Q cel in cultured marble solid surface applications(1)

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Q-Cel® Ultra-Light Hollow Microspheres Cultured Marble & Solid Surface Applications Q-Cel® Hollow Microspheres consist of hollow, inorganic microspheres that can be used in a range of plastics systems as lightweight additives Their spherical shape and low density (about 1/16 of the density of most mineral fillers) enable Q-Cel® Hollow Microspheres to extend plastics while reducing the weight As early as 1973, some manufacturers of cultured marble began using microspheres to reduce the density of their sinks and panels The need for lightweight filler gained momentum as larger vanities and cultured marble bathtubs increased in popularity This trend enhanced the value of microspheres since they not only reduce the weight of the cultured marble component, but also improve its resistance to hydrothermal shock The ease of installation for a 115Kg Q-Cel® Hollow Microspheres filled tub proved to be another sales advantage over a 180Kg tub made with calcium carbonate filler Principle Benefits Q-Cel® Hollow Microspheres provide many benefits when substituted for the more common mineral fillers Cultured marble modified with Q-Cel® Hollow Microspheres offers the following advantages: Improved resistance to hydrothermal shock Weight reduction in the range of 20 to 35 % Greater ease of finishing (drilling, sawing and sanding) Less tool wear Reduced packaging and shipping costs Increased production through faster mould turn- around Impact resistance Pigmentation value (whiter colour) Reduced catalyst consumption Q-Cel® helps prevent Thermal Cracking Cracking around the drain hole has been a fairly widespread problem in the cultured marble industry The radial cracking phenomenon generally occurs when the sinks are exposed to alternating hot and cold water temperature extremes Cultured Marble Institute certification requires that sinks withstand 500 cycles of alternating hot and cold water using a prescribed testing procedure Although recent developments in polyester resin technology have shown gains in resistance to the thermal cracking problem, the most dramatic improvements result when Hollow Microspheres are added to the formulation Extensive testing has been carried out to demonstrate the benefits of Q-Cel® Hollow Microspheres as a crack-inhibiting additive Replacing Calcium Carbonate with Q-Cel® Hollow Microspheres on an equivalent volume basis at several substitution levels provided a good safety margin in passing the 500 cycle test (Table 1) Table 1: Effect of Q-Cel® Hollow Microspheres on Thermal Shock Resistance of Cultured Marble Vanities % Wt Polyester Resin(1) 25 32.8 35.8 40.8 % Wt Q-Cel® 2.1 2.9 4.2 % Wt Calcium Carbonate 75 65.1 61.3 55.0 Gel Coat Cycles to Failure NA 1190 (2) 1500 (2) 1500 Matrix Cycles to Failure 600 (2) 1500 (2) 1500 (2) 1500 (1) A low viscosity general purpose resin (2) Test terminated at 1500 cycles with no failure Information contained in this publication (and otherwise supplied to users) is based on our general experience and is given in good faith, but we are unable to accept the responsibility in respect of factors which are outside our knowledge or control Potters Europe (EGM Division, Potters Hollow Spheres & Potters Europe are trading names of Potters Ballotini Limited Q-Cel®, Sphericel®, Spheriglass®, Spheriwhite® and Luxsil® are registered trademarks of Potters Industries LLC Ref:3-02-008-1-02 Several factors influence the way in which Q-Cel® Hollow Microspheres improve resistance to cracking Spherical Microspheres are superior to irregularly shaped calcium carbonate particles for avoiding stress concentrations The insulating value of the Hollow Spheres allows the heat from the resin exotherm to be held longer in the vanity and act to some extent as a substitute for the expensive post-curing which is sometimes used This insulating effect may prevent the rapid expansion or contraction on impact of hot or cold water Impact Resistance The impact resistance of cultured marble is as important to the consumer as to the manufacturer and installer Table 2: Cultured Marble Impact Resistance Test % Wt Q-Cel® 2.1 2.9 4.2 Impact Load (inch-lb)(1) First Failure (Gel Coat) Matrix Failure 109 141 117 283 115 248 173 265 (1) Gardner Impact Tester Model 144 Q-Cel® Hollow Microspheres in a marble matrix act as shock absorbers, preventing crack formation by dissipating the energy of impact loads better than a formula containing only calcium carbonate Laboratory testing with a Gardner falling dart impact tester indicated substantial improvements at several Q-Cel® Hollow Microspheres addition levels (Table 2) Finishing Properties The finishing operation is a major cost factor in most cultured marble manufacturing operations and, in some cases, installation requires drilling and sawing Table shows a comparison of sanding rates for a standard marble and a Q-Cel® Hollow Microspheres modified marble The table shows volume of material removed per minute of sanding Table 3: Sanding Properties of Cultured Marble (1) Minutes Sanding 10 Total at 10 minutes cm Removed per Minute Standard Formulation 0.84 0.63 0.47 0.31 0.3 5.09 4% Q-Cel® 3.18 2.42 2.28 2.61 1.95 24.86 (1)Air sander equipped with 3.5 X inch, 36 grit sandpaper At the start of the test, the Q-Cel® Hollow Microspheres modified part can be sanded in one-quarter of the time required to remove the same amount of material from the standard part After 10 minutes the paper used on the standard cultured marble is worn out It sands at only one-sixth the rate of the paper that has been sanding for 10 minutes on the marble containing Q-Cel® Hollow Microspheres Not only is the labour reduced considerably, but the lower sandpaper usage results in additional savings Another study compared the drilling rates of standard and lightweight cultured marble Drilling of the lightweight Q-Cel® Hollow Microspheres modified marble led to an 80 % reduction in labour Microscopic examination also revealed less