High density structural reaction injection molded composite containing a fabric of nonwoven spunbonded fibers made of a polyester core sheathed in a polyamide skin embedded in a polyurethane matrix
AssigneeBASF SE
InventorGregg S. Kuyzin
Life of this patent
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Abstract
A high density structural reaction injection molded (SRIM) composite having a fabric comprised of nonwoven spunbonded fibers made of a polyester core sheathed in a polyamide skin, is embedded in a polyurethane matrix, providing a part having a blister free surface upon baking in a paint oven. A baked part having a near Class A or Class A surface finish can be attained by adding a show surface veil made of a soft nonwoven polyester fiber mat to the polyurethane matrix over the nonwoven spun bonded fabric. These parts have structural applications which require high strength and good surface finishes, such as in automotive exterior panels.
Claims24
An essentially noncellular structural reaction injection molded composite having a density of about 1.0 g/cm.sup.3 or greater and a flexural modulus of about 500,000 p.s.i. or greater, comprising a fabric embedded in a polyurethane matrix, said fabric comprised of a nonwoven spunbonded fibers having a polyester core sheathed in a polyamide skin, and said polyurethane matrix having a viscosity from about 10 to about 2,000 cps., at 25.degree. C., upon injection into a mold.
A process of making an essentially noncellular structural reaction injection molded composite having a density of about 1.0 g/cm.sup.3 or greater and a flexural modulus of about 500,000 p.s.i. or greater, comprising reacting in the presence of a polymerization catalyst a polyisocyanate, an isocyanate reactive component containing active hydrogen functionalities and optionally a:
- a) water scavenger, a
- b) chain extender, a
- c) trimerization catalyst, a
- d) flame retardant, or
- e) fillers, or
- f) mixtures thereof, and
- injecting the reaction mixture having a viscosity from about 10 to about 2,000 cps. at 25.degree. C. into a mold containing a material comprised of nonwoven spunbonded fibers made of a polyester core sheathed in a polyamide skin.
Dependencies are inferred from the claim text.