SynoxolTM BEPD in PIA based Gelcoats
1 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD – PIA based Gelcoats

Contents→ What is Synoxol BEPD
→ Global vs. Americas sales volumes→ UPR composites & Gelcoats by resin type→ Gelcoat target applications for BEPD
→ BEPD technology positioning within gelcoats→ Value Propositions→ Technical data
→ Summary→ Commercial challenge

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PES resin reaction

An ester is the reaction product of an acid reacted with analcohol

A polyester is therefore the reaction product of a diacid with a dialcohol (otherwise known as a diol or glycol)

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Typical Acid Monomers used in PES Synthesis

Full Name

AKA

Terephthalic Acid

TPA (or PTA)

Excellent Hardness, good
weathering & flexibility

Isophthalic Acid

IPA (or PIA)

Excellent Weathering &Hardness

Phthalic Anhydride

PA

Good Flexibility & hardness

Adipic Acid

ADA (or AA)

Good Flexibility, reducesviscosity

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Structure

Benefits

Typical Diol Monomers used in PES Synthesis

Full NameAKA

Neopentyl Glycol

NPG

Hardness, Weathering

1,6-hexanediol

HDO

Flexibility

Monoethylene glycol

MEG

Reduces viscosity & cost

Diethylene glycol

DEG

Reduces viscosity & cost

1,4-cyclohexane dimethanol

CHDM

Hardness

2-Butyl-2-ethyl-1,3 propanediol SynoxolTM
BEPD
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Structure

Benefits

Flexibility, Improved
Hardness & Excellent
Weathering

What is SynoxolTM BEPDHigh performance glycol (diol) used in polyester, unsaturated polyester and polyester polyol synthesis
Structurally analogue to NPG

SynoxolTM BEPD

NPG

Most obvious difference between the two molecules is the increased chain length in the 2 position on the propanediol backbone

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SYNOXOL™ BEPD in PIA based Gelcoats
7 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SYNOXOL™ BEPD – PIA based Gelcoats

UPR Composites & Gelcoats by resin type
Unsaturated Polyester(UPR) Composites

Orthophthalicbased

Isophthalic (PIA)based

DCPD based(dicyclopentadiene)

Fibre Reinforced
Plastic (FRP)

Fibre Reinforced
Plastic (FRP)

Fibre Reinforced
Plastic (FRP)

GelcoatGelcoatGelcoatGelcoats

UPR

Vinyl Ester

Acrylicurethane

Orthophthalic based

Isophthalic (PIA) based

SynoxolTM BEPD positioned for PIA based UPR gelcoats
Dicyclopentadiene based
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Epoxy

For demanding applications• UV & water resistance• strong mechanical performanceSynoxolTM BEPD – PIA based Gelcoats

Target Applications

MarineTransportation
WindturbineBladesElectricalenclosures

SwimmingPools

Engineeredstone

Marble & solidsurfaces

Construction
9 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives••••

Electrical enclosures
Engineered stone
Marble & solids surfaces
Tub & Shower

SynoxolTM BEPD - PIA based Gelcoats

Technology positioning
Synoxol™ BEPD provides:••••

Excellent water resistance
Routes to VOC reduction
Good weathering performance
Shrinkage reduction on par with
DCPD resins

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SynoxolTM BEPD – PIA based Gelcoats

Value Propositions
Against other gelcoat technologies e.g. DCPD→

Enables formulation of low VOC, low shrinkage gelcoats similar to DCPD resins without compromising the benefits of Iso-NPG systems→

Delivers excellent water resistance approaching vinyl ester based gelcoats→

Superior weatherability compared to DCPD and Vinyl Ester systems

Against other PES gelcoats→Up to 20% less water absorption in comparison to isophthalic resin based benchmark consisting of NPG & other glycol blends→

Delivers excellent aesthetics - reduced shrinkage upon cure compared to traditional ortho & Iso-NPG gelcoats→

15% increased weatherability against the NPG analogue – over 1 year South Florida outdoor exposure - in isophthalic based UPRs→

Flexural strength improvement in isophthalic / styrene UPRs

→ Presents an opportunity to formulate isophthalic based UPRs with similar aesthetics and styrene content to dicyclopentadiene (DCPD) basedresins whilst preserving high durability & mechanical properties of the isophthalic resin.

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SYNOXOL™BEPD reduces VOC / Styrene emissions
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SynoxolTM BEPD – PIA based GelcoatsSYNOXOL™BEPD can reduce viscosity
Through replacement of NPG with SYNOXOL™ BEPD it is possible to reduce resin viscosity
This reduction in viscosity is also observed in Styrene/ MMA blends
Additional replacement of 1,2-PG with MEG can further reduce viscosity

60% solids in Styrene

60% solids in Styrene and Styrene/MMA (25%/15%)

60% solids in Styrene
A

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SynoxolTM BEPD – PIA based Gelcoats

Lower viscosity leads to lower VOC emissions
A
DHmonomers
resin/ wt % styrene/ wt% MMA/ wt% Viscosity/ cP
0%BEPD, 0%MEG
60400801
30% BEPD, 0% MEG
63370809
30%BEPD, 40%MEG
64360790

ADH

0%BEPD, 0%MEG
30% BEPD, 0% MEG
30%BEPD, 40%MEG606264252423151413584595590% styrene reduction
07.5
10% VOC reduction
07.5
1037.54042.50510Decreasing Styrene levels
Decreasing Styrene levels

