Method of forming a polyester preimpregnated fiberglass sheet

Claim 3

ABOUT 2 TO 10 WEIGHT PERCENT OF REACTIVE DILUENT, SELECTED FROM THE GROUP CONSISTING OF STYRENE, METHYL METHACRYLATE, VINYL, TOLUENE,DIALLYL PHTHALATE, VINYL ACETATE, CYCLOPENTADIENE AND ALLYL MALEATE, 3.ABOUT 30 TO 65 WEIGHT PERCENT FILLER COMPRISING ALUMINA TRIHYDRATE, AND

Claim 4

ABOUT 2 TO 10 WEIGHT PERCENT OF REACTIVE DILUENT, SELECTED FROM THE GROUP CONSISTING OF STYRENE, METHYL METHACRYLATE, VINYL, TOLUENE,DIALLYL PHTHALATE, VINYL ACETATE, CYCLOPENTADIENE AND ALLYL MALEATE, 3.ABOUT 30 TO 65 WEIGHT PERCENT FILLER COMPRISING ALUMINA TRIHYDRATE, AND

Claim 5

about 2 to 10 weight percent of reactive diluent, selected from the group consisting of styrene, methyl methacrylate, vinyl toluene, diallyl phthalate, vinyl acetate, cyclopentadiene and allyl maleate,

Claim 6

about 2 to 10 weight percent of reactive diluent, selected from the group consisting of styrene, methyl methacrylate, vinyl toluene, diallyl phthalate, vinyl acetate, cyclopentadiene and allyl maleate,

Claim 7

about 2 to 10 weight percent of styrene,

Claim 8

about 2 to 10 weight percent of styrene,

Claim 9

The method of claim 1 wherein the reactive diluent is styrene, the filler consists essentially of alumina trihydrate having a particle size between about 2 to 35 microns diameter, the fibrous mat is made of glass fibers, and the composition is semi-cured in step (E) by allowing it to thicken for at least 4 hours to a viscosity between about 10,000,000 to 80,000,000 cps.

Claim 10

The method of claim 2 wherein at least two filled, flame resistant mats are stacked up and laminated in an open press at a temperature above about 100*C and a pressure above about 200 psi, to provide a flame resistant, consolidated, bonded laminate having a surface substantially free of surface irregularities and excess resin.

Claim 11

about 30 to 65 weight percent of alumina trihydrate filler having a particle size between about 2 to 35 microns diameter,

Claim 12

about 30 to 65 weight percent of alumina trihydrate filler having a particle size between about 2 to 35 microns diameter,

Claim 13

about 30 to 65 weight percent filler comprising alumina trihydrate, and

Claim 14

about 30 to 65 weight percent filler comprising alumina trihydrate, and

Claim 15

AN EFFECTIVE AMOUNT OF HARDENER, EFFECTIVE TO CATALYZE THE ADMIXTURE ONLY AT TEMPERATURES ABOVE ABOUT 100*C; AND THEN B. ADDING TO THE ADMIXTURE, ABOUT 0.2 TO 5 WEIGHT PERCENT OF A THICKENER SELECTED FROM THE GROUP CONSISTING OF CALCIUM OXIDE, MAGNESIUM OXIDE AND MIXTURES THEREOF, TO PROVIDE A RESINOUS COMPOSITION HAVING A VISOCITY BETWEEN ABOUT 18,000 TO 30,000 CPS AT 25*C; AND THEN C. IMMEDIATELY COATING THE COMPOSITION AT ABOUT ROOM TEMPERATURE ONTO AT LEAST ONE SURFACE OF A FIBROUS MAT OF SUBSTANTIALLY FIXED FIBERS; AND THEN D. CAMPACTING THE COATED MAT AT ABOUT ROOM TEMPERATURE, TO CAUSE THE COMPOSITION TO FLOW AROUND THE FIBERS OF THE MAT AND COMPLETELY FILL THE MAT; AND THEN E. SEMI-CURING THE COMPOSITION WITHIN THE MAT AT ABOUT ROOM TEMPERATURE, BY ALLOWING THE COMPOSITION TO THICKEN TO A VISCOSITY OVER ABOUT 10,000,000 CPS AT 25*C, SAID FILLED POLYESTER COMPOSITION HAVING A WEIGHT RATIO OF RESIN COMPOSITION TO FIBER OF BETWEEN ABOUT 3:1 TO 1:1, TO FORM A FILLED, RESINOUS, FLAME RESISTANT MAT, CONTAINING A NON-FLOWABLE, FILLED, POLYESTER COMPOSITION.

