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US 5,332,536 AGranted
Molding resins and UV-transparent molds made from the resins for making fiber reinforced articles
AssigneeCook Composites and Polymers Co.
InventorRudolph H. Boeckeler
Life of this patent
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Abstract
UV-transparent forming tools or molds are prepared for molding resins comprising a urethane acrylate, e.g. urethane dimethacrylate oligomer, and an alpha,beta-ethylenically unsaturated monomer, e.g., styrene, cured in the presence of a peroxide initiator. The resins are tough, durable and have a wide range of other desirable properties.
Claims20
In the method of making a rigid, fiber reinforcement preform for use in making fiber reinforced molded articles, the method comprising:
- (A) applying a layer of reinforcing fibers coated with an ultraviolet light curable composition which contains a photohardenable material polymerizable under UV light and a polymerization photoinitiator onto a preform mold surface which has a configuration corresponding to at least a portion of the final molded article, and
- (B) exposing the coated fibers to UV light to cure substantially all of the composition to form an essentially rigid preform, the UV light passed through the preform mold surface,
- the improvement comprising using a preform mold surface made from a heat-cured casting of a liquid molding resin comprising in weight percent based on the total weight of the resin:
- (i) at least about 25% of a urethane acrylate which is a reaction product of:
- (a) at least one organic isocyanate compound having two reactive isocyanate groups, the compound represented by the formula OCN--R.sub.1 --NCO where R.sub.1 is an inertly-substituted or unsubstituted divalent aliphatic or cycloaliphatic radical of at least four carbon atoms;
- (b) at least one alpha,beta-ethylenically unsaturated alcohol represented by the formula ##STR2## where R.sub.2 is H or CH.sub.3, and R.sub.3 is an alkylene group of caprolactone group;
- and
- (c) at least one of a glycol or polyhydroxy polymer;
- (ii) at least about 10% of an alpha,beta-ethylenically unsaturated monomer of three to twelve carbon atoms;
- and
- (iii) a catalytic amount of a perioxide initiator.
8 more elements
In the method of making a fiber reinforcement mat, the method comprising the steps of:
- A. forming reinforcing fiber coated with an ultraviolet light curable composition which contains a photohardenable material polymerizable under ultraviolet light and a polymerization photoinitiator into a shaped structure on a preform mold surface, and
- B. exposing the coated fibers to UV light to cure substantially all of the composition whereby the fibers are bonded to one another to form the mat,
- the improvement comprising using a preform mold surface made from a heat-cured casting of a liquid mold resin comprising in weight percent based on the total weight of the resin:
- (i) At least about 25% of a urethane acrylate which is a reaction product of:
- (a) at least one organic isocyanate compound having two reactive isocyanate groups, the compound represented by the formula OCN--R.sub.1 --NCO where R.sub.1 is an inertly-substituted or unsubstituted divalent aliphatic or cycloaliphatic radical of at least four carbon atoms;
- (b) at least one alpha,beta-ethylenically unsaturated alcohol represented by the formula ##STR3## where R.sub.2 is H or CH.sub.3, and R.sub.3 is an alkylene group of caprolactone group;
- and
- (c) at least one of a glycol or polyhydroxy polymer;
- (ii) at least about 10% of an alpha,beta-ethylenically unsaturated monomer of three to twelve carbon atoms;
- and
- (iii) A catalytic amount of a perioxide initiator.
8 more elements
Dependencies are inferred from the claim text.