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SYNOXOL™BEPD improves water resistance
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SynoxolTM BEPD – PIA based GelcoatsSYNOXOLTM BEPD reduces water absorption

SYNOXOL™BEPD statistically proven to reduce water absorption above 20mol% addition levels•

30 mol% SYNOXOLTM BEPD reduces water absorption by 20%•

30mol% SYNOXOL™BEPD sufficient to mitigate water absorption increase arising from use of MMA•

Replacing 1,2-PG with MEG has zero impact to water absorption providing SYNOXOL™BEPD is used

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SYNOXOL™BEPD improves aesthetics
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SynoxolTM BEPD – PIA based GelcoatsSYNOXOLTM BEPD improves aesthetics

Addition of SYNOXOLTM BEPD leads to a statisticallysignificant reduction in shrinkage•30mol% SYNOXOLTM BEPD results in a 25% reductionin the degree of shrinkage

Degree of shrinkage is smaller in Styrene/MMA systems
compared to Styrene only systems•

SYNOXOL™ BEPD still reduces shrinkage by 20%

Incorporation of MEG has zero impact upon SYNOXOL™
BEPD’s impact on dimensional stability
This leads to high gloss, low print-through solution evenas styrene content diminishes

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SYNOXOL™BEPD improves flexural strength19 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD – PIA based Gelcoats
SynoxolTM BEPD improves Flexural strength

Replacing NPG with SynoxolTM BEPD at alevel≥ 20 mol% gives a statistically significant
increase in flexural strength of 14%
No additional changes observed whentested in MMA or MEG systems

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SYNOXOL™BEPD improves weatherability
21 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD – PIA based Gelcoats

Synoxol™BEPD improves weatherability
Selected resins used to prepare gelcoats for exposure at South Florida for 24 months:
Inclusion of 30mol% BEPD lead to a 15% increase in gloss retention after 12 months of Florida exposure
Incorporation of MEG up to 40mol% leads to no negative impact in gloss retention

22 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD – PIA based Gelcoats

SummaryReplacing NPG with SYNOXOLTM BEPD allows the formulation of higher molecular weight, lower viscosity and high solubility gelcoats
without any negative impact upon performance or mechanical properties.
These properties can be used to reduce Styrene emissions & overall VOC content; whilst maintaining high performance for demanding
applications
Incorporating MEG can also lower the viscosity of the resin; resulting further reduction of Styrene
Adding MEG also offsets some of the price increase incurred by the introduction of SynoxolTM BEPD
We have the majority of the in-house supporting data for this, along with the details discussed as part of the lapsed INEOS patent(EP1131372)

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Commercial applications of BEPD in Gel coats
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SynoxolTM BEPD

Swimming pools (and sanitaryware)
Low viscosity resin,
negates to use of excessive solvent
Instead, sag / hold-up with a thixotrope

Low viscosity,
hold upproperties
thixotropicallyadjusted
Resistance to shrinkage upon cure
UV durability
26 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives
Water resistanceSynoxolTM BEPD

Marine (Yachts and boats)
Production & Application Benefits
Low VOC – Low Styrene Content
Defect free moulding
Flexural strengthLower shrinkage upon cureLower viscosity
Ease of infusion
Ease of Application (Repair & New-Build)

Performance Benefits
Water resistance
UV Resistance Weatherability

27 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD

Windturbine Blades

Thermoset based composites represent around 80% of the market ofreinforced polymers. The advantages of thermosets are the possibility of low
temperature cure and lower viscosity (which eases infusion and thus,
allowing high processing speed).
Rain erosion performance
Flexibility + Hardness → Impact resistance
Defect free moulding
Flexural strength
Lower shrinkage upon cure
Lower viscosity
Ease of infusion – High processing speeds
28 | Synoxol™BEPD for use in UPR Gelcoats© Synthomer
Speciality
Additives
Water
resistance& Weatherability

Initially, polyester resins were used for composite blades. With thedevelopment of large and extra-large wind turbines, epoxy resins replaced bypolyester and are now used most often matrices of wind blade composites.
Still, recent studies (e.g by DSM Composite Resins) support arguments forthe return to unsaturated polyester resins, among them, faster cycle time andimproved energy efficiency in the production, stating that the newly developed
polyesters meet all the strength and durability requirements for large windbladesAppendix

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SynoxolTM BEPD – PIA based Gelcoats

UPR formulations

30 | Synoxol™BEPD for use in UPR Gelcoats © Synthomer Speciality Additives

SynoxolTM BEPD – PIA based Gelcoats

UPR formulations

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SynoxolTM BEPD – PIA based Gelcoats

Gelcoat formulation
Weight %Polyester, 60 % in styrene

63.2

Thixotropic additive, HDK N20 5

5.20

Talc, Finntalc M05

5.20

Styrene6.20

TiO2, Kemira 650

15.60

BYK 501 60.21

Grind for 20 min at 2000 rpm at T = max. 45 C
Styrene7.30

Promoter, Co-octoate 10%

0.12

Co-promoter, DMAA (Dimethylacetoacetamide)

0.1

Inhibitor, THQ 10%

0.07

Mix properly and add 2% MEK-Peroxide-50 as initiator just shortly before use.

56Wacker Chemical
BYK-Chemie

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