Note: Descriptions are shown in the official language in which they were submitted.
R 286 (1~)
~ 8 8
UNSATURATED POLYESTER COMPOSITIONS AND THEIR USE
The invention relates to unsaturated polyester compositions, in particular
to such polyester compositions which contain a copolymerisable volatile
reactive monomeric material. These polyester compositions are used in the
production of copolymers, by means of a catalyst, usually a peroxide, and
an accelerator yielding a polymerized polyester resin. Once the polymer-
isation reaction has been completed, a polymerized polyester results.
Sometimes also up to 30% (w/w) of thermoplastic polymer is present.
The resin frequently also contains fillers, thixotropic agents and re-
inforcement material like fibrous material, in particular glass fibre.
Fibre-reinforced laminated polyester resin constructions are usually
built up by techniques involving initiating and catalyzing the polyester
composition, impregnating the fibrous material and hardening. Hand lay-
up, spray-up, pressing and other wet-moulding techniques are usually
employed. More layers are usually subsequently superimposed, option-
ally with hardening in between.
The unsaturated, polymerizable, polyesters which are normally used for
the above techniques are based primarily on dicarboxylic acids and diols.
The dicarboxylic acid component normally comprises an ethylenically un-
saturated acid like maleic or fumaric acid and an aromatic acid such as
a phthalic acid. Optionally a saturated aliphatic or hydro-aromatic acid
such as succinic acid, adipic acid or tetrahydrophthalic acid is incor-
porated. The diol component normally comprises a C2-C6 diol such as e.g.
ethylene glycol, propylene glycol or diethylene glycol. Unsaturated al-
cohols may also be present, e.g. in the form of allyl esters. Polycar-
boxylic acids and polyols are sometimes incorporated to some extent but
their polyfunctional properties are usually compensated for by some mono-
functional material. Instead of the free carboxylic acids also their
functional derivatives such as anhydrides or lower alkyl esters can be
used. Also dicyclodienyl units and/or cyclopentadienyl units are some-
times incorporated.
The volatile reactive monomeric material comprises at least one ethyl-
enically unsaturated compound (e.g. a vinyl group) which is copolymer-
isable with the unsaturated polyester by means of an initiator and an
R 2~6 (R)
~ l~9 i~8
-- 2 -
and an accelerator, and this monomer also acts as a solvent for the un-
saturated polyester and improves the workability by modifying the proper-
ties, in particular the viscosity. Examples of suitable volatile monomeric
materials are styrene, vinyl toluene and a-methyl styrene, of which sty-
5 rene is preferred.
The commercially available unsaturated polyesters preferably contain
30-45%, but in general 30-60,' by weight of volatile reactive monomer.
10 A peroxide initiator is normally employed to copolymerize the polyester-
monomer composition, which polymerization is normally effected at ambient
or elevated temperatures. Peroxides, in particular organic peroxides, like
ketone peroxides, dioxydialkyl peroxides, diacyl peroxides etc., are used
and the particular initiator actually selected for a specific purpose de-
15 pends on the desired rate of polymerization. Quantities of up to a few
per cent of the initiator, based on the weight of the resin, are usually
sufficient. Curing accelerators such as certain metal salts and/or cer-
tain amines are usually also included in the composition to be polymerized.
20 A drawback of the unsaturated polyester composition used at present is
that during and after the application, but before completion of the poly-
merization a considerable amount of the volatile reactive monomeric mate-
rial evaporates, leading to objectionable losses in the polyester composi-
tion and to air pollution on the site where polyester resin objects are
25 manufactured.
Several attempts have been made to reduce or overcome this drawback. The
suggestion has been made to replace volatile reactive monomeric material
by less volatile material, but no suitable monomeric material for wet
30 application techniques was available. Attempts to reduce evaporation by
B covering the wet laminate with e.g. Cellophane ~ regenerated cellulose) ~
film have been made but found to be too cumbersome.
