Abstract: A coating may be incorporated in a molded composite article made via a process in which neither the coating nor the resin contact the mold surface. A multilayer sandwich structure is formed having two outside layers of flexible membranes, typically made of silicon. An interior dissolvable film is disposed between the two outer flexible membranes. A layer of fiber reinforcement is disposed between the dissolvable film and one of the flexible membranes. A coating is distributed between a flexible membrane and the dissolvable film, opposite the side having the reinforcement, wherein the film is only slowly soluble, or insoluble, in the coating. The coating is allowed to at least partially cure and a resin is infused through the reinforcement wherein the dissolvable film rapidly dissolves in the resin. The sandwich structure is formed around a mold and the resin is allowed to cure.

Abstract: A coating composition is produced by forming an aqueous dispersion of a crosslinking agent and a resin that comprises the reaction product of an alkyd polymer, an optional surfalkyd, diacetone acrylamide, another acrylate monomer and optionally aromatic monomers wherein the reaction product is neutralized with either ammonia or an amine. A coating of the aqueous dispersion on wood exhibits at least some of the following desired properties: rapid dry time, good tannin blocking, good resistance to picking up dirt, good hot box stability and good exterior durability. Additionally, the inventive coatings appear to provide improved crosslinking compared to coatings comprising resins not neutralized with an amine or ammonia and/or not containing a surfalkyd.

Abstract: A hybrid resin composition is described, the composition comprising: A. An A part composition comprising an aliphatic polyfunctional isocyanate compound and a free radical polymerization initiator; and B. A B part composition comprising an ethylenically unsaturated, substantially water-free polyester polyol and a polyurethane catalyst. The A part composition can contain a non-interfering solvent, e.g., styrene, and the B part composition typically has an acid value of 5 or less (based on solids). For outdoor use, the B part composition is preferably free of tertiary hydrogens, ether glycols and terephthalic acid residues.

Abstract: A low viscosity (and therefore low VOC) resin can be produced by limiting the molar ratio of the reactants, especially the dicarboxylic acid compound, used in the reaction. Specifically, reacting a reaction mixture comprising (i) one mole of a diepoxide having at least two glycidyl ether type epoxy groups; (ii) 0.5 to 2.0 moles of an unsaturated monocarboxylic acid; (iii) 0.1 to 0.5, preferably 0.1 to 0.3, moles of maleic anhydride; and, (iv) water, until substantially all of the epoxy groups disappear leads to the formation of a resin with a high shear (at least 500 s?1) viscosity of less than 1200 cP when measured in a 70% NVM (non-volatile matter) styrene solution. The resin may be used in barrier coatings, gel coatings, skin coatings and as a laminate resin.

Abstract: Unsaturated polyetherester resins, and processes for making them, are described which are useful for making curable thermoset resin compositions, intermediates for curable thermoset resin compositions, fiber-reinforced polymer composites, intermediates for making skin laminates for gel coated fiber-reinforced composites and gel coated polymer laminates. The unsaturated polyetherester resins are obtainable by reacting at least one acid-terminated unsaturated polyetherester resin with at least one aromatic polyol having at least one non-primary hydroxy group to produce an unsaturated polyetherester resin at least partially end-capped with an aromatic polyol. The described processes, compositions, methods and uses improve the chemical and/or water resistance of resin compositions, particularly composite materials having a gel coat.

Abstract: Curable thermoset resin compositions are described which are useful for imparting water and/or solvent resistance to gel coated fiber-reinforced polymers. Those compositions contain at least 5 weight-percent of an at least partially end-capped unsaturated polyetherester resin, an unsaturated polyester resin in a specified amount having a specified range of unsaturation, about 10 to about 70 weight-percent of at least one vinyl monomer and a curing agent. Methods and intermediates for making those compositions, use of the curable thermoset resin compositions to make fiber-reinforced polymer composites and skin laminate intermediates for the same, and articles manufactured using the same are also described. These compositions, methods and uses improve the chemical and/or water resistance of resin compositions, particularly composite materials having a gel coat.

