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Unsaturated polyester resins (UP resins) Lightweight constructions with Exolit Fiberglass reinforced composites play an important part in construction, transportation, tanks, pipes and electrical components. These composites can be manufactured by Sheet Moulding Compound (SMC)/Bulk Moulding Compound (BMC), Resin Transfer Moulding (RTM) processing or open mold techniques. Unsaturated polyester resins are important for those applications. Very often these composites have to fulfill stringent fire and safety regulations, necessitating the use of flame retardants. To meet these requirements, the use of halogenated UP resins (frequently combined with antimony trioxide as synergist) and aluminium trihydroxide (ATH, flame retardant filler) has become standard practice in recent years. But ATH in particular is likely to bring an increase in viscosity (owing to higher filler levels to reach the required fire retardation) and higher densities of the components. Moreover, halogenated flame retardants have come under public and legislative pressure because of widespread findings in the environment, toxic effects and the potential formation of halogenated dioxins by uncontrolled combustion [ lit.: Beard A., Angeler D. (2010): Flame Retardants: Chemistry, Applications, and Environmental Impacts. Wiley-VCH, Weinheim. Wiley-VCH. pp. 415-439. ] The Exolit grades offer major advantages especially in construction and rolling stock applications. By combining the Exolit products with aluminium trihydroxide stringent flammability requirements can be met even with low filler levels. In addition, Exolit grades can be used to formulate intumescent (gel)-coats which drastically improve the fire endurance of the whole composite part. Clariant is a world wide leader in the manufacturing of ammonium polyphosphate, one of the key raw materials for the formulation of intumescent (gel)-coatings. In addition to the traditional hand lay-up process, the Exolit flame retardants can be used in pultrusion and other advanced techniques. Advantages of systems with Exolit: · Low density of the components · Low processing viscosity · High glass contents are possible · Halogen free hand lay-up formulations are possible · Pultrusion and advanced composite techniques possible · Low smoke density, no corrosive combustion gases Figure 1: Formulation examples with Exolit AP 740 and AP 422 for different flame tests 250 Picture 1: Intumescent gel-coating after flammability test 200 FR content [phr] 150 100 50 0 BS 476 NF P 92 501 EN 45545 DIN 5510 part 2 UL 94 n Exolit AP 750 n Exolit AP 422 n ATH 6 Exolit for Thermosets
Table 3: Guiding formulations for UP composites under various processing methods Classification Product Loading [phr] Processing Construction BS 476 Class 1 Class 1 Exolit AP 740 100 Gelcoat BS 476 Exolit AP 740 50 Gelcoat Class 1 ATH 50 Laminate NF P 92 501 Epiradiateur Exolit AP 422 25 Class M2; 3 mm ATH 200 Laminate DIN 4102 part 1 Class B1; 4 mm Exolit AP 740 > 75 Pultrusion DIN 4102 part 1 Class B1; 4 mm Exolit AP 740 150 Gelcoat Additional comments: Exolit AP 422 can be replaced with an equivalent quantity of either Exolit AP 423 (fine grade material) or Exolit AP 462 (reduced water solubility) as required. The Exolit AP range can be used in combination with ATH in many halogen free thermoset systems. Exolit AP 740 and Exolit AP 742 are special combinations of ammonium polyphosphate with synergistic co-flame retardants. These products offer improved intumescent effects that are advantageous if a ready to use formulation is needed. Transport EN 45545; R1 HL 2 Exolit AP 740 125 Laminate EN 45545; R1 Exolit AP 740 100 Gelcoat HL 3 ATH 125 Laminate DIN 5510 Exolit AP 422 2 – 5 S3, SR2, ST2; 4 mm ATH 20 – 40 Laminate DIN 5510 Exolit AP 422 10 – 12 S4, SR2, ST2; 3 mm ATH 50 – 60 Laminate ASTM 162 Class A ASTM 662 DS 4 min 60 Exolit AP 740 100 Pultrusion ASTM 662 DS 4 min 25 Exolit AP 423 25 ATH 200 Pultrusion E&E UL 94 Exolit AP 422 15 – 25 Laminate V-0; 1.6 mm ATH 50 – 100 UL 94 Exolit AP 740 20 – 50 Laminate V-0; 1.6 mm 7
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Exolit® for

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