Core-shell polymer-containing epoxy resin composition, cured product thereof and method for preparing the same

A method for preparing a core-shell polymer-containing epoxy resin composition, the method comprising:

• mixing an aqueous media dispersion in which a core-shell polymer is dispersed in an aqueous media with an organic solvent having a solubility to water at 20° C. of from 5% by weight to 40% by weight, and mixing the resulting mixture with excess water such that a slurry solution comprising floating aggregates of the core-shell polymer is obtained;
• separating the floating aggregates of the core-shell polymer from a liquid phase to collect the core-shell polymer;
• mixing the collected core-shell polymer with an organic solvent such that a dispersion containing the core-shell polymer and the organic solvent is prepared;
• mixing the dispersion containing the core-shell polymer and the organic solvent with an epoxy resin;
• and
• distilling the organic solvent from the mixture of the dispersion containing the core-shell polymer and the epoxy resin, thereby preparing the core-shell polymer-containing epoxy resin composition,
• wherein the core-shell polymer-containing epoxy resin composition comprises:
• the epoxy resin;
• and
• from 1 to 100 parts by weight of the core-shell polymer with respect to 100 parts by weight of the epoxy resin,
• wherein the core-shell polymer has a volume average particle diameter of from 0.01 to 1 μm,
• a core part of the core-shell polymer has a glass transition temperature of less than 0° C.,
• a shell part of the core-shell polymer has a glass transition temperature of less than 25° C.,
• wherein the shell part of the core-shell polymer is obtained by polymerizing from 5 to 99% by weight of at least one monomer selected from the group consisting of alkoxy alkyl (meth)acrylate, methyl acrylate, ethyl acrylate, from 1 to 50% by weight of a monomer comprising an epoxy group, wherein the monomer comprising an epoxy group is at least one monomer selected from the group consisting of glycidyl (meth)acrylate, allyl glycidyl ether, and glycidyl alkyl (meth)acrylate, and from 0 to 50% by weight of other vinyl monomer, and
• wherein the epoxy resin comprises at least one polyepoxide selected from the group consisting of a polyglycidyl ether, a polyglycidylamine compound, an alicyclic epoxy resin, an addition reaction product of polyhydric alcohols and epichlorohydrin, a halogenated epoxy resin, and a hompolymer or copolymer of monomers containing unsaturated monoepoxide.