Unsaturated polyesters reinforcements

Reinforced plastics first became commercially available in the 1940s. Unsaturated polyester reinforced with fibrous glass is the most widely used reinforced plastic today. Chopped glass mats are used for sheet moulding compounds (SMC), bulk moulding compounds (BMC) and hand lay-up composites. 

Cyglas Unsaturated polyesters reinforced or not American Cyanamid... 

Burgueno et al. [28] developed a cellular biocomposite from unsaturated polyester reinforced with natural and glass fibers by means of casting pressure. The authors compared the performance of the cellular biocomposite panel (biopanel), against conventional systems used for building and residential construction, named precast pre-stressed hollow core concrete slab (PC/PS HC slab), precast pre-stressed solid concrete slab (PC/PS solid slab), and oriented wood strand board insulated structural panel (ISP). Results showed that PC/PS HC supported 31% more pressure than the biopanel. However the biopanel effectively competes with the solid PC/PS slab and supports 72 % more pressure than the ISP board. In addition, the performance of the biopanel was also compared by means of allowable pressure with two commercial panels made of E-glass/vinylester sandwich Durashield and Composolite. The biopanel outperformed the Composolite by 28%, while the Durashield outperformed biopanel by 17%. This evaluation shows that cellular biocomposite panels can effectively compete with commercial E-glass panels. 

Fracture by fatigue micromechanisms includes three successive stages of material deterioration. The first stage is manifested at the interface, in this zone the fracture occurring at relative small efforts. For instance, in the case of unsaturated polyesters reinforced with glass fibres, in the form of mats, it represents about 10% from the total fracture stress of the material, Figure 3.458. 

Used as fibres, particularly in textiles and film. Many other polyester polymers are of importance, e.g. unsaturated polyester resins from phthalic anhydride, propylene glycol and maleic anhydride used with reinforcement in boats, cars, etc. (alkyd resins). U.S. production 1983 1-7 megatonnes. 

Maleic anhydride itself has few, if any, consumer uses but its derivatives are of significant commercial interest (161). The distribution of end uses for maleic anhydride is presented in Table 9 for the year 1992 (182). The majority of the maleic anhydride produced is used in unsaturated polyester resin (see Polyesters, unsaturated). Unsaturated polyester resin is then used in both glass-reinforced appHcations and in unreinforced appHcations as shown in Table 10 (183). 

Carbon-Fiber Composites. Cured laminates of phenoHc resins and carbon-fiber reinforcement provide superior flammabiHty resistance and thermal resistance compared to unsaturated polyester and epoxy. Table 15 shows the dependence of flexural strength and modulus on phenoHc—carbon-fiber composites at 30—40% phenoHc resin (91). These composites also exhibit long-term elevated temperature stabiHty up to 230°C. 

Small amounts of TAIC together with DAP have been used to cure unsaturated polyesters in glass-reinforced thermo sets (131). It has been used with polyfunctional methacrylate esters in anaerobic adhesives (132). TAIC and vinyl acetate are copolymerized in aqueous suspension, and vinyl alcohol copolymer gels are made from the products (133). Electron cure of poly(ethylene terephthalate) moldings containing TAIC improves heat resistance and transparency (134). 

Unsaturated Polyester Resins (UPR). The principal uses are in putty, coatings, and adhesives. Glass-reinforced UPR is used for marine, constmction, and vehicle materials, as weU as for electrical parts. 

Polyester Resins. Reinforced polyester resins are thermosets based on unsaturated polyesters from glycols and dibasic acids, either or both of which contain reactive double bonds. The ratio of saturated to unsaturated components controls the degree of cross-linking and thus the rigidity of the product (see Polyesters, unsaturated). Typically, the glycols and acids are esterified until a viscous Hquid results, to which an inhibitor is added to prevent premature gelation. Addition of the monomer, usually styrene, reduces the viscosity to an easily workable level. 

Thermosetting unsaturated polyester resins constitute the most common fiber-reinforced composite matrix today. According to the Committee on Resin Statistics of the Society of Plastics Industry (SPl), 454,000 t of unsaturated polyester were used in fiber-reinforced plastics in 1990. These materials are popular because of thek low price, ease of use, and excellent mechanical and chemical resistance properties. Over 227 t of phenoHc resins were used in fiber-reinforced plastics in 1990 (1 3). PhenoHc resins (qv) are used when thek inherent flame retardance, high temperature resistance, or low cost overcome the problems of processing difficulties and lower mechanical properties. 

Unsaturated polyester resins predominate among fiber-reinforced composite matrices for several reasons. A wide variety of polyesters is available and the composites fabricator must choose the best for a particular appHcation. The choice involves evaluation of fabrication techniques, temperatures at which the resin is to be handled, cure time and temperature desked, and requked cured properties (see Polyesters, unsaturated). 

