Abstract: This invention describes water-based microsphere adhesive formulations to be used in the sheet-to-sheet coating process. These adhesives have proven to have excellent wet-out of a difficult, high-energy surface, good shear stability to allow die-coating or gravure-coating of the adhesive onto an intermediate carrier belt, good elasticity to allow the wet adhesive to cling to the intermediate belt until it is dried (or partially dried), good integrity to allow complete transfer from the intermediate carrier belt onto the final substrate, and repositionable properties in a final product composition.

Abstract: Improved processes for making plastic articles, such as carbonated beverage bottles made from PET, are disclosed. The process includes the step of molding a preform which comprises thermoplastic resin and glass pellets that are substantially uniformly dispersed in the resin. By including the glass pellets, the preform can be more easily and efficiently reheated, if necessary during production. Because the glass pellets are retained in a substantially uniform dispersion in the blown article, the article is not subject to electrostatic adhesion to other articles following release from the blow mold.

Abstract: The invention is directed at a composite material comprising a product of a combination of materials. The combination of materials comprises an inorganic filler comprised of ceramic cenospheres, a thermoplastic polymer and a coupling agent comprised of at least one fatty acid having at least 16 carbon atoms and at least one rosin acid having at least 16 carbon atoms. The combination may further comprise an organic filler comprised of cellulosic material and wherein the thermoplastic polymer has a melt temperature of less than the char temperature of the organic filler. The invention is further directed at a process for producing the composite material comprising the step of combining the components at a temperature of greater than or equal to the melt temperature of the thermoplastic polymer. Where the components include the organic filler, the process temperature is less than the char temperature of the organic filler.

Abstract: The present invention pertains to a one component curable epoxy resin composition which is storage-stable at ambient temperature and which maintains a post-cured high glass transition temperature (Tg) of above 130.degree. C. and a low coefficient of thermal expansion (CTE) of less than 1.76.times.10.sup.-5 cm/cm/.degree.C. over a temperature range of -30.degree. to 125.degree. C., and thus finds practical utility in tooling applications. The epoxy resin composition comprises an epoxy resin or mixture thereof, a multifunctional epoxy resin diluent, a boron trichloride amine complex, and at least one filler selected from the group consisting of a silica or a silicate. The invention also relates to the cured product.

Abstract: The present invention relates to a composition for use as a blowing agent in injection molding processes. More specifically, the present invention is a blowing agent composition comprising a molecular sieve and a foaming agent, wherein the foaming agent is carried by the molecular sieve and evolves to form foamed plastic products. In addition, the present invention is a foamed plastic resin containing a molecular sieve. Additionally, the present invention provides a composition and method for foaming moisture-sensitive polymers comprising the addition of molecular sieves and a poly-hydroxy ester. The present invention is also an encapsulated blowing agent on a polymer substrate.

Abstract: Method and composition for selectively removing liquid hydrocarbon from floors and other hard surfaces comprising granular polyisocyanurate foam. The composition desirably includes a particulate material having a bulk density greater than the polyisocyanurate foam for increasing the overall bulk density of the composition and imparting slip resistance to the floor or hard surface. Suitable particulate material includes angular sand and comminuted cellular glass. The granular polyisocyanurate foam and particulate material can be supplied from scrap material to reduce cost and landfill waste.

Abstract: A sprayable, high solids, low-volatiles composition is provided which may be used as a coating on a variety of substrates. The sprayable filler composition comprises a first filler/glazing component formed from a mixture of a resin, a filler, a mixture of thixotropic clays, a phosphosilicate, and a first organic solvent. The coating also has a second organic solvent component as well as a second catalyst component. The coating as applied to a substrate has a thickness of up to 6 mils without sagging, running or cracking.

Abstract: Method and composition for selectively removing liquid hydrocarbon from floors and other hard surfaces comprising granular polyisocyanurate foam. The composition desirably includes a particulate material having a bulk density greater than the polyisocyanurate foam for increasing the overall bulk density of the composition and imparting slip resistance to the floor or hard surface. Suitable particulate material includes angular sand and comminuted cellular glass. The granular polyisocyanurate foam and particulate material can be supplied from scrap material to reduce cost and landfill waste.

