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US4347331A
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Foamed, low density, highly extended unsaturated polyester resin syrup composition, a shaped article comprised of the composition and a process for preparing such article
Assignee: TANNER CHEMICALS Inc
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Filing: 1981-07-09
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Granted: 1982-08-31
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Expires: 2001-07-09
Abstract
Abstract A foamed, low density, highly extended, polymerized unsaturated polyester resin product which exhibits excellent fire, strength and insulative properties. The product is formed by combining a first component comprised of unsaturated polyester resin syrup, reactive, non-reinforcing, extender material capable of providing a blowing agent nd selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof and, optionally, non-reactive, non-reinforcing extender material with a second component comprised of an aqueous solution of aluminum hydroxie chloride and, optionally, non-reactive, non-reinforcing, extender material. When the two components are combined as a composition mixture, the reactive, non-reinforcing, extender material and the aluminum hydroxie chloride solution react to provide a blowing agent and to form a solid product which chemically binds the water originally present. If desired, a reinforcing filler material can be incorporated into the composition. A wide variety of shaped articles can be formed from the composition.
Inventors
- 👤 James M. Self
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 03:38
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0066; C08J9/04; C08J9/06; C08J9/08; C08J2367/00; C08J2367/06
Claims Analysis
Total Claims: 38
Claim 1
Independent Claim
115 words
A foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product comprising: (a) polymerized unsaturated polyester resin syrup; and (b) the reaction product of aqueous aluminum hydroxie chloride solution and reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof, wherein the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 2
Dependent Claim
115 words
A foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product comprising: (a) polymerized unsaturated polyester resin syrup; and (b) the reaction product of aqueous aluminum hydroxie chloride solution and reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof, wherein the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 3
Dependent Claim
89 words
The product of claim 1 wherein the composition includes a non-reactive, non-reinforcing extender material and wherein the original weight ratio of the sum of (i) the reactive, non-reinforcing extender material, (ii) the non-reactive, non-reinforcing, extender material, and (iii) the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the non-reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 4
Dependent Claim
80 words
The product of claim 2 wherein the original weight ratio of the sum of (i) the reactive, non-reinforcing extender, (ii) the non-reactive, non-reinforcing, extender material, and (iii) the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 5.0:1.0 and the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the non-reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is from about 3.0:1.0 to about 1.0:1.0.
Claim 5
Dependent Claim
14 words
The product of claim 3 wherein the non-reactive, non-reinforcing, extender material is aluminum trihydrate.
Claim 6
Dependent Claim
20 words
The product of claim 1 including from about 5 to about 25%, by total weight, of a reinforcing filler material.
Claim 7
Dependent Claim
13 words
The product of claim 5 wherein the reinforcing filler material comprises glass fibers.
Claim 8
Dependent Claim
45 words
The product of claim 6 wherein the reactive, non-reinforcing, extender material is selected from the group consisting of carbonate compounds of Groups IA metals, carbonate compounds of Group IIA metals, bicarbonate compounds of Group IA metals, bicarbonate compounds of Group IIA metals and mixtures thereof.
Claim 9
Dependent Claim
45 words
The product of claim 1 wherein the reactive, non-reinforcing, extender material is selected from the group consisting of carbonate compounds of Group IA metals, carbonate compounds of Group IIA metals, bicarbonate compounds of Group IA metals, bicarbonate compounds of Group IIA metals and mixtures thereof.
Claim 10
Dependent Claim
20 words
A shaped article comprised of the foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product of claim 1.
Claim 11
Dependent Claim
20 words
A shaped article comprised of the foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product of claim 2.
Claim 12
Dependent Claim
125 words
A highly extended, unsaturated polyester resin syrup composition mixture capable of forming a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, said composition mixture comprising: (a) unsaturated polyester resin syrup; (b) aqueous aluminum hydroxie chloride solution; and (c) reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof, wherein the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 13
Dependent Claim
125 words
A highly extended, unsaturated polyester resin syrup composition mixture capable of forming a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, said composition mixture comprising: (a) unsaturated polyester resin syrup; (b) aqueous aluminum hydroxie chloride solution; and (c) reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof, wherein the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 14
Dependent Claim
87 words
The composition mixture of claim 11 including a non-reactive, non-reinforcing, extender material and wherein the original weight ratio of the sum of (i) the reactive, non-reinforcing extender material, (ii) the non-reactive, non-reinforcing, extender material, and (iii) the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the non-reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 15
Dependent Claim
21 words
The composition mixture of claim 12 including from about 5 to about 25%, by total weight of a reinforcing filler material.
