US20130233739A1 - Acetoacetyl Thermosetting Resin for Zero VOC Gel Coat - Google Patents
Acetoacetyl Thermosetting Resin for Zero VOC Gel Coat Download PDFInfo
- Publication number
- US20130233739A1 US20130233739A1 US13/790,608 US201313790608A US2013233739A1 US 20130233739 A1 US20130233739 A1 US 20130233739A1 US 201313790608 A US201313790608 A US 201313790608A US 2013233739 A1 US2013233739 A1 US 2013233739A1
- Authority
- US
- United States
- Prior art keywords
- gel coat
- acetoacetate
- crosslinked
- oligomers
- polyhydroxy polyol
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 68
- 239000011347 resin Substances 0.000 title claims abstract description 68
- 229920001187 thermosetting polymer Polymers 0.000 title claims abstract description 38
- 125000002339 acetoacetyl group Chemical group O=C([*])C([H])([H])C(=O)C([H])([H])[H] 0.000 title claims description 22
- 238000010030 laminating Methods 0.000 claims abstract description 57
- 239000003054 catalyst Substances 0.000 claims abstract description 43
- 239000011342 resin composition Substances 0.000 claims abstract description 23
- 239000000203 mixture Substances 0.000 claims description 86
- 229920005862 polyol Polymers 0.000 claims description 77
- 150000003077 polyols Chemical class 0.000 claims description 76
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 54
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 50
- 239000000178 monomer Substances 0.000 claims description 46
- GQHTUMJGOHRCHB-UHFFFAOYSA-N 2,3,4,6,7,8,9,10-octahydropyrimido[1,2-a]azepine Chemical compound C1CCCCN2CCCN=C21 GQHTUMJGOHRCHB-UHFFFAOYSA-N 0.000 claims description 44
- 238000000034 method Methods 0.000 claims description 37
- 239000012855 volatile organic compound Substances 0.000 claims description 34
- -1 C1-C5 alkyl acetoacetate Chemical compound 0.000 claims description 30
- 239000000654 additive Substances 0.000 claims description 19
- 125000000524 functional group Chemical group 0.000 claims description 18
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 17
- KYVBNYUBXIEUFW-UHFFFAOYSA-N 1,1,3,3-tetramethylguanidine Chemical compound CN(C)C(=N)N(C)C KYVBNYUBXIEUFW-UHFFFAOYSA-N 0.000 claims description 15
- JKUYRAMKJLMYLO-UHFFFAOYSA-N tert-butyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OC(C)(C)C JKUYRAMKJLMYLO-UHFFFAOYSA-N 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 13
- 230000000996 additive effect Effects 0.000 claims description 12
- 239000000945 filler Substances 0.000 claims description 12
- 239000007787 solid Substances 0.000 claims description 12
- IMNIMPAHZVJRPE-UHFFFAOYSA-N triethylenediamine Chemical compound C1CN2CCN1CC2 IMNIMPAHZVJRPE-UHFFFAOYSA-N 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 9
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 claims description 9
- 239000000049 pigment Substances 0.000 claims description 9
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 8
- 239000013008 thixotropic agent Substances 0.000 claims description 8
- 238000005809 transesterification reaction Methods 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 7
- SGUVLZREKBPKCE-UHFFFAOYSA-N 1,5-diazabicyclo[4.3.0]-non-5-ene Chemical compound C1CCN=C2CCCN21 SGUVLZREKBPKCE-UHFFFAOYSA-N 0.000 claims description 6
- OEBXWWBYZJNKRK-UHFFFAOYSA-N 1-methyl-2,3,4,6,7,8-hexahydropyrimido[1,2-a]pyrimidine Chemical compound C1CCN=C2N(C)CCCN21 OEBXWWBYZJNKRK-UHFFFAOYSA-N 0.000 claims description 6
- FVKFHMNJTHKMRX-UHFFFAOYSA-N 3,4,6,7,8,9-hexahydro-2H-pyrimido[1,2-a]pyrimidine Chemical compound C1CCN2CCCNC2=N1 FVKFHMNJTHKMRX-UHFFFAOYSA-N 0.000 claims description 6
- WDJHALXBUFZDSR-UHFFFAOYSA-N acetoacetic acid Chemical group CC(=O)CC(O)=O WDJHALXBUFZDSR-UHFFFAOYSA-N 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 6
- 239000002253 acid Substances 0.000 claims description 5
- IBDVWXAVKPRHCU-UHFFFAOYSA-N 2-(2-methylprop-2-enoyloxy)ethyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OCCOC(=O)C(C)=C IBDVWXAVKPRHCU-UHFFFAOYSA-N 0.000 claims description 4
- WMYINDVYGQKYMI-UHFFFAOYSA-N 2-[2,2-bis(hydroxymethyl)butoxymethyl]-2-ethylpropane-1,3-diol Chemical compound CCC(CO)(CO)COCC(CC)(CO)CO WMYINDVYGQKYMI-UHFFFAOYSA-N 0.000 claims description 4
- DSKYSDCYIODJPC-UHFFFAOYSA-N 2-butyl-2-ethylpropane-1,3-diol Chemical compound CCCCC(CC)(CO)CO DSKYSDCYIODJPC-UHFFFAOYSA-N 0.000 claims description 4
- QWGRWMMWNDWRQN-UHFFFAOYSA-N 2-methylpropane-1,3-diol Chemical compound OCC(C)CO QWGRWMMWNDWRQN-UHFFFAOYSA-N 0.000 claims description 4
- CDBAMNGURPMUTG-UHFFFAOYSA-N 4-[2-(4-hydroxycyclohexyl)propan-2-yl]cyclohexan-1-ol Chemical compound C1CC(O)CCC1C(C)(C)C1CCC(O)CC1 CDBAMNGURPMUTG-UHFFFAOYSA-N 0.000 claims description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 4
- XYIBRDXRRQCHLP-UHFFFAOYSA-N ethyl acetoacetate Chemical compound CCOC(=O)CC(C)=O XYIBRDXRRQCHLP-UHFFFAOYSA-N 0.000 claims description 4
- 229910021485 fumed silica Inorganic materials 0.000 claims description 4
- 229940100573 methylpropanediol Drugs 0.000 claims description 4
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 claims description 4
- 229920000058 polyacrylate Polymers 0.000 claims description 4
- 239000000454 talc Substances 0.000 claims description 4
- 229910052623 talc Inorganic materials 0.000 claims description 4
- 239000004408 titanium dioxide Substances 0.000 claims description 4
- 239000004634 thermosetting polymer Substances 0.000 claims description 3
- QCUOCXSVXRRMPE-UHFFFAOYSA-N 2-methylbutan-2-yl 3-oxobutanoate Chemical compound CCC(C)(C)OC(=O)CC(C)=O QCUOCXSVXRRMPE-UHFFFAOYSA-N 0.000 claims description 2
- VYZKQGGPNIFCLD-UHFFFAOYSA-N 3,3-dimethylhexane-2,2-diol Chemical compound CCCC(C)(C)C(C)(O)O VYZKQGGPNIFCLD-UHFFFAOYSA-N 0.000 claims description 2
- XHRGPLDMNNGHCX-UHFFFAOYSA-N 3-Methylbutyl 3-oxobutanoate Chemical compound CC(C)CCOC(=O)CC(C)=O XHRGPLDMNNGHCX-UHFFFAOYSA-N 0.000 claims description 2
- REIYHFWZISXFKU-UHFFFAOYSA-N Butyl acetoacetate Chemical compound CCCCOC(=O)CC(C)=O REIYHFWZISXFKU-UHFFFAOYSA-N 0.000 claims description 2
- 239000004606 Fillers/Extenders Substances 0.000 claims description 2
- WRQNANDWMGAFTP-UHFFFAOYSA-N Methylacetoacetic acid Chemical compound COC(=O)CC(C)=O WRQNANDWMGAFTP-UHFFFAOYSA-N 0.000 claims description 2
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 claims description 2
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 2
- 239000000440 bentonite Substances 0.000 claims description 2
- 229910000278 bentonite Inorganic materials 0.000 claims description 2
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 2
- 239000000378 calcium silicate Substances 0.000 claims description 2
- 229910052918 calcium silicate Inorganic materials 0.000 claims description 2
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 claims description 2
- 229910052570 clay Inorganic materials 0.000 claims description 2
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 2
- 239000000347 magnesium hydroxide Substances 0.000 claims description 2
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 2
- 239000000395 magnesium oxide Substances 0.000 claims description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
- 229910052618 mica group Inorganic materials 0.000 claims description 2
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 claims description 2
- IDZAUPYMMSSVHP-UHFFFAOYSA-N pentyl 3-oxobutanoate Chemical compound CCCCCOC(=O)CC(C)=O IDZAUPYMMSSVHP-UHFFFAOYSA-N 0.000 claims description 2
- GVIIRWAJDFKJMJ-UHFFFAOYSA-N propan-2-yl 3-oxobutanoate Chemical compound CC(C)OC(=O)CC(C)=O GVIIRWAJDFKJMJ-UHFFFAOYSA-N 0.000 claims description 2
- DHGFMVMDBNLMKT-UHFFFAOYSA-N propyl 3-oxobutanoate Chemical compound CCCOC(=O)CC(C)=O DHGFMVMDBNLMKT-UHFFFAOYSA-N 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 239000003381 stabilizer Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims 3
- MFYURFVUHJEOAZ-UHFFFAOYSA-N C(CCCC)OC(CC(=O)CCCCCC)=O Chemical compound C(CCCC)OC(CC(=O)CCCCCC)=O MFYURFVUHJEOAZ-UHFFFAOYSA-N 0.000 claims 1
- 239000003570 air Substances 0.000 claims 1
- 239000003112 inhibitor Substances 0.000 claims 1
- 239000000805 composite resin Substances 0.000 abstract description 2
- 238000006243 chemical reaction Methods 0.000 description 15
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 14
- DAKWPKUUDNSNPN-UHFFFAOYSA-N Trimethylolpropane triacrylate Chemical compound C=CC(=O)OCC(CC)(COC(=O)C=C)COC(=O)C=C DAKWPKUUDNSNPN-UHFFFAOYSA-N 0.000 description 14
- 238000002360 preparation method Methods 0.000 description 14
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- 229910052757 nitrogen Inorganic materials 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 7
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 7
- 229920002554 vinyl polymer Polymers 0.000 description 7
- HZAXFHJVJLSVMW-UHFFFAOYSA-N 2-Aminoethan-1-ol Chemical compound NCCO HZAXFHJVJLSVMW-UHFFFAOYSA-N 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 6
- 239000000835 fiber Substances 0.000 description 6
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 6
- 238000004132 cross linking Methods 0.000 description 5
- 239000012973 diazabicyclooctane Substances 0.000 description 5
- 239000012263 liquid product Substances 0.000 description 5
- 229920000642 polymer Polymers 0.000 description 5
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 4
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 4
- 208000035155 Mitochondrial DNA-associated Leigh syndrome Diseases 0.000 description 4
- WDJHALXBUFZDSR-UHFFFAOYSA-M acetoacetate Chemical compound CC(=O)CC([O-])=O WDJHALXBUFZDSR-UHFFFAOYSA-M 0.000 description 4