Abstract: A light weight, vibration-damping composition having effective amounts of at least one butyl rubber, at least one tackifying resin, at least one pigment and substantially spherical microspheres is disclosed. The present composition has a specific gravity of about 1.0 to 1.2 and has effective damping effects at low temperatures as well as temperatures up to about 60.degree. C. This composition is effective for use in the transportation industry, the building industry, the aerospace industry and the appliance industry.

Abstract: A syntactic foam-core material and method for its production are disclosed wherein glass microspheres and chopped fiberglass are dispersed within a slurry comprised of a suitable resin such as an epoxy and a suitable solvent such as methyl ethyl ketone. Under carefully controlled vacuum and rate of addition conditions, the microspheres and chopped fiberglass are added to the slurry to form a light weight syntactic foam-core material. The material may either be stored under cold conditions for use at a later time as a B-stage material or it may be shaped and/or molded to conform to a desired configuration which, for example, may correspond with a desired component part. After curing, the material may be machined to final dimensions. The material may be characterized as a tightly packed network of resin-coated microspheres spaced by controlled, yet random voids comprising at least 20%, and more usually, between 23 and 25% by volume, of the fully-cured material.

Abstract: A coating composition for use in protecting metallic substrates from corrosion, comprising in weight percent, based on the total weight of the composition; from about 10% to 20% of a film forming substance; from about 45% to 55% of zinc powder, from about 25% to 35% of zinc dust; from about 1.5% to 2.5% of hollow glass microspheres having diameters ranging from 1 to about 150 microns and a true density of 0.3 to 1.1; from about 2% to 15% by weight of the film forming substance, of a hardener, about 1% to 2% by weight of the film forming substance, of an amorphous silica; and about 0.3% to 1% of a flow control agent.

Abstract: An improved thermal barrier coating for metal substrates such as superalloys is provided. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

Abstract: A reactive hot melt adhesive and/or sealing composition having a heat of crystallization in joules/gram of -2 or lower, comprising a curable heat-flowable adhesive material and a particulate filler, wherein said composition has a thermal conductivity of less than 0.30 W/m.multidot..degree.C. The invention also relates to a method of using the adhesive/sealer composition described herein to fill a cavity or recess in a substrate and the filled substrates formed thereby.

Abstract: The present invention relates to a novel retroreflective coating composition which can be suitably applied to a metal substrate using a conventional coral coating process and apparatus. The retroreflective coating composition provides a retroreflective film upon application by coral coating without additional processing steps. The retroreflective coating composition is comprised of (a) 45 to 60% of a resin binder system and (b) 55 to 40% of reflective transparent glass microspheres having a refractive index of 2.1 to 2.5 and a diameter of 20 to 60 microns. The resin binder system is comprised of a thermosetting ethyl acrylate-styrene copolymer, cross-linking resin, aromatic volatile solvent, anti-gelling stabilizer, colloidal suspending agent, dibasic ester acetate, and cross-linking accelerator, and have a refractive index of 1.5 to 1.9. Hence, the novel retroreflective coating composition can provide a retroreflective article with less manufacturing steps and at a lower cost.

Abstract: A separating agent which, when used as the packing material for reverse-phase liquid chromatography, has excellent baseline stability in the mobile phase and an increased number of steps of the detected peak in the measurement is provided. The agent comprises a polysaccharide derivative supported on a silica gel having surface silanol groups treated with a silylating agent having an aralkyl group.

Abstract: This invention relates to a reaction injection molding process for preparing a molded product comprising reacting, at an isocyanate index of about 70 to about 130,(a) an organic polyisocyanate;(b) one or more isocyanate-reactive compounds containing at least two isocyanate-reactive groups;(c) about 0.5 to about 40% by weight, based on the weight of the molded product, of rigid microspheres, wherein at least 95% of said microspheres have a particle size range of about 10 .mu.m to about 400 .mu.m and a median diameter of at least 120 .mu.m,(d) optionally, an inert gas dissolved in at least one of components (a) or (b) in an amount sufficient to produce a molded product having a density that is at least 1% less than the density of a molded product prepared in the same manner without using an inert gas but which is at least 0.2 g/cm.sup.3 ;(e) 0 to 45% by weight, based upon the weight of the molded product, of a reinforcing filler other than rigid microspheres; and(f) optionally, a blowing agent.

