Manufacturing Process of Epoxy Resins with Formulation (Synthesis, Epoxy Resin Adhesives and Epoxy Resin Coatings)

ei1234 2,032 views 48 slides Oct 01, 2016
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About This Presentation

Epoxy is a term used to denote both the basic components and the cured end products of epoxy resins, as well as a colloquial name for the epoxide functional group. Epoxy resin are a class of thermoset materials used extensively in structural and specialty composite applications because they offer a ...


Slide Content

Manufacturing Process of
Epoxy Resins
with Formulation
(Synthesis, Epoxy Resin Adhesives
and Epoxy Resin Coatings)

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Introduction
Epoxyisatermusedtodenoteboththebasiccomponentsandthe
curedendproductsofepoxyresins,aswellasacolloquialnamefor
theepoxidefunctionalgroup.Epoxyresinareaclassofthermoset
materialsusedextensivelyinstructuralandspecialtycomposite
applicationsbecausetheyofferauniquecombinationofproperties
thatareunattainablewithotherthermosetresins.
Epoxyresinsarecharacterizedbyepoxyequivalent(EEVV)/epoxy
value,hydrolysablechlorinecontent,totalchlorinecontent,
viscosity/softeningpoint,volatilecontent,colour,clarity,hydroxyl
value,ioniciron,sodiumandchlorinecontents.

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Epoxyresinsareagroupofsyntheticresins,whichareusedtomake
adhesivesandplastics.Owingtotheirversatility,highresistanceto
chemicals,durability,excellentadhesion,toughness,highelectrical
resistance,strongdurabilityatbothlowandhightemperatures,and
easetheyofferwhilepouringoncastwithoutforminganybubbles,
epoxyresinsarebecominganintegralpartofvariouscommercialand
industrialsectors.
Epoxybasedsolutioncoatingsareusedinmaintenanceandproduct
finishes,marinefinishes,masonryfinishes,structuresteelcoatingsand
tankcoatings,aircraftfinishes,applianceprimers,automotiveprimers,
caranddrumlinings,furniturefinishesandcollapsibletubecoatings.

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Theyareusedforconcretefloorpaints,gymandfloorvarnishes,
sparvarnishesetc.EpoxyResinsarealsousedindecorativefloor
applications,aschemicallyresistantmortarsandfloortopping
compound;inprintinginks,infabrictreatingapplicationsindental,
surgicalandprostheticapplicationsforbreakingpetroleum
emulsionsandforlightweightchemicallyresistantfoams.The
epoxyresinsareusedasadditivesforavarietyofotherplastic
materials,suchasvinylandacrylicresinsandnaturalandsynthetic
rubbers.
Theepoxyresinmarketisdrivenbyitsincreasingdemandin
variousapplicationssuchascoatings,adhesives,andcomposites.

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Thepaints&coatingssegmentisthelargestapplicationandis
projectedtoremainthesameintheoverallepoxyresinmarket,in
termsofvolume,duringtheforecastperiod.Economicexpansionin
thedevelopingcountriesofAsia-Pacificwillincreasethedemandof
epoxyresinforpaints&coatingsapplicationinbuilding&
constructionandautomotiveend-useindustries.
TheglobalepoxyresinmarketisexpectedtoreachUSD14.26billion
by2024.Themarketiswitnessingamoderategrowthrateowingto
increasingapplications,technologicaladvancements,andgrowing
demandinAsia-Pacific.Epoxyresinislargelyusedinpaints&
coatingsapplications.

Themarketisanticipatedtobedrivenbyend-useindustries
includingautomotive,aerospace,transportation,composites,
decorativecoatings,construction,industrial&marinecoatings,
electrical&electronics,especiallyinAsiaPacific.Epoxyresins
arethemostpreferredthermoplasticsformanufacturing
compositematerialsowingtotheirsuperiorpropertiesas
comparedtoothermaterials.
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Themajorcontentsofthebookaresynthesisandcharacteristicsofepoxy
resin,manufactureofepoxyresins,epoxidecuringreactions,thedynamic
mechanicalpropertiesofepoxyresins,physicalandchemicalpropertiesof
epoxyresins,epoxyresinadhesives,epoxyresincoatings,epoxycoating
giveintowater,electricalandelectronicapplications,analysisofepoxides
andepoxyresinsandthetoxicologyofepoxyresins.
Itwillbeastandardreferencebookforprofessionalsandentrepreneurs.
Thosewhoareinterestedinthisfieldcanfindthecompleteinformation
frommanufacturetofinalusesofepoxyresin.Thispresentationwillbe
veryhelpfultonewentrepreneurs,technocrats,researchscholars,libraries
andexistingunits.

