Patent Description:
Epoxy resins constitute a broad class of polymers having good adhesion and electrical properties, high glass transition temperatures, excellent resistance to corrosion and solvents and are well-known for their use in adhesives, coatings and composites. Those resins are characterized by epoxide groups which are cured via a crosslinking reaction with a multifunctional nucleophilic curing agent, such as amines, or a reaction with itself. This curing process is in general accelerated or even induced by a Lewis acidic or basic catalyst. Commonly known accelerators for epoxy/amine systems include for example alkylated phenols, particularly bisphenol A, nonylphenol or styrenated phenols, the combination of those alkylated phenols with tertiary amines, salicylic acid or benzyl alcohol. Examples of commercially available accelerators that are frequently applied include Novares® LS500, Sanko MSP, or Kumnox <NUM>. Despite a high efficiency and an inexpensive availability all those systems are confronted by different applicational or processing issues. For example, bisphenol-A shows allergenic as well as teratogenic properties and exhibits a high crystallization tendency in formulated systems resulting in a performance decrease. Nonylphenol acts as an endocrine disruptor limiting its application possibilities, meanwhile styrenated phenols and salicylic acid are currently under comparable considerations. The benzyl alcohol as volatile substance causes migration effects and declines the glass transition temperature of the cured epoxy resin, which is a critical property for many applications.

<CIT> describes a phenolic product prepared by reacting a phenol compound substituted with OH, C1-<NUM> alkyl or alkenyl or a phenyl group, a -C(CH<NUM>)<NUM>C<NUM>H<NUM> group or a -C(CH<NUM>)<NUM>C<NUM>H<NUM>OH group with a benzene compound substituted with two independent occurrences of -C(CH<NUM>)CH<NUM> or -C(CH<NUM>)<NUM>OH in the presence of an acidic catalyst.

<CIT> describes a curable epoxy resin composite formulation for preparing a composite shaped article comprising a reinforcing material and an epoxy resin composition comprising at least one epoxy resin having an average of more than one glycidyl ether group per molecule, at least one alkanolamine curing agent and at least one styrenated phenol.

<CIT> describes an adduct of styrenated phenols and hydroxylamines as well as a method of its synthesis. The resin is prepared via an acid catalyzed alkylation reaction. <CIT> describes a resin composition comprising an epoxy resin, a benzoxazine resin as hardener, a dicyclopentadiene phenol resin as hardener, and an amine hardener, wherein the resin composition is free of diallyl bisphenol A (DABPA).

<CIT> teaches an epoxy resin composition excellent in heat resistance and low in dielectric and a copper-clad laminate obtained by molding it, wherein the epoxy resin composition comprises (A) a compound obtainable by reacting an epoxy resin obtainable by glycidyl etherifying a <NUM>-methyl-<NUM>-(C4-C8)alkylphenol novolak with a halogen-containing bisphenol compound and (B) an epoxy hardener. <CIT> concerns a resin varnish composition with low dielectric constant, high thermal stability, low moisture absorption and superior fire retardance, used for laminates and circuit boards, comprising a cyclopentadiene-phenolic resin, epoxy resin, or dicyclopentadiene-dihydrobenzoxazine resin, or hybrids thereof, as well as a flame-retardant agent, curing agent, or accelerator, and solvent.

<CIT> describes an epoxy resin hardener comprising a synthetic resin obtained by the addition reaction of an aromatic hydrocarbon containing a phenolic hydroxyl group with a compound having at least two ethylenically unsaturated double bonds, as well as an epoxy resin composition comprising an epoxy resin and a hardener.

<CIT> relates to an epoxy resin composition for semiconductor encapsulation, which cures rapidly, has excellent molding fluidity, and results in a cured product exhibiting minimal moisture absorption and excellent solder crack resistance. The epoxy resin composition comprises a blend of an epoxy resin and a phenolic resin as hardener, as well as an organic filler and a curing accelerator.

The object of the invention is regarded in the provision of an accelerator for epoxy resins that does not have the disadvantages shown above. In particular, a nonvolatile, non-toxic polymeric accelerator system for curing of epoxy resins with comparable or improved acceleration properties like the prior art accelerators would be desirable.

This object is solved with an epoxy system comprising.

The invention is furthermore directed to the use of a phenolic polymer having a number average molar mass (Mn) of from <NUM> to <NUM>,<NUM>/mol comprising a phenol compound, a linker group L and end group E, said phenolic polymer having the structure as presented in formula <NUM> below:
<CHM>
wherein the linker group L has the meaning of
<CHM>
or
<CHM>
each end group E is a group of formula <NUM>, <NUM>, <NUM>, <NUM> or <NUM> with only one bond to a phenol compound in formula <NUM> or has the meaning of
<CHM>
and wherein.

The invention is furthermore directed to a kit of parts comprising.

The phenolic polymer according to the invention accelerates the curing of epoxy resins, for example in adhesive systems or in coatings. The hardened epoxy resins have good mechanical properties and also good chemical resistivity.

