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 a first set of fibers having a first length; and
a barrier layer disposed between the gel coat layer and the laminate layer;
wherein the barrier layer comprises a second set of fibers dispersed in a polyester resin, said second fibers having a second length shorter than the first length wherein the first length is 6 mm or greater and the second length is 1 mm or less.
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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.
21 Citations
42 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 a first set of fibers having a first length; and a barrier layer disposed between the gel coat layer and the laminate layer; wherein the barrier layer comprises a second set of fibers dispersed in a polyester resin, said second fibers having a second length shorter than the first length wherein the first length is 6 mm or greater and the second length is 1 mm or less. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. 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 (11, 12, 13, 14, 15, 16, 17, 18)
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19. 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, anda reinforcing fiber component comprising fibers having a length of 1 mm or less mixed with the resin component. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26)
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27. 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 applying the laminate formula comprises providing the laminate formula comprising 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; andwherein applying the barrier coat comprises providing second fibers having a length of 1 mm or less dispersed in a barrier coat polyester resin. - View Dependent Claims (28, 29, 30, 31, 32, 33)
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34. A method of producing an automotive body panel comprising the steps of:
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applying a gel coat composition to a 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 in the mold; curing at 50°
C. or less; andremoving the cured article from the mold, wherein applying the barrier coat comprises providing glass fibers having length of 1 mm or less dispersed in a polyester resin. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42)
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Specification