Saturated Polyester Resins and Flooring Applications

Saturated polyester resins represent a versatile class of polymers widely used across various industries due to their exceptional mechanical, thermal and chemical properties. Saturated polyester resins are a type of thermoset resin formed by the reaction of dicarboxylic acids with diols. The resulting polymer is a linear chain composed of repeating ester units that do not contain double or triple bonds. This imparts a series of properties to saturated polyester resins that make them attractive for various applications, including: • Good chemical resistance, • High strength and hardness, • Good electrical insulation properties, • Good water resistance, • Low moisture absorption, • Low shrinkage. Saturated polyester resins are used in a broad range of products, including: • Boats and other marine applications, • Fiberglass composites, • Electrical components, • Pipes and fittings, • Coatings and paints, • Adhesives. The most common dicarboxylic acids used in the manufacture of saturated polyester resins are phthalic anhydride and isophthalic acid. The most commonly used diols are ethylene glycol and propylene glycol. The choice of dicarboxylic acid and diol determines the properties of the resulting resin. For example, phthalic anhydride-based resins are harder and have better chemical resistance than isophthalic acid-based resins. Ethylene glycol-based resins are more flexible and have better water resistance than propylene glycol-based resins. Saturated polyester resins are a versatile and reliable material with a wide range of applications. They are relatively economical and easy to use, making them a popular choice for various products. Saturated polyester resins are a type of thermoset polymer formed by the reaction of a dicarboxylic acid with a dihydric alcohol. The resulting polymer has no double bonds in its backbone, which is why it is called "saturated". Saturated polyester resins are typically clear, colorless and odourless liquids and are used in various applications, including: • Paints and coatings, • Fiberglass composites, • Electrical insulation, • Adhesives, • Sealants. Saturated polyester resins offer a number of advantages over other resin types, including: • Good chemical resistance, • High strength and toughness, • Good electrical insulation properties, • Low cost. However, saturated polyester resins also have some disadvantages, such as: • Low heat resistance, • Poor UV resistance, • Shrinkage during curing. In general, saturated polyester resins are a versatile and cost-effective material suitable for various applications. However, it is important to be aware of their limitations before using them in a specific application. The formation of saturated polyester resin from the reaction of a dicarboxylic acid with a dihydric alcohol is a step-growth polymerization reaction. This means that the reaction advances one molecule at a time and each molecule of reactant reacts with one molecule of the other reactant. The reaction is initiated by a catalyst such as a strong acid or base. The first step in the reaction is the formation of an ester bond between the carboxylic acid and the alcohol. This bond is formed by the removal of a water molecule from the two molecules. The resulting ester molecule then reacts with another carboxylic acid or alcohol molecule to form a second ester bond. This process continues until all reactants are consumed and a long-chain polymer is formed. The resulting polymer has a repeating unit consisting of two carboxylic acid groups and two alcohol groups. The carboxylic acid groups are responsible for the chemical resistance of the polymer, while the alcohol groups are responsible for its hardness and flexibility. The absence of double bonds in the polymer backbone makes saturated polyester resins less reactive than unsaturated polyester resins. This also makes them more stable and less likely to deteriorate over time. However, it also makes them less resistant to heat and UV.

Applications:

Boats and other marine applications: Saturated polyester resins are used in the manufacture of various marine products, including boats, yachts and surfboards. They are a good choice for marine applications because they are resistant to water, chemicals and corrosion. Fiberglass composites: Saturated polyester resins are used to make fiberglass composites, which are strong and lightweight materials used in various applications, including boats, automobiles and aircraft. The resin is used to bind fiberglass fibres together to create a strong and durable composite material. Electrical components: Saturated polyester resins are used in the manufacture of electrical components such as insulators and connectors. They are a good choice for electrical applications because they are resistant to heat, electricity and moisture. Pipes and fittings: Saturated polyester resins are used to make pipes and fittings for various applications, including plumbing, irrigation and industrial use. They are a good choice for pipes and fittings because they are resistant to corrosion and chemicals. Coatings and paints: Saturated polyester resins are used to make various coatings and paints. They are a good choice for coatings and paints because they are durable, weather-resistant and easy to apply. Adhesives: Saturated polyester resins are used to make various adhesives. They are a good choice for adhesives because they are strong, flexible and resistant to water and chemicals.

Saturated Polyester Resins in Flooring Coating Applications:

Saturated polyesters used in flooring coatings typically are polymers with OH values of 3.5—9.5%. The greatest feature of saturated polyester compared to flooring coatings made from vegetable oil (ricinus communis) is that its hard structure and ability to carry significantly more filler provides an economical solution and alternative for flooring coatings. In particular, its ability to easily incorporate filler materials such as quartz compared to other alternatives can make the produced resin even more ergonomic. As the OH value of saturated polyester increases, the hardness value of the polymer film also increases and allows for the production of some rigid objects. Although polymeric MDI is preferred for curing saturated polyester systems in flooring coatings, isocyanate-containing components such as TDI are sometimes used. To improve performance in the curing process, zeolite, which is hydrated aluminium silicate, is frequently used as a moisture inhibitor due to its chemical and physical structure. For successful flooring coating, ground preparation with primer, followed by intermediate layer and top coat application will improve performance. Application is generally carried out with a trowel and to measure pressure hardness, hardness performance is measured with a shore D class hardness measuring device (minimum 80 shore).

Some of the advantages of using saturated polyester resins in flooring coatings include:

• Durability: Saturated polyester resins are highly durable and can withstand heavy traffic and wear and tear. They are also resistant to chemicals and moisture, making them a good choice for commercial and industrial applications. • Weather resistance: Saturated polyester resins are weather-resistant and can withstand exposure to sunlight and rain. This makes them a good choice for outdoor applications such as terraces and decks. • Easy to apply: Saturated polyester resins are relatively easy to apply and can be applied by hand or with a sprayer. This makes them a good choice for DIY projects. • Cost-effective: Saturated polyester resins are relatively inexpensive, making them a cost-effective option for flooring coatings.

Some disadvantages of using saturated polyester resins in flooring coatings include:

• Saturated polyester resins are not as strong as epoxy resins, so they may not be suitable for applications requiring high strength. • Saturated polyester resins are not as abrasion-resistant as epoxy resins, so they may not be suitable for applications where heavy foot traffic is expected. • Saturated polyester resins are not as chemically resistant as epoxy resins, so they may not be suitable for applications where chemicals are present.   References "Polyesters and Polyamides" by D. Eaves, J. Clegg, and R. Ward (ISBN: 978-1859574599) "Polyester and Alkyd Resin" by Ulrich Poth (ISBN 978-3-86630-735-3) "Polyester: Synthesen, Eigenschaften und Anwendungen" by J. H. Wendorff and A. Greiner (ISBN: 978-3110148883)   Dr. Çiğdem Yüceel - Project and R&D Manager Serkim Reçine Zeynel Turna - Business Development Specialist Serkim Reçine