It was further found that using the phenolic polymer according to the invention in epoxy systems or kit-of-parts according to the invention or as an accelerator may provide controlled acceleration properties in epoxy resins. At the same time, the phenolic polymer according to the invention may not result in the reduction of the mechanical strength of epoxy systems. Moreover, it was found that epoxy resins or epoxy systems comprising the phenolic polymer according to the invention may have a high mechanical resistance. Further, epoxy resins or epoxy systems comprising the phenolic polymer according to the invention may have a high chemical resistance. Epoxy resins or epoxy systems, in particular cured epoxy systems, comprising the phenolic polymer according to the invention may also have a high glass transition temperature (Tg). Epoxy resins or epoxy systems, in particular cured epoxy systems, comprising the phenolic polymer according to the invention may also have a high thermal stability. Lastly, epoxy resins or epoxy systems, in particular cured epoxy systems, comprising the phenolic polymer according to the invention may have an improved adhesion to metal and mineral surfaces and/or a higher corrosion resistance.

The phenolic polymer according to the invention may also be referred to as a terpolymer.

In the following, the components in the phenolic polymer and its properties are first described further.

According to a preferred embodiment of the invention, R<NUM> is H, C<NUM>-<NUM> alkyl, in particular C<NUM>-<NUM> alkyl, more particularly C<NUM>-<NUM> alkyl, or C<NUM>-<NUM> oxyalkyl, in particular C<NUM>-<NUM> oxyalkyl, more particularly C<NUM>-<NUM> oxyalkyl.

According to a preferred embodiment, the phenolic polymer has the structure as presented in formula <NUM> below:
<CHM>
wherein the linker group L has the meaning of
<CHM>
or
<CHM>.

According to a preferred embodiment, the linker group L has the meaning of
<CHM>
Formula <NUM>,
wherein R<NUM>, R<NUM>, and R<NUM> are as defined herein for formula <NUM>, in particular are H. It was found that phenolic polymers, in which the linker group L has the aforementioned meaning, in particular when R<NUM>, R<NUM>, and R<NUM> are H, have good properties. In particular, phenolic polymers with lower softening points can be achieved. With lower softening points, the processability and/or compatibility with other compounds such as epoxide resins may be improved.

The phenolic polymer can be prepared by polymerizing a phenol compound with one of the monomers of formulae 2a to 5a or a substituted or non-substituted C<NUM>-<NUM> cycloolefinic compound having at least two double bonds in a series of Friedel Crafts alkylation reactions. Alternatively to the monomers of formulae 2a to 5a, a monomer of formula 2b may be employed. The reaction is performed according to the known synthesis method of a Friedel Crafts alkylation reaction. The structure of the monomers according to formulae 2a to 5a or C<NUM>-<NUM> cycloolefinic compound, which act as the linker L in the polymerization reaction, is selected as follows:
<CHM>.

The structure of formula 2b is as follows
<CHM>
wherein R<NUM>, R<NUM>, and R<NUM> are as explained before with view to the residues of formula <NUM>, R<NUM> and R<NUM> are independently from each other H or C<NUM>-<NUM> alkyl and X is a hydroxyl group or a halogen selected of chlorine, bromine and iodine. Preferably, the residues R<NUM>, R<NUM>, R<NUM> and R<NUM> have the meaning of H and/or alkyl having <NUM> to <NUM> carbon atoms. In a particular preferred embodiment, the residues R<NUM>, R<NUM> have the meaning of H and the residues R<NUM> and R<NUM> have the meaning of -CH<NUM>. Most preferably, the residues R<NUM> and R<NUM> have the meaning of -CH<NUM>.

According to a preferred embodiment of the invention the residues R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM> and R<NUM> of the phenolic polymer of formula <NUM> and accordingly in the monomers according to formulae 2a, 3a, 4a and 5a have the meaning of H and/or alkyl having <NUM> to <NUM> carbon atoms. In a particular preferred embodiment, the residues R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM> and R<NUM> have the meaning of H.

Formulae 2a, 2b, 3a, 4a, 5a or the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound as shown above represent the starting compounds for the polymerization of the phenolic polymer whereas the groups of formulae <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> represent the corresponding resulting units L after polymerization in the phenolic polymer.

The starting compounds of formulae 2a, 3a, 4a, 5a and the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound can be used as purified substances, but can also be used in a way, where the specific starting compound is part of a compound mixture. In particular, this can be the case if divinylbenzene is used as a starting compound in the polymerization of the phenolic polymer. In case of employing such a compound mixture the starting compound, in particular the starting monomer for the linker group L, should be present in the mixture at least in an amount of <NUM> wt. % to <NUM> wt. %, preferred <NUM> wt. % to <NUM> wt. %, based on the weight of the compounds of the mixture.

The phenol compound, which is subjected to polymerization with the compounds of formulae 2a to 5a and the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound R<NUM> to produce a phenolic polymer of formula <NUM> can be selected from phenol, C<NUM>-<NUM> alkyl phenol, in particular C<NUM>-<NUM> alkyl phenol, more particularly C<NUM>-<NUM> alkyl phenol, even more particularly C<NUM>-<NUM> alkyl phenol, and C<NUM>-<NUM> oxyalkyl phenol, in particular C<NUM>-<NUM> oxyalkyl phenol, more particularly C<NUM>-<NUM> oxyalkyl phenol, even more particularly C<NUM>-<NUM> oxyalkyl phenol, for example, o-cresol, m-cresol, p-cresol, ethyl phenol and isopropyl phenol.