- SAQPWCPHSKYPCK-UHFFFAOYSA-N carbonic acid;propane-1,2,3-triol Chemical compound OC(O)=O.OCC(O)CO SAQPWCPHSKYPCK-UHFFFAOYSA-N 0.000 description 4
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- GTELLNMUWNJXMQ-UHFFFAOYSA-N 2-ethyl-2-(hydroxymethyl)propane-1,3-diol;prop-2-enoic acid Chemical class OC(=O)C=C.OC(=O)C=C.OC(=O)C=C.CCC(CO)(CO)CO GTELLNMUWNJXMQ-UHFFFAOYSA-N 0.000 description 1
- OMIGHNLMNHATMP-UHFFFAOYSA-N 2-hydroxyethyl prop-2-enoate Chemical group OCCOC(=O)C=C OMIGHNLMNHATMP-UHFFFAOYSA-N 0.000 description 1
- KUDUQBURMYMBIJ-UHFFFAOYSA-N 2-prop-2-enoyloxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCOC(=O)C=C KUDUQBURMYMBIJ-UHFFFAOYSA-N 0.000 description 1
- FHPDNLOSEWLERE-UHFFFAOYSA-N 3-(2-methylprop-2-enoyloxy)propyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OCCCOC(=O)C(C)=C FHPDNLOSEWLERE-UHFFFAOYSA-N 0.000 description 1
- GNSFRPWPOGYVLO-UHFFFAOYSA-N 3-hydroxypropyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCCCO GNSFRPWPOGYVLO-UHFFFAOYSA-N 0.000 description 1
- QZPSOSOOLFHYRR-UHFFFAOYSA-N 3-hydroxypropyl prop-2-enoate Chemical compound OCCCOC(=O)C=C QZPSOSOOLFHYRR-UHFFFAOYSA-N 0.000 description 1
- FJKZPONBPMKPLO-UHFFFAOYSA-N 3-prop-2-enoyloxypropyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OCCCOC(=O)C=C FJKZPONBPMKPLO-UHFFFAOYSA-N 0.000 description 1
- GZFANJYDVVSIMZ-UHFFFAOYSA-N 4-(2-methylprop-2-enoyloxy)butyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OCCCCOC(=O)C(C)=C GZFANJYDVVSIMZ-UHFFFAOYSA-N 0.000 description 1
- JFMGYULNQJPJCY-UHFFFAOYSA-N 4-(hydroxymethyl)-1,3-dioxolan-2-one Chemical compound OCC1COC(=O)O1 JFMGYULNQJPJCY-UHFFFAOYSA-N 0.000 description 1
- PICTWXAWDCLLKO-UHFFFAOYSA-N 4-prop-2-enoyloxybutyl 3-oxobutanoate Chemical compound CC(=O)CC(=O)OCCCCOC(=O)C=C PICTWXAWDCLLKO-UHFFFAOYSA-N 0.000 description 1
- FIHBHSQYSYVZQE-UHFFFAOYSA-N 6-prop-2-enoyloxyhexyl prop-2-enoate Chemical compound C=CC(=O)OCCCCCCOC(=O)C=C FIHBHSQYSYVZQE-UHFFFAOYSA-N 0.000 description 1
- TVQLXMHJNUMWAC-UHFFFAOYSA-N C=C(C)C(=O)OC1CC2CCC1(C)C2(C)C.C=C(C)C(=O)OCCOC(=O)CC(C)=O.CC(=O)CC(=O)OCCOC(=O)C(C)(C)C.CC(C)(C)C(=O)OC1CC2CCC1(C)C2(C)C Chemical compound C=C(C)C(=O)OC1CC2CCC1(C)C2(C)C.C=C(C)C(=O)OCCOC(=O)CC(C)=O.CC(=O)CC(=O)OCCOC(=O)C(C)(C)C.CC(C)(C)C(=O)OC1CC2CCC1(C)C2(C)C TVQLXMHJNUMWAC-UHFFFAOYSA-N 0.000 description 1
- JPKKZZNGJJAASZ-UHFFFAOYSA-N CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OC1CCC(C(C)(C)C2CCC(OC(=O)CC(C)=O)CC2)CC1.CC(C)(C1CCC(O)CC1)C1CCC(O)CC1 Chemical compound CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OC1CCC(C(C)(C)C2CCC(OC(=O)CC(C)=O)CC2)CC1.CC(C)(C1CCC(O)CC1)C1CCC(O)CC1 JPKKZZNGJJAASZ-UHFFFAOYSA-N 0.000 description 1
- ATIJPDHVYATLPE-UHFFFAOYSA-N CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OCCN1C(=O)N(CCOC(=O)CC(C)=O)C(=O)N(CCOC(=O)CC(C)=O)C1=O.O=C1N(CCO)C(=O)N(CCO)C(=O)N1CCO Chemical compound CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OCCN1C(=O)N(CCOC(=O)CC(C)=O)C(=O)N(CCOC(=O)CC(C)=O)C1=O.O=C1N(CCO)C(=O)N(CCO)C(=O)N1CCO ATIJPDHVYATLPE-UHFFFAOYSA-N 0.000 description 1
- LSNSFCCZCSAAFV-UHFFFAOYSA-N CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OCCNC(=O)OCC(COC(=O)CC(C)=O)OC(=O)CC(C)=O.NCCO.O=C(NCCO)OCC(O)CO.O=C1OCC(CO)O1 Chemical compound CC(=O)CC(=O)OC(C)(C)C.CC(=O)CC(=O)OCCNC(=O)OCC(COC(=O)CC(C)=O)OC(=O)CC(C)=O.NCCO.O=C(NCCO)OCC(O)CO.O=C1OCC(CO)O1 LSNSFCCZCSAAFV-UHFFFAOYSA-N 0.000 description 1
- URNRNGNLOVPRMR-UHFFFAOYSA-N CC(=O)CC(=O)OC(C)(C)C.CCC(CO)(CO)CO.CCC(CO)(CO)COC(=O)C1=CC=CC(C(=O)OCC(CC)(CO)CO)=C1.CCC(COC(=O)CC(C)=O)(COC(=O)CC(C)=O)COC(=O)C1=CC=CC(C(=O)OCC(CC)(COC(=O)CC(C)=O)COC(=O)CC(C)=O)=C1.O=C(O)C1=CC=CC(C(=O)O)=C1 Chemical compound CC(=O)CC(=O)OC(C)(C)C.CCC(CO)(CO)CO.CCC(CO)(CO)COC(=O)C1=CC=CC(C(=O)OCC(CC)(CO)CO)=C1.CCC(COC(=O)CC(C)=O)(COC(=O)CC(C)=O)COC(=O)C1=CC=CC(C(=O)OCC(CC)(COC(=O)CC(C)=O)COC(=O)CC(C)=O)=C1.O=C(O)C1=CC=CC(C(=O)O)=C1 URNRNGNLOVPRMR-UHFFFAOYSA-N 0.000 description 1
- ZVVCDABSBRGSDB-UHFFFAOYSA-N CC(=O)CC(=O)OC(C)(C)C.CCC(CO)(CO)CO.CCC(COC(=O)CC(C)=O)(COC(=O)CC(C)=O)COC(=O)CC(C)=O Chemical compound CC(=O)CC(=O)OC(C)(C)C.CCC(CO)(CO)CO.CCC(COC(=O)CC(C)=O)(COC(=O)CC(C)=O)COC(=O)CC(C)=O ZVVCDABSBRGSDB-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- KMTRUDSVKNLOMY-UHFFFAOYSA-N Ethylene carbonate Chemical compound O=C1OCCO1 KMTRUDSVKNLOMY-UHFFFAOYSA-N 0.000 description 1
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 238000006845 Michael addition reaction Methods 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- WUGQZFFCHPXWKQ-UHFFFAOYSA-N Propanolamine Chemical compound NCCCO WUGQZFFCHPXWKQ-UHFFFAOYSA-N 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 1
- 239000007983 Tris buffer Substances 0.000 description 1
- IAXXETNIOYFMLW-COPLHBTASA-N [(1s,3s,4s)-4,7,7-trimethyl-3-bicyclo[2.2.1]heptanyl] 2-methylprop-2-enoate Chemical compound C1C[C@]2(C)[C@@H](OC(=O)C(=C)C)C[C@H]1C2(C)C IAXXETNIOYFMLW-COPLHBTASA-N 0.000 description 1
- KNSXNCFKSZZHEA-UHFFFAOYSA-N [3-prop-2-enoyloxy-2,2-bis(prop-2-enoyloxymethyl)propyl] prop-2-enoate Chemical class C=CC(=O)OCC(COC(=O)C=C)(COC(=O)C=C)COC(=O)C=C KNSXNCFKSZZHEA-UHFFFAOYSA-N 0.000 description 1
- MPIAGWXWVAHQBB-UHFFFAOYSA-N [3-prop-2-enoyloxy-2-[[3-prop-2-enoyloxy-2,2-bis(prop-2-enoyloxymethyl)propoxy]methyl]-2-(prop-2-enoyloxymethyl)propyl] prop-2-enoate Chemical compound C=CC(=O)OCC(COC(=O)C=C)(COC(=O)C=C)COCC(COC(=O)C=C)(COC(=O)C=C)COC(=O)C=C MPIAGWXWVAHQBB-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000000370 acceptor Substances 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 125000002877 alkyl aryl group Chemical group 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 150000001414 amino alcohols Chemical class 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 150000001491 aromatic compounds Chemical class 0.000 description 1
- 125000003710 aryl alkyl group Chemical group 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- KDYFGRWQOYBRFD-NUQCWPJISA-N butanedioic acid Chemical compound O[14C](=O)CC[14C](O)=O KDYFGRWQOYBRFD-NUQCWPJISA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 229920006037 cross link polymer Polymers 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 125000004386 diacrylate group Chemical group 0.000 description 1
- WOWBFOBYOAGEEA-UHFFFAOYSA-N diafenthiuron Chemical compound CC(C)C1=C(NC(=S)NC(C)(C)C)C(C(C)C)=CC(OC=2C=CC=CC=2)=C1 WOWBFOBYOAGEEA-UHFFFAOYSA-N 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- GLVVKKSPKXTQRB-UHFFFAOYSA-N ethenyl dodecanoate Chemical compound CCCCCCCCCCCC(=O)OC=C GLVVKKSPKXTQRB-UHFFFAOYSA-N 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 238000009787 hand lay-up Methods 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
- 230000003301 hydrolyzing effect Effects 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 125000000879 imine group Chemical class 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 229940119545 isobornyl methacrylate Drugs 0.000 description 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 1
- 229940102253 isopropanolamine Drugs 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- YDKNBNOOCSNPNS-UHFFFAOYSA-N methyl 1,3-benzoxazole-2-carboxylate Chemical compound C1=CC=C2OC(C(=O)OC)=NC2=C1 YDKNBNOOCSNPNS-UHFFFAOYSA-N 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- GKTNLYAAZKKMTQ-UHFFFAOYSA-N n-[bis(dimethylamino)phosphinimyl]-n-methylmethanamine Chemical compound CN(C)P(=N)(N(C)C)N(C)C GKTNLYAAZKKMTQ-UHFFFAOYSA-N 0.000 description 1
- 125000004433 nitrogen atom Chemical group N* 0.000 description 1
- 229910017464 nitrogen compound Inorganic materials 0.000 description 1
- 150000002830 nitrogen compounds Chemical class 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid Chemical compound OC(=O)C1=CC=CC=C1C(O)=O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 description 1
- FSDNTQSJGHSJBG-UHFFFAOYSA-N piperidine-4-carbonitrile Chemical compound N#CC1CCNCC1 FSDNTQSJGHSJBG-UHFFFAOYSA-N 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 1
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000000518 rheometry Methods 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 125000004434 sulfur atom Chemical group 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 230000009182 swimming Effects 0.000 description 1
- 238000001721 transfer moulding Methods 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
Classifications
-
- 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
- C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D25/00—Details of other kinds or types of rigid or semi-rigid containers
- B65D25/14—Linings or internal coatings
-
- 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
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- 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
-
- 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
- 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
- C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
- C09D4/06—Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
-
- 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
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2237—Oxides; Hydroxides of metals of titanium
- C08K2003/2241—Titanium dioxide
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31909—Next to second addition polymer from unsaturated monomers
Definitions
- Embodiments of the invention relate generally to the field of gel coats and laminating resins, and more particularly to methods of making low viscosity, low to zero VOC acetoacetyl thermosetting resins for gel coat and laminating resin compositions utilizing a Michael-type addition crosslinking reaction.
