Reduction of Styrene Content in Unsaturated Polyester (UPE) and Vinyl Ester (VE) Resins

Identify a safe, cost-effective alternative to styrene that can be used as a reactive diluent in unsaturated polyester (UPE) and vinyl ester (VE) thermosetting resins for composite fabrication. The reactive diluent should replace at least 50% of the styrene while enabling the processability and performance properties of existing UPE and VE resins to be maintained.

Provide composite fabricators who are facing EH&S pressure to reduce styrene emissions from thermosetting UPE and VE resins with products that have the potential to reduce styrene exposure by 50% while maintaining existing processability and performance properties.

Thermoset composites that utilize unsaturated polyester (UPE) and vinyl ester (VE resins) find widespread application in the transportation and building & construction markets. Examples of applications include fiberglass-reinforced UPE resins for truck hoods and boat hulls, reinforced VE resins for corrosion-resistant pipes and tanks, and aggregate-containing UPE resins for solid surface, tub and shower applications.
Styrene is a key component in these formulations. It is a reactive diluent that serves two functions: 1) it serves as a diluent that reduces the viscosity of the UPE or VE resin to a useable viscosity and 2) it is a reactive monomer that participates in the free radical crosslinking reactions that occur during cure of the resin.

In recent years, styrene has come under increasing EH&S scrutiny. Since Risk = [Exposure x Hazard], our intent is to reduce possible worker exposure by providing formulations with significantly lower styrene content, particularly for open mold applications where workers are more prone to exposure to styrene vapors.. We would like to replace at least 50% of the styrene with an alternative reactive diluent.

We would like to introduce the first products within the next two to three years.