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TRANSCRIPT
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
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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
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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
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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
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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%)
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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)*
* Methyl Ethyl Ketone Peroxide
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)
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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.
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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
* Methyl Ethyl Ketone Peroxide
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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.
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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
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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
---- - - - -
--
----
---
------- - - - -
--
+++ +
++
+
+++ + +
+
+
++
+
+
++
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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
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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
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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
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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
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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
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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
7 minutes 9 minutes45 seconds
PATcure 2720 Cobalt Octoate 12%
Test Results in Orthopthalic Resin
Proper�es
Gel Start Time
Time to peakexotherm
Peak exothermtemperature 1250C/2570F 1280C/262.40F
20 minutes20 seconds
21 minutes10 seconds
10 minutes50 seconds
9 minutes25 seconds
PATcure 2720 Cobalt Octoate 12%
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%
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PATcure 2721 Test Results In Orthophthalic Resin
Proper�es
Gel Start Time
Time to peakexotherm
Peak exothermtemperature 1440C/291.20F 1360C/276.80F
17 minutes 19 minutes
8 minutes10 seconds
9 minutes
PATcure 2721 Cobalt Octoate 10%
Test Results Isophthalic Resin
Proper�es
Gel Start Time
Time to peakexotherm
Peak exothermtemperature 1550C/3110F 1400C/2840F
13 minutes 17 minutes
6 minutes15 seconds
8 minutes
PATcure 2721 Cobalt Octoate 10%
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 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 2721 Cobalt Octoate 10% PATcure 2721 Cobalt Octoate 10%
Orthophthalic resin cast Isophthalic resin cast
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PATcure 2722
Gel Dri� Time
Test Results In Orthophthalic Resin
Proper�es
Gel Start Time
Time to peakexotherm
Peak exothermtemperature 1440C/291.20F 1370C/278.60F
16 minutes 19 minutes
8 minutes 9 minutes15 seconds
PATcure 2722 Cobalt Octoate 6%
Test Results Isophthalic Resin
Proper�es
Gel Start Time
Time to peakexotherm
Peak exothermtemperature 1520C/305.60F 1420C/287.60F
14 minutes 17 minutes
6 minutes 7 minutes45 seconds
PATcure 2722 Cobalt Octoate 6%
Tes�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 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 2722 Cobalt Octoate 6% PATcure 2722 Cobalt Octoate 6%
Orthophthalic resin cast Isophthalic resin cast
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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 2716 Cobalt Octoate 6%
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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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