Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/04—Ingredients treated with organic substances
  • C08K9/06—Ingredients treated with organic substances with silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/36—Silica
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B82—NANOTECHNOLOGY
  • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
  • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/011—Nanostructured additives

Definitions

• Nanoparticle -enhanced thermoset resins have wide-ranging applications including fiber composites, sporting goods, jet engine parts, automotive parts, compressed gas cylinders, and compositions.
• One of the drivers for exploring the use of the nanoparticle resin modification is the enhanced strength/stiffness that is provided to composite parts using such resins, allowing for production of light-weight composite parts.
• the present invention provides a resin component.
• the resin component includes a curable resin.
• the resin component includes nanoparticles dispersed in the resin.
• the nanoparticles each independently include surface -bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups. At least one of the (Ci-C5o)hydrocarbyl groups is a (Ci-C5o)alkyl group and at least one of the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups is a (Ce- C5o)aryl group.
• the present invention provides a resin system.
• the resin system includes the resin component.
• the resin system also includes a curative component.
• the present invention provides a method of forming the resin system.
• the method includes combining the resin component with the curable component to form the resin system.
• the present invention provides a cured product of the resin system.
• the present invention provides a method of forming the cured product.
• the method includes curing a reaction mixture including the resin system. Curing the reaction mixture forms the cured product of the resin system.
• the present invention provides an article including the cured product of the resin system.
• the present invention provides a resin component including an epoxy resin.
• the epoxy resin is about 35 wt% to about 90 wt% of the resin component.
• the resin component includes nanoparticles dispersed in the resin.
• the nanoparticles have a particle size of about 5 nm to about 500 nm.
• the nanoparticles are about 15 wt% to about 65 wt% of the resin component.
• the nanoparticles each independently include surface -bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups.
• At least some of the (Ci-C5o)hydrocarbyl groups are chosen from a phenyl group and a (Ci-Cio)alkyl group, wherein the mole ratio of the phenyl group to the (Ci-Cio)alkyl group is about 95:5 to about 50:50.
• the resin component, resin systems including the same, and cured products thereof can have certain advantages over other curable materials and cured products thereof.
• the resin component of the present invention can have increased shelf life as compared to other resin components, such as by substantially maintaining its viscosity for a longer period of time than other curable resins.
• the resin system of the present invention can have lower viscosity than other resin systems, such that the resin system is processable and is suitable for resin transfer molding, filament winding, tow placement, resin infusion processes, pultrusion, or a combination thereof.
• the resin component contains a modified nanoparticle wherein at least one of the surface-bonded groups is selected to increase compatibility of the nanoparticle with the curable portion of the resin component.
• the resin component additionally contains a modified nanoparticle wherein a portion of the surface-bonded groups are selected to increase the hydrophobicity of the particle and the resin component.
• the resin component contains particles modified with one type of surface-bonded groups to increase compatibility and a second type of surface-bonded groups to increase hydrophobicity
• the resin component is characterized by having a viscosity which is sufficiently low to enable processing such as resin transfer molding, filament winding, tow placement, prepregging, resin infusion, pultrusion, and other similar processes.
• the viscosity of the resin component with both types of modifying groups above is equal to, less than, or significantly less than, the viscosity of a similar resin component with only the compatibilizing-type of surface modification.
• the cured product of the present invention can retain its glass transition temperature between relatively dry room temperature conditions and conditions that are hot, wet, or a combination thereof, more effectively than other cured products (e.g., less change in the T g after moisture exposure).
• the cured product of the present invention can absorb a lower weight percent of water from the air as compared to other cured products under the same conditions.
• the preservation of the glass transition temperature (e.g., less change in the T g after moisture exposure) and the rate and amount of water uptake from air are properties of the cured product that can be tuned by varying the type and distribution of the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups, the size of the nanoparticles, or a combination thereof.
• the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.
• substantially refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.
• substantially free of can mean having a trivial amount of, such that a composition is about 0 wt% to about 5 wt% of the material, or about 0 wt% to about 1 wt%, or about 5 wt% or less, or less than, equal to, or greater than about 4.5 wt%, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt% or less, or about 0 wt%.
• organic group refers to any carbon-containing functional group. Examples can include an oxygen-containing group such as an alkoxy group, aryloxy group, aralkyloxy group, oxo(carbonyl) group; a carboxyl group including a carboxylic acid, carboxylate, and a carboxylate ester; a sulfur-containing group such as an alkyl and aryl sulfide group; and other heteroatom-containing groups.
• Non-limiting examples of organic groups include OR, OOR, OC(0)N(R) 2 , CN, CF 3 , OCF 3 , R, C(O), methylenedioxy, ethylenedioxy, N(R) 2 , SR, SOR, SO2R, S0 2 N(R) 2 , SO3R, C(0)R, C(0)C(0)R, C(0)CH 2 C(0)R, C(S)R, C(0)OR, OC(0)R, C(0)N(R) 2 , OC(0)N(R) 2 , C(S)N(R) 2 , (CH 2 )o- 2 N(R)C(0)R, (CH 2 ) 0 - 2 N(R)N(R) 2 , N(R)N(R)C(0)R, N(R)N(R)C(0)OR, N(R)N(R)CON(R) 2 , N(R)S0 2 R, N(R)S0 2 N(R) 2 , N(R)C(0)OR
• substituted refers to the state in which one or more hydrogen atoms contained therein are replaced by one or more non-hydrogen atoms.
• functional group or “substituent” as used herein refers to a group that can be or is substituted onto a molecule or onto an organic group.
• substituents or functional groups include, but are not limited to, a halogen (e.g., F, CI, Br, and I); an oxygen atom in groups such as hydroxy groups, alkoxy groups, aryloxy groups, aralkyloxy groups, oxo(carbonyl) groups, carboxyl groups including carboxylic acids, carboxylates, and carboxylate esters; a sulfur atom in groups such as thiol groups, alkyl and aryl sulfide groups, sulfoxide groups, sulfone groups, sulfonyl groups, and sulfonamide groups; a nitrogen atom in groups such as amines, hydroxyamines, nitriles, nitro groups, N-oxides, hydrazides, azides, and enamines; and other heteroatoms in various other groups.
• a halogen e.g., F, CI, Br, and I
• an oxygen atom in groups such as hydroxy groups
• Non-limiting examples of substituents that can be bonded to a substituted carbon (or other) atom include F, CI, Br, I, OR, OC(0)N(R) 2 , CN, NO, N0 2 , ON0 2 , azido, CF 3 , OCF3, R, O (oxo), S (thiono), C(O), S(O), methylenedioxy, ethylenedioxy, N(R) 2 , SR, SOR, S0 2 R, S0 2 N(R) 2 , SO3R, C(0)R, C(0)C(0)R, C(0)CH 2 C(0)R, C(S)R, C(0)OR, OC(0)R, C(0)N(R) 2 , OC(0)N(R) 2 , C(S)N(R) 2 , (CH 2 )o- 2 N(R)C(0)R, (CH 2 ) 0 - 2 N(R)N(R) 2 , N(R)N(R)C(0)R, N(
• alkyl refers to straight chain and branched alkyl groups and cycloalkyl groups having from 1 to 40 carbon atoms, 1 to about 20 carbon atoms, 1 to 12 carbons or, in some embodiments, from 1 to 8 carbon atoms.
• straight chain alkyl groups include those with from 1 to 8 carbon atoms such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, and n-octyl groups.
• branched alkyl groups include, but are not limited to, isopropyl, iso-butyl, sec-butyl, t-butyl, neopentyl, isopentyl, and 2,2-dimethylpropyl groups.