The catalyst for the polymerization can be a Lewis acid or a Broensted acid. Preferably the calalyst is selected from AlCl<NUM>, BF<NUM>, ZnCl<NUM>, H<NUM>SO<NUM>, TiCl<NUM> or mixtures thereof. The catalyst can be used in an amount of from <NUM> to <NUM> mol %. After the phenol compound is melted by heating at a temperature of <NUM> to <NUM>, preferably <NUM> to <NUM>, or dissolved in a suitable solvent (e.g. toluene), the catalyst is added. Thereafter, a monomer compound selected of formulae 2a to 5a or the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound is added dropwise to the phenol compound. Alternatively, the catalyst is added to a mixture of the phenol compound and the monomer compound of formulae 2a to 5a or the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound. The reaction mixture may be cooled, for example from - <NUM> to <NUM>, when adding the catalyst. The time period of addition of a compound of formulae 2a, 3a, 4a, or 5a or the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound can be selected to be <NUM> minutes to <NUM> hours. The reaction can be continued for <NUM> to <NUM> hours. The polymerization reaction can be performed at a temperature of from <NUM> to <NUM>, preferably <NUM> to <NUM>. Preferably, the polymerization is performed at ambient pressure. The polymerization can be quenched by the addition of suitable additives, preferably lime. The obtained polymers can be purified by filtration and/or steam distillation.

The molar mass (Mn) of the phenolic polymer is in the range of from <NUM> to <NUM>,<NUM>/mol, preferably in the range of from <NUM> or <NUM> to <NUM>/mol.

The phenolic polymer preferably has a mass average molecular mass (Mw) of <NUM> to <NUM>,<NUM>/mol, more preferably from <NUM> to <NUM>,<NUM>/mol, even more preferably from <NUM> to <NUM>/mol.

The phenolic polymer preferably has a z-average molecular mass (Mz) of <NUM> to <NUM>,<NUM>/mol, more preferably from <NUM> to <NUM>,<NUM>/mol, even more preferably from <NUM>,<NUM> to <NUM>,<NUM>/mol.

The number average molecular mass (Mn), the mass average molecular mass (Mw), and the z-average molecular mass (Mz) may in particular be determined using gel permeation chromatography (GPC). In GPC, styrene-divinylbenzene copolymers may be used as column material. A <NUM> precolumn and three <NUM> <NUM>Å main columns may be used. A SECcurity<NUM>-System by PSS-Polymers may be used. The substances may be detected with an RI detector. Unstabilized ULC/MS-grade THF is preferably used as eluent. The measurements are preferably run isothermal at <NUM>. For the calibration curve, ReadyCal-Kit Poly(styrene) low (Mp <NUM>-<NUM>,<NUM> Da) by PSS-Polymer may be used as external standard.

It was found that phenolic polymers with lower molecular weights in the aforementioned ranges exhibited improved properties, in particular improved compatibility and miscibility with epoxy resins. This resulted in accelerated curing and in some cases in improved mechanical properties and/or improved chemical resistivity.

The phenolic polymer advantageously has a glass transition temperature (Tg) of from - <NUM> to <NUM>, preferably from -<NUM> to <NUM>, more preferably from -<NUM> to <NUM>, and most preferably from <NUM> to <NUM>. It was found that phenolic polymers with a glass transition temperature in the aforementioned ranges show good processability and/or good solubility in other compounds such as epoxy resins.

The glass transition temperature is preferably measured using differential scanning calorimetry (DSC). A DSC <NUM>/<NUM> with intra cooler from Mettler Toledo may be employed. For the measurement, aluminum crucibles with pin holes, in particular ME-<NUM> AL-Crucibles, may be employed. For the evaluation of the glass transition temperature, a heating-cooling-heating-cooling sequence may be employed with a heating / cooling rate of <NUM>/min within a measuring window between -<NUM> to <NUM>. The Tg evaluation is preferably performed in accordance to DIN <NUM>, in particular DIN <NUM>:<NUM>-<NUM>.

The phenolic polymer may comprise <NUM> wt. % to <NUM> wt. % of the phenol compound. The phenolic polymer may comprise <NUM> wt. % to <NUM> wt. % of the linker group L, in particular of difunctional monomers (linker L) selected from a divinylbenzene compound, a diclyclopentadiene compound or a compound of formula <NUM>, <NUM> or <NUM>, based on the weight (mass) of the phenolic polymer. The divinylbenzene compound is preferably a compound of formula <NUM>, more preferably a compound of formula <NUM> wherein R<NUM>, R<NUM>, and R<NUM> are as defined herein, most preferably wherein R<NUM>, R<NUM>, and R<NUM> are H. The dicyclopentadiene compound is preferably a compound of formula <NUM>. Further, the phenolic polymer may comprise <NUM> wt. % to <NUM> wt. %, in particular <NUM> wt. % to <NUM> wt. %, more particularly <NUM> wt. % to <NUM> wt. %, monofunctional monomers (end group E), based on the weight (mass) of the phenolic polymer. The term monofunctional monomer used before refers to a compound, which can be present in the starting mixture of compounds of formulae 2a, 4a, 5a and the optionally methyl or ethyl substituted C<NUM>-<NUM> cycloolefinic compound for the polymerization of the phenolic polymer, which however has only one double bond or one halogen capable to react in the polymerization reaction to obtain the phenolic polymer. Such modified starting compound or monofunctional starting compound acts as a chain stopper in the polymerization reaction. It can form the end group E of formula <NUM>. Further examples of end groups E are described below.