Abstract: A reactive hot melt adhesive and/or sealing composition having a heat of crystallization in joules/gram of -2 or lower, comprising a curable heat-flowable adhesive material and a particulate filler, wherein said composition has a thermal conductivity of less than 0.30 W/m..degree.C. The invention also relates to a method of using the adhesive/sealer composition described herein to fill a cavity or recess in a substrate and the filled substrates formed thereby.

Abstract: A flexible closed cell polymeric foam contains expandable graphite as fire retardant. The foam is prepared by mixing a polymer, a curing agent, at least one blowing agent and an expandable graphite at a temperature of at least 100.degree. C. but below a temperature causing activation of the blowing agent to foam a foamable mixture and thereafter heating the foamable mixture to activate the blowing agent and cause foaming. The method of preparation may additionally include a curing step in which the foamable mixture is heated under pressure to activate simultaneously each of a curing agent, which is preferably a free radical curing agent, and a foaming agent. The foams are capable of meeting the U.S. Federal Aviation Authority Standards, especially the oil burner test of FAR 25 Appendix F, part II.

Abstract: The present invention relates to a composition for use as a blowing agent in injection molding processes. More specifically, the present invention is a blowing agent composition comprising a molecular sieve and a foaming agent, wherein the foaming agent is carded by the molecular sieve and evolves to form foamed plastic products. In addition, the present invention is a method for preparing a blowing agent composition and a foamable blowing agent-resin mixture. Furthermore, the present invention is a foamed plastic resin containing a molecular sieve. Additionally, the present invention provides a composition and method for foaming moisture-sensitive polymers comprising the addition of molecular sieves and a poly-hydroxy ester. The present invention also advances a method of encapsulating a blowing agent on a polymer substrate and a corresponding encapsulated blowing agent composition.

Abstract: A low-density, porous material is prepared by mixing together microballoons and an oligomeric precursor to a polyesterimide polymer. The oligomeric precursor has an initial viscosity sufficiently low that it can flow and wet the microballoons when first heated to a polymerization processing temperature, and thereafter polymerize. Fibers may be controllably incorporated into the material during processing to impart specific properties, and air may be controllably incorporated into the material during processing to further decrease its density.

Abstract: Polyurethane/urea elastomers having an isocyanate equivalent index below 100, preferably from about 15 to about 80; containing an effective amount of polyisocyanate component, and an effective amount of an isocyanate reactive component comprising at least one polyamine and at least one polyol, wherein said elastomer contains from about 1 to about 199 equivalent percent amine per isocyanate equivalent.

Abstract: A pressure sensitive adhesive consisting of a polyurethane foam is used for adhering decorative parts to automobiles and other vehicles. The adhesive is characterized by high tensile strength and elongation, excellent peel strength and good thermal and mechanical stress tolerance.

Abstract: Disclosed herein is a precursor powder composition comprising a resin, a combination of zinc dust, zinc powder and zinc-coated microspheres and graphite, said powder being soluble in a solvent blend at a facility remote from the powder manufacturing facility, thereby, decoupling the powder manufacturing process from the end use of the powder which could be in a traditional solvent-based paint. Also disclosed are coating compositions for use in protecting metallic substrates from corrosion, comprising necessary additives and film forming substances including alkyl silicate, epoxy resins, powder and non-powder, and polyester resins, all the compositions being modified with about 4 to about 20 weight percent graphite powder based on total weight of the composition.

Abstract: A syntactic foam-core material and method for its production are disclosed wherein glass microspheres and chopped fiberglass are dispersed within a slurry comprised of a suitable resin such as an epoxy and a suitable solvent such as methyl ethyl ketone. Under carefully controlled vacuum and rate of addition conditions, the microspheres and chopped fiberglass are added to the slurry to form a light weight syntactic foam-core material. The material may either be stored under cold conditions for use at a later time or it may be shaped and/or molded to conform to a desired configuration which, for example, may correspond with a desired component part. After curing, the material may be machined to final dimensions.

Abstract: A syntactic foam in the form of a thin uniform sheet that possesses enhanced moisture resistance, which comprises a composite filled with hollow microspheres such as glass in a polymer matrix resin such as an epoxy resin where the resin encapsulates the microspheres and the filled composite at weight equilibrium has less than 15% of the available internal volume of the microspheres occupied by liquid water as determined by the LMA test. The process of making the sheet and composites incorporating the sheet is described.