Table of Contents
1. Synthesis and Characteristics of Epoxy Resin
Introduction
Structure of Epoxides
Epoxipationof Unsaturated Hydrocarbons
Catalytic Oxidation of Ethylene and Higher Olefins
Epoxidationby PeroxyAcids and Their Esters
Preparation of PeroxyAcids
In Situ Epoxidation
The EpoxidationMechanism
Unsaturated Materials
Epoxidationby Inorganic PeroxyAcids
Epoxidationwith Aliphatic and Aromatic Hydrocarbon Hydroperoxides
Epoxidationwith Chromic Acid and Chromyl Compounds
Biological Epoxidation
Dehydrohalogenationof Substituted Hydroxyl Compounds
The EpoxidationMechanism
HalohydrinFormation
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Epoxides from Epichlorohydrin
GlycidylEthers
GlycidylEsters
Nitrogen-Containing Epoxides
ThioglycidylEpoxides
Silicon-Containing Epoxides
OrganophosphorusEpoxides
Halogen-Containing Epoxides
Epoxides from HydroxySulfonatesor Halogenated Acetates
Epoxides from Glycols
Epoxidationby Condensation
DarzensGlycidicEster Condensations
Epoxides from Ylids
Epoxides from Halogenated Ketones and Nickel Carbonyl
Epoxides from the Reaction of Diazomethane with Aldehydes or Ketones
Epoxides Containing Unsaturation
Conclusions
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2.Manufacture of Epoxy Resins
Raw Materials
Manufacture
Plant Location
Machinery Needed
Profit
3.Epoxide-Curing Reactions
The Effect of Epoxide Structure on Reactivity with Curing Agents
The Mechanism of the Curing Reaction
PolyadditionReactions
Polyamines
Polyamides
Polyureas
Polyurethanes
Polyisocyanates
Polymercaptans
Polyhydric Alcohols
Polyphenols
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PolycarboxylicAcids
Polybasic Acid Anhydrides
Silanesand Silanols
Others
Polymerization
Anionic Catalysts
Cationic Catalysts
4.The Dynamic Mechanical Properties of Epoxy Resins
Basic Parameters
The Glassy Transition and Dynamic Mechanical Dispersion
Temperature and Frequency Interdependence
Experimental
Results and Discussion
Standard Measurements
Dynamic Measurements
Comparison of Results
Treatment by Reduced Variables
Conclusions
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5.Physical and Chemical Properties of Epoxy Resins
Solubility and Surface Properties
Network Structure and Physical Properties
Aging and Chemorheology
Bisphenola Epoxy Homopolymersand Copolymers
Thermal Transition Effects
Dynamic Mechanical Response
Relaxation and Fracture Properties
Properties Compared with Elastomers and Thermoplastics
6.Epoxy Resin Adhesives
Introduction
Theories of Adhesion and Aohesive-joint Strength
Wetting and Spreading Phenomena
Boundary-Layer Theory
Surface-Attachment Theory of Adhesive-Joint Strengths
Stress Distribution in Adhesive Joints
Rheological Aspects of Adhesives
Unified Interpretation of Adhesive-Joint Strengths
Physical and Mechanical Aspects of Epoxy-Resin Adhesives
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Dynamic Mechanical Techniques
Mechanical Behavior of Epoxy Adhesives During Joint Formation
Strength of Adhesive Materials
Chemical Aspects of Epoxy-based Adhesives
Curing Agents for BisphenolA Epoxy Adhesives
Modifiers for BisphenolA Epoxy Adhesives
Adhesives Based on Other Epoxy Materials
Technological Properties of Epoxy-adhesive Systems
Cure and Thermal Softening Behavior of Epoxy Adhesives
Stress and Environmental Durability of Adhesive Joints
Applications of Epoxy Adhesives
Future Prospects
7.Epoxy Resin Coatings
Classification of Epoxy-Resin Coatings
Epoxy Resins Commonly Used in Coatings
Epoxy-Resin Esters
Esters Produced from Solid Epoxy Resins
General Remarks
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Formulation Latitude
Esters Produced from Liquid Epoxy Resins
PrecatalyzedLiquid Epoxy Resin for the Production of Solid Epoxy Resins
and Epoxy-Resin Esters
Cooking Procedure
“Two-Step”Liquid-Epoxy-Resin Route to Epoxy-Resin Esters
Cooking Procedure
Solid-Epoxy-Resin Solution Coatings
Cold-Cured Epoxy-Resin Systems
Polyamine Curing Agents
Polyamine-Adduct Curing Agents
Polyamide-Resin Curing Agents
Polyamide-Adduct Curing Agents
Tertiary Amine Curing Agents
Industrial Maintenance Coatings Based on Cold-Cured Epoxy-Resin Systems
High-Film-Build Cold-Cured Epoxy-Resin Coatings
Application Instructions
Manufacturing Instructions
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Epoxy Baking Finishes
Epoxy-Phenolic Coating Systems
Epoxy-Urea-Formaldehyde Resin Coating Systems
Epoxy-Thermosetting Acrylic Coating Systems
Liquid Epoxy Resins in Solventlessand Super-High-Solids Systems
Special Application Equipment and Formulation for SolventlessSystems
Manufacturing Instructions
Application
KetimineCuring Agents
Manufacturing Instructions
Application
Curing Characteristics
Powder Coatings
Application Equipment
Epoxy-Resin Powder-Coating Formulations
Fusion-Produced Epoxy-Resin Powders
Manufacturing Instructions
Applications Instructions
Dry-blended Epoxy-Resin Powders
Manufacturing Instructions
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Application Instructions
Properties and Applications
Thermoplastic Epoxy Resins
Zinc-Rich and General Purpose Shop Primers
Manufacturing Instructions
Application Instructions
Manufacturing Instructions
Application Instructions
Thermoplastic-Epoxy-Resin CrosslinkedSystems
Water-Reducible Epoxy Resin Coatings
Water-Reducible Epoxy-Ester Baking Finishes
Manufacturing Instructions
Application Instructions
Water-Reducible Polyamide-Cured Epoxy-Resin Coatings
Manufacturing Instructions
Manufacturing Instructions
Water-Reducible Epoxy-Resin Coatings for Electrodeposition
General Remarks
Cooking Procedure
Application Instructions

