Document 2NoO535B5OXadk9BZJb464BL

PLAINTIFF'S EXHIBIT EPON RESINS FOR CASTING SC: 60-302 SHELL CHEMICAL COMPANY PLASTICS AND RESINS DIVISION NEW YORK, NEW YORK Shell Chemical Company is a Division of Shell Oil Company LAM 029339 ABS-018546 SP-1 CONTENTS Page No. Introduction........................................................................................................................................... Selection of EPON Resin Type............................................................................................... SP'3 Selection of Curing Agents........................................................................................................... Use of Curing Agent Accelerators............................................................................................ SP-6 Use of Modifying Agents............................................................................................................... Fillers...................... ................................................................................................................. Flexibilizers........................................................................................................................... Diluents..................................................................................................................................... Solvents..................................................................................................................................... SP-7 SP-7 SP-16 SP-18 SP-18 Application Considerations........................................................................................................... Release Agents..................................................................................................................... Prevention of Bubbles.................................................................. Mixing and Storage............................................................................................................... Dispensing Equipment......................................................................................................... SP-19 SP-19 SP-20 SP-20 SP-21 Data Section: Typical Cured EPON Resin Properties................................................... SP-22 Aliphatic Amine Cured Systems Aromatic Amine Cured Systems Cyclic Aliphatic Amine Cured Systems Tertiary Amine Cured Systems Acid Anhydride Cured Systems L*M 029340 ABS-018547 SP-2 INTRODUCTION The inherent properties of EPON Resins make these materials outstanding for use in many casting, potting and encapsulation applications. These resins form polymers that are strong, tough, resistant to chemical attack, and which have excellent electrical properties. It is the purpose of this brochure to indicate the various ways in which EPON Resins can be formulated to produce a com pound combining the best of these properties and at the same time, to meet the require ments of a specific application. The formulator will find in this brochure detailed discussions of curing agents, accelerators, fillers, flexibilizers, and diluents for use with EPON Resins. In addition, extensive data are provided on various EPON Resin curing agent systems, to assist him in the proper formulation of these compounds. LAM 029341 AES-018548 SP-10 The effect of fillers on the mechanical properties of resin systems varies. From a use standpoint, however, these properties are largely dependent on the properties of the filler itself. For example, powdered metal oxide fillers, such as aluminum oxide and iron oxide, increase the surface hardness of castings and decrease the ultimate tensile and compressive strengths (see Table II). The compressive yield strength and modulus of cast systems are, however, generally increased (see Figures 2 and 3). A noteworthy exception is atomized aluminum powder which has been found to cause a decrease in yield strength but will impart a definite degree of malleability to the cured product. TABLE II EFFECT OF FILLERS ON ULTIMATE STRENGTHS OF EPON RESIN CASTINGS0' FILLER None Black Iron Oxide Atomized Aluminum 2 7TF2 Asbestos Floats Water Ground Mica PHR ULTIMATE COMPRESSIVE STRENGTH (PSD 28,000 400 18,000 200 15,000 15 17,500 15 20,000 ULTIMATE TENSILE STRENGTH (PSD 12,500 4,500 6,500 7,000 7,500 ^EPON 828-Curing Agent Z Cure: 20 hours at 77F. (25C.) plus 24 hours at 150F. (65C.). 