Abstract: A free radical curable automotive body primer is provided that has a color change corresponding to the progress of the cure process until a dry to sand condition has been attained and an internal colored guide coat that does not change color given its exposure to ambient air and as a result, has a different color on the surface of the primer than when in bulk, allowing for the detection and removal of low spots or other imperfections from a vehicle body by additional sanding of the inventive primer to remove oxidized guide coat colorant surface regions. The cure color change is achieved through resort to at least one color changing dye that reacts with a free radical cure initiator during the vehicle body priming process and changes color to indicate when the primer composition has achieved a level of cure so as to be dry enough to sand.

Abstract: A vehicle bond filler formulation is provided that includes a part A having curable resin and a monomer reactive diluent. A part B storage-separate, cure initiator package contains a free-radical cure initiator. At least one color changing dye adapted to change color upon mixing the part A and the part B and within ±5 minutes of cure of the curable resin to a sandable condition is present in either the part A or a separate part C, a guide coat colorant, or a combination thereof. A process of for repairing a vehicle body is also provided that includes mixing a part A containing the at least one color changing dye with the part B to form an internal guide coat mixture applied to a substrate of the vehicle body in need of repair. The mixture cures causing the color changing dye to the terminal change color within ±5 minutes of cure of the curable resin to a sandable condition.

Abstract: A vehicle bond filler formulation is provided that includes a part A having curable resin and a monomer reactive diluent. A part B storage-separate, cure initiator package contains a free-radical cure initiator. At least one color changing dye adapted to change color upon mixing the part A and the part B and within ±5 minutes of cure of the curable resin to a sandable condition is present in either the part A or a separate part C, a guide coat colorant, or a combination thereof. A process of for repairing a vehicle body is also provided that includes mixing a part A containing the at least one color changing dye with the part B to form an internal guide coat mixture applied to a substrate of the vehicle body in need of repair. The mixture cures causing the color changing dye to the terminal change color within ±5 minutes of cure of the curable resin to a sandable condition.

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: An Additive Package is provided to adjust the cure properties of a two-part bonding filler across a temperature range of from 4 and 44 degrees Celsius. A low temperature additive speeds a cure rate between 4 and 15 degrees Celsius and a high temperature additive slows down a cure rate between 25 and 44 degrees Celsius. The amount of Additive Package is varied to account for the desired cure properties. The Additive Package includes a first unsaturated polyester resins with an average degree of unsaturation of 70-100 percent based on total acid and anhydride monomer content. A process for repairing a vehicle body is provided using the Additive Package. A kit for accomplishing repairs in an after-market repair setting is also provided.

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 free radical curable automotive body primer is provided that has a color change corresponding to the progress of the cure process until a dry to sand condition has been attained and an internal colored guide coat that does not change color given its exposure to ambient air and as a result, has a different color on the surface of the primer than when in bulk, allowing for the detection and removal of low spots or other imperfections from a vehicle body by additional sanding of the inventive primer to remove oxidized guide coat colorant surface regions. The cure color change is achieved through resort to at least one color changing dye that reacts with a free radical cure initiator during the vehicle body priming process and changes color to indicate when the primer composition has achieved a level of cure so as to be dry enough to sand.

Abstract: An Additive Package is provided to adjust the cure properties of a two-part bonding filler across a temperature range of from 4 and 44 degrees Celsius. A low temperature additive speeds a cure rate between 4 and 15 degrees Celsius and a high temperature additive slows down a cure rate between 25 and 44 degrees Celsius. The amount of Additive Package is varied to account for the desired cure properties. The Additive Package includes a first unsaturated polyester resins with an average degree of unsaturation of 70-100 percent based on total acid and anhydride monomer content. A process for repairing a vehicle body is provided using the Additive Package. A kit for accomplishing repairs in an after-market repair setting is also provided.