- gel coats are widely used in numerous applications as the external surface layer of composite molded articles.
- Gel coats are typically found on composite articles that are exposed to the environment requiring moisture resistance, resistance to cracking and similar properties, or articles that require a strong, flexible, abrasion and impact resistant surface and/or a smooth glossy finish. Examples of such articles include boat hulls, bath tub enclosures, pools, spas, and body panels on cars and trucks, among others.
- Such gel coated articles are typically formed by spraying a gel coat composition from a high pressure spray gun onto the inside surface of an open mold, applying the materials and a laminating resin for the composite article onto the gel coat, curing the gel coat and then removing the cured gel coated article from the mold.
- Gel coated articles can also be fabricated by applying the composite materials into a multi-part mold, injecting or applying the gel coat composition, closing the mold, curing the gel coat and then removing the cured gel coated article from the mold.
- Gel coats for composite articles are typically formulated from a thermosetting base resin system such as unsaturated polyester, acrylate and urethane type resins with incorporated fillers, pigments and other additives.
- the gel coat should exhibit low viscosity at high shear to allow for ease of application to the mold, but also resist sagging or running after it is applied.
- Another important property of gel coats is surface tackiness and cure time.
- a gel coat desirably produces a gel time of 10 to 20 minutes. Many low or zero VOC gel coats remain tacky after several hours of curing.
- the gel coat resin is mixed with reactive, polymerizable monomers such as styrene or methyl methacrylate (MMA), which are also used to reduce resin system viscosity in order to apply the gel coat by spraying.
- reactive, polymerizable monomers such as styrene or methyl methacrylate (MMA)
- MMA methyl methacrylate
- Conventional gel coat compositions contain 35 to 45 wt % of reactive monomers and other volatile organic compounds (VOCs).
- VOCs volatile organic compounds
- HAP hazardous air pollutants
- high boiling point monomers typically have higher viscosity and lower reactivity with a resin solid. As a result, a higher amount of high-boiling point monomers is required to replace the standard monomers in gel coat formulations and the resulting product is very slow to cure.
- the invention provides methods and gel coat and laminating resin compositions that overcome the above-described deficiencies and provide styrene free and zero VOC gel coats having a desirable viscosity for application, a fast gel time and set-up, and produce cured gel coats and laminating resins having a high degree of crosslinking with excellent performance properties.
- the invention provides methods for making styrene free and zero VOC gel coats.
- the method comprises:
- the gel coat composition can be used in making a gel coated article.
- the gel coated article is fabricated by:
- the resulting gel coated article comprises the cured thermoset gel coat bonded onto the surface of the article.
- the cured thermoset gel coat and laminating resin comprise crosslinked acetoacetate functionalized acrylate oligomers, and are preferably at least 50%, preferably 70 to 100%, crosslinked.
- the invention also provides methods for making a laminating resin composition.
- the method comprises:
- the laminating resin composition can be cured at ambient temperature to form a solid, crosslinked, thermoset resin comprising crosslinked acetoacetate-functionalized acrylate oligomers, with the laminating resin being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- the invention further provides a crosslinkable, styrene free and zero VOC gel coat composition.
- the crosslinkable gel coat composition comprises an acetoacetylated polyhydroxy polyol, one or more multifunctional acrylate monomers or oligomers, a base catalyst, and at least one additive component selected from the group consisting of fillers, pigments and thixotropic agents, and has a viscosity of about 50 to 1200 cps under high shear, and is curable under ambient conditions to form a solid thermoset gel coat comprising crosslinked acetoacetate-functionalized acrylate oligomers, the gel coat being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- the invention also provides a crosslinkable, styrene free and zero VOC laminating resin composition.
- the crosslinkable laminating resin composition comprises an acetoacetylated polyhydroxy polyol, one or more multifunctional acrylate monomers or oligomers, and a base catalyst, and has a Brookfield viscosity of about 50 to 1200 cps, and is curable under ambient conditions to form a laminating resin comprising crosslinked acetoacetate-functionalized acrylate oligomers, the laminating resin being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- the system is composed of separate containers packaged together, including:
- a system is also provided for forming a laminating resin composition.
- the system is composed of separate containers packaged together, including:
- Embodiments of the invention relate to methods of making zero VOC, crosslinkable, thermosetting resins from acetoacetate-functionalized polyhydroxy polyols and multifunctional acrylate monomers or oligomers for producing laminating resins and gel coat compositions, which are crosslinked using a Michael-type addition reaction with a base catalyst to obtain laminates and gel coated articles.
- the thermosetting resins have excellent curability at ambient or room temperatures.
- the process results in an at least 50%, preferably 70 to 100%, crosslinked thermoset polymer network that is VOC and styrene free with excellent mechanical properties.
- thermosetting resins are crosslinked without styrene or free-radicals, using a Michael-type addition reaction with a base catalyst at ambient temperatures to incorporate acrylate functionality into a multifunctional acetoacetylated polyhydroxy polyol to produce a thermoset, crosslinked polymer network in which the acetoacetate-functionalized acrylate oligomers are up to 100% crosslinked.
- viscosity refers to the viscosity of a polymer in monomer at 25° C. (77° C.) measured in centipoise (cps) using a Brookfield RV model viscometer. The viscosity under high shear is measured by a cone and plate (CAP) viscometer at a shear rate of 10,000 l/s.
- CAP cone and plate
- NVM non-volatile material dispersed in a volatile substance (e.g., monomer) as measured according to ASTM D1259.
- the acetoacetate-functionalized polyhydroxy polyol has at least two, and in some embodiments preferably at least three acetoacetyl functional groups per oligomer.
- the functionalized polyol is then blended with a multifunctional acrylate to form a thermosetting, crosslinkable resin.
- multifunctional acetoacetylated polyols can be prepared by reaction of a polyhydroxy polyol (also termed “polyhydric alcohol” or “polymeric polyol”), in a transesterification reaction with an alkyl acetoacetate compound, preferably a C 1 -C 5 alkyl acetoacetate.
- a polyhydroxy polyol also termed “polyhydric alcohol” or “polymeric polyol”
- an alkyl acetoacetate compound preferably a C 1 -C 5 alkyl acetoacetate.
- Suitable polyhydroxy polyol compounds have an average of at least two, preferably at least three (i.e., tripolyol), hydroxyl groups per molecule.
- Non-limiting examples of polyhydroxy polyols include methyl propanediol (MPD), trimethylolpropane (TMP), trimethylpentanediol, di-trimethylolpropane (di-TMP), butyl ethyl propanediol (BEPD), neopentyl glycol (NEO), pentaerythritol (Penta), di-pentaerythritol (di-Penta), tris-2-hydroxyethyl isocyanurate (THEIC), 4,4′-isopropylidenedicyclohexanol (hydrogenated bisphenol-A (HBPA), hydroxyl-functionalized acrylic polymers, among others, and mixtures of two or more of such compounds.
- the polyhydroxy polyol has a hydroxyl
- Non-limiting examples of suitable C 1 -C 5 alkyl acetoacetates include methyl acetoacetate (MAA), ethyl acetoacetate (EAA), n-propyl acetoacetate, isopropyl acetoacetate, n-butyl acetoacetate, tert-butyl acetoacetate (TBAA), pentyl (amyl) acetoacetate, n-pentyl acetoacetate, isopentyl acetoacetate, tert-pentyl acetoacetate, acetoacetate-functionalized acrylic polymer based on acetoacetoxyetheyl methacrylate, including copolymers with different acrylic monomers, among others, and mixtures of two or more of such compounds.
- MAA methyl acetoacetate
- EAA ethyl acetoacetate
- TBAA tert-butyl acetoacetate
- Procedures for preparing crosslinkable, functionalized acetoacetylated polyols by reaction of a polyol with an alkyl acetoacetate compound in a transesterification reaction are generally known in the art.
- the polyol and alkyl acetoacetate compounds are reacted in a transesterification reaction at a temperature of 90 to 200° C. for 3 to 15 hours to form the functionalized polyol.
- 10 to 90 wt % polyol is combined with 90 to 10 wt % alkyl acetoacetate, based on the total weight of the mixture.
- the acetoacetylated polyols have an acetoacetyl content within a range of from 5 to 80 weight %, a hydroxyl number within a range of 0 to 60 mg KOH/g, and acid value of 0 to 5 mg KOH/g, and a number average molecular weight (Mn) within a range of 250 to 6000 g mole ⁇ 1 , preferably 300 to 5000 g mole ⁇ 1 .
- the acetoacetate-functionalized polyol can be prepared in a multi-stage reaction in which the polyhydroxy polyol is initially reacted by the condensation reaction with a dicarboxylic acid/anhydride or polyacid with a glycol or polyol.
- suitable carboxylic acids include isophthalic acid, orthophthalic acid, terephtalic acid, succinic acid, adipic acid, maleic acid, fumaric acid, azelaic acid, 1,4-cyclohexane dicarboxylic acid, itaconic acid, sebacic acid, tetrahydrophthalic anhydride, trimelitic anhydride, among others, and mixtures of two or more of such compounds.
- the dicarboxylic acid and polyhydroxy polyol are reacted in a first stage reaction at 150 to 225° C. for about 5 to 20 hours, until an acid value of less than 20 mg KOH/g, preferably less than 10 mg KOH/g, is reached.
- the molar ratio of acid functional groups to hydroxyl functional groups is 0.2 to 0.8.
- an alkyl acetoacetate compound is mixed with the resulting polyester polyol and the reaction proceeds for about 3 to 15 hours to form the acetoacetate-functionalized polyol.
- 25 to 90 wt % of the polyester polyol is combined with 75 to 10 wt % alkyl acetoacetate, based on the total weight of the mixture.
- the acetoacetate-functionalized polyhydroxy polyol can be prepared in a multi-step reaction, in which a C 2 to C 13 alkanolamine is reacted with a cyclic, 5-ring hydroxy-functional carbonate in a first step to form a polyurethane polyol intermediate.
- the molar ratio of alkanolamine to the 5-ring carbonate is at or about close to 1 with slightly excess of carbonate.