• alkyl encompasses n-alkyl, isoalkyl, and anteisoalkyl groups as well as other branched chain forms of alkyl.
• Representative substituted alkyl groups can be substituted one or more times with any of the groups listed herein, for example, amino, hydroxy, cyano, carboxy, nitro, thio, alkoxy, and halogen groups.
• alkenyl refers to straight and branched chain and cyclic alkyl groups as defined herein, except that at least one double bond exists between two carbon atoms.
• alkenyl groups have from 2 to 40 carbon atoms, or 2 to about 20 carbon atoms, or 2 to 12 carbon atoms or, in some embodiments, from 2 to 8 carbon atoms.
• acyl refers to a group containing a carbonyl moiety wherein the group is bonded via the carbonyl carbon atom.
• the carbonyl carbon atom is bonded to a hydrogen forming a "formyl” group or is bonded to another carbon atom, which can be part of an alkyl, aryl, aralkyl cycloalkyl, cycloalkylalkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, heteroarylalkyl group or the like.
• An acyl group can include 0 to about 12, 0 to about 20, or 0 to about 40 additional carbon atoms bonded to the carbonyl group.
• An acyl group can include double or triple bonds within the meaning herein.
• An acryloyl group is an example of an acyl group.
• An acyl group can also include heteroatoms within the meaning herein.
• a nicotinoyl group (pyridyl-3 -carbonyl) is an example of an acyl group within the meaning herein.
• Other examples include acetyl, benzoyl, phenylacetyl, pyridylacetyl, cinnamoyl, and acryloyl groups and the like.
• the group containing the carbon atom that is bonded to the carbonyl carbon atom contains a halogen, the group is termed a "haloacyl" group.
• An example is a trifluoroacetyl group.
• aryl refers to cyclic aromatic hydrocarbon groups that do not contain heteroatoms in the ring.
• aryl groups include, but are not limited to, phenyl, azulenyl, heptalenyl, biphenyl, indacenyl, fluorenyl, phenanthrenyl, triphenylenyl, pyrenyl, naphthacenyl, chrysenyl, biphenylenyl, anthracenyl, and naphthyl groups.
• aryl groups contain about 6 to about 14 carbons in the ring portions of the groups.
• Aryl groups can be unsubstituted or substituted, as defined herein.
• Representative substituted aryl groups can be mono-substituted or substituted more than once, such as, but not limited to, a phenyl group substituted at any one or more of 2-, 3-, 4-, 5-, or 6-positions of the phenyl ring, or a naphthyl group substituted at any one or more of 2- to 8-positions thereof.
• heterocyclyl refers to aromatic and non-aromatic ring compounds containing three or more ring members, of which one or more is a heteroatom such as, but not limited to, N, O, and S.
• halo means, unless otherwise stated, a fluorine, chlorine, bromine, or iodine atom.
• hydrocarbon or “hydrocarbyl” as used herein refers to a molecule or functional group that includes carbon and hydrogen atoms.
• the term can also refer to a molecule or functional group that normally includes both carbon and hydrogen atoms but wherein all the hydrogen atoms are substituted with other functional groups.
• hydrocarbyl refers to a functional group derived from a straight chain, branched, or cyclic hydrocarbon, and can be alkyl, alkenyl, alkynyl, aryl, cycloalkyl, acyl, or any combination thereof. Hydrocarbyl groups can be shown as (C a -Cb)hydrocarbyl, wherein a and b are integers and mean having any of a to b number of carbon atoms.
• (Ci- C hydrocarbyl means the hydrocarbyl group can be methyl (Ci), ethyl (C2), propyl (C3), or butyl (C4), and (Co-Cb)hydrocarbyl means in certain embodiments there is no hydrocarbyl group.
• thermoset material refers to exposing to radiation in any form, heating, or allowing to undergo a physical or chemical reaction that results in hardening or an increase in viscosity.
• a thermoset material can be cured by heating or otherwise exposing to irradiation such that the material hardens.
• solvent refers to a liquid that can dissolve a solid, liquid, or gas.
• solvents are silicones, organic compounds, water, alcohols, ionic liquids, and supercritical fluids.
• room temperature refers to a temperature of about 15 °C to
• polymer refers to a molecule having at least one repeating unit and can include copolymers.
• the present invention provides a resin component.
• the resin component includes a curable resin, such as a thermoset resin.
• the resin component also includes nanoparticles.
• the nanoparticles are substantially homogeneously dispersed in the resin component.
• the nanoparticles each independently include surface -bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups. At least one of the (Ci-C5o)hydrocarbyl groups is a (Ci-C5o)alkyl group.
• the resin component can also include nanoparticles that are free of hydrophobic modification, that have a different modification, or can be free of nanoparticles other than the nanoparticles including the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups.
• the resin component can include one curable resin or more than more curable resin.
• the one or more curable resins can be any suitable proportion of the resin component, such that the resin component can be used as described herein.
• the one or more curable resins can be about 35 wt% to about 99 wt% of the resin component, about 35 wt% to about 90 wt%, about 35 wt% to about 60 wt%, about 35 wt% or less, or less than, equal to, or greater than about 36 wt%, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86, 88, 90, 92, 94, 96, 98, wt%, or about 99 wt% or more.
• the curable resin can be an epoxy resin, a curable imide resin (e.g., maleimide resins, but also including, for example, commercial K-3 polyiraides (available from DuPont) and polyiraides having a terminal reactive group such as acetylene, diacetylene, phenylethynyl, norbornene, nadirnide, or benzocyclobutane), a vinyl ester resin, an acrylic resin (e.g., (meth)acrylic esters or amides of polyols, epoxies, and amines), a bisbenzocyclobutane resin, a polycyanate ester resin, a diglycidyl ether of a bisphenol, or a combination thereof.
• the curable resins can be utilized in the form of monomers or prepolymers.
• Epoxy resins are well-known in the art and include compounds or mixtures of compounds which contain one or more epoxy groups.
• the compounds can be saturated or unsaturated, aliphatic, alicylic, aromatic, or heterocyclic, or can comprise combinations thereof.
• Compounds which contain more than one epoxy group e.g., poiyepoxides can be used.
• Poiyepoxides can include aliphatic or aromatic poiyepoxides.
• Aromatic poiyepoxides can be used, for example, for high temperature applications.
• Aromatic poiyepoxides are compounds containing at least one aromatic ring structure (e.g. a benzene ring) and more than one epoxy group, such as polyglycidyl ethers of polyhydric phenols (e.g., bisphenol A derivative resins, epoxy cresol- novolac resins, bisphenol F derivative resins, epoxy phenol-novolac resins), glycidyl esters of aromatic carboxylic acids, and glycidyl amines of aromatic amines.
• polyglycidyl ethers of polyhydric phenols e.g., bisphenol A derivative resins, epoxy cresol- novolac resins, bisphenol F derivative resins, epoxy phenol-novolac resins
• Aromatic poly epoxide can be a polyglycidyl ether of a polyhydric phenol.