Abstract: A flexible closed cell polymeric foam contains expandable graphite as fire retardant. The foam is prepared by mixing a polymer, a curing agent, at least one blowing agent and an expandable graphite at a temperature of at least 100.degree. C. but below a temperature causing activation of the blowing agent to foam a foamable mixture and thereafter heating the foamable mixture to activate the blowing agent and cause foaming. The method of preparation may additionally include a curing step in which the foamable mixture is heated under pressure to activate simultaneously each of a curing agent, which is preferably a free radical curing agent, and a foaming agent. The foams are capable of meeting the US Federal Aviation Authority Standards, especially the oil burner test of FAR 25 Appendix F, part II.

Abstract: A method of pore-size selective chemical modification of materials having pores of about 1 to 1,500 nm is disclosed. The resulting novel porous materials are particularly useful as separation media in chromatography, for selective isolation, adsorption and catalysis.

Abstract: A coating composition is based on polyvinyl chloride plastisol containing thermoplastic microspheres and is suitable for use as underbody compound for vehicles. The coating composition contains a mixture of expandable and expanded microspheres, in which the expandable microspheres expand at a temperature in the vicinity of the temperature at which the expanded microspheres begin to collapse. The mixture of microspheres solves the problem of a varying density of the coating when the plastisol is gelatinated.

Abstract: A composite mixture of spherical objects and lubricant useful for its cushioning properties is disclosed and claimed. The composite mixture may be composed of microspheres typically less than 2000 microns in diameter with inert atmospheres sealed within their interiors and any of a variety of lubricants facilitating sliding and rolling movement between microspheres. Typically the composite mixture includes lubricant in a quantity sufficient to substantially coat the exterior surface of essentially all of the spherical objects, but in a quantity less than would cause dispersion of the spherical objects in the lubricant sufficient to physically separate the spherical objects from each other and substantially reduce the sliding and rolling contact of the spherical objects with each other. The preferred lubricant is a visco-elastic fluid that has a principle molecule and a cross-linking agent.

Abstract: A stable and highly productive method for the preparation of silicone foam having uniform cells characterized by mixing the base and curing agent portions of an organosiloxane, along with a gas-containing hollow filler in a mixing device having a shear-stirring mechanism such that the organosiloxane begins to foam and cure when the shear-stirring mechanism is used to rupture the filler and mix the base and curing agent portions.

Abstract: The present invention is directed to a rigid or semirigid, filled resin material having a continuous phase which is a matrix containing a complex crosslinked network having an unsaturated polyester-polyurethene containing resin having fine multisize reinforcing particles and dispersed filler particles dispersed therein. The polyester-polyurethene network of the complex crosslinked network may interact with other polymer networks in the continuous phase either by crosslinking or by forming an interpenetrating polymer network. The complex crosslinked network immobilizes the fine multisize reinforcing particles and reacts with at least a surface layer of the dispersed filler particles. The present invention is also directed to a process for preparing the above rigid or semirigid, lightweight resin material, and to a composition for use in this process.

Abstract: A smooth-surfaced tape or sheet of composite syntactic material made up of a polyolefin and, as filler, hollow microspheres, is formed by extrusion through a die having a land length to thickness ratio less than 7:1 at a temperature of about 215.degree. C. Such tapes are wrapped around pipes to provide insulation.

Abstract: A coating composition for use in protecting metallic substrates from corrosion, comprising in weight percent, based on the total weight of the composition: from about 10% to 20% of a film forming substance; from about 45% to 55% of zinc powder; from about 25% to 35% of zinc dust; from about 1.5% to 2.5% of hollow glass microspheres having diameters ranging from 1 to about 150 microns and a true density of 0.3 to 1.1; from about 2% to 15 % by weight of the film forming substance, of a hardener; about 1% to 2% by weight of the film forming substance, of an amorphous silica; and about 0.3% to 1% of a flow control agent.

Abstract: Self-repairing, fiber reinforced matrix materials include a matrix material including inorganic as well as organic matrices. Disposed within the matrix are hollow fibers having a selectively releasable modifying agent contained therein. The hollow fibers may be inorganic or organic and of any desired length, wall thickness or cross-sectional configuration. The modifying agent is selected from materials capable of beneficially modifying the matrix fiber composite after curing. The modifying agents are selectively released into the surrounding matrix in use in response to a predetermined stimulus be it internal or externally applied. The hollow fibers may be closed off or even coated to provide a way to keep the modifying agent in the fibers until the appropriate time for selective release occurs.

