Owens-corning Fiberglas Corporation

Owens Corning Fiberglas Technology, Inc.

Edward L Wilson

Louis R Ross

Paul R Krumlauf

James V Gauchel

William G Hager

Edward J Kerle

Gordon P Armstrong

Ralph B Jutte

Robert J Gelin

Terry R Beaver

David R Hartman

Kuang-Hong Hsu

John J McCluskey

Richard T Linak

Walter D Cottrell

Allan B Isham

John D Rinehart

Ronald Z Bell

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one polysiloxane polyalkylene copolymer. The compatible components are compatible with the reacted unsaturated polyester and monomer during cure and impart improved surface characteristics when added to low-profile resin systems.

Unsaturated polyester resin compositions containing compatible

A sheet molding composition is provided which exhibits controllable thickening. The composition includes a low molecular weight polyester in which some of the chain ends have been endcapped with functional groups which are unable to react with the thickeners employed in the sheet molding composition. The sheet molding composition has a low viscosity of from about 6 to about 20 million centipoise which allows molding at low pressures of from about 100 to about 300 psi.

Sheet molding composition having controllable thickening

This development provides crystalline unsaturated polyesters having unreacted olefinically unsaturated monomer entrapped within its crystal lattice. The crystalline polyester can be used in high performance, structural SMC products or as a size or binder for glass fiber reinforcements or mats.

Crystalline polyesters

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one compound containing one or more ether substituents. The compatible component is compatible with the reacted unsaturated polyester and monomer during cure and imparts improved surface characteristics when added to low-profile resin systems.

Unsaturated polyester resin compositions containing compatible compounds

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one compound containing one or more sulfate, sulfonate or sulfone substituents. The compatible components are compatible with the reacted unsaturated polyester and monomer during cure and impart improved surface characteristics when added to low-profile resin systems.

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one compound containing one or more aromatic substituents. The compatible components are compatible with the reacted unsaturated polyester and monomer during cure and impart improved surface characteristics when added to low-profile resin systems.

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one compound containing one or more polyoxyethane substituents. The compatible component remains compatible when the polyester and monomer cure and imparts improved surface characteristics when added to low-profile resin systems.

Citrate ester compositions which are useful as compatible components in a resinous system for sheet molding compositions and have a general formula ##STR1## wherein X is selected from the group consisting of --OC.sub.3 H.sub.6).sub.3 --OCH.sub.3 and OH are disclosed. Also disclosed is a sheet molding composition which includes a four component resinous system comprising (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile thermoplastic polymer additives which cause phase separation and internal voids during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components which remain compatible when the polyester and monomer cure and impart improved surface characteristics when added to typical low-profile resin systems.

Citrate ester compounds and processes for their preparation

A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerizes with the unsaturated polyester; and, (d) one or more compatible components containing one or more polyoxyethane substituents. The compatible components remain compatible when the polyester and monomer cure and impart improved surface characteristics when added to typical low-profile resin systems.

Panels are disclosed which are suitable for joiner, non-structural bulkheads. The panels are a laminate having a central portion of gypsum or a magnesium oxy-chloride cement which may or may not be glass fiber reinforced and externally exposed fire-resistant skins directly bonded to opposite sides of the central or core material. These skins are formed of a solid phenol-formaldehyde glass resin composite such as for example a prepreg formed from a woven glass roving of a high strength, high melting point glass and a cured phenol-aldehyde resin.

Fire-resistant panel system

A process is provided for manufacturing ballistic resistant composites of an isophthalic thermoset polyester and woven roving made of magnesia aluminosilicate glass fibers. An impregnating solution is provided whereby pregregs can be conveniently formed and then vacuum bag molded. The ingredients in the impregnating solution are critically selected to provide prescribed viscosities after the elapse of certain periods of time and thereby allow the final articles to be formed in an economical and expedient manner.

Process for forming thick ballistic resistant materials

A process is provided for manufacturing ballistic resistant composites of an isophthalic thermoset polyester and woven roving made of magnesia aluminosilicate glass fibers. An impregnating solution is provided whereby prepregs can be conveniently formed and then vacuum bag molded. The ingredients i the impregnating solution are critically selected to provide prescribed viscosities after the elapse of certain periods of time and thereby allow the final articles to be formed in an economical and expedient manner.

Composite sheets of low pressure molding compounds sandwiched between films of polyethylene are thickened to a viscosity at which the film can be stripped from the composite by the application of low temperatures to at least the surface of the sandwiched composite.

Low temperature maturation of sheet molding compositions

A method and apparatus for producing a sheet molding composite are provided. The sheet molding composite consists of two outer sheets of plastic material between which is sandwiched a moldable material or compound containing fiber-reinforced resin. The resin-containing material is maintained in a deformable, flexible state until it is placed in a mold and subjected to heat, at which time it is cured in the shape of the final molded product. The molding composite is made by depositing a layer of a pre-blended resin-containing material on the upper surface of one of the sheets of plastic material and by then depositing a layer of randomly disposed glass fibers onto this first layer. A second layer of preblended resin-containing material from the same source is also deposited on an upper surface of a second of the plastic sheets. The latter sheet is then turned over and moved into parallel relationship with respect to the first sheet and with the second layer of resin-containing material moved into contact with the reinforcing fibers on the first layer of resin-containing material. The composite is then kneaded to thoroughly mix the fibers and resin-containing material and at least one of the plastic sheets and material therebelow is punctured by needles to remove air through the resulting passages. The resin can then be partially cured and the partially cured composite wound on a reel where it can be stored until molded. To obtain uniformity throughout the composite, the layers of resin-containing material deposited on the sheets must be uniform. Heretofore, this has required very careful blending of the materials for each of the sheets and very careful mixing thereof by kneading, when in the composite. In accordance with the invention, the layers of resin-containing material for the two outer sheets are supplied from the same source so that identical compositions are achieved for those layers. The blending and mixing steps are thus simplified or shortened by this arrangement with uniformity still being assured.

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Newark, OH, United States of America

Edward L Wilson