Abstract:
A method of making a thickened hardener composition useful in a two part resin system. The thickened hardener composition includes a carrier, a peroxide catalyst, and a thickening and volumetrically increasing agent, wherein the thickening and volumetrically increasing agent is microspheres. A method of making a thermoset resin from a two-part polyester resin system is also provided.

Description:
[0001]     This application is a continuation-in-part of U.S. application Ser. No. 11/178,652, filed Jul. 11, 2005, entitled Polyester Resin Composition. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to polyester resins and their use in primers, body fillers, adhesives, and putties that are used in repairs and surface finishing for metal and plastic substrates for architectural uses and construction, and for equipment and vehicles such as automotive, marine, agricultural and airborne vehicles, and industrial equipment.  
       BACKGROUND OF THE INVENTION  
       [0003]     Traditionally, the polyester repair markets have utilized well-defined processes in the area of damage repair. Unsaturated polyester resins, primers, fillers, adhesives, or putties are used to resurface and reshape damaged areas. For ease of understanding, the term “resin” will be used in the following description; however, it is to be understood that the term includes cured resins and prepolymers (uncured resins), primers, fillers, adhesives, and putties. The method for catalyzation and application of the resin is as much an art as it is a science. This is due in part to the very small amount of peroxide hardener (catalyst) that is used to cure the much larger amounts of unsaturated polyester resin properly. The optimum peroxide level needed to cure the resin is generally about 1 to 3 parts per hundred of the resin by weight. The resin and peroxide are packaged in separate containers, typically a large can for the filler (8 oz. to 55 gal.), and a small tube for the peroxide catalyst (0.25 oz. to 4 oz.).  
         [0004]     The user dispenses a variable amount of resin into a cup or onto a mixing board, and adds the peroxide catalyst, essentially guessing at the correct amount for proper catalyzation. The consequences of improper catalyzation of the resin include loss of adhesion to the substrate, uncured surface (tacky), cracking of the resin due to excessive heat generation, migration of uncured resin organics to subsequent coatings resulting in discoloration of top coats, outgassing of uncured material in the presence of ultraviolet or heat energy from sunlight or paint baking systems resulting in blistering and other damage to the topcoat, as well as other problems that may require removal and replacement of the repair.  
         [0005]     As a result, efforts have been made to control metering of the organic peroxide to ensure that the proper amount is mixed with the thermoset resin. Due to the nature of many of the commercially available peroxide solutions, which have a viscosity similar to water, dispensing in a mechanical metering system was difficult in non-spray applications. One attempt to solve this problem is described in U.S. Pat. No. 5,880,181, which disclosed organic peroxides in combination with a cellulose ester as a thickening agent, and a fumed silica and/or a hydrogenated castor oil as a thixotropic agent to form a thicker form of the organic peroxide.  
         [0006]     There remains a need in the art for a more volumetrically controllable form of the organic peroxide.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention meets this need by providing a method of making a thickened hardener composition useful in a two part resin system. The method includes providing a carrier; providing a peroxide catalyst; and adding a thickening and volumetrically increasing agent, wherein the thickening and volumetrically increasing agent are microspheres; and mixing the carrier, the organic peroxide, and the thickening and volumetrically increasing agent to form the thickened hardener composition.  
