Using low-cost, nonfunctional fillers in FRP applications often results in a loss of performance properties.  When a reduction in performance is undesirable, a better solution is to utilize ultra-low density polymeric microspheres.   

Benefits of Ultra-Low Density Polymeric Microspheres 

These functional fillers have numerous advantages when using them in your FRP formulations, including: 

Extend Resin with VOC Reduction

A 0.75% loading of E065-135D in a formula that is 55% filled will extend the resin roughly 17%. This extension means that you will use less resin, reducing emissions.  

There is a further reduction in VOC emissions attributed to the slowing of migration of styrene through the part, which traps it into the unit, resulting in vapor suppressant. Overall, the use of polymeric microspheres can reduce VOC.  

Related Article: What are Microspheres?

Cost Reduction with Microspheres

Polymeric microspheres are often used as a volumetric filler. A 0.75% addition of our Dualite® E065-135D to a 55% filled system can extend the resin by approximately 17%. This can reduce the cost of your formula.  

We can supply a math model (Excel spreadsheet), that will allow you to calculate the difference with and without polymeric microspheres and the effects on volume costing. 

Reduction in Specific Gravity

The addition of polymeric microspheres can reduce the specific gravity of your standard formula by 10-15%. This helps reduce slump or sag, especially in applications involving vertical surfaces.  

Weight Reduction of the Unit

Depending on how a unit is manufactured, the weight reduction attained using polymeric microspheres can have a positive effect on the work environment or in the application where it is used. After many plant visits, it is common to hear comments like “At the end of the day my back feels better.” If an employee in the plant or out in the field moves or picks up hundreds of these units a day the extra 10% can add up.  

Related Article: Understanding the Thermal Compatibility of Polymeric Microspheres

Improvement in Final Properties

The addition of polymeric microspheres will have positive effects on the final properties of your product. You will see a reduction in cracking which leads to better screw holding. Your final product will also have improved impact resistance.  

Reduction of Roll out and Sprayability

Polymeric microsphere-filled products exhibit a property called Viscobarotropism. This property is similar to thixotropy in that it refers to a reduction of viscosity. However, this reduction of viscosity is due to pressure, instead of shear.  

The formulas which contain polymeric microspheres have a certain viscosity, but when pressure (i.e. spray tip) is applied, the formula will temporarily thin. After the pressure is removed the formula will regain its original viscosity. This allows the material to be sprayed and to re-body after application. This property can help by reducing the amount of air entrapped during the application.  

Improve Acrylic Bonding

This property is attributed to the reduction of shrink in the reinforcement layer. We believe that the addition of polymeric microspheres would improve the bonding characteristics of resins, even low-shrink resins.  

Applicable in Flow Coater Technology

Polymeric microspheres have been shown to improve the movement of filled resin systems through flow coater applicators. 

The use of microspheres makes it possible to reduce the final density and weight of your FRP item. The amount of raw materials used in your FRP items can be reduced, thus realizing a reduction in cost. In addition, hollow polymeric microspheres will give improved impact resistance, a reduction in cracking, improved sprayability and better bonding to acrylics.  

Want to know more about our Dualite® polymeric microspheres?