5.7. Renewable Unsaturated Polyesters
Renewable or fossil UPs are thermosetting resins.
5.7.1. Renewable Grades
Partially renewable UPs are slowly developing but renewable content, sometimes including recycled materials, can be as low as 8% up to 55%. Biopolyols, originated, for example, in soy or glycerol released in the production of biodiesel, partly replace petroleum-based components.
Please note that green or bio- or eco-UP resins may be:
• derived from biologically renewable materials
• derived from recycled materials, and/or
• free of styrene.
Among others, let us quote some materials formulated for casting, cured-in-place pipe (CIPP), closed molding, and open mold laminating: EcoTek line by AOC, Envirez line by Ashland, Envirolite by Reichhold, Palapreg® ECO by DSM.
Palapreg® ECO is claimed composed from the highest renewable resource (55%) without making any sacrifice to product performance or production speeds.
AOC’s line of EcoTek® Green Technologies for composites and cast polymers offers specific grades for:
• Cast polymers
• Concretes
• CIPP green resins
• Closed mold green resins
• Corrosion green resins
• Open mold laminating green resins
Processability and end-use performance are claimed similar to those of fossil resins.
Table 5.34 displays some examples of properties of partially renewable UP resins aiming casting, CIPP and SMC (sheet molding compound, class A) applications.
For example, the Envirez 1807 UP resin by Ashland is produced using 25 wt% of grain-derived organic raw materials coming from soybean oil and corn-derived ethanol.
Table 5.34
Examples of Renewable UP Resin Properties (EcoTek™)
| Processing Method | Cast | CIPP (Cured-in-Place Pipe) | Class A SMC (Sheet Molding Compound) |
| Tensile strength, MPa | 61 | 60 | 54 |
| Tensile modulus, GPa | 4.0 | 4.6 | 3.6 |
| Tensile elongation, % | 2.1 | 1.7 | 1.8 |
| Flexural strength, MPa | 121 | 75 | 96 |
| Flexural modulus, GPa | 4.07 | 4.6 | 3.7 |
| Heat distortion temperature, 1.8 MPa, °C | 59 | 113 | 113 |
Table 5.35 displays some examples of properties of partially renewable UP resins for neat and SMC applications.
ENVIROLITE® by Reichhold, for example, ENVIROLITE® 31325-00, is an unpromoted, medium reactive, low viscosity UP molding resin derived in part from natural resources. Specifically, this product is based on soya oil derivatives and has a “green” content of 25%. The product is intended as a general purpose molding resin for SMC, bulk molding compound (BMC), and pultrusion applications. The resin leads to laminates with mechanical properties that are claimed similar to those of standard SMC, BMC, and pultrusion fossil resins.
Reichhold, Inc. has studied hybridized soybean oil-based UP resin systems compared to a typical UP resin system with a focus on the thermal and mechanical properties. The results (Table 5.36) show that the HDT and mechanical properties of the modified soybean resin systems increase as the amount of urethane segments increases.
Table 5.36 displays property examples of a traditional UP composite and three soy-based resins with increasing level of urethanes. These results relate to examples only and cannot be generalized. Data cannot be used for design purposes. These general indications should be verified by consultation with the producer of the selected grades and by tests under operating conditions.
Table 5.35
Examples of Renewable and Fossil Unsaturated Polyesters (Ashland)
| Composite | Renewable Resins | Fossil Resins | |||
| Resin biocontent (%) | 10 | 18 | 20–25 | 0 | 0 |
| Clear Casting Data | |||||
| Resin heat distortion temperature (HDT) (°C) | 200 | 134 | 135–175 | 177 | 177 |
| Elongation (%) | 1.0 | 2.1 | 1.4–1.6 | 1.25 | 1.25 |
| Tensile strength (MPa) | 40 | 25 | 90 | ||
| Tensile modulus (GPa) | 3 | 2 | 4 | ||
| Flex strength (MPa) | 57 | 50 | 125 | ||
| Flex modulus (GPa) | 3 | 3 | 4.5 | ||
| Elongation (%) | 1.6 | 1.5 | 4 | ||
| SMC Properties | |||||
| Glass content (%) | 29.5 | 32.5 | 30 | 29.9 | 29.3 |
| Tensile strength (MPa) | 80 | 100 | 103 | 95 | 86 |
| Tensile modulus (GPa) | 11.3 | 12.2 | 11–12 | 13.6 | 9.4 |
| Flex strength (MPa) | 180 | 235 | 194–250 | 260 | 170 |
| Flex modulus (GPa) | 11.7 | 13 | 9.8–12.3 | 14.7 | 10.0 |
| Elongation (%) | 1.20 | 1.65 | 1.75 | 1.70 | 1.30 |
Table 5.36
Property Examples of Experimental Soy-Based Hybridized Unsaturated Polyester Resins
| Base | Petroleum | Soy-Based Hybridized Unsaturated Polyester Resins | ||
| Urethane level | 0 | low | Medium | high |
| Barcol hardness | 24–28 | 34–36 | 39–42 | 40–41 |
| Heat distortion temperature (HDT), °C | 78 | 84 | 95 | 107 |
| Flexural strength, MPa | 76 | 101 | 127 | 139 |
| Flexural modulus, GPa | 2.1 | 2.7 | 3.1 | 3.2 |
| Tensile strength, MPa | 44 | 58 | 70 | 73 |
| Tensile modulus, GPa | 2 | 2.4 | 2.7 | 2.7 |
| Elongation at break, % | 4.1 | 3.7 | 3.9 | 3.9 |
Polynt Composites (http://www.ccpcomposites.com/) proposes Enviroguard, a biosourced UP range, targeting all composites industry processes giving a carbon footprint 10–30% less than traditional resins.