It has also been suggested to add a small amount of certain organic
35 compounds such as higher amides to the polyester composition, which
impede evaporation of the volatile reactive monomer, but this has not
appeared satisfactory. The incorporation of certain paraffins and mix-
tures thereof in polyester compositions has also been proposed, in
a~
1 ~9 ~8
BI~ P t~C O, ~OD al~l~
European Pat.~ppln. No. 7~100727/~ nter alia to improve polymerization
on the surface so as to avoid tacky surfaces, due to the "air-inhibi-
tion effect". The incorporation of certain waxes has also been suggest-
ed for the same purpose, e.g. in German Pat.Specn. No. 1,956,376. This
5 results in products with parafiin or wax on the surface, resulting in a
very poor adhesion of subsequent layers, unlesscumbersome sanding was
carried out between superimposing. There has been a need of simple addi-
tives decreasing evaporation without affecting the mechanical properties
of laminates, in particular adhesion between the layers.
It has now been found that improved unsaturated polyester compositions
with decreased evaporation of volatile monomeric material and excellent
adhesion between superimposed layers can be obtained by the incorporation
of small amounts of at least one higher molecular weight hydrocarbon to-
15 gether with a lower molecular weight organic compound of the class consist-
ing of alkylaromatic compounds, alkenyl aromatic compounds, alkylol aroma-
tic compounds and aliphatic alcohols, each in amounts of from 0.005 to 3%,
preferably 0.01 to 1.0% by weight of the polyester composition.
20 The higher molecular weight hydrocarbons used according to the invention
have an average molecular weight of at least 250 but below 700, preferably
between 350 and 550, and a softening point above 30C, preferably between
45 and 55C. Such hydrocarbons usually contain mainly straight-chain paraf-
fins, some branched-chain paraffins, aromatic groups and/or olefinic groups
25 and/or naphthenic groups. Suitable hydrocarbons are commercially available
as such or may be obtained by blending several commercial grades together.
The lower molecular weight organic compounds consisting of the class com-
prising aromatic hydrocarbons, such as alkyl benzenes, alkenyl benzenes and
30 alkylol benzenes, and alcohols contain 10-30, preferably 15-20 carbon atoms.
Suitable compounds are butyl benzene, nonyl benzene, n-dodecyl benzene, te-
trapropylene benzene, hexadecylbenzene, octadecyl benzene and dihydronaph-
thalene,)in which the substituent may be straight- or branched-chained or
cyclo-alipha~ic. The alkyl benzenes are preferred in practising the present
35 invention, because their effect in preventing delamination is superior. Fur-
ther,monoalcohols:n-octanol-1, 2 ethylhexanol-1, dodecanol-1, tetradecylol-1
and hexadecanol-1, benzyl alcohols and higher homologues thereof can be used.
+) = i.e. substituted benzenes
R 286 (R)
I 1 ~9 1~
-- 4 -
In view of the fact that higher alcohols are generally known to promoteevaporation (cf. U.S.P, 3,3~2.031, col.1,par.1), it was quite surprising
that combination of paraffins and higher alcohols in unsaturated polyes-
ters resulted in both a reduced evaporation and an exeellent adhesion.
If the weight ratio of higher molecular weight hydrocarbon to lower mole-
cular weight compound as defined above is between 1:20 and 1:2, in parti-
cular 1:10 and 1:4, excellent results as regards suppressing evaporation
and retaining adhesion between superimposed layers can be obtained without
sanding of the previous layer before laying up the next layer.
It is therefore an embodiment of the invention to provide improved un-
saturated polyester compositions showing a reduced tendency towards
evaporation of the volatile reactive monomer and an excellent ad~esion
between the layers of the laminate, and to provide methods for the pre-
paration of such improved polyester compositions.
In another embodiment of the invention moulded goods are manufactured
by polymerizing a polyester composition as described above without
appreciable losses of monomeric material and with a reduced air pollu-
tion by incorporating a peroxide initiator and a~celerator and curing.
The invention thus provides an improved method for laminating polyester
compositions in which less volatile reactive monomer escapes (reduction
to about 10% of original evaporation figure), providing products in which
the strength between the layers of the laminate is not impaired. The
following experiments have been made and illustrate the invention in
conjunction with the Examples.
Experiment _l
An unsaturated polyester resin prepared from 1 mole of maleic anhydride,
1 mole of phthalic anhydride and 2.1 moles of propylene glycol was dissol-
ved in 40 wt.% of styrene, showed a viscosity of 0.3 Pa s at 20C and an
acid value of 22 and was used in the absence of a peroxide initiator.
