Two-Component Epoxy Formulation with Low-Toxicity Polyamine Curing
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Solution Overview
Problem
Existing epoxy resin systems often contain hazardous and toxic constituents, necessitating labeling that complicates environmental protection and safety, and there is a need for low-toxicity alternatives without compromising physicochemical properties.
Innovation Solution
A two-component curable composition comprising an epoxy resin and a mixture of polyamines, including meta-xylenediamine (MXDA), cycloaliphatic and aliphatic primary diamines, and a phenolic aldehyde resin, with a stoichiometric ratio of amine hydrogen atoms to epoxy groups ranging from 0.5:1 to 1.2:1, to achieve low toxicity and maintain performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional epoxy resin systems are used to achieve excellent chemical resistance and mechanical properties, then performance characteristics are improved, but toxicity and harmful effects increase
Solution Approach 1:
The patent changes the chemical composition parameters by replacing toxic traditional curatives with non-toxic polyamine mixtures containing specific compounds (cycloaliphatic diamines, aromatic diamines, and their reaction products). This parameter change maintains the desired chemical resistance and mechanical properties while eliminating harmful toxicity associated with conventional epoxy systems
Solution Approach 2:
The patent creates a composite curative system by combining multiple polyamine components (cycloaliphatic diamines, aromatic diamines, and reaction products) in specific ratios. This composite approach achieves the desired performance characteristics through synergistic effects while maintaining low toxicity across all components
2Object-generated harmful factors
If Mannich bases are used as curatives to lower toxicity, then harmful factors are reduced, but viscosity increases and processibility deteriorates
Solution Approach 1:
The patent changes the molecular weight and structure parameters of the curative by selecting specific polyamine compounds with optimized molecular sizes. The combination of cycloaliphatic diamines, aromatic diamines, and their reaction products achieves low toxicity while maintaining appropriate viscosity and processibility through controlled molecular parameters
Solution Approach 2:
The patent creates a composite curative system that combines multiple polyamine components with different molecular weights and viscosities. This composite approach balances the low toxicity benefit with acceptable processibility by leveraging the complementary properties of each component in the mixture
3Object-generated harmful factors
If polyamine mixtures are used to achieve low toxicity, then harmful factors are reduced, but formulation complexity increases
Solution Approach 1:
The patent segments the curative system into distinct functional components: cycloaliphatic diamines, aromatic diamines, and reaction products, each serving specific purposes in the formulation. This segmentation allows for systematic development and optimization of the mixture while managing formulation complexity through structured component selection
Solution Approach 2:
The patent creates a universal curative system where the polyamine mixture serves multiple functions simultaneously: providing low toxicity, ensuring adequate reactivity with epoxy groups, controlling viscosity, and delivering desired mechanical properties. This multi-functionality reduces the need for additional additives and simplifies the overall formulation
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 exhibits reduced carcinogenicity, mutagenicity, and toxicity, while retaining excellent chemical resistance, thermal resistance, and processability, making it suitable for coatings, adhesives, and sealants.
Implementation Method 1
a second component comprising: b) a mixture of polyamines of which each polyamine has at least two amine hydrogens reactive toward epoxide groups
Data Source
AI summary
The present invention is directed to a two-component (2K) curable composition comprising:a first component comprising:a) at least one epoxy resin; and,a second component comprising:b) a mixture of polyamines of which each polyamine has at least two amine hydrogens reactive toward epoxide groups, said mixture comprising:b) i) meta-xylenediamine (MXDA); and,b) ii) at least one cycloaliphatic primary diamine; and/or,b) iii) at least one aliphatic primary diamine compound, which compound further comprises one or more secondary amine groups; and,c) at least one phenolic aldehyde resin obtained by reacting at least one phenolic compound and at least one aldehyde having the general formula Ra—(CHO)b, wherein:Ra is H, C1-C18 alkyl, C2-C18 alkenyl, C6-C18 aryl, C7-C18 alkylaryl or C7-C18 aralkyl; and,b is 1 or 2,wherein said curable composition is characterized by a stoichiometric ratio of the amine hydrogen atoms of said second component to the epoxy groups of said first component (a) of from 0.5:1 to 1.2:1, preferably from 0.8:1 to 1.0:1.