The Dow Chemical Company

Patrick H Martin

Theodore L Parker

Paul G Schrader

Ritchie A Wessling

Stephen E Bales

Peter K Kim

James L Dunn, Jr

John K Ward

Alvin W Baker

Robert E Hefner, Jr

Horst G Langer

Terrence L Caskey

Gregory A Stevens

Kent D Campbell

Robert R Stringham

Robert DeVellis

Robin A Withers

Stephen L Michaels

This invention relates to a low heat release, low density, fiber-reinforced composite comprising a matrix comprising a thermoplastic polymer selected from the group consisting of polyarylsulfone, polyethersulfone, polyetheretherketone, polyetherketoneketone, a copolycarbonate of 4,4'-thiodiphenol and at least one member of the group consisting of bisphenol A, 9,9-bis(4-hydroxyphenyl) fluorene, and 1,1-bis-(4-hydroxyphenyl)-1-phenyl ethane, a copolycarbonate of bisphenol A and 9,9-bis(4-hydroxyphenyl) fluorene, 1,1-bis(4-hydroxyphenyl)-1-phenyl ethane polycarbonate, bisphenol A polycarbonate, and polyetherimide, and from about 10 to about 70 percent by weight of the composite of randomly oriented reinforcing fibers, less than 0.5 inch in length, distributed throughout the matrix. The matrix has a void volume of from about 20 to about 90 percent by volume. The composite has a thermoplastic skin layer on each of the major surfaces thereof. A process for making the composite is also disclosed.

Low heat release polymeric composites

This invention relates to a low heat release, low density, fiber-reinforced composite comprising a matrix comprising a thermoplastic polymer selected from the group consisting of polyarylsulfone, polyethersulfone, polyetheretherketone, polyetherketoneketone, a copolycarbonate of 4,4'-thiodiphenol and at least one member of the group consisting of bisphenol A, 9,9-bis(4-hydroxyphenyl)fluorene, and 1,1-bis(4-hydroxyphenyl)-1-phenyl ethane, a copolycarbonate of bisphenol A and 9,9-bis(4-hydroxyphenyl)fluorene, 1,1-bis(4-hydroxyphenyl)-1-phenyl ethane polycarbonate, bisphenol A polycarbonate, and polyetherimide, and from about 10 to about 70 percent by weight of the composite of randomly oriented reinforcing fibers, less than 0.5 inch in length, distributed throughout the matrix. The matrix has a void volume of from about 20 to about 90 percent by volume. The composite has a thermoplastic skin layer on each of the major surfaces thereof. A process for making the composite is also disclosed.

Vinyl ester/styrene mixtures are flexibilized by addition thereto of minor amounts of urethanes which (1) comprise at least one polyglycol moiety and two urethane groups and are terminated by vinyl-reactive end groups, and (2) form a dispersed second phase in the cured mixture. The flexibilized compositions otherwise largely retain the characteristic properties of the unflexibilized mixtures.

Toughening of cured vinyl ester resins by inclusion in the uncured

Liquid epoxy resins can be converted to non-sintering, relatively low equivalent weight, flakable solid opoxides having relatively low melt viscosities by advancing the resins with 1,1,1-tri(hydroxyphenyl)alkanes or -alkenes in which the alkane or alkene moiety contains from 1 to 11 carbons.

High functionality, low melt viscosity, flakable solid epoxy resin with

Liquid epoxy resins can be converted to non-sintering, relatively low equivalent weight, flakable solid epoxides having relatively low melt viscosities by advancing the resins with 1,1,1-tri(hydroxyphenyl)alkanes or -alkenes in which the alkane or alkene moiety contains from 1 to 11 carbons.

A composition of matter comprising either at least about 80 wt. % of a monomeric or oligomeric polyglycidyl ether of tris(hydroxyphenyl)alkanes;

High temperature epoxy resin composition with reduced viscosity

Polyester and polyesteramide alkyds containing no polycycloalkenyl end groups, in admixture with non-resinous vinyl monomers, are flexibilized by inclusion in the mixtures of about 1 to 20 parts by weight of a polyglycol moiety-comprising, vinyl reactive, urethane oligomer per hundred parts of the alkyd.

Compositions of unsaturated polyesters or polyesteramides and efficient

The hydrolyzable 'chloride' contents of epoxides prepared from epihalohydrins and phenols, aromatic amines or &gt;N-H group-containing heterocycles are considerably reduced by a second dehydrochlorination step which comprises dissolving the epoxide in a solvent having the characteristics of a 1:1 by weight blend of methylethylketone and toluene and treating it with amounts of base and water ensuring a final base concentration equivalent to that of about 4 wt. % aqueous NaOH.

