Initial Development of Composite Repair Resins With Low Hazardous Air Pollutant Contents

Report No. ARL-TR-4667
Authors: John J. La Scala; Scott Bingham; Kevin S. Andrews; James M. Sands; Giuseppe R. Palmese
Date/Pages: December 2008; 32 pages
Abstract: Unsaturated polyester-based repair resins, such as Bondo, are widely used for automotive repair, marine repair, sporting equipment repair, and household repair of metal, composites, plastics, and wood. Commercial repair resins usually contain 10 to 40 weight-percent styrene, which is a hazardous air pollutant (HAP). Reducing HAPs in Army materials has become a high priority because of Environmental Protection Agency regulations, including the Defense Land Systems for Miscellaneous Equipment National Emissions Standard for Hazardous Air Pollutants (NESHAP) and the Reinforced Plastic Composites NESHAP. Fortunately, nonvolatile fatty acid monomers can be used to replace the styrene in these repair resins. Fatty acid monomers were formulated with vinyl ester or unsaturated polyester monomers to match the glass transition temperature of commercial repair resins. Various inorganic fillers were incorporated to match the rheological and mechanical properties of commercial repair resins. These resins have zero to low HAP contents and therefore are well within emissions regulations and reduce toxicity effects on workers.
Distribution: Approved for public release
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Last Update / Reviewed: December 1, 2008