TWO-COMPONENT MOLD RELEASE SYSTEM AND METHOD

Abstract: A release agent system provides a water-soluble releasing interface which permits a plurality of cycles of the mold between applications with reaction-injection molding materials such as glass-reinforced urethane. The system can provide on the mold surface a base coat, including a polymer release agent with groups capable of bonding to the mold surface (e.g., a carboxy-terminated silicone) and a bonding or cross-linking agent (e.g., tetraisopropyltitanate), which reacts with and cross links the polymer and provides bonding with the mold surface and for soap-like materials, and a releasing film, which is a water-soluble soap-material (e.g., one or more water-soluble, metallic salts of long-chain fatty acids such as sodium myristate). Such a system can be particularly adapted for use with urethane RIM materials.

Description: -1- T O-COMPONENT MOLD RELEASE SYSTEM AND METHOD Technical Field This invention is directed to a system and method employing two, sequentially applied materials to facilitate the release of a molded article from the mold surface, and to a system and method which is par¬ ticularly advantageous for providing a water-soluble releasing interface having a permanence permitting the manufacture of a plurality of molded articles by reac- tion injection molding, most particularly with rein¬ forced and unreinforced urethane materials, between applications of the release system . Background Art In the injection-molding of plastic parts, it is generally advisable to provide a release agent on the surface of the mold to facilitate the release and removal of the molded part from the mold. It is desir¬ able in any injection-molding operation that a multi¬ plicity of mold cycles is obtained between applications of the release agent. In the past, a number of release agents have been available to permit such operation; for example, such release agents include those sold by FreKote, Inc. , under its trademarks. -2- Investigation of reaction-injection molding, now referred to as RIM, was undertaken by both chemical and equipment suppliers in the middle 1960 's. The reaction-injection molding process involves the injec- tion molding of parts from highly reactive liquid com¬ ponents of a chemical system. Reaction-injection mold¬ ing was of particular interest in the automotive indus¬ try which, in its efforts to comply with the United States government regulations on achieving higher mile- ages for its automobiles and on collision standards for its bumper systems, faced the problem of reducing body weight and producing resilient front-end parts associ¬ ated with its bumper systems. As a result of this developing interest in the automotive industry, many chemical companies became heavily involved in formulat¬ ing systems using urethane intermediates for molding large elastomeric automotive parts. In the early 1970 's, suitable machinery for reaction-rejection molding became available; and small-scale production was started. By the model year 1975, several automobile manufacturers were manufacturing reaction-injection molded urethane' parts; and an increasing demand has developed in succeeding years for the use of RIM elas¬ tomers in producing not only the resilient parts asso- ciated with automotive bumper systems, but spoilers, air dams, wheel flares, and other body parts as well. More recently, urethane elastomers have been provided with reinforcement, such as glass fibers to extend the use of the RIM process for molding exterior body parts, such as fenders and door panels. The reinforcement of the RIM elastomers has provided increased stiffness, has reduced the thermal expansion of molded parts, and has extended the weight advantages of RIM materials such as urethane to many parts of the automobile body. While the introduction of the RIM process into commercial manufacturing operations has been pioneered by the automotive industry, the RTM process O. H -3- ' is not limited to the production of automotive parts. The continuing development and introduction of RIM molding materials extends reaction-injection molding to the production of a wide variety of non-automotive parts The reaction-injection molding process is experiencing growth in its application and use because of many advantages. Reaction-injection molding permits low mold pressures and low mold temperatures. The low injection molding pressures reduce the clamping force required at the mold and low molding temperatures mean significantly lower energy requirements compared with other molding processes. Reaction-inj ction molding requires reduced heat energy because many of the chemi¬ cal reactions, for example those obtained with urethane materials, are