5.7.2. Applications
Some commercial or experimental applications are quoted, for example, without claiming to be exhaustive.
• A collaborative effort from United Soybean Board (USB), Ashland, and various partners including John Deere & Co. results in a series of molded parts for the Model 9750 John Deere Harvester™ combine introduced in August 2003. Deere & Co. has further specified soy-derived composite products made from SMC, in most of their SMC parts, including tractor hoods. More than 100 kg of soy composite are installed on each Harvester™ combine. Ashland and its collaborators are working to expand the product offerings into other markets, including construction and transportation.
• CIPP.
• Casting with reactivity, stability, viscosities, density, peak temperature, and other properties similar to petrochemical-based products. A new resin system derived from renewable and recycled material is designed to be blended with aluminum trihydrate to provide fire retardant properties for mass transit applications.
• DSM develops Palapreg® ECO P55-01 resin with 55% biobased content and claims the resin has been qualified in the automotive industry for vehicle body parts, including exterior panels. Tests by tier-1 Automotive OEMs have proven that this high renewable content is achieved without making any sacrifice to product performance or processing speeds. Palapreg® ECO P55-01 has already been commercially used to produce outdoor benches with SMC technology. Moreover, with certain variations, it can also be applied in other processing techniques such as resin transfer molding (RTM), hand layup, and infusion for a wide range of potential applications in building and construction.
5.7.3. Reminder of Fossil-Sourced Unsaturated Polyester General Properties
Partially renewable UPs are claimed having properties and characteristics of the same order as fossil UPs and could be processed by clients’ equipment without the need for any drastic adjustments. The following information deals with general properties of fossil UPs and, of course, some properties of renewable UP can be different. So, keeping equal all the other parameters, do not make a short-sighted replacement of fossil polymer by the same weight of biosourced material without preliminary feasibility studies. Often, the recipe or/and processing conditions must be adjusted.
5.7.3.1. Overview
UPs are obtained by the reaction between diacids or anhydrides containing a proportion of double bonds and a diol or glycol. The mixing of saturated and unsaturated acids, their type, the nature of the diols, and the versatility of the recipes lead to diverse chemical natures:
• Ortho or isophthalic acids with various types of alcohols,
• Vinylesters,
• Bisphenolics,
• Diallylphthalates, etc.
The processing conditions vary
• Hot or room temperature curing
• With or without postcure.
The UPs can be modified, for example, with the example:
• Melamines: UP/MF
• Isocyanates…
Consequently, the neat UP resins have varied properties that filling and reinforcement diversify even more to lead to a very broad range of characteristics and uses. Unless otherwise specified, the indications that follow relate to the most current types.
The UPs are the first-class matrix for general purpose, mass-produced composites with a good technical level, generally with glass fiber reinforcement: shipbuilding, automotive and railway bodies, anticorrosive, electricity, tanks, etc.
Advantages
Attractive price/property ratios, good mechanical and electrical properties, fairly good heat and creep behaviors, aesthetics, choice of rigidities, resistance to a great number of chemicals, resistance to light, weathering and water in spite of surface deteriorations; possibilities of transparency and food contact for suitable grades, broad range of colors, ease of some manual processing methods, possibility of lightening by controlled foaming, suitability for the manufacture of very large composite parts (shipbuilding).
Drawbacks
Natural flammability, significant shrinkage of the current grades, industrialization and reproducibility difficulties for some processes, limited behavior to bases, acids, and boiling water except for special grades; decomposition by oxidizing strong acids, attack by some solvents.
Special Grades
• Hand and spray layup molding, impregnation, SMC, BMC, thick molding compound (TMC), a highly automated process using molding compounds (ZMC). compression, injection, pultrusion, filament winding, centrifugation, long or short glass fiber reinforcement, for thin or thick parts, for shipbuilding, for gelcoat; more or less reactive, more or less thixotropic, food contact, foamed, controlled damping, low shrink, low profile, fireproofed, preaccelerated, rigid, semirigid, flexible, high elongation at break, high or very high transparency, improved light or hydrolysis or heat stability, low emission of styrene or environment friendly, cold hardening, hot hardening, toughened, light color, resistant to cracking…
• For casting, encapsulation, inclusion, cements, concretes, for large blocks, buttons, molds.
