Sprayable Epoxy Adhesive Composition With Rapid Ambient Crosslinking
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Solution Overview
Problem
Sprayable thermosetting compositions face challenges in achieving low viscosity for deposition while maintaining desirable physical properties, controlling reactivity, and ensuring rapid crosslinking to prevent material flow, often limited by high molecular weight polymers and viscosity constraints.
Innovation Solution
A two-part system comprising a first component with epoxy resins and a second component with phosphate esters, both having viscosities of 500 cps or less, which rapidly crosslink at ambient temperatures, allowing impingement mixing and spray application without sensitivity to mixing ratios or moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high molecular weight polymers are used to maintain physical properties, then the material has desirable physical characteristics, but the viscosity becomes too high for spray applications
Solution Approach 1:
The system divides the material into two separate components (resin and curative) that are applied separately and then chemically combined. This allows each component to have optimized properties for its specific function - the resin can be low viscosity for sprayability while the curative provides crosslinking for physical strength.
Solution Approach 2:
The patent changes the chemical state of the material from a single high-viscosity phase to a two-component system where one component (resin) maintains low viscosity for sprayability while the other (curative) provides crosslinking. The chemical reaction between components occurs after application, transforming the material properties in-situ.
2Ease of manufacture
If the viscosity is reduced to 500 cPs or less for spray applications, then the material becomes sprayable, but the reactivity and crosslinking control become difficult
Solution Approach 1:
By separating the resin and curative into different components, the system maintains low viscosity in the stored state while enabling controlled reactivity through chemical combination after application. The resin can be sprayed at low viscosity without premature reaction.
Solution Approach 2:
The curative acts as an intermediary that is stored separately but becomes active only when mixed with the resin. This intermediary component enables controlled reactivity initiation after application, allowing the resin to remain stable and sprayable during storage and application.
3Manufacturing precision
If the resin to curative ratio is precisely controlled for accurate formulation, then the material properties are optimized, but the sensitivity to mixing ratio increases
Solution Approach 1:
The system changes from a single-formulation approach requiring precise ratio control to a two-component system where the resin and curative are applied separately. This reduces sensitivity to mixing ratio variations while maintaining optimal material properties through controlled chemical reaction after application.
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 system maintains low viscosity for sprayability, rapid crosslinking, and desirable physical properties, reducing the risk of material flow and enabling stable deposition with controlled reactivity and thixotropic behavior, while being insensitive to mixing ratios and moisture.
Implementation Method 1
a first component including an epoxide functional constituent and optionally a blowing agent decomposition initiator in the case of foamable compositions, and a second component including an acidic constituent that functions as a curing agent
Implementation Method 2
provide rapid crosslinking that initiates creation of a 3-dimensional structure of the material
Implementation Method 3
the liquid ingredients for the material should be low viscosity at the deposition temperature, preferably highly shear thinning
Data Source
AI summary
A two-part system comprising a first component including one or more epoxy resins and an epoxy functional material, the epoxy functional material having a functionality of greater than 4 and a viscosity of 500 cps or less according to ASTM D2556-14 at 23°; and a second component including one or more phosphate esters and having a viscosity during deposition of 500 cps or less according to ASTM D2556-14 at 23°.