exothermic, reducing the amount of heat that is needed to maintain proper mold temperature. Mold costs are substantially reduced with reaction- injection molding. Both thin and heavy wall sections are attainable with parts manufactured by reaction- injection molding. Furthermore, reaction-injection molding permits parts that are generally free from flow and stress lines and also free from molded-in stresses which cause warpage and stress cracking. Complex shapes and variable wall thicknesses and ribbing are readily obtainable in RIM-molded parts, and it is possible to mold very large parts in a single operation, eliminating the need for smaller parts and subassembly steps. In spite of all its advantages, the reaction- molding process has been burdened with one continuing problem: the release of the molded part from the mold surface. The reaction-injection molding process re¬ quires the injection of highly reactive chemical inter¬ mediates directly into the mold. The mold surface and any release agent applied to the mold surface are thus exposed to the reactive chemical components of the system and to their exothermic reaction. In addition, the presence of reinforcing materials, such * as glass _4_ fibers has gravely aggravated the problem by introducing their abrasive action on any release agents placed on the mold surface. The abrasive removal of release agents from the mold surface by reinforcing materials exposes the mold surface itself to the reactive compo¬ nents and their reaction. This problem has inhibited the adoption of the otherwise highly attractive RIM process. It in¬ creases the time necessary to produce parts by the RIM process and thus increases the cost of the resulting parts. For example, the cycle time for the production of a single-urethane part can be on the order of 60 to 120 seconds, which is generally typical for RIM urethane- molding systems. The application of release agent to the mold surface generally takes 30 to 60 seconds of that total time. Thus, if a satisfactory release agent were available, the production time for RIM urethane parts could be reduced by the time required for appli¬ cation of the release agent. With the best release agents available prior to this invention, however, only one or two urethane parts could be produced by the RIM process before it became necessary to recoat the mold surface with a release agent. In addition, with the prior release agents, it became necessary to cease production frequently and clean the mold to remove the release agent from those areas in which it builds up. The release agents which have been in use with reaction-injection molding have generally been waxes or soaps applied in one coating. A soap-like release agent that has been used in the past includes a water-alcohol solution of oleic acid and caustic soda. The sodium oleate film produced by this soap-like release agent is water soluble and can be removed from the molded article by washing it with water. The sodium oleate film generally provides only one release and generall requires that the mold be coated after each cycle; i.e., after the production of each molded part. In addition, such soap-like films are not uniformly removed from the mold with each molded part; an exces¬ sive, build-up can develop on differing areas of the mold; and it becomes necessary, from time to time, that the mold be removed from production and cleaned. The time-consuming and wasteful applications of such films v/ith each cycle of the mold and the removal of the mold from production for cleaning interrupt production of RIM molded parts and substantially increase their costs. Waxes have been used in an effort to obtain more than one cycle between applications of the release agent. While waxes generally provide more than one cycle of the mold, and thus more than one part between applications of the release agent, the parts obtained from wax-coated molds have required solvent washing to remove the wax from the surface. In the automotive industry, particularly, RIM- olded parts are generally part of the body shell and must be painted. Painting, and the resulting finish, of an automotive body must be of the highest possible quality since the cosmetic appearance of the automobile body is believed to be critical to the sale of auto¬ mobiles. The presence of any wax on a molded part pre¬ vents a satisfactory finish. Solvent-washing each part is costly, time-consuming, and imposes a potentially hazardous step in the manufacture of such parts. Thus, manufacturers seeking to introduce the reaction-injection molding process into their manufac¬ turing operations in an effort to achieve the advantages accompanying the use of such a process have been retarded prior to this invention by