US20180291231A1 - Epoxy resin-based gel coat for surface finishing of components made of fibre-reinforced plastics - Google Patents

Epoxy resin-based gel coat for surface finishing of components made of fibre-reinforced plastics Download PDF

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Publication number
US20180291231A1
US20180291231A1 US16/004,441 US201816004441A US2018291231A1 US 20180291231 A1 US20180291231 A1 US 20180291231A1 US 201816004441 A US201816004441 A US 201816004441A US 2018291231 A1 US2018291231 A1 US 2018291231A1
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Prior art keywords
composition
gelcoat
recited
main component
component
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US16/004,441
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Jens Buening
Jochen Wehner
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Mankiewicz Gebr and Co GmbH and Co KG
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Mankiewicz Gebr and Co GmbH and Co KG
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Priority to US16/004,441 priority Critical patent/US20180291231A1/en
Publication of US20180291231A1 publication Critical patent/US20180291231A1/en
Abandoned legal-status Critical Current

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    • 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
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/0427—Coating with only one layer of a composition containing a polymer binder
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/046—Forming abrasion-resistant coatings; Forming surface-hardening coatings
    • C08J7/047—
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
    • C08L75/04—Polyurethanes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2475/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2475/04—Polyurethanes
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y02E10/721—
    • 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]
    • Y10T428/31511—Of epoxy ether

Definitions

  • the present invention relates to compositions based on epoxy resins for the production of gelcoats and the use of said gelcoats for the surface treatment of fiber reinforced plastics.
  • the present invention also relates to processes for the production of the gelcoats, as well as to processes for the manufacture of surface treated components made of fiber reinforced plastics, in particular to manufacturing processes that employ prepegs.
  • Surfaces of laminates or components composed of fibers such as glass fibers, carbon fibers, or plastic fibers in a matrix of curable resins such as epoxy resins, unsaturated polyester resins, or vinyl ester resins generally feature less acceptable surfaces, which, moreover, are not resistant to light and weathering. These must first be treated with protective coatings if these components are to be employed in applications for which decorative or weather-resistant surfaces are required.
  • Components' surfaces are as a rule painted with suitable coating materials, predominantly weather-resistant and anticorrosive paints, for example, those based on aliphatic polyurethanes.
  • suitable coating materials predominantly weather-resistant and anticorrosive paints, for example, those based on aliphatic polyurethanes.
  • the surfaces to be painted must, however, first undergo complex pretreatment.
  • Surfaces ready for painting are usually obtained following a number of process steps. The surface of the demolded component is first sanded to effect a complete removal of any mold releasing agents. The surface is then coated or smoothed with a filling compound to level out any surface defects such as pores or individual protruding fibers exposed by the sanding treatment. Once the filling compound has hardened, the surface is again sanded to obtain a smooth surface ready for painting.
  • a gelcoat is a composition based on a resin system and is applied to the surfaces of components using an in-mold composite construction process.
  • the use of gelcoats yields smooth surfaces during the manufacturing process of the component, which surfaces are ideal for sanding.
  • the surfaces may then be painted immediately following sanding.
  • the gelcoat is generally placed in a component mold as the first layer, which is then pre-cured or incipiently gellated to an extent at which the dryness grade 6 in accordance with DIN 53 150 has been reached, at which it complies with the mechanical requirements for subsequent processing.
  • Fibers for example, in the form of woven fabrics, non-woven fabrics, or laid webs, and the laminating resin containing the thermosetting resin employed as a matrix are then placed on the partially gellated gelcoat film. The entire composition is then hardened to completion.
  • the gelcoat film must be sufficiently stable that the fibers can be applied, and where necessary removed again, without damaging the film. In the case of extremely large molds, such as rotor blades for wind turbines, woven fabrics or non-woven fabrics are usually applied by hand. It must consequently also be possible to walk on the gelcoat film without the film sustaining damage.
  • the filler distributed in the resin system forms a framework which provides the required mechanical stability with only minimal precuring or only after minimal progression of the curing reaction of the gelcoat.
  • the use of transparent gelcoats is more advantageous since laminating flaws, such as gas bubbles or dry areas in the laminate which have not been coated by resin, can be readily detected and repaired following removal of the component from the mold.
  • Transparent gelcoats not containing filler require a much more intense curing process to0 achieve the required stability of the film. More intense progression of the curing reaction, however, results in considerably shorter laminating times.
  • the laminating time is taken to be the amount of time occurring between the point in time at which the gelcoat placed in the mold becomes tack-free and the point in time at which the gelcoat film must be sufficiently laminated to provide adhesion between the gelcoat and the laminate.
  • An aspect of the present invention is to provide improved materials and procedures to allow for the use of transparent gelcoats, in particular in prepreg procedures, whilst retaining the known advantages thereof.
  • the present invention provides a composition for the manufacture of a gelcoat which includes a main component and a curing component.
  • the main component comprises at least one epoxide resin selected from the group consisting of glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylolpropane triglycidyl ethers, and mixtures thereof, and up to 5 wt.-% of at least one of a filler and a pigment based on a total weight of the main component.
  • the curing component comprises at least one cycloaliphatic amine.
  • the main component or the curing component further comprises at least one polytetrahydrofuran polyol.
  • the gelcoat is transparent.
  • compositions of the present invention for the production of a gelcoat contain a main component which contains at least one or more epoxy resins, and a curing component which contains one or more amines.
  • a curing component which contains one or more amines.
  • the epoxy resin-based gelcoats according to the present invention do not indicate any monomeric emissions. They also show only minimal shrinkage during curing, or no shrinkage at all, and thus avoid stresses in the composite material or gelcoat boundary surface so as to provide a stable boundary surface.
  • Epoxy resin-based composite materials (EP) moreover demonstrate excellent adhesion to the gelcoats of the present invention.
  • Epoxy resins suitable for use in the present invention are aromatic glycidyl compounds such as glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, phenol novolak glycidyl ethers, cresol novolak glycidyl ethers, glyoxal tetraphenol tetraglycidyl ethers, p-tert.
