Surface appearance and processing characteristics for urethane-catalyzed low profile-modified polyester-polyurethane hybrid resins

A process for making polyester-polyurethane resin molding compositions comprising reacting:

• (A) an A-side composition comprising a polyfunctional isocyanate compound and a free radical polymerization catalyst with,
• (B) a B-side composition wherein the B-side composition comprises:
• (1) a urethane catalyst, and
• (2) an ethylenically unsaturated monomer solution having dissolved therein from about 40 wt. % to about 90 wt. % based on total B-side, of a substantially water-free, unsaturated polyester polyol which is the reaction product of:
• (a) an unsaturated dicarboxylic acid, dianhydride, anhydride, or derivative thereof, and
• (b) a saturated dicarboxylic acid, dianhydride, anhydride or derivative thereof, in amounts such that the level of unsaturation is greater than about 2.5 moles/Kg where the fumarate levels are greater than 95%, and
• (c) a diol composition which is present in a molar excess to achieve a polyol equivalent weight ranging from about 250 to about 1000,
• said polyester-polyurethane hybrid resin molding composition further comprising a low profile additive and further wherein the polyol resin composition has an acid number less than five.

A polyester-polyurethane hybrid resin molding system comprising:

• (A) an A-side composition comprising a polyfunctional isocyanate compound and a free radical polymerization catalyst with,
• (B) a B-side composition wherein the B-side composition comprises:
• (1) a urethane catalyst, and
• (2) an ethylenically unsaturated monomer solution having dissolved therein from about 40 wt. % to about 90 wt. % based on total B-side, of a substantially water-free, unsaturated polyester polyol which is the reaction product of:
• (a) an unsaturated dicarboxylic acid, dianhydride, anhydride, or derivative thereof, and
• (b) a saturated dicarboxylic acid, dianhydride, anhydride or derivative thereof, in amounts such that the level of unsaturation is greater than about 2.5 moles/Kg wherein the fumarate levels are greater than 95%, and
• (c) a diol composition which is present in a molar excess to achieve a polyol equivalent weight ranging from about 250 to about 1000,
• said polyester-polyurethane hybrid resin molding composition further comprising a low profile additive and further wherein the polyol resin composition has an acid number less than five.

A composition useful in the preparation of a polyester-polyurethane hybrid resin, the composition comprising (A) a urethane catalyst, and (B) an ethylenically unsaturated monomer solution having dissolved therein from about 40 weight percent to about 90 weight percent, based on the total weight of the composition, of a substantially water-free, unsaturated polyester polyol which is the reaction production of:

• 1. an unsaturated dicarboxylic acid, dianhydride, anhydride, or derivatives thereof, and
• 2. a saturated dicarboxylic acid, dianhydride, anhydride, and derivatives thereof, in amounts such that the level of unsaturation is greater than about 2.5 moles/Kg polyol wherein the fumarate levels are greater than 95%, and
• 3. a diol composition which is present in a molar excess to achieve a polyol equivalent weight ranging from about 250 to about 1000,
• the polyol resin composition having an acid number less than five.