the problem of part removal from the mold surface and a lack of any satis¬ factory release agent for the RIM process. Only soaps, with the attendant cost associated with their repeated -6- application to the mold surface and the cleaning asso¬ ciated with their build-up in the mold, and waxes, with the requirement for solvent cleaning of the resulting molding parts, have been available to the manufacturer prior to this invention. Disclosure of Invention < It has been discovered that the two-stage system of this invention can provide a water-soluble releasing interface which permits a plurality of cycles of the mold between applications with such reaction- injection molding materials as reinforced urethane. The two-coat release system provides on the mold surface a base coat, including a polymer release agent with groups capable of bonding to the mold surface and a bonding or cross-linking agent which reacts with and cross links the polymer and provides bonding with the mold surface and for soap-like materials, and a topcoat, which can be a water-soluble, soap-like material or mixtures of soap-like materials. Water-soluble metallic salts of long-chain fatty acids are preferred for use in such topcoats. Such a system, particularly as adapted for use with urethane RIM materials, can include the provision of a base coat having carboxy- erminated silicone for the polymer and tetraisopropyltitanate to provide cross-linking and bonding for the soap-like material and a topcoat of sodium myristate to provide a releasing interface for the molded urethane parts. This two-coat release system may be applied to the mold surface a number of ways, but the preferable method is currently believed to be by spraying the two- stage system onto the mold surface as two, successively applied, liquid coatings. The first part of the system or coating is provided by placing the polymer/bonding and cross- linking agent of the base coat in solution in, preferably, a volatile carrier to minimize its OMPI -7- application time. With the silicone polymer-tetra- isopropyltitanate system preferred for urethanes, such a carrier includes a mixture of an aliphatic hydrocarbon and a chloro-fluorocarbon. The silicone polymer and tetraisopropyltitanate are present in the carrier in a range from about 11.0 percent by weight to about 0.7 percent by weight, and the ratio of silicone to tetra¬ isopropyltitanate ranges from about 20 to 1 to about 2 to 1, with higher ratios being preferred. The second part or coating of the system is provided by carrying the water-soluble, soap-like material or materials in a deionized water and alcohol solution. A preferred topcoat, sodium myristate, is carried in a solution of deionized water and an alcohol, such as isopropyl alcohol, whose pH is adjusted to a range of from about 8.9 to about 9.0. The total sodium myristate solids in the preferred solution is about 4 percent, and it is desirable to add a fluorocarbon sur¬ factant to the solution. In other preferred coatings, sodium oleate can be combined with sodium myristate to provide a film with toughness, integrity, and improved releasing qualities. Use of the two-part release system of this invention provides a method for molding a plurality of articles from reinforced urethane materials. The inner surface of the mold is provided with a base coat by spraying a heavy coating of the first part onto the mold surface and allowing it to dry. The second part of the release system is then sprayed upon the base coat that is provided on the mold surface. Following application of the two-part release system, the mold can be used for manufacture of a plurality of parts by cycling it repeatedly through its steps of injecting the urethane material and fiber reinforcements, curing the reinforced urethane into a molded article and removing the molded article. After a plurality of such steps, only reapplication of the second part to OMPI •■ Ri;;. -: -8- reinforce the topcoat is necessary to prepare the inner surface of the mold for another plurality of cycles. Best Mode For Carrying Out the Invention This invention includes the discovery that an effective release system for reaction-injection molding processes can include multiple components in two coats applied to the mold surface and that the base coat can include materials providing effective bonding to both the mold surface and at its exposed surface and that a water-soluble release agent may be thereby bonded to the mold surface and provide a releasing interface over a multiplicity of molding cycles. The base coat includes two basic components. One of the components is a polymer which is preferably capable of providing a releasing interface. The second component, however, is a reactive