Abstract: A low tack, low VOC gel coat is disclosed comprising a unsaturated polyester resin derived from maleic anhydride and up to about 30% of an organic solvent. The resin is characterized by: a viscosity of less than or equal to about 1750 cp at 70% NVM in styrene; a glass transition temperature greater than or equal to about 11° C.; and a weight average molecular weight less than or equal to about 6,050. A process for making such a gel coat is also disclosed.

Abstract: Described is a process for making acrylic resins suitable as polymeric surfactants used in emulsion polymerization, as pigment grinding resins and for preparing dispersions used as overprint varnishes. The feedstock is styrene, &agr;-methyl styrene, acrylic acid and a polymerization initiator and is preferably free of solvent. This mix is passed through a continuous tube reactor run at a controlled range of pressure and relatively low residence time and temperature. Optimally, when the polymer/unreacted monomers blend exits the reactor and is devolatilized, the recovered monomers are used to make up part of the feedstock.

Abstract: A compositon useful as an intermediate for a skin laminate and a fiber-reinforced composite comprises: (A) At least 5 wt. % of an at least partially end-capped unsaturated polyetherester wherein the end-capping compound includes a compound having at least one epoxy group; (B) an unsaturated polyester resin such that the weight ratio unsaturated polyester resin (B):polyetherester resin (A) is from about 10:90 to about 90:10; (C) from about 10 to about 70 wt. % of at least one vinyl monomer such as styrene; and (D) a curing agent such as a free radical initiator and an accelerator.

Abstract: The invention is high temperature emulsion composition comprising borax and a substantially water-insoluble polymer prepared by aqueous suspension polymerizing a blend of monomers, said blend comprising a plasticizing amount by weight of at least one plasticizing alkyl acrylate monomer, a hardening amount by weight of at least one hardening alkyl acrylate monomer and a crosslinking amount by weight of at least one multi-ethylenically unsaturated monomer, in an aqueous suspension comprising a water-soluble polymer component comprising at least one acrylic polymer having carboxylate functionality, its method of use and coated substrates made therewith.

Abstract: Polyester resin-based molding compositions, and methods for making and using the same, are described which have an improved maturation profile upon addition of a thickening agent. The improved maturation profile results from the presence of at least one multivalent metal salt of a non-fatty acid or anhydride in the molding composition added in accordance with the invention.

Abstract: Unsaturated polyetherester resins, and processes for making them, are described which are useful for making curable thermoset resin compositions, intermediates for curable thermoset resin compositions, fiber-reinforced polymer composites, intermediates for making skin laminates for gel coated fiber-reinforced composites and gel coated polymer laminates. The unsaturated polyetherester resins are obtainable by reacting at least one acid-terminated unsaturated polyetherester resin with at least one aromatic polyol having at least one non-primary hydroxy group to produce an unsaturated polyetherester resin at least partially end-capped with an aromatic polyol. The described processes, compositions, methods and uses improve the chemical and/or water resistance of resin compositions, particularly composite materials having a gel coat.

Abstract: The invention is high temperature emulsion composition comprising borax and a substantially water-insoluble polymer prepared by aqueous suspension polymerizing a blend of monomers, said blend comprising a plasticizing amount by weight of at least one plasticizing alkyl acrylate monomer, a hardening amount by weight of at least one hardening alkyl acrylate monomer and a crosslinking amount by weight of at least one multi-ethylenically unsaturated monomer, in an aqueous suspension comprising a water-soluble polymer component comprising at least one acrylic polymer having carboxylate functionality, its method of use and coated substrates made therewith.