Claim 16

AN EFFECTIVE AMOUNT OF HARDENER, EFFECTIVE TO CATALYZE THE ADMIXTURE ONLY AT TEMPERATURES ABOVE ABOUT 100*C; AND THEN B. ADDING TO THE ADMIXTURE, ABOUT 0.2 TO 5 WEIGHT PERCENT OF A THICKENER SELECTED FROM THE GROUP CONSISTING OF CALCIUM OXIDE, MAGNESIUM OXIDE AND MIXTURES THEREOF, TO PROVIDE A RESINOUS COMPOSITION HAVING A VISOCITY BETWEEN ABOUT 18,000 TO 30,000 CPS AT 25*C; AND THEN C. IMMEDIATELY COATING THE COMPOSITION AT ABOUT ROOM TEMPERATURE ONTO AT LEAST ONE SURFACE OF A FIBROUS MAT OF SUBSTANTIALLY FIXED FIBERS; AND THEN D. CAMPACTING THE COATED MAT AT ABOUT ROOM TEMPERATURE, TO CAUSE THE COMPOSITION TO FLOW AROUND THE FIBERS OF THE MAT AND COMPLETELY FILL THE MAT; AND THEN E. SEMI-CURING THE COMPOSITION WITHIN THE MAT AT ABOUT ROOM TEMPERATURE, BY ALLOWING THE COMPOSITION TO THICKEN TO A VISCOSITY OVER ABOUT 10,000,000 CPS AT 25*C, SAID FILLED POLYESTER COMPOSITION HAVING A WEIGHT RATIO OF RESIN COMPOSITION TO FIBER OF BETWEEN ABOUT 3:1 TO 1:1, TO FORM A FILLED, RESINOUS, FLAME RESISTANT MAT, CONTAINING A NON-FLOWABLE, FILLED, POLYESTER COMPOSITION.

Claim 17

about 0.2 to 3 weight percent of a hardener, effective to catalyze the admixture at temperatures of about 100*C, selected from the group consisting of tertiary butyl perbenzoate, benzoyl peroxide and dicumyl peroxide, and

Claim 18

about 0.2 to 3 weight percent of a hardener, effective to catalyze the admixture at temperatures of about 100*C, selected from the group consisting of tertiary butyl perbenzoate, benzoyl peroxide and dicumyl peroxide, and

Claim 19

The method of claim 3 wherein the admixture contains about 0.2 to 3 weight percent of a hardener selected from the group consisting of tertiary butyl perbenzotate, benzoyl peroxide and dicumyl peroxide.

Claim 20

an effective amount of hardener, effective to catalyze the admixture only at temperatures above about 100*C; and then B. adding to the admixture, about 0.2 to 5 weight percent of a thickener selected from the group consisting of calcium oxide, magnesium oxide and mixtures thereof, to provide a resinous composition having a viscosity between about 18,000 to 30,000 cps at 25*C; and then C. immediately coating the composition at about room temperature onto at least one surface of a fibrous mat of substantially fixed fibers; and then D. compacting the coated mat at about room temperature, to cause the composition to flow around the fibers of the mat and completely fill the mat; and then E. semi-curing the composition within the mat at about room temperature, by allowing the composition to thicken to a viscosity over about 10,000,000 cps at 25*C, said filled polyester composition having a weight ratio of resin composition to fiber of between about 3:1 to 1:1, to form a filled, resinous, flame resistant mat, containing a non-flowable, filled, polyester composition.

