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Additives for CompositesAdditives for Composites

A Sustainable Approach to Modern Coating Technology

Patcham (FZC) is a well-established manufacturer of specialty addi�ves headquartered in the United Arab Emirates. Since its incep�on, Patcham has steadily grown into a leading supplier of addi�ves for Composites, Paints & Coa�ngs, Inks and PVC.

The Company’s Pat-Add range of addi�ves includes we�ng & dispersing agents, air release agents, levelling agents and rheology modifiers. With focus on environmental sustainability, the company manufactures products using green raw materials where possible. All our products are APEO and formaldehyde free and several have low or no VOC.

The PATcure series of products includes a full range of accelerators in stable, easy to use liquid form. PATcure accelerators are available in various metal concentra�ons and carriers.

Patcham has built a strong manufacturing and R & D infrastructure that enables a rapid transi�on from concept to products. The company has strategically located technical service laboratories, offices and representa�ves around the world to provide efficient customer service. In addi�on, a well developed robust network enables it to deliver its products and services to customers around the globe with minimal lead �me.

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Table of Contents

Introduc�on

Manufacturing Processes of Thermoset Composites

Patcham Addi�ves

Air Release Agents

Leveling Agents

Rheology Modifiers

We�ng and An�-Se�ling Agents

We�ng and Dispersing Agents for Colorants

Patcham UPR Accelerators

1

2

3

6

8

11

13

15

1w w w . p a t c h a m l t d . c o m

The innova�on in composite technology today provides an alterna�ve to conven�onal structural materials such as concrete, steel, aluminum and wood. A combina�on of proper�es like high strength, low weight, non-corrosive, and electrical insula�on make composites an ideal material for structural purpose.

Composites which is also known as Fiber-Reinforced Polymer (FRP) composites are made from a resin matrix that is reinforced with an engineered, man-made or natural fiber or other reinforcing material. The fiber provides strengths and s�ffness while more flexible matrix (resin) provides shape and protec�on. Composites may also con-tain fillers, addi�ves, core materials or surface finishes designed to improve the manu-facturing process, appearance and performance of the final product.

Introduction

Commonly used Raw Materials for Composites

MATRIX(Resin)

Provides strength and s�ffness (glass, carbon, aramid, basalt, natural fibers)

Protects and transfersload between fibers (polyester, epoxy,vinyl ester, others)

Creates a material with a�ributessuperior to either component alone

FIBER FIBER COMPOSITE MATRIX

+ =

Pigments/Fillers• ATH• Kaolin Clay• White Pigment• Colored Pigments

Resins• Unsaturated

Polyester• Vinyl Esters• Epoxy Resins• Polyurethane

Addi�ves•••

•

Reinforcements••••

Air Release AgentsLeveling AgentsWe�ng andDispersing AgentsRheology Modifiers

Glass FibersCarbon FibersAramid FibersNatural Fibers


A. Open Molding Process Hand Lay-up Spray-up Filament Winding

B. Closed Molding Vacuum Bag Molding Vacuum Infusion Processing Resin Transfer Molding Compression Molding Pultrusion Reinforced Reac�on Injec�on Molding Centrifugal Cas�ng Con�nuous Lamina�on

C. Cast Open Molding Gel Coated Cultured Stone Molding Solid Surface Molding

Manufacturing Processes of Thermoset Composites


Entrapped and stabilized air remains as micro- or macro-foam in the system a�er curing and acts as source of porosity, weak points, insufficient fiber we�ng and poor mechanical proper�es in composite materials.

The introduc�on of Patcham’s air release agents helps to release the entrapped foams even from highly viscous systems.