  • butylphenol glycidyl ethers cresyl glycidyl ethers, N,N-diglycidyl aniline, p-aminophenol triglycid, tetraglycid-4,4′-methylene dianiline, cycloaliphatic glycidyl compounds such as methyl tetra hydro phthalic diglycidyl ether, hexahydrophthalic diglycidyl ether, cyclohexane dimethanol diglycidyl ether, glycidyl ethers of hydrated bisphenol A and glycidyl ethers of hydrated bisphenol F, epoxidated cycloolefins, aliphatic glycidyl ethers such as trimethylolpropane triglycidyl ether, the diglycidyl ethers of 1,6-hexane diol and 1,4-butane diol, n-dodecyl
  • Low-viscosity and medium-viscosity fluid epoxy resin types, semi-solid and solid epoxy resin types as well as combinations thereof may also be used.
  • the use of glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylol propane triglycidyl ethers and combinations thereof can, for example, be used.
  • Epoxy resins are used in quantities of from 40 to 90%, for example, between 60 and 80%, and, for example, between 65 and 75% by weight, based on the main component.
  • the composition furthermore contains one or more polyols.
  • the polyols may be present in the main component as well as in the curing component.
  • the polyols can, for example, be used in the main component.
  • Suitable polyols include polyacrylate polyols, polyester polyols, polyether polyols, polycarbonate polyols, polycaprolactones, and polyurethane polyols.
  • the average molecular weights based on the number average of polyols can, for example, be 1000 to 3000 g/mol, for example, between 1500 and 2500 g/mol, and, for example, between 1800 and 2000 g/mol.
  • the polyols are applied in amounts of from 2 to 40%, for example, between 5 and 30%, and, for example, between 10 and 20%, by weight of polyols, based on the main component including the polyols.
  • Polytetrahydrofuran polyols can, for example, be used.
  • fillers and/or pigments may be added in small amounts.
  • the fillers are considered below to be particulate substances virtually insoluble in the application medium and are used in order to influence the optical characteristics. They may moreover also be conducive to increasing volume in order to achieve or improve technical properties.
  • the term pigments relates below to substances that are virtually insoluble in the application medium and that are applied as chromophoric substances or dyes.
  • the compositions of the present invention are very slightly dulled with fillers and/or pigments to facilitate management thereof to the effect that material which has already been applied is more readily discernible during the application process.
  • the content of fillers and/or pigments in the main component of the compositions of the present invention can, for example, be not more than 5%, for example, not more than 2%, for example, not more than 1%, and, for example, not more than 0.5%, by weight of the main component.
  • the composition will become non-transparent if greater quantities are added.
  • Suitable fillers and pigments include mineral materials such as kaolin or talcum, synthetic materials such as barium sulphate or calcium carbonate, and also inorganic or organic pigments as used conventionally in paint production, and combinations thereof. Titanium dioxide or soot can, for example, be used in accordance with the present invention.
  • the curing component can, for example, contain one or more amines.
  • Suitable amines include polyamines selected from the group consisting of polyethylene polyamines such as ethylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, pentaethylene hexamine, pentane-1,3-diamine, 2-methyl pentamethylene diamine, propylene amines such as propylene diamine, dipropylene triamine, dimethylaminopropylamine, trimethyl hexamethylene diamine, polyether polyamines such as polyoxypropylene diamines or polyoxypropylene triamines, polyoxypropylene polyamines, polyoxyethylene polyamines, polytetrahydrofuran polyamines, or butanediolether diamines or N-aminopropyl cyclohexyl amine, alkylene diamines such as hexamethylene diamine, trimethylhexamethylene diamine,
  • Cycloaliphatic amines and in particular isophorone diamine, can, for example, be used.
  • the amines are added in quantities of from 60 to 100%, for example, between 80 and 95%, and, for example, between 85 and 95% by weight of the curing component.
  • the curing components of the present invention may additionally include accelerants.
  • Suitable accelerants are tertiary amines such as N,N-dimethyl aniline or dimethyl benzylamine, alkoxides, imidazoles, Mannich bases such as (dimethyl aminomethyl)phenol or tris(dimethyl aminomethyl)phenol, boron trifluoride complexes, Broensted acids, alkyl phenols, polyphenols, onium salts, triarylsulfonium salts, iron arene complexes or salts of alkali metals or of alkaline earth metals such as lithium bromide or calcium nitrate.
  • Accelerants can, for example, include phenols, polyphenols, alkali metal salts or alkaline earth metal salts. Calcium nitrate tetrahydrate can, for example, be added.
  • the accelerator is added in quantities of from 0.2 to 40%, for example, from 0.5 to 20%, and, for example, from 1 to 10% by weight of the curing component.
  • the composition contains plasticisers.
  • Suitable plasticisers are polyurethane prepolymers having blocked isocyanate groups.
  • the plasticisers can be present in the main component as well as in the curing component.
  • Isocyanate prepolymers blocked with substituted phenols and/or pyrazoles can, for example, be added in the main component as described in EP 0688803 A1, the disclosure of which is incorporated by reference herein.
  • Linear polymers having terminal isocyanate groups blocked with alkylphenol groups can, for example, be used. If the plasticisers are added to the curing component, isocyanate prepolymers in which the isocyanate groups are blocked with secondary monoamines, as described in EP 0457089 A2, can, for example, be used. The disclosure of EP 0457089 A2 is incorporated by reference herein.
  • compositions according to the present invention may further contain conventional additives as commonly used by the person skilled in the art.
  • Rheology modifiers such as fumed silica, flow control agents or defoamers, for example, may thus be used in the usual quantities.
  • epoxy resins and amines can, for example, be used in the molar ratio of epoxy groups to N—H-groups reactive to epoxy groups (EP:N—H) of from 1 to 0.7 to 1 to 1.4, for example, from 1 to 0.8 to 1 to 1.3, and, for example, from 1 to 0.9 to 1 to 1.2.
  • the gelcoats which can be produced from the compositions according to the present invention are transparent, that is to say, they exhibit a poor hiding power.