• Vinylester grades for chemical and heat resistance.
• Some special grades can be UV curable.
Processing
Hand and spray layup molding, compression, injection, transfer, SMC, BMC, TMC, ZMC…, RTM, infusion, pultrusion, filament winding, centrifugation, impregnation, casting, encapsulation, inclusion, machining, coating.
Certain processes such as hand and spray layup molding, inclusion, casting, encapsulation are manual.
Consumption
UP consumption in industrialized countries accounts for 15–23% of the total thermoset consumption and is approximately 2% of the total plastic consumption. According to the country, consumption has grown or declined slightly in the last few years.
Applications
The main application markets are as follows:
• Building and civil engineering
• Industry
• Electrical engineering, consumer goods
• Transport.
Examples of operational or development parts are listed as follows.
Automotive
• Bodies and parts, from mass production to small series or even a single unit: passenger cars, 4WD, monospaces, trucks and lorries, utilities, buses; sports, recreational, special vehicles; caravans, motorhomes…
• Bodies of niche or medium output vehicles, body panels, rear floors, decklids, roofs, fenders, doors, inner doors, bonnets, tailgates, front-ends for mass production vehicles, caps, trunk lids, bodies of sports cars; roofs for vans; bumper beams and side protection of mass production vehicles; spring leafs for vans.
• Particle filter systems, engine covers and sumps; supports of batteries; headlight reflecting housing.
• Truck front panels, roof and side spoilers for truck cabins, engine hoods, front fenders; pickup truck boxes; shelters, ambulance cells, trailer or special vehicle bodies.
• Cabins, cabin doors for farm tractors.
Building and Civil Engineering
• Boarding for buildings, sloping roofs of petrol stations, modular roofs of stadiums, protection for industrial facilities, mobile guardrooms, external walls in sandwich panels, prefabricated houses, gables of dormer windows, pediments for building entrances, roofs and stained glass for churches, roof tiles.
• Roofs and weatherboarding of agricultural or industrial buildings, sporting equipment, general purpose rooms.
• Balconies, floors of balconies, parapets, cornices, colonnades, interior partitions for building restoration; architectural panels, profiles for doors and windows for factories, houses, buildings; exterior spotlight housings.
• Sinks and counter tops for kitchens.
• Fire doors in fireproofed UP.
• Portals of gardens, translucent or opaque roofs, skylights in single or double wall sheets, shutters for factories, housings of waterproofed lights, industrial lighting cases; footbridges for maintenance of subway tunnels.
• Pedestrian bridge; 40 m bridge for pedestrian traffic, snow clearance motor devices and equipment up to 5 tonnes; bridge floor beams, elements of road toboggans, panels for soundproofing walls.
• External cabinets for automatic devices for traffic lights, telephone relays; cover plates of buried gas meter, roofs of rural shelters of bus stops; frames, formworks, cofferings, bonnets, bodies, housings for equipment protections.
• Main sewers for buildings, pipes, and fittings for industrial waste water coming from the semiconductor, mining, paper and pulp industries; rehabilitation of pipes without digging trenches by the use of uncured soft tubes. Piping up to 10 m in diameter, chemical or wine tanks up to 10 m in diameter.
• Gratings, gratings for piers with truck traffic, gutters for surface water along motorways; cable shelves for the Channel Tunnel in fireproofed acrylic pultruded sections.
• Chimneys for factories up to 7 m in diameter.
• Blades up to 12.5 m length for wind turbines, masts, telephone posts, telegraph pole supports.
• Fireproofed panels and structures for oil rigs, sandwich structures for protection of underwater oil wellheads.
• Molds for concrete elements.
Shipbuilding, Water Sports
• Shipbuilding from dinghies up to minesweepers including all the types of race or pleasure boats, sailboards and surfboards, hulls of catamarans; hovercrafts, pilot boats, floating shopping centers, dry dock caissons, sluice gates.
• Fireproofed glass fiber-reinforced polyester for offshore oil rigs: safety shelters, floors, explosion-proof panels, pultruded profiles for bearing floors, gratings, handrails, duckboards, ladders.
• Swimming pools.
• Sailboards, canoes, fishing boats, dinghies of mass distribution.
Electricity, Electronics
• Electricity meter housing, low-voltage fuse boxes, low- and medium-voltage boxes, supports of terminals, connectors, switch parts, housing, and handles or soles of domestic iron; handles and buttons of grills and pressure cookers; buttons.
• Dishes for satellite TV aerials, urban lampposts, cable shelves, frames and carcasses of solar panels, tubes for scanners (1 m in diameter).
• Vinylester fuel cell plates.
• Electricity inclusions.
