TOUGHENED EPOXY COMPOSITION

Abstract: A toughened ambient temperature cure epoxy ad­ hesive resin having excellent adhesion to metals, polyure­ thane, and fibre-reinforced polyesters contains polyepi­ chlorohydrin in the resin components. The cured com­ position has good sandibility, flexibility and toughness superior to conventional epoxies.

Description: TOUGHENED EPOXY COMPOSITION TECHNICAL FIELD The present invention relates to a toughened epoxy resin. Polyepichlorohydrin is utilized in an epoxy component which reacts with a hardener component to produce the resin. More specifically, the present invention relates to the use of liquid polyepichlorohydrin to toughen room temperature cured resins. BACKGROUND ART Heretofore, polyepichlorohydrin elastomer solids have been used in the precision molding of intricate rubber parts since they have a highly fluid nature at elevated temperatures. However, such elastomers have never been utilized in association with room temperature cured epoxy resins. R. S. Drake in an article entitled "A Survey of Rubber-Toughened Thermosets from Concept to Commercial Use," Proc. Polym. Mat. Sci. & Eng. Vol. 49, 1983, pages 220-222; traces the history of polybutadiene/acrylonitrile elastomers which have been used to toughen or modify thermoplastics and thermosets, for example epoxy resins. Similarly, Alan R. Siebert in an article entitled Morphology and Dynamic Mechanical Behavior of Rubber-Toughened Thermosets,g Proc. Polym. Mat. Sci. & Eng., Vol. 49, 1983, pages 427-431 reviews the work of various persons incorporating low levels of a liquid carboxylic acid terminated butadiene-acrylonitrile copolymer to a normally brittle epoxy resin, whereby the crack resistance and impact strength were significantly improved. Bimodal particle systems, phase inversion, adhesive and composite systems, and the like are also discussed. However, none of these references teach or even suggest the use of polyepichlorohydrin in a room temperature cured epoxy resin. Another category of tough structural adhesives is the rubber-toughened acrylics. U. S. Patent Nos. 4,051,195 to McWharter; 4,117,038 to Lehmann; and 4,126,504 to Wolinski thus relate to acrylic adhesives. Although Wolinski discloses poly(ethers of epichlorohydrin), such compounds are classified as non-reactive elastomers. U. S. Patent Nos. 3,966,837 and 4,107,116 to Riew, although containing polyepichlorohydrin, relates to a one component system when reaction of the polyepichlorohydrin only occurs at elevated temperatures. This is in sharp contrast from applicant's invention which reacts at ambient temperature with the hardener, and not the epoxy and further relates to a two-component system. Similarly, Sakamoto, U. S. Patent No. 3,945,972 relates to the use of polyepichlorohydrin monoglycidyl ether in a reactive diluent prepared by polymerizing epichlorohydrin and methylepichloro- hydrin with a monohydric phenol or alcohol and treating the resultant addition polymer with an alkaline substance. Reaction occurs at elevated temperatures apparently with the epoxy and not a hardner. Hence, it is readily distinguished. The remaining patents generally relate to epoxy resins. For example, U. S. Patent No. 4,128, 531 relates to the use of polyfunctional isocyanates, whereas 4,135,037 relates to epoxidized rubbery copolymers and rosin-based tackifiers. U.S. Patent No. 4,273,889 relates to a blend of epoxy resins with isopropenyl phenol linear polymers. U.S. Patent No. 4,383,060 relates to an epoxy adhesive containing an imadazole curing agent. U.S. Patent No. 4,397,998 is a rapid curing epoxy composition containing a polyalkylene ether glycol. SUMMARY OF THE INVENTION Accordingly, it is an aspect of the present invention to produce a toughened epoxy resin. It is a further aspect of the present invention to produce a toughened epoxy resin, as above, wherein polyepichlorohydrin is utilized in the epoxy component. It is still another aspect of the present invention to produce a toughened epoxy resin, as above, having properties such as excellent adhesion, flexibility, sandibility, and the like. It is a yet further aspect of the present invention to produce a toughened epoxy resin, as above, wherein said polyepichlorohydrin reacts with said hardener through a grafting reaction. It is yet another aspect of the present invention to produce a toughened epoxy resin, as above, wherein optionally an amine terminated butadiene-acrylonitrile copolymer is utilized in the hardener component. These and other aspects of the present invention will become apparent from the following specification which more fully describes