Abstract:
A process for the accelerated cure of an epoxy resin is disclosed. The resulting epoxy resin may be used in protective coatings, adhesives, seamless and terrazo flooring and caulking and sealing compositions. The resulting resin system is also useful, for example, in casting, potting, in escapulating, grouting and patching. The process involves mixing an epoxy resin of the polyhydric phenol, polyglycidyl ether type with a novel accelerator-hardener which is a condensation product of phenol, formaldehyde and an aminoalkylene derivative of a polyoxyalkylenepolyamine.

Description:
BACKGROUND OF THE INVENTION 
     This application is a continuation-in-part of Application Ser. No. 865,053, Dec. 27, 1977, now abandoned. 
    
    
     The present invention relates to the field of curing epoxy resins. 
     Polyoxypropylenepolyamines react with epoxy resins at a rate which is unsatisfactorily slow for certain applications. In order to provide a rate of cure which is satisfactory for most uses an accelerator must be used with the polyoxypropylenepolyamines in order to speed the rate of cure. 
     Lee, Henry and Neville, Kris, Handbook of Epoxy Resins, McGraw-Hill Book Co., N.Y., 1967, pp. 7-14, describes the use of N-(2-aminoethyl)piperazine as an epoxy curing agent and at pp. 11-18 describes the use of salicyclic acid as an accelerator for urea-formaldehyde epoxy resin coatings. Bobby Leger&#39;s U.S. Pat. No. 3,462,393 (Aug. 18, 1969) teaches the use of polyoxyalkylenepolyamines as curing agents for a polyglycidyl ether of a phenolic compound. 
     U.S. Pat. No. 3,639,928 claims the use of a combination of N-(3-aminopropyl)piperazine and salicyclic acid as an accelerator combination with polyoxyalkylenepolyamine for curing epoxy resins. 
     U.S. Pat. No. 3,734,965 describes the use of a condensation product of phenols, aldehydes and polyoxypropyleneamines. 
     SUMMARY OF THE INVENTION 
     The invention is a process for the accelerated cure of an epoxy resin composition of the polyhydric phenol, polyglycidyl ether type. The process involves mixing the epoxy resin with an accelerator-hardener which is a condensation product of phenol, formaldehyde and an aminoalkylene derivative of a polyoxyalkylenepolyamine. The invention is also the condensation product above and the resulting cured epoxy resin. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The epoxy resin used herein can be any of the well known epoxy resins having an epoxy equivalency of more than one, for example, the polyglycidyl ether of polyhydric phenol. As is well known in the art, these resins may be prepared by condensing epichlorohydrin with a polyhydric alcohol or phenol, for example, ethylene glycol, diethylene glycol, glycerol, diglycerol, catechol, resorcinol, a trihydroxybenzene, a di(hydroxyphenyl) methane, a di(hydroxyphenyl) ethane, a di(hydroxyphenyl) propane, etc. The epoxy resin is derived from condensing epichlorohydrin with 2,2-bis(p-hydroxyphenyl) propane, known generally as bisphenol-A and having an epoxide equivalent weight of from 175 to 195. 
     The aminoalkylene derivatives of polyoxyalkylenepolyamines can be made by reacting polyoxyalkylenepolyamines with acrylonitrile followed by hydrogenation of the product. For example, polyoxypropylenepolyamines used as starting materials include compounds of the following formulae: 
     
         (I) H.sub.2 NCH(CH.sub.3)CH.sub.2 [OCH.sub.2 CH(CH.sub.3)].sub.x NH.sub.2 
    
     where x= 2 to 40, and ##STR1## where x+ y+ 3= 3 to 40, and ##STR2## where x+ z= 2 to 10 and y= 1 to 50 
     After reaction with acrylonitrile and subsequent hydrogenation the resulting aminoalkylene derivative of polyoxyalkylenepolyamines having the following formulae: 
     
         (IA) H.sub.2 NCH.sub.2 CH.sub.2 CH.sub.2 HNCH(CH.sub.3)CH.sub.2 [OCH.sub.2 CH(CH.sub.3)].sub.x NHCH.sub.2 CH.sub.2 CH.sub.2 NH.sub.2 
    
     where x= 2 to 40, and ##STR3## where x+ y+ z= 3 to 40, and ##STR4## where x+ z= 2 to 10 and y= 1 to 50 
     It is preferred to use phenol but substituted phenols are also useful in the condensate. The substituted phenols include, for example, mono- or polyhydric phenols with at least one reactive nuclear position available for substitution (o or p.). Examples: o-, m-, p-cresol, resorcinol, pyrocatechol, hydroquinone, phloroglucinol, pryogallol, α and β-naphthol, p-tert-butylphenol, 4,4&#39;-dihydroxydiphenylmethane, 4,4&#39;-dihydroxydiphenylether, 4,4&#39;-dihydroxydiphenylsulphone. It is preferred to use formaldehyde but useful aldehydes include both aliphatic and aromatic aldehydes, for example: acetaldehyde, butyraldehyde, benzaldehyde. Aldehydes of the general formula below are useful: 
     