• Fuel cell plates.
Industry, Anticorrosion
• Formworks, hoods, bonnets, panels, housings, casings for machines; pump housings, gas washers, flue gas scrubbers, pipes and fittings for industrial sewage water, factory chimneys, chemical tanks, settling tanks.
• Butterfly valves for water, acid and alkali solutions.
• Compressed-air tanks, fuel tanks for railcars; storage or transport tanks for fuel, foodstuffs, drinking water, wine, chemicals.
• Drainage pipes DIN 40 up to 2000.
• Containers for part transports for the nuclear industry, aeronautics.
Furniture
• Baths, basins, sanitary wares, tubs; cabins or sanitary blocks; false marbles, onyx for sanitary.
• Cabins and doors of public toilets.
• Traffic signs, urban notice boards, signposts for motorways, benches of bus shelters, public benches, Parisian newspaper kiosks, urban telephone shelters, roofs of phone boxes, housing for cash dispensers.
• Seats for communities.
• Urban dustbins, old paper containers.
Appliances
• Structural elements, bodies, roofs and doors for display units, refrigerating window displays, refrigerated mobile shops, refrigerating lorries and semitrailers, refrigerated vans and other vehicles, cold stores.
• Housing and handles or soles of domestic irons, handles and buttons of grills, and pressure cookers.
Transport
• High-speed train noses; cabins, doors, floors of funiculars in sandwich.
• Window frames for high-speed trains, pillars of Berlin S-Bahn.
• Bumpers, energy-absorbing fenders.
• Luggage racks for trains, seat frames, individual shelves.
• Reflectors.
• Careenages for race motorbikes.
• Heating insulation sheaths for trains.
Art, Decoration, Publicity, Leisure Parks
• Concrete for molding of statues (Nikki de St Phalle), knick-knacks and various items, blocks for sculpture, stained-glass windows.
• Giant-advertising articles, bodies and subjects for carrousels, play areas, leisure parks in glass beads or fiber-reinforced resins.
• Cinema, theater or television decors, dismountable scenes.
• Figurines up to 35 m high, decors, plays; cars, planes, and so on for carrousels; giant toboggans, beams of medieval houses for leisure and theme parks.
• Decorative objects in foamed resins.
Packaging
• High-tech or aesthetical packaging such as containers for nuclear industry, aeronautics, and radomes; storage bins, cases for double bass.
Miscellaneous
• Sandable cements for metal or composite repairs.
• Leg prostheses, surgical corsets, reconstructing plasters for tortoise shells.
• Terrace coating, buffing wheels, swimming pools.
• Fishing rods.
• Scientific inclusions.
Initial Thermal Behavior
The HDT A (1.8 MPa) are very variable according to the type of resin and the reinforcements used:
• 30°C for a neat flexible grade,
• Up to more than 200°C for a rigid reinforced grade.
Although UPs are thermoset resins, moduli can decrease rather rapidly when the temperature rises:
• For example, for a given neat current grade, the flexural modulus falls by 50% between 20°C and 80°C.
• On the other hand, for another given glass fiber-reinforced grade, the flexural modulus retention is much higher:
• At 93°C: 66% Retention
• At 121°C: 43% Retention
• At 149°C: 27% Retention
Long-Term Thermal Behavior
The continuous use temperatures in an unstressed state generally vary from 90°C up to 140°C.
Higher temperatures can be withstood for shorter times, especially for the heat-resistant grades such as vinylesters.
The UL temperature indices of specific grades range from 105°C to 180°C for the electrical and mechanical properties including impact.
Figure 5.22 Vinylester composite aging at 160, 182, 204°C: examples of flexural strength retention versus aging time (month).
These results relate to the tested grades only and cannot be generalized.
Fig. 5.22 demonstrate the huge effect of temperature on aging: the half-lives are very short at 182°C and 204°C and can be acceptable at 160°C for some uses.
Low Temperature Behavior
The glass transition temperatures are high, for example, 90–210°C.
Polyester resins and composites are often used at low temperatures in automotive, building, and refrigerating industries.
5.7.3.2. Optical Properties
Transparent and colorless grades are available, used for the manufacture of cover plates or scientific or electric components or technical inclusions.
The refractive indexes, for specific grades, are in the range 1.52–1.56.
For transparent glass fiber-reinforced composites, the grades with low refractive indexes near to that of glass (1.548) are preferred.
5.7.3.3. Mechanical Properties
The mechanical properties, rigidity, impact resistance, and creep are very variable according to the grades and the reinforcements. However, generally, the behavior is satisfactory and allows many mechanical applications as composite matrices.
Figs. 5.23, 5.24, and 5.25 indicate the general evolution of the main mechanical properties of the resins and composites as the fraction and the length of fibers increase. The aim of these graphs is only to illustrate a principle and they are not graduated. For more precise, data see the tables at the end of this subchapter.
