초록 ▼

A molding process, resinous formulations for use in the process, and the resulting products are disclosed characterized in that the product comprises mainly a bulk or fill resinous body having a film or skin of a cross-linked polyester resin formed about the body. Even though the body has intricate

A molding process, resinous formulations for use in the process, and the resulting products are disclosed characterized in that the product comprises mainly a bulk or fill resinous body having a film or skin of a cross-linked polyester resin formed about the body. Even though the body has intricate curving surface contours, the film is smooth and free of surface tears and blemishes. The product is molded by first spraying formulated, dry particles of a partially cured polyester resin against a hot female mold to cause the particles to fuse and flow and form a substantially continuous skin or film on the female mold. Thereafter, the bulk resin is added and the mold is heated to cure the polyester resin as well as the bulk resin and to interreact the bulk and polyester resins together to mold the bulk resin with a film of the polyester resin.

대표청구항 ▼

A process for molding in a mold having relatively sharp bends and intricately curving, irregular surface contours a two-part bulk article comprising a sheet molding compound of relatively inferior physical properties, subject to exhibiting sink marks, porosity, waviness, pits, dimples, and the like

A process for molding in a mold having relatively sharp bends and intricately curving, irregular surface contours a two-part bulk article comprising a sheet molding compound of relatively inferior physical properties, subject to exhibiting sink marks, porosity, waviness, pits, dimples, and the like after molding, defining the bulk of said article, and a resinous film of relatively superior physical properties, having little or no tears or film blemishes after molding, coating said sheet molding compound, said process comprising: coating the intricately curving, irregular surface contours of said mold while hot with particles of a partially cured, cross-linking polyester resin, substantially all of said particles containing within the particulate form said polyester resin, a catalytic amount of a peroxide catalyst, and a flow agent, causing said particles to fuse and bond from the heat of the mold and coalesce into a substantially continuous film coating said mold, said flow agent causing said polyester resin particles to flow along the mold after said fusing, filling the mold with a bulk, curable, organic sheet molding compound compatible with said polyester resin, and then heating the mold to cure said bulk fill resin to the shape of the mold and finally cure said polyester film while adhering the film to said molded bulk fill resin, said molded film having little or no tears or film blemishes in spite of the intricately curving irregular surface contours of the mold.