Composite repair resins containing minimal hazardous air pollutants and volatile organic compound
AssigneesDrexel University, The Government of the United States of America, AS Represented By the Secretar
InventorsJOHN JOSEPH LA SCALA, GIUSEPPE RAFFAELLO PALMESE, JAMES MATTHEW SANDS
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Abstract
The present invention relates to a composition and method for fabricating composite resins that produce either reduced or zero volatile organic compound (VOC) and zero hazardous air pollutant (HAP) emissions. The non-volatile reactive diluents of the composite resin, fatty acid monomers, enhance the stability, shelf-life, flexibility and strength of the composite resin. The resins incorporating fatty acid monomers may be used to repair military equipment or for any commercial repair purposes.
Claims30
A composition curable to form a composite resin comprising a resin binder and a filler material, wherein the resin binder comprises a mixture of:
- a cross-linking polymer compound,
- at least one fatty acid monomer selected from the group consisting of:
- wherein each of R, R2 and R4 contain 2-30 carbon atoms and are selected from the group consisting of a saturated alkyl residue, an unsaturated alkyl residue;
- an acetylenic alkyl residue, a hydroxy alkyl residue, a carboxylic acid alkyl residue, a divinyl ether alkyl residue, a sulfur-containing alkyl residue, an amide alkyl residue, a methoxy alkyl residue, a keto alkyl residue, a halogenated alkyl residue, a branched methoxy alkyl residue, a branched hydroxy alkyl residue, an epoxy alkyl residue, a fatty acyl-CoA alkyl residue, a cyclopropane alkyl residue, a cyclopentenyl alkyl residue, a cyclohexyl alkyl residue, a furanoid alkyl residue, a phenylalkanoic alkyl residue, and a lipoic alkyl residue;
- R1 is a fatty acid segment having a backbone length of 1-25 carbon atoms selected from the group consisting of a saturated alkylene segment, an unsaturated alkylene segment;
- an acetylenic alkylene segment, a hydroxy alkylene segment, a divinyl ether alkylene segment, a sulfur-containing alkylene segment, an amide alkylene segment, a methoxy alkylene segment, a keto alkylene segment, a halogenated alkylene segment, a branched methoxy alkylene segment, a branched hydroxyl alkylene segment, an epoxy alkylene segment, a fatty acyl-CoA alkylene segment, a cyclopropane alkylene segment, a cyclopentenyl alkylene segment, a cyclohexyl alkylene segment, a furanoid alkylene segment, a phenylalkanoic alkyl segment, and a lipoic alkylene segment;
- R3 is selected from the group consisting of H and an alkyl residue having 1-10 carbon atoms;
- and
- R5 is an unsaturated cyclic alkyl residue having 10-50 carbon atoms optionally substituted with a group selected from R1 and R4;
- and
- optionally a volatile monomer, wherein the curable composition contains not more than 15% by weight of the volatile monomer, based on the total weight of the curable composition.
A composition curable to form a composite resin comprising a resin binder and a filler material, wherein the resin binder is a mixture of:
- a cross-linking polymer compound, and
- at least one fatty acid monomer;
- and
- optionally a volatile monomer, wherein the curable composition contains not more than 15% by weight of the volatile monomer, based on the total weight of the curable composition;
- and
- wherein the composite resin comprises 0-50% by weight talc, 0-50% by weight magnesium carbonate, 0-30% by weight, sodium metaborate, 0-35% by weight fibrous glass, 0-30% by weight silica thickener, 0-10% by weight glass microspheres, 0-10% by weight phenolic microballoons, 0-30% by weight alumina, and 0-30% by weight sand.
A composition curable to form a composite resin comprising a resin binder and a filler material, wherein the resin binder is a mixture of:
- a cross-linking polymer compound, and
- at least one fatty acid monomer;
- and
- optionally a volatile monomer, wherein the curable composition contain's not more than 15% by weight of the volatile monomer, based on the total weight of the curable composition;
- and
- wherein the composite resin comprises 5-40% by weight talc, 5-40% by weight magnesium carbonate, 0-20% by weight, sodium metaborate, 0-25% by weight fibrous glass, 0-20% by weight silica thickener, 0-10% by weight glass microspheres, 0-10% by weight phenolic microballoons, 0-10% by weight alumina, and 0-10% by weight sand.
A composition curable to form a composite resin comprising a resin binder and a filler material, wherein the resin binder is a mixture of:
- a cross-linking polymer compound, and
- at least one fatty acid monomer;
- and
- optionally, a volatile monomer, wherein the curable composition contains not more than 15% by weight of the volatile monomer, based on the total weight of the curable composition;
- and
- wherein the composite resin comprises 15-35% by weight talc, 15-30% by weight magnesium carbonate, 0-10% by weight, sodium metaborate, 0-15% by weight fibrous glass, 0-15% by weight silica thickener, 0-10% by weight glass microspheres, 0-10% by weight phenolic microballoons, 0-10% by weight alumina, and 0-10% by weight sand.
A composition curable to form a composite resin comprising a resin binder and a filler material, wherein the resin binder is a mixture of:
- a cross-linking polymer compound, and
- at least one fatty acid monomer;
- and
- optionally a volatile monomer;
- wherein the curable composition contains not more than 15% by weight of the volatile monomer, based on the total weight of the curable composition;
- and
- wherein the curable composition is cured in the presence of a free-radical inhibitor that retards decomposition of a free-radical initiator or prevents polymerization due to the decomposition of a free-radical initiator.
Dependencies are inferred from the claim text.