  • the hiding power of the gelcoat according to the present invention is defined in DIN EN ISO 2814 on a checkered card. The hiding power measured thereby can only be ascertained at a film thickness of more than 1 mm. The film thickness of an applied gelcoat is considerably less and usually measures approx. 500 ⁇ m.
  • the gelcoats according to the present invention show relatively short gellation times. Due to these short gellation times, the hold time for the mold is reduced considerably, allowing for shorter mold hold cycles.
  • the materials are tenacious and not brittle in the form of a gelcoat film in an insidiously gellated state.
  • a comparison with regular transparent gelcoats shows considerably superior elongation at break and tear propagation strength in the case of the gelcoat according to the present invention. Repositioning of applied prepregs according to the present invention without causing damage thereto is also possible when using the gelcoat films.
  • the gelcoats according to the present invention exhibit the mechanical stability required for subsequent processing stages. They in particular also fulfill the requirements for the manufacture of laminates or fiber plastic composite components in the prepreg process. As with the conventional, filled gelcoats, they also exhibit excellent adhesion to the laminate, are easily sanded in a cured state, and are suitable for the application of paint thereon.
  • the present invention also provides the use of the gelcoat according to the present invention for the surface treatment of fiber plastic composite components or laminates.
  • the gelcoat can, for example, be applied to surfaces of the component using the in-mold method.
  • the gelcoat film is placed in the component mold as a first layer to this end.
  • the composition according to the present invention is first added to a mold following mixing of its reaction components, the main component and the curing component, within the pot life.
  • the pot life is the period during which the mix remains workable. It begins at the point in time at which the two reaction components are mixed and ends at the point in time at which the viscosity of the reaction mixture has risen to such an extent that it is possible to apply a layer that is even in thickness.
  • the layer obtained following gellation is sufficiently mechanically stable that it does not sustain damage upon application of the laminating resin and the fibers, but is sufficiently reactive to create a stable bond when the laminating resin cures.
  • the laminating resins used are epoxy resins, unsaturated polyester resins, and vinyl ester resins.
  • the fibers used are woven fabrics, laid webs, and non-woven fabrics of glass, carbon, or plastic fibers.
  • the gelcoats according to the present invention can, for example, be used for the surface treatment of epoxy resin composite materials because they exhibit better adhesion to these materials than gelcoat based on other resinous systems. They also do not contain any volatile monomers and are therefore less encumbering with regard to industrial hygiene.
  • the present invention also provides a method for manufacturing surface-treated fiber plastic composite components or laminates. Firstly, the required two components, the main component and the curing component, are mixed with the composition of the present invention. The mixture is transferred to the component mold as a first layer using the application method conventionally applied by the expert, for example, by painting, rolling, spraying, or pouring. The applied mixture is then gellated or pre-cured to form a gelcoat film. Fibers in the form of woven fabrics, laid webs, or non-woven fabrics, as well as the laminating resin are then applied to the gelcoat film. In the next stage, the entire composite mixture is hardened to form the desired component. The component is then removed from the mold and its surface is subsequently sanded and then painted.
  • Fibers and laminating resins can be applied to the gelcoat film by various methods. Usual laminating methods, such as the vacuum bag method, the injection method, the infusion method, and the wet laminating method are known to the person skilled in the art.
  • One way of producing the fiber composite material involves the use of prepregs. Prepregs are impregnated resin/fiber mats which are placed in the component mold. The resin is partially pre-cured and exhibits relatively strong adhesion properties at room temperature.
  • One problem incurred by the use of prepregs is that of repositioning on the gelcoat film. Component molds are generally pretreated with a mold release agent to ensure that the gelcoat film itself will not stick to the mold.
  • the gelcoat When adhesive prepreg is applied to the gelcoat and then removed therefrom, the gelcoat should not tear or break. Since there is no adhesiveness relatively to the mold, the gelcoat film must accordingly be mechanically stable.
  • the gelcoats according to the present invention form films which exhibit the required mechanical properties, and can therefore be used in prepreg methods.
  • the compositions of the present invention also require only short gellation times. Since the curing process is considerably quicker in the prepreg method than in other methods, they are particularly suitable for use in these methods also for this reason.
  • gelcoat compositions according to the present invention are examined below to compare the properties of the gelcoats according to the present invention with those of commercially-used transparent gelcoats.
  • the elongation at break was determined via a mandrel bending test in accordance with the test specification set forth in DIN EN ISO 1519. Metal plates, to which the coating under test were applied, were bent around a mandrel. The smaller the radius of the mandrel around which the plate could be bent without damaging or fracturing the coating, the greater the elongation at break of the coating.
  • the tear propagation resistance was determined via tear propagation tests in accordance with test specification set forth in DIN EN ISO 13937-2. The force necessary to enlarge a crack in the coating undergoing examination was measured. The greater the applied force, the more tear-resistant the coating.
  • the prepreg repositioning was determined via the following test set-up which simulates a laminate structure in a component mold.
  • a mold release agent was applied to a sufficiently large metal plate.
  • a gelcoat composition was then coated over an area of 1 m 2 on the prepared plate.
  • the composition was gellated on the gelcoat film at the prescribed temperature and for the prescribed duration.
  • a prepreg of dimensions DIN A4 was laid centrally on the gelcoat film and pressed down firmly with a defined force for 1 minute. The prepreg was then removed swiftly at an angle of 90 °. Visible damage to the gelcoat film was rated as follows:
  • Tables 2a and 2b show the results of the tests on gelcoat films gellated under various conditions.
  • the gelcoats according to the present invention show considerably improved values in relation to elongation at break and tear growth resistance.
  • the removal of a prepreg applied under pressure did not cause any damage to the gelcoat according to the present invention. It may thus be applied in processes involving prepregs without incurring the usual disadvantages.
  • the following tests for adhesion of the laminate to the gelcoat, for sandability, and for paintability were performed on the cured laminates.
