Method of molding fiber reinforced articles

Claim 1

An improved process for preparing fiber reinforced articles which comprises the steps of (a) providing in a heated matched metal die mold a bonded web of one or more fibers with a melting point or glass transistion temperature above 130° C., (b) providing in an accumulator zone a liquid body of a thermosettable organic material having a viscosity determined at 120° C., in the absence of curing agent, of less than about 50 centipoise, and which is curable upon heating to a thermoset resin composition, the viscosity of said liquid body being maintained essentially constant in the accumulator zone by keeping its temperature below that at which curing of said material is substantial, (c) closing said mold containing said web, (d) injecting at least a portion of said thermosettable organic material under pressure from said accumulator zone into the mold to thereby fill the cavity in said mold, (e) initiating the curing of said materials by subjecting the materials to a temperature by heating the mold, which is above the temperature at which the curing of said materials is initiated, and (f) opening said mold and removing the cured thermoset article therefrom, wherein the improvement comprises using a thermosettable organic material comprising (a) a thermosettable organic material containing two or more polymerizable carbon-carbon double bonds, (b) an ethylenically unsaturated monomer which forms a liquid homogeneous mixture with and it copolymerizable with (a) and is different from (a), and (c) an effective amount of an initiator or a mixture of initiators characterized by ten-hour half life temperature, or in the case of a mixture of initiators, an average ten hour half life temperature, of greater than about 50° C. and less than 105° C., which produces on decomposition less than 1.0 milliliter of gas per gram of resin as measured at a temperature of 25° C. and a pressure of one atmosphere.