US4785040A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Phenolic molding materials and processes
Assignee: Occidental Chemical Corp
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Filing: 1985-10-04
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Granted: 1988-11-15
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Expires: 2005-10-04
Abstract
Abstract Novel phenolic molding compositions comprise (1) a resole phenolic resin, (2) an alkaline earth metal hydroxide or oxide, and/or a silane compound, and (3) a mixture of clay and talc fillers and/or microballoons. The composition also generally contains a mold release agent, and a silane coupling agent. The alkaline earth metal hydroxide or oxide is preferably calcium and/or magnesium hydroxide or oxide. A mixture of the calcium and magnesium compounds is most preferred. The foregoing molding compositions are applied to glass fibers or filaments to provide compositions useful in sheet molding compound processes, pultrusion processes, filament winding, and continuous laminating processes, as well as in ram injection molding and transfer molding.
Inventors
- 👤 Manoj K. Gupta
- 👤 Donald W. Hoch
- 👤 Gideon Salee
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 12:06
CPC Classifications
C; C08; C08K; C08K3/00; C08K3/34; C08K3/346; B; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/50; C08K3/18; C08K3/20; C08K3/22; C08K7/00; C08K7/16; B29C70/52; B29K; B29K2061/00; B29K2061/04
Claims Analysis
Total Claims: 47
Claim 1
Independent Claim
73 words
A phenolic molding composition comprising (1) a resole pheolic resin, (2) an alkaline earth metal hydroxide or oxide, or a mixture of more than one alkaline earth metal hydroxide or oxide or a silane compound, and (3) a mixture of clay and tac fillers, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said pheolic resin.
Claim 2
Dependent Claim
73 words
A phenolic molding composition comprising (1) a resole pheolic resin, (2) an alkaline earth metal hydroxide or oxide, or a mixture of more than one alkaline earth metal hydroxide or oxide or a silane compound, and (3) a mixture of clay and tac fillers, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said pheolic resin.
Claim 3
Dependent Claim
26 words
The composition of claim 1 wherein component (3) is a mixture of clay and talc, and wherein component (2) is calcium and/or magnesium hydroxide or oxide.
Claim 4
Dependent Claim
30 words
The composition of claim 2 wherein the weight ratio of calcium hydroxide or oxide to magnesium hydroxide or oxide is from about 100 to 0 to about 40 to 60.
Claim 5
Dependent Claim
60 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of the oxide or hydroxide of calcium and magesium, and (3) a mixture of clay and talc fillers, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 6
Dependent Claim
60 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of the oxide or hydroxide of calcium and magesium, and (3) a mixture of clay and talc fillers, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 7
Dependent Claim
30 words
The composition of claim 4 wherein the weight ratio of calcium hydroxide or oxide to magnesium hydroxide or oxide is from about 80 to 20 to about 40 to 60.
Claim 8
Dependent Claim
27 words
The composition of claim 4 wherein the weight ratio of clay to talc is in the range of about 60 to 40 to about 20 to 80.
Claim 9
Dependent Claim
11 words
The composition of claim 4 which also contains a silane compound.
Claim 10
Dependent Claim
9 words
The composition of claim 4 which also contains microspheres.
Claim 11
Dependent Claim
104 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of calcium hydroxide and magnesium hydroxide wherein the weight ratio of calcium hydroxide to maagnesium hydroxide is from about 80 to 20 to about 40 to 60, (3) a mixture of clay and talc fillers, wherein the weight ratio of clay to talc is in the range of about 60 to 40 to about 20 to 80, and (4) a silane compound, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 12
Dependent Claim
104 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of calcium hydroxide and magnesium hydroxide wherein the weight ratio of calcium hydroxide to maagnesium hydroxide is from about 80 to 20 to about 40 to 60, (3) a mixture of clay and talc fillers, wherein the weight ratio of clay to talc is in the range of about 60 to 40 to about 20 to 80, and (4) a silane compound, wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 13
Dependent Claim
11 words
The phenolic molding composition of claim 9 which also contains microspheres.
Claim 14
Dependent Claim
75 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a silane compound, and (3) a mixture of clay and talc fillers, wherein the weight ratio of clay to talc is in he range of about 60 to 40 to about 20 to 80, and wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 15
Dependent Claim
75 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a silane compound, and (3) a mixture of clay and talc fillers, wherein the weight ratio of clay to talc is in he range of about 60 to 40 to about 20 to 80, and wherein component (3) is present in said molding composition in a proportion of at least about 20 parts by weight per 100 parts by weight of said phenolic resin.
Claim 16
Dependent Claim
54 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) an alkaline earth metal hydroxide or oxide, or a silane compound, and (3) mirosphres, wherein component (3) is present in said molding composition in a proportion of at least about 10 parts by weight per 100 parts by weight of said phenolic resin.
Claim 17
Dependent Claim
54 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) an alkaline earth metal hydroxide or oxide, or a silane compound, and (3) mirosphres, wherein component (3) is present in said molding composition in a proportion of at least about 10 parts by weight per 100 parts by weight of said phenolic resin.
Claim 18
Dependent Claim
15 words
The composition of claim 12 wherein component (2) is calcium and/or magnesium hydroxide or oxide.
Claim 19
Dependent Claim
30 words
The composition of claim 13 wherein the weight ratio of calcium hydroxide or oxide to magnesium hydroxide or oxide is from about 100 to 0 to about 40 to 60.
Claim 20
Dependent Claim
54 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of the oxide or hydroxide of calcium and magnesium, and (3) microspheres, wherein component (3) is present in said molding composition in a proportion of at least about 10 parts by weight per 100 parts by weight of said phenolic resin.