• Aromatic poiyepoxides can include glycidyl esters of aromatic carboxylic acids, for example, phthalic acid diglycidyl ester, isophthalic acid diglycidyl ester, trimellitic acid triglycidyl ester, and pyromeilitic acid tetraglycidyl ester, and mixtures thereof; N- glycidylaminobenzenes, for example, M ,N-digly cidylbenzeneamine, bis(N,N-diglycidyl-4- aminophenyi)methane, l,3-bis(N,N-dig1ycidylamino)benzene, and N,N ⁇ digiyeidyl-4 ⁇ glycidyloxybenzeneamine, and mixtures thereof; and the polyglycidyl derivatives of polyhydric phenols,
• the poiyglycidyl ethers of polyhydric phenols can be the diglycidyl ethers of bisphenol that have pendant carbocyclic groups, such as 2,2-bis[4-(2,3-epoxypropoxy)p enyl]norcamphane, 2,2-bis[4-(2,3- epoxypropoxy)phenyI]decahydro-l,4,5,8-dimethanonaphthalene, or 9,9-bis[4-(2,3- epoxypropoxy)phenyI] fluorene .
• Aliphatic polyepoxides can include 3',4'-epoxycyclohexylmethyl-3,4- epoxycyclohexanecarboxylate, 3,4-epoxycyclohexyloxirane, 2-(3 ',4' -epoxycyclohexyl)-5, 1 ' ' -spiro- 3",4"-epoxycyclohexane-l,3-dioxane, bis(3,4-epoxycyclohexylmethyl)adipate, the diglycidyl ester of linoleic dimer acid, 1 ,4-bis(2,3-epoxypropoxy)butane, 4-( 1 ,2-epoxyethyl)- 1 ,2-epoxycyciohexane, 2,2- bis(3,4-epoxycyclohexy3)propane, poiyglycidyl ethers of aliphatic polyols such as
• Maleimide resins can include bismaleimides, polymaleirnides, or polyaminobismaleiraides, such as ⁇ , '-bismaleimides.
• the ⁇ , ⁇ '-bismaleimide can be a ⁇ , ⁇ '- bismaleimides of 1,2-ethanediamine, 1 ,6-hexanediamine, trimethyl- 1 ,6-hexanediamine, 1,4- benzenediamine, 4,4'-methylenebisbenzenamine, 2 -methyl- 1,4-benzenediamine, 3,3'- methylenebisbenzenamine, 3,3 '-sulfonylbisbenzenamine, 4,4'-sulfonylbisbenzenamine, 3,3'- oxybisbenzenamine, 4,4 ' -oxybi sbenzenamine, 4,4 ' -methyl enebiscyclohexanam ine, 1,3- benzenedimethanamme, 1,4-benzenedimethanamine, 4,4' ⁇ cyclohexan
• Co-reactants for use with bismaleiniides can include any of a wide variety of unsaturated organic compounds, such as those having multiple unsaturation (e.g., etliylenic, acetylenic, or both).
• acrylic acids and amides and the ester derivatives thereof for example, acrylic acid, methaciylic acid, acrylamide, methaciylamide, and methylmethacrylate; dicyanoethylene; tetracyanoethylene; allyl alcohol; 2,2'-diallylbisphenol A; 2,2 , -dipropenylbisphenol A; diallylphthalate: triallyhsocyanurate; triallylcyanurate; M-vinyl-2-pyrrolidinone; N -vinyl caprolactam: ethylene glycol dimethacrylate; diethylene glycol dimethaciy late; trimethyfolpropane triacrylate; tnmethylolpropane trimethacrylate; pentaerythritol tetramethacryiate; 4-allyl-2-methoxyphenol; triallyl trimellitate; di vinyl benzene; dicyclopentadienyl aery late; dicyciopenta
• Poiycyanate ester resins can include 1,2-dicyanatobenzene, 1,3-dicyanatobenzene, 1,4- dicyanatobenzene, 2,2'-dicyanatodiphenylmethane, 3,3 '-dicyanatodiphenylmethane, 4,4'- dicyanatodiphenylmetbane, and the dicyanates prepared from bisphenol A, bisphenol F, or bisphenol S. Tri- and higher functionality cyanate resins can be used.
• the resin component can include one type of nanoparticie having the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups or can include more than one type of such nanoparticles.
• the one or more hydrophobically-modified nanoparticles can form any suitable proportion of the resin component, such as about 1 wt% to about 65 wt% of the resin component, or about 15 wt% to about 65 wt%, or about 1 wt% or less, or less than, equal to, or greater than about 2 wt%, 4, 6, 8, 10, 12, 14, 15, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 1, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51 , 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 64 wt%, or about 65 wt% or more.
• the nanoparticles can include any suitable material, such as silica, titania, alumina, zirconia, vanadia, chromia, iron oxide, antimony oxide, tin oxide, calcium carbonate, calcite, or a combination thereof.
• the nanoparticles can be silica nanoparticles, and in some embodiments can be substantially free of materials other than silica.
• the resin component can be formed by combining the curable resin with a sol including the nanoparticles and a solvent, followed by evaporation of the solvent.
• the nanoparticles can have any suitable particle size (e.g., largest dimension of the particle), such as about 1 nm to less than about 1,000 nm, about 5 nm to about 500 nm, about 10 nm to about 200 nm, or about 1 nm or less, or less than, equal to, or greater than about 2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136, 138, 140, 142, 144, 146, 148, 150, 152, 154, 156, 158, 160, 165, 170, 175, 180, 185, 190, 195, 200, 210, 220, 230, 240, 250, 275, 300, 325, 350
• the particle size can be measured in any suitable way, such as via transmission electron microscopy (TEM).
• TEM transmission electron microscopy
• the nanoparticles have one average particle sizes.
• the nanoparticles are distributed across multiple particle sizes such that the nanoparticles have more than one average particle size, such as at least two average particle sizes.
• a first average particle size can be about 1 nm to less than about 1,000 nm, about 5 nm to about 500 nm, about 10 nm to about 200 nm, or about 1 nm or less, or less than, equal to, or greater than about 2, 3, 4, 5, 10, 20, 30, 40, 50, 75, 100, 125, 150, 175, 200, 225, 250, 275, 300, 350, 400, 450, 500, 600, 700, 800, 900 nm, or less than about 1000 nm
• a second average particle size can be about 1 nm to less than about 1,000 nm, about 5 nm to about 500 nm, about 10 nm to about 200 nm, or about 1 nm or less, or less than, equal to, or greater than about 2, 3, 4, 5, 10, 20, 30, 40, 50, 75, 100, 125, 150, 175, 200, 225, 250, 275, 300, 350, 400, 450, 500, 600, 700, 800, 900 nm, or less
• the nanoparticles can include one surface-bonded hydrophobically-modifying (Ci-).
• At least one of the surface-bonded hydrophobically- modifying (Ci-C5o)hydrocarbyl groups can be a (Ce-Cst aryl group, or a phenyl group.
• the (Ci- C5o)alkyl surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl group can be a (Ci-Cio)alkyl group.
• the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl group can be a methyl, ethyl, or isooctyl group.
• the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups can be derived from any suitable material, such as from monohydric alcohols, polyols, organosilanes, organotitanates, or combinations thereof.
• the surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl group can be bonded to the nanoparticle via a -SiR ⁇ R 2 - linker, such that the nanoparticle (NP) and the hydrophobically modifying (Ci-C5o)hydrocarbyl group (G) have the structure NP-SiR 1 R 2 -G, wherein R 1 and R 2 are chosen from a (Ci-Ci5)alkyl group, a (Ci-Ci5)alkoxy group, a (Ce- Ci8)aryl group, and an -0-C(0)-(Ci-Ci5)alkane group.
• modified nanoparticles including the surface-bonded hydrophobically-modifying
• (Ci-C5o)hydrocarbyl groups can be formed by reacting unmodified nanoparticles with a silane having the structure:
• R 1 , R 2 , and R 3 can be independently chosen to provide surface functionalization or to form a bond to the nanoparticle.