  • the gelcoat compositions were placed in a mold and gellated, the prepreg was then applied to the gelcoat film. The mold was sealed and a vacuum bag attached and evacuated. The entire composition was then cured, the curing conditions being prescribed by the respective prepreg used. The following tests were performed on the cured laminates.
  • the elongation at break was determined using the aforementioned mandrel bending test. Metal strips were coated in gelcoat as described above, the gelcoat being gellated and cured under the same temperature conditions as those applied for curing of the prepreg laminates. The smaller the mandrel diameter, the greater the elongation at break.
  • the adhesive strength of the gelcoat on the laminate was determined by means of pull-off tests in accordance with test specification set forth in DIN EN ISO 4624. The greater the force required to pull off the seal, the stronger the adhesion.
  • the laminate surfaces were first sanded with grade 180 sandpaper. The sanding dust was then removed from the surface, which was then painted with a suitable commercially available paint.
  • the adhesion thereof i.e., its adhesive strength, was determined by means of stripping tests in accordance with test specification set forth in DIN EN ISO 4624. The greater the tension required to pull off the film, the stronger the adhesion.
  • Table 3 shows the results on the surface-treated laminate according to the present invention compared with regular surface-treated laminates.
  • the laminates according to the present invention also fulfill, as in the case of the regular laminates, all requirements with regard to adhesion, sandability, and paintability.

Abstract

A composition for the manufacture of a gelcoat includes a main component and a curing component. The main component includes at least one epoxide resin selected from glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylolpropane triglycidyl ethers, and mixtures thereof, and up to 5 wt.-% of at least one of a filler and a pigment based on a total weight of the main component. The curing component includes at least one cycloaliphatic amine. The main component or the curing component further includes at least one polytetrahydrofuran polyol. The gelcoat is transparent.

Description

  • CROSS REFERENCE TO PRIOR APPLICATIONS
  • This application is a continuation of U.S. application Ser. No. 14/402,314, filed on Nov. 20, 2014, which is a U.S. National Phase application under 35 U.S.C. § 371 of International Application No. PCT/DE2013/000272, filed on May 21, 2013 and which claims benefit to German Patent Application No. 10 2012 010 583.5, filed on May 21, 2012. The International Application was published in German on Nov. 28, 2013 as WO 2013/174362 A1 under PCT Article 21(2).
    • FIELD
  • The present invention relates to compositions based on epoxy resins for the production of gelcoats and the use of said gelcoats for the surface treatment of fiber reinforced plastics. The present invention also relates to processes for the production of the gelcoats, as well as to processes for the manufacture of surface treated components made of fiber reinforced plastics, in particular to manufacturing processes that employ prepegs.
    • BACKGROUND
  • Surfaces of laminates or components composed of fibers such as glass fibers, carbon fibers, or plastic fibers in a matrix of curable resins such as epoxy resins, unsaturated polyester resins, or vinyl ester resins generally feature less acceptable surfaces, which, moreover, are not resistant to light and weathering. These must first be treated with protective coatings if these components are to be employed in applications for which decorative or weather-resistant surfaces are required.
  • Components' surfaces are as a rule painted with suitable coating materials, predominantly weather-resistant and anticorrosive paints, for example, those based on aliphatic polyurethanes. To ensure sufficient adhesion of the coating to the component, the surfaces to be painted must, however, first undergo complex pretreatment. Surfaces ready for painting are usually obtained following a number of process steps. The surface of the demolded component is first sanded to effect a complete removal of any mold releasing agents. The surface is then coated or smoothed with a filling compound to level out any surface defects such as pores or individual protruding fibers exposed by the sanding treatment. Once the filling compound has hardened, the surface is again sanded to obtain a smooth surface ready for painting.
  • One alternative to this time-consuming and laborious pretreatment process is the application of a gelcoat. A gelcoat is a composition based on a resin system and is applied to the surfaces of components using an in-mold composite construction process. The use of gelcoats yields smooth surfaces during the manufacturing process of the component, which surfaces are ideal for sanding. The surfaces may then be painted immediately following sanding. The gelcoat is generally placed in a component mold as the first layer, which is then pre-cured or incipiently gellated to an extent at which the dryness grade 6 in accordance with DIN 53 150 has been reached, at which it complies with the mechanical requirements for subsequent processing. Fibers, for example, in the form of woven fabrics, non-woven fabrics, or laid webs, and the laminating resin containing the thermosetting resin employed as a matrix are then placed on the partially gellated gelcoat film. The entire composition is then hardened to completion. The gelcoat film must be sufficiently stable that the fibers can be applied, and where necessary removed again, without damaging the film. In the case of extremely large molds, such as rotor blades for wind turbines, woven fabrics or non-woven fabrics are usually applied by hand. It must consequently also be possible to walk on the gelcoat film without the film sustaining damage.
  • Use has until now been made of filled gelcoats. The filler distributed in the resin system forms a framework which provides the required mechanical stability with only minimal precuring or only after minimal progression of the curing reaction of the gelcoat. The use of transparent gelcoats is more advantageous since laminating flaws, such as gas bubbles or dry areas in the laminate which have not been coated by resin, can be readily detected and repaired following removal of the component from the mold. Transparent gelcoats not containing filler require a much more intense curing process to0 achieve the required stability of the film. More intense progression of the curing reaction, however, results in considerably shorter laminating times. The laminating time is taken to be the amount of time occurring between the point in time at which the gelcoat placed in the mold becomes tack-free and the point in time at which the gelcoat film must be sufficiently laminated to provide adhesion between the gelcoat and the laminate.
  • For these reasons, transparent gelcoats are as yet only employed for the production of laminates using liquid laminating resins. In prepreg procedures, the mechanical stability of the gelcoat film must be considerably higher since the tackiness of the prepreg impedes handling and, in particular, application thereof on the gelcoat film. It is not generally possible to adjust positioning since the film will tear upon removal of the prepreg from the gelcoat film, or the entire composition might even be wrenched out of the mold. If the gelcoat film is subjected to more intense curing to attain greater stability, however, the laminating time will be insufficient for the formation of laminate layers, particularly in relatively large molds.
