New Low Cost Resins Systems

The objective of this proposal is to develop a new and affordable resin that is curable and has a low viscosity at ambient temperature when used in the fabrication of fiberglass reinforced composite articles. The article, a 48”x48”x0.25” fiberglass fabric (24 ounces per square yard), will be subjected to a room corner test by the Navy as a proof of concept and validation of the superiority of the newly developed resin. The Problem Many have tried to accomplish the objective of developing an affordable, low viscosity resin that is curable at ambient temperature in the past. Although Derakane® 510A, the workhorse of the industry, meets almost all the requirements at ambient temperature; it has a very short pot-life as well as a short time to ignition when subjected to flame. The presence of styrene and other suspect carcinogens as well as the high heat release of the cured laminate make it unsuitable for the Navy’s present and future usage. The solution to this problem is clear, development of an affordable, lower viscosity, non-carcinogenic, non-toxic replacement for phenolic resins and halogenated vinyl esters, specifically Derakane® 510A must be achieved. The composite panels produced from this new resin are expected to meet the time to ignition, low heat release and non-smoking requirements set forth by the Navy. This resin will be superior to Derakane® 510A in physical, thermal and rheological properties, as well as flame and chemical resistance. The Opportunity It has been shown that a thermoset system based on bisphenol C when properly processed will meet and exceed most fire or flame resistance requirements. However, there are associated processing limitations to the Cyanation of bisphenol C.