Segmented Epoxy Hardener Adducts for Viscosity Control
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Solution Overview
Problem
Cold curing epoxy systems often form undesirable mixed adducts, which can lead to technical performance issues and are not compliant with regulations like TSCA and REACH, and achieving high adduction without forming mixed adducts is challenging, especially when one amine is in low molar ratio, resulting in highly viscous or gelled materials.
Innovation Solution
A process involving the production of separate adducts from difunctional epoxy and Isophorondiamine (IPDA) and m-Xylylenediamine (MXDA), along with an accelerator and modifier, to form a hardener composition that avoids mixed adducts and maintains a technically manageable viscosity, allowing for high adduction without excessive free amine content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high adducted hardener contains only a small amount of one amine to eliminate mixed adducts, then compliance with regulations is improved, but the equivalent or molar ratio becomes too high producing highly viscous or gelled material
Solution Approach 1:
The invention divides the hardener composition into two separate adduct components: a first adduct containing a first amine and a second adduct containing a second amine. Each adduct is produced separately through controlled reaction of epoxy with its respective amine, eliminating mixed adduct formation while maintaining manageable viscosity through proper phase separation and composition control.
Solution Approach 2:
The invention controls the equivalent ratio of the first amine to the second amine within a specific range (0.8:1 to 1.2:1) to optimize the balance between regulatory compliance and viscosity management. This parameter control ensures that neither amine dominates excessively, preventing gelation while meeting regulatory requirements for eliminating mixed adducts.
2Ease of manufacture
If mixed adducts are formed in the hardener, then the production process is simpler, but technical performance problems occur and regulatory compliance is compromised
Solution Approach 1:
The production process is segmented into two independent reaction stages: first adding epoxy to the first amine to form the first adduct, then adding epoxy to the second amine to form the second adduct. This segmentation prevents mixed adduct formation while maintaining production efficiency through systematic process control and eliminates the need for complex separation steps.
Solution Approach 2:
The invention performs preliminary adduction reactions separately for each amine before final hardener formulation. By pre-forming the first adduct and second adduct in separate controlled reactions, the system ensures pure components are created beforehand, preventing mixed adduct formation in the final product while simplifying the overall 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 solution effectively eliminates the formation of mixed adducts, ensuring compliance with regulations and producing a hardener with desirable viscosity and performance characteristics, suitable for industrial applications such as coatings and floorings.
Implementation Method 1
producing a first adduct comprising a reaction product of a difunctional epoxy and Isophrondiamine (IPDA); producing a second adduct comprising a reaction product of a difunctional epoxy and m-Xylylenediamine (MXDA)
Data Source
AI summary
A process comprising: a) producing a first adduct comprising a reaction product of a difunctional epoxy and Isophrondiamine (IPDA); b) producing a second adduct comprising a reaction product of a difunctional epoxy and m-Xylylenediamine (MXDA) and c) contacting i) the first adduct; ii) the second adduct; iii) an accelerator; and iv) a modifier to form a hardener composition, is disclosed. The hardener composition can be used with an epoxy compound to form a curable composition.