the invention. In general, a two-part ambient temperature curing epoxy resin, comprises: an epoxy component and a hardener component; said epoxy component com prising an epoxy resin and polyepichlorohydrin, the amount of said polyepichlorohydrin being from about 2 percent to about 25 percent by weight based upon the total weight of said epoxy component; said hardener component comprising a hardener. BEST MODE FOR CARRYING OUT THE INVENTION A toughened epoxy resin is produced from a two part ambient temperature curing epoxy resin formulation having an epoxy component and a hardener component. Polyepichlorohydrin is present in the epoxy component and, upon cure, is chemically incorporated into the resin as through a grafting reaction with either the cured epoxy-hardener resin product and/or the hardener. The epoxy compound can be conventional compounds such as cycloaliphatic epoxies, epoxidized novolacs, or an epoxy compound derived from an epichlorohydrin and a dihydric phenol. Dihydric phenols are exemplified by resorcinol, hydroquinone, bisphenol A, p,p'-dihydroxybenzophenone, p,p'-dihydroxydiphenyl, p,p'-dihydroxyphenyl ethane, bis(2- hydroxynaphthyl) ethane, 1,5-dihydroxynaphthalene with bisphenol A being preferred. A preferred epoxy compound is-the diglycidyl ethers of bisphenol A (DGEBA). Such epoxies are well known to those skilled in the art and generally have epoxy groups on each end with a low molecular weight (from about 900 to about 3,000) polymer. The epoxy component conventionally contains fillers and pigments of the type common to the epoxy field with examples of such conventional items in cluding crystalline quartz, bayrtes, magnetite, silicates, aluminum silicates, calcium sulfates, calcium carbonate, talc, titania, clays, barium salts, and the like. Naturally, an amount is utilized depending upon the desired end hardness of the epoxy resin and generally ranges from about 5 to about 80 percent by weight and preferably from about 40 to about 70 percent by weight, based upon the total weight of the epoxy component. Should it be desired that sandibility is not an important aspect of the final epoxy resin, a smaller amount of filler can be utilized, as from about 0 to about 30 percent by weight. Polyepichlorohydrin is an hydroxyl terminated liquid polyether having the fonnula EMI5.1 wherein m ranges from about 8 to about 48 and preferably from about 15 to about 37. Hence, the polymer has a number average molecular weight of from about 800 to about 5,000 and desirably from about 1,500 to about 3,800. Polyepichlorohydrin is available as Hydrin 10X1 Polymer or Hydrin 10X2 Polymer, a trademark of the B. F. Goodrich Company. The amount of polyepichlorohydrin utilized in the present invention ranges from about 2 to 25 percent by weight, and preferably from about 5 to about 15 percent by weight based upon the total weight of the epoxy component. Considering now the hardener component, generally any conventional or common epoxy hardener can be utilized as well known in the art and literature with representative examples including the various aliphatic polyamines, the various polyamides and their derivatives, aromatic polyamines, polymercaptans, polyphenols, polybasic acids, polysulfides, polybasic anhydrides, and the like. The polymercaptans constitute a preferred hardener. Polymercaptans useful in the practice of the present invention are prepared by reacting an allyl ether such as the allyl ether of polyoxypropylated pentaerythritol, or polyoxypropylated sorbitol, with hydrogen sulfide in benzene in the presence of an azo catalyst such as 2,2'-azobis-(2,4dimethyl valeronitrile) at a pressure in the range of 80 to 388 psi and a temperature in the range of 200 to 90 C. A more complete description of the preparation of the polymercaptans used in the practice of the present invention can be found in U. S. Patent No. 4,092,293, the disclosure of which is incorporated herein by reference. A specific and preferred example is a mercaptan of the following formula: EMI6.1 where x is at least 2, and preferably 3, where R is an aliphatic hydrocarbon known to the art and n is at least 1 and preferably 1 or 2. Such a mercaptan is a liquid polymer which imparts rapid-cure characteristics to epoxy compounds in combination with various amines and is commercially available as Dion DPM 3-800LC, a trademark of the Diamond Shamrock Chemical Corporation. Various conventional or common accelerators may be utilized, desirably amine accelerators and desirably tertiary amine accelerators of the formula: EMI7.1 where d is an integer of from 1 to 3 inclusive, x is hydrogen or