    • SUMMARY
  • An aspect of the present invention is to provide improved materials and procedures to allow for the use of transparent gelcoats, in particular in prepreg procedures, whilst retaining the known advantages thereof.
  • In an embodiment, the present invention provides a composition for the manufacture of a gelcoat which includes a main component and a curing component. The main component comprises at least one epoxide resin selected from the group consisting of glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylolpropane triglycidyl ethers, and mixtures thereof, and up to 5 wt.-% of at least one of a filler and a pigment based on a total weight of the main component. The curing component comprises at least one cycloaliphatic amine. The main component or the curing component further comprises at least one polytetrahydrofuran polyol. The gelcoat is transparent.
    • DETAILED DESCRIPTION
  • The compositions of the present invention for the production of a gelcoat contain a main component which contains at least one or more epoxy resins, and a curing component which contains one or more amines. Unlike the conventional gelcoat resin systems based on radically curing resins, such as unsaturated polyesters (UP), vinyl esters, or acrylate-terminated oligomers, the epoxy resin-based gelcoats according to the present invention do not indicate any monomeric emissions. They also show only minimal shrinkage during curing, or no shrinkage at all, and thus avoid stresses in the composite material or gelcoat boundary surface so as to provide a stable boundary surface. Epoxy resin-based composite materials (EP) moreover demonstrate excellent adhesion to the gelcoats of the present invention.
  • Epoxy resins suitable for use in the present invention are aromatic glycidyl compounds such as glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, phenol novolak glycidyl ethers, cresol novolak glycidyl ethers, glyoxal tetraphenol tetraglycidyl ethers, p-tert. butylphenol glycidyl ethers, cresyl glycidyl ethers, N,N-diglycidyl aniline, p-aminophenol triglycid, tetraglycid-4,4′-methylene dianiline, cycloaliphatic glycidyl compounds such as methyl tetra hydro phthalic diglycidyl ether, hexahydrophthalic diglycidyl ether, cyclohexane dimethanol diglycidyl ether, glycidyl ethers of hydrated bisphenol A and glycidyl ethers of hydrated bisphenol F, epoxidated cycloolefins, aliphatic glycidyl ethers such as trimethylolpropane triglycidyl ether, the diglycidyl ethers of 1,6-hexane diol and 1,4-butane diol, n-dodecyl glycidyl ether, n-tetradecyl glycidyl ether, as well as glycidyl ethers of polyoxyethylene polyols. Low-viscosity and medium-viscosity fluid epoxy resin types, semi-solid and solid epoxy resin types as well as combinations thereof may also be used. In accordance with the present invention, the use of glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylol propane triglycidyl ethers and combinations thereof can, for example, be used. Epoxy resins are used in quantities of from 40 to 90%, for example, between 60 and 80%, and, for example, between 65 and 75% by weight, based on the main component.
  • The composition furthermore contains one or more polyols. The polyols may be present in the main component as well as in the curing component. In accordance with the present invention, the polyols can, for example, be used in the main component. Suitable polyols include polyacrylate polyols, polyester polyols, polyether polyols, polycarbonate polyols, polycaprolactones, and polyurethane polyols. The average molecular weights based on the number average of polyols can, for example, be 1000 to 3000 g/mol, for example, between 1500 and 2500 g/mol, and, for example, between 1800 and 2000 g/mol. The polyols are applied in amounts of from 2 to 40%, for example, between 5 and 30%, and, for example, between 10 and 20%, by weight of polyols, based on the main component including the polyols. Polytetrahydrofuran polyols can, for example, be used.
  • In order to facilitate application of the transparent gelcoat, fillers and/or pigments may be added in small amounts. The fillers are considered below to be particulate substances virtually insoluble in the application medium and are used in order to influence the optical characteristics. They may moreover also be conducive to increasing volume in order to achieve or improve technical properties. The term pigments relates below to substances that are virtually insoluble in the application medium and that are applied as chromophoric substances or dyes. The compositions of the present invention are very slightly dulled with fillers and/or pigments to facilitate management thereof to the effect that material which has already been applied is more readily discernible during the application process. In this regard, the content of fillers and/or pigments in the main component of the compositions of the present invention can, for example, be not more than 5%, for example, not more than 2%, for example, not more than 1%, and, for example, not more than 0.5%, by weight of the main component. The composition will become non-transparent if greater quantities are added. Suitable fillers and pigments include mineral materials such as kaolin or talcum, synthetic materials such as barium sulphate or calcium carbonate, and also inorganic or organic pigments as used conventionally in paint production, and combinations thereof. Titanium dioxide or soot can, for example, be used in accordance with the present invention.
  • In an embodiment of the present invention, the curing component can, for example, contain one or more amines. Suitable amines include polyamines selected from the group consisting of polyethylene polyamines such as ethylene diamine, diethylene triamine, triethylene tetramine, tetraethylene pentamine, pentaethylene hexamine, pentane-1,3-diamine, 2-methyl pentamethylene diamine, propylene amines such as propylene diamine, dipropylene triamine, dimethylaminopropylamine, trimethyl hexamethylene diamine, polyether polyamines such as polyoxypropylene diamines or polyoxypropylene triamines, polyoxypropylene polyamines, polyoxyethylene polyamines, polytetrahydrofuran polyamines, or butanediolether diamines or N-aminopropyl cyclohexyl amine, alkylene diamines such as hexamethylene diamine, trimethylhexamethylene diamine, or methyl pentamethylene diamine, cycloaliphatic amines such as tricyclododecane diamine, N-aminoethyl piperazine, isophorone diamine, or diaminocyclohexane, aromatic amines such as diaminodiphenylmethane or diaminodiphenylsulfone, araliphatic amines such as m-xylylene diamine and modifications thereof, for example, polyaminoamides, Mannich bases and epoxy adducts, as well as combinations thereof. Cycloaliphatic amines, and in particular isophorone diamine, can, for example, be used. The amines are added in quantities of from 60 to 100%, for example, between 80 and 95%, and, for example, between 85 and 95% by weight of the curing component.
