NZ734958B2 - Fillers - Google Patents

Fillers

Info

Publication number
NZ734958B2
NZ734958B2 NZ734958A NZ73495816A NZ734958B2 NZ 734958 B2 NZ734958 B2 NZ 734958B2 NZ 734958 A NZ734958 A NZ 734958A NZ 73495816 A NZ73495816 A NZ 73495816A NZ 734958 B2 NZ734958 B2 NZ 734958B2
Authority
NZ
New Zealand
Prior art keywords
resin
composition
gel coat
hydrophilic
cured
Prior art date
Application number
NZ734958A
Other versions
NZ734958A (en
Inventor
Owen H Decker
pamela Duncan
Kurt Kirby
Jeffrey J Laven
Original Assignee
Polynt Composites Usa Inc
Filing date
Publication date
Priority claimed from US14/631,984 external-priority patent/US10160882B2/en
Application filed by Polynt Composites Usa Inc filed Critical Polynt Composites Usa Inc
Publication of NZ734958A publication Critical patent/NZ734958A/en
Publication of NZ734958B2 publication Critical patent/NZ734958B2/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B13/00—Conditioning or physical treatment of the material to be shaped
    • B29B13/06—Conditioning or physical treatment of the material to be shaped by drying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/12—Making granules characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/22—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2503/00—Use of resin-bonded materials as filler
    • B29K2503/04—Inorganic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • 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
    • 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
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/15—Heterocyclic compounds having oxygen in the ring
    • C08K5/151—Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
    • C08K5/1535—Five-membered rings
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D167/06—Unsaturated polyesters having carbon-to-carbon unsaturation
    • C09D167/07—Unsaturated polyesters having carbon-to-carbon unsaturation having terminal carbon-to-carbon unsaturated bonds

Abstract

powdered filler composed of solid particles of a cured thermosetting composition comprising a resin modifier such as fumed silica, methods of preparing the cured solid particles, compositions comprising the powdered filler, and articles made from the compositions are disclosed. In embodiments, the solid particles are spherical shaped, transparent or translucent, and have a mean particle size of less than 20 µm.

Claims (14)

What is claimed:
1. A method of preparing a powdered resin filler, comprising: a) combining a thermosetting ethylenically-unsaturated curable composition, a surfactant, a curing agent and a hydrophilic resin modifier to form a resin blend composition, wherein the hydrophilic resin modifier is hydrophilic fumed silica; b) dispersing the resin blend composition in an aqueous medium to form an oil-in- water emulsion or dispersion; c) curing the oil-in-water emulsion or dispersion to form a particle slurry; and d) drying the particle slurry to a powder form comprising resin particles having a mean particle size of 1 to 20 µm.
2. The method of Claim 1, wherein the resin particles are transparent or translucent.
3. The method of Claim 1, wherein the resin particles are substantially spherical shaped.
4. The method of Claim 1, further comprising, after drying the particle slurry, reducing the size of the particles.
5. The method of Claim 1, wherein the cure of the aqueous emulsion or dispersion is initiated at 0 to 65°C.
6. The method of Claim 1, wherein drying the particle slurry is at a temperature of 50 to 150°C for 2 to 60 hours.
7. The method of any of the foregoing claims, wherein the thermosetting ethylenically- unsaturated curable composition is in an amount greater than the hydrophilic resin modifier.
8. A powdered filler consisting essentially of cured resin particles prepared by the method of any of the foregoing claims. 29 of 31 20504857_1 (GHMatters) P43299NZ00
9. A powdered filler, consisting essentially of cured resin particles having a mean particle size of 1 to 20 µm, wherein the resin particles are the reaction product of curing a resin blend composition in an oil-in-water emulsion or dispersion comprising: A. a thermosetting ethylenically-unsaturated curable composition; B. surfactant; C. hydrophilic resin modifier, wherein the hydrophilic resin modifier is hydrophilic fumed silica; and D. curing agent. wherein the thermosetting ethylenically-unsaturated curable composition is in an amount greater than the hydrophilic resin modifier.
10. The powdered filler of Claims 8 or 9, wherein the resin blend composition comprises: A. 75 to 98 Wt. % ethylenically-unsaturated thermosetting composition; B. 0.5 to 5 Wt. % surfactant; C. 0.5 to 12 Wt.% hydrophilic resin modifier; and D. 0.5 to 5 Wt. % curing agent; the Wt. % based on the total weight of the resin blend composition.
11. A gel coat composition, comprising: the powdered filler of claims 8 or 9 dispersed in a resin matrix; the resin particles comprising a cured thermoset composition and a hydrophilic resin modifier, wherein the resin particles are visually non-differentiable from the resin matrix.
12. A gel coat composition of Claim 11 with an L value of 6 to 7.2.
13. A method of preparing a gel coat composition, comprising combining 50 to 99 Wt.% gel coat composition and 1 to 50 Wt.% of the powdered filler of Claims 8 or 9, based on the total weight of the gel coat composition. 30 of 31 20504857_1 (GHMatters) P43299NZ00
14. A method of preparing a gel coated article, comprising: A. Applying a layer of a gel coat composition to a surface of a mold, the gel coat composition comprising a resin matrix with the powdered filler of Claims 8 or 9 dispersed therein; B. Allowing the gel coat composition to partially cure; C. Applying a composite material and laminating resin onto the layer of the partially cured gel coat composition; D. Allowing the gel coat composition and laminating resin to cure within the mold to form a composite article having a surface coated with the cured gel coat; and E. Removing the gel coated article from the mold; wherein the resin particles of the powder filler in the gel coat are visually non-differentiable from the resin matrix of the cured gel coat.
NZ734958A 2016-02-25 Fillers NZ734958B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/631,984 US10160882B2 (en) 2015-02-26 2015-02-26 Fillers
PCT/US2016/019526 WO2016138243A1 (en) 2015-02-26 2016-02-25 Fillers

Publications (2)

Publication Number Publication Date
NZ734958A NZ734958A (en) 2024-01-26
NZ734958B2 true NZ734958B2 (en) 2024-04-30

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