Molding compounds

Claim 2

A new and improved process for producing molding compounds comprising: mixing a liquid aldehyde condensate resole with inorganic fillers containing a divalent base to form a paste with the ratio of the resole to fillers being between 4:1 and 1:5, incorporating inorganic fibers into the paste, and converting the resole into a thickened state around the fillers to produce a mechanically handleable molding compound in which the resin will not separate from the filler.

Claim 3

The method of claim 1 wherein said resole is converted to a thickened handleable state after the fibers are incorporated therein.

Claim 4

The method of claim 2 wherein said paste solids comprises at least 50% by weight of inorganic filler.

Claim 5

The method of claim 3 wherein said condensate is a phenol-formaldehyde condensate.

Claim 6

A new and improved process of making sheet molding compound comprising: mixing a liquid aldehyde condensate resole with inorganic fillers containing a divalent base to form a paste with the ratio of the resole to fillers being between 4:1 and 1:5, flowing the paste into a first sheet, adding a layer of chopped fibers to said first sheet, placing a second sheet of paste on top of said layer of fibers, squeezing said first and second layers of paste together around the fibers, converting the resole into a thickened state around the fillers and fibers to produce a mechanically handleable sheet molding compound.

Claim 7

A new and improved process of making sheet molding compound comprising: mixing a liquid aldehyde condensate resole with inorganic fillers containing a divalent base to form a paste with the ratio of the resole to fillers being between 4:1 and 1:5, flowing the paste into a first sheet, adding a layer of chopped fibers to said first sheet, placing a second sheet of paste on top of said layer of fibers, squeezing said first and second layers of paste together around the fibers, converting the resole into a thickened state around the fillers and fibers to produce a mechanically handleable sheet molding compound.

Claim 8

The method of claim 5 wherein said resole is converted to a B-stage after the sheet molding compound is made.

Claim 9

The method of claim 6 wherein said paste solids comprises at least 50% by weight of inorganic filler.

Claim 10

The method of claim 7 wherein said condensate is a phenol-formaldehyde condensate.

Claim 11

The method of claim 7 wherein said sheet molding compound is dehydrated while the resole is being B-staged.

Claim 12

The product produced by the process of claim 9.

Claim 13

A new and improved sheet molding compound comprising: inorganic fibers embedded in inorganic powderous fillers coated with an aldehyde condensate binder, said binder being B-staged in situ around the filler and fibers and being in a ratio to the fillers of between 4:1 and 1:5.

Claim 14

A new and improved sheet molding compound comprising: inorganic fibers embedded in inorganic powderous fillers coated with an aldehyde condensate binder, said binder being B-staged in situ around the filler and fibers and being in a ratio to the fillers of between 4:1 and 1:5.

Claim 15

The sheet molding compound of claim 11 wherein said fillers comprise at least 50% by weight of the filler and binder.

Claim 16

The sheet molding compound of claim 12 wherein said binder is a phenol-formaldehyde condensate.

Claim 17

The sheet molding compound of claim 12 wherein said sheet molding compound is dehydrated to convert the binder to a solid state.

Claim 18

A molding compound comprising: short lengths of inorganic fibers embedded in a paste comprising inorganic powderous fillers that are dispersed throughout an aldehyde condensate binder, said binder being B-staged in situ around the fillers and fibers and being in a ratio to the fillers of between 4:1 and 1:5.

Claim 19

A molding compound comprising: short lengths of inorganic fibers embedded in a paste comprising inorganic powderous fillers that are dispersed throughout an aldehyde condensate binder, said binder being B-staged in situ around the fillers and fibers and being in a ratio to the fillers of between 4:1 and 1:5.

Claim 20

The molding compound of claim 15 wherein said fibers are chopped to lengths between 1/8-inch and 1/2-inch, and the inorganic powderous fillers comprise from 50 to 80% by weight of said paste.

Claim 21

The molding compound of claim 16 wherein said fibers are chopped glass fibers.