material capable of cross-linking the polymer and providing bonding. Such second components are commonly used as thin coatings on a variety of surfaces to improve adhesion. It is be- lieved that the second component in the base coat sur¬ prisingly reacts with the functional terminations of the polymer, cross-linking the polymer molecules, and bonds to the surface (i.e., steel, aluminum, epoxy, etc.) of the molds commonly used and provides functionality at the exposed surface of the base coat within the mold for bonding a second releasing agent. In the system developed for use as a release agent for the reaction-i jection molding of urethane materials, the first component of the base coat com- prises a carboxy-terminated silicone, a particularly effective carboxy-terminated silicone being that sold by Dow Corning as DC7119. The second component of the base coat is a titanate, a particularly effective titanate being tetraisopropyltitanate marketed by E. I. Du Pont under their trade name Tyzor TPT. In creating one part of a coating for application to the mold, these OMPI -9- co ponents are placed in a liquid carrier including an aliphatic hydrocarbon, such as Isopar C, a solvent sold under this trademark by Exxon and having a boiling range of 208°-222° F. and a chloro-fluorocarbon such as that sold by E. I. Du Pont under their trademark Freon TF. The ratio of carboxy-terminated silicone to tetra- isopropytitanate lies in a range of about 20:1 to about 2:1. The concentration of the first and second co - ..ponents in this carrier are generally in a range from about 11.0 percent by weight to about 0.7 percent by weight. While base coats formed from coatings having components lying within the ranges set forth above are superior to those of any known release agent, preferred results are generally obtained with a first coating containing about 5.5 percent to about 11.0 percent by weight of non-volatile materials and a ratio of carboxy- terminated silicone to tetraisopropyltitanate of 20:1 to 10:1. Base coats having a ratio of carboxy- , terminated silicone to tetraisopropyltitanate of about 10:1 are believed to have somewhat of an advantage in reducing the transfer of silicone to the molded parts in later cycles, as the topcoat has been depleted, while base coats having a ratio of 20:1 tend to provide a greater number of releases between applications of the topcoat. The water-soluble topcoat, incorporated into the system of this invention with a second part or coating, includes preferably one or more water-soluble, soap-like materials. Metallic salts of a long-chain fatty acids are preferred. Such water-soluble, soap¬ like materials include, most preferably, sodium myristate and can include sodium oleate. Sodium myristate is harder, provides more resistance to removal, and maintains itself longer on the base coat than sodium oleate. Sodium oleate can enhance the flow of rein¬ forced urethane into the mold and can improve the "slip" -10- of the part and the releasing qualities of the film. Sodium myristate provides a tougher film with greater integrity in the presence of reinforcing glass fiber and can permit the removal of parts while "green" (i.e., before they are completely cured) without dis¬ tortion. Sodium sulfates of long-chain fatty alcohols, such as sodium laurel sulfate, can also be used in some applications. The solids content of such a coating material lies preferably in a range of about 2 percent by weight to about 15 percent by weight, with solids contents in the range of 4 percent to 6 percent being preferred. The topcoat is also placed in a liquid carrier. For example, sodium myristate is placed in solution in a mixture of deionized water and an alcohol such as isopropyl or normal propyl alcohol. Deionized water prevents the heavy metals in the water from exchanging with the sodium ion and forming insoluble, heavy-metal salts which precipitate from the solution. The de- ionized water and alcohol carrier is adjusted to provide a pH in the range of from about 8.9 to about 9.0 to assist in placing the sodium myristate in solution. In addition, it has been found that it is preferable that the second coating contain about 4 percent by weight sodium myristate and a fluorocarbon surfactant such as FC-430, marketed by the 3M Corporation. The fluorocarbon surfactant is preferably added to the second coating in quantities of about 1.7 grams per gallon. Surfactants other than FC-430 may function as well. The use of alcohol as a carrier speeds up the vaporization of the carrier of the second coating from the mold surface, and deionized water reduces any hazard that may be associated with the use of alcohol. Normal propyl alcohol is preferred over isopropyl alcohol where