p. 1



# OAR Box 1413 Prepped by Ollie Stewart



# Document

Number: 

# 68 ) 11-1-6 8 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:23 PM

Sheet 68 of 114P. 2 

## 2'f 

# ~ V RESI N AN D GE L COA TUPDAT E 

# Faster , Cleaner , Stronger : A Resi nan dGe l Coat Developmen t

Updat e

New resins may
move the judgment about converting from open to closed molding toward larger parts and lower volumes. B Y JOSEP H S
. MCD1RMDTT~ ) 

### C01^P0S.lTES-SERVl€ESXQaM)RAT}0 N



# rn i^6\jd\ 

# )*4. (JU 

### <t%A—*- 

# T h e spiri t

behin dth e a dslogan " "no t you r father' s car..., " applie s t o resi n system s today
. Exactl y fifty year s afte r th e commercializatio no f ambient-cur e thermosets , th e technolog y i s stil l continuall y improving
. A surve y o f producer s reveal s wha t

the y perceiv e th e curren t marke t i s lookin g fo r

an dho w thei r R& D i s responding
. Processor s wh o hav e no t ha daproduc t

revie w wit hthei r

supplie r recend y ma y wis ht o ask , literally , "what' s cooking? " An dwha t

i s no t see nmigh t

b e aske dfor
. Her e ar e highlight s o f recen t produc t introdiicrinn s an ddi e issue s the y address
. Thi s surve y focuse s o nunsaturate d polyeste r development s sinc e thermoplas

tics (Jun e 1997) , epox y pre-preg s (Marc h 1997) , phenolic s (Februar y 1997) , an d polyurethan e (Octobe r

1996 ) hav e recend y bee nreviewe di nComposites Fabrication. Cleane r fo r Laminators , Affordabl e fo r Pres s Molder s Wha t ar e th e benefit s t o user s o f th e ne w resi nofferings ? On e majo r trend , low

pressur e moldin g composit e (LPMC) , appeal s t o severa l custome r groups . T o th e open-proces s contac t

molde r

requirin g emissio nreduction , fo r eithe r industria l hygien e limit s o r

environmenta l permits , enablin g resin s fo r

low-cos t close dmoldin g provid e a noptio nno t

availabl e i nth e past
. T o existin g compressio nmolder s wh o nee d agreate r cos t advantag e agains t

competin g materials , LP.M C offer s saving s i ncagita l investmen t

an doperatin g p\pgns e compare dto_pre\A c •^.moldin g avmpound.-CSMC)
. On e approac ht o lo w pressur e system s wa s pioneere di nEnglan dan di s well

establishe ddiroug hlicens e i nth e U.S
. A physica l thickener- asolid , crystallin e for m o f polyester-melt s whe nprocesse di na heate dmold , greatl y reducin g th e viscosit y ofth e compound
. Thu s i t ca nb e molde da t lowe r pressure , bu t

delive r surfac e finish , strength , an dtherma l requirement s comparabl e t o SMC
. Moldin g a t lo w pressur e reduce s th e cos t o f th e press , give s avariet y o f

lower-cos t

toolin g options , an d save s operatin g energ y costs
. Th e secon d approac ht o di e sam e benefit s i s throug h thickene r chemistry , eithe r

b y rheolog y modifiers , o r

findin g way s t o reduc e fille r loadin g throug htweakin g lo w profil e additiv e chemistry
. Th e resul t i s alow

density , ligh t

SM C whic hca nb e produce d o nastandar dcompound-makin g machine
. Low-densit y SM C reportedl y ca nb e molde da t

pressure s a s lo w a s 1. 4 MPa , whe nth e processin g temperatur e i s a t 150° C (300°F)
. Othe r supplier s recom men dahighe r