- suitable alkanolamines also referred to as “amino alcohols”
- suitable alkanolamines include monoethanolamine (MEA), propanolamine, isopropanol amine, and 2-aminobutanol, among others, and mixtures of two or more of such compounds.
- suitable 5-ring carbonates include glycerine carbonate (GC), ethylene carbonate, propylene carbonate and butylene carbonate, among others, and mixtures of two or more of such compounds.
- the alkanolamine and 5-ring hydroxy-functional carbonate are reacted at 20 to 75° C. for about 5 to 8 hours.
- the resulting polyurethane polyol is mixed with an alkyl acetoacetate compound and reacted for about 3 to 15 hours to form the functionalized acetoacetylated polyol.
- the acetoacetate-functionalized polyhydroxy polyol can be prepared in a multi-step reaction, in which the polyol is formed through free radical copolymerization of vinyl monomers and at least one vinyl monomer containing hydroxyl groups.
- the resulting polyol contains at least two, preferably three, hydroxyl functional groups in each polymer.
- suitable vinyl monomers containing hydroxyl groups include hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, and hydroxylpropyl methacrylate, among others, and mixtures of two or more of such compounds.
- Non-limiting examples of suitable vinyl monomers include aromatic compounds such as styrene, alpha-methyl styrene, vinyl toluene, vinyl phenol and the like, and unsaturated esters such as acrylic and methacrylic ester, vinyl laurate and the like, among others, and mixtures thereof.
- the resulting polyol is mixed with an alkyl acetoacetate compound and reacted for about 3 to 15 hours to form the functionalized acetoacetylated polyol.
- the acetoacetate functionalized polyhydroxy polyol is made directly by free radical copolymerization of vinyl monomers and at least one vinyl monomer contains acetoacetate functional group.
- the resulting copolymer contains at least two, preferably three, acetoacetate functional groups in each polymer.
- Non-limiting examples of suitable vinyl monomers containing acetoacetate functional group include acetoacetoxyethyl methacrylate (AAEM), acetoacetoxyethyl acrylate (AAEA), acetoacetoxypropyl methacrylate, acetoacetoxypropyl acrylate, acetoacetoxybutyl methacrylate, and acetoacetoxybutyl acrylate, among others, and mixtures thereof.
- AAEM acetoacetoxyethyl methacrylate
- AAEA acetoacetoxyethyl acrylate
- acetoacetoxypropyl methacrylate acetoacetoxypropyl acrylate
- acetoacetoxybutyl methacrylate acetoacetoxybutyl methacrylate
- acetoacetoxybutyl acrylate among others, and mixtures thereof.
- the resulting acetoacetylate-functionalized polymer is a thermosetting, crosslinkable resin, having at least two, and in some embodiments at least three, acetoacetyl functional groups per polymer, which can be used, for example, in the formulation of laminating resins and gel coat compositions.
- Gel coats are compositions in a curable (e.g., pre-cured) state, composed of a blend of one or more of the acetoacetate-functionalized polyhydroxy polyol resin material with one or more multifunctional acrylate monomers and/or oligomers and one or more additives. Gel coats are typically free of fibers.
- the acetoacetate-functionalized polyol is combined with the one or more multifunctional acrylate monomers or oligomers.
- the molar ratio of the acetoacetate functional group to acrylate functional group is 0.2 to 5.0, and preferably, a molar ratio of 0.3 to 3.0.
- 15 to 70 wt % of the acetoacetate-functionalized polyol is combined with 15 to 70 wt % of one or more multifunctional acrylate monomers or oligomers and 2 to 40 wt-% additives, based on the total weight of the mixture.
- the gel coat composition can be prepared by high speed dispersion of the filler, pigment and other additives into the resin mixture.
- the viscosity of the gel coat composition (without catalyst) can range from 8,000 to 25,000 cps, and preferably 10,000 to 20,000 cps when measured by Brookfield viscometer at 4 rpm.
- Multifunctional acrylate monomers include trimethylolpropane triacrylate (TMPTA), di-trimethylolpropane tetraacrylate, tris(2-hydroxy ethyl)isocyanurate triacrylate, ethoxylated trimethylolpropane triacrylate, polyethylene glycol diacrylate, neopentyl glycol diacrylate, pentaerythritol tetraacrylate, 1,2-ethylene glycol diacrylate, 1,6-hexanediol diacrylate, 1,12-dodecanol diacrylate, hexanediol diacrylate, tripropylene glycol diacrylate, dipropylene glycol diacrylate, amine modified polyether acrylates, glycerol propoxylate triacrylate, dipentaerythritol pentaacrylate, dipentaerythritol hexaacrylate, ethoxylated
- the gel coat composition includes one or more additive components, for example, one or more fillers, pigments, and/or other additives such thixotropic agents, promoters, stabilizers, extenders, wetting agent, leveling agents, air release agents, as practiced in the art to adjust and enhance the molding properties (e.g., color effect, sprayability, sag resistance, mechanical property consistency, etc.).
- Gel coats are typically free of fibers.
- fillers for gel coats include inorganic (mineral) fillers, such as clay, magnesium oxide, magnesium hydroxide, aluminum trihydrate (ATH), calcium carbonate, calcium silicate, mica, aluminum hydroxide, barium sulfate, talc, etc., and organic fillers.
- the amount of filler in the gel coat composition can generally range from 5 up to 30 wt %, based on the total weight of the gel coat composition.
- Suitable pigments include inorganic pigments, such as titanium dioxide.
- Thixotropic agents include silica compounds such as fumed silica and precipitated silica, and inorganic clays such as bentonite clay, which, if included, can be present in an amount ranging from 0.3 up to 6 wt %, based on the total weight of the gel coat composition.
- the acetoacetate-functionalized polyhydroxy polyol resin material can be combined with one or more multifunctional acrylate monomers/oligomers (as described above) to form a curable laminating resin composition.
- the laminating resin composition is composed of 10 to 90 wt % of the acetoacetate-functionalized polyol combined with 90 to 10 wt % of multifunctional acrylate monomers/oligomers, based on the total weight of the mixture.
- the ratio of the functionalized polyol to multifunctional acrylate monomer/oligomer is 0.2 to 8.5, and more preferably a ratio of 0.25 to 8.0 (w/w).
- the viscosity of the laminating resin composition is preferably about 50 to 1200 cps.
- the laminating resin composition is combined with a base catalyst, and can be utilized in many applications such as for coatings and in reinforced composite products by various open and closed molding processes such as spray-up, hand lay-up, resin transfer molding and wet molding.
- the gel coat composition is combined with a base catalyst and applied as an in-mold coating, typically by manual application or using a gel coat spray technique, onto the surface of a mold that is in the shape and form of the desired article (e.g., bathtub, car or aircraft part, boat hull, swimming pool, etc.).
- the gel coat is allowed to partially cure such that it is tacky to tacky-free.
- the amount of base catalyst included in the gel coat composition is typically 0.2 to 2.5% by weight, based on the total weight of the composition.
- the viscosity of the gel coat (with catalyst) can range from 8,000 to 25,000 cps, and preferably 10,000 to 20,000 cps measured by Brookfield viscometer at 4 rpm.
- the gel time of the gel coat is 5 to 30 minutes at ambient temperature.
- gel time refers to the time from catalyzation of the gel coat (or laminating resin) to cessation of flow.
- Crosslinking of the laminating resin and gel coat occurs by a base-catalyzed Michael-type addition reaction of the acetoacetate-functionalized polyhydroxy polyol and multifunctional acrylate monomers or oligomers at ambient temperatures (about 20 to 25° C.), without heat or UV radiation.
- the base catalysts are nitrogen containing compounds, which can be represented by the general formula R x R y R z N, where R x , R y , and R z each individually may represent hydrogen, or a C 1 -C 20 alkyl, aryl, alkylaryl or arylalkyl group, that each optionally may contain one or more hetero-atoms (e.g. oxygen, phosphor, nitrogen or sulfur atoms) and/or substituents.
- hetero-atoms e.g. oxygen, phosphor, nitrogen or sulfur atoms
- the group may be linear or branched; they also may contain one or more unsaturations or substituents.
- This general formula R x R y R z N also represents nitrogen compounds, wherein the nitrogen atom shown in the formula is part of a cyclic system formed by two of the groups R x , R y , and R z , or is present in the form of an imine group or as a phosphazene.
- Non-limiting examples of suitable base catalysts include 1,8-diazabicyclo-[5.4.0]undec-7-ene (DBU), 1,5-diazabicyclo[4,3,0]non-5-ene (DBN), 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD), 7-methyl-1,5,7-triazabicyclo[4,4,0]dec-5-ene (MTBD), tetramethylguanidine (TMG) and 1,4-diazabicyclo[2.2.2]octane (DABCO), and N′-butyl-N′′,N′′-dicyclohexylguanidine, and the like.
- DBU 1,8-diazabicyclo-[5.4.0]undec-7-ene
- DBU 1,5-diazabicyclo[4,3,0]non-5-ene
- TBD 1,5,7-triazabicyclo[4,4,0]dec-5-ene
- TMD 7-methyl
- the base catalyst can be combined with an organic solvent such as methanol, ethanol, propanol, n-butyl alcohol, acetone, methyl ethyl ketone, among others, and mixtures thereof.
- an organic solvent such as methanol, ethanol, propanol, n-butyl alcohol, acetone, methyl ethyl ketone, among others, and mixtures thereof.
- the base catalyst is used neat (absence of a solvent).
- the article can be a fully or partially cured polymer resin or composite of reinforcing material in a polymer resin matrix.
- a reinforcing material for forming the article is laid into the open mold onto the partially cured gel coat material.
- reinforcing materials include glass fiber, polyethylene fiber, carbon fiber, metal fiber, ceramic fiber, or other material used in the composite plastics industry.
- dry fibers e.g., glass fibers, glass fiber matt, etc.
- the reinforcing material is then wet out by applying a laminating resin in a curable (i.e., pre-cured) state that has been combined with a base catalyst.
- the laminating resin is composed of 10 to 90 wt % of the acetoacetate-functionalized polyol, 90 to 10 wt % of multifunctional acrylate monomers or oligomers, and 0.2 to 2.5 wt % base catalyst, based on the total weight of the mixture.
- the laminating resin is allowed to cure to form a hardened fiber-reinforced resin composite in the desired shape within the mold.
- the gel coat becomes an integral part of the finished laminate article by forming a covalent interfacial bond with the laminating resin that is used.
- the gel coat provides a primary bond at the interface with the composite article, unlike the application of a resin coating onto the formed article.
- Curing of the laminating resin can be conducted at ambient temperature for about 4 to 40 hours.
- the gel coated, composite article can then be removed from the mold for use.
- the laminate can undergo a post-cure, for example, by heating the mold to an elevated temperature (i.e., to 65° C.) to further increase the degree of cure.
- the gel coats of the invention provide a durable and high weather- and wear-resistant coating with good hydrolytic stability, and/or an aesthetic finished surface to the article being produced to improve surface appearance.
- the gel coats also provide a resilient, light-stable surface covering and, in embodiments, are sufficiently pigmented to yield a desired color.
- the base catalyzed Michael addition of acetoacetylated resins to acrylate acceptors produces crosslinked networks with low to no volatile organic compounds (VOCs).
