Composites of metal-modified urea-melamine-formaldehyde resins and fillers

Claim 2

A composite molded product comprising the pressure molded and cured product produced by the process comprising: (a) uniformly blending about 80 to about 60% by weight of expanded perlite particles with an aqueous solution of about 20 to 40% by weight of a thermosetting Group IVB metal-modified urea-melamine-formaldehyde resin to produce a composite mixture, whereafter said composite mixture is directly charged into a mold; (b) molding the composite mixture in said mold under a pressure of about 9 to 14 kg/cm 2 to produce a molding; and (c) curing the molding at a temperature of about 65° to 95° C. to produce the composite molded product to thereby thermoset the same.

Claim 3

The molded product of claim 1, wherein said metal-modified urea-melamine-formaldehyde resin is a titanium-modified urea-melamine-formaldehyde resin.

Claim 4

The molded product of claim 1, wherein the amount of said expanded perlite particles is about 75 to 80% by weight and the amount of said metal-modified urea-formaldehyde resin is about 20 to 25% by weight.

Claim 5

The molded product of claim 1, wherein said expanded perlite particles have a particle size ranging from about 0.15 to 4.0 mm.

Claim 6

A reinforced composite molded product comprising the pressure molded and cured product produced by the process comprising: (a) uniformly blending about 79 to 40% by weight of expanded perlite particles with an aqueous solution of about 20 to 40% by weight of a thermosetting Group IVB metal-modified urea-formaldehyde resin and about 1 to 20% by weight of a fibrous reinforcing material to produce a composite mixture, whereafter said composite mixture is directly charged into a mold; (b) molding the composite mixture in said mold under a pressure of about 9 to 14 kg/cm 2 to produce a molding; and (c) curing the molding at a temperature of about 65° to 95° C. to produce the composite molded product to thereby thermoset the same.

Claim 7

A reinforced composite molded product comprising the pressure molded and cured product produced by the process comprising: (a) uniformly blending about 79 to 40% by weight of expanded perlite particles with an aqueous solution of about 20 to 40% by weight of a thermosetting Group IVB metal-modified urea-formaldehyde resin and about 1 to 20% by weight of a fibrous reinforcing material to produce a composite mixture, whereafter said composite mixture is directly charged into a mold; (b) molding the composite mixture in said mold under a pressure of about 9 to 14 kg/cm 2 to produce a molding; and (c) curing the molding at a temperature of about 65° to 95° C. to produce the composite molded product to thereby thermoset the same.

Claim 8

The reinforced composite molded product of claim 5, wherein said metal-modified urea-melamine-formaldehyde resin is a titanium-modified urea-melamine-formaldehyde resin.

Claim 9

The reinforced composite molded product of claim 5, wherein the amount of said expanded perlite particles is about 60 to 55% by weight, the amount of said metal-modified urea-formaldehyde resin is about 20 to 25% by weight and said reinforcing fiber is 15 to 20% by weight.

Claim 10

The reinforced composite molded product of claim 5, wherein said expanded perlite particles have a particle size ranging from 0.15 to 4.0 mm.

Claim 11

The reinforced composite molded product of claim 5, wherein the fibrous reinforcing material is an organic fibrous reinforcing material, an inorganic fibrous reinforcing material or a mixture thereof.

Claim 12

The reinforced composite molded product of claim 9, wherein the fibrous reinforcing material is fiberglass, newsprint fiber, wood fiber or polyester fiber.

Claim 13

A reinforced composite molded product comprising the pressure molded and cured product produced by the process comprising: (a) uniformly blending about 68 to 36% by weight of expanded perlite particles, an aqueous solution of about 17 to 36% by weight of a thermosetting Group IVB metal-modified urea-melamine formaldehyde resin, about 1 to 18% by weight of a fibrous reinforcing material and about 14 to 10% by weight of a filler material to produce a composite mixture, whereafter said composite mixture is directly charged into a mold; (b) molding the composite mixture in said mold under a pressure of about 9 to 14 kg/cm 2 to produce a molding; and (c) curing the molding at a temperature of about 65° to 95° C. to produce the composite molded product to thereby thermoset the same.

Claim 14

A reinforced composite molded product comprising the pressure molded and cured product produced by the process comprising: (a) uniformly blending about 68 to 36% by weight of expanded perlite particles, an aqueous solution of about 17 to 36% by weight of a thermosetting Group IVB metal-modified urea-melamine formaldehyde resin, about 1 to 18% by weight of a fibrous reinforcing material and about 14 to 10% by weight of a filler material to produce a composite mixture, whereafter said composite mixture is directly charged into a mold; (b) molding the composite mixture in said mold under a pressure of about 9 to 14 kg/cm 2 to produce a molding; and (c) curing the molding at a temperature of about 65° to 95° C. to produce the composite molded product to thereby thermoset the same.

Claim 15

The reinforced composite molded product of claim 11, wherein said metal-modified urea-melamine-formaldehyde resin is a titanium-modified urea-melamine-formaldehyde resin.

Claim 16

The reinforced composite molded product of claim 11, wherein said expanded perlite particles have a particle size ranging from 0.15 to 4.0 mm.

Claim 17

The reinforced composite molded product of claim 11, wherein said filler material is selected from the group consisting of clay, mica, silica, alumina and wood flour.

Claim 20

The method of claim 15, wherein said expanded perlite particles have a particle size ranging from about 0.15 to 4.0 mm.

Claim 21

The method of claim 15, wherein said metal-modified urea-melamine-formaldehyde resin is a titanium-modified urea-melamine-formaldehyde resin.

Claim 22

The method of claim 15, wherein during step (a) there is further uniformly blended a fibrous reinforcing material to produce said composite mixture.

Claim 23

The method of claim 18, wherein the fibrous reinforcing material is an organic fibrous reinforcing material, an inorganic fibrous reinforcing material or a mixture thereof.

Claim 24

The method of claim 19, wherein the fibrous reinforcing material is fiberglass, newsprint fiber, wood fiber or polyester fiber.

Claim 25

The method of claim 18, wherein said composite mixture further comprises a filler.

Claim 26

The method of claim 21, wherein said filler is selected from the group consisting of clay, mica, silica, alumina and wood flour.