Crosslinkable thermoplastic compositions and processes therefor

Claim 2

A REINFORCED POLYESTER MOLDING COMPOSITION WHICH IS A DRY, FREE-FLOWING, SELF-FEEDING SOLID AT ROOM TEMPERATURE, FUSIBLE AND INJECTION MOLDABLE AT TEMPERATURES BETWEEN ABOUT 65*C AND ABOUT 107*C AND CROSSLINKABLE TO THE THERMOSET STATE UPPON HEATING AT SUBSTANTIALLY HIGHER TEMPERATURES, COMPRISING: A. A POLYUNSATURATED POLYMER RESIN HAVING A MELTING POINT ABOVE ABOUT 65*C B. IN PROPORTIONS BY WEIGHT OF FROM ABOUT 5 95 TO ABOUT 70 30 BASED UPON SAID POLYESTER RESIN, AN ACRYLIC CROSSLINKING AGENT OF ONE OF THE FOLLOWING TYPES:

Claim 3

The composition according to claim 1 wherein the proportion of (b) to (a) is from about 10/90 to 50/50 by weight.

Claim 4

The composition according to claim 1 wherein (c) comprises about 0.1 to 2% of the combined weight of (a)+(b).

Claim 5

The composition of claim 1 wherein (c) is chosen from the group consisting of t-butyl peracetate; methyl ethyl ketone peroxides; t-butyl perbenzoate; 2,5-dimethyl-2,5-bis(t-butylperoxy)hexane; di-t-butyl peroxide; 2,5-dimethyl-2-5-bis(t-butyl peroxy) hexyl-3; 2,4-pentanedione peroxide; t-butyl hydroperoxide; 2,5-dimethyl-2,5-bis(benzoylperoxy) hexane; t-butyl percrotonate; di-t-butyl diperoxyphthalate; a,a''-bis(t-butylperoxy) diisopropylbenzene; n-butyl-4,4-bis(t-butylperoxy)valerate; dicumyl peroxide; 1,1,3,3-tetramethyl butyl hydroperoxide; cumene hydroperoxide; 2,5-dimethyl hexane-2,5-dihydroperoxide; acetyl acetone peroxide; and t-butyl peroxy isopropyl carbonate.

Claim 6

The composition of claim 1 wherein (d) is chosen from the groups consisting of glass fibers, asbestos, synthetic organic fibers and graphite fibers.

Claim 7

The composition of claim 1 wherein a minor amount of a stabilizer is also present in said composition to safeguard same against premature crosslinking.

Claim 8

The composition according to claim 6 wherein said stabilizer is hydroquinone, hydroquinone monomethyl ether, butylated hydroxy toluene, butylated hydroxy anisole, 2,6-di-t-butyl-4-methyl phenol or mixtures thereof.

Claim 9

The composition of claim 1 wherein said molding composition is fusible at temperatures below abOut 93*C.

Claim 10

The molding composition of claim 1 wherein said crosslinking agent is the condensate of hydroxymethyl diacetone acrylamide having a molecular weight in the range of 400 to 1000.

Claim 11

The molding composition of claim 1 wherein said solid filler material is calcium carbonate, calcium silicate, clay, aluminum silicate, magnesium silicate, silica, hydrated kaolin, wood flour, aluminum trihydrate, antimony trioxide, zinc borate, mica or mixtures thereof.

Claim 12

A molding composition which is a self-feeding solid at room temperature and has a melting point above about 65*C comprising: a. a solid polyunsaturated thermosettable polyester which is a condensation product of at least one dihydric alcohol and at least one dicarboxylic acid or ester-forming derivative thereof, b. a crosslinking agent which is methylene bis acrylamide, ethylene glycol diacrylate, ethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, trimethylol propane triacrylate, pentaerythritol tetramethacrylate, bisphenol A dimethacrylate, tetramethylene diacrylate, tetramethylene dimethacrylate or the condensate of hydroxymethyl diacetone acrylamide having a molecular weight of 400 to 3000, wherein the weight ratio of said polyester to said crosslinking agent ranges from about 30/70 to 95/5, c. a peroxide-type initiator having a 10 hour half-life above about 93*C in an amount of about 0.1 to 2% based on the combined weight of said polyester and crosslinking agent, d. reinforcing fibers in an amount of about 5 to 75% based on the weight of said composition, and e. inorganic filler material in an amount from about 5 to about 75% by weight of said composition wherein the combined weight of said polyester and said crosslinking agent is maintained at at least 20% by weight of said composition.

Claim 13

A molding composition which is a self-feeding solid at room temperature and has a melting point above about 65*C comprising: a. a solid polyunsaturated thermosettable polyester which is a condensation product of at least one dihydric alcohol and at least one dicarboxylic acid or ester-forming derivative thereof, b. a crosslinking agent which is methylene bis acrylamide, ethylene glycol diacrylate, ethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, trimethylol propane triacrylate, pentaerythritol tetramethacrylate, bisphenol A dimethacrylate, tetramethylene diacrylate, tetramethylene dimethacrylate or the condensate of hydroxymethyl diacetone acrylamide having a molecular weight of 400 to 3000, wherein the weight ratio of said polyester to said crosslinking agent ranges from about 30/70 to 95/5, c. a peroxide-type initiator having a 10 hour half-life above about 93*C in an amount of about 0.1 to 2% based on the combined weight of said polyester and crosslinking agent, d. reinforcing fibers in an amount of about 5 to 75% based on the weight of said composition, and e. inorganic filler material in an amount from about 5 to about 75% by weight of said composition wherein the combined weight of said polyester and said crosslinking agent is maintained at at least 20% by weight of said composition.

Claim 14

The composition according to claim 11 wherein said crosslinking agent is the condensate of hydroxymethyl diacetone acrylamide having a molecular weight in the range of 400 to 1000.

Claim 15

The composition of claim 11 wherein a minor amount of a stabilizer is also present in said composition to safeguard same against premature crosslinking.

Claim 16

The composition according to claim 11 wherein said filler material is calcium carbonate, calcium silicate, clay, aluminum silicate, magnesium silicate, silica, hydrated kaolin, wood flour, aluminum trihydrate, antimony trioxide, zinc borate, mica or mixtures thereof.

Claim 17

The composition according to claim 13 wherein the said filler material comprises a mixture of aluminum hydrate, zinc borate, and antimony trioxide.

Claim 18

The composition according to claim 13 wherein said filler material is present in an amount of about 15 to 75% by weight of said composition.