  • The curing components of the present invention may additionally include accelerants. Suitable accelerants are tertiary amines such as N,N-dimethyl aniline or dimethyl benzylamine, alkoxides, imidazoles, Mannich bases such as (dimethyl aminomethyl)phenol or tris(dimethyl aminomethyl)phenol, boron trifluoride complexes, Broensted acids, alkyl phenols, polyphenols, onium salts, triarylsulfonium salts, iron arene complexes or salts of alkali metals or of alkaline earth metals such as lithium bromide or calcium nitrate. Accelerants can, for example, include phenols, polyphenols, alkali metal salts or alkaline earth metal salts. Calcium nitrate tetrahydrate can, for example, be added. The accelerator is added in quantities of from 0.2 to 40%, for example, from 0.5 to 20%, and, for example, from 1 to 10% by weight of the curing component.
  • The composition contains plasticisers. Suitable plasticisers are polyurethane prepolymers having blocked isocyanate groups. The plasticisers can be present in the main component as well as in the curing component. Isocyanate prepolymers blocked with substituted phenols and/or pyrazoles can, for example, be added in the main component as described in EP 0688803 A1, the disclosure of which is incorporated by reference herein.
  • Linear polymers having terminal isocyanate groups blocked with alkylphenol groups can, for example, be used. If the plasticisers are added to the curing component, isocyanate prepolymers in which the isocyanate groups are blocked with secondary monoamines, as described in EP 0457089 A2, can, for example, be used. The disclosure of EP 0457089 A2 is incorporated by reference herein.
  • The compositions according to the present invention may further contain conventional additives as commonly used by the person skilled in the art. Rheology modifiers such as fumed silica, flow control agents or defoamers, for example, may thus be used in the usual quantities.
  • In accordance with the present invention, the use of epoxy resins and amines can, for example, be used in the molar ratio of epoxy groups to N—H-groups reactive to epoxy groups (EP:N—H) of from 1 to 0.7 to 1 to 1.4, for example, from 1 to 0.8 to 1 to 1.3, and, for example, from 1 to 0.9 to 1 to 1.2.
  • The gelcoats which can be produced from the compositions according to the present invention are transparent, that is to say, they exhibit a poor hiding power. The hiding power of the gelcoat according to the present invention is defined in DIN EN ISO 2814 on a checkered card. The hiding power measured thereby can only be ascertained at a film thickness of more than 1 mm. The film thickness of an applied gelcoat is considerably less and usually measures approx. 500 μm.
  • The gelcoats according to the present invention show relatively short gellation times. Due to these short gellation times, the hold time for the mold is reduced considerably, allowing for shorter mold hold cycles. The materials are tenacious and not brittle in the form of a gelcoat film in an insidiously gellated state. A comparison with regular transparent gelcoats shows considerably superior elongation at break and tear propagation strength in the case of the gelcoat according to the present invention. Repositioning of applied prepregs according to the present invention without causing damage thereto is also possible when using the gelcoat films.
  • Despite their transparency, the gelcoats according to the present invention exhibit the mechanical stability required for subsequent processing stages. They in particular also fulfill the requirements for the manufacture of laminates or fiber plastic composite components in the prepreg process. As with the conventional, filled gelcoats, they also exhibit excellent adhesion to the laminate, are easily sanded in a cured state, and are suitable for the application of paint thereon.
  • The present invention also provides the use of the gelcoat according to the present invention for the surface treatment of fiber plastic composite components or laminates. The gelcoat can, for example, be applied to surfaces of the component using the in-mold method. The gelcoat film is placed in the component mold as a first layer to this end. The composition according to the present invention is first added to a mold following mixing of its reaction components, the main component and the curing component, within the pot life. The pot life is the period during which the mix remains workable. It begins at the point in time at which the two reaction components are mixed and ends at the point in time at which the viscosity of the reaction mixture has risen to such an extent that it is possible to apply a layer that is even in thickness. The layer obtained following gellation is sufficiently mechanically stable that it does not sustain damage upon application of the laminating resin and the fibers, but is sufficiently reactive to create a stable bond when the laminating resin cures. Examples of the laminating resins used are epoxy resins, unsaturated polyester resins, and vinyl ester resins. Examples of the fibers used are woven fabrics, laid webs, and non-woven fabrics of glass, carbon, or plastic fibers. To provide sufficient adhesion between laminating resin and gelcoat, the gelcoat layer must be brought into contact with the laminating resin within the laminating period of the gelcoat. The laminating resin and gelcoat will then harden to completion.
  • The gelcoats according to the present invention can, for example, be used for the surface treatment of epoxy resin composite materials because they exhibit better adhesion to these materials than gelcoat based on other resinous systems. They also do not contain any volatile monomers and are therefore less encumbering with regard to industrial hygiene.
  • The present invention also provides a method for manufacturing surface-treated fiber plastic composite components or laminates. Firstly, the required two components, the main component and the curing component, are mixed with the composition of the present invention. The mixture is transferred to the component mold as a first layer using the application method conventionally applied by the expert, for example, by painting, rolling, spraying, or pouring. The applied mixture is then gellated or pre-cured to form a gelcoat film. Fibers in the form of woven fabrics, laid webs, or non-woven fabrics, as well as the laminating resin are then applied to the gelcoat film. In the next stage, the entire composite mixture is hardened to form the desired component. The component is then removed from the mold and its surface is subsequently sanded and then painted.
  • Fibers and laminating resins can be applied to the gelcoat film by various methods. Usual laminating methods, such as the vacuum bag method, the injection method, the infusion method, and the wet laminating method are known to the person skilled in the art. One way of producing the fiber composite material involves the use of prepregs. Prepregs are impregnated resin/fiber mats which are placed in the component mold. The resin is partially pre-cured and exhibits relatively strong adhesion properties at room temperature. One problem incurred by the use of prepregs is that of repositioning on the gelcoat film. Component molds are generally pretreated with a mold release agent to ensure that the gelcoat film itself will not stick to the mold. When adhesive prepreg is applied to the gelcoat and then removed therefrom, the gelcoat should not tear or break. Since there is no adhesiveness relatively to the mold, the gelcoat film must accordingly be mechanically stable. The gelcoats according to the present invention form films which exhibit the required mechanical properties, and can therefore be used in prepreg methods. The compositions of the present invention also require only short gellation times. Since the curing process is considerably quicker in the prepreg method than in other methods, they are particularly suitable for use in these methods also for this reason.