2 Johns-Manville Corporation. LAM 029342 ABS-018549 REPRINTED FROM SC:5S-110 SEPTEMBER 1959 Undesirable Bolted Construction Avoided in Production of Portable Military Shelters by Epoxy Bonding Aluminum Components By NEIL KVASNAK Craig Systems, Inc., Lawrence, Mass. 1 he recasting of U.S. Army divi sions from three regiments into five battle groups brought with it a de mand for easily transportable "mes sage centers and sub-centers for use in a redesigned system of battle communications. Several years of testing and development have re cently led to the perfection of a shelter which basically consists of two high-strength, heat-treated alu minum skins which are epoxy bonded to extruded aluminum fram ing members. Called "Helicop-Huts," the air transportable shelters are used for the housing and protection of elec tronic systems during operation, transit and storage. They were pio neered by Craig Systems, Inc., and provide load-carrying characteristics with as high as a 15 to 1 payload/ weight ratio. Conventional Construction Until about ten years ago, most mobile shelters employed conven tional construction, i.e., structural framework, an outer metallic skin, usually glass fiber insulation, and an inner skin of plywood or pressed board. In the main, all of these shel ters were quite cumbersome and not at all suitable for transport by air. In addition, before the switch to using structural adhesives, bolted constructions proved undesirable for mobile military use since the bolts always required clearance holes. Un der the stress of field use the bolts would work loose and water leaked into the shelter with subsequent damage to installed equipment. Riveted and welded constructions also proved impractical because shel ters made in this manner were still too heavy for rapid transportation by air. The new shelters are basically sandwich-type constructions and weigh about two-thirds less than comparable previous units. In them, the space between the inner and outer aluminum skins is filled with a light-weight, foamed-in-place iso cyanate core. In addition to its inherent tough ness and resistance to chemicals and weathering, adhesive bonding was selected for joining the skins and framing members because it made possible shelters of high temper alu minum alloy, 6061-T6. This thin, high-strength aluminum could not be used on previous shelters because welding heat inevitably annealed the metal. Curing Epoxy Adhesives Epoxy adhesives can be cured at room temperature or low heat and therefore do not affect the temper of the aluminum. During the course of research and development studies, tensile shear tests (in accordance with MIL-A-5090A) showed that the bond strength available with epoxy adhesives was 80 per cent creator than the minimum specified by the government. The adhesive used is based on Shell Chemical Corp.'s Eponresins LAM 029343 ABS-018550 and is produced by Lawrence Adhe sive and Chemical Co., Lawrence. Mass, it is a thixotropic I non sagging I metal-to-metal bonding agent supplied as a two-component system involving a resin and a curing agent. As has been pointed out. framing members for the floor, root and wall of the shelters are angular alu minum extrusions. Where specified, vertical mounting ribs and other ex truded members are inserted between the wall skins to serve as anchoring mediums for the fastening of elec tronic and other equipment. All of the individual frames and ribs are bonded together with the epoxy. The aluminum skins are then also bonded to the extrusions: once the adhesive has cured, the bond be tween extrusions' and panels is vir tually indestructible. Assembled panels are filled with the isocyanate foam which is capable of transferring some shear between the inner and outer skins by distri bution of shear loading. The foam also imparts tensile, shear and com pression loading to the vertical mem bers embedded within the core ma terial. Finally, the fire-resistant foam also serves as an excellent in sulation medium. Completed floor, roof and wall panels are bonded together to form the enclosed shelter. For additional weather protection, all exterior seams and joints are filleted with the adhesive. Enclosures are built in sizes from 4"i' x 5' x 6' up to 6C/ x 6K.' x 14', and have an assured service life of five years. Recently, the rugged ness of the foamed-in-place panels and bonded aluminum constructions was graphically illustrated when the shelters passed a grueling battery of tests. The S-144 shelter, weighing only 350 pounds, was loaded with 1500 pounds of simulated electronic equipment and dropped ten times from one to ten-foot heights with out damage. In actual helicopter transport, fiat drops up to two feet were made without deforming the shelter or damaging the equipment. Equally successful were HelicopHut tests for insulation, air tightness, snow load, temperature range, hu midity. salt spray, and fording. In the latter test, a shelter loaded with 7000 pounds of simulated equip ment. w'as successfully floated free in water. At the panel assembly division of the Craig pianf, floor and roof panels are formed and wall panels are laid up and bonded with epoxy adhesive. View of the shelter assembly area where fin ished panels and ex trusions are combined to form the completed alu minum communications shelter. REPRINTED BY SHELL CHEMICAL CORPORATION 50 West 50th Street, New York 20, New York AES-018551 LAM 029344