• R 1 , R 2 , and R 3 can be independently chosen from a (Ci-Ci5)alkyl group, a (Ci- Ci5)alkoxy group, a (C6-Ci8)aryl group, and an -0-C(0)-(Ci-Ci5)alkane group, wherein at least one of R 1 , R 2 , and R 3 is a (Ci-Ci5)alkoxy group or an -0-C(0)-(Ci-Ci5)alkane group.
• G can be the hydrophobically-modifying (Ci-C5o)hydrocarbyl group.
• the nanoparticle including the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl group can be formed via treatment of the nanoparticle with phenyltrimethyloxysilane, diphenyldimethoxysilane, triphenylmethoxysilane, isooctyltrimethoxysilane, diisooctyldimethoxysilane, triisooctylmethoxysilane, methyltrimethoxy silane, dimethyldimethoxy silane, trimethylmethoxy silane, phenyltriacetoxysilane, diphenyldiacetoxy silane, triphenylacetoxysilane, ethyltriacetoxy silane, diethyldiacetoxysilane, triethylacetoxysilane, methyltriacetoxy silane, dimethyldiacetoxy silane, trimethylacetoxysilane, isooctyltriacet
• the surface -bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups can include one kind of the (Ci-C5o)hydrocarbyl groups, or can include a blend of more than one kind of the (Ci-C5o)hydrocarbyl groups.
• the surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups can include a blend of a (C6-C5o)aryl group and a (Ci-C5o)alkyl group, such as a blend of a phenyl group and a (Ci-Cio)alkyl group (e.g., methyl, ethyl, or isooctyl).
• the surface- bonded hydrophobically-modifying (C6-C5o)aryl groups and the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl groups can have a mole ratio of about 99: 1 to about 1 :99, about 95:5 to about 50:50, about 90: 10 to about 70:30, or about 99: 1 or more, or less than, equal to, or greater than about 95:5, 90: 10: 88: 12, 86: 14, 84: 16, 82: 18, 80:20, 78:22, 76:24, 74:26, 72:28, 70:30, 65:35, 60:40, 55:45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85, 10:90, 5:95, or about 1 :99 or less.
• the resin component including the nanoparticles with surface -bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups including a blend of a (C6-C5o)aryl group and a (Ci-C5o)alkyl group can have any number of suitable properties.
• a cured product of the resin component and a curative component can absorb a smaller amount of moisture over a given time period as compared to a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component over the same time period and under the same conditions.
• a cured product of the resin component and a curative component can have a change in glass transition temperature between the two conditions of after drying for 10 days at 80 °C air at ambient humidity (e.g., uncontrolled humidity conditions) and after exposure to 85% humidity air at 85 °C for 10 days that is smaller than the depression or reduction in glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component between the same two conditions.
• a cured product of the resin component and a curative component can have a higher glass transition temperature after drying for 10 days at 80 °C air at low humidity as compared to the glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component under the same conditions.
• a cured product of the resin component and a curative component can have a higher glass transition temperature after exposure to 85% humidity air at 85 °C for 10 days as compared to the glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (C6-C5o)aryl group and the curative component under the same conditions.
• the nanoparticles, the curable resin, the resin component, the resin system, or a combination thereof can be substantially free of inorganic water-soluble salts, such as KOH, NaOH, NH4OH, or a combination thereof.
• inorganic water-soluble salts such as KOH, NaOH, NH4OH, or a combination thereof.
• Such salts can result from ion-exchange processes.
• the presence of such salts can cause an increase in viscosity.
• the present invention provides a resin system.
• the resin system includes the resin component and a curative component.
• the resin component can be any suitable embodiment of the resin component described herein, for example, including a curable resin and nanoparticles dispersed in the resin each independently including surface -bonded hydrophobically- modifying (Ci-C5o)hydrocarbyl groups, with at least one of the (Ci-C5o)hydrocarbyl groups being a (Ci- C5o)alkyl group.
• the resin system is a curable system; for example, the resin component and the curative component can be cured together to form a cured product thereof when placed under suitable conditions.
• the resin system can be a thermoset resin system, wherein heating of the resin system can cause the resin system to cure.
• the resin system can be substantially homogeneously mixed, such that the resin component and the curative component are substantially homogeneously mixed.
• the C5o)hydrocarbyl groups can form any suitable proportion of the resin system.
• the nanoparticles can be about 1 wt% to about 80 wt% of the resin system, about 15 wt% to about 50 wt%, about 20 wt% to about 45 wt%, or about 1 wt% or less, or less than, equal to, or greater than about 2 wt%, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 55, 60, 65, 70, 75 wt%, or about 80 wt% or more.
• the resin component can be any suitable proportion of the resin system.
• the resin component can be about 1 wt% to about 99 wt% of the resin system, about 60 wt% to about 90 wt% of the resin system, or about 1 wt% or less, or less than, equal to, or greater than about 2 wt%, 3, 4, 5, 6, 8, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 85, 90, 95, 96, 97, 98 wt%, or about 99 wt% or more.
• the curative component can form any suitable proportion of the resin system.
• the curative component can be about 1 wt% to about 99 wt% of the resin system, about 3 wt% to about 55 wt%, or about 1 wt% or less, or less than, equal to, or greater than about 2 wt%, 3, 4, 5, 6, 8, 10, 15, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, 97, 98 wt%, or about 99 wt% or more of the resin system.
• the curative component can be present in an amount of about 0.1 to about 2 times a stoichiometric amount of the curable resin (e.g., wherein a 1: 1 ratio is the amount of curative component such that all non-catalytic components thereof react completely with the resin component leaving substantially no excess resin component behind), such as about 0.1 times a stoichiometric amount of the curable resin or less, or less than, equal to, or greater than 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, or about 1.9 or more.
• the curative component can include any suitable component that can cure with (e.g., react with or catalyze to form a hardened material) the resin component.
• the curative component can include a curing agent, a catalyst, a crosslinker, or a combination thereof.
• the curing agent, crosslinker, or combination thereof can substantially form the entirety of the curative component, while in other embodiments other materials can be present in the curative component.
• the curative component can include an anhydride, an amine curing agent, an amide curing agent, a polycarboxylic acid, a polyphenol, or a combination thereof.
• the curative component can include a substituted or unsubstituted phthalic anhydride, a hydrogenated derivative of a substituted or unsubstituted phthalic anhydride, a dicyandiamide, a diaminodiphenylsulfone, or a combination thereof.
• Epoxy resin curing agents can include an anhydride such as a substituted or unsubstituted phthalic anhydride, a hydrogenated derivative of a substituted or unsubstituted phthalic anhydride, or chlorendic anhydride; an amine curing agent such as ethylenediamine, diethylenetriamine, aminoethylethanolamine, and the like, diaminodiphenylsulfone, 9,9-bis(4-aminophenyl)fluorene, 9,9- bis(3-chloro-4-(aminophenyl)fluorene; an amide curing agent such as dicyandiamide; a polycarboxylic acid such as adipic acid; a polyphenol such as bisphenol A; or a combination thereof.
• Examples of curing agents can include those disclosed in U.S. Patent No. 4,684,678 (Schultz et al), which is hereby incorporated by reference as if reproduced herein in its entirety.
• ⁇ , ⁇ '-bismaleimide resins can be cured using diamine curing agents, or by other mechanisms, e.g., co-cure with aromatic olefins (such as bis-allylphenyl ether, 4,4'-bis(o- propenylphenoxy)benzophenone, or ⁇ , ⁇ '-diallyl bisphenol A) or thermal cure via a self-polymerization mechanism.