  • Examples of gelcoat compositions according to the present invention are examined below to compare the properties of the gelcoats according to the present invention with those of commercially-used transparent gelcoats.
  • TABLE 1a
    Composition of Main Component
    Content in parts by weight
    Substance S1 S2 S3
    Bisphenol A diglycidyl ether 25 25 25
    Bisphenol F diglycidyl ether 10 10 10
    Trimethylol propane triglycidyl ether 40 47 40
    Polytetramethylene oxide polyol 12 — —
    Polypropylene oxide polyol — 15 12
    Plasticiser 10 — 10
    Fumed silica 2.99 3 2.99
    Titanium oxide 0.01 — 0.01
  • TABLE 1b
    Composition of Curing Component
    Content in parts by weight
    Substance HA HB
    Isophorone diamine 65 92
    Phenolic accelerator 35 —
    Calcium nitrate tetrahydrate — 4
    Propandiol — 4
  • TABLE 1c
    Composition of Gelcoat
    Main Curing Molar proportion
    Example No. component component MP
    1.1 S1 HB 1.09
    1.2 S1 HA 1.13
    1.3 S2 HB 0.87
    1.4 S3 HA 1.07
    2.1 Commercially available transparent gelcoat
    2.2 Commercially available transparent gelcoat
  • The following tests for elongation at break properties, tear propagation resistance, and prepreg re-position ability were performed on gelcoat films gellated under various curing conditions.
  • The elongation at break was determined via a mandrel bending test in accordance with the test specification set forth in DIN EN ISO 1519. Metal plates, to which the coating under test were applied, were bent around a mandrel. The smaller the radius of the mandrel around which the plate could be bent without damaging or fracturing the coating, the greater the elongation at break of the coating.
  • The tear propagation resistance was determined via tear propagation tests in accordance with test specification set forth in DIN EN ISO 13937-2. The force necessary to enlarge a crack in the coating undergoing examination was measured. The greater the applied force, the more tear-resistant the coating.
  • The prepreg repositioning was determined via the following test set-up which simulates a laminate structure in a component mold. A mold release agent was applied to a sufficiently large metal plate. A gelcoat composition was then coated over an area of 1 m2 on the prepared plate. The composition was gellated on the gelcoat film at the prescribed temperature and for the prescribed duration. A prepreg of dimensions DIN A4 was laid centrally on the gelcoat film and pressed down firmly with a defined force for 1 minute. The prepreg was then removed swiftly at an angle of 90 °. Visible damage to the gelcoat film was rated as follows:
  •
    ++ No changes
    + Detachment of the gelcoat film from the metal plate at up to three
    positions without damaging the gelcoat film itself
    0 Detachment at up to 10 positions with damage at a maximum of
    three positions
    − Increased damage of the gelcoat film
    −− Total detachment of the gelcoat film from the metal plate
  • Tables 2a and 2b show the results of the tests on gelcoat films gellated under various conditions. The gelcoats according to the present invention show considerably improved values in relation to elongation at break and tear growth resistance. In contrast to commercially available gelcoats, the removal of a prepreg applied under pressure did not cause any damage to the gelcoat according to the present invention. It may thus be applied in processes involving prepregs without incurring the usual disadvantages.
  • TABLE 2a
    Properties of the gelcoat film gellated at 60° C.
    (Temperature was maintained until a dryness grade of 6
    according to DIN 53 150 was reached.)
    Gelcoat no.
    1.1 1.2 1.3 1.4 2.1 2.2
    Elongation at break
    Mandrel diameter in [mm] 40 25 8 12 1) 1)
    without fracture
    Mandrel diameter in [mm] 25 20 6 8 220 220
    with fracture
    Tear growth resistance
    Force in [N/mm] 3.7 1.1 0.5 2.8 2) 2)
    Prepreg repositioning ability
    Damage assessment ++ ++ + ++ −− −−
    1) Value was not determined
    2) Value not measurable due to splintering of the coating
  • TABLE 2b
    Properties of the Gelcoat Film Gellated at 23° C.
    (Temperature was maintained for 18 hours.)
    Gelcoat no.
    1.1 1.2. 1.3 1.4 2.1 2.2
    Elongation at break
    Mandrel diameter in [mm] 40 55 40 25 1) 1)
    without fracture
    Mandrel diameter in [mm] 32 40 32 32 220 220
    with fracture
    Tear growth resistance
    Force in [N/mm] 4.3 4.5 0.3 2.1 2) 2)
    Prepreg repositioning ability
    Damage assessment ++ ++ + ++ −− −−
    1) Value was not determined
    2) Value not measurable due to splintering of the coating
  • The following tests for adhesion of the laminate to the gelcoat, for sandability, and for paintability were performed on the cured laminates. The gelcoat compositions were placed in a mold and gellated, the prepreg was then applied to the gelcoat film. The mold was sealed and a vacuum bag attached and evacuated. The entire composition was then cured, the curing conditions being prescribed by the respective prepreg used. The following tests were performed on the cured laminates.
  • The elongation at break was determined using the aforementioned mandrel bending test. Metal strips were coated in gelcoat as described above, the gelcoat being gellated and cured under the same temperature conditions as those applied for curing of the prepreg laminates. The smaller the mandrel diameter, the greater the elongation at break. The adhesive strength of the gelcoat on the laminate was determined by means of pull-off tests in accordance with test specification set forth in DIN EN ISO 4624. The greater the force required to pull off the seal, the stronger the adhesion.