         [0008]     Another aspect of the invention is a method of making a thermoset resin from a two-part polyester resin system. The method includes providing thickened hardener composition comprising: providing a carrier; providing a peroxide catalyst; and adding a thickening and volumetrically increasing agent, wherein the thickening and volumetrically increasing agent is microspheres; mixing the carrier, the organic peroxide, and the thickening and volumetrically increasing agent to form the thickened hardener composition; providing a resin composition comprising a reactive polymer, a reactive monomer, or combinations thereof; mixing the thickened hardener composition and the resin composition in a ratio of about 1:10 to about 1:2; and curing the mixture to the form the thermoset resin.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0009]     The present invention involves a polyester primer, resin, filler, adhesive, or putty that can be applied to metal substrates, such as cold rolled steel, galvanized steel, and aluminum, as well as to plastic substrates, such as polyesters, polyurethanes, polyolefins, sheet molding compounds (SMC), and bulk molding compounds (BMC).  
         [0010]     The invention makes use of microspheres as a thickener and volumetrically increasing agent. The use of the microspheres allows for the manipulation of the volumetric ratio of the peroxide dispersion side in relation to the resin side.  
         [0011]     The ability to measure the mix ratio of catalyst to resin accurately will reduce or eliminate the most common problems associated with unsaturated polyester repair product use, and will increase the value of the product to the user.  
         [0012]     The microspheres can be glass, plastic, or ceramic, as desired. The microspheres add volume while lowering density. The lower density has performance and distribution benefits. A composition containing microspheres can be sanded easily because the sanding is cutting through mostly air. Less dense putties also have better sag resistance on vertical surfaces. In terms of distribution, lighter products are less expensive to ship.  
         [0013]     Glass microspheres have an advantage due to their ease of sanding. They also have very low oil absorption, decreasing resin contribution, and lowering costs. The low oil absorption also provides unique and desirable flow characteristics.  
         [0014]     The size and density of microspheres can vary widely. Some are relatively large and light at about 0.13 g/cc, such as K-1 3M Scotchlite™ glass bubbles available from 3M, or Q-Cel 6014 available from Potters Industries Inc., while others are smaller and heavier at about 0.6 g/cc, such as S-60 3M Scotchlite™ glass bubbles available from 3M, or 60P18 available from Potters Industries Inc. Because of the size and density variations, the total weight range of the microspheres in the peroxide dispersion can vary from about 1% for the larger, lighter microspheres, to about 50% for the smaller heavier microspheres.  
         [0015]     The present invention can include either a non-reactive carrier or a reactive carrier. Non-reactive carriers include, but are not limited to plasticizers for peroxides. Examples of plasticizers include, but are not limited to, benzoate plasticizers, phthalate plasticizers, and short chain saturated polyesters. Suitable phthalate plasticizers include, but are not limited to, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diisobutyl phthalate, butyl benzyl phthalate, and combinations thereof. The plasticizer can be purchased in combination with the peroxide catalyst. Examples of products containing both plasticizers and peroxide catalysts include, but are not limited to, those available from Akzo Nobel under the designation Perkadox BTW-50, from Norac under the designation Benox B-50, and a 50% Benzoyl Peroxide Paste available from Catalyst Systems.  
         [0016]     The use of a reactive carrier greatly increases the challenge of stabilization of the blend. It will be a reactive component in the system, but it can be stabilized in the presence of the catalyst alone. Suitable reactive carriers include, but are not limited to low molecular weight non-styrenated unsaturated polyesters, diglycidal ether bis-phenol A based epoxies, and bis-phenol A alkoxylates. Suitable low molecular weight non-styrenated unsaturated polyesters include, but are not limited to, short chain unsaturated aliphatic dicarboxylic acid based polyesters. Suitable short chain unsaturated aliphatic dicarboxylic acid based polyesters include, but are not limited to, maleates and fumarates with a viscosity in the range of about 100 to about 10,000 cps, generally about 100 to about 2,000.  