• aromatic olefins such as bis-allylphenyl ether, 4,4'-bis(o- propenylphenoxy)benzophenone, or ⁇ , ⁇ '-diallyl bisphenol A
• Polycyanate resins can be crosslinked by application of heat and/or by using catalysts such as zinc octoate, tin octoate, zinc stearate, tin stearate, copper acetylacetonate, or chelates of iron, cobalt, zinc, copper, manganese, and titanium with bidentate ligands such as catechol.
• catalysts such as zinc octoate, tin octoate, zinc stearate, tin stearate, copper acetylacetonate, or chelates of iron, cobalt, zinc, copper, manganese, and titanium with bidentate ligands such as catechol.
• the viscosity of the resin system can be suitable for preparation of a composite article via a process requiring a low viscosity resin system, such as via resin transfer molding, filament winding, tow placement, resin infusion processes, pultrusion, or a combination thereof.
• the viscosity of the resin system can be any suitable viscosity.
• the resin system after mixing at room temperature, can have a room temperature complex viscosity of about 0.1 Pa s to about 300 Pa s, about 1 Pa-s to about 100 Pa s, or about O.
• Pa s or less or less than, equal to, or greater than about 0.5 Pa s , 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, or about 300 Pa s or more.
• the resin system can include any one or more optional ingredients, or can be free of any one of more optional ingredients.
• the resin system can optionally include, or be free of, a catalyst, dye, flame retardant, pigment, impact modifier, flow control agent, reactive diluent, de- foamer (e.g., to reduce foam upon mixing or using), a curing accelerator, a catalyst, filler, solvent, urea, or a combination thereof.
• the catalyst can be a thermally-activated catalytic agent, such as a Lewis acid or base, tertiary or quaternary amine, imidazole, complexed Lewis acid, or organometallic compounds or salts thereof.
• the resin system can have any water content which enables the cured parts to adequately perform in the end-use application. Understanding that water content can affect the T g , the performance considerations can include the maintenance of an adequate T g to preserve the necessary strength and modulus for the end-use application.
• the cured resin system can be substantially free of water.
• the cured resin system can have a water content of less than or equal to about 5 wt% of the resin system, or about 0 wt% to about 2 wt%, or about 0 wt%, or about 0.1 wt% or less, or less than, equal to, or greater than about 0.2, 0.3, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.5, 3, 3.5, 4, or 4.5 wt%.
• the present invention provides a method of forming the resin system.
• the method can be any suitable method that forms an embodiment of a resin system disclosed herein, such as including a resin component and a curative component, wherein the resin component includes a curable resin and nanoparticles dispersed in the resin each independently including surface- bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups, with at least one of the (Ci- C5o)hydrocarbyl groups being a (Ci-C5o)alkyl group.
• the method can include combining the resin component with the curable component to for the resin system.
• the method can include mixing the resin component and the curable component such that the resin component and the curable component are substantially homogeneously mixed.
• the present invention provides a cured product of the resin system.
• the cured product can be any suitable cured product of an embodiment of the resin system described herein, such as a cured product of a resin system including a resin component and a curative component, wherein the resin component includes a curable resin and nanoparticles dispersed in the resin each independently including surface -bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups, with at least one of the (Ci-C5o)hydrocarbyl groups being a (Ci-C5o)alkyl group.
• the cured product of the resin system can have any suitable properties consistent with the compositions of the resin systems described herein.
• the total moisture uptake can be about 0 wt% to about 3 wt%, or about 1.5 wt% to about 2.5 wt%, or about 0 wt%, or about 0.1 wt% or less, or less than, equal to, or greater than about 0.2 wt%, 0.3, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.8, or about 3 wt% or more.
• the glass transition temperature of the cured product of the resin system can have better retention under hot and wet conditions as compared to other resin systems.
• a change in glass transition temperature of the cured product between conditions of after 10 days at 80 °C air at ambient humidity (e.g., uncontrolled humidity) and after exposure to 85% humidity air at 85 °C for 10 days can be about 10 °C to about 60 °C, or about 25 °C to about 40 °C, or about 10 °C or less, or less than, equal to, or greater than about 15 °C, 20, 25, 26, 28, 30, 32, 34, 36, 38, 40, 45, 50, 55 °C, or about 60 °C or more.
• the cured product of the resin system can have any suitable water content.
• the cured product of the resin system can be substantially free of water.
• the cured product of the resin system can have a water content of less than or equal to about 5 wt% of the cured product, or about 0 wt% to about 2 wt%, or about 0 wt%, or about 0.1 wt% or less, or less than, equal to, or greater than about 0.2, 0.3, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, 2, 2.5, 3, 3.5, 4, or 4.5 wt%.
• the present invention provides a method of forming the cured product.
• the method can be any suitable method that forms an embodiment of the cured product formed herein, for example, a cured product of a resin system including a resin component and a curative component, wherein the resin component includes a curable resin and nanoparticles dispersed in the resin each independently including surface -bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups, with at least one of the (Ci-C5o)hydrocarbyl groups being a (Ci-C5o)alkyl group.
• the method can include mixing at least the resin component and the curative component to form the reaction mixture.
• the resin system can be a thermoset resin system, and curing the reaction mixture including the resin system can include heating the reaction mixture.
• the resin system can have a low viscosity such that it is readily processable via various techniques during formation of the cured product.
• the resin system can be of sufficiently high viscosity and have an appropriate rheological profile with temperature such that it is readily processable into a pre-preg (or a fabric which is pre-impregnated with the resin system).
• the curing can include application of heat, electron beam radiation, microwave radiation, ultraviolet or visual radiation, or a combination thereof.
• the method of forming the cured product can include a resin transfer molding process.
• Fibers can be first shaped into a preform which can then be compressed to final part shape in a metal mold. Hie resin system can then be pumped into the mold and heat-cured.
• the method of forming the cured product can include a filament winding process, which is typically used to prepare cylinders or other composites having a ci rcular or oval cross-sectional shape, in this process, a fiber tow or an array of tows is impregnated with the resin system by running it through a resin system bath and then winding the impregnated tow onto a mandrel. The resulting composite can then be heat-cured.
• a filament winding process which is typically used to prepare cylinders or other composites having a ci rcular or oval cross-sectional shape
• the method of forming the cured product can include a pultrusion process. Pultmsion is a continuous process used to prepare constant cross-section parts. The method can include wetting out a large array of continuous fibers in a bath of the resin system, then pulling the resulting wet array through a heated die, where trapped air is squeezed out and the resin system is cured.
• the method of forming the product can include forming a pre-preg (or a fabric which is pre-impregnated with the resin system), which is subsequently shaped and cured.
• the present invention provides an article including the cured product.
• the article can be any suitable article that includes an embodiment of the cured product described herein, for example, a cured product of a resin system including a resin component and a curative component, wherein the resin component includes a curable resin and nanoparticles dispersed in the resin each independently including surface -bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups, with at least one of the (Ci-C5o)hydrocarbyl groups being a (Ci-C5o)alkyl group.
• the article can include a composite including fibers impregnated with the cured product.
• the article can include a substrate including a coating that includes the cured product.
• An article including fibers can include any suitable type of fibers, such as organic or inorganic fibers, for example, carbon or graphite fibers, glass fibers, ceramic fibers, boron fibers, silicon carbide fibers, polyimide fibers, poiyamide fibers, polyethylene fibers, and the like, and combinations thereof.
• Fibers of carbon, glass, or poiyamide are can be used and can have advantages including low cost, good physical properties, and facile processing.