  • In order to assess the laminate surfaces treated with gelcoat, their sandability, i.e., their abrasion resistance, and their paintability, i.e., the adhesion of paint coats on their surfaces, were determined. The resistance to abrasion was determined gravimetrically in accordance with test specification set forth in ASTM D 4060 using a S33 wheel rotating at 500 rpm under a load of 1000 g. The greater the difference in weight, the higher the abrasion resistance and, consequently, the better the sandability.
  • For the purpose of assessing the paintability, the laminate surfaces were first sanded with grade 180 sandpaper. The sanding dust was then removed from the surface, which was then painted with a suitable commercially available paint. On completion of curing of the paint film, the adhesion thereof, i.e., its adhesive strength, was determined by means of stripping tests in accordance with test specification set forth in DIN EN ISO 4624. The greater the tension required to pull off the film, the stronger the adhesion.
  • Table 3 shows the results on the surface-treated laminate according to the present invention compared with regular surface-treated laminates. The laminates according to the present invention also fulfill, as in the case of the regular laminates, all requirements with regard to adhesion, sandability, and paintability.
  • TABLE 3
    Properties of the Cured Laminates
    Gelcoat no.
    1.1 1.2. 1.3 1.4 2.1 2.2
    Elongation at break
    Mandrel diameter in [mm] 70 70 85 70 70 85
    with no fracture
    Mandrel diameter in [mm] 55 55 70 55 55 70
    with fracture
    Adhesion of gelcoat
    to laminate
    Stripping tension in [N/mm2] 9.1 9.8 8.7 9.2 8.9 8.8
    Taber abrasion
    Difference in [mg] 986 864 793 891 762 1)
    Adhesion paint on gelcoat
    Stripping tension in [N/mm2] 6.3 5.3 6.1 5.9 6.6 4.4
    1) Not determined
  • The present invention is not limited to embodiments described herein; reference should be had to the appended claims.

Claims (17)

What is claimed is:
1. A composition for the manufacture of a gelcoat, the composition comprising:
a main component comprising,
at least one epoxide resin selected from the group consisting of glycidyl ethers of bisphenol A, glycidyl ethers of bisphenol F, trimethylolpropane triglycidyl ethers, and mixtures thereof, and
up to 5 wt.-% of at least one of a filler and a pigment based on a total weight of the main component; and
a curing component comprising at least one cycloaliphatic amine,
wherein,
the main component or the curing component further comprises at least one polytetrahydrofuran polyol, and
the gelcoat is transparent.
2. The composition as recited in claim 1, wherein the main component comprises up to 2 wt.-% of the at least one of a fillers and a pigment based on the total weight of the main component.
3. The composition as recited in claim 1, wherein the at least one epoxide resin of the main component is present in an amount of from 40 to 90 wt.-% based on the total weight of the main component.
4. The composition as recited in claim 1, wherein the main component comprises the at least one polytetrahydrofuran polyol in an amount of from 2 to 40 wt.-% based on the total weight of the main component.
5. The composition as recited in claim 4, wherein the at least one polytetrahydrofuran polyol has an average molecular mass of from 1000 to 3000 g/mol based on a number average molecular weight.
6. The composition as recited in claim 1, wherein the at least one cycloaliphatic amine of the curing component is present in an amount of from 60 to 100 wt. % based on a total weight of the curing component.
7. The composition as recited in claim 1, wherein the at least one cycloaliphatic amine is isophorone diamine.
8. The composition as recited in claim 1, wherein the at least one epoxide resin comprises epoxide groups and the at least one cycloaliphatic amine comprises N—H groups, the epoxide groups and the N—H groups being present in a molar ratio of from 1 to 0.7 to 1 to 1.4.
9. The composition as recited in claim 1, wherein the composition further comprises at least one plasticizer selected from the group consisting of polyurethane prepolymers having blocked isocyanate groups.
10. The composition as recited in claim 1, wherein the main component further comprises at least one plasticizer consisting of isocyanate prepolymers blocked with at least one of substituted phenols and pyrazoles.
11. The composition as recited in claim 1, wherein the curing component further comprises at least one plasticizer consisting of isocyanate prepolymers blocked with secondary monoamines.
12. A method of using a gelcoat for a surface treatment of a fiber reinforced compound plastics material, the method comprising:
providing a fiber reinforced compound plastics material;
providing the composition as recited in claim 1;
manufacturing the gelcoat from the composition; and
surface treating the fiber reinforced compound plastics material with the gelcoat.
13. A method for manufacturing a surface-treated fiber-reinforced compound plastics material as a construction element, the process comprising:
providing the composition as recited in claim 1;
mixing the main component and the curing component of the composition so as to obtain a mixture;
placing the mixture in a component mold;
allowing the mixture to gel so as to form a gelcoat film;
applying a woven fabric, a non-woven fabric, or a laid fabric together with a laminating resin to the gelcoat film so as to obtain a laminate; and
curing the laminate so as to form the construction element.
14. The method as recited in claim 13, further comprising:
providing the woven fabric, the non-woven fabric, or the laid fabric together with the laminating resin as at least one prepreg; and
applying the at least one prepreg on the gelcoat film so as to obtain the laminate.
15. The method as recited in claim 13, wherein the mixture is placed in the component mold and the mixture allowed to gel so as to form a gelcoat film in a non-covering thickness.
16. A structural element of a fiber-reinforced compound plastics material, wherein a surface of the structural element is coated with the gelcoat layer produced from the composition as recited in claim 1.
17. The structural element as recited in claim 16, wherein the structural element is a rotor blade for a wind turbine.
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DE112013002600A5 (en) 2015-02-12
MX367174B (en) 2019-08-07
IN2014DN07594A (en) 2015-05-15
CA2867755C (en) 2016-10-11
CN104185662B (en) 2019-08-16
US20150093582A1 (en) 2015-04-02
US10023762B2 (en) 2018-07-17
BR112014028806A2 (en) 2018-05-29
KR20140143831A (en) 2014-12-17
MX2014009966A (en) 2014-11-25
CN104185662A (en) 2014-12-03
DE102012010583A1 (en) 2013-11-21
KR101738485B1 (en) 2017-05-22
WO2013174362A1 (en) 2013-11-28

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