Abstract: An Additive Package is provided to adjust the cure properties of a two-part bonding filler across a temperature range of from 4 and 44 degrees Celsius. A low temperature additive speeds a cure rate between 4 and 15 degrees Celsius and a high temperature additive slows down a cure rate between 25 and 44 degrees Celsius. The amount of Additive Package is varied to account for the desired cure properties. The Additive Package includes a first unsaturated polyester resins with an average degree of unsaturation of 70-100 percent based on total acid and anhydride monomer content. A process for repairing a vehicle body is provided using the Additive Package. A kit for accomplishing repairs in an after-market repair setting is also provided.

Abstract: A vehicle body repair formulation is provided that includes a polyester resin having a degree of unsaturation of between 25 and 100 molecule percent based on total acid and anhydride content. The polyester resin is dissolved or suspended in a monomer reactive diluent. Microspheroids are provided to enhance the sandability of a cured formulation. An initiator package is also provided. The reactive diluent/monomer can be chosen to be non-stryrenic to improve performance properties. A process for repairing a vehicle body is provided using ambient conditions alone or in combination with thermal source to aid in cure after applied to the vehicle body in need of repair.

Abstract: A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.

Abstract: A vehicle bond filler formulation is provided that includes a part A having curable resin and a monomer reactive diluent. A part B storage-separate, cure initiator package contains a free-radical cure initiator. At least one color changing dye adapted to change color upon mixing the part A and the part B and within ±5 minutes of cure of the curable resin to a sandable condition is present in either the part A or a separate part C, a guide coat colorant, or a combination thereof. A process of for repairing a vehicle body is also provided that includes mixing a part A containing the at least one color changing dye with the part B to form an internal guide coat mixture applied to a substrate of the vehicle body in need of repair. The mixture cures causing the color changing dye to the terminal change color within ±5 minutes of cure of the curable resin to a sandable condition.

Abstract: Tooling packages for mold building structures, mold structures, and methods of making mold structures are described.

Abstract: An Additive Package is provided to adjust the cure properties of a two-part bonding filler across a temperature range of from 4 and 44 degrees Celsius. A low temperature additive speeds a cure rate between 4 and 15 degrees Celsius and a high temperature additive slows down a cure rate between 25 and 44 degrees Celsius. The amount of Additive Package is varied to account for the desired cure properties. The Additive Package includes a first unsaturated polyester resins with an average degree of unsaturation of 70-100 percent based on total acid and anhydride monomer content. A process for repairing a vehicle body is provided using the Additive Package. A kit for accomplishing repairs in an after-market repair setting is also provided.

Abstract: A method for finishing a repaired surface is described. The method includes wiping a sealer on the repaired surface to seal microporosity in the repaired surface, the sealer consisting essentially of a mixture of polymer, at least one filler, solvent, and optionally microspheres; and applying a top coat to the sealed surface without sanding the sealed surface, the top coat being free of visible pinholes. Sealers and tools for applying surface sealers are also described.

Abstract: A vehicle body repair formulation is provided that includes a polyester resin having a degree of unsaturation of between 25 and 100 molecule percent based on total acid and anhydride content. The polyester resin is dissolved or suspended in a monomer reactive diluent. Microspheroids are provided to enhance the sandability of a cured formulation. An initiator package is also provided. The reactive diluent/monomer can be chosen to be non-stryrenic to improve performance properties. A process for repairing a vehicle body is provided using ambient conditions alone or in combination with thermal source to aid in cure after applied to the vehicle body in need of repair.

Abstract: A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.

Abstract: A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.

Abstract: Tooling packages for mold building structures, mold structures, and methods of making mold structures are described.

Abstract: A high build tooling compound suited for plug building by extrusion process with conventional FRP dispensing equipment is described. The material is based on urethane hybrid and unsaturated polyester resin mixture with additives to provide low shrinkage and low exotherm. The formulation allows building a desired part thicknesses from 0.5 to 3 inches in one application. Methods of making a plug are also described.