According to a preferred embodiment, the end group E may have the meaning of
<CHM>
<CHM>
or
<CHM>.

When using end groups E that are different from H, in particular end groups E with the meaning of the aforementioned formulas, the accelerating properties of the phenolic polymer can be adjusted. It was found that when the aforementioned end groups E were incorporated into the phenolic polymer, the acceleration could be increased. Moreover, the compatibility of the phenolic polymer with other compounds, in particular epoxy resins, could be improved.

The end group E may also have the meaning of a C<NUM>-<NUM> cycloalkyl group optionally substituted with a methyl group or an ethyl group.

Accordingly, the end group E may advantageously be obtained from monofunctional monomers having the meaning of
<CHM>
<CHM>
<CHM>
or
<CHM>.

The end group E may also be obtained from a monomer having the meaning of a C<NUM>-<NUM> cycloolefinic compound with only one double bond optionally substituted with a methyl group or an ethyl group.

According to an embodiment, the end group E has the meaning of
<CHM>
<CHM>
wherein R<NUM>, R<NUM>, R<NUM>, R<NUM>, and R<NUM> are independently from each other H or C<NUM>-<NUM> alkyl, preferably wherein independently from each other R<NUM> is H, R<NUM> is H or CH<NUM>, R<NUM> is H or CH<NUM>, R<NUM> is C<NUM>-<NUM> alkyl, and R<NUM> is C<NUM>-<NUM> alkyl.

According to a preferred embodiment, the end group E has the meaning of
<CHM>
wherein R<NUM>, R<NUM>, and R<NUM> are independently from each other H or C<NUM>-<NUM> alkyl, preferably H.

According to a preferred embodiment, the linker group L has the meaning of
<CHM>
Formula <NUM>,.

The phenolic polymer may have a high OH content, preferably of <NUM> to <NUM> wt. %, in particular preferred <NUM> to <NUM> wt. % based on the weight of the phenolic polymer. The phenolic polymer preferably has a softening point according to ASTM <NUM> up to <NUM>, more preferred <NUM> to <NUM>, most preferred <NUM> to <NUM>.

Further properties of the epoxy system according to the invention are described below.

The epoxy systems may be one part epoxy systems or two part epoxy systems. In one part epoxy systems, the epoxy resin, the hardener, the accelerator and other components are in particular part of the same mixture. In one part epoxy systems the hardeners are latent reactive at ambient temperature and become active at high temperature. In one part epoxy systems, the hardener preferably comprises anhydride, thiol and/or phenol functionalities. Examples of latent hardeners are dicynamide, BF<NUM> complexes such as BF<NUM> monoethylamine complex, aromatic amines, and imidazoles such as <NUM>-ethyl-<NUM>-methyl imidazole. However, also hardeners comprising carboxylic acid and/or isocyanate functionalities can be used in one part systems. Accelerators or optional additional accelerators in one part epoxy systems can in particular be amines which reveal catalytic activity at curing temperature. In two part epoxy systems, the epoxy resin and the hardener are separate. The epoxy resin and the hardener are combined to effect cross-linking of the epoxy resin and the hardener. The hardeners in two part epoxy systems are preferably amines or their derivates. Accelerators in two part epoxy systems may in particular be incorporated into the hardener part. Accelerators or optional additional accelerators in two part epoxy systems may in particular be compounds containing functionalities of amine, phenol, alcohol, thiol or carboxylic acid. In the one part or the two part epoxy systems, the epoxy resin may be present cross-linked with the hardener.

The epoxy system may in particular also comprise a hardener comprising amine, anhydride, phenolic, and/or thiol, in particular amine, functionalities. If the phenolic polymer according to the invention is used as an accelerator, the epoxy system preferably contains a hardener. If the phenolic polymer according to the invention is used as a hardener, the epoxy system may contain the hardener comprising amine, anhydride, phenolic, and/or thiol, in particular amine, functionalities as a co-hardener. In the epoxy systems, the epoxy resin may be present cross-linked with the hardener.

Examples of hardeners or co-hardeners comprising amine functionalities may be selected from, for example, but are not limited to, aliphatic amines, dicyandiamide, substituted guanidines, phenolic, amino, benzoxazine, anhydrides, amido amines, polyamides, polyamines, carbodiimides, urea formaldehyde and melamine formaldehyde resins, ethanolamine, ethylenediamine, diethylenetriamine (DETA), triethyleneaminetetramine (TETA), <NUM>-(o-tolyl)-biguanide, amine-terminated polyols, aromatic amines such as methylenedianiline (MDA), toluenediamine (TDA), diethyltoluenediamine (DETDA), diaminodiphenylsulfone (DADS), and mixtures thereof.

Examples of hardeners or co-hardeners comprising anhydride functionalities are phthalic anhydride, trimellitic anhydride, nadic methyl anhydride (also referred to as methyl-<NUM>-norbornene-<NUM>,<NUM>-dicarboxylic anhydride), methyl tetrahydrophthalic anhydride, methyl hexahydrophthalic anhydride and mixtures thereof.