- VOCs volatile organic compounds
- the cured gel coat and/or laminating resin is at least 50% crosslinked, and preferably 70 to 100% crosslinked. Such crosslinking can be assessed, for example, by measuring the residual reaction exotherm by differential scanning calorimetry (DSC).
- a gel coat composition was prepared by mixing, respectively, 252 g of the IPA-TMP Tetra-Acetoacetate from Example 4, 184 g of TMPTA, 120 g of titanium dioxide, 30 g of talc and 4 g of fumed silica under high shear.
- the gel coat composition had a Brookfield viscosity of 20,000 centipoise (cps) at 25° C. (77° C.) at 4 rpm.
- a laminating resin was prepared by mixing, respectively, 263 g of IPA-TMP Tetra (Acetoacetate) from Example 4 and 285 g of TMPTA.
- the laminating resin composition had a Brookfield viscosity of 900 centipoise (cps) at 25° C. (77° C.).
- a catalyst solution of DBU was prepared by dissolving 20 g DBU in 7 g ethanol. The solution is a clear liquid.
- a catalyst solution of DABCO was prepared by dissolving 30 g DABCO in 20 g ethanol. The solution is a clear liquid.
- Example 7 200 g of the gel coat composition from Example 7 was mixed with 2.7 g DBU catalyst solution from Example 9 by hand.
- Example 8 200 g of the laminating resin from Example 8 was mixed with 2.48 g (1.24 wt-%) DBU catalyst solution from Example 9.
- a 1 ⁇ 8′′ laminate was formed by applying a 1.5 oz chop-strained mat and the laminating resin/DBU catalyst mixture onto the gel coat film. The laminate was allowed to cure for 16-20 hours at ambient temperature (25° C.), then removed from the mold and cut into test parts.
- Gel coat formulations were prepared by mixing, respectively, TMPTris (Acetoacetate) (150 g) prepared from Example 1, the acetoacetate-functionalized methacrylate copolymer resin (68 g) prepared from Example 6, TMPTA (184 g), heptadecafluorodecyl acrylate (9 g, Zonyl TA-N from DuPont), titanium dioxide (120 g), talc (30 g) and fumed silica (4 g).
- the gel coat composition had a Brookfield viscosity of 16650 centipoise (cps) at 25° C. (77° C.) at 4 rpm.
- the gel coat composition (200 g) prepared from Example 7 was mixed with the catalyst solution of DBU (1.0 g) and ethanol (0.3 g), and sprayed on a waxed and buffed flat tempered glass plate to a thickness of 15-40 MILS (1 MIL-0.001 inch). After 20 min., the gel coat film was tacky free and a barrier coat (ARMORGUARD from CCP) was sprayed onto the film to a thickness of 23 MILS.
- a 1 ⁇ 8′′ laminate is made using chopped fiberglass and a polyester resin (STYPOL LSPA-2200, 40% mat/60% resin). Methyl ethyl ketone peroxide (MEKP) co-initiator at 1.2 wt % is used to cure the polyester resin. The laminate is allowed to cure for 16-20 hours at room temperature, then removed from the mold and cut into test parts.
- the gel coat composition (200 g) prepared from Example 7 was mixed with the catalyst solution of DABCO (1.0 g) and ethanol (1.0 g), and sprayed on a waxed and buffed flat tempered glass plate to a thickness of 15-40 MILS (1 MIL-0.001 inch). After 12 hr., the gel coat film was somewhat tacky and a barrier coat (ARMORGUARD from CCP) was sprayed onto the film to a thickness of 23 MILS.
- a 1 ⁇ 8′′ laminate is made using chopped fiberglass and a polyester resin (STYPOL LSPA-2200, 40% mat/60% resin). Methyl ethyl ketone peroxide (MEKP) co-initiator at 1.2 wt % is used to cure the polyester resin. The laminate is allowed to cure for 16-20 hours at room temperature and 5 hours at 100° C., then removed from the mold and cut into test parts.
- the mechanical properties of the examples have comparable properties to typical unsaturated polyester resins.
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Abstract
Description
- Embodiments of the invention relate generally to the field of gel coats and laminating resins, and more particularly to methods of making low viscosity, low to zero VOC acetoacetyl thermosetting resins for gel coat and laminating resin compositions utilizing a Michael-type addition crosslinking reaction.
- The application of gel coats are widely used in numerous applications as the external surface layer of composite molded articles. Gel coats are typically found on composite articles that are exposed to the environment requiring moisture resistance, resistance to cracking and similar properties, or articles that require a strong, flexible, abrasion and impact resistant surface and/or a smooth glossy finish. Examples of such articles include boat hulls, bath tub enclosures, pools, spas, and body panels on cars and trucks, among others.
- Such gel coated articles are typically formed by spraying a gel coat composition from a high pressure spray gun onto the inside surface of an open mold, applying the materials and a laminating resin for the composite article onto the gel coat, curing the gel coat and then removing the cured gel coated article from the mold. Gel coated articles can also be fabricated by applying the composite materials into a multi-part mold, injecting or applying the gel coat composition, closing the mold, curing the gel coat and then removing the cured gel coated article from the mold.
- Gel coats for composite articles are typically formulated from a thermosetting base resin system such as unsaturated polyester, acrylate and urethane type resins with incorporated fillers, pigments and other additives. The gel coat should exhibit low viscosity at high shear to allow for ease of application to the mold, but also resist sagging or running after it is applied. Another important property of gel coats is surface tackiness and cure time. A gel coat desirably produces a gel time of 10 to 20 minutes. Many low or zero VOC gel coats remain tacky after several hours of curing.
- Typically, the gel coat resin is mixed with reactive, polymerizable monomers such as styrene or methyl methacrylate (MMA), which are also used to reduce resin system viscosity in order to apply the gel coat by spraying. Conventional gel coat compositions contain 35 to 45 wt % of reactive monomers and other volatile organic compounds (VOCs). The presence of high amounts of styrene and other VOCs results the emission of styrene vapors and other hazardous air pollutants (HAP), which are closely regulated by government regulations. Consequently, the composites industry is very interested in providing gel coats that emit low to zero VOCs.
- However, there are difficulties in attaining gel coats having low to zero VOCs and acceptable application and performance properties. Several approaches have been described for addressing these requirements. One way to reduce VOCs is to reduce the molecular weight of the resin, which leads to a lower viscosity and lower styrene need. However, in application, a gel coat made with a lower molecular weight resin tends to remain tacky for long periods of time. The use of higher molecular weight resins results in higher viscosities that hamper spray applications of the gel coat composition, which generally require a viscosity in the range of 50 to 1200 cps under high shear. In order to achieve target viscosity, monomers with high boiling point are used to replace monomers which contribute to VOC. These high boiling point monomers typically have higher viscosity and lower reactivity with a resin solid. As a result, a higher amount of high-boiling point monomers is required to replace the standard monomers in gel coat formulations and the resulting product is very slow to cure.
- There remains a significant need for a resin material that provides good rheology properties for in-mold coating applications, fast curing and a better cured gel coat product having low to zero VOCs and a high degree of crosslinking.
- The invention provides methods and gel coat and laminating resin compositions that overcome the above-described deficiencies and provide styrene free and zero VOC gel coats having a desirable viscosity for application, a fast gel time and set-up, and produce cured gel coats and laminating resins having a high degree of crosslinking with excellent performance properties.
- In embodiments, the invention provides methods for making styrene free and zero VOC gel coats. In one embodiment, the method comprises:
-
- reacting a polyhydroxy polyol having at least two, preferably three, hydroxyl groups per molecule with a C1-C5 alkyl acetoacetate in a transesterification process to form a crosslinkable, multifunctional acetoacetylated polyhydroxy polyol having at least two acetoacetyl functional groups per oligomer; and
- combining the acetoacetylated polyhydroxy polyol with one or more multifunctional acrylate monomers or oligomers, at least one additive component, and a base catalyst, to form a crosslinkable, thermosetting gel coat composition having a viscosity of about 50 to 1200 cps under high shear.
- In use, the gel coat composition can be used in making a gel coated article. In embodiments, the gel coated article is fabricated by:
-
- applying the thermosetting gel coat composition as an in-mold coating to a surface of a mold;
- allowing the gel coat composition to cure at ambient temperature to form a partially crosslinked, tacky to tacky-free gel coat;
- applying a material to be molded onto the partially crosslinked gel coat;
- applying a crosslinkable laminating resin onto said material, the laminating resin comprising an acetoacetylated polyhydroxy polyol having at least two, preferably three, acetoacetyl functional groups per oligomer, one or more multifunctional acrylate monomers or oligomers and a base catalyst; and
- allowing the laminating resin and the gel coat to cure at ambient temperature to a solid, crosslinked, thermoset resin being styrene free with zero VOCs.
- The resulting gel coated article comprises the cured thermoset gel coat bonded onto the surface of the article. In embodiments, the cured thermoset gel coat and laminating resin comprise crosslinked acetoacetate functionalized acrylate oligomers, and are preferably at least 50%, preferably 70 to 100%, crosslinked.
- The invention also provides methods for making a laminating resin composition. In embodiments, the method comprises:
-
- reacting a polyhydroxy polyol having at least two, preferably three, hydroxyl groups per molecule with a C1-C5 alkyl acetoacetate in a transesterification process to form a crosslinkable, multifunctional acetoacetylated polyhydroxy polyol having at least two, preferably three, acetoacetyl functional groups per oligomer; and
- combining the acetoacetylated polyhydroxy polyol with one or more multifunctional acrylate monomers or oligomers and a base catalyst to form a crosslinkable, thermosetting laminating resin composition having a Brookfield viscosity of about 50 to 1200 cps.
- The laminating resin composition can be cured at ambient temperature to form a solid, crosslinked, thermoset resin comprising crosslinked acetoacetate-functionalized acrylate oligomers, with the laminating resin being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- The invention further provides a crosslinkable, styrene free and zero VOC gel coat composition. In an embodiment, the crosslinkable gel coat composition comprises an acetoacetylated polyhydroxy polyol, one or more multifunctional acrylate monomers or oligomers, a base catalyst, and at least one additive component selected from the group consisting of fillers, pigments and thixotropic agents, and has a viscosity of about 50 to 1200 cps under high shear, and is curable under ambient conditions to form a solid thermoset gel coat comprising crosslinked acetoacetate-functionalized acrylate oligomers, the gel coat being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- The invention also provides a crosslinkable, styrene free and zero VOC laminating resin composition. In an embodiment, the crosslinkable laminating resin composition comprises an acetoacetylated polyhydroxy polyol, one or more multifunctional acrylate monomers or oligomers, and a base catalyst, and has a Brookfield viscosity of about 50 to 1200 cps, and is curable under ambient conditions to form a laminating resin comprising crosslinked acetoacetate-functionalized acrylate oligomers, the laminating resin being styrene free with zero VOCs and preferably at least 50%, preferably 70 to 100%, crosslinked.