         RHCO wherein R= H--, CH.sub.3 --, C.sub.2 H.sub.5 --C.sub.4 H.sub.9 or 
    
     The preparation of the condensation product is performed as follows but obvious deviations from this scheme are included in our invention: phenol, formaldehyde and a small amount of triethylamine is heated at reflux (˜100° C.) for 1-2 hours and then cooled to &lt;50° C. Amine (aminoalkylene derivative of polyoxyalkylenepolyamines) addition is begun while raising the temperature to about 165° C. while water is removed. Water is removed until overhead temperature drop is noted. The product is then vacuum stripped at 150° C./30mm for 2-4 hours. 
     The pressure is atmospheric except where vacuum stripping is noted. No pH adjustment is made during the reaction. The ratio of aminoalkylene derivative of polyoxyalkylenepolyamine/phenol/formaldehyde may range about 3/1/1 to 1/1/1. These variables are only guidelines and should not be construed as limitative of the invention claimed hereinafter. 
     For curing epoxy resins, the hardening agent (the condensate herein) is usually added in an amount such that there is one reactive --NH group in the hardener component for each epoxy group in the epoxy resin component. These are known as stoichiometric quantities. The stoichiometric quantity can be calculated from a knowledge of the chemical structure and analytical data on the components. In general it is advantageous to use up to 10 percent excess of the accelerated hardener over the stoichiometric amount. 
     The curing temperature range of the ambient temperatures are from about 0° to about 45° C. Post cures at temperatures up to about 200° C. are optional. The cured epoxy resins of the invention are useful in castings, coatings, adhesives, laminates, filament-reinforced composites, seamless flooring, terrazzo flooring, crushed-stone aggregates and in grouting, caulking and sealing compositions. 
    
    
     EXAMPLE I 
     Preparation of a condensate of the aminopropylene derivative of a 230 molecular weight polyoxypropylenepolyamine with phenol and formaldehyde. 
     
         ______________________________________Reactants:______________________________________JEFFAMINE®D-230 Bis(propylamine)*                  1338 g. (JEFFAMINE®D-230 BPA)Phenol                  355 g.Formaldehyde            306 g. (37% soln.)Triethylamine(TEA)      10 g.______________________________________ *JEFFAMINE D-230 is a polyoxypropylenepolyamine of formula I (x is about 2.6) and JEFFAMINE D-230 Bis(propylamine) is the aminopropylene derivativ of JEFFAMINE D-230. 
    
     The phenol, formaldehyde and TEA were added to a reactor and heated to reflux temperature (about 100° C.) for 2 hours and then cooled to 95° C. The JEFFAMINE D-230 BPA was added to the mixture in the reactor while raising the temperature to about 135° C. The product was then vacuum stripped at 130° C./30mm for 2 hours. 
     EXAMPLE II 
     Preparation of a condensate of the aminopropylene derivative of a 400 molecular weight polyoxypropylenepolyamine with phenol and formaldehyde. 
     
         ______________________________________Reactants:______________________________________JEFFAMINE®D-400 Bis(propylamine)*                  1368 g.Phenol                  259 g.Formaldehyde            223 g. (37% soln.)Triethylamine (TEA)     9.25 g.______________________________________ *JEFFAMINE D-400 is a polyoxypropylenepolyamine of formula I (x is about 5.6) and JEFFAMINE D-400 is Bis(propylamine) BPA is the aminopropylene derivative of JEFFAMINE D-400. 
    
     The procedure in Example I was followed except the maximum temperature of the reactor was 165° C. prior to vacuum stripping. 
     EXAMPLE III 
     
         __________________________________________________________________________Acceleration of Cure Through Use of Phenol-FormaldehydeCondensate of an Aminoalkylene Derivative of aPolyoxyalkylpolyamineFormulation:       A   B   C   D__________________________________________________________________________Epoxy Resin (EEW 190)              100 100 100 100JEFFAMINE D-400 Bis(propylamine)              46  --  --  --JEFFAMINE D-400 BPA** Phenol Formaldehyde Condensate              --  52  --  --JEFFAMINE D-230 Bis(propylamine)              --  --  30  --JEFFAMINE D-230 BPA Phenol Formaldehyde Condensate              --  --  --  38Gel time, mins. (200 g. mass)              160.3                  92.4                      73.5                          30.8Peak Exotherm, ° C.              160.0                  126.5                      224.0                          213.0Time to peak, mins.              178.0                  114.0                      85.0                          43.0__________________________________________________________________________ 
    