Friction
Generally, polyesters are not used for friction parts.
Creep
Creep is highly dependent on the reinforcement and load.
For the two following examples concerning the same composite, the sets are doubled when the load increases by 50%:
• 0.2% after 1000 h under a stress of 14 MPa that is a creep modulus of 7 GPa.
• 0.4% after 1000 h under a stress of 21 MPa that is a creep modulus of 5.250 GPa.
In another example (after Amoco data, Bulletin GTSR-127), two beams, one cast and the other pultruded, are tested with a three-point bending method for more than 100 days and the deflections are studied versus testing time (Fig. 5.26). These two examples are not comparable because all the conditions are different (matrix, reinforcement, process, loading) and that leads to highly dissimilar results: the more loaded beam bends less than the less loaded one.
All these results prove that each material grade must be tested before use.
Dimensional Stability
The molding shrinkage is difficult to control with some processes, making mass production difficult.
Postshrinkage depends on the resin, the reinforcements, and the hardening cycles. It can be negative.
Dynamic Fatigue
The dynamic fatigue behavior is generally quite acceptable but depends on the reinforcements and the matrix. The two following examples concern composites with different matrices and reinforcements:
• For a given glass fiber reinforcement and resin: 107 cycles for a given load
• Different glass fiber reinforcement and resin: 106 cycles for 50% of this load.
In other tests (after Amoco data, Bulletin IP-81), the range of endurance strengths (Fig. 5.27) in cyclic loading of samples immersed in water is very broad according to the type of UP (iso- or orthopolyesters) and the number of cycles.
Figure 5.27 Unsaturated polyester: examples of endurance strengths versus the number of cycles in water.
All these results prove that each material grade must be tested before use.
5.7.3.4. Aging
Weathering
UPs are broadly used in those applications where long-time weathering is implied: automotive, shipbuilding, and building. For a judicious choice of grades, a suitable hardening and an adapted gelcoat used for the protection of fibers and composites, the mechanical properties remain at an acceptable level, and the slight yellowing can be controlled. Preliminary tests, taking account of the particular conditions of use, are necessary.
Chemicals
Resistance to moisture and hot water is generally good and is improved for the special so-called “hydrolysis stabilized or resistant” grades. Degradation by boiling water can be significant.
Table 5.37 (after Amoco data, Bulletin IP-93) displays some performance retention data versus the immersion times and temperatures for two UPs and one vinylester. The vinylester performs better than the two UPs, which have very different behaviors.
Many anticorrosive, antiacid, and antialkali grades have an improved chemical resistance. These improvements are specific and each particular case will have to be subjected to an examination.
The oxidizing acids break up UPs. The other acids and bases have variable effects, often limited.
The UPs are attacked by aromatic hydrocarbons, chlorinated ketones, esters, and solvents but are resistant to aliphatic hydrocarbons and alcohols.
In the following list, there appear, by way of examples, a certain number of chemicals that could, after satisfying preliminary tests, be transportable and storable in anticorrosive polyester resin composite vessels.
• More or less dilute solutions of hydrochloric, sulfuric, nitric, phosphoric acids; acetic acid, vinegar, fatty acids.
• Bleaching agents.
• Alcohols.
• Alums.
• Ammonia.
Table 5.37
Unsaturated Polyester: Performance Retention After Immersion in Hot Water
| Resin | Flexural Strength, MPa | Flexural Modulus, GPa | Barcol Hardness | |||
| Polyester A | Polyester B | Polyester A | Polyester B | Polyester A | Polyester B | |
| Initial | 17 | 18 | 0.6 | 0.6 | 45 | 45 |
| Retention after 100 h in water at 100°C, (%) | 70 | 20 | 80 | 50 | 90 | 90 |
| Resin | Polyester A | Vinylester | Polyester A | Vinylester | Polyester A | Vinylester |
| Initial | 17 | 22 | 0.6 | 0.5 | 45 | 39 |
| Retention after 100 h in water at 100°C, (%) | 70 | 90 | 80 | 90 | 90 | 90 |
| Polyester | Vinylester | Polyester | Vinylester | Polyester | Vinylester | |
| Initial | 16 | 22 | 0.8 | 0.9 | 52 | 48 |
| Retention after 8760 h in water at 71°C, (%) | 81 | 63 | 84 | 88 | 98 | 98 |
• Drinking water, seawater; domestic, urban, or industrial aqueous effluents.
• Products for water treatment.
• Acrylic emulsion.
• Fertilizer.
• Acid smokes.
• Gas oil, oils.
• Glycols.
• H2S.
• Vegetable oils.
• Milk, whey.
• Sugar syrup.
• Saline solutions.
• SO2.
For food contact, many food grades are proposed and can be used after testing.
Fire Resistance
The oxygen indices (21, for example) and fire behavior classifications are naturally weak but can be highly improved by the addition of fireproofing agents, making it possible to reach the V0 UL94 rating. The other properties can be more or less affected.