Claim 16
Dependent Claim
46 words
The composition mixture of claim 13 wherein the reactive, non-reinforcing extender material is selected from the group consisting of carbonate compounds of Group IA metals, carbonate compounds of Group IIA metals, bicarbonate compounds of Group IA metals, bicarbonate compounds of Group IIA metals and mixtures thereof.
Claim 17
Dependent Claim
38 words
The composition mixture of claim 14 wherein the reactive, non-reinforcing, extender material is selected from the group consisting of sodium carbonate, potassium carbonate, magnesium carbonate, calcium carbonate, sodium bicarbonate, potassium bicarbonate, calcium bicarbonate, magnesium bicarbonate and mixtures thereof.
Claim 18
Dependent Claim
98 words
A highly extended, unsaturated polyester resin syrup composition mixture capable of forming a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, said composition mixture comprising: (a) from about 12 to about 33 parts by weight of unsaturated polyester resin syrup; (b) from about 4 to about 30 parts by weight of aqueous aluminum hydroxie chloride solution; and (c) from about 15 to about 50 parts by weight of reactive non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof.
Claim 19
Dependent Claim
98 words
A highly extended, unsaturated polyester resin syrup composition mixture capable of forming a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, said composition mixture comprising: (a) from about 12 to about 33 parts by weight of unsaturated polyester resin syrup; (b) from about 4 to about 30 parts by weight of aqueous aluminum hydroxie chloride solution; and (c) from about 15 to about 50 parts by weight of reactive non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof.
Claim 20
Dependent Claim
20 words
The composition mixture of claim 16 including from about 15 to about 50%, by weight, of non-reactive, non-reinforcing, extender material.
Claim 21
Dependent Claim
90 words
The composition mixture of claim 17 comprising: (a) from about 15 to about 30 parts by weight of unsaturated polyester resin syrup; (b) from about 5 to about 15 parts by weight of aqueous aluminum hydroxie chloride solution; (c) from about 20 to about 50 parts by weight of reactive non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic compound, inorganic bicarbonate compounds and mixtures thereof; and (d) from about 20 to about 50%, by weight, of non-reactive, non-reinforcing, extender material.
Claim 22
Dependent Claim
21 words
The composition mixture of claim 18 including from about 5 to about 25%, by total weight, of a reinforcing filler material.
Claim 23
Dependent Claim
14 words
The composition mixture of claim 19 wherein the reinforcing filler material comprises glass fibers.
Claim 24
Dependent Claim
45 words
The composition mixture of claim 20 wherein the reactive, non-reinforcing, extender material selected from the group consisting of carbonate compounds of Group IA metals, carbonate compounds of Group IIA metals, bicarbonate compounds of Group IA metals, bicarbonate compounds of Group IIA metals and mixtures thereof.
Claim 25
Dependent Claim
175 words
A process for preparing a shaped article comprising: (a) preparing a first component comprising (i) unsaturated polyester resin syrup, and (ii) reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof; (b) preparing a second component comprising (i) an aqueous solution containing from about 25 to about 65%, by weight, of aluminum hydroxie chloride. (c) mixing the first and second component to form a composition mixture; (d) shaping the composition mixture into the configuration of the article; and (e) curing the composition mixture to form a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, wherein the composition mixture has an original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup of from about 0.5:1.0 to about 10.0:1.0 and an original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution of less than about 5.0:1.0.