         [0017]     Suitable peroxide catalysts include, but are not limited to, ketone peroxides, cumyl hydroperoxides, dibenzoyl peroxides, peroxyesters, peroxyketals, and peroxydicarbonates. Suitable ketone peroxides include, but are not limited to, methyl ethyl ketone peroxide, 2,4-pentadione peroxide, methyl isobutyl ketone peroxide, acetyl acetone peroxide, cyclohexanone peroxide.  
         [0018]     The hardener side can also include fillers such as talcs, carbonates, pigments, rheological modifiers, pigment wetting and dispersing agents, parrafins, and fiber reinforcements.  
         [0019]     The resin side of the system can include a reactive polymer, or a monomer, or a combination of the two. Suitable reactive polymers include, but are not limited to, unsaturated polyesters, vinyl esters, and hybrid epoxy-polyester, hybrid urethane-polyester, and hybrid acrylate-polyester systems that polymerize by way of a free radical mechanism. Suitable monomers include, but are not limited to, styrene, vinyl toluene, other methyl styrene monomers, methyl methacrylate, and other acrylate monomers.  
         [0020]     The resin side can also include fillers such as talcs, carbonates, pigments, rheological modifiers, microspheres, pigment wetting and dispersing agents, paraffins, and fiber reinforcements.  
         [0021]     The microspheres can be included in the hardener side so that the volume of the hardener and resin compositions are approximately the same. The ratio of the volume of the hardener side to the volume of the resin side is generally about 1:10 to about 1:1, typically about 1:10 to about 1:2. With the volume ratio in this range, it is much easier to provide the correct amount of hardener for the amount of resin used, eliminating the guesswork of prior art systems.  
         [0022]     Controlling the volume of each side will allow the use of a variety of mixing tube applicators. One example of mixing tube applicator is a double barrel mixing tube applicator which has the hardener composition on one side and the resin composition on the other side. The plunger dispenses the hardener composition and resin composition in the proper amounts so that they can be mixed and applied.  
         [0023]     Another suitable mixing tube applicator is a “universal cartridge.” The universal cartridge incorporates both sides of the product in a single barrel. It uses a front and back chambers with a transfer tube from the back to deliver both sides in the correct ratio. The benefit of a universal cartridge is the ability to use it with any caulk gun, instead of specific side by side guns. Suitable universal cartridge delivery systems are described in U.S. Pat. Nos. 5,310,091 and 6,938,797.  
         [0024]     In order that the invention may be more readily understood, reference is made to the following examples which are intended to illustrate the invention, but not limit the scope thereof.  
       EXAMPLE 1  
       [0025]     This test was designed to test the effect of soda lime borosilicate microspheres on the hardener composition. The use of glass microspheres allowed large volumetric increases to the hardener composition in relation to the resin composition of the two-part system. The reactive carrier was short chain dipropylene glycol (DPG) maleate that is non-diluted with monomer, the catalyst was Benzoyl Peroxide (50%), antioxidant 1 was 2,6-di-tertiary-butyl-n,n-dimethylamino-para-cresol, and antioxidant 2 was 2,6-di-tertiary-butyl-para-cresol.  
                                                                                     Raw Material   A   B   C   D   E   F                                Reactive Carrier   73.7   66.6   66.6   66.6   66.6   66.6       Microspheres   15.8   16.7   16.7   16.7   16.7   16.7       Benzoyl Peroxide (50% paste)   10.5   16.7   16.7   16.7   16.7   16.7       1,4 NQ Soln               1.5 * 10 −3     1.5 * 10 −3         Antioxidant 2           2.5 * 10 −3     2.5 * 10 −3     5.0 * 10 −3     5.0 * 10 −3         Antioxidant 1           1.5 * 10 −3     1.5 * 10 −3     1.5 * 10 −3     1.5 * 10 −3         Total   100   100   100   100   100   100       Shelf Stability   &gt;90 days   &gt;90 days   &gt;330 days   &gt;330 days   &gt;330 days   &gt;330 days                  
 
