Two-Component Epoxy Formulation for Rapid Gelation
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Solution Overview
Problem
Existing epoxy resin systems face challenges in achieving rapid gelation, which is necessary for applications like depositing on vertical substrates or in additive manufacturing, as they tend to drip or collapse due to slow gelation times, and elevating temperature is not always practical.
Innovation Solution
A two-component (2K) curable composition is developed, comprising a first component with 80-100 wt.% partially (meth)acrylated epoxy resin and a second component with a polyamine, optimized to achieve a gel time of less than 10 minutes at 25°C, using a specific ratio of amine hydrogen equivalents to epoxy and acrylate groups, and featuring epoxy resins like bisphenol A based diglycidylethers for fast gelation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the gel time of the curable composition is reduced by elevating the temperature of the epoxy resin system and/or the substrate, then the gelation speed is improved, but it may not always be practical to apply heat per se or the high temperatures required
Solution Approach 1:
The patent changes the chemical parameters of the resin system by using partially (meth)acrylated epoxy resins with specific functionality ratios and polyamine hardeners with controlled equivalent weights, enabling rapid gelation at room temperature without requiring temperature elevation
Solution Approach 2:
The patent replaces the thermal mechanism (heating) with a chemical mechanism (specific resin-hardener combinations) to achieve the same effect of rapid gelation, eliminating the need for external heat application
2Reliability
If conventional epoxy resin systems are used, then the material maintains good chemical resistance and mechanical properties, but the gelation time is too slow for vertical substrate deposition or additive manufacturing
Solution Approach 1:
The patent creates a composite curable composition combining partially (meth)acrylated epoxy resins with polyamine hardeners, achieving both rapid gelation and maintained mechanical/chemical properties through synergistic interaction between components
Solution Approach 2:
The patent modifies the functional parameters of the epoxy system by using resins with epoxy-to-(meth)acrylate group ratios of 1:1 to 1:3 and polyamines with specific amine hydrogen equivalent weights, enabling fast gelation while preserving cured material properties
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 achieves a fast gel time of less than 5 minutes at 25°C, enabling stable deposition on substrates and preventing structural collapse, while maintaining the physicochemical properties of the cured product.
Implementation Method 1
a two-component (2K) curable composition based on a partially (meth)acrylated epoxy resin... containing a partially (meth)acrylated epoxy resin in a first component and an amine functional hardener or curative in a second component
Data Source
AI summary
The present invention is directed to a two-component (2K) curable composition comprising:a first component comprising, based on the weight of the component:from 80 to 100 wt. % of a) i) at least one partially (meth)acrylated epoxy resin; and,from 0 to 20 wt. % of a) ii) at least one epoxy resin distinct from said resin a) i); and,a second component comprising b) at least one polyamine having at least two amine hydrogens reactive toward epoxide groups,wherein said curable composition is characterized by a ratio of the amine hydrogen equivalent of said at least one polyamine (b) to the total equivalents of epoxy groups and acrylate groups of said first component (a) of from 0.5:1 to 1.05:1.