Air Release Agents

Air release agents , emulsified into fine droplets, penetrate into the foam lamella and disrupt the foam stabilizing surfactant layer

Mechanism

Lower the elas�city of the lamella for easy destabiliza�on

Destabiliza�on leading to rupture of the lamella

Spread rapidly across the disrupted surfactant layer

Air release mechanism


Pat-Add AF 75

Polymeric air release agent for UPR systems, gelcoats Demonstrates rapid de-aera�on

Wide compa�bility

Func�ons at low dosages

For pigmented and highly filled systems

Pat-Add AF 75 Performs efficiently even at lower dosage

Table 1. Formula�on of clear laminates

Raw Materials

Unsaturated polyester resin

Step 1:Mix RM 1,2&3 in a clean glass bo�le at 2000 RPM for 5 min & rate defoaming behaviorStep 2:A�er comple�on of defoaming add hardener & mix well For 1 minStep 3:Pour into mold & rate defoaming during cure.

Co (Accelerator)

Pat-Add AF 75/Reference

Hardener (MEKP)*

Total

100.001

2

3

4

1.50

0.15

2.00

103.65

phrRM No. Procedure

* Methyl Ethyl Ketone Peroxide

Performance in UPR White Cast

Blank Pat-Add AF 75 (0.15%)

BlankPat-Add AF 75

(0.10%)Pat-Add AF 75

(0.15%)Reference

(0.30%)Reference

(0.30%)


Pat-Add AF 76

Silicone-free, polymeric de-aerator and defoamer for UPR systems, as well as PUR and epoxy systems

Demonstrates rapid de-aera�on and excellent compa�bility in a wide variety of resin based formula�ons

Maintains clarity without altering film proper�es of laminates or composites

Highly recommended for transparent systems

1

2

3

4

RM No.

Table 2. Formula�on of clear laminates

Raw Material

UPR Step 1:Mix RM 1,2&3 in a clean glass bo�le at 2000 RPM for 5 min & rate defoaming proper�es.Step 2:A�er comple�on of defoaming add hardener & mix well for 1min .Step 3:Pour in to mold & rate defoaming during cure.

PATcure 2716

Pat-Add 76/Reference

Hardener (MEKP)*


Total

100.00

0.25

0.30

1.50

102.05

phr Process Details

Performance test in UPR Clear Laminates

Haze Value22.3 2.9 30.6

Blank Pat-Add AF 76 (0.30%) Reference (0.30)


Leveling agents are added to systems to lower their surface tension and to form a defect free surface. The general mechanisms of performance is explained in the below figure.

Leveling Agents

Performance of Leveling Agent

Addi�on of small quan�ty of leveling agent lowers surface tensionof the liquid.


Pat-Add LE 1065

Table 4. Formula�on of UPR White Topcoat

Raw MaterialsRM No.

Ortho UPR1

2

3

4

5

Step 1:Add RM 1 to 4 to a clean vessel and start mixing at 3000 RPM for 30min then allow the sample to rest for 1HR

Step 2:Add Hardener and mix well for 1min and apply to glass panel and observe we�ng behavior

TiO2

PATcure 2716

Pat-Add LE 1065

Hardener (MEKP)*

100.00

15.00

0.25

0.60

Total 117.85

2.00

phr Process Details

Table 3. Proper�es of UPR White Topcoat

Parameters

Gloss (20⁰, 60⁰)

Spreadability/We�ng

Cratering/Incompa�bility

90, 97

Poor

Severe

90, 97

Excellent

Absent

Reference Pat-Add LE 1065

Appearance of UPR White Topcoat

Efficient surface tension reducer

Effec�ve at very low concentra�ons

Promotes film leveling and avoids forma�on of craters

Suitable for pigmented as well as clear systems



Rheology ModifiersPat-Add Rheol 253

A liquid rheology modifier for UPR systems

Demonstrates excellent compa�bili-ty in a wide variety of systems

Does not require any chemical ac�va�on

Boosts thixotropic behavior and reduces risk of sedimenta�on in UPR gel coat systems

Interac�on of Pat-Add Rheol 253 with Fumed Silica

Fumed silica and clay–based addi�ves are used as solid thixotropes to control UPR formula�ons. Hydro-gen bonding creates a three-dimen-sional network, resul�ng in pseudo plas�c and thixotropic flow behavior.

