Toughened epoxy resin composition

Patent metadata

Field	Value
Publication number	US-10947337-B2
Application number	US-201816155008-A
Country	US
Kind code	B2
Filing date	Oct 9, 2018
Priority date	Apr 13, 2016
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

A toughened epoxy resin composition includes an end-capped polyalkylene oxide (A), an epoxy resin (B), an epoxy curing agent (C), and a core shell polymer (D). The end-capped polyalkylene oxide (A) has a number average molecular weight of 1500 to 5000, and 40% or more of a total number of ends of the end-capped polyalkylene oxide (A) are capped with at least one selected from the group consisting of an alkyl group, an allyl group, and an aryl group. A weight ratio of the end-capped polyalkylene oxide (A) to the core shell polymer (D) is 10/90 to 90/10. The core shell polymer (D) comprises a core layer in an amount of 70 to 95% by weight and the core layer is one or more selected from the group consisting of diene rubber, (meth)acrylate rubber, organosiloxane rubber, styrene polymer, and (meth)acrylate polymer.

First claim

What is claimed is:

1. A toughened epoxy resin composition comprising:
an end-capped polyalkylene oxide (A);
an epoxy resin (B);
an epoxy curing agent (C); and
a core shell polymer (D),
wherein the end-capped polyalkylene oxide (A) has a number average molecular weight of 1500 to 5000,
wherein 40% or more of a total ends of the end-capped polyalkylene oxide (A) are capped with at least one group selected from the group consisting of an alkyl group, an allyl group, and an aryl group,
wherein a weight ratio of the end-capped polyalkylene oxide (A) to the core shell polymer (D) is 10/90 to 90/10,
wherein the core shell polymer (D) comprises a core layer in an amount of 70 to 95% by weight per 100% by weight of the core shell polymer (D),
wherein the core layer is one or more selected from the group consisting of diene rubber, (meth)acrylate rubber, organosiloxane rubber, styrene polymer, and (meth)acrylate polymer, and
wherein the core shell polymer (D) further comprises a shell layer that contains a copolymer comprising 60 to 99% by weight of an alkyl group-containing (meth) acrylate monomer unit, 1 to 40% by weight of an epoxy group-containing vinyl monomer unit, and 0 to 25% by weight of a monomer unit different from the alkyl group-containing (meth) acrylate monomer unit and the epoxy group-containing vinyl monomer unit.

2. The composition according to claim 1 , wherein the end-capped polyalkylene oxide (A) is at least one selected from the group consisting of a polypropylene oxide, a polybutylene oxide, and an oxy-3-methyltetramethylene/oxybutylene copolymer.

3. The composition according to claim 2 , wherein the capped ends of the end-capped polyalkylene oxide (A) are capped with the allyl group and/or the alkyl group.

4. The composition according to claim 3 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

5. The composition according to claim 2 , wherein 70% or more of the total number of ends of the end-capped polyalkylene oxide (A) are capped.

6. The composition according to claim 2 , wherein the core shell polymer (D) further comprises a shell layer that contains a copolymer comprising 60 to 99% by weight of an alkyl group-containing (meth) acrylate monomer unit, 1 to 40% by weight of an epoxy group-containing vinyl monomer unit, and 0 to 25% by weight of a monomer unit different from the alkyl group-containing (meth) acrylate monomer unit and the epoxy group-containing vinyl monomer unit.

7. The composition according to claim 2 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

8. The composition according to claim 1 , wherein the capped ends of the end-capped polyalkylene oxide (A) are capped with the allyl group and/or the alkyl group.

9. The composition according to claim 8 , wherein 70% or more of the total number of ends of the end-capped polyalkylene oxide (A) are capped.

10. The composition according to claim 8 , wherein the core shell polymer (D) further comprises a shell layer that contains a copolymer comprising 60 to 99% by weight of an alkyl group-containing (meth) acrylate monomer unit, 1 to 40% by weight of an epoxy group-containing vinyl monomer unit, and 0 to 25% by weight of a monomer unit different from the alkyl group-containing (meth) acrylate monomer unit and the epoxy group-containing vinyl monomer unit.

11. The composition according to claim 8 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

12. The composition according to claim 1 , wherein 70% or more of the total number of ends of the end-capped polyalkylene oxide (A) are capped.

13. The composition according to claim 12 , wherein the core shell polymer (D) further comprises a shell layer that contains a copolymer comprising 60 to 99% by weight of an alkyl group-containing (meth) acrylate monomer unit, 1 to 40% by weight of an epoxy group-containing vinyl monomer unit, and 0 to 25% by weight of a monomer unit different from the alkyl group-containing (meth) acrylate monomer unit and the epoxy group-containing vinyl monomer unit.

14. The composition according to claim 12 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

15. The composition according to claim 1 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

16. A cured product formed from the composition of claim 1 .

17. The composition according to claim 1 , wherein an amount of the end-capped polyalkylene oxide (A) is 0.5 to 20% by weight per 100% by weight of a sum of the end-capped polyalkylene oxide (A), the epoxy resin (B), the epoxy curing agent (C), and the core shell polymer (D).

18. The composition according to claim 1 , wherein the end-capped polyalkylene oxide (A) has the number average molecular weight of 1500 to 3000.

19. A method for preparing the composition of claim 1 , comprising mixing a dispersion in which the core shell polymer (D) is dispersed in the epoxy resin (B), the end-capped polyalkylene oxide (A), and the epoxy curing agent (C).

20. A method for preparing the composition of claim 1 , comprising mixing a dispersion in which the core shell polymer (D) is dispersed in the end-capped polyalkylene oxide (A), the epoxy resin (B), and the epoxy curing agent (C).

Assignees

• Kaneka Corp

Inventors

• Miyatake Nobuo

Classifications

• C08G59/4253 Primary

  Rubbers · CPC title

• C08G59/18

  Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups {; e.g. general methods of curing} · CPC title

• C08L71/02

  Polyalkylene oxides · CPC title

• C08L51/00

  Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds (for ABS polymers C08L55/02); Compositions of derivatives of such polymers · CPC title

• C08L63/00

  Compositions of epoxy resins; Compositions of derivatives of epoxy resins · CPC title