pressure , fo r

exampl e 2. 1 MPa , bu t

offerin g atrade-of

f i ntempera
ture , dow nt o 11 0 C°(240"F)
. I ngeneral , LPM C typicall y require s on e quarte r t o on e thir dth e pressur e o f SM C molding , measure di npound s pe r squar e inch
. Thi s mean s th e capabilit y o f compressio n moldin g i n33 0 to nt o 50 0 to npresses , a fractiono f

th e capita l expens e o f million

dolla r high-tonnag e SM C equipment
. Th e LPM C accommodatio no f aluminum , nicke l shell , o r

eve nhigh-temperatur e epox y toolin g mean s asaving s o f a t leas tP. 3

on e diir do n stee l mold s fo r SMC
. Cos t i s no t th e onl y benefi t

o f th e ne w compressio n moldin g compounds
. Par t

desig n capabili

tie s ar e expanded
. Kenworth' s T200 0 heav y truc k

wa s engineere d wit haroo f

cap , a1501b
. SM C charg e wit ha36-inc hvertica l draw
. Th e siz e an dconfiguratio n o f thi s par t woul dno t

hav e bee n possibl e wit hconventiona l SM C unles s di e processo r

upgrade dhi s existin g press . Fo r resi ntransfe r molder s steppin g u p t o LPMC , eliminatio n o f

th e dr y preform , consisten t

Clas s "A " surfac e finish, an dles s wast e ar e improvement s ove r thei r presen t capabilities
. Fo r open-proces s molders , LPM C offer s dramati c improvemen t i n cycl e time , mor e consisten t quality , an dles s secondar y trimming , i n additio nt o environmenta l benefits
.



# tha n on e wa y t o ski n a
That' s wh yReichhol d Chemical s introduce s th e bes t way—Hydre x10 0 th e lates t innovatio n i n marin e laminatin g resins

. Whe n i t come s t o high-performanc e boats , you , an d you r customer s have extremel yhig h standard s Fortunately , s o doe s Hydre x100

. Th e uniqu e formul a of Hydre x10 0 offer s greate rimpac t resistance , highe rhea t distortio n temperatures , an d unsurpasse d protectio n agains t osmoti cblistering

. Plus , Hydre x10 0 i s th e onl y100 % viny l este rresi n wit h th e handlin g propertie s o f a genera l purpos e polyeste ro rDCPD-blende d product

. I t cure s fast , work s easil yint o fiber
glass , an d yield s a n amazin g profile

. Giv e u s a cal l fo rmor e detail s o n Hydre x100

. You'l l fin d it s benefits ru n more tha n jus t ski n dee p American Industries

. uses:Hydrex

100 for the hulls on its Sonic USA Boats (from skin coat up to stringerplacement) and on decks.


# tf REICHHOL D 

### Fo r mor e information , cal l u s toll-fre e a t 1-888-HYDREX- 1 Circl e 4 1 o n Reade r Servic e Car d Com e visi t u s a t COMPOSITE S '9 7 a t Boot h » 31 3 Ar e Environmenta l Issue s Drivin g Resi nDevelopment ? No t entirely , a s eviden t from produc t developmen t

discusse d later
. Bu t man y i n th e FR Pcompos ite s industr y are discussin g occupa tiona l healt han denvironmenta l emissio nissue s fromth e standpoin t o f resi n reformulation
. Th e open proces s molde r

abl e t o phas e ou t spra y applicatio n an dmanua l roll

ou t o f larg e resi n surface s expose dt o ai r flow, wil l lowe r

worke r exposur e t o styren e belo w 2 0 part s pe r millio n (ppm ) wit heas e i f h e adopt s close dmolding
. Whil e 50pp mi s di e curren t goa l o f industry' s arrange men t wit hOSHA , th e threshol d limi t valu e i s lowe r