To enhance and boost the three dimensional structure, liquid rheology modifier can be added to increase thixotropy or reduce the loading of clays and fumed silica.


Table 5. Formula�on of UPR Gel Coat

Raw Materials

RM No.

UPR Resin1

2

3

4

5

6

7

86.72

Pat-Add Rheol 253

0.13

Pigment R 902 7.8

Aerosil 200 2

Cobalt 1% drier 2.55

Pat-Add AF 75 0.5Pat-Add LE 1065 0.3

Total 100.00

Parts by weight

Process Details

Viscosity profile of UPR Gel coat

Sag Resistance of Gel Coat

Pat-Add Rheol 253 Ini�al

5 RPM0

5000

10000

15000

20000

25000

30000

35000

40000

Visc

osity

, cps

33700

27100

32300

25150

10 RPM

18800

14900

18400

13700

20 RPM

11120

9300

10700

9000

50 RPM

5810

5170

5500

5050

100 RPM

3770

3520

3730

3470

Pat-Add Rheol 253 A�er Stability

Reference A�er Stability

Reference Ini�al

Step 1:Add RM 1,2 and mix in the vessel at 500 RPM Step2:Add RM 3,4 and mix at 3000 RPM for 30 minStep 3:Add RM 5,6,7 and mix for 5min at 500RPM, complete batch process and check ini�al viscosity using Brookfield Viscometer at various RPM.Repeat the same viscosity reading process a�er 12 hrs and a�er 24 hrs.

Reference Pat-Add Rheol 253

Pigments/Fillers

Pigments/Fillers

Pigments/Fillers

Polymeric W/D Agent


Without we�ng and dispersing addi�ves, pigments and fillers in a composite cannot be properly stabilized and once dispersed, would not remain evenly suspended in the mixture.

Addi�ves containing one or more pigment affinic groups providing strong adsorp�on on pigment surface.

Resin/solvent compa�ble chains pro-truding into the surrounding vehicle.

During processing of gelcoats or compos-ites the pigment agglomerates are broken down into smaller par�cles. The cohesive forces within a pigment agglomerate increase with decreasing par�cle size. The we�ng and dispersing agent has to enable we�ng of these par�cle surfaces, stabilize them and affirm a sa�sfactory performance of the composite.The we�ng and dispersing agents works on either of the following mechanism-

a) Steric stabiliza�onb) Electrosta�c repulsion

Dispersing and Wetting Steric Repulsion

Stabiliza�on increases with thickness of electrical double layer

Electrostatic repulsion

The Wetting and Dispersing Process

Dispersing and Wetting Agents

Chargesfrom thepigment& we�ngagent

Pigments/Fillers

---- - - - -

--

----

---

------- - - - -

--

+++ +

++

+

+++ + +

+

+

++

+

+

++


We�ng and dispersing addi�ve for dispersion of commonly used fillers such as Aluminum trihydroxide (ATH) and Calcium carbonate

Reduces compound viscosity for high filler loading

Provides an�-se�ling proper�es even at lower system viscosity

For spray lay-ups, hand lay-ups and cas�ng

Wetting and Anti-Settling Agent

Pat-Add DA 2702

Table 6. Formula�on of ATH/CaCO3 based slurry

Table 7. Proper�es of ATH/CaCO3 based slurry

Raw Materials

RM No.

Ortho UPR / ISO UPR 59.751

2

3

Pat-Add DA 2702/Reference

0.25

ATH/ CaCO3 40.00

Total 100.00

Percentweight

Process Details

Step 1: Add RM 1,2, in a clean vessel and mix well at 500 RPM for 5minStep 2: Gradually add RM 3 and mix well at 1500 RPM for 30 min and complete the batch process

Performance of Pat-Add DA 2702 in UPR

Proper�es

Ini�al Viscosity In KU 106.4 121.0A�er 24 hrs. Viscosity in KU 102.3 122.6

Degree ofSepera�on(Observa�on done a�er 24 hrs.)

