Current modifiers for toughening thermosetting systems exhibit significant drawbacks including depression of the glass transition temperature, instability of the formulation and difficulty of use. Core Shell Rubber (CSR) particles have been used successfully for more than 40 years in thermoplastic applications but have had limited success in thermosetting systems due to agglomeration of the particles. The agglomeration of the particles results in a non-homogeneous material and corresponding poor and inconsistent performance attributes. Kaneka Texas Corporation has developed a proprietary process for dispersing core shell domains into various thermosetting resins. The 100nm CSR particles are perfectly dispersed and remain so during normal storage conditions and during normal formulating process. The CSR particles are never dried and then shear mixed in to the resin, but instead they are dispersed directly in to the thermoset resin as a liquid. The resulting coatings utilizing this new technology exhibits improved adhesion, abrasion, impact resistance, and durability without sacrificing glass transition temperature or other thermal properties related to the cross link density. The coating will also show increased corrosion resistance. If used in adhesives and composites, increased lap shear and fracture toughness is observed. The Kaneka nano-sized CSR thermoset master-batches are also clean and very easy to use relative to current toughening products. This presentation discusses the merits and use of these novel toughening agents for thermosetting systems.
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