i n mos t othe r countries , an d20pp mma y soo n appea r o n Nort hAmeric aMateria l Safety Dat aSheet s a s aresul t o f recommendation s unde r discussio n withi nth e America nConferenc e o f Governmenta l Industria l Hygienists
. Th e conversio n t o close d moldin g woul dals o tower afacility' s environmenta l emission s o f styren e b y a t leas t athir dan di n som e case s b y 90%
. Thi s wil l mak e Clea n Ai r A apermit s easier

t o acquir e unde r generi c volatil e organi c compoun d (VOC ) contro l requirement s an di s likel y t o eas e complianc e wit hEPA' s futur e Maximu mAvailabl e Contro ' Technolog y (MACT ) standar dfoi controllin g specifi c Hazardou s Ai r Pollutant s (HAPs)
. Unfortunately , conversio nt o close dmoldin g wil l no t b e a n industry-wid e "silve r bullet " whic hfinishes of f regulator y mandates
. Processor s an ddi e specifyin g engineer s wh o ar e thei r customer s hav e man y example s o f essentia l FR Pproduct s whic har e simpl y to o large , hav e to o comple x athree

dimensiona l shape , o r ar e no t require di n sufficien t

volum e t o eve r mak e close dmoldin g feasible
. Eve n wit hth e optio n o f resi n infusio nunde r

avacuu mbag , ther e wil l alway s b e som e assignment s fo r whic hspra y (o r

flow-coated) applicatio nan droll-ou t wil l b e appropriate , accordin g t o thes e /producers
. Resi n suppliers~agree , althoug hsom e mentio n dia t th e 'line " betwee n wha t

i s viabl e fo r

!
. *. \close dmoldin g i s likel y t o drif t to \V , llarge r pan s an dlowe r

volumes
. 'v\ Al l o f thi s mean s tha t

resi n 

# 2 1 0 Composites Fabrication! 'August 199 7

## r !«¥«' * Ji^T'fW fT-i^SWJf^-^' T P. 4



### Norma l gelcoa t

gelcoatdrople t styren e

Figur e 1

. Theor

yo f environmenta l ge l coat
. 

# *€

>

producer s ar e workin g t o improv e th e environmenta l resin s die y develope d t o compl y wid i Californi aRul e 1162' s complianc e optio n o f les s tha n 35 % styren e conten t

for genera l purpos e resins
. Bu t

ther e i s alimi t

t o takin g th e styren e ou t

an dcontinuin g t o hav e aprodu awhic hwil l cross lin k int o cure ddurabl e goods
. Industr y consensu s i s tha t th e geniu s o f composite s i s thei r

versatility
. Thu s arang e o f

formulation s wit hvariou s styren e content s wil l b e neede dt o perfor mth e numerou s function s require do f

engineere dmaterials
. Fo r thi s reason , resi nsupplier s ma y undertak e t o discus s wid i EP A th e implication s o f

definin g reinforce d plastic s industr y MAC T i n awa y similar t o control s no w i n plac e fo r th e pain t

an dcoatin g industry , namel y b y definition s o f VO C conten t for broadl y generi c produas
. Suc ha n approac hwoul dinhibi t th e developmen t

o f engineere dresin s i n future generations , for

exampl e i n civil engineering , energ y transmis

sion , an denvironmentally-desirabl e transportatio n equipment
. Th e resul t

i s R& D work

o n resin s whic hwil l mak e close d moldin g feasibl e an dlower-emissio n resin s for othe r cases . Bu t

ther e i s ampl e evidenc e o f

produc t develop

men t innon-environmenta l areas . Hig hproductivit y characteristic s suc h a s cure-on-deman dresins ; fire retar
dan t systems ; improve dphysical s suc ha s toughness , weadierability , 1 2 Composites Fabrication! 'August 199 7 an dmaske dprint-dirough-al l ar e stil l imponan t

i n activity
. No t

t o mentio n securin g hig hperformanc e a t lowe r cos t b y substitutin g mor e availabl e petrochemica l buildin g blocks
. Laminatin g Resins : First , th e Physical s Recreationa l boatin g ma y b e on e o f FRP' s mos t