- Also provided is a system for forming a gel coat composition. In an embodiment, the system is composed of separate containers packaged together, including:
-
- a container of a curable, thermosetting gel coat composition comprising a crosslinkable, multifunctional acetoacetylated polyhydroxy polyol having at least two, preferably three, acetoacetyl functional groups per oligomer, one or more multifunctional acrylate monomers or oligomers and at least one additive component selected from the group consisting of fillers, pigments and thixotropic agents for a gel coat;
- a container of a base catalyst selected from the group consisting of 1,8-diazabicyclo-[5.4.0]undec-7-ene (DBU), 1,5-diazabicyclo[4,3,0]non-5-ene (DBN), 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD), 7-methyl-1,5,7-triazabicyclo[4,4,0]dec-5-ene (MTBD), tetramethylguanidine (TMG) and 1,4-diazabicyclo[2.2.2]octane (DABCO), and N′-butyl-N″,N″-dicyclohexylguanidine, and mixtures thereof; and
- directions for combining the contents of the containers to form a thermosetting gel coat composition, which, in embodiments, has a viscosity of about 50 to 1200 cps under high shear, is curable at ambient temperature to form a crosslinked, styrene free and zero VOC thermoset gel coat comprising crosslinked acetoacetate-functionalized acrylate oligomers, which is preferably at least 50%, preferably 70 to 100%, crosslinked.
- A system is also provided for forming a laminating resin composition. In an embodiment, the system is composed of separate containers packaged together, including:
-
- a container of a curable, thermosetting laminating resin composition comprising a crosslinkable, multifunctional acetoacetylated polyhydroxy polyol having at least two, preferably three, acetoacetyl functional groups per oligomer and one or more multifunctional acrylate monomers or oligomers;
- a container of a base catalyst selected from the group consisting of 1,8-diazabicyclo-[5.4.0]undec-7-ene (DBU), 1,5-diazabicyclo[4,3,0]non-5-ene (DBN), 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD), 7-methyl-1,5,7-triazabicyclo[4,4,0]dec-5-ene (MTBD), tetramethylguanidine (TMG) and 1,4-diazabicyclo[2.2.2]octane (DABCO), and N′-butyl-N″,N″-dicyclohexylguanidine, and mixtures thereof; and
- directions for combining the contents of the containers to form a thermosetting laminating resin composition, which, in embodiments, has a Brookfield viscosity of about 50 to 1200 cps, is curable at ambient temperature to form a crosslinked, styrene free and zero VOC thermoset laminating resin comprising crosslinked acetoacetate-functionalized acrylate oligomers, which is preferably at least 50%, preferably 70 to 100%, crosslinked.
- Embodiments of the invention relate to methods of making zero VOC, crosslinkable, thermosetting resins from acetoacetate-functionalized polyhydroxy polyols and multifunctional acrylate monomers or oligomers for producing laminating resins and gel coat compositions, which are crosslinked using a Michael-type addition reaction with a base catalyst to obtain laminates and gel coated articles. The thermosetting resins have excellent curability at ambient or room temperatures. In embodiments, the process results in an at least 50%, preferably 70 to 100%, crosslinked thermoset polymer network that is VOC and styrene free with excellent mechanical properties.
- The thermosetting resins are crosslinked without styrene or free-radicals, using a Michael-type addition reaction with a base catalyst at ambient temperatures to incorporate acrylate functionality into a multifunctional acetoacetylated polyhydroxy polyol to produce a thermoset, crosslinked polymer network in which the acetoacetate-functionalized acrylate oligomers are up to 100% crosslinked.
- Unless otherwise specified herein, the term “viscosity” refers to the viscosity of a polymer in monomer at 25° C. (77° C.) measured in centipoise (cps) using a Brookfield RV model viscometer. The viscosity under high shear is measured by a cone and plate (CAP) viscometer at a shear rate of 10,000 l/s. The term “NVM” refers to non-volatile material dispersed in a volatile substance (e.g., monomer) as measured according to ASTM D1259.
- Unless stated otherwise, all percent and ratios of amounts are by weight.
- The acetoacetate-functionalized polyhydroxy polyol has at least two, and in some embodiments preferably at least three acetoacetyl functional groups per oligomer. The functionalized polyol is then blended with a multifunctional acrylate to form a thermosetting, crosslinkable resin.
- In embodiments of the invention, multifunctional acetoacetylated polyols can be prepared by reaction of a polyhydroxy polyol (also termed “polyhydric alcohol” or “polymeric polyol”), in a transesterification reaction with an alkyl acetoacetate compound, preferably a C1-C5 alkyl acetoacetate.
- Suitable polyhydroxy polyol compounds have an average of at least two, preferably at least three (i.e., tripolyol), hydroxyl groups per molecule. Non-limiting examples of polyhydroxy polyols include methyl propanediol (MPD), trimethylolpropane (TMP), trimethylpentanediol, di-trimethylolpropane (di-TMP), butyl ethyl propanediol (BEPD), neopentyl glycol (NEO), pentaerythritol (Penta), di-pentaerythritol (di-Penta), tris-2-hydroxyethyl isocyanurate (THEIC), 4,4′-isopropylidenedicyclohexanol (hydrogenated bisphenol-A (HBPA), hydroxyl-functionalized acrylic polymers, among others, and mixtures of two or more of such compounds. In embodiments, the polyhydroxy polyol has a hydroxyl number of from 30 up to 1850 mg/KOH/g, and a number average molecular weight of 90 up to 5000 g/mol.
- Non-limiting examples of suitable C1-C5 alkyl acetoacetates (esters of acetoacetic acid) include methyl acetoacetate (MAA), ethyl acetoacetate (EAA), n-propyl acetoacetate, isopropyl acetoacetate, n-butyl acetoacetate, tert-butyl acetoacetate (TBAA), pentyl (amyl) acetoacetate, n-pentyl acetoacetate, isopentyl acetoacetate, tert-pentyl acetoacetate, acetoacetate-functionalized acrylic polymer based on acetoacetoxyetheyl methacrylate, including copolymers with different acrylic monomers, among others, and mixtures of two or more of such compounds.
- Procedures for preparing crosslinkable, functionalized acetoacetylated polyols by reaction of a polyol with an alkyl acetoacetate compound in a transesterification reaction are generally known in the art. In embodiments, the polyol and alkyl acetoacetate compounds are reacted in a transesterification reaction at a temperature of 90 to 200° C. for 3 to 15 hours to form the functionalized polyol. In some embodiments, 10 to 90 wt % polyol is combined with 90 to 10 wt % alkyl acetoacetate, based on the total weight of the mixture.
- In embodiments, at least 70% of the hydroxyl groups of the polyhydroxy polyol are converted to acetoacetyl groups, and more preferably 80 to 100% of the hydroxyl groups are converted. In embodiments, the acetoacetylated polyols have an acetoacetyl content within a range of from 5 to 80 weight %, a hydroxyl number within a range of 0 to 60 mg KOH/g, and acid value of 0 to 5 mg KOH/g, and a number average molecular weight (Mn) within a range of 250 to 6000 g mole−1, preferably 300 to 5000 g mole−1.
- In embodiments, the acetoacetate-functionalized polyol can be prepared in a multi-stage reaction in which the polyhydroxy polyol is initially reacted by the condensation reaction with a dicarboxylic acid/anhydride or polyacid with a glycol or polyol. Non-limiting examples of suitable carboxylic acids include isophthalic acid, orthophthalic acid, terephtalic acid, succinic acid, adipic acid, maleic acid, fumaric acid, azelaic acid, 1,4-cyclohexane dicarboxylic acid, itaconic acid, sebacic acid, tetrahydrophthalic anhydride, trimelitic anhydride, among others, and mixtures of two or more of such compounds. In embodiments, the dicarboxylic acid and polyhydroxy polyol are reacted in a first stage reaction at 150 to 225° C. for about 5 to 20 hours, until an acid value of less than 20 mg KOH/g, preferably less than 10 mg KOH/g, is reached. In embodiments, the molar ratio of acid functional groups to hydroxyl functional groups is 0.2 to 0.8. In a second stage reaction, an alkyl acetoacetate compound is mixed with the resulting polyester polyol and the reaction proceeds for about 3 to 15 hours to form the acetoacetate-functionalized polyol. In embodiments, 25 to 90 wt % of the polyester polyol is combined with 75 to 10 wt % alkyl acetoacetate, based on the total weight of the mixture.
- In another embodiment, the acetoacetate-functionalized polyhydroxy polyol can be prepared in a multi-step reaction, in which a C2 to C13 alkanolamine is reacted with a cyclic, 5-ring hydroxy-functional carbonate in a first step to form a polyurethane polyol intermediate. In embodiments, the molar ratio of alkanolamine to the 5-ring carbonate is at or about close to 1 with slightly excess of carbonate. Non-limiting examples of suitable alkanolamines (also referred to as “amino alcohols”) include monoethanolamine (MEA), propanolamine, isopropanol amine, and 2-aminobutanol, among others, and mixtures of two or more of such compounds. Non-limiting examples of suitable 5-ring carbonates include glycerine carbonate (GC), ethylene carbonate, propylene carbonate and butylene carbonate, among others, and mixtures of two or more of such compounds.
- In embodiments, the alkanolamine and 5-ring hydroxy-functional carbonate are reacted at 20 to 75° C. for about 5 to 8 hours. In a second stage reaction, the resulting polyurethane polyol is mixed with an alkyl acetoacetate compound and reacted for about 3 to 15 hours to form the functionalized acetoacetylated polyol.
- In another embodiment, the acetoacetate-functionalized polyhydroxy polyol can be prepared in a multi-step reaction, in which the polyol is formed through free radical copolymerization of vinyl monomers and at least one vinyl monomer containing hydroxyl groups. The resulting polyol contains at least two, preferably three, hydroxyl functional groups in each polymer. Non-limiting examples of suitable vinyl monomers containing hydroxyl groups include hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, and hydroxylpropyl methacrylate, among others, and mixtures of two or more of such compounds. Non-limiting examples of suitable vinyl monomers include aromatic compounds such as styrene, alpha-methyl styrene, vinyl toluene, vinyl phenol and the like, and unsaturated esters such as acrylic and methacrylic ester, vinyl laurate and the like, among others, and mixtures thereof. In a second stage reaction, the resulting polyol is mixed with an alkyl acetoacetate compound and reacted for about 3 to 15 hours to form the functionalized acetoacetylated polyol.
- In another embodiment, the acetoacetate functionalized polyhydroxy polyol is made directly by free radical copolymerization of vinyl monomers and at least one vinyl monomer contains acetoacetate functional group. The resulting copolymer contains at least two, preferably three, acetoacetate functional groups in each polymer. Non-limiting examples of suitable vinyl monomers containing acetoacetate functional group include acetoacetoxyethyl methacrylate (AAEM), acetoacetoxyethyl acrylate (AAEA), acetoacetoxypropyl methacrylate, acetoacetoxypropyl acrylate, acetoacetoxybutyl methacrylate, and acetoacetoxybutyl acrylate, among others, and mixtures thereof.
- The resulting acetoacetylate-functionalized polymer is a thermosetting, crosslinkable resin, having at least two, and in some embodiments at least three, acetoacetyl functional groups per polymer, which can be used, for example, in the formulation of laminating resins and gel coat compositions.
