Product Bulletin

CELLOBOND™ Phenolic Resins and PHENCAT ™ Catalysts

Composites

CELLOBOND Phenolic Resins for the Manufacture of Fire Safe Composite Materials

CELLOBOND resin systems are part of Hexion's Bakelite® family of phenolic resins. These resins are designed to be used in combination with PHENCAT Catalysts for the cost-effective manu-facture of composites by conventional processes where a high degree of fire safety, excellent mechanical properties or resistance to high temperatures is required. They are particularly suited to structural and decorative applications in the rail, marine, offshore and construc-tion industries.

The wide variety of catalyst systems and finishing options that Hexion provides offers unrivalled performance, processing options and design flexibil-ity. Where aesthetics are important, an in-mold phenolic surface paste primer is available for post-painting operations; additionally, decorative films or modi-fied gel coat systems can be used.

CELLOBOND Resin and PHENCAT Catalyst Systems include resins and catalysts to suit most common com-posite processing techniques.

Resins

Availability

Resins are normally supplied in stan-dard 200 liter steel drums containing 220 kg net, and 1,000 liter IBCs (inter-mediate bulk containers) containing 1,220 kg net.

Selection of Resin and Catalyst System

For guidance, the table below illustrates the preferred resin / catalyst combina-tions for a variety of processes.

Storage

Acid-cured resins have a shelf life of 2 months from the date of delivery when stored at 20 °C, and heat-cured resins have a shelf life of 1 month. To minimize ageing effects, drums should be stored in a cool place out of direct sunlight. The shelf life may be extended by stor-age at lower temperatures. Resins may be stored at -18 °C for periods of up to 6 months.

CELLOBOND™ Resins

Resins grade Viscosity at 25 °C [ cP ]

Specific Gravity [ g/ml ]

pH Water Content [ % ]

Free Phenol [ % ]

Free Formaldehyde [ % ]

Standard Pot Life [ min ]

Catalyst cured

CELLOBOND J2027X 180 – 270 1.220 – 1.230 7.0 – 7.6 14.0 – 16.0 7.0 – 10.0 1.0 max 5–8

CELLOBOND J2027L 270 – 395 1.220 – 1.230 7.3 – 7.5 10.0 – 13.0 8.0 – 10.0 3.0 max 5–8

CELLOBOND J2042L Thixotropic (TI=1.7 – 3.8)

1.220 – 1.250 7.3 – 7.8 10.0 – 13.0 10.0 max 3.0 max 5–8

CELLOBOND J6020L 1,000 – 3,000 1.220 – 1.250 5.5 – 6.5 5.0 max 10.0 – 15.0 1.0 max Fast

Heat cured

CELLOBOND J20 / 1256L 450 – 750 1.230 – 1.240 8.5 – 9.2 9.0 – 13.0 8.0 – 10.0 3.0 max 150 sec at 150 °C

CELLOBOND™ / PHENCAT™ Process Combinations

Process Resin Catalyst

Hand Lamination CELLOBOND J2027L or J2042L PHENCAT P10 or P382

Spray Deposition CELLOBOND J2027L or J2027X PHENCAT P15 or P382

Warm Press Molding CELLOBOND J2027L PHENCAT P10, P15 or P382

Resin Transfer Molding CELLOBOND J2027X or J2027L PHENCAT P382

Pultrusion (catalyst cure) CELLOBOND J2027L or J2027X PHENCAT P10 or P382

Pultrusion (thermal cure) CELLOBOND J20/1256L -

Vacuum Injection CELLOBOND J2027X or J2027L PHENCAT P15 or P382

Resin Infusion (e.g. SCRIMP) CELLOBOND J2027X or J2027L PHENCAT P382

Continuous Lamination CELLOBOND J2027L PHENCAT P10 or P382

Syntactic Foam CELLOBOND J2027L or J6020L PHENCAT P10, P15 or P382

Catalysts

Surface Paste

Three catalysts are offered for use with CELLOBOND resins, these are PHENCAT 10, PHENCAT 15 and PHEN-CAT 382 Catalysts.

PHENCAT 10 Catalyst is a general-purpose catalyst for processes such as contact molding.

PHENCAT 15 Catalyst is a fast action catalyst specifically designed for resin injection and spray applications where pot life is of lesser importance.

CELLOBOND thixotropic phenolic sur-face paste improves moldings’ surface finish direct from the mold. This mate-rial is intended primarily for overcoating with a suitable paint system such as the fire retardant, low smoke systems available, for example, from Trimite, Mankieweitz or DuPont.