Claim 26
Dependent Claim
175 words
A process for preparing a shaped article comprising: (a) preparing a first component comprising (i) unsaturated polyester resin syrup, and (ii) reactive, non-reinforcing, extender material capable of providing a blowing agent which is selected from the group consisting of inorganic carbonate compounds, inorganic bicarbonate compounds and mixtures thereof; (b) preparing a second component comprising (i) an aqueous solution containing from about 25 to about 65%, by weight, of aluminum hydroxie chloride. (c) mixing the first and second component to form a composition mixture; (d) shaping the composition mixture into the configuration of the article; and (e) curing the composition mixture to form a foamed, low density, highly extended, polymerized unsaturated polyester resin syrup product, wherein the composition mixture has an original weight ratio of the sum of the reactive, non-reinforcing, extender material and the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup of from about 0.5:1.0 to about 10.0:1.0 and an original weight ratio of the reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution of less than about 5.0:1.0.
Claim 27
Dependent Claim
94 words
The process of claim 22 wherein at least the second component includes non-reactive, non-reinforcing, extender material whereby the composition mixture has an original weight ratio of the sum of (i) the non-reactive, non-reinforcing, extender material, (ii) the non-reactive, non-reinforcing, extender material, and (iii) the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 10.0:1.0 and the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the non-reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is less than about 5.0:1.0.
Claim 28
Dependent Claim
24 words
The process of claim 23 wherein the composition mixture includes from about 5 to about 25%, by total weight, of a reinforcing filler material.
Claim 29
Dependent Claim
13 words
The process of claim 24 wherein the reinforcing filler material comprises glass fibers.
Claim 30
Dependent Claim
17 words
The process of claim 24 wherein the viscosities of the first and second components are approximately equal.
Claim 31
Dependent Claim
81 words
The process of claim 24 wherein the original weight ratio of the sum of (i) the reactive, non-reinforcing extender material, (ii) the non-reactive, non-reinforcing, extender material, and (iii) the aqueous aluminum hydroxie chloride solution to the unsaturated polyester resin syrup is from about 0.5:1.0 to about 5.0:1.0 and the original weight ratio of the sum of the reactive, non-reinforcing, extender material and the non-reactive, non-reinforcing, extender material to the aqueous aluminum hydroxie chloride solution is from about 3.0:1.0 to about 1.0:1.0.
Claim 32
Dependent Claim
54 words
The process of claim 27 wherein the reactive, non-reinforcing, extender material is selected from the group consisting of carbonate compounds of Group IA metals, carbonate compounds of Group IIA metals, bicarbonate compounds of Group IA metals, bicarbonate compounds of Group IIA metals and mixtures thereof and the non-reactive, non-reinforcing, extender material is aluminum trihydrate.
Claim 33
Dependent Claim
68 words
A two-component, storageable, easily mixed system for producing a foamed, low density, highly extended unsaturated polyester resin product comprising: as a resin-containing component: Unsaturated polyester resin syrup and finely divided particulate inorganic carbonate or bicarbonate; and as the other component: Aqueous aluminum hydroxie chloride and finely divided particulate non-reactive extender; said unsaturated polyester resin syrup comprising from 33 to 67 percent of the weight of the two components.
Claim 34
Dependent Claim
68 words
A two-component, storageable, easily mixed system for producing a foamed, low density, highly extended unsaturated polyester resin product comprising: as a resin-containing component: Unsaturated polyester resin syrup and finely divided particulate inorganic carbonate or bicarbonate; and as the other component: Aqueous aluminum hydroxie chloride and finely divided particulate non-reactive extender; said unsaturated polyester resin syrup comprising from 33 to 67 percent of the weight of the two components.
Claim 35
Dependent Claim
22 words
The composition of claim 29 wherein the finely divided particulate inorganic carbonate or bicarbonate has a particle size less than 3 microns.
Claim 36
Dependent Claim
13 words
The composition of claim 29 wherein the said resin-containing component is milled together.
Claim 37
Dependent Claim
20 words
The composition of claim 29 wherein the said other component contains a catalyst for polymerization of unsaturated polyester resin syrup.
Claim 38
Dependent Claim
12 words
The composition of claim 29 wherein the said other component contains surfactant.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1985-08-30 | 1986-03-01 | 1986-08-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-08-30 | 1990-03-01 | 1990-08-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-08-30 | 1994-03-01 | 1994-08-31 | $7700.00 | Window Closed / Lapsed |