No Separa�on

No Separa�on

Isophthalic UPRPat-AddDA 2702

Reference


Enables high loading of ATH and fillers

Strong reduc�on of viscosity and improves flow and leveling behav-ior of polyester cas�ng resin

Pat-Add DA 2709

Table 8. Tes�ng formula�on for We�ng Agent

Step 1:Add RM 1,2, in a clean vessel and mix well at 200 RPM for 5min Step 2:Gradually add RM 3, 4 and mix well at 500 RPM for 30 min and complete the batch process.

Viscosity at 60 phr ATH loading Viscosity at 160 phr ATH loading

Raw materialRM No.

ISO : Ortho Process Details

ISO UPR1

2

3

4

50:50 70:30

60 phr 160 phr

50:50 70:30

50 70 50 70

Ortho UPR 50 30 50 30

Pat-Add DA 2709 0.6 0.6 1 1

ATH (13-15 µm) 60 60 160 160Total 160.6 160.6 261 261

Does not affect curing characteris-�cs

For cultured marbles, onyx and polymer concrete cas�ng systems

Iso:Ortho 50:50Blank Pat-Add DA 2709

1100

1150

1200

1250

1300

1350

1400

1450

1500

Visc

osity

, cps

Iso:Ortho 70:30Blank Pat-Add DA 2709

130

140

150

160

170

180

190

Visc

osity

, poi

se

Iso:Ortho 50:50 Iso:Ortho 70:30

Wetting & Dispersing additive based on green chemistry


Being electroneutral gives be�er inter-ac�on with both acidic and alkaline pigments thus prevents floccula�on.

Wetting and Dispersing Agent

Pat-Add DA 895

Can be used for developing various colorants based on different resin-systems

Improves color strength

Allows high loading of pigments

Enhances stability

Gives be�er flow and low viscosity to the colorants

Pigments Addi�ve dosage

TiO2 and Inorganic Pigments

10 % on Oil Absorp�on value

Organic Pigments

30 - 50% on BET value

Carbon Black Pigments 30-50 % SOP

Stability of colorants50

40

30

20

10

0PW 6 R 902Ini�al viscosity A�er stability viscosity

Note: Viscosity checked by Brookfield CAP 2000 viscometer at 100 RPMusing Spindle no. 3

Sp. Black 4 PB 15:3

Visc

osity

Poi

se

Pat-Add DA 895 in Colorants

Applica�ons

Styrene freeUPR Colorants

Styrene basedUPR Colorants

Epoxy and Vinyl Ester Colorants

Solvent free andsolventbased epoxy

colorantsTable 9. Dosage recommenda�on for

Pat-Add DA 895

Solubility and Compa�bility of Pat-Add DA 895

Flow behavior RMPC in UPR Styrene free

PW 6 - 60% PBlk 7 - 15% PB 15:3 - 14%

Solvents Resins- Reac�ve Diluents- Acetate Solvents- Hydrocarbons

- Epoxy / Vinyl Ester Resins- Castor Oil- Unsaturated Polyester Resins


In UPR cas�ng , desired color could be achieved by adding a par�cular amount of colorant. RMPC with Pat-Add DA 895 displayed good color development in a precast UPR. Formula below is a typical example of precast.

Flooding and floa�ng are problems in many composite systems. If pigment concentra�on is uniform on the sur-face but not through the thickness of the film, one refers to ‘flooding’ (hori-zontal separa�on). If, however, concen-tra�on differences are visible across the surface of the paint film, one refers to ‘floa�ng’ (ver�cal separa�on).

UPR Colored Precast

2% RMPC Phthalo Blue 15:3 2% RMPC PBlk 7

RMPC in UPR Styrene free Gel coat

Flood free brush applica�on

Floa�on free Gelcoat

Ini�al A�er 24 hr Ini�al A�er 24 hr

Raw material Phr

Isophthalic Resin 100.0Pat-Add LE 1065 0.30Pat-Add AF 75 0.50

Cobalt 12% 0.125Total 100.925

2% �nt withRMPC PBlk 7

2% �nt withRMPC PB 15:3

No brush mark andfloccula�on observed

Table 10. Formula�on of UPR Cast


PATcure Accelerators

Cobalt Accelerators, very effec�vely, decompose organic peroxide ini�ators to form the free radicals that promote cross-linking of unsaturated resins.