flammability of the release agent may be a consideration. In using the system above, the first part or coating material such as a solution of carboxy-terminated silicone and tetraisopropyltitanate in the aliphatic hydrocarbon-Freon carrier is sprayed onto the mold sur¬ face at an operating temperature which is generally in the range of 140° to 160 F. to create a base coat. A relatively heavy coating, for example, greater than 2 mils, is preferably applied to the mold surface. This coating dries almost on contact to produce a somewhat rough and tacky film. The second part or coating material, such as a solution of sodium myristate in deionized water and isopropyl alcohol, is then sprayed upon the coated mold surface. The second coating dries within a second or two, thereby preparing the mold sur¬ face for molding. The mold then may be used to prepare a plu- rality of parts. The topcoat is clear, colorless (water-like) , and has a matt finish. The base coat is yellow in color, satiny, and somewhat tacky. After a sufficient number of cycles to deplete the topcoat, the base coat will begin to transfer to the molded parts. since the polymer incorporated into the base coat is a silicone release agent, depletion of the topcoat does not generally interfere with the release of molded parts from the mold, but is not desirable because it can interfere with the paintability of the parts. Thus, in normal operation, the system of the invention provides a plurality of molded parts from the water-soluble top¬ coat and continues to operate with only reapplication of the topcoat. The number of releases obtained from the flat surfaces of molds between reapplications of release agent is substantially greater than the number of re¬ leases obtained from those portions of the mold which have deep undercuts and contours. Accordingly, it is frequently unnecessary to apply the top coating to the flat surfaces in each application. A comparison of systems and their performance in production can be made on a reaction-injection -12- molding machine for molding plaques 18 inches by 30 inches by three-sixteenths inches thick. The systems compared below include a base coat applied from a coat¬ ing material including Dow Corning DC7119 carboxy- terminated silicone and DuPont Tyzor TPT tetraisopropyl¬ titanate and a topcoat including sodium myristate applied from a solution of 4 percent by weight. Ratio of Solids Content DC7119 to of Base Material System Tyzor TPT Releases Coating 1 20:1 > 20 11.0% 2 10:1 - » ■ - 10 11.0% 3 20:1 a * - 13 5.5% 4 10:1 • P-13 5.5% 5 5:1 10 5.5% 6 2:1 9 5.5% 7 5:1 5 6.3% 8 2:1 6 7.7% With systems including a base coat applied from a coating including DC7119 carboxy-terminated silicone and Tyzor TPT tetraisopropyltitanate in a 20:1 ratio from a coating material with 11 percent by weight solid content, the following comparisons were obtained: Solids Content of Top Coating System Top Coat Releases Material 1 Sodium Myristate ^-20 4.0% 2 Sodium Myristate 4 7.5% 3 Sodium Myristate 10 10.6% 4 Sodium Myristate 3 17.3% 5 Sodium Myristate ^10 6.0% and Sodium Laurel to Sulfate 7-20 Systems of this invention can be used in the manufacture of automotive fascia on full-scale RIM pro¬ duction machines. For example, full-scale Chevrolet Monte Carlo Fascia can be molded from urethane RIM materials by reaction-injection molding using the system of this invention; and a plurality of RIM-molded Monte Carlo Fascia can be obtained between applications of release agent. Where the base coat of the system OMPI " v,il'O -13- includes DC7119 carboxy-terminated silicone and Tyzor TPT tetraisopropyltitanate in the ratio of 20:1, as a result of application to a Monte Carlo Fascia mold from a coating material including 5.5 percent by weight solids, as many as 10 or more Monte Carlo Fascia can be produced between applications of the topcoat, where the topcoat includes sodium myristate applied from a second coating including 4 percent by weight of solids. With the ratio of DC7119 carboxy-terminated silicone to Tyzor TPT tetraisopropyltitanate reduced to 10:1 in the base coat, more than 10 Monte Carlo Fascia can also be produced between applications of the topcoat of sodium myristate. In the production of automotive parts using a urethane system reinforced with glass fiber to the level of 23 percent by weight, six releases of the parts may be obtained from the mold without reapplication of the topcoat. With prior systems, one release was difficult to obtain. The system of the invention may be used with other coating formulations. As noted above, a coating material providing sodium myristate in the releasing film is particularly preferred because of its hardness and toughness and ability to form abrasion-resistant