Claim 21
Dependent Claim
54 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of the oxide or hydroxide of calcium and magnesium, and (3) microspheres, wherein component (3) is present in said molding composition in a proportion of at least about 10 parts by weight per 100 parts by weight of said phenolic resin.
Claim 22
Dependent Claim
30 words
The composition of claim 15 wherein the weight ratio of calcium hydroxide or oxide to magnesium hydroxide or oxide is from about 80 to 20 to about 40 to 60.
Claim 23
Dependent Claim
11 words
The composition of claim 15 which also contains a silane compound.
Claim 24
Dependent Claim
75 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of calcium hydroxide and magnesium hydroxide wherein the weight ratio of calcium hydroxide to magnesium hydroxide is from about 80 to 20 to about 40 to 60, (3) a filler component consisting essentially of microspheres in a proportion of about 10 to less than 30 parts by weight per 100 parts by weight of said phenolic resin, and (4) a silane compound.
Claim 25
Dependent Claim
75 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a mixture of calcium hydroxide and magnesium hydroxide wherein the weight ratio of calcium hydroxide to magnesium hydroxide is from about 80 to 20 to about 40 to 60, (3) a filler component consisting essentially of microspheres in a proportion of about 10 to less than 30 parts by weight per 100 parts by weight of said phenolic resin, and (4) a silane compound.
Claim 26
Dependent Claim
45 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a silane compound, and (3) a filler component consisting essentially of microspheres in a proportion of about 10 to less than 30 parts by weight per 100 parts by weight of said phenolic resin.
Claim 27
Dependent Claim
45 words
A phenolic molding composition comprising (1) a resole phenolic resin, (2) a silane compound, and (3) a filler component consisting essentially of microspheres in a proportion of about 10 to less than 30 parts by weight per 100 parts by weight of said phenolic resin.
Claim 28
Dependent Claim
34 words
A composition suitable for use in bulk molding comprising the compositon of claim 1 wherein the viscosity of the composition is in the range of about 100,000 to about 500,000 centipoises at 33° C.
Claim 29
Dependent Claim
34 words
A composition suitable for use in sheet molding comprising the composition of claim 1 wherein the viscosity of the composition is in the range of about 8000 to about 30,000 centipoises at 33° C.
Claim 30
Dependent Claim
40 words
A composition suitable for use in pultrusion molding, continuous laminating or filament winding processes comprising the composition of claim 1 wherein the viscosity of the composition is in the range of about 1000 to about 2000 centipoises at 33° C.
Claim 31
Dependent Claim
34 words
A composition suitable for use in bulk molding comprising the composition of claim 9 wherein the viscosity of the composition is in the range of about 100,000 to about 500,000 centipoises at 33° C.
Claim 32
Dependent Claim
34 words
A composition suitable for use in sheet molding comprising the composition of claim 9 wherein the viscosity of the composition is in the range of about 8000 to about 30,000 centipoises at 33° C.
Claim 33
Dependent Claim
40 words
A composition suitable for use in pultrusion molding, continuous laminating or filament winding processes, comprising the composition of claim 9 wherein the viscosity of the composition is in the range of about 1000 to about 2000 centipoises at 33° C.
Claim 34
Dependent Claim
26 words
The process comprising subjecting the phenolic molding composition of claim 1 and inert fibers to a bulk molding process and recovering the product of the process.
Claim 35
Dependent Claim
26 words
The process comprising subjecting the phenolic molding composition of claim 1 and inert fibers to a sheet molding process and recovering the product of the process.
Claim 36
Dependent Claim
25 words
The process comprising subjecting the phenolic molding composition of claim 1 and inert fibers to a pultrusion process and recovering the product of the process.
Claim 37
Dependent Claim
26 words
The process comprising subjecting the phenolic molding composition of claim 1 and inert fibers to a continuous laminating process and recovering the product of the process.
Claim 38
Dependent Claim
26 words
The process comprising subjecting the phenolic molding composition of claim 1 and inert fibers to a filament winding process and recovering the product of the process.
Claim 39
Dependent Claim
33 words
The process for producing a molding compound which comprises mixing the composition of claim 1 with inert fibers and converting the composition to a thickened state to produce a mechanically handleable molding compound.
Claim 40
Dependent Claim
59 words
The process for producing a sheet molding compound which comprises depositing the phenolic molding composition of claim 1 onto a first sheet, adding a layer of chopped fibers to the composition on the first sheet, depositing additional phenolic molding composition to the layer of chopped fibers, and pressing the resulting composite to form a mechanically handleable sheet molding compound.
Claim 41
Dependent Claim
20 words
The process of claim 32 wherein the sheet molding compound is warmed to form a strippable, moldable sheet molding compound.
Claim 42
Dependent Claim
61 words
The process for producing a pultruded product which comprises passing a filament into a vessel containing the phenolic molding composition of claim 1 to saturate the filament, passing the resulting filament through an orifice to squeeze out excess phenolic molding composition and compress the resulting composite, and passing the resulting composite through an extrusion die to heat and cure the product.
Claim 43
Dependent Claim
11 words
The molded and cured product of the process of claim 26.
Claim 44
Dependent Claim
11 words
The molded and cured product of the process of claim 27.
Claim 45
Dependent Claim
9 words
The cured product of the process of claim 28.
Claim 46
Dependent Claim
9 words
The cured product of the process of claim 29.
Claim 47
Dependent Claim
9 words
The cured product of the process of claim 30.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-11-15 | 1992-05-16 | 1992-11-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-11-15 | 1996-05-16 | 1996-11-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-11-15 | 2000-05-16 | 2000-11-15 | $7700.00 | Window Closed / Lapsed |