Abstract: Described is a process for making acrylic resins suitable as polymeric surfactants used in emulsion polymerization, as pigment grinding resins and for preparing dispersions used as overprint varnishes. The feedstock is styrene, .alpha.-methyl styrene, acrylic acid and a polymerization initiator and is preferably free of solvent. This mix is passed through a continuous tube reactor run at a controlled range of pressure and relatively low residence time and temperature. Optimally, when the polymer/unreacted monomers blend exits the reactor and is devolatilized, the recovered monomers are used to make up part of the feedstock.

Abstract: Laminated, molded plastic articles having an excellent abrasion resistant coating are prepared by a 2-step process including applying to a mold surface a 100% reactive coating composition, at least partially curing the coating composition, applying to the exposed surface of the cured coating composition a thermoplastic material, and curing the thermoplastic material to form the laminated molded article. The coating composition includes a polyfunctional acrylic monomer, such as dipentaerythritol monohydroxypentacrylate, a mono functional acrylic monomer, such as hydroxymethylacrylate, an acrylic-soluble thermoplastic, such as cellulose acetate butyrate, an aminoplast resin, such as melamine-formaldehyde, and a free radical initiator. The coating composition is at least partially cured by either UV or IR radiation.

Abstract: Fiber-reinforced thermosetting polyester composites containing in excess of 30 wt %, based on the weight of the composite, reinforcing fiber, are made by a vacuum-assisted transfer molding technique from a 1-phase composite matrix precursor comprising a polyester, a reactive monomer, and a low-profile additive. The polyester has a molecular weight/double bond factor of between about 150 and 190, styrene is a preferred reactive monomer, and a preferred low-profile additive is a thermoplastic polymer with a weight average molecular weight in excess of 3,000 and which is miscible in the polyester and reactive monomer. The polyester composite is formed by coating the surface of a mold with a gel coat; applying a skin laminate over the partially cured gel coat; applying a fiber reinforcement to the skin laminate; closing the mold; and injecting the 1-phase matrix precursor while the mold is under vacuum.

Abstract: An improved two-stage process for the preparation of polyester resins is provided which involves an initial reaction of a dicarboxylic acid such as isophthalic acid with an alkylene oxide such as ethylene or propylene oxide in the presence of a catalyst to form an oligoester reaction mixture, followed by a second stage reaction between the oligoester reaction mixture and a dibasic acid or anhydride; a first-stage catalyst is employed which has a thermal decomposition temperature substantially at or below the second-stage reaction temperature. The most preferred first-stage catalyst is benzyltriethylammonium chloride.

Abstract: An apparatus and process for the recovery of airborne anhydrides such as anhydride vapor or dust wherein these airborne anhydrides are contacted with hot glycol, such as diethylene glycol, in the liquid phase to first dissolve and then react with the airborne anhydrides yielding a useable by-product, such as half-esters. In the preferred embodiment, first airborne anhydrides are introduced at the top of a venturi where the anhydrides are contacted with diethylene glycol of at least 270.degree. F. The airborne anhydrides dissolve in the glycol and then react with the glycol to form a solution of half-esters and glycol. The venturi enhances the contact between the glycol and the first airborne anhydrides, facilitating the dissolution of the anhydrides in the glycol. Second airborne anhydrides are introduced at the discharge side of the venturi such that the second airborne anhydrides dissolve in unreacted hot glycol and then react to form additional half-esters.

Abstract: The invention relates to polyester-polyurethane hybrid resins containing halogenated aromatic polycarboxylate moieties to obtain flame retardance without significantly affect the preparation, processing and physical properties of the hybrid resins.

Abstract: Uncured polyester resins are removed from the surfaces of processing equipment, e.g. mixing and injection heads, by a cleaning solution comprising:A. At least about 50 weight percent of at least one dibasic acid ester, such as DBE;B. A sufficient amount of at least one free radical polymerization inhibitor, e.g. hydroquinone, to inhibit the cure of the polyester resin system; andC. A sufficient amount of at least one chelating agent, e.g. tartaric acid, to inhibit the promotional effects of the metal-ion promoter of the free radical polymerization catalyst system.