films of significant integrity in the presence of glass- fiber reinforced urethanes. Such sodium myristate- containing films generally increase significantly the number of releases of reinforced urethane parts between applications. Some applications, however, benefit from the combination of sodium myristate and sodium oleate in the releasing film. Such combined films, while con¬ tinuing to demonstrate the improved durability charac¬ teristic of sodium myristate films, seem to provide a softer, slicker finish and improved slip and releasing qualities. OMPI Vv t?o -1 - Ξxamples of other coating materials that may be used to provide improved releasing qualities with reaction-injection molding include: RELEASE AGENTS II III Deionized Water 56.87% 73.46% Isopropyl Alcohol 31.59% _— Normal Propyl Alcohol . 18.14% Myristic Acid 3.56% 3.63% Caustic Soda 0.53% 0.61% Freon TF 7.64% 4.19% FC-430 69gm/50 gal 100gm/50 gal These coating materials provide improved re¬ leasing films as topcoats in the two-part system of this invention and also provide improved releasing films when used alone as release agents. Other release agents combining sodium myristate with sodium oleate in the film can be provided by preparing a sodium oleate- carrying material from about 62 percent deionized water, about 34 percent isopropyl alcohol, about 3.5 percent oleic acid, and 0.5 percent caustic soda and mixing the sodium oleate-carrying material with Release Agents II and III above as follows: Release Agent IV includes 90 percent by weight of Release Agent III and 10 percent by weight of the above sodium oleate-carrying material; Release Agent V includes 80 percent by weight of Release Agent II and 20 percent by weight of the above sodium oleate-carrying material; Release Agent VI includes 50 percent by weight of Release Agent III and 50 percent by weight of the above sodium oleate-carrying material. Release Agents IV, V, and VI provide improved releasing properties, alone or as a topcoat in the two- component system, but less durability than the Release Agents II and II, particularly in the presence of urethanes heavily reinforced with glass fibers. Release agents combining sodium myristate and sodium oleate are frequently used in more complexly shaped molds where improved release is necessary. Using the system of this invention, the molded parts can be washed with water and successfully painted. The invention now permits reaction-injection molding using urethane materials and providing multiple releases from the mold, with the systems that are both reinforced and unreinforced. The invention permits the RIM machines to operate at substantially greater speeds and substantially enhances their productivity through the reduction of down time due to removal of mold release buildups, and reapplications of the release agents. The parts released from molds treated with the system of this invention have a consistent cosmetic appearance that may be easily cleaned and painted. Although we have described a specifically preferred embodiments of the invention, other embodi¬ ments may be developed without departing from the spirit and scope of the following claims.

Claims: -16- CLAIMS : 1. A two-part mold release system, characterized by: a first part comprising a carboxy-terminated silicone and a bonding agent partially reactive with the carboxy-terminated silicone and capable of providing bonding with fatty acid salts and a fast evaporating carrier for said silicone and bonding agent, and a second part comprising a water-soluble metallic salt of a long chain fatty acid in a deionized water-alcohol solution. 2. - The two-part mold release system of claim 1 characterized in that the bonding agent is a titanate. 3. The two-part mold release system of claim 2 characterized in that said silicone and bonding agent comprise from about 0.7 percent to about 11.0 percent by weight of the first part, and the ratio of silicone to bonding agent varies from about 20:1 to about 2:1. 4. The two-part mold release system of claim 3 characterized in that the silicone and bonding agent comprise about 5.5 percent to about 11.0 percent by weight of the first part and the ratio of silicone to bonding agent varies from about 20:1 to about 10:1. 5. The two-part mold release system of claim 2 characterized in that said bonding agent is tetra¬ isopropyltitanate. 6. The two-part mold release system of claim 5 characterized in that the carrier is a mixture of an aliphatic hydrocarbon and a chloro-fluorocarbon. -17- 7. The two-part mold release system of claim 1 characterized in that the water-soluble, metallic fatty acid salt of the second part is about 4 percent by weight of sodium myristate, in a solution of deionized water and isopropyl alcohol having a pH in the range of about 8.9 to about 9.0, and wherein the solution includes a fluorocarbon surfactant. 