8.Epoxy Coating Give into Water
9.Electrical and Electronic Applications : Sealants and Foams
Electronic and Electrical Applications
Introduction
Casting
Potting
Encapsulation
Coatings
Sealing
Molding
Formulation of the Resin System
Internal Stresses
Rapid Cures
FlexibilizingEpoxy Resins
Fillers
Reactive Diluents
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Cycloaliphatic Epoxides
High-Temperature Epoxy-Resin Systems
Flame-Retardant Epoxy Resins
Colorless Epoxy Resins
Epoxy Formulations
Molding
Molding Compounds
Molding Technology
Liquid-Injection Molding
Pellets and Preforms
Epoxy Sealants
Epoxy Foams
Gas-Blown Foams
Syntactic Foams
One-Package Foams
Epoxy-Foam Applications
Epoxy Strippers
Handling of Epoxy Casting Systems
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10.Analysis of Epoxides and Epoxy Resins
Uncured Epoxy Resins
Qualitative Tests
Detection of Free Epoxy Groups
Determination of Epoxy Group—Lithium-Chloride Test
Reagents
Procedure
Determination of Epoxy Group—Periodic Acid Test
Reagents
Procedure
Determination of Epoxy Group—Pyrolysis Test
Reagents
Procedure
Determination of Epoxy Group—LepidineTest
Reagents
Procedure
Detection of the BisphenolA Skeleton
Reagents
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Procedure
Determination of BisphenolA Epoxy Resins in Coatings—Nitric Acid Test
Reagents
Reagent
Procedure
Determination of BisphenolA Epoxy Resins—Filter-Paper Test
Reagents
Procedure
Determination of BisphenolA Epoxy Resin—Formaldehyde Test
Reagents
Procedure
Determination of BisphenolA Epoxy Resins—PhenylenediamineTest
Reagent
Procedure
Detection of Epoxy Resins Based on 4,4-’-Diamino-diphenylmethane
Determination of Epoxy Resins Based on 4,4'-Diaminodiphenylmethane
Reagents
Procedure
Detection of Other Epoxy Resins
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Quantitative Tests of the Epoxy Group
HydrohalogenationMethods
Estimation of Epoxy Group—Hydrochloric Acid in Dioxane, Methyl Ethyl
Ketone, or Dimethylformamide
Reagents
Procedure
Calculations
Estimation of the Epoxy Group—PyridiniumChloride in Pyridine
Reagents
Procedure
Hydrohalogenationby Direct Titration
Estimation of Epoxy Group
Reagents
Procedure
Calculations
Other Chemical Methods
Estimation of Other Functional Groups
Hydroxyl Group
a-Glycol Group
Estimation of a-Glycol Group
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Reagents
Procedure
Calculation
Chlorine
Esterification Equivalent Weight
Estimation of Esterification Equivalent Weight
Reagents
Procedure
Calculation
Infrared Spectroscopy
Technique
Epoxide Absorption Bands
Epoxy Resins
Quantitative Estimation
Following the Degree of Cure
Other Physical Methods
Ultraviolet Spectroscopy
Electron Spin and Nuclear Magnetic Resonance Methods
Gas Chromatography
Paper Chromatography
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Thin-Layer and Gel-Permeation Chromatography
Handling Properties
Molecular Weight
Softening Point
Viscosity
Color
Blends and Compounds
Hardeners and Accelerators
Organic Acid Anhydrides
Determination of Acid and Anhydride Content
Reagents
Procedure
Calculations
Amines
Determination of Amine Number
Reagents
Procedure
Calculation
The Curing Process
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Curing Characteristics of Epoxy Resin-Hardener Systems
Determining the Degree of Cure
Analysis of Cured Epoxy Resins
11.The Toxicology of Epoxy Resins
Introduction
Experimental Method
Materials
Acute Toxicity
Chronic Toxicity
Irritation
Sensitization
Results
Acute Toxicity
Chronic Toxicity
Irritation
Sensitization
Medical Experience with Epoxy Resins
Comment
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