• Such fibers can be in the form of a unidirectional array of individual continuous fibers, woven fabric, knitted fabric, yarn, roving, braided constructions, or non-woven mat.
• a composite article can contain, e.g., about 30 vol % to about 80 vol% fibers, or about 45 vol% to about 70 vol % fibers, depending upon structural application requirements.
• Table 1 describes abbreviations used in the Examples.
• Table 2 describes materials used in the Examples.
• a master batch of IR-120 was rinsed with deionized water at 21°C until the eluent water was clear. The resulting cleaned ion exchange resin was then maintained at an approximately 90 wt% aqueous suspension.
• Example 3 The procedure generally described in Example 1 was repeated, wherein the 2.7 grams of PTMS was reduced to 2.4 grams, and the 0.36 grams IOTMS was increased to 0.71 grams, corresponding to a mole ratio of 80:20 phenyltrimethoxysilane isomeric octyltrimethpoxysilanes.
• Example 3 The procedure generally described in Example 1 was repeated, wherein the 2.7 grams of PTMS was reduced to 2.4 grams, and the 0.36 grams IOTMS was increased to 0.71 grams, corresponding to a mole ratio of 80:20 phenyltrimethoxysilane isomeric octyltrimethpoxysilanes.
• Example 3 The procedure generally described in Example 1 was repeated, wherein the 2.7 grams of PTMS was reduced to 2.4 grams, and the 0.36 grams IOTMS was increased to 0.71 grams, corresponding to a mole ratio of 80:20 phenyltrimethoxysilane isomeric octyltrime
• Example 1 The procedure generally described in Example 1 was repeated, wherein the 2.7 grams of PTMS was reduced to 2.1 grams, and the 0.36 grams IOTMS was increased to 1.1 grams, corresponding to a mole ratio of 70:30 phenyltrimethoxysilane isomeric octyltrimethpoxysilanes.
• NP1A 1.120 parts by weight NP1A was added to an open head stainless steel mixing vessel at 70 °F (21.1 °C). Most of 1.0 parts by weight 1M2P was then slowly mixed into to the NP 1 A by means of a pneumatically driven impeller. Separately, 0.0150 parts by weight PTMS was mixed with the remainder of the 1.0 part by weight 1M2P, after which it was added slowly to the vessel, and mixing continued for another 30 minutes at 70 °F (21.1 °C). This mixture was then fed into a 27-liter stainless steel continuous flow hydrothermal reactor, the known designs of which are described in Adschiri, et al., J. Am. Ceram. Soc, 75 (4), 1019-1022 (1992), U.S.
• Patent No. 5,453,262 (Dawson, et al.) and PCT published application No. WO 2009/120848 (Tiefenbruck, et al).
• Reactor temperature was 150 °C
• backpressure set 330 psi (2.3 MPa)
• the residence time was 35 minutes.
• the resultant functionalized nanoparticle sol was designated "FNP1A”.
• WFE Wiped Film Evaporator
• a feed mixture for Comparative Example A was processed as follows. 4.770 parts by weight FNP1A, 0.653 parts by weight FNP2A and 1.000 parts by weight EPON826 epoxy resin were transferred to a 380L kettle. The kettle was kept at 25°C and the components were agitated for 40 minutes, after which agitation was stopped and the feed mixture was allowed to settle for 1 hour. In most cases, phase separation occurred such that there was a clear solvent layer on top and an opaque emulsion layer in the bottom of the kettle. The clear solvent layer was removed by decanting, and weighed. The weight of the decanted material was calculated as a percentage of the original weight of the components added, and is reported in Table 4.
• the emulsion layer from the Phase Separation was metered into a WFE using a 1 square meter BUSS FILMTRUDER counter current polymer processor.
• the WFE rotor was set at a speed of 340 rpm with a 25 HP (18.6 KW) drive and steam zones 1 and 2 at a temperature of 108 °C, Zone 3 temperature of 144°C, Zone 4 temperature of 134°C and a vacuum level of between 3.6-3.9 KPa.
• the nanoparticle-containing resin system for CE-1 was designated Resin 1 as indicated in Table 4. The remainder of the Comparatives and Examples and the correlation to the Resin Number can be found in Table 6.
• Comparative Example A and C, and Examples 4 and 5 were prepared as generally described above, according to the conditions listed in Table 4. Parts by weight EPON826 was 1.00.
• a feed mixture for Comparative Example B was processed as follows. 5.9344 parts by weight FNP1B and 1.000 part by weight EPON826 epoxy resin were blended until homogeneous in a plastic container at 70 °F (21.1 °C). After agitation, the mixture was allowed to settle for approximately 1 hour, resulting in a clear solvent-rich upper layer, and an opaque emulsion in the bottom layer. The clear solvent-rich layer was decanted and weighed, and the weight percentage of the solvent layer determined, as reported in Table 5. 0.102 parts by weight EPON826, 0.250 parts by weight H107 and 0.307 parts by weight BA were added to the feed mixture and agitation resumed until homogeneous, approximately 15 minutes.
• the homogeneous emulsion was then fed into a stainless steel rolled film evaporator, model "KDL-6", 0.06 m 2 , obtained from ChemTech, Inc., Rockwell, Illinois.
• RFE conditions included a feed rate of 7 ml/min, a rotor speed 315 rpm, a vacuum of between 3.6-3.7 KPa, and a jacket temperature of 148°C.
• the distillate / condensate was collected in a trap cooled by a glycol water chiller held at 0°C.
• the nonvolatile RFE effluent product was collected in a separate vessel, and designated Resin 2.
• Examples 6-11 (Resins 6 through 11) were prepared as generally described above, and the feed mixtures were prepared according to the compositions listed in Table 5. With respect to Comparative B and Example 6, after the HTR Effluent (amounts in Table 5) was initially agitated with 1.00 parts by weight of EPON826, then allowed to settle for approximately 1 hour, a phase separation occurred. After the decant, the listed amounts (Table 5) of EPON826, H107 and BA were added. With respect to Examples 7 through 11, there was no initial phase separation when the HTR Effluent and 1.00 parts of the EPON826 epoxy resin were the only components agitated together.
• Comparative Examples B and C, and Examples 1 through 8 were prepared as generally described above, according to the compositions listed in Table 6.
• Comparative C and Examples 4 and 5 contain BYK as described in Tables 6 and 4.
• Cured material from Examples 1-3 was cut into 20 by 20 by 2 mm sections. Two sections were dried above desiccant in a sealed bottle for 48 hours at 65 °C. The sections were weighed, then placed above a layer of water in a desiccator. The desiccator was sealed and transferred to an oven set at 80 °C. The sections were removed on a weekly basis, blotted dry, and reweighed before returning them back to the desiccator. This process continued until no further weight gain was recorded, from which the total water uptake was determined. Water Uptake - Test Procedure 2.
• Silica content of resin components and cured resin samples was determined using a model TGA 500 thermogravimetric analyzer, obtained from TA Instruments, New Castle, Delaware. Samples were heated in air from 30°C to 850°C at 20°C/min. The noncombustible residue was taken to be the resin's original nanosilica content.
• Glass transition temperature (Tg) of Examples 1-3 was determined using a model RDA-
• T g of Examples 4- 1 1 and Comparative Examples A-C was determined using a model
• Comparative A the water uptake was reduced from 2.42 wt% down to 2.20 wt%. This corresponds to a lower water uptake in Comparative A which had a bi-modal size distribution of functionalized nanoparticles in the resin component, while Comparative B sample had a monomodal size distribution of functionalized nanoparticles in the resin component.