These catalysts are blends of organic and inorganic acids and therefore must be handled with care. Reference should be made to the appropriate Material Safety Data Sheets.

PHENCAT 382 Catalyst is a delayed-action catalyst that is activated at low temperatures, typically 60 – 80 °C. It offers up to a fourfold increase in pot life and reduced exotherm risk in isothermal RTM or press processes.

The choice of catalyst depends upon the processing characteristics required. The properties of each catalyst are as follows:

Availability and Storage

Surface paste is supplied in 25 liter open-topped steel drums containing 25 kg net. Phenolic paste has an ex-pected working life of 2 months when stored at 20 °C. To minimize ageing effects, kegs should be stored in a cool place out of direct sunlight. Usable working life may be extended by storage at reduced temperatures. Surface paste should not be frozen.

Availability

PHENCAT Catalysts are supplied in thermoplastic kegs or drums containing 25 kg net.

All catalysts are normally available from stock.

Storage

PHENCAT Catalysts have a shelf life of at least 12 months if stored in a cool, dry place. They should not be allowed to freeze.

Surface Paste

Grade Color

CELLOBOND™ SP 053 natural

PHENCAT™ Catalysts

Product Normal level of use [ % by resin weight ]

Pot Life at 23 °C Density at 25 °C [ g/ml ]

Viscosity at 25 °C [ cP ]

PHENCAT 10 4 – 10 6 – 20 min 1.23 25 – 30

PHENCAT 15 2 – 8 1 – 4 min 1.31 250 – 300

PHENCAT 382 3 – 8 25 min – 8 hrs 1.43 200 – 300

Fire Performance of a Phenolic Composite

Fire Performance

Test Fire Properties Measured

Ignitability Ignitability Direct Flame

Rate of Heat Release

Effective Heat of Combustion

Total Heat Release

Flame Spread

Smoke Dynamic

Smoke Cumulative

Toxic Gases

Oxygen Index BS 2782 (Method 141) ASTM D2863, NES 714, ISO 4589

> 55%

Temperature Index > 420 °C

Small Flame (Bunsen) UL 94 VO

BS 476 Pt 6 I < 6 L < 12 (Class 0)

BS 476 Pt 7 Class 1

Cone Calorimeter 128 kW/m2 Qe 50 kW/m2

22.3 MJ/kg SEA 182 m2/kg Qe 50 kW/m2

IMO Surface Flammability A 16 / Res. 653

Pass, Bulkhead, Wall and Ceiling Linings

Pass, Bulkhead, Wall and Ceiling Linings

Pass, Bulkhead, Wall and Ceiling Linings

Pass, Bulkhead, Wall and Ceiling Linings

NT Fire 004 < Curve 1 Light Absorption < 2% Full Deflection

OSU Calorimeter 26 kW/m2 Painted

39 kW.min/m2

BS 6853 Smoke 3m Cube Test Annex D

Ao On < 1.0 Ao Off < 1.5 Category 1

BS 6853 Toxicity R Value Annex B

Index < 1.0

NBS Smoke Box ASTM E 662

DM NF 55 F91

ATS 1000.001 Ds 1.5 mins 5 4mins 25

Pass

NES 711 Smoke Index 4

NES 713 Index < 5

NF F 16-101 M1 F1

Brandschacht B1

ASTM E 84 FS Index 5-10

ASTM E 162 FS Index 2

ASTM E 662 Ds (1.5) ≤ 100Ds (4.0) ≤ 200Very low smoke

ISO 5658-2 CFE > 20 HL3

ISO 5660 Mahre < 60 HL3

ISO 5659-2 Ds (4) < 150VOF (4) < 300HL3

CIT < 0.75 HL3

Fire Certifications

Certification for Rail

NF F 16-101

Test Performance Category

EN 45545-2 HL3

BS 6853 1A

NF F 16-101 M1/F1

DIN 5510 S4 SR2 ST2

NFPA 130 PASS

Certification for Aerospace / Military

Performance in Fire Resistance Tests

Test Performance of Hexion CELLOBOND™ FRP Phenolic Laminate

Performance Category

CAA 8 Issue 2 Pass

ATS 1000.001 DS 1.5 ,oms. 5, 4 mins, 25 Pass

BS2782 > 250 °C Pass

MIL-R-9299C (Type A) Pass

MIL-R-9299C (Type B) Pass

FAR 25.853 Pass

Certification for Marine

Performance in Fire Resistance Tests

Test Test Type Performance achieved

BS 476: Part 22 Fire Insulation and Integrity < 1 hour insulation and integrity

ISO 9705 Room Corner Test Pass (heat and smoke release)