wear on drill bits Information contained in this publication (and otherwise supplied to users) is based on our general experience and is given in good faith, but we are unable to accept the responsibility in respect of factors which are outside our knowledge or control Potters Europe (EGM Division, Potters Hollow Spheres & Potters Europe are trading names of Potters Ballotini Limited Q-Cel®, Sphericel®, Spheriglass®, Spheriwhite® and Luxsil® are registered trademarks of Potters Industries LLC Ref:3-02-008-1-02 Field Experience Extensive field testing of Q-Cel® Hollow Microspheres in production shops has confirmed the advantages observed in the laboratory The use of the Microspheres has also led to some other benefits noted by various manufacturers For example, some Q-Cel® Hollow Microspheres users have been able to simplify the expensive customdesigned crates used to prevent the vanities from breaking in shipment The lower weight of the microsphere-modified marble also makes handling easier and reduces operator fatigue Many shops have been able to reduce white pigment concentration with Q-Cel® Hollow Microspheres additions Although they not have strong pigmentation properties themselves, the Microspheres enhance the whiteness of the cultured marble In some cases, the clarity of veining on vertical surfaces was improved by the addition of Hollow Microspheres The thixotropic nature of the Q-Cel® Hollow Microspheres resin system tends to hold the coloured sections together during pouring so that smearing is minimised In addition, some production shops have noted reduced warping and improved mould release characteristics Processing Parameters Q-Cel® Hollow Microspheres were developed as lightweight, economical fillers for plastics They are recommended for those applications where low shear, low pressure processing conditions prevail The typical properties of Q-Cel® Hollow Microspheres are listed in Table Table 4: Typical Properties of Q-Cel® Hollow Microspheres Physical Form Free-flowing powder Colour White Effective Density From 0.14 g/cc to 0.70 g/cc Particle Size Range 60-90 micron Working Pressure From 250 psi (1.8 Mpa) to 3500 psi (24 Mpa) The primary incentive for replacing part of the calcium carbonate filler with Q-Cel® Hollow Microspheres is weight reduction The formulations listed in Table can be used as general guidelines to obtain the indicated weight reductions In preparing these formulations, the typical order of addition should be resin, catalyst, calcium carbonate, Q-Cel® Hollow Microspheres The calcium carbonate should be mixed until uniformly dispersed Add the Q-Cel® Hollow Microspheres, one half at a time, and mix until the particles are thoroughly “wetted out" and dispersed - about one to three minutes for each addition of Q-Cel® Hollow Microspheres Low-shear mixing equipment, such as ribbon blender’s blade or sigma mixers, is suitable for use with Hollow Spheres Planetary mixers or other vertical mixers may also be used at low shear and speed Variable speed mixers with two blades that operate independently also work well to blend in Hollow Microspheres Operate the mixer at high speed to incorporate calcium carbonate into the resin Use the lower speed to disperse the spheres Keep blending time for the microspheres to a minimum High shear mixers such as Cowles dissolvers, dispersators, or roll mills that are commonly used in paint production should be avoided Information contained in this publication (and otherwise supplied to users) is based on our general experience and is given in good faith, but we are unable to accept the responsibility in respect of factors which are outside our knowledge or control Potters Europe (EGM Division, Potters Hollow Spheres & Potters Europe are trading names of Potters Ballotini Limited Q-Cel®, Sphericel®, Spheriglass®, Spheriwhite® and Luxsil® are registered trademarks of Potters Industries LLC Ref:3-02-008-1-02 Table 5: Suggested Addition Rates of Q-CEL® Hollow Microspheres Target Weight Reduction (%) 35 30 25 22 Addition Level (%Wt) Polyester Resin 38.5 35.0 34.0 32.1 Calcium Carbonate 57.7 62.0 64.0 66.0 Q-Cel® 3.8 3.0 2.0 1.9 Safety Information Q-Cel® Hollow Microspheres are moderately alkaline, and prolonged exposure may irritate the respiratory tract In dusty environments, the use of NIOSH-approved mask or respirators is recommended Material Safety Data Sheets (MSDS) will be supplied on request Other Product Range: Sphericel® Ultra-Fine Weight Reducing Hollow Glass Microspheres Spheriglass® Performance-Enhancing Solid Glass Microspheres Spheriwhite® Colour-Enhancing Solid Glass Microspheres Luxsil® Cosmetic Microspheres For further information about our range of Hollow Glass Microspheres, please not hesitate to contact us: Potters Hollow Spheres Pontefract Road Barnsley S71 1HJ South Yorkshire United Kingdom Tel +44 (0) 1226 704 516 Fax +44 (0) 1226 207 615 E-mail: PQHS-Sales@pottersgroup.com Website: www.potterseurope.com Information contained in this publication (and otherwise supplied to users) is based on our general experience and is given in good faith, but we are unable to accept the responsibility in respect of factors which are outside our knowledge or control Potters Europe (EGM Division, Potters Hollow Spheres & Potters Europe are trading names of Potters Ballotini Limited Q-Cel®, Sphericel®, Spheriglass®, Spheriwhite® and Luxsil® are registered trademarks of Potters Industries LLC Ref:3-02-008-1-02 ... factor in most cultured marble manufacturing operations and, in some cases, installation requires drilling and sawing Table shows a comparison of sanding rates for a standard marble and a Q-Cel ... modified marble The table shows volume of material removed per minute of sanding Table 3: Sanding Properties of Cultured Marble (1) Minutes Sanding 10 Total at 10 minutes cm Removed per Minute Standard... After 10 minutes the paper used on the standard cultured marble is worn out It sands at only one-sixth the rate of the paper that has been sanding for 10 minutes on the marble containing Q-Cel