Subject Code: CH315 Course Title: Plastic Technology

Unit-3

Thermosetting polymers: Preparation, properties and applications of phenol

formaldehyde, unsaturated polyester, urea and melamine formaldehyde, epoxy
resins.

Suggested Books
Brydson's Plastics Materials/ M. Gilbert/ Elsevier 2016
Plastics Technology: Introduction and Fundamentals/ C. 2019
Bonten/ Carl Hanser Verlag GmbH & Company KG
Plastics Technology Handbook, Fourth Edition/ M. Chanda, S.K. 2006
Roy/ CRC Press.
 Epoxy (Epoxide)Resin
I G farben: 1939: German Patent: described liquid polyepoxides
P Castan: 1943: US Patent: Curing of epoxy resin with dibasic acids: exploited
by CIBA company

S.O. Greenlee: extensive work on epoxy resin

Key Players

Hexion DowDuPont Nan Ya Plastics Corporation

Olin Kudoko Chemical

Huntsman Corporation

Chang Chun Group

 Epoxy Resin
Raw Materials
Bis Phenol A Epichlorohydrin

Dissolve in Mixture stir continuously for 16 hours

2 moles of
1 mole Bis
epichlorohydrin
phenol A Heat : 105°C to110 °C
Add 2 moles of NaOH (drop wise)

Resin layer separated,

dried with sodium
sulphate
 Epoxy Resin
NaOH
+

NaOH

Diglycidyl ether
 Epoxy Resin
Effect of Reactant ratio on Molecular weight
Molar ratio Molar ratio of Molecular Softening point
epichlorohydrin NaOH/ weight (C)
/ Bisphenol A epichlorohydrin
2.0 1.1 415 43
1.4 1.3 791 84
1.33 1.3 802 90
1.25 1.3 1133 100
1.2 1.3 1420 112

Prepare low molecular weight polymer with DP of 3

React with Bis Phenol A in presence of alkali

 Epoxy Resin

When n= 0, the product is diglycidyl ether, MW=340

When n=10, MW=3000 Low degree of Polymerization
Commercial resin MW= approx. 4000
 Epoxy Resin
The epoxide resin of the glycidyl ether are characterized by
✓ Resin Viscosity Highly viscous, 40-100 poise at 25°C
✓ Epoxide equivalent Measure of the amount of epoxy groups
Determine by reacting known quantity of resin with HCl, and measure
unconsumed acid by back titration

✓ Hydroxyl equivalent Determine by reacting the resin by acetyl chloride

✓ Molecular weight and its distribution

✓ Melting point

✓ Heat distortion temperature

 Epoxy Resin Curing/ Crosslinking

Carried out through the epoxy group or the hydroxy groups

Curing agents

Acid hardening system

Amine hardening systems
Ex :Diethylenetriamine (9-10 PHR),
Triethylenetetramine (12-13 PHR)
Highly reactive primary aliphatic amines
Cure glycidyl ether at room temperature
High exotherm on cure: 250°C
Acid anhydride preferred as they
produce less water on cure
(Ex: Phthalic anhydride (30-35 PHR,
Hexahydro phthalic anhydride (80PHR)
Curing temperature=120°C
Less skin sensitive

Highly volatile, skin sensitive Give Low exotherm on cure

Epoxy Resin Amine Hardening systems
Epoxy Resin Amine Hardening systems

Examples
Epoxy Resin Acid Hardening systems
Epoxy Resin Acid Hardening systems
 Epoxy Resin Compounding

Unmodified epoxide resin: high viscosity and high rigidity

Diluents: Free flowing liquids to reduce the viscosity Tend to retard cure
Xylene (unreactive)
Some time skin irritants
Reactive: phenyl glycidyl ether,
octylene oxide
< 10 PHR

Filler: Cost reduction, reduce curing shrinkage, reduce

exotherm, May increase thermal conductivity
Sand, metal oxide, glass fiber, carbon fiber

Plasticizer Enhance the flexibility of the product

Low molecular weight polyamide, polysulphide, polyamines,
polyglycol diepoxides
Epoxy Resin
Properties
 Epoxy Resin
Properties
•Resistance to chemicals, particularly alkaline environments
•Heat resistance
•Adhesion to a variety of substrates
•High tensile, compression, and bend strengths
•Low shrinkage during curing
•High electrical insulation and retention properties
•Corrosion resistance
•Cures under a wide range of temperatures
•Resistance to fatigue. They are the building blocks for adhesives,
coatings, reinforced plastics, and composite materials such as fiberglass
and carbon fiber
Epoxy Resin Applications
 Epoxy Resin Applications
Construction: Laminated wood, walls, roofs, flooring

Paints and coatings: Outdoor coatings, sealers, heavy-duty protective coatings, industrial
and automotive paints, primers, and sealers.

Industrial tooling and composites: Molds, master models, laminates, castings, fixtures,
and other industrial production aids, as well as carbon-fiber-reinforced and composite
parts.

Turbine technology: Wind turbine blades.

Electrical systems and electronics: Motors, generators, transformers, gear switches,

bushings, insulators, printed wiring boards (PWBs), potting, and semiconductor
encapsulants.

Aerospace: In the aerospace industry, among others, epoxy is used as a structural glue
that is reinforced with glass, Kevlar, boron, or carbon fiber.
Epoxy Resin Applications
 Epoxy Resin Applications

Pouring electronics into resin is a common way to provide greater protection

against mechanical damage, high temperature, chemicals, and UV radiation. This
treatment allows you to significantly extend the life of electronic equipment.
Epoxy Resin Applications
 Epoxy Coatings
Epoxy coatings are popular because they provide a quick drying, tough, and
protective coating for metals and other materials.

White Goods Coating Applications: An epoxy coating is often used as the powder
coating on washers, driers, and other “white goods” because it is durable and easy
to apply.

Automotive and Marine Applications: An epoxy

coating will act as a primer to prevent corrosion
and ensure the adhesion of paints on automobiles
and boats.
 Epoxy Coatings

Steel Corrosion Resistant Coatings: Fusion Bonded Epoxy Powder Coatings are
used for corrosion protection in steel pipes and fittings used in the oil and gas
industry, water transmission pipelines, and concrete reinforcing rebar.

Metal Can and Container Coating: Metal cans and containers are often treated
with an epoxy coating to prevent rusting especially when used to package acidic
foods such as tomatoes

Flooring Applications: Epoxy coatings can be used

as epoxy floor paint in industrial or commercial
applications.