• Embodiment 1 provides a resin component comprising:
• nanoparticles dispersed in the resin each independently comprising surface- bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups, wherein at least one of the (Ci- C5o)hydrocarbyl groups is a (Ci-C5o)alkyl group.
• Embodiment 2 provides the resin component of Embodiment 1, wherein the curable resin is about 35 wt% to about 99 wt% of the resin component.
• Embodiment 3 provides the resin component of any one of Embodiments 1-2, wherein the curable resin is about 35 wt% to about 90 wt% of the resin component.
• Embodiment 4 provides the resin component of any one of Embodiments 1-3, wherein the curable resin is an epoxy resin, a curable imide resin, a vinyl ester resin, an acrylic resin, a bisbenzocyclobutane resin, a polycyanate ester resin, a maleimide resin, a diglycidyl ether of a bisphenol, or a combination thereof.
• the curable resin is an epoxy resin, a curable imide resin, a vinyl ester resin, an acrylic resin, a bisbenzocyclobutane resin, a polycyanate ester resin, a maleimide resin, a diglycidyl ether of a bisphenol, or a combination thereof.
• Embodiment 5 provides the resin component of any one of Embodiments 1-4, wherein the curable resin is an epoxy resin.
• Embodiment 6 provides the resin component of any one of Embodiments 1-5, wherein the nanoparticles are about 1 wt% to about 65 wt% of the resin component.
• Embodiment 7 provides the resin component of any one of Embodiments 1-6, wherein the nanoparticles are about 15 wt% to about 65 wt% of the resin component.
• Embodiment 8 provides the resin component of any one of Embodiments 1-7, wherein the nanoparticles comprise silica, titania, alumina, zirconia, vanadia, chromia, iron oxide, antimony oxide, tin oxide, calcium carbonate, calcite, or a combination thereof.
• Embodiment 9 provides the resin component of any one of Embodiments 1-8, wherein the nanoparticles are silica nanoparticles.
• Embodiment 10 provides the resin component of any one of Embodiments 1-9, wherein the nanoparticles have a particle size of about 1 nm to less than about 1,000 nm.
• Embodiment 1 1 provides the resin component of any one of Embodiments 1- 10, wherein the nanoparticles have a particle size of about 5 nm to about 500 nm.
• Embodiment 12 provides the resin component of any one of Embodiments 1- 1 1, wherein the nanoparticles have a particle size of about 10 nm to about 200 nm.
• Embodiment 13 provides the resin component of any one of Embodiments 1- 12, wherein the nanoparticles have at least two average particle sizes.
• Embodiment 14 provides the resin component of any one of Embodiments 1- 13, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl group is a (Ce-Cst aryl group.
• Embodiment 15 provides the resin component of any one of Embodiments 1- 14, wherein at least one of the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups is a phenyl group.
• Embodiment 16 provides the resin component of any one of Embodiments 1- 15, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl group is a (Ci-Cio)alkyl group.
• Embodiment 17 provides the resin component of any one of Embodiments 1- 16, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl group is a methyl, ethyl, or isooctyl group.
• Embodiment 18 provides the resin component of any one of Embodiments 1- 17, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups are derived from monohydric alcohols, polyols, organosilanes, organotitanates, or combinations thereof.
• Embodiment 19 provides the resin component of any one of Embodiments 1- 18, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl group is bonded to the nanoparticle via a -SiR ⁇ R 2 - linker, wherein R 1 and R 2 are independently chosen from a bond to the nanoparticle, a (Ci-Ci5)alkyl group, a (Ci-Ci5)alkoxy group, a (C6-Ci8)aryl group, and an -0-C(0)-(Ci- Ci5)alkane group.
• the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl group is bonded to the nanoparticle via a -SiR ⁇ R 2 - linker, wherein R 1 and R 2 are independently chosen from a bond to the nanoparticle, a (Ci-Ci5)alkyl group, a (Ci-Ci5)alkoxy group, a (C6-C
• Embodiment 20 provides the resin component of any one of Embodiments 1- 19, wherein the nanoparticles comprising the surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups are formed by reacting an unmodified nanoparticle with a silane having the structure:
• R 1 , R 2 , and R 3 are independently chosen from a (Ci-Ci5)alkyl group, a (Ci-Ci5)alkoxy group, a (C6-Ci8)aryl group, and an -0-C(0)-(Ci-Ci5)alkane group, wherein at least one of R 1 , R 2 , and R 3 is a (Ci-Ci5)alkoxy group or an -0-C(0)-(Ci-Ci5)alkane group, and
• G is the hydrophobically-modifying (Ci-C5o)hydrocarbyl group.
• Embodiment 21 provides the resin component of any one of Embodiments 1-20, wherein the nanoparticle comprising the surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl group is formed via treatment of the nanoparticle with phenyltrimethyloxysilane, diphenyldimethoxysilane, triphenylmethoxysilane, isooctyltrimethoxysilane, diisooctyldimethoxysilane, triisooctylmethoxysilane, methyltrimethoxysilane, dimethyldimethoxysilane, trimethylmethoxysilane, phenyltriacetoxysilane, diphenyldiacetoxysilane, triphenylacetoxysilane, ethyltriacetoxysilane, diethyldiacetoxysilane, triethylacetoxysilane, methyltriacetoxysilane,
• Embodiment 22 provides the resin component of any one of Embodiments 1-21, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups comprise a blend of more than one kind of the (Ci-C5o)hydrocarbyl groups.
• Embodiment 23 provides the resin component of any one of Embodiments 1-22, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups comprise a blend of more than one kind of (Ci-C5o)alkyl group.
• Embodiment 24 provides the resin component of any one of Embodiments 1-23, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups comprise a blend of a (C6-C5o) ryl group and the (Ci-C5o)alkyl group.
• Embodiment 25 provides the resin component of Embodiment 24, wherein the surface- bonded hydrophobically-modifying (C6-C5o) ryl groups and the surface-bonded hydrophobically- modifying (Ci-C5o)alkyl groups have a mole ratio of about 99: 1 to about 1 :99.
• Embodiment 26 provides the resin component of any one of Embodiments 24-25, wherein the surface-bonded hydrophobically-modifying (Ce-Cst aryl groups and the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl groups have a mole ratio of about 95:5 to about 50:50.
• Embodiment 27 provides the resin component of any one of Embodiments 24-26, wherein the surface-bonded hydrophobically-modifying (Ce-Cst aryl groups and the surface-bonded hydrophobically-modifying (Ci-C5o)alkyl groups have a mole ratio of about 90: 10 to about 70:30.
• Embodiment 28 provides the resin component of any one of Embodiments 24-27, wherein a cured product of the resin component and a curative component absorbs a smaller amount of moisture over a given time period as compared to a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component over the same time period and under the same conditions.
• Embodiment 29 provides the resin component of any one of Embodiments 24-28, wherein a cured product of the resin component and a curative component has a change in glass transition temperature between the two conditions of after drying for 10 days at 80 °C air at low humidity and after exposure to 85% humidity air at 85 °C for 10 days that is smaller than the change in glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component under the same two conditions.
• Embodiment 30 provides the resin component of any one of Embodiments 24-29, wherein a cured product of the resin component and a curative component has a higher glass transition temperature after drying for 10 days at 80 °C air at low humidity as compared to the glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (C6-C5o) ryl group and the curative component under the same conditions.