Examples of hardeners or co-hardeners comprising phenolic functionalities are bisphenol A, bisphenol F, <NUM>,<NUM>-bis(<NUM>-hydroxyphenyl)-ethane, hydroquinone, resorcinol, catechol, tetrabromobisphenol A, novolacs such as phenol novolac, bisphenol A novolac, hydroquinone novolac, resorcinol novolac, naphthol novolac, and mixtures thereof.

Examples of hardeners or co-hardeners comprising thiol functionalities are aliphatic thiols such as methanedithiol, propanedithiol, cyclohexanedithiol, <NUM>-mercaptoethyl-<NUM>,<NUM>-dimercaptosuccinate, <NUM>,<NUM>-dimercapto-<NUM>-propanol(<NUM>-mercaptoacetate), diethylene glycol bis(<NUM>-mercaptoacetate), <NUM>,<NUM>-dimercaptopropyl methyl ether, bis(<NUM>-mercaptoethyl) ether, trimethylolpropane tris(thioglycolate), pentaerythritol tetra(mercaptopropionate), pentaerythritol tetra(thioglycolate), ethyleneglycol dithioglycolate, trimethylolpropane tris(β-thiopropionate), tris-mercaptan derivative of tri-glycidyl ether of propoxylated alkane, and dipentaerythritol poly(β-thiopropionate); halogen-substituted derivatives of the aliphatic thiols; aromatic thiols such as di-, tris- or tetra-mercaptobenzene, bis-, tris- or tetra-(mercaptoalkyl)benzene, dimercaptobiphenyl, toluenedithiol and naphthalenedi thiol; halogen-substituted derivatives of the aromatic thiols; heterocyclic ring-containing thiols such as amino-<NUM>,<NUM>-dithiol-sym-triazine, alkoxy-<NUM>,<NUM>-dithiol-sym-triazine, aryloxy-<NUM>,<NUM>-dithiol-sym-triazine and <NUM>,<NUM>,<NUM>-tris(<NUM>-mercaptopropyl) isocyanurate; halogen-substituted derivatives of the heterocyclic ring-containing thiols; thiol compounds having at least two mercapto groups and containing sulfur atoms in addition to the mercapto groups such as bis-, tris- or tetra(mercaptoalkylthio)benzene, bis-, tris- or tetra(mercaptoalkylthio)alkane, bis(mercaptoalkyl) disulfide, hydroxyalkylsulfidebis(mercaptopropionate), hydroxyalkylsulfidebis(mercaptoacetate), mercaptoethyl ether bis(mercaptopropionate),<NUM>,<NUM>-dithian-<NUM>,<NUM>-diolbis(mercaptoacetate), thiodiglycolic acid bis(mercaptoalkyl ester), thiodipropionic acid bis(<NUM>-mercaptoalkyl ester), <NUM>,<NUM>-thiobutyric acid bis(<NUM>-mercaptoalkyl ester), <NUM>,<NUM>-thiophenedithiol, bismuththiol and <NUM>,<NUM>-dimercapto-<NUM>,<NUM>,<NUM>-thiadiazol, and mixtures thereof.

Exemplary epoxy resins may comprise at least one epoxy resin based on bisphenol A, bisphenol F, novolac, phenol resin, epoxidized natural oils and any polyalcohols. These compounds may also have been reacted with for example epichlorohydrin. Other exemplary epoxy resins are described in <CIT>, column <NUM>, lines <NUM> to <NUM>.

The epoxy resins mentioned herein can be pigmented and filled systems with pigments and/or fillers, for example iron oxides, titanium dioxide, organic pigments, calcium carbonates, talcum, barium sulphonates, silica, mica, glas pearls, sand, alumina trioxide, magnesium oxides, or zinc phosphates.

The epoxy resins mentioned herein can contain reactive or non reactive diluents. Examples of reactive diluents are low molecular mass compounds with <NUM> to <NUM> glycidyl functionalities with linear or cyclic backbones with <NUM> to <NUM> carbon units or ether backbones or, ester backbones. Examples of non reactive diluents are aceton, keton, esters, ether, aromatic solvents or their mixtures.

Consequently, also the epoxy systems may contain the above-mentioned pigments and/or fillers and/or reactive diluents and/or non-reactive diluents.

The epoxy resins and the epoxy systems mentioned herein may be used for coatings, for example flooring coatings, construction coatings, metal coatings, for adhesives, for sealants, particularly for structure adhesives in metal construction, in wood and concrete construction, for lamination, in particular for lamination of electronic circuits and equipments, for composites and casting applications, for chemical dowels, for electrical encapsulation. The same applies to the epoxy systems mentioned herein.

The phenolic polymer described herein as part of the epoxy system according to the invention may also be used as an accelerator for the curing of epoxy resins. When the phenolic polymer of the invention is used as an accelerator for the curing of epoxy resins a hardener comprising amine, anhydride, phenolic, and/or thiol functionalities is preferably present. More preferably, a hardener comprising amine functionalities is present.

The phenolic polymer described herein as part of the epoxy system according to the invention may also be used as a hardener for epoxy resins. When the phenolic polymer of the invention is used as a hardener for the curing of epoxy resins, a co-hardener comprising amine, anhydride, phenolic, and/or thiol functionalities, in particular comprising amine functionalities, may also be present.