Cobalt Accelerators PATcure Cobalt 12%10%

8%6%

Octoates White spirit

Cobalt may be used on its own or in conjunc�on with other metals listed above.

Cobalt is typically used at 0.005 to 0.020 %, based on weight metal / binder solids

*Do not premix cobalt with peroxides as it could cause and explosion hazard.

Gel-�me-dri� suppressor – PATcure Co 21 NeoPre-accelerated resins are very prac�cal because only one addi�onal component, the peroxide catalyst, must be added to cure the resin at room temperature. However, pre-promoted resins can be suscep�ble to a shelf life stability problem known as gel-�me dri�. Gel �me dri� is defined as a change in the resin’s measured gel �me compared to the original gel �me measured at the �me of its manufacture.

Potassium Accelerators improve the efficacy of cobalt improving discolora�on. Assists in polymeriza�on.

Potassium Accelerators

Copper Accelerators reduce the peak exotherm. Improve shelf life.

Copper Accelerators

Zinc Accelerators reduce the reac�on rate allowing for clearer and more consistent polymers.

Zinc Accelerators

Sodium Accelerators produce slightly less discolora�on than Potassium accelerators.

Sodium Accelerators

Calcium Accelerators improve the ac�on of cobalt and reduce gel �me dri� in pigmented systems.

Calcium Accelerators

PATcure Cobalt 12%10%

6%Octoates Xylene

PATcure Cobalt 12%10%

6%Octoates High flash point

PATcure Cobalt 12% Neo NeodecanoateHigh flash point2 EHA freeAroma�c free

PATcure Cobalt 12% AcAc Acetylacetonate Low discolora�onAroma�c free

PATcure Potassium 15% Octoates High Flash PointAroma�c free

PATcure 2801 Potassium 15% WW Octoates Water White

High Flash Point

PATcure Potassium 10% Acetate Improved effect on CobaltHigh Flash Point

PATcure Copper 8% Naphthenate

PATcure Copper 10% Neodecanoate High Flash Point2 EHA free

PATcure Copper 12% Octoates High Flash PointEconomical

PATcure Zinc 8% Naphthenate

PATcure Zinc 8%16%18%22%

Octoates High Flash Point

PATcure Zinc 18% Naphthenate High Flash Point2 EHA free

PATcure Calcium 6% Octoates High Flash PointNeutral

PATcure Sodium 8% Octoates High Flash Point

PATcure Calcium 10% High Flash Point

PATcure 2716 Colorless accelerator Replacement for Co 6

PATcure Cobalt 21% Neo Neodecanoate High flash point2 EHA free


PATcure 2720

Test Results in Isophthalic Resin

Proper�es

Gel Start Time

Time to peakexotherm

Peak exothermtemperature 1370C/278.60F 1410C/285.80F

13 minutes 19 minutes25 seconds


PATcure 2720 Cobalt Octoate 12%

Test Results in Orthopthalic Resin

Proper�es

Gel Start Time


Peak exothermtemperature 1250C/2570F 1280C/262.40F

20 minutes20 seconds



9 minutes25 seconds


Gel Dri� TimeTes�ng done at room temperatue (220C-270C/71.60F-80.60F)

