Barrier coat for open tool molding
First Claim
1. A multilayer composite article comprising:
- a gel coat layer comprising a thermosetting resin;
a fiber reinforced laminate layer comprising first fibers having a first length; and
a barrier layer disposed between the gel coat layer and the laminate layer;
wherein the barrier layer comprises second fibers dispersed in a polyester resin, said second fibers having a second length shorter than the first length.
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Accused Products
Abstract
A multilayer composite contains a gel coat layer, a laminate layer, and a barrier layer disposed between the gel coat and the laminate layer. The laminate contains from 40-80% by weight paste and from 20-60% by weight reinforcing fibers. The barrier coat also comprises a cured polyester resin, and contains reinforcing fibers shorter than those in the laminate layer. The barrier layer has sufficient flexibility to avoid cracking during demolding and handling. Preferably, the barrier layer exhibits an elongation at break of more than 1%, and more preferably about 2% or more. The resin of the barrier layer can contain up to about 25% by weight of the resin of an isophthalic acid based polyester resin. The composites can be made using an open tool molding process.
19 Citations
45 Claims
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1. A multilayer composite article comprising:
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a gel coat layer comprising a thermosetting resin;
a fiber reinforced laminate layer comprising first fibers having a first length; and
a barrier layer disposed between the gel coat layer and the laminate layer;
wherein the barrier layer comprises second fibers dispersed in a polyester resin, said second fibers having a second length shorter than the first length. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An automotive body panel comprising:
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a gel coat layer;
a laminate layer; and
a barrier coat disposed between the gel coat and the laminate layer, wherein the barrier coat comprises a polyester resin and reinforcing fibers of length 1 mm or less. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19)
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20. A barrier coat composition comprising:
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a resin component comprising;
80-100 parts of dicyclopentadiene resin and up to 20 parts of an isophthalic acid resin, and a reinforcing fiber component comprising fibers having a length of 1 mm or less. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27)
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30. A method for preparing a composite article by spray up operation, comprising the steps of:
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applying a gel coat into a mold;
applying a barrier coat over the gel coat in the mold; and
applying a laminate formula over the barrier coat, wherein the laminate formula contains 20-60% by weight of first reinforcing fibers having a first length of 6 mm or greater and 40-80% by weight of a paste comprising a laminate coat polyester resin;
wherein the barrier coat comprises second fibers having a length less than the first length dispersed in a barrier coat polyester resin. - View Dependent Claims (31, 32, 33, 34, 35, 36)
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37. A method of producing an automotive body panel comprising the steps of:
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applying a gel coat composition to mold surface;
applying a barrier coat composition to the gel coat in the mold;
applying a fiber reinforced laminate composition comprising fibers having a first length onto the barrier coat and the mold;
curing at 50°
C. or less; and
removing the cured article from the mold, wherein the barrier coat comprises polyester resin and glass fibers having a second length shorter than the first length. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45)
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Specification