 Samples maintained at ambient temperature. 
 
 All values representative of percentage by weight of the peroxide dispersion. 
 
         [0026]     The results showed that the peroxide could be stabilized in a non-diluted low viscosity unsaturated polyester resin in the presence of microspheres.  
       EXAMPLE 2  
       [0027]     Typical sample formulations for different mix ratios are shown.  
                                                                                 1:10   1:4   1:2   1:1                                    Resin Composition                       Styrenated Unsaturated   43.74   35.23   28.28   24.33       Polyester Resin       Monomer   8.75   12.92   16.06   17.92       Wax   0.07   0.07   0.07   0.07       Tetrahydrophthalic acid   1.94   1.88   1.81   1.77       TiO 2     2.43   2.35   2.26   2.21       Rheological Modifier   0.49   0.47   0.45   0.44       Microtalc   13.37   12.92   12.44   12.16       Calcium Carbonate   12.15   11.75   11.34   11.06       Microspheres   8.51   5.87   4.52   1.66       Hardener Composition       Reactive Carrier   4.86   11.74   16.97   19.91       Microspheres   1.22   2.35   3.39   6.08       Benzoyl Peroxide (50% paste)   2.43   2.35   2.26   2.21       Antioxidant 1   0.01   0.02   0.03   0.04       Antioxidant 2   0.03   0.08   0.12   0.14       Total   100.00   100.00   100.00   100.00                  
 
 All values are representative of percent by weight of the total composition (peroxide dispersion and resin). 
 
       EXAMPLE 3  
       [0028]     This example was designed to test how gel times were affected by the amount of reactive carrier. The resin promoter was N-(2-Hydroxyethyl)-N-methyl-para-toluidine.  
                                                                         Resin Composition   2:1   4:1                                        Unsaturated Polyester   90   120           Unsaturated Polyester   40   40           Styrene Monomer   49   39           Wax Soln. 33%   9   9           Tetrahydrophthalic acid   8   8           TiO 2     10   10           Resin Promoter   0.5   0.5           Rheological Modifier   2   2           Talc   55   55           Calcium Carbonate   50   50           S-22 Microspheres   20   25               333.5   358.5                      
 
         [0029]                                                                              Peroxide Composition                                                Low MW Non-Styrenated   70   40           Polyester           Benzoyl Peroxide   10   10           (50% paste)           S-22 Microspheres   15   10               95   60           Gel Times   5.0   3.33                        
 All values are representative of gram weight of the total composition (peroxide composition and resin composition). 
 
         [0030]     With the use of a promoter and manipulation of the inhibiter level, the gel and cure rates can be customized for a particular application.  
       EXAMPLE 4  
       [0031]     The stability of the peroxide catalyst was evaluated using various antioxidants and inhibitors. NQ solution is 10% 1,4-Naphthaquinone (inhibitor)/90% methanol.  
                                                                     Peroxide Composition   1   2   3   4                                Low MW Non-Styrenated   33.3   33.3   33.3   33.3       Polyester       Benzoyl Peroxide   8.3   8.3   8.3   8.3       (50% paste)       S-22 Microspheres   8.3   8.3   8.3   8.3       Antioxident 2   0.125   0.125   0.25   0.25       Antioxidant 1   0.075   0.075   0.075   0.075       NQ Soln       0.075       0.075       Gel Times   14.0   12.0   28.0   22.0       Gel Time After 1 Year       9.0       14.0                  
 
 All values are representative of gram weight of the total composition (peroxide composition). 
 
         [0032]     Samples 1-4 were placed in an oven at 110° F. The samples gelled in two weeks. Samples maintained at ambient temperature (68-78° F.) remained gel free for over 1 year.  
         [0033]     After 1 year, the gel time was retested for Samples 2 and 4. The gel time dropped from 12 to 9 minutes for Sample 2, and it dropped from 22 to 14 minutes for Sample 4. This indicates that the inhibitors and antioxidants have been partially consumed.  
       EXAMPLE 5  
       [0034]     This example was designed to determine whether the performance characteristics of existing peroxide catalyzed products could be matched by embodiments of the invention. A low molecular weight non-styrenated polyester with a resin promoter and a benzoyl peroxide (50%) catalyst were blended with a styrenated resin without the other typical components being present.  
                                                         Styrenated Polyester            Low MW Non-Styrenated                   Resin       Polyester   50%   60%   70%   90%   Promotor               50%   5′30″                       40% (2 + 1)       4′00″       40% (2 + 1)       1′00″           0.6%       30% (4 + 1)           3′40″       30% (4 + 1)           1′00″       0.5%       10% (10 + 1)               3′00″       10% (10 + 1)               1′00″   0.4%                  
 
 All values representative of percentage by weight of the resin blend. 
 