matur e markets , bu t

th e technolog y neve r

cease s t o loo k

fo r improvements
. Modifie dvinylester s hav e bee n availabl e a s laminatin g resin s fo r som e time , bu t

a t leas t on e 100 % vinyleste r

ha s bee n introduce d dii s year . Suc haprodu ai s expecte d t o hav e highe r

hea t distortio n temperatur e (HDT ) an dphysica l propenies
. I t

i s designe dfo r

th e fabricatio n o f

smal l t o larg e FR P structure s wit hhig hproductio n rate s a t roo mtemperature
. Boat s builder s findtha t suc h resin s provid e alo w wate r absorp

tio n rate , hig hstrength , an da n improve dprofile
. Benefit s o f thes e physica l propenie s includ e superio r bliste r resistance , resistanc e t o impact , an dminimize dprint

throug ht o ensur e smoot hsurfaces
. Supplier s formulat e suc haresi n s o tha t i t wet s ou t

reinforcement s rapidly , whic htranslate s t o minimize dvoids , whil e allowin g user s t o easil y maintai nresin-to

glas s ratios
. Th e hig hHD T allow s th e resi nt o retai n it s physica l propenie s at

elevate dtemperatures
. A stabl e gel tim e give s boat



# 3 builder s consisten t ge l an dcure s wit hvaryin g level s o f

catalyst
. Sinc e i t i s athixotropi c laminatin g resin , th e produc t

resist s saggin g an d drainin g durin g lay-up
. Th e goal i n suc hdevelopmen t i
. t o hav e di e performanc e o f vinylester , bu t th e user-friendl y propenie s o f a DCP D o r

general-purpos e polyester
. Thos e benefit s ar e o f

interes t outsid e th e marin e molders , s o th e produc t can b e successful i nswimmin g pool s an dsp aconstructio n a s well , Apa n fromvinylester , th e sam e supplie r i s addressin g hi s customers ' goa l o f faste r cur e time
. A ne v hybri dRT M resi n promise s greate r productivit y throug heasie r pumping , lo w resistanc e t o flow i n th e mold , an dimprove dwet-ou t o f di e reinforcemen t

eve nwhe n filled hig h60 % t o 65 % levels
. Fir e Resistanc e aTarge t Improvemen t

i n material s for

th e buil t environmen t

i s als o afocu s o i unsaturate dpolyeste r

resi n produc t development
. On e exampl e i s th e respons e t o fire safet

y standard s fo

r mas s transit , whic hten dt o b e mor e stri ai n Europe
. Th e first generatio n answer-hig hfiller

loading s t o "fire harden " FR Pcomponents-mak e fo r ven ' difficult

moldin g conditions
. B y workin g wid i ane w grad e o f alumin a trioxid e an dane w wettin g an dispersin g agent , modifie dacrylii
. resin s hav e bee n formulate dt o ver y lo w viscosity , resultin g i n shor t cycle times fo r RT M molding
. Rai l car sea t shell s an dinterio r

panel s ar e on e successfu l application
. Th e RT M resi n developmen t

was cite dfo

r th e Vinc i Awar da t

April' s Europea n composite s trad e fair

i n Paris
. Combinin g flam e retardanc e wit hresistanc e t o corrosiv e environ

ment s i s stil l anothe r

opportunity
. Scrubbers , fans , an dductwork

expose dt o hot , acidi c environment s frequently nee dreplacement , bu t les s s o a s th e industria l catalogue s carr) ' awide r

rang e o f

performanc e FR Pequipment
. Antimon y trioxid e a t 3 % t o 5 % loading s can achiev e a Clas s 1 flame sprea dratin g belo w 1 5 o n th e AST M E-8 4 tunne l test , in a resi n syste mwhic hmaintain s hig h mechanica l properties , an delonga

tio n in th e rang e o f

3.6 % Anothe r supplie r

ha s formu

late dapremiu mflame-retardan t corrosio nresi n for

cos t saving s b y reducin g antimon y trioxid e conten tP. 5



# Product s Cite d i n Thi s Articl e CFA's policy of

avoiding the appearance of commercial endorsement

is balanced

by recent

reader feedback asking

for suppliercontact

information. Trade names and suppliers listed below are listed

in the sequence ofthe article's product discussion. Please note that suppliers not

mentioned

in this article may have analogous products and are well

worth processors'contact.