hydroxyl, and y is 1 or 2. Included among such amines are benzyl dimethylamine; dimethylaminomethyl phenol; dimethylaminoethyl phenol; 2,4-di(dimethylaminomethyl) phenol; 2,4,6-tri(dimethylaminomethyl) phenol; alpha methyl benzyldimethylamine. Other amines which are suitable for use in the practice of the present invention include dimethylcyclohexylamine; N,N'-dimethylpiperazine; dimethylamino ethanol; N-methyl diethanolamine; triethylamine; with diethylene triamine being a preferred amine. The amount of the amine accelerator typically is from about 1 percent to about 20 percent by weight and preferably from about 2 percent to about 10 percent by weight based upon the total weight of the hardener component. Desirably, the hardener component also contains fillers as of the same type and in the same amounts as the epoxy component. Once again, should it be desired that the final epoxy resin need not have good sandibility properties, a lower amount of filler is utilized. The epoxy resin of the present invention can be formed by combining the epoxy component and the hardener component as above described to produce a cure at ambient temperature. In addition to the polyepichlorohydrin in the epoxy component, a second modifier may be utilized in the hardener component. Desirably, the second modifier is a copolymer of butadiene and acrylonitrile having an acrylonitrile content of from about 5 to about 26 percent by weight and preferably from about 8 to about 18 percent by weight. Preferably, an amine terminated butadiene-acrylonitrile polymer is desirable. Specific examples include Hycar Polymer 1300X16 and 1300X21, a trademark of the B. F. Goodrich Company. The amount of the polybutadiene acrylonitrile copolymer ranges from about 2 to about 25 percent by weight and preferably from about 5 to about 15 percent by weight based upon the total weight of the hardener component and the molecular weight ranges from about 3,000 to about 5,000, with from about 3,500 to about 4,800 being preferred. Generally, adequate toughening effects are readily obtained solely through the use of polyepichlorohydrin in the epoxy component and hence the copolymer of butadiene and acrylonitrile need not be utilized. According to the present invention, since polyepichlorohydrin exists in the epoxy component and the optional butadiene-acrylonitrile copolymer exists in the hardener component, a system exists wherein both such rubbery type compounds will not react with their respective carriers, that is epichlorohydrin with the epoxy compound and the polybutadiene acrylonitrile with the mercaptan compound. Hence, the two part epoxy resin system has good shelf stability. However, upon mixing, the epoxy compound will, of course, curingly react with the mercapan compound and the polyepichlorohydrin will react with the hardener. That is, not only does the polyepichlorohydrin graftingly react with the hardener epoxy backbone, but it will also undergo a grafting reaction with the hardener. Should the optional butadiene acrylonitrile copolymer be utilized, it would chemically react with the epoxy. Thus, the polyepichlorohydrin compound would be tied into the cured epoxy yielding a truly toughened system. All such reactions occur at an ambient temperature, that is from about 150 to about 500C, with 0 0 from about 17 to 25 C being preferred. The excess by weight of said epoxy to said hardener is from about 200:1 to about 1:1, with from about 3:1 to 1:1 being preferred. The ratio of the epoxy component to said hardener component is from about 50:1 to about 1:50 with from about 4:1 to 1:4 being preferred. The primary reaction between the epoxy compound and the hardener generally occurs within a few to several minutes, whereas the secondary reaction of the polyepichlorohydrin usually occurs within a 24 hour period. In addition to the above compounds, small amounts of various additives may be added such as colorants, diluents, and the like. The cured epoxy composition of the present invention unexpectedly has a large improvement in toughness and yet maintains excellent adhesion with flexibility comparable to compositions of the same general type of epoxy. The epoxy resin system of the present invention can thus be utilized in any typical epoxy situation, and especially in those situations where an extremely tough and flexible epoxy is needed. Specific uses include a patch or repair for urethane bumpers or as a portion of an automotive door panel, and the like. The invention will be better understood by reference to the following examples. EXAMPLE 1 A two-part epoxy formulation described below was prepared. The formulation