All the details concerning the phenolic polymer, the epoxy resin, the hardener, the accelerator, optional additional accelerators, and optional additional compounds described above in the context of the epoxy system apply to the use of the phenolic polymer accordingly.

In particular, the phenolic polymer described herein as part of the epoxy system according to the invention may serve at room temperature or below as an accelerator. At higher temperatures, the phenolic polymer of the invention may also serve as a hardener. It was found that the phenolic polymer yields particularly good results as a hardener for epoxy resins at a temperature of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

Preferably, the phenolic polymer described herein as part of the epoxy system according to the invention is used at room temperature or below, in particular at -<NUM> to <NUM>, more particularly at <NUM> to <NUM> as an accelerator for epoxy resins.

When the phenolic polymer is used as an accelerator or as a hardener for epoxy resins, the phenolic polymer is preferably part of an epoxy system, preferably an epoxy system according to the invention.

As hardener, the phenolic polymer may be used in different amounts depending on the desired degree of cross-linking. As hardener, the phenolic polymer is preferably used at a ratio of OH:epoxy groups of <NUM>:<NUM> to <NUM>:<NUM>, preferably <NUM>:<NUM> to <NUM>:<NUM>, based on the total mass of the epoxy system, in particular in casting, lamination and adhesive applications. As accelerator, the phenolic polymer is preferably used in an amount of <NUM> to <NUM> wt. %, more preferable <NUM> to <NUM> wt. % and even more preferably <NUM> to <NUM> wt. %, based on the total mass of the epoxy system.

Moreover, the invention also provides for a kit-of-parts comprising an epoxy resin and the phenolic polymer described herein as part of the epoxy system according to the invention, and a hardener comprising amine, anhydride, phenolic, and/or thiol, in particular amine, functionalities. The kit-of-parts according to the invention is preferably a two part epoxy system.

All the details concerning the phenolic polymer, the epoxy resin, the hardener, the accelerator, optional additional accelerators, and optional additional compounds described above in the context of the epoxy system apply to the kit-of-parts accordingly.

In the kit-of-parts, the phenolic polymer and the hardener are preferably present as a mixture that optionally contains a solvent.

The following examples serve to further explain the invention.

Phenol (<NUM>) was dissolved in toluene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the addition of BF<NUM>*(OEt<NUM>) (<NUM>). Divinyl benzene (<NUM>, <NUM>% purity) was added dropwise via the dropping funnel over a period of <NUM> minutes to the reaction mixture. After the addition the solution was stirred for <NUM> hours at a reaction temperature of <NUM>. The polymerization was quenched by addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of the characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) was dissolved in toluene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the addition of BF<NUM>*(OEt<NUM>) (<NUM>). Dicyclopentadiene (<NUM>, <NUM>% purity, <NUM>% vinyl aromatics (indene, methyl styrene isomers) provided by Braskem) was added dropwise via the dropping funnel over a period of <NUM> minutes to the reaction mixture. After the addition the solution was stirred for <NUM> hours at a reaction temperature of <NUM>. The polymerization was quenched by addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as red solid. The results of the characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) was dissolved in toluene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the addition of BF<NUM>*(OEt<NUM>) (<NUM>,<NUM>). Dicyclopentadiene (<NUM>, <NUM>% purity, <NUM>% vinyl aromatics (indene, methyl styrene isomers) provided by Braskem) was added dropwise via the dropping funnel over a period of <NUM> minutes to the reaction mixture. After the addition the solution was stirred for <NUM> hours at a reaction temperature of <NUM>. The polymerization was quenched by addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as red solid. The results of the characterization of the phenolic polymer are presented in the table below.

<NUM>-Tert-octylphenol (<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the addition of BF<NUM>*(OEt<NUM>) (<NUM>). Divinylbenzene (<NUM>, <NUM>% purity: divinylbenzene : ethylvinylbenzene = <NUM>:<NUM>) was added dropwise via the dropping funnel over a period of <NUM> minutes to the reaction mixture. After the addition the solution was stirred for <NUM> hours at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) and divinylbenzene (<NUM>, <NUM>% purity: divinylbenzene : ethylvinylbenzene = <NUM>:<NUM>) was dissolved in Xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) and divinylbenzene (<NUM>, <NUM>% purity: divinylbenzene : ethylvinylbenzene = <NUM>:<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>,<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) and divinylbenzene (<NUM>, <NUM>% purity: divinylbenzene : ethylvinylbenzene = <NUM>:<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>) and diisopropenylbenzene (<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>), styrene (<NUM>) and diisopropenylbenzene (<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>), styrene (<NUM>) and diisopropenylbenzene (<NUM>) was dissolved in Xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

Phenol (<NUM>), α-methylstyrene (<NUM>) and diisopropenylbenzene (<NUM>) was dissolved in xylene (<NUM>) in a three-neck flask equipped with a dimroth coil condenser and a dropping funnel at <NUM> followed by the portion wise addition of BF<NUM>*(OEt<NUM>) (<NUM>). The reaction mixture was cooled by an ice bath. After the addition the solution was stirred for <NUM> hour at a reaction temperature of <NUM>. The polymerization was quenched by the addition of chalk. Filtration of the crude product and purification via steam distillation at <NUM> yielded the resin as colorless solid. The results of characterization of the phenolic polymer are presented in the table below.

