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, the resin consisting essentially of vinyl ester resin or a combination of vinyl ester resin and polyester resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator, or inhibitor, or both; about 3 to about 10 wt % microspheres; 0 to about 20 wt % fiber; 0 to about 20 wt % filler; 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: 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: The present disclosure relates generally to reinforced composite resin formulations used for molding body panels for transportation vehicles. Particularly, but not by way of limitation, the disclosure relates to low-density thermosetting composite molding compounds used to mold body panels and having a density of less than 1.6 grams/cubic centimeter and excellent surface smoothness without the use of hollow glass microspheres.

Abstract: The present disclosure relates generally to resin formulations for sheet molding compounds. Particularly, but not by way of limitation, the disclosure relates to low-density thermosetting sheet molding compounds (SMC) comprising a treated inorganic clay, a thermosetting resin, a low profile agent, a reinforcing agent, a low-density filler, and substantially the absence of calcium carbonate. The thermosetting SMC are used to prepare exterior and structural thermoset articles, e.g. auto parts and panels, etc that have Class A Surface Quality.

Abstract: This invention relates to low-density thermosetting sheet molding compounds (SMC) including a treated inorganic clay, a curative, a low profile agent, a reinforcing agent, and preferably a low-density filler. The thermosetting SMC are used to prepare exterior and structural thermoset articles, e.g. auto parts, panels, etc.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay treated in situ with an intercalation agent and a non-aqueous, chemically reactive, organic intercalation facilitating agent, wherein the amount of intercalation facilitating agent is sufficient to facilitate intercalation and to disperse said inorganic clay. The thermosetting inorganic clay nanodispersions comprise an inorganic clay dispersed in an intercalating agent and an intercalation facilitating agent. Thermosetting inorganic clay nanodispersions are used to prepare thermosetting nanocomposite articles.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay and at least one organometallic compound. The thermosetting inorganic clay nanodispersions are used to prepare thermosetting articles.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay and at least one organometallic compound. The thermosetting inorganic clay nanodispersions are used to prepare thermosetting articles.

Abstract: This invention relates to low-density thermosetting sheet molding compounds (SMC) comprising a treated inorganic clay, a curative, a low profile agent, a reinforcing agent, and preferably a low-density filler. The thermosetting SMC are used to prepare exterior and structural thermoset articles, e.g. auto parts, panels, etc.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay treated in situ with an intercalation agent and a non-aqueous, chemically reactive, organic intercalation facilitating agent, wherein the amount of intercalation facilitating agent is sufficient to facilitate intercalation and to disperse said inorganic clay. The thermosetting inorganic clay nanodispersions comprise an intercalated inorganic clay dispersed in an intercalation facilitating agent. Thermosetting inorganic clay nanodispersions are used to prepare thermosetting nanocomposite articles.

Abstract: This invention relates to thermosetting inorganic clay nanodispersions comprising an inorganic clay treated in situ with an intercalation agent and a non-aqueous, chemically reactive, organic intercalation facilitating agent, wherein the amount of intercalation facilitating agent is sufficient to facilitate intercalation and to disperse said inorganic clay. The thermosetting inorganic clay nanodispersions comprise an inorganic clay dispersed in an intercalating agent and an intercalation facilitating agent. Thermosetting inorganic clay nanodispersions are used to prepare thermosetting nanocomposite articles.

Abstract: The invention relates to exothermic sleeve compositions comprising (a) an oxidizable metal where the oxidizable metal comprises aluminum dross, and (b) an oxidizing agent capable of generating an exothermic reaction. The invention also relates to sleeve mixes prepared with the sleeve compositions, the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions and the use of the sleeves to prepare metal castings.

Abstract: This invention relates to insulating sleeve compositions comprising (1) a major amount of hollow aluminosilicate microspheres, and (2) fine silica. The sleeve compositions are used to form sleeve mixes by mixing them with a chemically reactive binder. Sleeves are formed from the sleeve mix and are cured in the presence of a catalyst by the cold-box or no-bake cuing process. The invention also relates to a process for casting metal parts using a casting assembly where the sleeves are a component of the casting assembly. Additionally, the invention relates to the metal parts produced by the casting process.

Abstract: The invention relates to an exothermic sleeve composition comprising (a) an oxidizable metal where the oxidizable metal comprises fine aluminum as the major component, and (b) an oxidizing agent capable of generating an exothermic reaction. The invention also relates to the use of the sleeve composition to prepare sleeves, the sleeves prepared with the sleeve compositions, and the use of the sleeves to prepare metal castings.

Abstract: This invention relates to exothermic and insulating sleeve mixes comprising (1) a sleeve composition comprising stabilized hollow aluminosilicate microspheres, and (2) a chemically reactive binder. Sleeves are formed from the sleeve mix and are cured in the presence of a catalyst by the cold-box or no-bake curing process. The invention also relates to a process for casting metal parts using a casting assembly where the sleeves are a component of the casting assembly. Additionally, the invention relates to the metal parts produced by the casting process.

Abstract: Insulating sleeve mixes that contain hollow aluminosilicate microspheres, an organic binder, and boric acid and/or a phosphate, and their uses.

Abstract: This invention relates to heat cured binder systems comprising as separate Parts: Part I comprising (a) a soluble source of silica, (b) an alcohol, and preferably (c) a surfactant; and Part II comprising an alkali aluminate. The binder systems are mixed with a refractory to form a refractory mix. The resulting refractory mix is shaped and heated at an elevated temperature to form a cured refractory shape, particularly a preform. Heat is applied by warm air, baking in an oven, microwave, or preferably by hot-box equipment.

Abstract: This invention relates to heat curable alumino-silicate binder systems comprising as three separate parts (1) a soluble source of silica, (2) a caustic solution of an alkali silicate, and (3) aluminum silicate, and an alcohol which may be incorporated into (1), (2), or both. The binder systems are mixed with an aggregate to form a mix. The resulting mix is shaped and heated at an elevated temperature to form a cured shape, particularly foundry cores and molds. Heat is applied by warm air, baking in an oven, microwave, or preferably by hot-box equipment.

Abstract: This invention relates to heat-cured foundry binders comprising in admixture (1) a source of soluble silica, and (2) a source of soluble alumina, such that the source of silica, source of alumina, or both contain an alkali metal. The binder components form a saturated solution when they are mixed with an aggregate. The resulting mix is shaped and heated at an elevated temperature to form a cured foundry shape. Heat is applied by warm air with warm-box equipment, baking in an oven, microwave, and preferably from hot-box equipment.