Covalently compatible in-mold coating compositions for use with epoxy

• US 7,431,789 B2
• Filed: 07/14/2004
• Issued: 10/07/2008
• Est. Priority Date: 07/15/2003
• Status: Expired due to Fees

• Current Assignee: VRAC LLC
• Original Assignee: VRAC LLC
• Inventors: Smith, Mitchell D., Mack, Patrick E.
• Primary Examiner(s): BUTTNER, DAVID J
• Application Number:
  US10/891,584
• Publication Number:
  US 20050048214A1
• Time in Patent Office: 1,546 Days
• Field of Search: None
• US Class Current: 156/245
• CPC Class Codes: B29C 2037/0035 the coating being applied as liquid, gel, paste or the like
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C09D 133/04 Homopolymers or copolymers of esters C09D143/04 takes precedence
• CPC Class Codes: C09D 4/00 Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16

Abstract

A covalently-compatible in-mold gelcoat composition for use with epoxy matrix resins, including fiber-reinforced substrates, wherein the gelcoat composition comprises an acrylate ester component. Also disclosed is a process for using such composition.

Claims

1. A process for forming a molded plastic substrate comprising:

providing a mold;

providing an epoxy matrix resin base comprising an amine component;

providing a gelcoat composition comprising;

a base resin comprising an ethylenically unsaturated matrix; and

a reactive diluent consisting of one or more functional monomers selected from Formula I,

2. The process of claim 1, wherein at least one functional monomer of the reactive diluent is a methacrylated isobornyl component.

3. The process of claim 1, wherein the gel coat composition comprises a reactive diluent consisting of at least two different functional monomers of formula I.

4. The process of claim 1, wherein the amine component comprises an aliphatic amine.

5. The process of claim 1, wherein at least one functional monomer of the reactive diluent of the gelcoat is isobornyl methacrylate.

6. The process of claim 1, wherein the base resin of the gelcoat comprises unsaturated polyester.

7. The process of claim 1, wherein at least one functional monomer of the reactive diluent of the gelcoat is ethoxylated trimethylpropane triacrylate.

8. The process of claim 1, wherein at least one functional monomer of the reactive diluent of the gelcoat is trimethylpropane trimethacrylate.

9. The process of claim 1, wherein the reactive diluent of the gelcoat consists of isobornyl methacrylate, ethoxylated trimethylpropane triacrylate, and trimethylpropane trimethacrylate.

10. The process of claim 9, wherein the base resin of the gelcoat consists of unsaturated polyester and urethane methacrylate oligomer.

11. The process of claim 1, wherein the gelcoat composition comprises a base resin consisting of unsaturated polyester and urethane methacrylate oligomer;

and reactive diluent consisting of isobornyl methacrylate, ethoxylated trimethylpropane triacrylate, and trimethylpropane trimethacrylate.

12. The process of claim 1, wherein the gelcoat composition consists of a base resin consisting of unsaturated polyester and urethane methacrylate oligomer;

a reactive diluent consisting of isobornyl methacrylate, ethoxylated trimethylpropane triacrylate, and trimethylpropane trimethacrylate;

a UV stabilizer;

a promotion package;

a free radical component;

a stabilizer package;

a thixotropic agent;

a filler;

a pigment; and

an initiator.

13. The process of claim 12, wherein the gelcoat composition consists of a base resin consisting of unsaturated polyester and urethane methacrylate oligomer;

a reactive diluent consisting of isobornyl methacrylate, ethoxylated trimethylpropane triacrylate, and trimethylpropane trimethacrylate;

a UV stabilizer;

a promotion package;

a free radical component consisting of phenothiazine;

isobornyl methacrylate;

a stabilizer package consisting of hydroquinone;

isobornyl methacrylate;

a thixotropic agent consisting of fumed silica;

a filler consisting of wollastonite clay;

a pigment consisting of titanium dioxide white dispersion; and

an initiator consisting of methyl ethyl ketone peroxide.

14. A process for forming a molded plastic substrate comprising:

providing a mold;

providing an epoxy matrix resin base comprising an amine component;

providing a gelcoat composition comprising;

a base resin comprising an ethylenically unsaturated matrix; and

a reactive diluent consisting of one or more functional monomers of Formula I,

15. The process of claim 14, wherein the base resin of the gelcoat comprises unsaturated polyester.

16. The process of claim 14, wherein at least one functional monomer of the reactive diluent is a methacrylated isobornyl component.

17. The process of claim 14, wherein the gel coat composition comprises a reactive diluent consisting of at least two different functional monomers of formula I.

18. The process of claim 14, wherein the amine component comprises an aliphatic amine.

19. The process of claim 14, wherein at least one functional monomer of the reactive diluent of the gelcoat is isobornyl methacrylate.