Abstract: A single component curable composition is provided that includes a resin curable by free radicals. Free radicals are initiated by the inclusion of at least one photo-initiator, at least one thermal radical initiator, and at least one thermal cationic radical initiator, all present in a premixed state as the single component. The composition is able to cure to a depth beyond the penetration of photons into composition. Once cure is initiated with an ultraviolet or infrared light source, the light source need not illuminate the composition until cure is complete. The resulting composition has a user selected working time that is effectively infinite and the viscosity stable while working prior to initiating cure. A method for repairing a surface imperfection on a vehicle body is also provided along with a novel cured mass with a thickness of up to 7 mm.

Abstract: A bond fill composition is provided that includes a part A including a curable resin having a degree of unsaturation, an inorganic hydrate filler present in an amount to confer fire suppression time of 60 seconds or less upon cure, and a monomer reactive diluent in which the curable resin is dissolved or suspended. A part B storage-separate, free-radical cure initiator package is provided that includes a free-radical cure initiator. A process for repairing a vehicle body includes mixing the part A with the part B to form a mixture. The mixture is applied to a substrate of the vehicle body in need of repair. Upon curing to form a fill, the vehicle body is repaired and the fill is a sandable surface.

Abstract: A process for repairing a surface includes the mixing an epoxy resin formulation part A with a part B. The part A includes phenolic epoxy resin, polyol epoxy resin, or lipid epoxy resin, or a combination thereof. The part B includes a curing agent of only an aliphatic amine, a phenalkamine, a phenalkamide, or a combination thereof, to form a mixture. The mixture is applied to a substrate of the surface in need of repair to a thickness of up to 6.35 mm. The mixture cures on the substrate under conditions adapted to a dry to sand condition in 120 to 200 minutes. A process of operating a repaired marine substrate in a water contacting environment with limited water absorption is also provided. A composition for use in these processes is also provided.

Abstract: A free radical cure catalyst composition is provided that includes a free radical cure catalyst present as a paste at 20° C. A cure inhibitor is dissolved in a solvent compatible with the free radical cure catalyst paste to form an inhibitor solution that is mixed into the paste. A filler composition is also provided that includes an ethylenically unsaturated resin, a crosslinking agent; and the free radical cure catalyst composition. A method of repairing a vehicle body is provided that includes an uncured layer of the composition as noted above is applied to a substrate. The uncured layer is modified during a working time of from 8 to 35 minutes. The uncured layer is allowed to cure under free radical conditions to form a cured layer.

Abstract: A process for repairing a marine surface is provided that includes the mixing of the part A and the part B until a terminal color change occurs within ±5 minutes of cure. The mixture is applied to a substrate of the marine surface in need of repair to a thickness of up to 6.35 mm. The cured mass has water absorption less than of 0.2% in freshwater or 0.15% in ocean water salinity. A marine repair composition is provided that includes in a part A: an unsaturated vinyl ester resin, a reactive diluent, a cure promoter, a cure inhibitor, a corrosion inhibitor and a filler. The part B includes a free-radical cure initiator stored separately from the part A until mixed with the part A to form the composition.

Abstract: A method for repairing a defect in a vehicle exterior body surface is provided that includes a scan data set being generated that corresponds to the dimensional surface boundaries of the defect. A manufacturing data set is created for an object at least in part complementary to the defect from the scan data. The object is formed from the manufacturing data set with a layered manufacturing device. The object is joined to the defect to repair the vehicle exterior body surface. An object is also provided formed of a thermoplastic or a UV cured polymer with a shape that is at least at least in part complementary to a defect vehicle exterior body surface. The object having a void therein with the shape configured to receive an insert or a fastener therein.

Abstract: A method for repairing surface imperfections on a vehicle body includes the application of an uncured layer to a thickness of up to 0.254 mm of a primer composition comprising: a polyester resin, an acrylated urethane resin, a crosslinking agent, a solvent, and a particulate filler to the vehicle body. The uncured layer is exposed to actinic radiation to induce cure of the uncured layer to form a coating to fill the surface imperfection on the vehicle body. A surface coating primer composition is also provided that includes a polyester resin; an acrylated urethane oligomer or polymer; a crosslinking agent; a solvent; a photoinitiator; and a particulate filler. The uncured composition has a viscosity of between 100 and 800 centipoise.

Abstract: A method for repairing small surface imperfections on a vehicle body is provided that includes the application of an uncured layer to a thickness of up to 1.02 mm of a composition inclusive of a polyester resin, an acrylated urethane resin, a defoamer, and a particulate filler to the vehicle body or a cured putty thereon. The uncured layer is then exposed to actinic radiation to induce cure of the uncured layer to form a coating to fill the small surface imperfection on the vehicle body. A one component, UV-cured putty material for repairing small surface imperfections is also provides inclusive of a polyester resin, an acrylated urethane oligomer or polymer, a defoamer, a photoinitiator, and a particulate filler. The composition has an uncured viscosity of between 9,000 and 13,000 centiPoise.

Abstract: A free radical cure catalyst composition is provided that includes a free radical cure catalyst present as a paste at 20° C. A cure inhibitor is dissolved in a solvent compatible with the free radical cure catalyst paste to form an inhibitor solution that is mixed into the paste. A filler composition is also provided that includes an ethylenically unsaturated resin, a crosslinking agent; and the free radical cure catalyst composition. A method of repairing a vehicle body is provided that includes an uncured layer of the composition as noted above is applied to a substrate. The uncured layer is modified during a working time of from 8 to 35 minutes. The uncured layer is allowed to cure under free radical conditions to form a cured layer.

Abstract: A bond fill composition is provided that includes a part A including a curable resin having a degree of unsaturation, an inorganic hydrate filler present in an amount to confer fire suppression time of 60 seconds or less upon cure, and a monomer reactive diluent in which the curable resin is dissolved or suspended. A part B storage-separate, free-radical cure initiator package is provided that includes a free-radical cure initiator. A process for repairing a vehicle body includes mixing the part A with the part B to form a mixture. The mixture is applied to a substrate of the vehicle body in need of repair. Upon curing to form a fill, the vehicle body is repaired and the fill is a sandable surface.