• Embodiment 31 provides the resin component of any one of Embodiments 24-30, wherein a cured product of the resin component and a curative component has a higher glass transition temperature after exposure to 85% humidity air at 85 °C for 10 days as compared to the glass transition temperature observed for a cured product of a corresponding resin component having a lower mole ratio of the (Ci-C5o)alkyl group to the (Ce-Cst aryl group and the curative component under the same conditions.
• Embodiment 32 provides the resin component of any one of Embodiments 1-31, wherein the surface-bonded hydrophobically-modifying (Ci-C5o)hydrocarbyl groups comprise a blend of a phenyl group and a (Ci-Cio)alkyl group.
• Embodiment 33 provides the resin component of any one of Embodiments 1-32, wherein the nanoparticles, the curable resin, the resin component, or a combination thereof, are substantially free of inorganic water-soluble salts.
• Embodiment 34 provides the resin component of any one of Embodiments 1-33, wherein the nanoparticles, the curable resin, the resin component, or a combination thereof, are substantially free of KOH, NaOH, NH4OH, or a combination thereof.
• Embodiment 35 provides a resin system comprising
• Embodiment 36 provides the resin system of Embodiment 35, wherein the resin component and the curative component are substantially homogeneously mixed.
• Embodiment 37 provides the resin system of any one of Embodiments 35-36, wherein the resin system is a curable system.
• Embodiment 38 provides the resin system of any one of Embodiments 35-37, wherein the nanoparticles are about 1 wt% to about 80 wt% of the resin system.
• Embodiment 39 provides the resin system of any one of Embodiments 35-38, wherein the nanoparticles are about 15 wt% to about 50 wt% of the resin system.
• Embodiment 40 provides the resin system of any one of Embodiments 35-39, wherein the resin system is a thermoset resin system.
• Embodiment 41 provides the resin system of any one of Embodiments 35-40, wherein the resin component is about 1 wt% to about 99 wt% of the resin system.
• Embodiment 42 provides the resin system of any one of Embodiments 35-41, wherein the resin component is about 60 wt% to about 90 wt% of the resin system.
• Embodiment 43 provides the resin system of any one of Embodiments 35-42, wherein the curative component is about 1 wt% to about 99 wt% of the resin system.
• Embodiment 44 provides the resin system of any one of Embodiments 35-43, wherein the curative component is about 3 wt% to about 55 wt% of the resin system.
• Embodiment 45 provides the resin system of any one of Embodiments 35-44, wherein the curative component is present in an amount of about 0.1 to about 2 times a stoichiometric amount of the curable resin.
• Embodiment 46 provides the resin system of any one of Embodiments 35-45, wherein the curative component comprises a curing agent, a catalyst, a crosslinker, or a combination thereof.
• Embodiment 47 provides the resin system of any one of Embodiments 35-46, wherein the curative component comprises an anhydride, an amine curing agent, an amide curing agent, a polycarboxylic acid, a polyphenol, or a combination thereof.
• the curative component comprises an anhydride, an amine curing agent, an amide curing agent, a polycarboxylic acid, a polyphenol, or a combination thereof.
• Embodiment 48 provides the resin system of any one of Embodiments 35-47, wherein the curative component is a substituted or unsubstituted phthalic anhydride, a hydrogenated derivative of a substituted or unsubstituted phthalic anhydride, a dicyandiamide, a diaminodiphenylsulfone, or a combination thereof.
• the curative component is a substituted or unsubstituted phthalic anhydride, a hydrogenated derivative of a substituted or unsubstituted phthalic anhydride, a dicyandiamide, a diaminodiphenylsulfone, or a combination thereof.
• Embodiment 49 provides the resin system of any one of Embodiments 35-48, wherein the viscosity of the resin system is suitable for preparation of a composite article via resin transfer molding, filament winding, tow placement, resin infusion processes, pultrusion, or a combination thereof.
• Embodiment 50 provides the resin system of any one of Embodiments 35-49, further comprising a catalyst, dye, flame retardant, pigment, impact modifier, flow control agent, reactive diluent, de-foamer, a curing accelerator, a catalyst, filler, solvent, urea, or a combination thereof.
• Embodiment 51 provides the resin system of any one of Embodiments 35-50, wherein after mixing at room temperature the resin system has a room temperature complex viscosity of 0.1 Pa- s to about 300 Pa s.
• Embodiment 52 provides the resin system of any one of Embodiments 35-51, wherein after mixing at room temperature the resin system has a room temperature complex viscosity of about 1 Pa s to about 100 Pa s.
• Embodiment 53 provides a method of forming the resin system of any one of
• Embodiments 35-52 comprising combining the resin component with the curable component to form the resin system.
• Embodiment 54 provides a cured product of the resin system of any one of
• Embodiment 55 provides the cured product of Embodiment 54, wherein after exposure to 85 °C air with 85% humidity after 11 days the total moisture uptake is about 0 wt% to about 3 wt%.
• Embodiment 56 provides the cured product of any one of Embodiments 54-55, wherein after exposure to 85 °C air with 85% humidity after 11 days the total moisture uptake is about 1.5 wt% to about 2.5 wt%.
• Embodiment 57 provides the cured product of any one of Embodiments 54-56, wherein a change in glass transition temperature of the cured product between conditions of after 10 days at 80 °C air at low humidity and after exposure to 85% humidity air at 85 °C for 10 days is about 10 °C to about 60 °C.
• Embodiment 58 provides the cured product of any one of Embodiments 54-57, wherein a change in glass transition temperature of the cured product between conditions of after 10 days at 80 °C air at low humidity and after exposure to 85% humidity air at 85 °C for 10 days is about 25 °C to about 40 °C.
• Embodiment 59 provides the cured product of any one of Embodiments 54-58, wherein the cured product has a water content of less than or equal to about 5 wt%.
• Embodiment 60 provides the cured product of any one of Embodiments 54-59, wherein the cured product has a water content of about 0 wt% to about 2 wt%.
• Embodiment 61 provides a method of forming the cured product of any one of
• Embodiments 54-60 the method comprising:
• Embodiment 62 provides the method of Embodiment 61, further comprising mixing at least the resin component and the curative component to form the reaction mixture.
• Embodiment 63 provides the method of any one of Embodiments 61-62, wherein curing the reaction mixture comprising the resin system comprises heating the reaction mixture.
• Embodiment 64 provides an article comprising the cured product of any one of
• Embodiment 65 provides the article of Embodiment 64, wherein the article comprises a composite comprising fibers impregnated with the cured product.
• Embodiment 66 provides the article of any one of Embodiments 64-65, wherein the article comprises a substrate comprising a coating comprising the cured product.
• Embodiment 67 provides a resin component comprising:
• an epoxy resin wherein the epoxy resin is about 35 wt% to about 90 wt% of the resin component;
• nanoparticles dispersed in the resin the nanoparticles having a particle size of about 5 nm to about 500 nm, wherein the nanoparticles are about 15 wt% to about 65 wt% of the resin component, the nanoparticles each independently comprising surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups, wherein at least some of the (Ci-C5o)hydrocarbyl groups are chosen from a phenyl group and a (Ci-Cio)alkyl group, wherein the mole ratio of the phenyl group to the (Ci-Cio)alkyl group is about 95 :5 to about 50:50.
• surface-bonded hydrophobically-modifying (Ci- C5o)hydrocarbyl groups wherein at least some of the (Ci-C5o)hydrocarbyl groups are chosen from a phenyl group and a (Ci-Cio)alkyl group, wherein the mo
• Embodiment 68 provides the resin component, resin system, cured product, method, or article of any one or any combination of Embodiments 1-67 optionally configured such that all elements or options recited are available to use or select from.

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