Sheet Molding Compound Composition with Silane-Coated Glass
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Solution Overview
Problem
High loadings of hollow glass bodies in sheet molding compounds lead to unworkable viscosity due to aggregation and friction, making it difficult to process, and existing polyolefin compositions lack the necessary mechanical properties for automotive applications.
Innovation Solution
A composition comprising unsaturated polyester resin and hollow glass bodies with a silane compound coating, which reduces viscosity and enhances mechanical properties, allowing for higher glass loadings and improved processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If high loading of hollow glass bodies (55 vol.-%) is used in unsaturated polyester resin systems, then weight reduction is improved, but viscosity becomes unworkable due to aggregation and friction
Solution Approach 1:
A silane-modified polyester polymer is introduced as an intermediary substance that acts as a dispersing agent and viscosity controller. This intermediary polymer prevents aggregation of hollow glass bodies and maintains workable viscosity even at high loadings of 55 vol.-%, thereby enabling both weight reduction and processability.
Solution Approach 2:
The invention changes the chemical and physical parameters of the polyester system by incorporating silane-modified polymer chains with specific molecular weights (100-1000 g/mol) and silane content (1-10 wt.-%). These parameter changes enable the system to accommodate high glass body loadings while maintaining acceptable viscosity and processability.
2Weight of moving object
If polyolefins are used with high loading of glass microspheres, then weight reduction is achieved, but mechanical properties are insufficient for automotive applications
Solution Approach 1:
The invention creates a composite material system combining unsaturated polyester resin with silane-modified polymer chains and hollow glass bodies. This composite approach provides both the weight reduction benefits of high glass loading and the mechanical strength required for automotive applications, overcoming the limitations of polyolefin-based systems.
3Strength
If conventional silane treatment is used on hollow glass bodies, then bonding strength is improved, but viscosity control at high loadings is insufficient
Solution Approach 1:
The invention modifies the silane treatment parameters by using silane compounds with specific structures (formula A with Ra1 and Ra2 groups) and controlling the silane content (1-10 wt.-% relative to glass body weight). These parameter changes enable simultaneous achievement of strong bonding and adequate viscosity control even at 55 vol.-% glass loading.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves lower viscosity and superior mechanical properties, enabling ultra-lightweight applications with sound tensile strength, impact resistance, and fatigue resistance, suitable for the automotive industry.
Implementation Method 1
the at least one hollow glass body comprises at least one coating layer on (at least a part of) its surface obtained (or obtainable) by treating the at least one hollow glass body with a treatment composition comprising at least one silane compound
Implementation Method 2
It is further directed at the use of at least one silane compound, an oligomer or a polymer thereof, to control the viscosity of a liquid mixture comprising an unsaturated polyester and at least one hollow glass body
Implementation Method 3
the methacryl group on the surface of the hollow glass bodies can bond with (or couple to) components in the sheet molding compound system
Implementation Method 4
leading to stronger, more durable mechanical properties of the final system
Data Source
AI summary
A composition is made that is suitable for the manufacturing of sheet molding compounds, and a method for preparing the composition is developed. A method for making an article using the composition is developed, and an article with the composition, at least one such article being a mobility device, is made. The viscosity of a liquid mixture comprising an unsaturated polyester and at least one hollow glass body is controlled with at least one silane, a hydrolysate, an oligomer, and/or a polymer thereof.