Ppg Industries, Inc.

Union Carbide Chemicals and Plastics Company, Inc.

David E Dana

Steven J Morris

Ernest L Lawton

Peter C Gaa

George L Brodmann

Eric Raymond Pohl

Enrico J Pepe

Shiu-Chin Huang Su

Thomas P Unites

Howard J Hudson

Richard A Davis

Edward A Martine

Tsao-Chin C Huang

The present invention provides a mat adapted to reinforce a thermosetting matrix material to form a composite, composites formed therefrom, and methods related thereto. The mat includes a primary, supporting layer having a plurality of randomly oriented essentially continuous glass fiber strands. The primary layer has about 1 to about 10 weight percent of the mat on a total solids basis. The mat also includes a secondary layer positioned upon and supported by a surface of the primary layer, the secondary layer including a plurality of glass fiber strands. The mean average length of the glass fiber strands of the secondary layer ranges from about 20 to about 125 millimeters. The strands of the primary layer are entangled with the strands of the secondary layer by needling the primary layer and the secondary layer together.

Glass fiber strand mats, thermosetting composites reinforced with the

Silylated polyester resins comprising the acid salt of a Michael addition adduct of an aminoorganosilane and a conjugated unsaturated polyester resin containing a polyethylene oxide chain segment useful for sizing glass fiber reinforcement of polyester molding composites.

Glass fiber size

Addition interpolymers with pendant ionic moieties and pendant reactable silane moieties are prepared by addition polymerization of ethylenically unsaturated monomers having ionic moieties with organofunctional silane compounds having ethylenic unsaturation in the organofunctional moiety of the silane where the silane also has reactable alkoxy and/or hydroxy group. The addition polymerization is performed in the presence of a free radical initiator at an elevated temperature up to around 90.degree. C. and in a nonoxidizing atmosphere. The amount of the ionic monomer is effective to result in the interpolymer having at least water dispersibility and most suitably water emulsifiability and the amount of the silane monomer is in the range of about 1 to about 15 weight percent of the interpolymer. The interpolymer may be prepared with one or more additional ethylenically unsaturated monomers where the amount does not decrease the ionic character of the interpolymer below that which renders the interpolymer water emulsifiable.

Silyated addition polymers with pendant ionic moieties

Addition interpolymers with pendant ionic moieties and pendant reactable silane moieties are prepared by addition polymerization of ethylenically unsaturated monomers having ionic moieties with organofunctional silane compounds having ethylenic unsaturation in the organofunctional moiety of the silane where the silane also has a reactable alkoxy and/or hydroxy groups. The addition polymerization is performed in the presence of a free radical initiator at an elevated temperature up to around 90.degree. C. and in a nonoxidizing atmosphere. The amount of the ionic monomer is effective to result in the interpolymer having at least water dispersibility and most suitably water emulsifiability and the amount of the silane monomer is in the range of about 1 to about 15 weight percent of the interpolymer. The interpolymer may be prepared with one or more additional ethylenically unsaturated monomers where the amount does not decrease the ionic character of the interpolymer below that which renders the interpolymer water emulsifiable.

Silylated addition polymers with pendant ionic moieties

Chemically treated glass fibers of the present invention provide good processing properties in reinforcing thermosetting polymers while resulting in fiber reinforced thermosetting materials having good strength properties. The chemically treated glass fibers have a dried residue of an aqueous chemical treating composition having: two film forming polymers, at least an acryloxy alkyl trialkoxysilane, a fiber lubricant and polyester curing agent and water. One film forming polymer is a polyvinylacetate copolymer having a low solubility in acetone and the other film forming polymer is unsaturated, curable, essentially linear polyester polymer. The fiber lubricant is a nonionic polyethylene-containing polymer or a cationic lubricant like polyalkylene polyamine polyamino amide, and partially amidated polyalkylenimines and mixtures thereof present in an effective lubricating amount. The nonionic lubricant may be used and the cationic lubricant is used in conjunction with a fuzz reducing agent such as silylated polyazamide. Additional components which may be present include: an amino organofunctional silane coupling agent, and a polyoxyethylene polymer having a molecular weight in the range of 100,000 to 5 million. The dried residue is present on the fibers in the strand in an amount in the range of around 1.5 to 3 percent LOI. Also, the dried strands have a post treatment with an antistatic agent before the strands are utilized as reinforcement for thermosetting materials.

Chemically treated glass fibers for reinforcing polymers

Chemically treated glass fiber reinforcement for thermosetting polymers having a moisture reduced residue of an aqueous chemical treating composition consisting essentially of a vinyl acetate-organosilane copolymer, a vinyl silane coupling agent, an amino-organo silane coupling agent, at least one cationic lubricant, polyoxyethylene, an antistatic agent, an aqueous dispersible or emulsifiable wax with a surfactant and water.

Chemically treated glass fibers for reinforcing thermosetting polymers

A process is provided for making an aqueous dispersible, polyurethane or poly(urethane-urea) polymer which has internal pendant, siliconate anions. The aqueous dispersion is prepared from a reaction product of polyisocyanates, organic compounds with at least 2 active hydrogens, and organosilane which is at least monofunctional in reaction with isocyanate groups on at least one organic moiety of the organo silane and also has at least one hydrolyzed or hydrolyzable groups associated with the silicone atom. Optionally, a hydrophilic additive may also be a comonomer in preparing the reaction product. The polymeric reaction product is formed at temperatures less than 200.degree. C. at atmospheric pressure. The polymeric reaction product is combined with water to form an oil-in-water dispersion and the pH of the aqueous dispersion is maintained at least about 7, when the silyl concentration on the reaction product is at least about 0.1 weight percent based on the water in the dispersion. The polymer can be a prepolymer that is chain extended in the aqueous dispersion. The aqueous dispersion can also be prepared from a prepolymer that is devoid of any organosilane used as a comonomer but where the prepolymer is dispersed and chain-extended with an organosilane that is difunctional in the isocyanate polyaddition reaction. The aqueous dispersion of the polyurethane resin is used in coating myriad substrates such as inorganic oxide substrates.

Process for producing aqueous dispersions, internally silylated and

An aqueous dispersible, isocyanate-containing polymer or prepolymer or chain extended polymer is provided which has internal pendant, reactable silane groups and which can also have internal dispersing aids. The aqueous dispersible, isocyanate-containing polymer, prepolymer, or chain extended polymer produces an aqueous dispersion of a polyurethane polymer having pendant reactable siliconate anions. The isocyanate-containing polymer is prepared from polyisocyanates, organic compounds with at least 2 active hydrogens, and organosilane which is at least monofunctional in reaction with isocyanate groups on at least one organic moiety of the organosilane. The organosilane also may have hydrolyzed or hydrolyzable groups associated with the silicone atom. The prepolymer is formed at temperatures less than 200.degree. C. at atmospheric pressure in a one shot or two step process. The polymer is combined with water to form an oil-in-water dispersion, and, if it is a prepolymer, the molecular weight is increased through chain extension. The pH of the aqueous dispersion of the polyurethane is maintained at least around 7 when the silyl concentration of the polymer is greater than 0.1 weight percent of the water in the dispersion. The aqueous dispersion can also be prepared from a prepolymer that is devoid of any organosilane used as a comonomer and where the prepolymer is dispersed and chain-extended with the difunctional organo silane. The aqueous dispersion of the polyurethane resin is used in coating myriad substrates such as inorganic oxide substrates.

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Pittsburgh, PA, United States of America

David E Dana