- Gel coats (also termed “gel coat compositions”) are compositions in a curable (e.g., pre-cured) state, composed of a blend of one or more of the acetoacetate-functionalized polyhydroxy polyol resin material with one or more multifunctional acrylate monomers and/or oligomers and one or more additives. Gel coats are typically free of fibers. In embodiments, the acetoacetate-functionalized polyol is combined with the one or more multifunctional acrylate monomers or oligomers. Preferably, the molar ratio of the acetoacetate functional group to acrylate functional group is 0.2 to 5.0, and preferably, a molar ratio of 0.3 to 3.0. In embodiments, 15 to 70 wt % of the acetoacetate-functionalized polyol is combined with 15 to 70 wt % of one or more multifunctional acrylate monomers or oligomers and 2 to 40 wt-% additives, based on the total weight of the mixture.
- The gel coat composition can be prepared by high speed dispersion of the filler, pigment and other additives into the resin mixture. The viscosity of the gel coat composition (without catalyst) can range from 8,000 to 25,000 cps, and preferably 10,000 to 20,000 cps when measured by Brookfield viscometer at 4 rpm.
- Multifunctional acrylate monomers. Non-limiting examples of suitable multifunctional acrylate monomers include trimethylolpropane triacrylate (TMPTA), di-trimethylolpropane tetraacrylate, tris(2-hydroxy ethyl)isocyanurate triacrylate, ethoxylated trimethylolpropane triacrylate, polyethylene glycol diacrylate, neopentyl glycol diacrylate, pentaerythritol tetraacrylate, 1,2-ethylene glycol diacrylate, 1,6-hexanediol diacrylate, 1,12-dodecanol diacrylate, hexanediol diacrylate, tripropylene glycol diacrylate, dipropylene glycol diacrylate, amine modified polyether acrylates, glycerol propoxylate triacrylate, dipentaerythritol pentaacrylate, dipentaerythritol hexaacrylate, ethoxylated pentaerythritol tetraacrylate, and the like, as well as mixtures and combinations thereof.
- Additives. The gel coat composition includes one or more additive components, for example, one or more fillers, pigments, and/or other additives such thixotropic agents, promoters, stabilizers, extenders, wetting agent, leveling agents, air release agents, as practiced in the art to adjust and enhance the molding properties (e.g., color effect, sprayability, sag resistance, mechanical property consistency, etc.). Gel coats are typically free of fibers.
- Examples of fillers for gel coats include inorganic (mineral) fillers, such as clay, magnesium oxide, magnesium hydroxide, aluminum trihydrate (ATH), calcium carbonate, calcium silicate, mica, aluminum hydroxide, barium sulfate, talc, etc., and organic fillers. The amount of filler in the gel coat composition can generally range from 5 up to 30 wt %, based on the total weight of the gel coat composition. Suitable pigments include inorganic pigments, such as titanium dioxide. Thixotropic agents include silica compounds such as fumed silica and precipitated silica, and inorganic clays such as bentonite clay, which, if included, can be present in an amount ranging from 0.3 up to 6 wt %, based on the total weight of the gel coat composition.
- In embodiments, the acetoacetate-functionalized polyhydroxy polyol resin material can be combined with one or more multifunctional acrylate monomers/oligomers (as described above) to form a curable laminating resin composition. In embodiments, the laminating resin composition is composed of 10 to 90 wt % of the acetoacetate-functionalized polyol combined with 90 to 10 wt % of multifunctional acrylate monomers/oligomers, based on the total weight of the mixture. Preferably, the ratio of the functionalized polyol to multifunctional acrylate monomer/oligomer is 0.2 to 8.5, and more preferably a ratio of 0.25 to 8.0 (w/w). The viscosity of the laminating resin composition is preferably about 50 to 1200 cps.
- In use, the laminating resin composition is combined with a base catalyst, and can be utilized in many applications such as for coatings and in reinforced composite products by various open and closed molding processes such as spray-up, hand lay-up, resin transfer molding and wet molding.
- In use, the gel coat composition is combined with a base catalyst and applied as an in-mold coating, typically by manual application or using a gel coat spray technique, onto the surface of a mold that is in the shape and form of the desired article (e.g., bathtub, car or aircraft part, boat hull, swimming pool, etc.). The gel coat is allowed to partially cure such that it is tacky to tacky-free.
- The amount of base catalyst included in the gel coat composition is typically 0.2 to 2.5% by weight, based on the total weight of the composition. For optimal processibility, gel time and cure time, the viscosity of the gel coat (with catalyst) can range from 8,000 to 25,000 cps, and preferably 10,000 to 20,000 cps measured by Brookfield viscometer at 4 rpm. Preferably, the gel time of the gel coat is 5 to 30 minutes at ambient temperature. The term “gel time” refers to the time from catalyzation of the gel coat (or laminating resin) to cessation of flow.
- Crosslinking of the laminating resin and gel coat occurs by a base-catalyzed Michael-type addition reaction of the acetoacetate-functionalized polyhydroxy polyol and multifunctional acrylate monomers or oligomers at ambient temperatures (about 20 to 25° C.), without heat or UV radiation. The base catalysts are nitrogen containing compounds, which can be represented by the general formula RxRyRzN, where Rx, Ry, and Rz each individually may represent hydrogen, or a C1-C20 alkyl, aryl, alkylaryl or arylalkyl group, that each optionally may contain one or more hetero-atoms (e.g. oxygen, phosphor, nitrogen or sulfur atoms) and/or substituents. The group may be linear or branched; they also may contain one or more unsaturations or substituents. This general formula RxRyRzN also represents nitrogen compounds, wherein the nitrogen atom shown in the formula is part of a cyclic system formed by two of the groups Rx, Ry, and Rz, or is present in the form of an imine group or as a phosphazene. Non-limiting examples of suitable base catalysts include 1,8-diazabicyclo-[5.4.0]undec-7-ene (DBU), 1,5-diazabicyclo[4,3,0]non-5-ene (DBN), 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD), 7-methyl-1,5,7-triazabicyclo[4,4,0]dec-5-ene (MTBD), tetramethylguanidine (TMG) and 1,4-diazabicyclo[2.2.2]octane (DABCO), and N′-butyl-N″,N″-dicyclohexylguanidine, and the like. In embodiments, the base catalyst can be combined with an organic solvent such as methanol, ethanol, propanol, n-butyl alcohol, acetone, methyl ethyl ketone, among others, and mixtures thereof. In preferred embodiments, the base catalyst is used neat (absence of a solvent).
- The article can be a fully or partially cured polymer resin or composite of reinforcing material in a polymer resin matrix. In embodiments, a reinforcing material for forming the article is laid into the open mold onto the partially cured gel coat material. Non-limiting examples of reinforcing materials include glass fiber, polyethylene fiber, carbon fiber, metal fiber, ceramic fiber, or other material used in the composite plastics industry. In embodiments, dry fibers (e.g., glass fibers, glass fiber matt, etc.) are laid onto the partially cured gel coat within the open mold.
- The reinforcing material is then wet out by applying a laminating resin in a curable (i.e., pre-cured) state that has been combined with a base catalyst. In embodiments, the laminating resin is composed of 10 to 90 wt % of the acetoacetate-functionalized polyol, 90 to 10 wt % of multifunctional acrylate monomers or oligomers, and 0.2 to 2.5 wt % base catalyst, based on the total weight of the mixture.
- The laminating resin is allowed to cure to form a hardened fiber-reinforced resin composite in the desired shape within the mold. The gel coat becomes an integral part of the finished laminate article by forming a covalent interfacial bond with the laminating resin that is used. The gel coat provides a primary bond at the interface with the composite article, unlike the application of a resin coating onto the formed article.
- Curing of the laminating resin can be conducted at ambient temperature for about 4 to 40 hours. The gel coated, composite article can then be removed from the mold for use. In some embodiments, the laminate can undergo a post-cure, for example, by heating the mold to an elevated temperature (i.e., to 65° C.) to further increase the degree of cure.
- The gel coats of the invention provide a durable and high weather- and wear-resistant coating with good hydrolytic stability, and/or an aesthetic finished surface to the article being produced to improve surface appearance. The gel coats also provide a resilient, light-stable surface covering and, in embodiments, are sufficiently pigmented to yield a desired color. The base catalyzed Michael addition of acetoacetylated resins to acrylate acceptors produces crosslinked networks with low to no volatile organic compounds (VOCs). In embodiments, the cured gel coat and/or laminating resin is at least 50% crosslinked, and preferably 70 to 100% crosslinked. Such crosslinking can be assessed, for example, by measuring the residual reaction exotherm by differential scanning calorimetry (DSC).
- The invention will be further described by reference to the following detailed example. This example is not meant to limit the scope of the invention that has been set forth in the foregoing description. Variation within the concepts of the invention is apparent to those skilled in the art. The disclosures of the cited references throughout the application are incorporated by reference herein.
- The following examples are illustrations of the present invention. They are not to be taken as limiting the scope of the claimed invention. Unless stated otherwise, all percent and ratios of amounts are by weight.
- Materials and Abbreviations.
- The following materials were used in the Examples below.
-
Ingredient SR355 Di-trimethylolpropane tetraacrylate(Sartomer Co.) SR368 Tris(2-hydroxy ethyl)isocyanurate triacrylate(Sartomer Co.) SR454 Ethoxylated trimethylolpropane triacrylate(Sartomer Co.) TMPTA Trimethylolpropane triacrylate DBU 1,8-Diazabicyclo-[5.4.0]undec-7-ene DABCO 1,4-Diazabicyclo[2.2.2]octane TMG Tetramethylguanidine - A 3 liter, 4-neck round-bottom flask fitted with mechanical stirrer, pressure equalizing addition funnel (nitrogen inlet), thermocouple connected to a controller and heating mantle, was charged with 604 g (4.50 mol) trimethylolpropane (TMP), 850 g toluene and 303 g (1.92 mol) tert-butyl acetoacetate. The mixture was heated to about 110° C. Additional tert-butyl acetoacetate, 1881 g (11.89 mol), was gradually added into flask through additional funnel over about 5 hours. After all tert.-butyl acetoacetate was added, the mixture temperature was increased gradually to 135° C. and keep at this temperature for 2 hours. A vacuum (26″ Hg) was applied to remove unreacted liquid and a slight yellow liquid product of 1713 g was obtained.
- The reaction is illustrated in Scheme 1 below.
- A 2 liter, 4-neck round-bottom flask fitted with mechanical stirrer, pressure equalizing addition funnel (nitrogen inlet), thermocouple connected to a controller and heating mantle, was charged with 628 g (2.40 mol) tris(hydroxyl ethyl)isocyanurate (THEIC) and 1140 g (7.20 mol) tert-butyl acetoacetate. The mixture was heated gradually to about 150° C. in 5 hours and keep at this temperature for another 2 hours. A vacuum (26″ Hg) was applied to remove unreacted liquid and a yellow liquid product of 1214 g was obtained.
- The reaction is illustrated in Scheme 2 below.
- A 1 liter, 4-neck round-bottom flask fitted with mechanical stirrer, pressure equalizing addition funnel (nitrogen inlet), thermocouple connected to a controller and heating mantle, was charged with 481 g (2.00 mol) 4,4′- isopropylidenedicyclohexanol (hydrogenated bisphenol-A (HBPA)) and 163 g (1.03 mol) tert-butyl acetoacetate. The mixture was heated to about 110° C. Additional tert-butyl acetoacetate, 502 g (3.17 mol), was gradually added into flask through additional funnel over about 3 hours. After all tert-butyl acetoacetate was added, the temperature was increased gradually to 150° C. and keep at this temperature for 2 hours. A vacuum (26″ Hg) was applied to remove unreacted liquid and a yellow liquid product of 865 g was obtained.