As can be seen from the exemplary syntheses above, the properties of the polymeric phenolic polymer can be varied in a wide range.

The molar mass distribution (Mn, Mw, Mz) was estimated via gel permeation chromatography (GPC) with a SECcurity<NUM>-System supplied by the company PSS-Polymers. The used column system consists of a <NUM> precolumn and three <NUM> <NUM>Å main columns filled with a styrene divinylbenzene copolymer as column material. For substance detection a refraction index (RI) detector was used. Unstabilized ULC/MS-grade THF was used as eluent supplied by the company Biosolve. Each measurement run was performed isothermal at <NUM>. ReadyCal-Kit Poly(styrene) low (Mp <NUM> - <NUM><NUM> Da) was used as external standard supplied by PSS-Polymer.

The glass transition temperature (Tg) was estimated with a DSC <NUM>/<NUM> with intra cooler supplied by the company Mettler Toledo. Aluminum crucibles with pin hole with a volume of <NUM>µl (Me-<NUM> AL-Crucibles) were used as sample vessels. The sample weight amounted to <NUM> - <NUM>. For the evaluation of the thermal properties, a heating-cooling-heating-cooling sequence was chosen as analytical method with a heating / cooling rate of <NUM>/min within a measuring window between -<NUM> to <NUM>. The Tg evaluation was performed in accordance to DIN <NUM>.

The softening points were estimated via the method "Ring & Ball" in accordance to ASTM D <NUM> "Softening point of asphalt and pitch - Mettler cup and ball method". A FP <NUM> Central Processor in combination with a FP <NUM> HT Dropping Point Cell supplied by Mettler Toledo was used a testing device.

The hydroxyl content was estimated via a potentiometric titration in accordance to DIN <NUM>-<NUM> (<NUM>-methylimidazol catalyzed acetylation of free OH-groups with acetic anhydride followed by a titration with <NUM> NaOH). The measurement was performed with an automated titration unite (Titrando in combination with Titroprozessor <NUM> Touch Control and Dosimate <NUM>. <NUM>) supplied by Deutsche Metrohm GmbH & Co.

The phenolic polymer, for example the DVBP resins prepared in the examples above, is suitable as modifier in coatings, adhesives, and composite formulations. Particularly in epoxy-based systems it is usable as accelerator and chemical resistance enhancer.

To investigate its effect in epoxy systems the divinylbenzene phenol (DVBP) resin derived from the synthetis example <NUM> was tested in the curing of the commercially available epoxy resin Epikote <NUM>® with the curing agent Epicure Agent <NUM>®. For comparison purposes the epoxy system without additional accelerator (Std. ) as well as the influence of a styrenated phenol, Novares® LS500 a commonly applied accelerator for the curing of epoxy resins, were tested with epoxy resin Epikote <NUM>® and curing agent Epicure Agent <NUM>®. Furthermore, the influence on the mechanical properties and chemical resistance of cured epoxy resins was investigated.

Epikote <NUM>® and a mixture of Epicure Agent <NUM>® and the corresponding accelerator as shown in table <NUM> were added to a <NUM> plastic cup at room temperature and mixed in a speed mixer at <NUM> rpm for <NUM>.

Afterwards the corresponding amounts of sample were extracted for the different application tests. Curing was conducted at room temperature.

<NUM> of the above shown mixture were extracted for a rheological analysis, which was directly started after the mixing of the substances and transferred to the rheometer. The curing process was analyzed via a rheometer in accordance with the general procedure at <NUM>. The time-dependent results of the rheological analysis are shown in Table <NUM> and <FIG>. Table <NUM> displays representative time points of the time-viscosity relationship during the rheology measurement. <FIG> show the complete complete development of the viscosity over time.

As shown above the viscosity in each experiment increased exponentially after a distinct amount of time. Both, the viscosities of the epoxy systems of curing example <NUM> with styrenated phenol and curing example <NUM> increased faster than the standard system in curing example <NUM> without additional additives indicating an acceleration effect. Furthermore, the effect of the phenolic polymer exemplified by the synthesis example <NUM> on the acceleration of the curing process in curing example <NUM> exceeds the styrenated phenol in curing example <NUM>.

The complex viscosity of the epoxy curing was measured with an Anton Paar MCR302 rheometer. An aluminum plate system (PP15 Geometry) was used. The measurement was performed isotherm at <NUM> in oscillation mode at a frequency of <NUM> rads-<NUM> with a shear gap of <NUM>. The deformation was started at <NUM>% and was reduced to <NUM>% with <NUM>%/min. After the deformation reduction to <NUM>% the rest of the measurement was performed at this deformation level until a torque of <NUM> mNm was reached.

The pendulum hardness of the cured epoxy resins was measured with an BYK-Gardner pendulum hardness tester according to König (DIN <NUM><NUM>). <NUM> each of the different mixtures were poured in a defined mold and stored at room temperature for <NUM> day prior to the initial measurement. The prepared samples were clamped in the tester and the pendulum was locked in the starting position. The measurement was initiated by the pendulum release. The measurements were repeated after <NUM>, <NUM>, <NUM> and <NUM> weeks storage time. The results of the measurements are shown in Table <NUM>.

