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Epoxy
or polyepoxide is a thermosetting epoxide polymer
that cures when mixed with a catalyzing agent
or "hardener". Most common epoxy resins
are produced from a reaction between epichlorohydrin
and bisphenol-A. The first commercial attempts
to prepare resins from epichlorohydrin occurred
in 1927 in the United States. Credit for the first
synthesis of bisphenol-A based epoxy resins is
shared by Dr. Pierre Castan of Switzerland and
Dr. S.O. Greenlee in the United States in 1936.
Dr. Castan's work was licensed by Ciba, Ltd. of
Switzerland and Ciba went on to become one of
the 3 major epoxy resin producers worldwide. The
epoxy business of Ciba was spun-off and later
sold in the late 1990s and is now the Advanced
Materials Business unit of Huntsman Corporation
of the United States. Dr. Greenlee's work was
for a company called Devoe-Reynolds of the United
States. Devoe-Reynolds was a player in the early
days of the epoxy resin industry, but later sold
its business to Shell Chemical (now Resolution
Polymers). |
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Industry |
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Today
the epoxy industry amounts to more than US$5 billion
in North America and about US$15 billion world-wide.
It is made up of approximately 50 - 100 manufacturers
of basic or commodity epoxy resins and hardeners of
which the big 3 are Resolution Polymers (formerly Shell;
whose epoxy tradename is "Epon"), Dow Chemical
(tradename "D.E.R."), & Huntsman Advanced
Materials (formerly Ciba; tradename "Araldite").
The other 50+ smaller epoxy manufacturers primarily
produce epoxies only regionally (not world-wide), produce
epoxy hardeners only, produce specialty epoxies, or
produce epoxy modifiers.
These commodity epoxy manufacturers
mentioned above typically do not sell epoxy resins in
a form usable to most end users, so there is another
group of companies that purchase epoxy raw materials
from the major producers and then compounds (blends,
modifies, or otherwise customizes) epoxy systems out
of these raw materials. This class of companies is typically
known as "formulators". The vast majority
of the epoxy systems sold are produced by these smaller
formulators and they account for greater than 60% of
the dollar value of the overall epoxy market. There
are hundreds of ways that these formulators can modify
epoxies — by adding mineral fillers (ex. talc, silica,
alumina, etc.), by adding flexibilizers, viscosity reducers,
colorants, thickeners, accelerators, adhesion promoters,
etc. These modifications are made to reduce costs, to
improve performance, and to improve processing convenience.
As a result a typical formulator sells dozens, hundreds,
or even thousands of formulations — each carefully tailored
to the requirements of a particular application or market.
The applications for epoxy based materials
are extensive and include coatings, adhesives and composite
materials like carbon fiber and glass-reinforced plastic
(although polyester, vinyl ester, and other thermosetting
resins are also used for glass-reinforced plastic).
The chemistry of epoxies and the range of commercially
available variations allows cure polymers to be produced
with a very broad range of properties. In general, epoxies
are known for their excellent adhesion, chemical and
heat resistance, good to excellent mechanical properties
and very good electrical insulating properties, but
almost any property can be modified (for example silver-filled
epoxies with good electrical conductivity are widely
available even though epoxies are typically electrically
insulating).
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| Epoxies find significant use in many applications
including the following: |
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Paints and coatings |
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Examples
include powder coatings for washers, driers and other
"white goods". Epoxy coatings are also widely
used as primers to improve the adhesion of automotive
and marine paints especially on metal surfaces where
corrosion (rusting) resistance is important. Metal cans
and containers are often coated with epoxy coatings
to prevent rusting especially for foods like tomatoes
that are acidic. Epoxy resins are also used for high
performance & decorative flooring applications especially
terrazzo flooring, Chip Flooring [1]and colored aggregate
flooring
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Adhesives |
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Epoxy
adhesives are a major part of the class of adhesives
called "structural adhesives" or "engineering
adhesives" (which also includes polyurethane, acrylic,
cyanoacrylate, and other chemistries.) These high performance
adhesives are used in the construction of airplanes,
automobiles, bikes, golf clubs, skis, snow boards, and
many other applications where high strength bonds are
required. Epoxy adhesives can be developed that meet
almost any application. They are exceptional adhesives
for wood, metal, glass, stone, and some plastics. They
can be made flexible or rigid, transparent or opaque/colored,
fast setting or extremely slow. Epoxy adhesives are
almost unmatched in heat and chemical resistance among
common adhesives. In general, epoxy adhesives cured
with heat will be more heat and chemical resistant then
the same formulation cured at room temperature.
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Industrial tooling and composites |
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Epoxy
systems are also used in industrial tooling applications
to produce molds, master models, laminates, castings,
fixtures, and other industrial production aids. This
"plastic tooling" replaces metal, wood and
other traditional materials and generally improved the
efficiency and either lowers the overall cost or shortens
the lead-time for many industrial processes. Epoxies
are also used in producing fiber reinforced or composite
parts. They are more expensive than polyester resins
and vinyl ester resins, but generally produce stronger
more temperature resistant composite parts.
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Electrical systems and electronics |
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Epoxy
resin formulations are also important in the electronics
industry and are used in many parts of electrical systems.
In electrical power generation, epoxy systems encapsulate
or coat motors, generators, transformers, switchgear,
bushings, and insulators. Epoxy resins are excellent
electrical insulation materials and they protect electrical
components from short circuiting, dust, humidity and
other environmental factors that could damage the electrical
equipment. In the electronics industry, epoxy resins
are the primary resin used in overmolding integrated
circuits and transistors, and making printed circuit
boards. The largest volume type of circuit board - an
"FR-4 board" - is nothing but a sandwich of
several layers of glass cloth bonded together into a
composite by an epoxy resin. Epoxy resins are also used
in bonding copper foil to circuit board substrates and
are a major component of the solder mask used on many
circuit boards.
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Consumer and marine applications |
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Epoxies
are sold in many hardware stores - typically as two
component kits. They are also sold in many boat shops
as repair resins for marine applications. Epoxies typically
are not the outer layer of a boat because they are negatively
affected by long term exposure to UV light. But they
are often used during boat repair and assembly and then
are over coated with polyester gel coats or marine varnishes
that protect the epoxies from UV exposure. Epoxies are
fairly easy to distinguish from polyester thermosets,
as commercially marketed epoxy materials typically use
1:1 ratio of resin to hardener, or similar convenient
mix ratio, while polyester thermoset materials typically
use a ratio of at least 10:1 between resin to hardener
(or "catalyst." Also, epoxy materials tend
to harden somewhat more gradually, while polyester materials
tend to harden more abruptly. |
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