S0 9 of the composition was poured into a pan with a surface of 193.5 cm2
and a side of S mm height and exposed to the atmosphere at 20C and the
weight losses were recorded:
R 286 (R)
l 15~ 8
-- 5 --
after 0.5 h50 g/sq.m.
after 1 h100 g/sq.m.
after 1.5 h150 g/sq.m.
after 2 h200 g/sq.m.
Another sample of the polyester composition was polymerized by incorpora-
ting 17O(w/w) of a cobalt octoate solution in xylene containing 1% of me-
tal and 2% of a 50% solution of methylethyl ketone peroxide in dimethyl
phthalate. In order to determine the adhesion between the layers 3 layers
10 of glass mat (450 9 glass fibre per sq.m. per layer) were impregnated with
the polyester composition (glass percentage 30 (w/w)), and polymerized
for 4 days at room temperature, after which a same laminate was applied on
top of it and polymerized for 24 h at room temperature, followed by an
after-cure of 4 h at 80C and 2 h at 110C.
Forced mechanical delamination testing according to British Standard (BS)
2782-p3 341A (1977) showed visually that a 100% adhesion of the surfaces
had been obtained.
20 Experiments 2, 3, 4 and 5
The procedure of Experiment 1 was repeated, however with addition to the
polyester composition of 0.025, 0.05, 0.10 and 0.15% (w/w) of refined,
substantially straight-chain paraffin wax (mp 52-54C), average molecular
weight 500), respectively. Evaporation after impregnating a glass mat was
25 determined by weight loss expressed in grams per square meter. Also the
adhesion of the surfaces was determined. The results are tabulated below.
2 3 4 5
Amount of paraffin added (in %) 0 0.025 O.OS0.10¦0.15
Evaporation g/sq.m. 0.5 h 50 40 25 7 I 4
1 h 100 50 35 11 6
1.5 h 150 70 40 16 6
2 h 200 90 45 20 6
Adhesi on (BS 2782-p3 (341A)1977 100 100 10050 10
Modified +) forced delamination test 100 1~0 S010 O
+) Modified as to composition and testing of a curved strip
R 286 (R)
1 8 ~
-- 6 --
Example I
-
Experiment 1 was repeated using 0.15,i (w/w) of semi-refined, mainly
straight-chain paraffin (mp 48-50C, average molecular weight 400)
and 1% of n-dodecyl benzene. Evaporation was as follows:
5 after 0.5 h 4 g/sq.m
after 1 h 6 g/sq.m
after 1.5 h 7 gtsq.m
after 2 h 8 g/sq.m.
10 Upon curing and after-curing the adhesion between the layers was de-
termined as described above and showed an adhesion of 100%, according
to both testing methods, of the surfaces. A similar result was obtained
when n-hexadecyl benzene was used instead of n-dodecyl benzene.
15 Example II
The procedure of Example I was repeated, using however:
0.1% of semi-refined paraffin (mp 50-52C, average molecular weight 450),
0.5% of 2-ethylhexanol.
20 The styrene evaporation was:
after 0.5 h 6 g/sq.m
after 1 h 9 g/sq.m
after i.5 h 12 g/sq.m
after 2 h 14 g/sq.m.
25 The adhesion was 100% according to BS 2782-341A p3 (1977), but on modi-
fied forced delamination it was 90%.
Example III
The procedure of Example I was repeated, usi ng:
30 0.5% of nonanol and
0.1% of a 1:1 mixture of refined/semi-refined paraffins (mp abt. 48C,
average molecular weight 400 (mixture)).
The styrene evaporation was:
35 after 0.5 h 7 g/sq.m
after 1 h 10 g/sq.m
after 1.5 h 13 g/sq.m
after 2 h 15 g/sq.m.
R 286 (R)
The adhesion according to BS 2782-34lA p3 (1977) was 100%, but on
modified forced delamination it was 85
_a~
5 The procedure of Example I was repeated, using 0.05% tetraline and
0.10% of a semi-refined paraffin (mp 40-42C, average molecular weight
300).
Evaporation was as follows:
10 after 0.5 h 7 g/sq.m
after 1 h 11 g/sq.m
after 1.5 h16 g/sq.m
after 2 h20 g/sq.m.
15 The adhesion according to BS 2782-341A p3 (1977) waslûO%, but on modi-
fied forced delamination it was 90,~.