Start Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11

Orthophthalic 20.2 21.3 22 21.3 22 22.3 22.3 22.4 23 22.3 22.45 21.3

Isophthalic 13 12.5 13.05 13 13 13.05 13.1 13.05 13.15 12.55 13.3 13.15

5

10

15

20

25

Gel T

ime,

Min

s

PATcure 2720 is an economic replacement of Cobalt accelerator 12%

Orthophthalic resin cast Isophthalic resin cast

PATcure 2720 Cobalt Octoate 12% PATcure 2720 Cobalt Octoate 12%


PATcure 2721 Test Results In Orthophthalic Resin

Proper�es

Gel Start Time



17 minutes 19 minutes

8 minutes10 seconds

9 minutes


Test Results Isophthalic Resin

Proper�es

Gel Start Time


Peak exothermtemperature 1550C/3110F 1400C/2840F


6 minutes15 seconds

8 minutes


Gel Dri� TimeTes�ng done at room temperatue (220C-270C/71.60F-80.60F)


Orthophthalic 8.1 9.3 9 9.3 8.45 9 9.3 9.15 8.45 9.3 8.45 9.15

Isophthalic 6.15 5.5 6.05 6 6 6.05 6.1 6.05 6.15 5.55 6.3 6.15

4

6

8

10

Gel T

ime,

Min

sPATcure 2721 is an economic replacement of Cobalt accelerator 10%




PATcure 2722

Gel Dri� Time

Test Results In Orthophthalic Resin

Proper�es

Gel Start Time






Test Results Isophthalic Resin

Proper�es

Gel Start Time






Tes�ng done at room temperatue (220C-270C/71.60F-80.60F)


Orthophthalic 8 9.15 9.3 9.15 9 8.45 9.15 9.3 9 9.15 8.45 9

Isophthalic 6 6.15 6.05 6 5.55 6.05 6.15 6.05 6.15 6 5.55 6.15

4

6

8

10

Gel T

ime,

Min

sPATcure 2722 is an economic replacement of Cobalt accelerator 6%




PATcure 2716Colorless Cobalt Accelerator

Colorless Cobalt accelerator

Weight to weight replacement for Cobalt 6%

Proper�es

Standard Gel Time(18-28 minutes)

Appearance of Cas�ng Colorless and Clear

Typical formula�on :Resin 100g, Accelerator 0.25g, MEKP 1.5g

23 minutes

PATcure 2716

Gel Dri� TimeTes�ng at room temperatue (220C-270C/71.60F-80.60F)

0 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11

Ortho Resin 23 21.3 24 21.3 22 24 25 24.3 25.5 21.3 22 24

Iso resin 23 21.3 21.4 21.3 21.3 22.3 24.3 25 23.4 21.3 21.3 23

15

18

21

24

27

30

GEL

TIM

E IN

MIN

STORAGE

Ortho Resin Iso resin

Actual Cured Mold



PATcure 2801 Water White Potassium Octoate 15%

Potassium Octoate is o�en used as a synergist or promoter along with Cobalt in unsaturated polyester resin systems. PATcure 2801 is designed as a par�al replace-ment of cobalt for use in gel coat and hand lay-up unsaturated polyesters.

The use of PATcure 2801 helps to obtain a lighter colored unsaturated polyester resin cast and minimizes gel �me dri� upon ageing.

Specification data

Clarity of PATcure 2801

Physical state Clear Liquid

Color (APHA) ˂100

% Non-vola�le Ma�er ≥ 92.0%

% Metal content 15.0 + 0.2%

Water (KF) 3.0 – 5.0 %

Specific Gravity at 25°C (77°F) 1.090 - 1.120

PATCHAM (FZC)

P.O. Box: 7753,Saif Zone, Sharjah, UAETel: +971-6-5570035Fax: +971-6-5570038Email: [email protected]

PATCHAM INDIA

B-52, Pravasi Industrial EstateVishweshwar Nagar, Off Aarey RoadGoregoan (E), Mumbai - 400 063 (India)Tel: +91-22-29272471Email: [email protected]

PATCHAM EUROPE BV

Klavermaten 65-1 7472 DD GoorNetherlandsEmail: [email protected]

PATCHAM USA LLC

10 Commerce RoadFairfield, New Jersey - 07004Tel: (201) 293-4282Fax: (201) 820-0818Email: [email protected]

The information given in this booklet is intended for technical guidance without obligation. Ver. 1.0

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