Abstract The specification describes a process for making a sheet molding compound wherein a layer of resin-filler paste that includes a thickening agent and a hardening catalyst is put down upon a first layer of sheet material; a layer of glass fibers that are sized with a material which induces wet out is placed thereon; following which another layer of the resin-filler paste containing the catalyst is placed thereon and covered by a second layer of sheet material. The sandwich thus formed is fed into the bite of rollers which squeeze out air and compress the resinfiller paste around the sized fibers, following which the composite is placed under further compaction that includes a perforating means which forces needle-like members through at least one layer of the sheet material, through the resin-filled paste, and into the layer of fibers for the removal of remaining entrapped air. The glass fibers which are used are sized with a material that includes both a hardening resin, and a nonhardening resin. Specifically, the fibers are coated with an unsaturated polyester resin and a saturated polyester resin which are preferably deposited on the glass fibers as emulsified particles.
The composite of claim 1 wherein the fibers are coated with a polyester resin material containing at least approximately 5 percent of a saturated polyester resin.
Claim 2
Dependent Claim
41 words
The composite of claim 2 wherein the molding compound comprises the following approximate percentages by weight: 42.7 unsaturated polyester resin, 0.85 dicumyl peroxide, 0.09 2,5-dimethyl hexyl-2,5-di (peroxybenzoate), 1.7 zinc stearate, 6.4 polyethylene homopolymer, 43.7 CaCO3 filler, 4.27 styrene, 1.28 hydrated CaO.
Claim 3
Dependent Claim
76 words
A composite from which glass fiber-reinforced articles can be formed including a layer of a molding compound comprising a catalyzed resin-filler paste surrounding randomly disposed glass fibers coated with a coupling agent, a smooth sheet of plastic material on each of opposite major faces of said layer, at least one of said layers of sheet material having a multiplicity of holes therein disposed in a predetermined, repetitive pattern, said layer being in a pliable, non-tacky state.
Claim 4
Dependent Claim
19 words
A composite according to claim 4 wherein longitudinally extending edges of said sheets are uncoated and are folded over.
Claim 5
Dependent Claim
17 words
A composite according to claim 5 characterized further by said sheets of plastic material are polyethylene films.