cures on mixing at room temperature to give the following properties after 16 hours of room temperature aging. Tensile shear strength. Solvent wiped mild steel laps (ASTM-D-1002-64) 1600 psi T Peel. ASTM-D-1876. Solvent wiped steel 9 pLi The same formulation with the polyepichlorohydrin replaced by a polybutadiene acrylonitrile liquid elastomer, carboxy terminated, exhibited properties of only 300 psi tensile shear and 4 pLi T peel. Thus, the polyepichlorohydrin is acting as a true toughener and is not producing simply a soft epoxy. FORMULATION PART A Weight DGBPA resin (Ciba-Gigy 6010) 37.80 Polyepichlorohydrin (Goodrich 10X-1) 10.00 Blended inorganic fillers 61.20 Total ¯ 100.00 PART B Weight Mercaptan terminated liquid polymer (Dion 3 800LC) 28.42 Tertiary aliphatic amine accelerator (Dow DEH 20) 5.69 Amine terminated liquid elastomer (ycar ATBN 1300 x 16) 5.00 Blended inorganic fillers 60.89 Total 100.00 The blended fillers were chosen from: magnetite, barytes, calcium carbonate, silica, and aluminum silicate. Parts A and B were mixed in equal amounts. As apparent from the above comparative data, at least a two-fold increase in tensile peel was achieved with at least a five-fold increase in tensile shear strength over previous standard toughened epoxies. EXAMPLE 2 A two-part epoxy formulation described below was prepared. The formulation was cured at room temperature by mixing 7 parts of A with 2 parts of B. The formulation was used as a body filler on automotive plastic panels, i.e., sheet molding compound (polyester) S.M.C. and reaction injection molded urethane (R.I.M.). The formulation cures to give a repair which may be sanded to a smooth finish and which exhibits superior resistance to cracking and debonding upon flexing the automotive panels as compared to standard polyester body fillers, such as Loctites Easy Does It and White PART A Weight DGBPA 25.12 Polyepichlorohydrin 9.97 Blended inorganic fillers 64.91 Total 100.00 PART B Weight Mercaptan terminated liquid polymer 63.88 Tertiary aliphatic amine accelerator 12.79 Blended inorganic fillers 23.33 Total 100.00 The same compounds were used as in Example 1. The fillers were chosen from: magnetite, barytes, calcium carbonate, silica, and aluminum silicate. While in accordance with the patent statutes, a preferred embodiment and best mode have been described in detail, the invention is not limited thereto, but rather by the scope of the attached claims.

Claims: WHAT IS CLAIMED IS: 1. In a two-part epoxy resin composition of the type having a first part comprising an epoxy component and a second part comprising a hardener component, wherein said composition is curable at ambient temperatures; an improved composition characterized in that said epoxy component comprises an epoxy resin and polyepichlorohydrin, the amount of said polyepichlorohydrin being from 2 percent to 25 percent by weight based upon the total weight of said epoxy component; and said hardener component comprises an epoxy hardener. 2. A two-part ambient epoxy resin composition according to claim 1, characterized by one or more of the following features (a) the number average molecular weight of said polyepichlorohydrin is from. 800 to 5,000 and the ratio of said epoxy component to said hardener component is from 50:1 to 1:50; (b) said hardener comprises an aliphatic polyamine, a polyamide, a derivative of polyamide, an aromatic polyamine, a polymercaptan, a polyphenol, a polybasic acid, a polybasic anhydride, a polysulfide, and combinations thereof, the molecular weight of said polyepichlorohydrin is from 1,500 to 3,800, and the amount thereof is from 5 percent to 15 percent by weight; and (c) further including an accelerator, the amount of said accelerator ranging from 1 to 20 percent by weight based upon the total weight of said hardener component, wherein (i) said accelerator preferably is an amine accelerator of the formula EMI14.1 where d is an integer of from 1 to 3 inclusive, x is hydrogen or hydroxyl, and y is 1 or 2, and (ii) said epoxy compound preferably is a diglycidyl ether of bisphenol A, wherein said hardener comprises a mercaptan of the formula EMI14.2 where x is at least 2, n is at least 1, and R is an aliphatic hydrocarbon, and wherein said ratio of said epoxy component to said hardener component is from 4:1 to 1:4. 