     EXAMPLE IV 
     
         ______________________________________Development of Adhesion: Curing withPhenol . Formaldehyde Condensatevs. JEFFAMINE D-230 BPAFormulation           A         B______________________________________Epoxy resin (EEW 185) 100       100JEFFAMINE D-230 Bis(propylamine)                 30        --JEFFAMINE D-230 BPA . Phenol . Formaldehyde Condensate                 --        38Tensile shear strength, psiafter curing for:  4 hours                 &lt;5        0  8 hours             900       1100 16 hours             2200      2900  24 hours            1200      3000______________________________________ 
    
     EXAMPLE V 
     
         __________________________________________________________________________Comparison of Condensation Product of This InventionWith Similar Condensate Using PolyoxypropyleneaminesComparison of Properties: Curing with JEFFAMINE D-400;D-400 . Phenol . formaldehyde Condensate and BPA D-400 . Phenol .formaldehyde CondensateFormulation:    A      B      C__________________________________________________________________________Epoxy resin (EEW 185)           100    100    100JEFFAMINE D-400 50     --     --D-400 . Phenol . CH.sub.2 O Cond.           --     75     --BPAD-400 . Phenol . CH.sub.2 O Cond.           --     --     55Brook. visc., cps., R.T.           500    3800   4700Gel time, mins (200 g. mass)           ˜300                  142    28.3Peak exotherm, ° C.           --     71.5   164.0Time to peak temp., mins.           --     180    38.0Drying time, 6-mil film Set-to-touch, hrs.           13.3.sup.2                  9.9    4.0 Thru-dry, hrs. 15.2   13.2   5.0Rev. impact, in-lbs to fail cure: 24 hr., R.T.           &gt;160   148    &gt;160 7 day, R.T.    &gt;160   12     20 14 day, R.T.   &gt;160   100    100Properties of cured 1/8&#34; castings:.sup.1Izod impact strength, ft-lbs/in.           0.52   0.97   0.94Tensile strength, psi           8200   9100   9300Tensile modulus, psi           399000 456000 438000Elongation at break, %           3.7    4.6    6.0Flexural strength, psi           12200  13200  14200Flexural modulus, psi           400000 447000 457000HDT, ° C., 264 psi/66 psi           41.5/42                  46/50  56/59Shore D hardness, 0-10 sec.           80-77  84-82  86-85% wt. gain, 1 hr. acetone boil           --     13.67  5.36% wt. gain, 24 hr. H.sub.2 O boil           --     2.34   2.94 .sup.1 Cured 2 hrs. 80°, 3 hrs. 125° C.? .sup.2 D-400 Concn. = 55 phr. 
    
     
         Comparison of Properties: Curing with JEFFAMINE D-400,D-300 . Phenol . CH.sub.2 O Condensate and BAPD-400 . 155 Phenol .sup..CH.sub.2 O Condensate(Acc. Curing, R.T.)Formulation:    A      B      C__________________________________________________________________________Epoxy resin (EEW 185)           100    100    100JEFFAMINE D-400 45     --     --D-400 . Phenol . CH.sub.2 O Cond.           --     75     --BPAD 400 . Phenol . CH.sub.2 O Cond.           --     --     55Acc. 398        10     10     10Brook. visc., cps., R.T.           --     3800   5000Gel time, mins. (200 g. mass)           41.0   31.2   14.2Peak exotherm, ° C.           163.0  164.0  194.0Time to peak, mins.           --     42.0   19.5Drying time, 6-mil film Set-to-touch, hrs.           8.3    6.0    2.0 Thru-dry, hrs. 11.8   8.8    3.0Rev. impact, in-lbs to fail Cure: 24 hr., R.T.           &gt;160   &gt;160   &gt;160 1 hr. 110° C.           &gt;160   &gt;160   80 7 day, R.T.    &gt;160   88     20 14 day, R.T.   &gt;160   &gt;160   80Properties of cured 1/8&#34; castings:.sup.1Izod impact strength, ft-lbs/in.           0.62   0.88   0.98Tensile strength, psi           7500   7000   9600Tensile modulus, psi.           388000 418000 452000Elongation at break, %           5.1    20.8   5.0Flexural strength, psi.           9900   10900  15100Flexural modulus, psi.           335000 336000 451000HDT, ° C., 264 psi/66 psi           40/42.5                  37/39  48/49Shore D hardness, 0-10 sec.           83-80  82-80  82-80% wt. gain, 1 hr. acetone boil           --     14.40  9.06% wt. gain, 24 hr. H.sub.2 O boil           --     4.67   3.75__________________________________________________________________________ .sup.1 Cured 7 days, R.T. 
    
     It is clear from the above example that the drying times and touch times are much less using the condensate of the invention than with the prior art condensate or using polyoxypropyleneamines alone.