process while maintaining high mechanical performance
3Ease of manufacture
If thermoplastic resins are used to achieve indefinite shelf life and short molding time, then ease of manufacture is improved, but raw material cost increases
Solution Approach 1:
The patent employs a composite material system that combines the advantages of both thermoplastic and thermoset resins. The base resin is thermoplastic for easy processing and long shelf life, while incorporated crosslinkable groups provide thermoset-like performance after curing. This composite approach achieves cost-effective manufacturing with both indefinite shelf life and short molding times
4Adaptability or versatility
If conventional thermoplastic resins are used to achieve remoldability and impact toughness, then adaptability is improved, but adhesion to fibers and high temperature resistance worsen
Solution Approach 1:
The patent applies preliminary action by incorporating crosslinkable functional groups into the thermoplastic resin structure before processing. These groups remain dormant during molding, allowing remoldability and impact toughness, but activate during or after molding to provide strong fiber adhesion and high temperature resistance, ensuring both adaptability and reliability
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 crosslinkable thermoplastic resins provide superior adhesion to fibers, high temperature resistance, and improved processability, combining the benefits of both thermosets and thermoplastics, with enhanced mechanical and thermal properties.
Implementation Method 1
reacting a bis-benzoxazine monomer and a bifunctional comonomer to form a polymer containing at least one crosslinkable group
Implementation Method 2
curing the crosslinkable thermoplastic resin composition by applying an external stimulus to form the cured thermoplastic resin
Data Source
AI summary
A crosslinkable thermoplastic resin composition may include a polymer formed from the reaction between a bis-benzoxazine monomer and a bifunctional comonomer having phenol, amine, and/or thiol functional groups, wherein the polymer contains at least one crosslinkable group. A method of forming a crosslinkable thermoplastic resin composition may include reacting a bis-benzoxazine monomer and a bifunctional comonomer to form a polymer containing at least one crosslinkable group. A method of forming a cured thermoplastic resin may include curing the crosslinkable thermoplastic resin composition by applying an external stimulus.