• Physically-thickene dlo w pressur e moldin g compound , patente da s Crysti c Impre g fromScot t Bade r Ltd. , i s availabl e i n th e U.S
. fro mNationa l Composite s Inc. , Sout hBend , IN , (219 ) 289-4589
. • Th e thickenin g agen t an drheolog y modifie r approac ht o lo w pressur e SM C i s represente db y th e Neulon ® LoBar TM technolog y bein g develope db y Unio n Carbide , Charleston , WV , (304 ) 747-5152
. • Carefu l balanc e o f

resi n chemistry , thickeners , an d SM C formulatio n ar e behin dth e SM C Lite TM produc t availabl e fromAshlan dComposit e Polymers , Columbus , OH , (614)790-3333
. • Th e low-pressur e SM C formulate dfo r dee p dra w section s i s Ultry l lo w profil e UP Rfrom Alpha/Owen s Corning , Collierville , TN , (901 ) 854

- 2800
. • High-performanc e laminatin g resi nfo r marine , pool , an dsp abuilders : Hydrex ® 100 , a100 % vinyleste r fromReichhol dChemicals , Inc. , Researc hTriangl e Park , NC,(919)990-7500
. • Fire-resistan t

RT M compoun dwit hlo w viscosit y incorporate s alumin atrihydrat e designate dON-90 4 fromMartinswerk , German y an dBEVTC- W99 6 wettin g agen t

fro mBY K

ChemieUSA , (203 ) 265

- 2086 , i n Ashland'sMODA R835 S resi n fro m Ashlan dComposit e Polymers , Columbus , OH , (614 ) 790-3333. : v
• Flam e retardan t

corrosio nresin s wit h1.5 % antimon y trioxide , DIO NFR ® 9300 , ar e availabl e throug hReichhold' s Corrosio n Hotlin e a t (800 ) 752-0600
. • Fast-cur e hybri dRTM.resin , Polylite ® 31507 , ar e availabl e fro mReichhold' s Closed ; Moldin g team : a t
•• : -(SOO)
. 431*1920: ' :

- : --;'.'-'r'Try '•''• • Fir e retardanc e an dcorrosio n resistanc e fo r hot ,

. ,acidic:enyirbnmentsareE.cprnbine di n ane w serie s o f v resins , le db y K299FR , fromAlpha/Owen s Corning , :

. : Cplli?rvilie,. ^ : : •
• Lo w styrene.emissio n ge l Coat s wit hbot hperfbr

- ; .•* ' manc e an dproductivit y advantage s ar e availabl e from, arriph g p.therS, : Nest e Chemicals , whic huse s Nest e LS EGelcbat.a s tirad e name . Nest e Polyeste r EInc. , Fo n Smith , AR,.(501 ) 646-7865
. ' ; t o 1.5% , bu t stil l achievin g th e Clas s 1 flame sprea drating
. Th e faster

cur e objeaiv e i s addresse di nane w hybri dRT M resin
. Thi s produ ai s formulate d fo r lo w viscosity , givin g eas y pumpin g result s an dgoo dwet
ou t o f reinforcemen t

eve nwhe n fille da t 60-65 % levels
. (Se e to p phot o onjiageJU

Ge l Coats : Emissio n Reductio n Bring s Othe r Benefit s Th e ne w generatio n o f low-' , styren e conten t

