Epoxy formulations, processing

Consist of a range of chemicals which promote cross-linking can initiate cure by catalysing ( catalysts , hardeners, initiators), speed up and control cure (activators, promoters) or perform the opposite function (inhibitors) producing thermosetting compounds and specialised thermoplastics (e.g. peroxides in polyesters, or amines in epoxy formulations). The right choice of a cure system is dependent on process, process temperature, application and type of resin. 

Fillers and extenders are used in epoxy adhesive formulations to improve properties and to lower cost. Properties that can be selectively improved include both the processing properties of the adhesive as well as its performance properties in a cured joint. However, the use of fillers can also impair certain properties. Typically, the formulator has to balance the improvements against property decline. The advantages and disadvantages of filler addition in epoxy formulations are listed in Table 9.1. Common fillers used in epoxy formulations and the properties that they are used to modify are shown in Table 9.2. 

The incorporation of particulate fillers into the liquid epoxy formulation can be achieved with any of the processes mentioned above by the use of roll mills or screw-type kneaders. If the formulation is solid, fillers may be blended into the product by the use of a pebble mill or the like. After blending, they may be rolled under pressure and then ground if desired. 

The work described herein relates primarily to lamination and bonding processes. However, the techniques are generic to most forms of thermoset resin processing. In the discussion which follows many of the resin systems contain glycidyl amines. The bulk of the epoxy formulations used in the aerospace industry today are based on tetraglycidylmethylenedianiline, I (TGMDA) and with diaminodi phenylsulfone, II (DOS). Systems based on... 

Newer developments include also RIM and RRIM machines for the processing of polyamide and epoxy formulations. 

RIM And RRIM Machines For The Processing Of Nylon And Epoxy Formulations... 

Another class of adherends is that of thermoplastic polymers. In contrast to metal adherends, thermoplastics are not impenetrable and thus absorption effects can be expected in addition to adsorption phenomena. Hence, given sufficient conditions for preferential absorption, a considerable mass uptake by the thermoplastic can occur, potentially resulting in significant stoichiometric imbalances on the epoxy side. Apart from the driving force for absorption of molecules from the liquid epoxy formulation, it is the diffusivity of these molecules within the thermoplastic which plays a major role in the interdiffusion process. In particular, the diffusivity is affected by the mobility of the host molecules. Thus enhancement of diffusivity occurs in the glass transition region and at higher temperatures when intermolecular cooperative motion is activated. 

The development of an epoxy formulation containing a high number of components can be very resource and time-consuming. Techniques such as design of experiments (DOE) are useful tools to facilitate the formulation development process and to obtain optimum performance (131,132). Future developments should include application of high throughput techniques to epoxy formulation development and optimization. 

Cost bilizers. In most cases the alkyl tin stabilizets ate particularly efficient heat stabilizers for PVC without the addition of costabilizers. Many of the traditional coadditives, such as antioxidants, epoxy compounds, and phosphites, used with the mixed metal stabilizer systems, afford only minimal benefits when used with the alkyl tin mercaptides. Mercaptans are quite effective costabilizets for some of the alkyl tin mercaptides, particularly those based on mercaptoethyl ester technology (23). Combinations of mercaptan and alkyl tin mercaptide ate currendy the most efficient stabilizers for PVC extmsion processes. The level of tin metal in the stabilizer composition can be reduced by up to 50% while maintaining equivalent performance. Figure 2 shows the two-roU mill performance of some methyl tin stabilizers in a PVC pipe formulation as a function of the tin content and the mercaptide groups at 200°C. 

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