Description

Epoxy is a term used to denote both the basic components and the cured end products of epoxy resins, as well as a colloquial name for the epoxide functional group. Epoxy resins, also known as polyepoxides are a class of reactive prepolymers and polymers which contain epoxide groups. Epoxy resins may be reacted (cross-linked) either with themselves through catalytic homopolymerisation, or with a wide range of co-reactants including polyfunctional amines, acids (and acid anhydrides), phenols, alcohols and thiols. These co-reactants are often referred to as hardeners or curatives, and the cross-linking reaction is commonly referred to as curing. Reaction of polyepoxides with themselves or with polyfunctional hardeners forms a thermosetting polymer, often with high mechanical properties, temperature and chemical resistance. Epoxy has a wide range of applications, including metal coatings, use in electronics / electrical components, high tension electrical insulators, fiber-reinforced plastic materials and structural adhesives.

Bisphenol A Epoxy Resin
The most common and important class of epoxy resins is formed from reacting epichlorhydrin with bisphenol A to form diglycidyl ethers of bisphenol A. The simplest resin of this class is formed from reacting two moles of epichlorhydrin with one mole of bisphenol A to form the bisphenol A diglycidyl ether (commonly abbreviated to DGEBA or BADGE). DGEBA resins are transparent colourless-to-pale-yellow liquids at room temperature, with viscosity typically in the range of ***5 Pa.s at *5°C. Industrial grades normally contain some distribution of molecular weight, since pure DGEBA shows a strong tendency to form a crystalline solid upon storage at ambient temperature.

Bisphenol F Epoxy Resin
Bisphenol F may also undergo epoxidation in a similar fashion to bisphenol A. Compared to DGEBA, bisphenol F epoxy resins have lower viscosity and a higher mean epoxy content per gramme, which (once cured) gives them increased chemical resistance.

Novolac Epoxy Resin
Reaction of phenols with formaldehyde and subsequent glycidylation with epichlorhydrin produces epoxidised novolacs, such as epoxy phenol novolacs (EPN) and epoxy cresol novolacs (ECN). These are highly viscous to solid resins with typical mean epoxide functionality of around 2 to 6. The high epoxide functionality of these resins forms a highly crosslinked polymer network displaying high temperature and chemical resistance, but low flexibility.

Aliphatic Epoxy Resin
Aliphatic epoxy resins are typically formed by glycidylation of aliphatic alcohols or polyols. The resulting resins may be monofunctional (e.g. dodecanol glycidyl ether), difunctional (butanediol diglycidyl ether), or higher functionality (e.g. trimethylolpropane triglycidyl ether). These resins typically display low viscosity at room temperature (*****0 mPa.s) and are often referred to as reactive diluents. They are rarely used alone, but are rather employed to modify (reduce) the viscosity of other epoxy resins. This has led to the term ‘modified epoxy resin’ to denote those containing viscosity-lowering reactive diluents. A related class is cycloaliphatic epoxy resin, which contains one or more cycloaliphatic rings in the molecule (e.g. 3,*-epoxycyclohexylmethyl*3,*-epoxycyclohexane carboxylate). This class also displays low viscosity at room temperature, but offers significantly higher temperature resistance than the aliphatic epoxy diluents. However, reactivity is rather low compared to other classes of epoxy resin, and high temperature curing using suitable accelerators is normally required.

Glycidylamine Epoxy Resin
Glycidylamine epoxy resins are higher functionality epoxies which are formed when aromatic amines are reacted with epichlorhydrin. Important industrial grades are triglycidyl-p-aminophenol (functionality 3) and N,N,N,N-tetraglycidyl*4,*-methylenebis benzylamine (functionality 4). The resins are low to medium viscosity at room temperature, which makes them easier to process than EPN or ECN resins. This coupled with high reactivity, plus high temperature resistance and mechanical properties of the resulting cured network makes them important materials for aerospace composite applications.

Applications: Paints and coatings, Adhesives, Industrial tooling and composites, Electrical systems and electronics, Consumer and marine applications, Aerospace applications