- The reaction is illustrated in Scheme 3.
- To a three-neck, round-bottom flask equipped with a mechanical stirrer, thermocouple connected to a controller and heating mantle, a Dean-Stark trap, a nitrogen inlet, and a water condenser, was charged 831 g (5.00 mol) isophthalic acid (IPA) and 1342 g (10.00 mol) trimethylolpropane (TMP). The mixture was allowed to react at 215° C. for 8 hours until the acid number was determined to be less than 3.0 mg KOH/g equivalent.
- To 1038 g of the above resulting polyester polyol, 1684 g tert-butyl acetoacetate was gradually added over about 3 hours at 160-170° C. After all tert-butyl acetoacetate was added, the temperature was increased gradually to 180° C. and kept at this temperature for another 2 hours. A vacuum (26″ Hg) was applied to remove unreacted liquid and a yellow liquid product of 1846 g was obtained.
- The reaction is illustrated in scheme 4.
- To a three-neck, round-bottom flask equipped with a mechanical stirrer, thermocouple connected to a controller and heating mantle, a Dean-Stark trap, a nitrogen inlet, and a water condenser, was charged 184 g (3.00 mol) ethanolamine (EA). 358 g (3.00 mol) 4-hydroxymethyl-1,3-dioxolan-2-one (glycerine carbonate (GC)) was added into the flask over 0.5 hr at 20-40° C. The mixture was allowed to react at 40-75° C. for 6 hours.
- To the resulting urethane tripolyol, 1424 g tert-butyl acetoacetate was added and the temperature was increased gradually to 140° C. and kept at this temperature for another 3 hours. A vacuum (26″ Hg) was applied to remove unreacted liquid and a dark yellow liquid product of 1239 g was obtained.
- The reaction is illustrated in Scheme 5.
- To a three-neck, round-bottom flask equipped with a mechanical stirrer, thermocouple connected to a controller and heating mantle, a Dean-Stark trap, a nitrogen inlet, and a water condenser, was charged 500 g of xylene. A monomer solution of 638 g (2.87 mol) isobornyl methacrylate, 1052 g (4.91 mol) acetoacetoxyethyl methacrylate, 66 g dicumyl peroxide and 3 g 2-mercaptoethanol was added over 4 hr at 140° C. The mixture was allowed to react at 140° C. for another 2 hr. A vacuum (26″ Hg) was applied to remove xylene and unreacted liquid. The obtained methacrylate copolymer is solid at room temperature.
- The reaction is illustrated in Scheme 6 below.
- A gel coat composition was prepared by mixing, respectively, 252 g of the IPA-TMP Tetra-Acetoacetate from Example 4, 184 g of TMPTA, 120 g of titanium dioxide, 30 g of talc and 4 g of fumed silica under high shear. The gel coat composition had a Brookfield viscosity of 20,000 centipoise (cps) at 25° C. (77° C.) at 4 rpm.
- A laminating resin was prepared by mixing, respectively, 263 g of IPA-TMP Tetra (Acetoacetate) from Example 4 and 285 g of TMPTA. The laminating resin composition had a Brookfield viscosity of 900 centipoise (cps) at 25° C. (77° C.).
- A catalyst solution of DBU was prepared by dissolving 20 g DBU in 7 g ethanol. The solution is a clear liquid.
- A catalyst solution of DABCO was prepared by dissolving 30 g DABCO in 20 g ethanol. The solution is a clear liquid.
- 200 g of the gel coat composition from Example 7 was mixed with 2.7 g DBU catalyst solution from Example 9 by hand. The gel coat composition was sprayed on a waxed and buffed flat tempered glass plate to a thickness of 15-40 mils (1 mil=0.001 inch). After 20 minutes at room temperature (25° C.), the gel coat film was tacky free.
- 200 g of the laminating resin from Example 8 was mixed with 2.48 g (1.24 wt-%) DBU catalyst solution from Example 9. A ⅛″ laminate was formed by applying a 1.5 oz chop-strained mat and the laminating resin/DBU catalyst mixture onto the gel coat film. The laminate was allowed to cure for 16-20 hours at ambient temperature (25° C.), then removed from the mold and cut into test parts.
- Gel coat formulations were prepared by mixing, respectively, TMPTris (Acetoacetate) (150 g) prepared from Example 1, the acetoacetate-functionalized methacrylate copolymer resin (68 g) prepared from Example 6, TMPTA (184 g), heptadecafluorodecyl acrylate (9 g, Zonyl TA-N from DuPont), titanium dioxide (120 g), talc (30 g) and fumed silica (4 g). The gel coat composition had a Brookfield viscosity of 16650 centipoise (cps) at 25° C. (77° C.) at 4 rpm.
- The gel coat composition (200 g) prepared from Example 7 was mixed with the catalyst solution of DBU (1.0 g) and ethanol (0.3 g), and sprayed on a waxed and buffed flat tempered glass plate to a thickness of 15-40 MILS (1 MIL-0.001 inch). After 20 min., the gel coat film was tacky free and a barrier coat (ARMORGUARD from CCP) was sprayed onto the film to a thickness of 23 MILS. A ⅛″ laminate is made using chopped fiberglass and a polyester resin (STYPOL LSPA-2200, 40% mat/60% resin). Methyl ethyl ketone peroxide (MEKP) co-initiator at 1.2 wt % is used to cure the polyester resin. The laminate is allowed to cure for 16-20 hours at room temperature, then removed from the mold and cut into test parts.
- The gel coat composition (200 g) prepared from Example 7 was mixed with the catalyst solution of DABCO (1.0 g) and ethanol (1.0 g), and sprayed on a waxed and buffed flat tempered glass plate to a thickness of 15-40 MILS (1 MIL-0.001 inch). After 12 hr., the gel coat film was somewhat tacky and a barrier coat (ARMORGUARD from CCP) was sprayed onto the film to a thickness of 23 MILS. A ⅛″ laminate is made using chopped fiberglass and a polyester resin (STYPOL LSPA-2200, 40% mat/60% resin). Methyl ethyl ketone peroxide (MEKP) co-initiator at 1.2 wt % is used to cure the polyester resin. The laminate is allowed to cure for 16-20 hours at room temperature and 5 hours at 100° C., then removed from the mold and cut into test parts.
- Clear castings were prepared by mixing the resin, acrylate, and catalyst listed in Table 1 (below) by hand and pouring the resin mixture into a cavity between two glass plates with ⅛″ spacing. The resin was cured at ambient temperature overnight and post-cured at 100° C. for 5 hours. The cured resins were tested for physical properties according to ASTM D638, D648, and D790. The results are listed in Table 1.
-
TABLE 1 Physical properties of clear casting of resin Example 15 16 17 18 19 20 21 Resin, weight (g) Ex 1, 100 Ex 1, 100 Ex 1, 55 Ex 2, 162 Ex 4, 132 Ex 5, 165 Ex 1, 150 Ex 6, 68 Acrylate, weight (g) TMPTA, SR355, SR368, 48 TMPTA, TMPTA, TMPTA TMPTA 100 100 SR454, 76 124 143 g 113 184 TMPTA, 55 Catalyst, weight (g) TMG, 0.7 DBU, 0.7 Ex 10, 3.6 Ex 9, 2.3 Ex 9, 2.3 Ex 9, 2.4 Ex 9, 2.3 Viscosity (cp) 95 310 1000 1000 900 — 340 Mechanical Properties Tensile Strength (psi) 7500 6680 10460 10760 6510 8720 8840 Tensile Modulus (ksi) 451 449 514 509 420 456 468 Elongation (%) 2.3 1.9 3.2 3.9 1.7 4.3 3.6 Flex Strength (psi) 13730 12610 17270 18130 16700 8600 1510 Flex Modulus (ksi) 432 438 488 510 477 318 433 HDT (° C.) 62 48 70 77 86 34 69 - The mechanical properties of the examples have comparable properties to typical unsaturated polyester resins.
- The invention has been described by reference to detailed examples and methodologies. These examples are not meant to limit the scope of the invention. It should be understood that variations and modifications may be made while remaining within the spirit and scope of the invention, and the invention is not to be construed as limited to the specific embodiments disclosed. The disclosures of references cited in the application are incorporated by reference herein.
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US14/800,245 Abandoned US20160108248A1 (en) | 2012-03-09 | 2015-07-15 | Acetoacetyl Thermosetting Resin for Gel Coat |
US15/821,168 Active 2033-10-10 US11091651B2 (en) | 2012-03-09 | 2017-11-22 | Acetoacetyl thermosetting resin for gel coat |
Country Status (14)
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US (3) | US20130233739A1 (en) |
EP (1) | EP2823000A1 (en) |
KR (1) | KR102258870B1 (en) |
CN (2) | CN111690277A (en) |
AU (1) | AU2013229383B2 (en) |
BR (1) | BR112014019279A2 (en) |
CA (1) | CA2865461C (en) |
EA (1) | EA201491664A1 (en) |
HK (1) | HK1199898A1 (en) |
MX (1) | MX2014009992A (en) |
MY (2) | MY191989A (en) |
PH (1) | PH12014501951A1 (en) |
WO (1) | WO2013132077A1 (en) |
ZA (1) | ZA201405845B (en) |
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WO2019139069A1 (en) * | 2018-01-15 | 2019-07-18 | 共栄社化学株式会社 | Unsaturated group-containing ester compound, polymer, thermosetting resin composition, and cured film |
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US11820923B2 (en) | 2018-12-11 | 2023-11-21 | Eastman Chemical Company | Controlled cure for compositions comprising acetoacetylated resins |
US11920050B2 (en) * | 2018-12-11 | 2024-03-05 | Eastman Chemical Company | Self-curable and low temperature curable coating compositions |
CN115335467A (en) * | 2020-03-30 | 2022-11-11 | 汉高股份有限及两合公司 | Curable potting composition free of highly interesting substances |
Also Published As
Publication number | Publication date |
---|---|
MY191989A (en) | 2022-07-21 |
MY168751A (en) | 2018-11-30 |
CN111690277A (en) | 2020-09-22 |
KR102258870B1 (en) | 2021-05-31 |
US20160108248A1 (en) | 2016-04-21 |
EP2823000A1 (en) | 2015-01-14 |
PH12014501951B1 (en) | 2014-11-24 |
BR112014019279A2 (en) | 2019-08-20 |
CA2865461C (en) | 2021-11-02 |
MX2014009992A (en) | 2014-11-25 |
WO2013132077A1 (en) | 2013-09-12 |
CA2865461A1 (en) | 2013-09-12 |
CN104204109A (en) | 2014-12-10 |
ZA201405845B (en) | 2015-08-26 |
US20180094142A1 (en) | 2018-04-05 |
PH12014501951A1 (en) | 2014-11-24 |
AU2013229383B2 (en) | 2017-01-12 |
EA201491664A1 (en) | 2014-12-30 |
US11091651B2 (en) | 2021-08-17 |
KR20140131953A (en) | 2014-11-14 |
AU2013229383A1 (en) | 2014-09-25 |
HK1199898A1 (en) | 2015-07-24 |
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