8. A base coating for a mold release system, characterized by: a mixture of a carboxy-terminated silicone and a bonding agent in solution in an aliphatic hydro¬ carbon and chloro-fluorocarbon, said bonding agent being capable of bonding with said carboxy-terminated silicone and providing with its unbonded portion funσ- tional groups reactive with fatty acid salts, whereby said base coat will bond to the surface of a metallic mold and provide a base and bonding for a fatty acid- based mold release coating. 9. The base coating of claim 8 characterized in that said bonding agent is tetraisopropyltitanate, the ratio of silicone to tetraisopropyltitanate lies in a range of from about 20:1 to about 2:1 and the solids content of silicone and tetraisopropyltitanate in said coating lies in the range of about 11.0 percent by weight to about 0.7 percent by weight. 10. The base coating of claim 9 characterized in that the ratio of silicone to tetraisopropyltitanate is in the range of about 20:1 to about 10:1 and the solids content is about 5.5 percent by weight. 11. The base coating of claim 9 characterized in that the ratio of silicone to tetraisopropyltitanate is in the range of about 20:1 to about 10:1 and the solids content is about 11.0 percent by weight. -18- 12. The base coating of claim 9 characterized in that the"ratio of silicone to tetraisopropyltitanate is about 20:1 and the solids content is about 11.0 percent by weight. 13. A water-soluble release agent characterized by a solution of sodium myristate in deionized water and isopropyl alcohol, said deionized water and alcohol having a pH of about 8.9 to about 9.0, and said sodium myristate being present in about 4 percent by weight. 14. The water-soluble release agent of claim 13 characterized in that said solution includes at least 0.4 percent sodium oleate. 15. The water-soluble release agent of claim 13 characterized in that said solution contains a small amount of fluorocarbon surfactant. 16. A method of preparing a surface for molding, characterized by: providing said mold surface with a first coating having a first polymer material with reactive functional groups capable of bonding with the mold sur¬ face and also having a second material with functional groups that are reactive with the first polymer material and with a water-soluble agent, said second material being present in such quantity that it only partially reacts with said first material, and further providing said mold surface with a second coating over said first coating, said second coating comprising a water-soluble release agent. 17. The method of claim 16 characterized in that the water-soluble release agent is one or more metallic salts of long-chain fatty acids. O PI _ -19- 18. The method of claim 17 characterized in that the water-soluble release agent is selected from a group consisting of sodium myristate and sodium oleate. 19. The method of claim 16 characterized in that the water-soluble release agent is a metallic salt of a long-chain fatty acid and a sodium sulfate of a long- chain fatty alcohol. 20. The method of claim 19 characterized in that the water-soluble release agent is sodium myristate and sodium laurel sulfate. 21.- A method of reaction-injection molding urethane parts from a mold, characterized by: providing said mold with a first coating having a carboxy-terminated silicone and tetraisopropyltitanate, the ratio of carboxy-terminated silicone to tetra¬ isopropyltitanate being about 20:1 to about 2:1, and providing said mold with a second coating including sodium myristate over said first coating, whereby multiple urethane parts may be molded before reapplica- tion of said second coating is needed and wherein said urethane parts may be prepared for painting by washing with water. 22. A mold prepared for manufacture of reinforced urethane molding materials, characterized by: an inner surface to define the shape of an article, and a coating on the inner surface adapted to receive a release agent, said coating comprising a first polymer material with reactive functional groups capable of bonding to groups that are reactive with the first polymer and with a release agent. -20- 23. A mold prepared for manufacture of reinforced urethane"molding materials, characterized by: an inner surface to define the shape of an article, a base coat on the inner surface of the mold including a carboxy-terminated silicone, and a bonding agent providing bonding for the silicone and soap-like materials, and a topcoat over the base coat on the mold sur- face including a water-soluble, soap-like material capable of bonding to the bonding agent of the base coat. 24.