Abstract: Methods and apparatus are disclosed for producing a composition material which embodies both physical and chemical properties of a physically expanded polymer and specific structural and/or chemical properties of solid particles fully encapsulated within membranes in the expanded polymer.

Abstract: A low density RRIM/RIM article formed of rigid foamed polyurethane which has incorporated in it, hollow glass microspheres with a compressive strength greater than 4,000 psi and a maximum size of 120 microns. This low density RRIM/RIM fascia may have physical properties and continuous high gloss painted outer skin comparable to conventional RRIM/RIM products while having reduced density in comparison to such product.

Abstract: A low-density, porous material is prepared by mixing together microballoons and an oligomeric precursor to a polyetherimide polymer. The oligomeric precursor has an initial viscosity sufficiently low that it can flow and wet the microballoons when first heated to a polymerization processing temperature, and thereafter polymerize. Fibers may be controllably incorporated into the material during processing to impart specific properties, and air may be controllably incorporated into the material during processing to further decrease its density.

Abstract: A filled aliphatic thermoplastic urethane automotive air bag door tear seam insert is formed of a polyol, a chain extender, an organic diisocyanate, an antioxidant, a urethane catalyst, and a weakening filler wherein the filler is present in a range of approximately 60% to 80% by weight and is selected from the group consisting of anhydrous calcium sulfate, nepheline syenite and hollow silica-alumina alloy microspheres and combinations thereof. The filler may be only one of the group members or any combination thereof and in either equal or unequal proportions. The insert is adapted to be molded in place in a cover skin cast there about. The cast cover skin including the tear seam insert may be coated with a light stable paint; or for light stability and color matching, the urethane elastomer forming the cover skin and insert is formulated to include an ultra violet stabilizing agent(s) and a color pigment(s) in certain critical concentrations to obtain the desired effect.

Abstract: A reactive hot melt adhesive and/or sealing composition having a heat of crystallization in joules/gram of -2 or lower, comprising a curable heat-flowable adhesive material and a particulate filler, wherein said composition has a thermal conductivity of less than 0.30 W/m..degree.C. The invention also relates to a method of using the adhesive/sealer composition described herein to fill a cavity or recess in a substrate and the filled substrates formed thereby.

Abstract: The present invention is directed to a rigid, lightweight filled resin foam having voids dispersed in a continuous phase which is formed from a polyester hybrid resin having reinforcing particles dispersed therein. The hybrid resin forms a complex crosslinked network which may interact with other polymer networks in the continuous phase either by crosslinking or by forming an interpenetrating polymer network. The present invention is also directed to a process for preparing the above rigid, lightweight resin foam, and to a composition for use in this process. The foam of the present invention is useful in building materials and the like requiring high tensile and compressive strength and corrosion and thermal resistance.

Abstract: A modeling dough comprising gelled poly(vinyl alcohol), water and a filler provides a dough resistant to flaking, cracking, and crumbling. In the disclosed invention, the poly(vinyl alcohol) resin is gelled, thereby providing a water-based resin system that is not sticky yet very ductile. Prior to drying, the dough also exhibits the properties of bounceability and the ability to pick up newsprint. After the dough is air-dried, the poly resin serves to bind the components into a solid, durable product. The filler accounts for a large portion of the volume of the dough, so the overall volume is not greatly affected by water loss upon drying. The dough is water-based and easy to wash from skin, carpets, and other surfaces. Dyes and pigments can be easily incorporated into the formula. The dried product is sandable and paintable.

Abstract: An abradable coating is provided for use on a composite substrate which has a coefficient of thermal expansion substantially similar to that of the substrate and which is formed with a matrix resin of the same type of resin used to form the substrate. In particular, with a composite substrate formed from carbon or graphite fibers impregnated with a polyimide resin, an abradable coating formed from carbon or glass microballoons in a polyimide resin matrix has been found to avoid delamination as a result of thermal cycling between -65.degree. F. and 500.degree. F. Accordingly, that abradable coating is particularly suitable for use with composite compressor shrouds in gas turbine engines and aircraft auxiliary power units.