This is also known as Bulk Moulding Compound (BMC). It is blended through a mix of unsaturated polyester resin, crosslinking monomer, catalyst, mineral fillers and short-length fibrous reinforcement materials such as chopped glass fibre, usually in lengths of 6-25 mm. They are all mixed in different proportions to obtain the required electromechanical properties. The mix is processed and cured for a specific time, under a prescribed pressure and temperature, to obtain the DMC. 

At about the same time, an allyl resin known as CR39 was introdueed in the United States as a low-pressure laminating resin. This was followed in about 1946 with the introduction of unsaturated polyester laminating resins which are today of great importance in the manufaeture of glass-reinforced plasties. Alkyd moulding powders were introduced in 1948 and have since found specialised applications as electrical insulators. 

World production of unsaturated polyester resins in 1997 was of the order of 1.7 X 10 tonnes, with the USA accounting for about 45% and Western Europe 27%. Over 75% is used in reinforced plastics, with the rest being used for such diverse applications as car repair putties, cultured marble , wood substitution and surface coatings. The pattern of consumption in 1993 of reinforced polyesters in the USA was reported as ... 

Nowadays the major thermosetting resins used in conjunction with glass fibre reinforcement are unsaturated polyester resins and to a lesser extent epoxy resins. The most important advantages which these materials can offer are that they do not liberate volatiles during cross-linking and they can be moulded using low pressures at room temperature. Table 3.1 shows typical properties of fibre reinforced epoxy. 

The surface energy of fibers is closely related to the hydrophilicity of the fiber [38]. Some investigations are concerned with methods to decrease hydrophilicity. The modification, of wood cellulose fibers with stearic acid [43] hydrophobizes those fibers and improves their dispersion in polypropylene. As can be observed in jute-reinforced unsaturated polyester resin composites, treatment with polyvinylacetate increases the mechanical properties [24] and moisture repellency. 

Chemical compounds that contain methylol groups (-CH2 OH) form stable, covalent bonds with cellulose fibers. Those compounds are well known and widely used in textile chemistry. Hydrogen bonds with cellulose can be formed in this reaction as well. The treatment of cellulose with methylolmelamine compounds before forming cellulose unsaturated polyesters (UP) composites decreases the moisture pickup and increases the wet strength of reinforced plastic [48,49]. 

Oxidation of n-hutane to maleic anhydride is becoming a major source for this important chemical. Maleic anhydride could also be produced by the catalytic oxidation of n-butenes (Chapter 9) and benzene (Chapter 10). The principal use of maleic anhydride is in the synthesis of unsaturated polyester resins. These resins are used to fabricate glass-fiber reinforced materials. Other uses include fumaric acid, alkyd resins, and pesticides. Maleic acid esters are important plasticizers and lubricants. Maleic anhydride could also be a precursor for 1,4-butanediol (Chapter 9). 

Maleic anhydride is important as a chemical hecause it polymerizes with other monomers while retaining the double bond, as in unsaturated polyester resins. These resins, which represent the largest end use of maleic anhydride, are employed primarily in fiber-reinforced plastics for the construction, marine, and transportation industries. Maleic anhydride can also modify drying oils such as linseed and sunflower. 

Unsaturated polyesters, glass flake and fiber reinforced... 

Unsaturated polyesters The formation of the coating occurs in situ by the reaction between polyester resin and styrene, activated by a catalyst such as organic peroxide. The main use as coatings is in the formation of glass fiber or glass flake, reinforced plastics. 

A pyrolysis technique was investigated as a method for the chemical recycling of glass fibre-reinforced unsaturated polyester SMC composites. The proeess yielded liquid products and gases and also a solid residue formed in the pyrolysis of glass fibres and fillers. The solid residue was used as a reinforeement/filler in unsaturated polyester BMC composites, and the influenee on mechanical properties was studied in comparison with BMC prepared entirely from virgin materials. 

The largest single use of maleic anhydride is in the preparation of unsaturated polyester resins. It is first esterihed with a polyalcohol (two or more hydroxyls) and then the double bond is copolymerized (crosslinked) with a vinyl monomer such as styrene to form a rigid structure. Such resins are usually reinforced with hberglass (FRP). Maleic anhydride is also used to make oil additives and agricultural chemicals. 

Unsaturated polyester resins based on maleic anhydride are widely used in coatings to manufacture boat hulls and truck caps and a variety of other uses where a smooth, weatherproof, hard-surfaced material is desired. Because these resin types are inherently brittle, hberglass is frequently added for reinforcement. Consumphon of unsaturated polyesters in the U.S. is well over a billion pounds per year, with about 50% going into construction and the marine industry. 

The unsaturated polyester-styrene combination, is used as the resin matrix, in Fibre-reinforced plastics (FRP) structures. These resins also find use as decorative coatings. 

Finally, glass-reinforced unsaturated polyesters are well known as building materials for boats, yachts and cars and generally termed fibre-glass resin . The preparation, properties and applications of these unsaturated polyesters are summarized in Chapter 21, while the chemistry and properties of a new unsaturated polyester resin for fibre-reinforced composite materials are discussed in Chapter 22. 

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