Electrical Properties
The insulating properties are good and allow many electric applications. However, dielectric rigidity can reach relatively low values.
Antistatic grades are marketed with surface and transverse resistivities notably lowered.
The UPs are used in the manufacture of electromagnetic shieldings.
Joining
Welding and joining with solvents are useless for all the thermosetting resins.
Only adhesives chosen after rigorous tests are permitted for joining. The parts should not be subjected to high stresses.
After cleaning by abrasion or/and with solvents, polyesters can be stuck with epoxy adhesives, polyurethanes, cyanoacrylates, or acrylic resins whose performances are compatible with the operating conditions.
Primers and specific adhesives have been developed for joining to metals.
Decoration
Gelcoats and paints are extensively used for the decoration and the protection of the aspect parts for automotive, shipbuilding, building, appliances, etc., applications. The UPs are also used for the realization of sculptures, stained glass, inclusions, etc.
Bulk coloring is frequently used.
5.7.3.5. Trade Name and Producer Examples
Trade name examples: Ampal, Atlac, Crestomer, Crystic, Derakane, Envirez, Envirotec, Enydyne, Hexion, Maxguard, Menzolit BMC and SMC, Modar, Norsodyne, Norsomix, Palapreg, Palatal, Premi-Glas, Procore, Rutaform, Synolite, Vestopal.
Producer examples
| AOC | http://www.aoc-resins.com/ |
| Ashland | http://www.ashland.com/ |
| Cray Valley | http://www.crayvalley.co.za/ |
| DSM | http://www.dsm.com/ |
| Kyocera | http://www.kyocera-chemi.jp/english/ |
| Menzolit | http://www.menzolit.com/ |
| Momentive | http://www.momentive.com/ |
| Raschig | http://www.raschig.de/ |
| Reichhold | http://www.reichhold.com/ |
| Saudi Industrial Resins Limited | http://www.sir-ltd.com/ |
| Scott Bader | http://www.scottbader.com/ |
5.7.3.6. Property Tables
Tables 5.38–5.42 relate to examples only and cannot be generalized. Data cannot be used for design purposes. These general indications should be verified by consultation with the producer of the selected grades and by tests under operating conditions.
Table 5.38
Unsaturated Polyester Unreinforced Resins for Casting and Molding, Matrices for Composites: Examples of Resin Properties
| Standard, Neat | Flexible, Neat | Fireproofed Unreinforced | |
| Density, g/cm3 | 1.1–1.4 | 1.1–1.3 | 1.2–1.4 |
| Shrinkage, % | 0.05–2 | ||
| Water absorption, 24 h, % | 0.1–0.6 | 0.2–2.5 | 0.01–2.5 |
| Shore hardness, D | 84–94 | ||
| Barcol hardness | 35–60 | 20–30 | 35–50 |
| Tensile strength, MPa | 25–90 | 4–15 | 40–90 |
| Elongation at break, % | 1.5–4 | 10–300 | 1.5–4 |
| Tensile modulus, GPa | 2–4.5 | 2–3 | |
| Flexural strength, MPa | 50–125 | ||
| Flexural modulus, GPa | 3–1.5 | 2–3.5 | 3–1.5 |
| Compression strength, MPa | 150–180 | ||
| Notched impact D 256, J/m | 10–25 | 25–100 | |
| Notched impact, kJ/m2 | 5–15 | 10–20 | 5–12 |
| Heat distortion temperature (HDT) A (1.8 MPa), °C | 50–150 | 30–90 | 70–95 |
| CUT unstressed, °C | 90–140 | 90–140 | 90–140 |
| Thermal conductivity, W/mK | 0.1–0.4 | 0.1–0.5 | 0.1–0.5 |
| Specific heat, cal/g/°C | 0.3–0.4 | 0.2–0.4 | |
| Coefficient thermal expansion, 10−5/°C | 6–12 | 6–12 | 2–10 |
| Surface resistivity | 1012 | 1012 | 1012 |
| Volume resistivity, ohm cm | 1015 | 1015 | 1015 |
| Dielectric constant | 3–7 | 3–7 | 3–7 |
| Loss factor, l0−4 | 20–1000 | 20–1000 | 20–1000 |
| Dielectric strength, kV/mm | 15–15 | 15–15 | 15–45 |
| Arc resistance, s | 60–200 | 60–200 | 60–200 |
| Oxygen index, % | 21–30 | 21–30 | 25–10 |