As follows from Table <NUM>, the epoxy system containing the phenolic polymer as accelerator of curing example <NUM> reached a high pendulum hardness value already at the beginning of the measurement (<NUM> weeks). By contrast, the epoxy system without any accelerator hat a lower pendulum hardness at the beginning of the measurement and the epoxy system containing the styrenated phenol as accelerator displayed an even lower initial pendulum hardness. After the first week, all of the curing examples displayed higher pendulum hardness values. Thereafter, the pendulum hardness remained fairly constant for the curing example <NUM> containing the phenolic polymer of synthesis example <NUM> as accelerator while the curing example <NUM> without any accelerator displayed a larger increase in the pendulum hardness after the first week. By contrast, the epoxy system containing the styrenated phenol accelerator displayed a significant increase in the pendulum hardness even from week <NUM> to week <NUM>.

The tensile strength and elongation at break of the cured epoxy resins were measured via a Shimadzu Autograph AGS-X tensile testing machine. Each of the different mixtures were poured in defined bone shaped molds and stored at room temperature for <NUM> weeks. Prior to the measurement the dimensions of the samples were determined. The measurements were performed with a starting gauge length of <NUM> at room temperature with a speed of <NUM>/min. The results of the measurements and calculated average values are shown in Table <NUM>.

Low molecular mass accelerators like styrenated phenols but also benzylalcohol or nonylphenol often cause softening of the epoxy systems that are exemplified by a high elongation at break The phenolic polymer of synthetis example <NUM> has only a small effect on the mechanical properties compared to the epoxy system without any accelerator as shown in the tensile tests (Table <NUM>).

<NUM> of each of the different mixtures were poured in <NUM> defined molds, which were stored at room temperature for <NUM> weeks. Afterwards the sample weight was determined followed by the immersion of the respective sample in a <NUM> closed glass bottle filled with <NUM> of the distinct test media. The following test media were employed:.

Every week the samples were taken out from the glass bottles, cleaned from residual test media and weighed. After the weighing the samples were returned to the glass bottle. The process was repeated for <NUM> weeks.

Both curing example <NUM> and curing example <NUM> show an improvement to the storage stability of the cured epoxy resins under aqueous conditions (Table <NUM>), which is indicated by reduced weight gain caused by swelling effects. When employing an accelerator, the weight gain was reduced to <NUM> wt. % (curing example <NUM>) and <NUM> wt. % (curing example <NUM>) in contrast to <NUM> wt. % (curing example <NUM>).

Both under acidic (Table <NUM>) and under basic (Table <NUM>) conditions, the hydrophilization properties of the accelerator of synthesis example <NUM> become evident. The swelling has been reduced under acidic conditions from <NUM> wt. % (curing example <NUM>) to <NUM> wt. % (curing example <NUM>) and under basic conditions from <NUM> wt. % (curing example <NUM>) to <NUM> wt. % (curing example <NUM>). In both cases the effect is comparable to the styrenated phenol of curing example <NUM> (acidic <NUM> wt. %; basic <NUM> wt.

Both the cured epoxy system of curing example <NUM> (phenolic polymer of synthesis example <NUM> as accelerator) and of curing example <NUM> (no accelerator) showed very high chemical resistance to xylene. Almost no swelling effects (<NUM> wt. % curing example <NUM>; <NUM> wt. % curing example <NUM>) could be observed during the test period (Table <NUM>). In comparison, the styrenated phenol accelerator of curing example <NUM> deteriorated the resistance significantly. After <NUM> weeks a weight gain of <NUM> w% was detected for curing example <NUM>.

Claim 1:
An epoxy system comprising
an epoxy resin and
a phenolic polymer having a number average molar mass (Mn) of from <NUM> to <NUM>,<NUM>/mol, determined as indicated in the specification, comprising a phenol compound, a linker group L and end group E, said phenolic polymer having the structure as presented in formula <NUM> below:
<CHM>
wherein the linker group L has the meaning of
<CHM>
or
<CHM>
each end group E is a group of formula <NUM>, <NUM>, <NUM>, <NUM> or <NUM> with only one bond to a phenol compound in formula <NUM> or has the meaning of
<CHM>
and wherein
R<NUM> is H, C<NUM>-<NUM> alkyl, or C<NUM>-<NUM> oxyalkyl, or C<NUM>H<NUM>(CR<NUM>R<NUM>)o-Z-, preferably H, C<NUM>-<NUM> alkyl, or C<NUM>-<NUM> oxyalkyl,
R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM> and R<NUM> are independently from each other H or C<NUM>-<NUM> alkyl,
R<NUM> and R<NUM> are H, OH, NO<NUM>, halogen, C<NUM>-<NUM> alkyl or C<NUM>-<NUM> oxyalkyl,
R<NUM> and R<NUM> are C<NUM>-<NUM> alkyl or C<NUM>-<NUM> cycloalkyl,
R<NUM> is C<NUM>-<NUM> cycloalkyl, optionally substituted with a methyl or an ethyl group,
R<NUM>, R<NUM>, and R<NUM> are independently from each other H or C<NUM>-<NUM> alkyl, preferably -CH<NUM>,
R<NUM> and R<NUM> are independently of each other H or CH<NUM>
Z is a covalent bond or -O-,
o is <NUM> or <NUM>,
m is an integer from <NUM> to <NUM> and
n is an integer of from <NUM> to <NUM>.