IMO MSC.36 (63) IMO Code of Safety for High Speed Craft Fire Restricting Material

IMO MSC.61 (67) Smoke and Toxicity Conformance to Resolution

NES 711 Smoke Index Smoke Index 4

NES 713 Toxicity Index Toxicity Index < 5

Performance in these tests is usually laminate construction and design dependent.

Phenolic GRP Physical Properties (35 – 45% glass as CSM)

Property Performance

Density 1.4 – 1.6 x 103 kg/m3 (min)

Thermal Conductivity 0.20 – 0.24 W/mK

Coefficient of Linear Thermal Expansion 10–15x10-6 /°C

Calorific Value 13 x 103 kJ/kg

Heat Distortion Temperature 250 °C

Surface Resistivity 109 Ohms (105 Ohms at 1% carbon black)

Shrinkage in Cure 0.2 – 0.3% (in plane) 1.5 – 2.0% (perp. to plane)

Water Vapor Permeability 11 g / mm / m2 / 24 hrs

Flexural Strength 150 – 230 MN/m2

Flexural Modulus 5,000 – 7,500 MN/m2

Tensile Strength 90 – 150 MN/m2

Tensile Modulus 5,000 – 6,000 MN/m2

Elongation at Break 1.8 – 2.5 %

Izod Impact Strength 550 – 750 J/m

Mechanical Properties of Phenolic Composites

Mechanical Properties (Glass reinforcement unless otherwise specified)

Reinforcement Fiber Content [ % wt ]

Density [ g/ml ]

Flexural Strength [ MPa ]

Flexural Modulus [ Gpa ]

Tensile Strength [ MPa ]

Tensile Modulus [ GPa ]

Elongation at Break [ % ]

Notched Izod Impact Strength [ kJ/m2 ]

Compr. Strength [ MPa ]

Compr. Modulus [ GPa ]

None 0 - 80 – 115 3.0 – 3.5 30 – 50 3.0 – 3.8 1.0 – 2.0 - - -

Chopped Strand Mat 35 – 45 1.40 – 1.60 150 – 220 5.5 – 7.5 100 – 150 5.5 – 7.5 1.8 – 2.5 70 – 80 150 – 200 6 – 10

Continuous Filament Mat

25 – 35 1.35 – 1.50 75 – 125 4.0 – 5.5 40 – 60 4.5 – 6.0 1.0 – 2.0 - - -

Woven Roving 50 – 60 70 – 80

1.65 – 1.75 1.75 – 1.85

30 – 450 450 – 600

12 – 20 20 – 28

200 – 300 350 – 450

13 – 17 20 – 25

2.1 – 2.4 2.0 – 2.2

- 175 – 195

190 – 220 250 – 300

14 – 18 20 – 25

Woven Cloth (Style 7781)

70 – 80 1.75 – 1.85 300 – 600 17 – 24 300 – 400 16 – 20 2.0 – 3.0 - - -

Unidirectional 60 – 70 1.70 – 1.80 800 – 1,200 28 – 40 - - 1.0 – 1.5 - - -

Carbon Cloth (5H satin) 40 – 45 1.40 – 1.60 450 – 550 25 – 40 300 – 400 28 – 40 - - - -

Properties are based on composites made with reinforcements as recommended by Hexion Inc. Property ranges are a function of glass content and relative phenolic compatibility. Advice should be sought if optimum properties are required.

Users of this information should verify the suitability of these materials for themselves.

Long Term Marine Exposure of Phenolic Laminates

Marine Exposure of Phenolic Laminates (CSM Glass Reinforcement at 35%)

Tensile Strength [ MPa ]

Tensile Modulus [ GPa ]

Elongation at Break [ % ]

Flexural Strength [ MPa ]

Flexural Modulus [ GPa ]

Glass Content [ %wt ]

Original Properties 137 13.4 1.3 - - -

1 Year Exposure 141 12.9 1.3 - - -

3 Years Exposure 128 13.9 1.6 227 14.0 60

Exposure site: Solent Estuary, UK (within tidal zone). Applied strain: 0.2% in flexure.

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