Claim 21

an effective amount of hardener, effective to catalyze the admixture only at temperatures above about 100*C; and then B. adding to the admixture, about 0.2 to 5 weight percent of a thickener selected from the group consisting of calcium oxide, magnesium oxide and mixtures thereof, to provide a resinous composition having a viscosity between about 18,000 to 30,000 cps at 25*C; and then C. immediately coating the composition at about room temperature onto at least one surface of a fibrous mat of substantially fixed fibers; and then D. compacting the coated mat at about room temperature, to cause the composition to flow around the fibers of the mat and completely fill the mat; and then E. semi-curing the composition within the mat at about room temperature, by allowing the composition to thicken to a viscosity over about 10,000,000 cps at 25*C, said filled polyester composition having a weight ratio of resin composition to fiber of between about 3:1 to 1:1, to form a filled, resinous, flame resistant mat, containing a non-flowable, filled, polyester composition.

Claim 22

The method of claim 3 wherein the coated mat is compacted by passing it through at least one set of rollers which exert a pressure on the coated fibrous mat.

Claim 23

0 to about 10 weight percent of a flexibilizer; and then B. adding to the admixture about 0.2 to 5 weight percent of a thickener selected from the group consisting of calcium oxide, magnesium oxide and mixtures thereof, to provide a resinous composition having a viscosity between about 18,000 to 30,000 cps at 25*C; and then C. immediately coating the composition at about room temperature onto at least one of two moving sheets of plastic material; D. feeding a glass fiber mat at the same rate of speed as and between the moving plastic sheets so that the coating contacts and coats at least one surface of the mat; E. feeding the composite of coated mat and top and bottom plastic sheets between at least one set of rollers, at about room temperature, which exert a pressure on the composite to compact the composite and cause the composition to flow around the glass fibers of the mat and completely fill the mat; and then F. feeding the composite onto a take-up reel; and then G. semi-curing the compsition within the mat at about room temperature, by allowing the composition within the mat to thicken for at least 4 hours from the time of compacting, to a viscosity between about 10,000,000-80,000,000 cps at 25*C, said filled polyester composition having a weight ratio of resin composition to glass fiber of between about 3:1 to 1:1, to form a filled, Resinous, flame resistant mat containing a non-flowable filled polyester composition, H. unrolling the composite and stripping the top and bottom plastic sheets from the mat; and then I. placing at least two of the filled, flame resistant mats on top of each other and molding them in an open press, at a temperature above about 100*C and a pressure above about 200 psi, to provide a flame resistant, consolidated, bonded laminate, having a surface substantially free of surface irregularities and excess resin.

Claim 24

0 to about 10 weight percent of a flexibilizer; and then B. adding to the admixture about 0.2 to 5 weight percent of a thickener selected from the group consisting of calcium oxide, magnesium oxide and mixtures thereof, to provide a resinous composition having a viscosity between about 18,000 to 30,000 cps at 25*C; and then C. immediately coating the composition at about room temperature onto at least one of two moving sheets of plastic material; D. feeding a glass fiber mat at the same rate of speed as and between the moving plastic sheets so that the coating contacts and coats at least one surface of the mat; E. feeding the composite of coated mat and top and bottom plastic sheets between at least one set of rollers, at about room temperature, which exert a pressure on the composite to compact the composite and cause the composition to flow around the glass fibers of the mat and completely fill the mat; and then F. feeding the composite onto a take-up reel; and then G. semi-curing the compsition within the mat at about room temperature, by allowing the composition within the mat to thicken for at least 4 hours from the time of compacting, to a viscosity between about 10,000,000-80,000,000 cps at 25*C, said filled polyester composition having a weight ratio of resin composition to glass fiber of between about 3:1 to 1:1, to form a filled, Resinous, flame resistant mat containing a non-flowable filled polyester composition, H. unrolling the composite and stripping the top and bottom plastic sheets from the mat; and then I. placing at least two of the filled, flame resistant mats on top of each other and molding them in an open press, at a temperature above about 100*C and a pressure above about 200 psi, to provide a flame resistant, consolidated, bonded laminate, having a surface substantially free of surface irregularities and excess resin.

Claim 27

The method of claim 6 wherein the plastic materials coated in step (C) are polyethylene sheets.

Claim 28

The method of claim 6 wherein the top and bottom plastic sheets of the composite are not stripped until the composition is allowed to thicken for at least 4 hours.

Claim 29

The method of claim 6 wherein the composition is coated on the sheet of plastic material that contacts the top of the fiber mat.