- The mold of claim 23 characterized in that the bonding agent of the base coat is tetraisopropyl- titanate and the topcoat comprises sodium myristate. 25. A method of molding a plurality of articles by reaction-injection molding, characterized by: a first step of providing a mold having an inner surface to shape the article and providing the inner surface of the mold with a two-coating release system by the second and third steps of applying a first coating to the inner surface in a heavy coating to provide bonding the first coating to the inner surface of the mold and to the second coating, and applying the second coating to the first coating to provide a releasing surface for the molded article, and a fourth step of injecting into the mold materials that react to form a solid and curing said materials into a molded article, and a fifth step of removing the molded article, and repeating a plurality of times the fourth and fifth steps. OiXSl " -21- 26. The method of claim 25 characterized in that urethane"material and fiber reinforcement for the urethane material are injected into the mold. 27. A two-part mold release system characterized by: a base coat including a first release agent and a bonding agent; and a topcoat including a second release agent; said base coat bonding with said mold surface and with said topcoat. 28. A two-part release system as recited in claim 27 characterized in that said first release agent comprises a polymer release agent capable of bonding to said mold surface and in that said bonding agent com- prises a bonding agent reactive with said polymer release agent and with said second release agent. 29. A two-part release system as recited in claim 28 characterized in that said second release agent comprises a water-soluble release agent. 30. A two-part release system as recited in claim 29 characterized in that said water-soluble release agent comprises one or more water-soluble metallic salts of long-chain fatty acids. 31. A two-part release system as recited in claim 30 characterized in that said water-soluble release agent is selected from the group consisting of sodium myristate and sodium oleate. 32. A two-part release system as recited in claim 29 characterized in that said water-soluble release agent comprises from about 2 percent to about -22- 15 percent by weight of sodium myristate in a solution of deionized water and alcohol. 33. A two-part release system as recited in claim 32 characterized in that said solution of deionized water and alcohol has a pH in the range of about 8.9 to about 9.0, and wherein said solution further includes a fluorocarbon surfactant. 34. A two-part release system of claim 31 charac¬ terized in that the water-soluble release agent selected from the group consisting of sodium myristate and sodium oleate is carried in a deionized water and alcohol solution and comprises about 4 percent by weight of the solution. 35. A two-part release system as recited in claim 28 characterized in that said polymer release agent comprises a silicone release agent. 36. A two-part release system as recited in claim 35 characterized in that said bonding agent com¬ prises a titanate. 37. A two-part release system as recited in claim 36 characterized in that said silicone release agent comprises carboxy-terminated silicone. 38. A two-part release system as recited in claim 37 characterized in that said titanate comprises tetraisopropyltitanate. 39. A two-part release system as recited in claim 35 characterized in that the ratio of silicone release agent to bonding agent varies from about 20:1 to about 2:1. " -23- 40. A two-part release system as recited in claim 39"characterized in that the ratio of silicone release agent to bonding agent varies from about 20:1 to about 10:1. 41. A two-part release system as recited in claim 35 characterized in that said base coat is carried in a liquid carrier for said silicone and said bonding agent. 42. A two-part release system as recited in claim 41 characterized in that said carrier comprises a mixture of an aliphatic hydrocarbon and a chloro- fluorocarbon. 43. A two-part release system as recited in claim 42 characterized in that said silicone release agent and said bonding agent comprise from about 0.7 percent to about 11 percent by weight in said carrier. 44. A two-part release system as recited in claim 43 characterized in that said silicone release agent and said bonding agent comprise from about 5.5 percent to about 11 percent by weight in said carrier.

Inventors: CLARK SHELDON L, PAJAUJIS FRANK PRANAS, CLARK, SHELDON, L., PAJAUJIS, FRANK, PRANAS
Applicants: FREKOTE INC, FREKOTE, INC.
Application year: 1984
Main classification: B29C1
IPC codes: B29C33, B29C67