Abstract: A low-density hot melt adhesive is disclosed. Low-density filler, preferably hollow glass microspheres, is added to a hot melt adhesive to provide a hot melt adhesive having a specific gravity preferably between 0.7 and 0.93. The low-density hot melt adhesive is more effectively separated from cellulosic materials such as cardboard and kraft paper during recycling operations which separate contaminants such as adhesives from cellulosic fibers based upon the density of the adhesive.

Abstract: Easily removable, environmentally safe, low-density, syntactic foams are disclosed which are prepared by mixing insoluble microballoons with a solution of water and/or alcohol-soluble polymer to produce a pourable slurry, optionally vacuum filtering the slurry in varying degrees to remove unwanted solvent and solute polymer, and drying to remove residual solvent. The properties of the foams can be controlled by the concentration and physical properties of the polymer, and by the size and properties of the microballoons. The suggested solute polymers are non-toxic and soluble in environmentally safe solvents such as water or low-molecular weight alcohols.

Abstract: A process for preparing a silicon carbide foam by impregnating a polyurethane foam with a suspension of silicon powder in an organic resin, heating progressively to polymerize the resin, heating further to carbonize the polyurethane foam and resin, and finally further heating to carburize the silicon contained in the resin suspension by means of carbon obtained from the carbonization of the foam and resin. The foam obtained is characterized by high macroporosity and a mesoporosity which is variable according to the carburizing temperature.

Abstract: A column packing material to be used in gel permeation chromatography (GPC) consists of support particles with a mean particle diameter of 1 to 50.mu. of which the matrix is formed by an inorganic or organic, polymeric and porous hard material with a mean pore diameter of 6 to 50 nm and a pore volume of 0.1 to 3 ml/g, the matrix pores containing chemically bound polymer chains. The column packing material of the invention is characterized in that the polymer chains consist of linear, permeable and not-crosslinked polymers with an upper exclusion limit between 200 and 200,000, the pores of the matrix being entirely filled by the polymer chains. The method of the invention is characterized in that the pores of the support particles are filled by polymer chains chemically bound to the pore surfaces, these polymer chains being permeable to solvents and partly to dissolved substances.

Abstract: A composition is described with comprises a mixture of(A) from about 5% to about 60% by weight of at least one water-insoluble polymer;(B) from about 1% to about 30% by weight of inorganic or synthetic resinous hollow microspheres; and(C) from about 20% to about 70% of at least one volatile organic liquid which is a solvent for the polymer of (A).The compositions also may contain (D) at least one solid particulate inorganic filler. Adhesive compositions such as solvent cements prepared in accordance with the present invention are characterized as low V(olatile) O(rganic) C(hemical) compositions wherein the VOC is, for example, less than 500 or even less than 400 grams per liter.

Abstract: An insulating material consisting essentially of fly ash particles and a binder and a method for making the same. In one embodiment of the present invention, fly ash particles are mixed with a dissipating foam which contains a binder. The foam acts to spread the binder and separate the fly ash particles, thereby coating the fly ash particles with the binder. When the foam dissipates the binder acts to bind the fly ash particles together in clusters. The clusters of fly ash particles are then suitable to be used as blown-in insulation.

Abstract: A composition is described with comprises a mixture of(A) from about 5% to about 60% by weight of at least one water-insoluble polymer;(B) from about 1% to about 30% by weight of inorganic or synthetic resinous hollow microspheres; and(C) from about 20% to about 85% of at least one volatile organic liquid which is a solvent for the polymer of (A).The compositions also may contain (D) at least one solid particulate inorganic filler. Adhesive compositions such as solvent cements prepared in accordance with the present invention are characterized as low VOC compositions wherein the VOC is, for example, less than 500 or even less than 400 grams per liter.

Abstract: A sprayable, high solids, low-volatiles filler composition is provided which may be used as a coating on a variety of substrates. The sprayable filler composition comprises a first filler/glazing component formed from a mixture of a resin, a filler, a mixture of thixotropic clays, activated fumed silica, hollow glass microspheres, and a ketone solvent. The sprayable filler composition has a second catalyst component. The glazing/filler component is blended with the catalyst component, preferably either internally or externally of the spray nozzle, and the resultant sprayable filler composition is sprayed onto a substrate. The resulting cured coating provides a sandable surface which is corrosion resistant.