Composite repair resins containing minimal hazardous air pollutants and volatile organic compound

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.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part of U.S. non-provisional patent application Ser. No. 11 / 124,551, filed May 6, 2005, currently pending, pursuant to 35 U.S.C. §120, which, in turn, claims the benefit of U.S. provisional patent application No. 60 / 569,379, filed on May 7, 2004, pursuant to 35 U.S.C. §119(e).BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to a composition and method for fabricating composite resins with reduced and zero volatile organic compound (VOC) and hazardous air pollutant (HAP) emissions. More specifically, the present invention relates to composites or resins incorporating fatty acid monomers for use as a repair resin.[0004]2. Brief Description of the Prior Art[0005]Composite resins used to repair equipment, vehicles, planes and watercraft typically contain 10%-20% by weight hazardous air pollutants (HAP) and volatile organic compounds (VOC). HAP and VOC chemicals...

AI Technical Summary

Problems solved by technology

Consequently, the military generates thousands of pounds of hazardous waste from expired resins annually.

Moreover, because it is impractical to use enclosures and trapping devices, field repair resins are typically cured in the open, generating a significant amount of HAP emissions.

The high reactivity of the current repair resin chemistry results in a short shelf-life of less than 1 year; thermal and mechanical properties decrease rapidly upon expiration of the shelf-life.

This is particularly problematic in view of the fact that military equipment must be able to withstand extreme conditions.

Therefore typical military repair resins, such as Bondo™, 6294 Dent Filler, 887 Metal-2-Metal Reinforcement and other vinyl ester composite resins, lack sufficient durability and material properties to endure military applications.

Military equipment is frequently subject to damaged by impact of a foreign object, ballistic impact, moisture intrusion and expansion, corrosion, collision and maintenance-induced damage.

The degree of damage may range from: light damage, requiring only aesthetic repairs and coating repairs; moderate damage, requiring repair of delaminations, small patches and edge repairs, to heavy damage, requiring full depth, core and substructure repairs.

Unfortunately, E-beam instruments impose a high capital cost and are not portable, making military field repair impractical.

Furthermore, E-beam curable resins are not a drop-in alternative to current repair resins, and are therefore not highly desired by the end users.

Epoxy resins were also found inadequate, in part because epoxy resins cost approximately four times the amount of vinyl ester (VE) and unsaturated polyester (UPE) resins.

Inaccurate ratios or poor mixing can result in poor and inconsistent properties.

Epoxies can be cured using agents, such as a dicyandiamide, where exact mix ratios are not important, but cure of these systems does not occur until elevated temperatures, which is impractical for field repair.

Simply reducing the styrene content in composite resins, however, causes one of two significant problems.

If the resin is filled to the same extent with inorganic fillers for the low styrene formulation as it is with the regular formulation, the low HAP repair resin will have an unacceptably high viscosity.

Alternatively, lower filler contents can be used, but these will detrimentally affect the stiffness of the resulting repair.

These substitutions generally produce inferior resin viscosity and properties in comparison to styrene-based thermosetting resins.

Moreover, 2-hydroxymethacrylate produces significant VOC emissions.

These resins, however, suffer from poor polymer performance and poor interfacial adhesion in fiber-matrix composites.

Furthermore, studies have shown that these additives do not effectively decrease styrene emissions during the time-scale of use.

Although these resins reduce HAP and VOC emissions, the patents do not disclose the capability of completely eliminating HAP and VOC components or emissions.

Nor do these patents present inorganically filled formulations that are useable for repair applications.

However, until now, fatty acids have not been used as reactive diluents in thermosetting liquid molding resins.

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