Method of preparing epoxy resins having low hydrolyzable chloride

The invention is an improved process for preparing epoxy resin/phosphoric acid reaction products having high enough phosphomonoester contents to be water-dispersible (as base salts) and low enough free acid contents to yield water-resistant cured coatings. The phosphoric acid is provided as an acid source material deriveable by the reaction of a hydroxylic P--OH functionality-limiting agent (blocking agent) with phosphoric anhydride as such or as a reaction product thereof with less than six molecular proportions of water. A resin solvent, which may also function as the P--OH blocking agent but otherwise is inert and acceptable as part of the final coating resin formulation, is employed as the reaction medium. The epoxide/acid reaction is allowed to proceed, effectively in the absence of water, until the content in the reaction mixture of species indistinguishable from H.sub.3 PO.sub.4 by base-titration has dropped to a minimum. Then enough water to hydrolyze the phosphopolyesters present is added and the hydrolysis is carried out, thereby cleaving the ester groups formed from the blocking agent and generating the P--OH groups needed for salification. The disclosed resin compositions are of particular utility for coating the interiors of beverage cans.

Process for epoxy phosphate coating resins

Solutions of amine-salified phosphoresins and the free amine in organic solvents are converted to stable dispersions of the salified resins in water by steam stripping under conditions such that at least part of the water is provided as condensed steam.

Method of converting resin solution to aqueous dispersion

Triethylamine and water are simultaneously removed from solutions in organic solvents, by liquid/liquid extraction with concentrated aqueous solutions of (C.sub.2 H.sub.5).sub.3 N.H.sub.3 PO.sub.4 which preferably contain free phosphoric acid as well. Upon heating of the resulting extract, the water and amine taken up are boiled off and the extractant regenerated. The method is of particular value in the preparation of aqueous coating compositions comprising reaction products of polyether epoxides and H.sub.3 PO.sub.4 in organic media. The reaction product is salified with triethylamine in excess, in the presence of added water. The organic solvent is boiled off, together with the excess amine and some of the water, to form an aqueous dispersion of the salified product and a distillate which can be processed by the method of the invention. The recovered solvent, water and amine may be recycled.

Use of aqueous triethylamine/phosphoric acid salt solutions to extract

Substrates are coated with relatively high molecular weight epoxy resin coatings by applying to a substrate a mixture comprising

Process for coating substrates with high molecular weight epoxy resins

Hydrophobic, thermoset resins having highly desirable properties in coatings applications can be prepared from novel, water-thinnable, base-neutralized, acidic reaction products of orthophosphoric acid with hydrophobic, nominally-difunctional polyether epoxide resins having average epoxide equivalent weights (EEW) of from about 172 to about 5500. The phosphate groups in these products, when formed with fugitive bases, are thermally decomposable to yield resins which are not rapidly self-converting as such but are rapidly heat convertible in admixture with any of several types of curing agents. The functional groups responsible for water solubilization are utilized (and reacted out) in curing of the resins. The invention provides a method of utilizing hydrophobic, high performance polyether epoxide type polymers in aqueous coating systems having the ability to wet metal surfaces.

Method of water-solubilizing high performance polyether epoxide resins,

An apparatus for applying a coating composition to an article and drying the solvent from the so applied coating prior to introduction of the coated article into the ambient atmosphere, comprising a housing or chamber in a generally 'J' shape in which the small upwardly turned portion of the 'J' defines an inner compartment isolated from the ambient atmosphere by the 'J' configuration when the chamber is filled with a volatile solvent vapor and the inner compartment vapors are at an elevated temperature with respect to the remainder of the vapors in the chamber. The apparatus is provided with condensing means at the ambient atmosphere entrance and exit, a source of solvent vapors which may be integral with the chamber, and a means to introduce heat to the vapors and articles when they are in the inner compartment. The apparatus also includes article handling and moving means for transporting articles to be coated into, through and out of the apparatus as well as spray or dip means to apply the coating to the article.

Apparatus for coating surfaces

Phosphoric acid is reacted with mono- or polyfunctional epoxides containing methyol or alkoxymethyl groups, to provide resins which are curable simply by heating and contain as much as about 30 weight percent of phosphoric acid. Improved flame retardancy and water resistance are imparted to structural foams by impregnating them with these resins and curing in-situ.

Growing community of inventors

Danville, CA, United States of America

Patrick H Martin