gel coat s ha s not ; experience dsufficien t

years , o f commercia l us e t o allo w averdict. ; Bu t several gel coat

formulators
. i appear o n diei r way t o provin g \

. "neve r say i t can' t b e done. " Styren e content s as lo w a s 26 % o f th e spray applie dresi nar e bein g repone dfo

r standar dwhit e gel coats
. Tha t

i s dow nfrom37 % onl y recend y an dpotentiall y abi g hel p t o processor s bumpin g thei r hea do n atons-per-year

emissio n ceilin g i n thei r

clea nair permit
. Ther e i s eve n aperformanc e benefi t ir i bette r weathering , a s on e woul dexpea , sinc e ther e i s les s styren e availabl e t o caus e yellowing
. Ther e i s als o better
. retentio no f

glos s o n exposur e t o sunlight
. Bac k

inth e shop , ther e i s abenefi t

i n les s shrinkag e ofth e gel coat layer an dprobabl y a smoothe r surface , wid i faster

cur e time. Par t

o f th e emissio nreduc

tionb y overspray contro l o f lo w emissio n gel-coa

t an dspray appli

catio n i ngeneral , lie s i n large r particl e siz e (see Figure Io n pag e 12)
. Whe ngel coat

i s applie din man y smal l droplets , the
. greate r surfac e are aincrease s mistin g an d di e amoun t

o f emissio n from overspray . A larger

transfer parti- : ci e result s inles s styren e availabl e for airborn e discharge
. .:"." : Ge l coa t

supplier s secur e : credibilit y b y not
. guaranteein g specifi c emissio nreductio n levels;
. Whil e reduaion s o f

30% , 50% , an di non e cas e 90 % ar e cited , a great pa no f emissio n reduaio n depend s o noperato r

trainin g t o maximiz e . transfe r

-efficiency
. Whe n goo dapplicatio n techniqu e i s combinedwit hdi e new ' coatin g -materials , require d filmthicknes s can . b e reache d withles s materia l an dexpens e i s save d(see "Th e Spra y Operators ' Anthem, " Composites Fabrication, Ma y 1997 , pp.34-35)
. Ge l coa t supplier s contacte
for
. thi s articl e reporte dan impression , rathe r

tha n a n identifiabl e ne w produ aseries
. Market s fo r

ultra-clea r

an d extremel y weather-resistan t product s ar e showin g sign s o f bein g willin g t o compensat e th e processo r fo r upgradin g ra w materials
. Afte r

som e year s o f cost-cutting , anecdote s imph
. ther e i s aretur n t o mor e aggres siv e us e o f

neopenty l glyco l t o achiev e extrem e clarity , ultra

viole t ligh t stability , an dflexural strength
. Thi s i s goo dnews , on e sourc e explains , fo r

performanc e

- . market s whic hwil l nee daflexible ; toug hcosmeti c surfac e t o harmoniz e wit hupgrade d vinyleste r laminates
. That' s No t

Al l Folks ! Sta y tune dfo r

ne w produc t Introduction s a t

COMPOS

ITE S '9 7 i n Octobe r 1997
. Several supplier s tol du s the y ar e plannin g significan t

announce ment s relate dt o diei r

technol

og y lat e thi s yea r

an dother s
• earl y nex t

year . Ge l coa t

produ e ers , i n particular , ar e workin g wit hne w bas e resin s an dne w way s t o formulat e existin g products
. Ther e ar e als o .improvement s i n pigment s
• i waitin g t o com e o nstage
. I n \othe r cases , th e high-margi n i condition s o f

afe w year s ag o 'resulte di nbasic , researc h j program s wit hupstream , Ichemica l intermediat e suppli

ers * an dsevera l o f

thes e ar e soo n t o b e revealed
. A
Joseph' McDermott,: a ; Contributing Editor/: to,

• Composites Fabrication, offers independent

management consulting at

Composites Services Corporation located

in CresskiUj New Jersey.