| General Chemical Properties | |
| Light | Good behavior. Possible slight surface attack with yellowing. Special grades are weathering-resistant |
| Weak acids | None to light attack |
| Strong acids | Attack. Special grades are acid-resistant |
| Bases | Attacked to a greater or lesser degree according to the nature, concentration, and temperature. |
| Solvents | Resistant to alcohols, aliphatic hydrocarbons. Attacked by aromatic hydrocarbons, ketones, esters, chlorine containing. |
| Water | Generally, fair resistance to moderately hot water. Attacked by boiling water. |
| Food contact | Possible |
Table 5.39
Filled or Short Fiber-Reinforced Unsaturated Polyesters (UP): Examples of Resin Properties
| Matrix | UP, Antistatic | UP | UP | UP Modified, Melamine |
| Filler | Unknown | Textile Fiber | Short Glass Fiber | Cellulose |
| Density, g/cm3 | 1.7–1.73 | 1.7–1.8 | 1.9–2.1 | 1.7–1.9 |
| Shrinkage, % | 0.1–0.15 | 0.01–0.2 | 0.01–0.1 | 0.01–0.4 |
| Tensile strength, MPa | 30–62 | |||
| Flexural strength, MPa | 90–140 | 60–80 | 60–100 | 60–90 |
| Flexural modulus, GPa | 9–11 | |||
| Notched impact, kJ/m2 | 3–3.5 | 3–4.5 | 2–3 | |
| Heat distortion temperature (HDT) A (1.8 MPa), °C | >200 | 100–130 | 160–250 | 120–140 |
| Coefficient thermal expansion, 10−5/°C | 1.8–2 | |||
| Surface resistivity | 107 | 1011 | 1012 | 1010 |
| Volume resistivity, ohm cm | 1010 | 1014 | 1015 | 1014 |
| Dielectric rigidity, kV/mm | 1–2 | |||
| Arc resistance, s | 130–140 | 140–150 | 150–180 | 120–130 |
| Oxygen index, % | 30–32 | |||
| UL94 rating | V0 | HB to V0 | HB to V0 | |
| General chemical properties are subject to the compatibility of the fillers and reinforcements with the ambient conditions. If the fillers are adapted, the chemical properties are similar to those of the polyester matrix. | ||||
Table 5.40
Unsaturated Polyester BMC (Bulk Molding Compound): Examples of Composite Properties
| Glass Fiber, % Level | 7 | 10–20 | 22–28 | 18 Fire Retardant, Halogen Free |
| Density, g/cm3 | 1.76 | 1.7–1.9 | 1.76–1.95 | 1.95 |
| Shrinkage, % | 0.02 | 0.01–0.2 | −0.06–0.15 | 0.18 |
| Water absorption, 24 h, % | 0.1–0.2 | 0.1–0.2 | 0.1–0.2 | 0.1–0.2 |
| Tensile strength, MPa | 30–40 | 30–35 | ||
| Flexural strength, MPa | 55 | 40–135 | 90–115 | 90 |
| Flexural modulus, GPa | 5.5 | 7–11 | 9–11 | 9 |
| HDT A (1.8 MPa), °C | >200 | >200 | >200 | >200 |
| Specific heat, cal/g/°C | 0.26–0.34 | 0.26–0.34 | 0.26–0.34 | |
| Coefficient thermal expansion, 10−5/°C | 2 | 2 | 2 | 2 |
| Surface resistivity | 1012 | 1012 | 1011 | 1011 |
| Volume resistivity, ohm cm | 1014 | 1014 | 1015 | 1014 |
| Dielectric constant | 4 | 4 | ||
| Dielectric rigidity, kV/mm | 10–15 | 10–15 | 10–15 | 10–15 |
| Oxygen index, % | 34 | 22–15 | 22–32 | 80 |
| UL94 rating | V0 | HB to V0 | HB to V0 | V0 |
Table 5.41
Unsaturated Polyester SMC (Sheet Molding Compound): Examples of Composite Properties
| Standard Grades | ||||
| Glass Fiber, % Level | 10–20 | 25–30 | 32–40 | 50% |
| Density, g/cm3 | 1.7–1.8 | 1.7–1.9 | 1.77–1.84 | 1.63 |
| Shrinkage, % | 0.05–0.15 | −0.1–0.18 | −0.08–0.1 | 0.01 |
| Water absorption, 24 h, % | 0.1–0.7 | 0.3–0.7 | 0.1–0.2 | |
| Tensile strength, MPa | 48–110 | 80–110 | ||
| Elongation at break, % | 1.6–2 | |||
| Tensile modulus, GPa | 10–12.5 | |||
| Flexural strength, MPa | 90–120 | 150–210 | 210–420 | 200 |
| Flexural modulus, GPa | 6–8 | 7.5–14 | 11–15 | 11–16 |
| HDT A (1.8 MPa), °C | >200 | >200 | >200 | >200 |
| Glass transition, °C | 140–210 | |||
| Specific heat, cal/g/°C | 0.26–0.34 | 0.26–0.34 | 0.26–0.34 | |
