Hollow element filled curable body repair compounds

Abstract

A curable body repair material is described. The curable body repair material includes a curable polymeric resin, and a plurality of hollow elements. The curable body repair includes less than 3% by number of hollow elements having a diameter greater than 100 micrometers. Method of making and using the same are also described.

1 . A curable body repair material comprising:
 a curable polymeric resin; and   a plurality of hollow glass elements;   
       wherein, the curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 75 micrometers. 
     
     
         2 . A curable body repair material according to  claim 1 , wherein each hollow element, forming the plurality of hollow elements, has a diameter of less than 90 micrometers. 
     
     
         3 . A curable body repair material according to  claim 1 , wherein each hollow element, forming the plurality of hollow elements, has a diameter of less than 75 micrometers. 
     
     
         4 . A curable body repair material according to  claim 1 , wherein each hollow element, forming the plurality of hollow elements, has a diameter of less than 60 micrometers. 
     
     
         5 . A curable body repair material according to  claim 1 , wherein each hollow element, forming the plurality of hollow elements, has a diameter of less than 45 micrometers. 
     
     
         6 . A curable body repair material according to  claim 1 , wherein the plurality of hollow elements comprises 5 to 70% vol of the curable body repair material. 
     
     
         7 . A curable body repair material according to  claim 1 , wherein the curable polymeric resin comprises a mixture of an unsaturated polyester resin, and a styrene monomer. 
     
     
         8 . A curable body repair material according to  claim 1 , wherein the plurality of hollow elements comprises hollow glass elements. 
     
     
         9 . A curable body repair material according to  claim 1 , wherein the curable body repair material comprises less than 0.5% vol air or gas, not including the air or gas contained within the hollow elements. 
     
     
         10 . A curable body repair material according to  claim 1 , wherein the curable body repair material further comprises a catalyst. 
     
     
         11 . A method of manufacturing a curable body repair material comprising:
 combining a curable polymeric resin and a plurality of controlled diameter hollow glass elements to form a curable body repair material, wherein the plurality of hollow elements have an average diameter of less than 75 micrometers and the curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 100 micrometers.   
     
     
         12 . A method according to  claim 11 , further comprising removing substantially all hollow elements having a diameter greater than 75 micrometers from a plurality of hollow elements to form the controlled diameter hollow elements. 
     
     
         13 . A method according to  claim 12 , wherein the removing step comprises sieving the plurality of hollow elements to remove substantially all hollow elements having a diameter greater than 75 micrometers. 
     
     
         14 . A method according to  claim 12 , wherein the removing step comprises removing substantially all hollow elements having a diameter greater than 75 micrometers from the plurality of hollow elements to form a plurality of controlled diameter hollow elements. 
     
     
         15 . A method according to  claim 12 , wherein the removing step comprises removing substantially all hollow elements having a diameter greater than 60 micrometers from the plurality of hollow elements to form a plurality of controlled diameter hollow elements. 
     
     
         16 . A method according to  claim 11 , wherein the curable polymeric resin step comprises providing a curable polymeric resin comprising a mixture of an unsaturated polyester resin, and a styrene monomer. 
     
     
         17 . A method of repairing a body comprising;
 applying a curable body repair material onto a damaged body substrate, the curable body repair material comprising a curable polymeric resin and a plurality of hollow glass elements having an average diameter of less than 75 micrometers and the curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 75 micrometers;   curing the curable body repair material to form a solid body repair material; and   sanding the solid body repair material to expose hollow element pinholes in the solid body repair material.   
     
     
         18 . A method according to  claim 17 , further comprising applying a polymeric layer to the solid body repair material to substantially fill the hollow element pinholes. 
     
     
         19 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material having less than 0.5% vol air or gas, not including the air or gas contained within the hollow elements. 
     
     
         20 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material comprising a curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 90 micrometers. 
     
     
         21 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material comprising a curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 75 micrometers. 
     
     
         22 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material comprising a curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 60 micrometers. 
     
     
         23 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material comprising a curable body repair material comprises less than 3% by number hollow elements having a diameter greater than 45 micrometers. 
     
     
         24 . A method according to  claim 17 , wherein the applying a curable body repair material step comprises applying a curable body repair material onto a substrate, the curable body repair material comprising a catalyst. 
     
     
         25 . A method according to  claim 18 , wherein the applying a polymeric layer step comprises applying a polymeric primer or paint layer to substantially fill the hollow element pinholes, wherein the primer or paint layer has a dry thickness in a range from 1 to 100 micrometers.