3. A two-part epoxy resin composition according to either of claims 1 or 2, characterized by one or botch of the following features: (a) including from 5 to 80 percent by weight of a filler in said epoxy component, and from 5 to 80 percent by weight of a filler in said hardener component; and (b) wherein said accelerator comprises an amine accelerator, preferably a tertiary amine accelerator of the formula: EMI14.3 wherein d is an integer of from 1 to 3 inclusive, x is hydrogen or hydroxyl, and y is 1 or 2; benzyl dimethylamine; dimethylaminomethyl phenol; dimethylaminoethyl phenol; 2,4-di(dimethylaminometilyl) phenol; 2,4,6-tri(dimethylaminomethyl) phenol; alpha methyl benzyldimethylamine; dimethylcyclohexylamine; N,N'-dimethylpiperazine; dimethylamino ethanol; N-methyl diethanolamine or triethylamine. 4. A two-part epoxy composition according to any of claims 1 to 3, characterized by including a butadiene-acrylonitrile copolymer in said hardener component, the amount of said copolymer ranging from 2 percent to 25 percent based upon the total weight of said hardener component, the amount of said acrylonitrile in said copolymer ranging from 5 to 26 percent by weight, and the molecular weight of said copolymer ranging from 3,000 to 5,000. 5. A two-part epoxy resin composition according to claim 4, characterized in that the amount of said copolymer ranges from 5 percent to 15 percent, the amount of acrylonitrile in said copolymer ranges from 8 to 18 percent by weight, the molecular weight of said copolymer ranges from 3,000 to 5,000; said accelerator is diethylene triamine; and, said epoxy compound preferably is a diglycidyl ether of bisphenol A, wherein said hardener comprises a mercaptan of the formula EMI15.1 where x is at least 2, R is an aliphatic hydrocarbon, and n is 1 or 2, and wherein the amount of said epoxy component to said hardener component is from about 4:1 to about 1:4. 6. In an epoxy-resin of the type comprising the ambient temperature-cured reaction product of an epoxy component and a hardener component, the improvement characterized in that said epoxy component comprises an epoxy compound and polyepichlorohydrin, the amount of said polyepichlorohydrin being from 2 percent to 25 percent by weight based upon the total weight of said epoxy component, the number of average molecular weight of said epoxy component ranging from 800 to 5,000; and said hardener component comprises a hardener. 7. An epoxy resin according to claim 6, characterized by one or both of the following features: (a) the ratio of said epoxy component to said hardener component is from about 50:1 to 1:50; and (b) including from 5 percent by weight to 80 percent by weight of a filler in said epoxy component, and including from 5 percent to 80 percent by weight of a filler in said hardener component. 8. An epoxy resin according to either of claims 6 or 7, characterized in that the molecular weight of said polyepichlorohydrin is from 1,500 to 3,800, and wherein said hardener is a polymercaptan having the formula EMI16.1 where x is at least 2, n is at least 1, and R is an aliphatic hydrocarbon, and wherein said ratio of said epoxy component to said hardener component is from 4:1 to 1:4. 9. An epoxy resin according to claim 8, characterized by one or more of the following features: (a) the ratio of said epoxy component to said hardener component is from 4:1 to 1:4, the amount of said polyepichlorohydrin is from 5 percent to 15 percent by weight, said epoxy compound is a diglycidyl ether of bisphenol A, and said polymercaptan hardener has the formula EMI17.1 where x is at least 2, R is an aliphatic hydrocarbon, and n is 1 or 2, and the ratio of said epoxy component to said hardener component is from 4:1 to 1:4; and wherein said epoxy resin component preferably also includes a filler preferably in the range of from 5 to 80 percent by weight of said epoxy component, and said hardener component also includes a filler preferably in the range of from 5 to about 80 percent by weight of said filler component; (b) including a butadieneacrylonitrile copolymer having a molecular weight of from 3,000 to 5,000, the amount of acrylonitrole in said copolymer ranging from 5 percent to 26 percent by weight, and the amount of said copolymer ranging from 2 percent to 25 percent by weight based upon the total weight of said hardener component; and wherein the molecular weight of said copolymer preferably is from 3,500 to 4,800, the amount of said acrylonitrole in said copolymer is from 8 percent to 18 percent by weight, and the amount of said copolymer in said hardener component is from 5 percent to 15 percent by weight. 10. Use of an epoxy resin according to any of claims 6 to 9 in an automobile, preferably in a bumper or an exterior portion of said automobile.

Inventors: DRAIN, KIERAN FRANCIS
Applicants: LOCTITE CORPORATION
Application year: 1984
Main classification: C08L63
IPC codes: C08G59, C08L63