| Coefficient thermal expansion, 10−5/°C | 2 | 1.6–2.3 | 2 | 2 |
| Surface resistivity | 1012 | 1011 | 1012 | 1011 |
| Volume resistivity, ohm cm | 1014 | 1014 | 1014 | 1014 |
| Dielectric constant | 4 | |||
| Dielectric rigidity, kV/mm | 10–15 | 10–15 | 10–15 | 10–15 |
| Oxygen index, % | 22–24 | 22–27 | ||
| UL94 rating | HB to V2 | HB to V2 | ||
| Special Grades | ||||
| Glass Fiber, % Level | Unknown UD | 20–33, Foamed | Unknown, Fire Retardant | 25 Fire Retardant, Halogen Free |
| Density, g/cm3 | 1.8 | 1.3–1.43 | 1.84–2.1 | 1.95 |
| Shrinkage, % | −0.03–0.3 | −0.08–0.12 | −0.04–0.1 | 0.04 |
| Water absorption, 24 h, % | 0.5–0.7 | 0.2–0.3 | 0.1–0.2 | |
| Tensile strength, MPa | 92–285 | 40–71 | 51 | 40–50 |
| Flexural strength, MPa | 230–750 | 60–150 | 130–200 | 120 |
| Flexural modulus, GPa | 14–22 | 4.5–12 | 11 | 5.5 |
| HDT A (1.8 MPa), °C | >200 | >200 | >200 | >200 |
| Specific heat, cal/g/°C | 0.26–0.34 | 0.26–0.34 | 0.26–0.34 | |
| Coefficient thermal expansion, 10−5/°C | 1.1–1.5 | 1.7–2 | 2 | 2 |
| Surface resistivity | 1011 | 1011 | 1011 | 1012 |
| Volume resistivity, ohm cm | 1014 | 1014 | 1014 | 1014 |
| Dielectric constant | 4 | 4 | 4 | |
| Dielectric rigidity, kV/mm | 10–15 | 10–15 | 10–15 | |
| Oxygen index, % | 22 | 22 | 50–78 | 45–50 |
| UL94 rating | HB | HB | V0 | V0 |
Table 5.42
Other Glass Fiber-Reinforced Unsaturated Polyesters: Examples of Composite Properties
| Matrix | Unsaturated Polyester | Unsaturated Polyester | Acrylate Urethane |
| Reinforcement | Mat | Mat | Mat |
| Glass fiber, % level | 20–30 | 40–50 | 33 |
| Density, g/cm3 | 1.3–1.5 | 1.5–1.75 | |
| Tensile strength, MPa | 65–90 | 130–170 | 112–131 |
| Elongation at break, % | 2 | 2 | 2–3 |
| Tensile modulus, GPa | 5–7 | 9–10 | 6–7 |
| Flexural strength, MPa | 115–145 | 180–220 | 206–218 |
| Flexural modulus, GPa | 5–7 | 9–11 | 6–7 |
| Compression strength, MPa | 110–135 | 165–200 | 145–174 |
| Compression modulus, GPa | 5–6 | ||
| Interlaminar shear strength, MPa | 24 | ||
| Notched impact D 256, J/m | 1410–1420 | ||
| HDT A (1.8 MPa), °C | >200 | >200 | >200 |
| Thermal conductivity, W/m K | 0.14–0.19 | 0.2–0.3 | |
| Coefficient thermal expansion, 10−5/°C | 3–4 | 2–2.4 |
| Matrix | Unsaturated Polyester | Unsaturated Polyester | Unsaturated Polyester | Acrylate Urethane |
| Reinforcement | Fabric | Fabric | Roving | Roving |
| Glass Fiber, % Level | 40–50 | 50–60 | 70–80 | 50 |
| Density, g/cm3 | 1.5–1.75 | 1.6–1.85 | 1.9–2.1 | |
| Tensile strength, MPa | 200–240 | 240–275 | 400–800 | 260–300 |
| Elongation at break, % | 2 | 2 | 2 | 1.6–2 |
| Tensile modulus, GPa | 10–14 | 14–18 | 21–26 | 17–20 |
| Flexural strength, MPa | 220–260 | 260–300 | 400–500 | 380–410 |
| Flexural modulus, GPa | 10–14 | 14–18 | 10–12 | |
| Compression strength, MPa | 150–180 | 180–200 | 220–240 | |
| Compression modulus, GPa | 13 | |||
| Interlaminar shear strength, MPa | 28–29 | |||
| Notched impact D 256, J/m | 1300–1470 | |||
| HDT A (1.8 MPa), °C | >200 | >200 | >200 | >200 |
| Thermal conductivity, W/m K | 0.19–0.25 | 0.25–0.31 | 0.37–0.41 | |
| Coefficient thermal expansion, 10−5/°C | 1.8–2.2 | 1.6–1.8 | 1.2–1.4 |
As previously said, renewable UPs are claimed having properties and characteristics of the same order as homologous fossil UPs and can be processed by clients’ equipment without the need for any drastic adjustments. The following information deals with general properties of fossil UPs and, of course, some properties of renewable grades can be different.
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