 All samples catalyzed at 4% by weight benzoyl peroxide (50% paste dispersion). 
 
         [0035]     The gel times for different polyester blends were measured. The addition of a promoter succeeded in decreasing the gel time to the desired 1 minute time for various blend ratios.  
         [0036]     Suitable 2:1, 4:1, and 10:1 formulations corresponding to the above experiment are shown below.  
                                                                                 Resin Composition   2:1   4:1   10:1                                        Styrenated Polyester   250   300   360           Styrene   110   110   110           Wax Soln. 33%   1.0   0.8   0.6           Tetrahydrophthalic acid   16   16   16           TiO 2     20   20   20           Rheological Modifier   4   4   4           Talc   110   110   110           Calcium Carbonate   100   100   100           S-22 Microspheres   40   50   65                      
 
         [0037]                                                                                      Peroxide Composition                                                    Low MW Non-Styrenated   150   100   40           Polyester           Benzoyl Peroxide   20   20   20           (50% paste)           S-22 Microspheres   30   20   5                        
 All values are representative of gram weight of the total composition (peroxide composition and resin composition). 
 
       EXAMPLE 6  
       [0038]     A hardener composition was prepared according to the following formulation. The base composition was then mixed with microspheres in order to evaluate the effect of different microspheres. Antioxidant 2 solution was 10% antioxidant 2, and 90% low molecular weight non-styrenated unsaturated polyester. Antioxidant 2 solution was 50% antioxidant 1, and 50% methanol.  
                                                                                     Hardener Composition       1   2   3   4   5                                Low MW Non-Styrenated   300                           Polyester       DiGlycidal Ether       Bisphenol A Epoxy   100       Benzoyl Peroxide   300       (50% paste)       Antioxidant 2 soln   20       Antioxidant 1 soln   6       Premix Total   726   140   140   140   140   140       Precipitated Silica Thickening       5   5       Agent       Fumed Silica Thickening               2.5   2.5       Agent       60P18 Microspheres       20       20       S-60 Microspheres           20       20               165   165   162.5   162.5   140       Gel Time 10 to 1 with       11:00   11:20   11:10   11:05   11:05       lightweight polyester body       filler                  
 
 All values are representative of gram weight of the total composition (peroxide composition and resin composition). 
 
         [0039]     The use of different microspheres did not impact the gel time. The gel time of examples 1-4 was comparable to that of a hardener without silica thickening agent or microspheres.  
       EXAMPLE 7  
       [0040]     This was designed to test the high temperature stability of hardener containing the microspheres in cartridges. The peroxide was a ketone peroxide, 2,4 pentadione peroxide, and antioxidant 3 was 15% aqueous N-isopropylhydroxylamine solution.  
                                                                                 Hardener Composition   1   2   3                                        Low MW Non-Styrenated   30   40   40           Polyester           DiGlycidal Ether           Bisphenol A Epoxy   10           Peroxide       30   30           Benzoyl Peroxide (50% paste)   30           Antioxidant 2   0.273           Antioxidant 1   0.1           Antioxidant 3   0.05           60P18 Microspheres   15   15           Precipitated Silica   5   5               90.423   90.0   90.0           120° F. Stability   7 days                         All values are representative of gram weight of the total composition.             
 
         [0041]     The filled ketone peroxide samples did not show decomposition, but did have outgassing after 3 days at 120° F. This may have been due to solvents present in the ketone peroxide formula from the supplier which escaped at high pressure.  
         [0042]     Peroxides are extremely temperature sensitive. However, the relationship between temperature and decomposition is not linear. At room temperature (68-78° F.), peroxide dispersions containing reactive carrier and/or non-reactive carriers with microspheres as the thickening and volumetrically increasing agent have been stable for over one year. At 100° F., they have been stable for several months, while at 120° F., gelling occurred in about 14 to 16 days.  
         [0043]     Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.