Process for the production of molded article of fiber-reinforced thermosetting resin, and materials therefor

Abstract: A process for the production of a molded article of a thermosetting resin composition by injection of a raw material component mixture containing an active hydrogen compound (A) with a polymerizable vinyl monomer (B) and a raw material component containing a polyisocyanate compound (C) into a fiber (D) for a reaction injection molding, and a material which is a mixture of the active hydrogen compound (A) with the polymerizable vinyl monomer (B) or a combination of the mixture with the polyisocyanate compound (C).

Description: This invention relates to a process for the production of a moulded article of a fiber-reinforced thermosetting resin, and a material for producing a moulded article of a fiber-reinforced thermosetting resin composition. The present process can be used in fields requiring the moulding of large-sized articles e.g. in the fields of automobile industry, construction industry, etc. And, the present material for producing a moulded article of a fiber-reinforced thermosetting resin composition has characteristics which can provide a short cure time and impart the moulded article with excellent impact resistance. Moulded articles of a fiber-reinforced thermosetting resin composition have been hitherto produced by hand lay-up moulding, press moulding, pultrusion, filament winding moulding, resin transfer moulding, or the like. In the moulding of large-sized articles, the hand lay-up moulding method has advantages in that its mould cost is low and requires no equipment investment. However, its moulding cycle is long, and since glass mats are impregnated with resin by handwork, it is difficult to increase the glass content in the moulded article in view of a spring-back problem of the glass mats. In press moulding, the moulding cycle is short. However, a high pressure is required to press a sheet molding compound (SMC) and a bulk molding compound (BMC) which are so thickened that they can be molded. And, the larger the intended molded article is, the higher the investment for a pressing machine and a mold therefor is. Further, pultrusion molding and filament winding molding have a problem in that the shape of a molded article is considerably limited. Of the above-described methods, resin transfer molding is the most suitable to mold large-sized articles. Further, there is also a molding method called "Structural-RIM (S-RIM) molding", in which two reactive liquids are injected into and reacted in a mold, which is preliminarily charged with a reinforcing material, to achieve higher strength by using a RIM machine used in the field of urethane. This molding method is considered to come under the category of resin transfer molding in a broad sense in view of the molding process thereof. Conventional resin transfer molding and the S-RIM differ from each other in the injection machine used. In resin transfer molding, due to the use of a constant-pressure injection machine, the injection time varies with the back pressure which is generated depending upon the filling degree of glass fiber in the mold. Therefore, when the glass content is increased to obtain a molded article having high strength, the injection time is considerably long, although resins having a low reaction rate and a gel time adjustable by means of an inhibitor and catalyst system, such as ordinary unsaturated polyester resins, can be used without problems. In a resin system comprising an unsaturated polyester resin and a polyisocyanate compound to obtain a molded article having higher strength and elastic modulus, a reaction having a high reaction rate is involved. Therefore, if injection takes a long period of time, the reaction proceeds to cause a high increase in viscosity during injection, and as a result, injection cannot be continued any longer. In such a resin system, it is therefore necessary to complete the injection within a constant and short period of time irrespective of the degree of back pressure within the mold. Since a RIM machine is an injection machine having a constant injection rate (flow rate), there is hardly any back pressure-induced change in the injection time and hence it is suitable for a reaction system having a high reaction rate. Even in such a machine, however, when resins are injected at a high rate into a mould which is highly charged with glass fiber, a considerably high back pressure is generated and sometimes surpasses pump capability so that the machine stops or liquid leakage sometimes occurs in a connection portion between mixing head and mould. As described above, when a molded article having a high glass content for high strength is formed, both the resin transfer molding and the S-RIM involve a back pressure problem. That is, in order to complete moulding in a short period of time, it is necessary to reduce the back pressure thereby to make it possible to inject resins smoothly and to complete promptly after the resin injection, reaction of the resins and curing of the resultant moulded article. For this purpose, it is essential to use resins of low viscosity and to keep viscosity low by controlling the reaction rate during injection. However, there has been no resin that can meet such requirements. It is an object of this invention to provide fiber-reinforced thermosetting resin compositions suitable for a method of moulding large-sized articles, in particular for reaction injection molding, resin transfer molding and structural-reaction injection molding. It is yet another object of this invention to provide a fiber-reinforced thermosetting resin composition of low viscosity which permits reaction of the resins and curing of the resultant moulded article promptly after injection of the resins and allows to keep viscosity low by controlling the reaction rate during injection. It is a still further object of this invention to provide a thermosetting resin composition which can be cured in a short period of time. Further, it is another object of this invention to provide a combination of raw materials for producing a molded article of a thermosetting resin composition having excellent impact resistance. According to this invention, there is provided a reaction injection moulding process for the production of a moulded article from a thermosetting resin composition by injection of a raw material component mixture containing an active hydrogen compound (A) and a polymerizable vinyl monomer component (B) and a component containing a polyisocyanate compound (C) into a mold containing a fiber (D) for a reaction injection molding, wherein (1) the active hydrogen compound (A) is formed by mixing an unsaturated polyester (a 1 ) produced from a dicarboxylic acid component comprising 40 to 100 mole% of an unsaturated dicarboxylic acid or an anhydride thereof and a polyhydric alcohol containing primary hydroxyl groups which polyester has a hydroxyl value of 110 to 280 mgKOH/g, preferably 150 to 250 mgKOH/g and an acid value of not more than 5 mgKOH/g, with at least one member selected from the group consisting of (a 2 ) an unsaturated epoxy ester produced from an epoxy compound having at least one epoxy group in the molecule and an epoxy equivalent of 70 to 200, preferably 140 to 200 and a polymerizable unsaturated monobasic acid and (a 3 ) an acrylic compound having an acryloyl group and a hydroxyl group in the molecule, (a 1 ), (a 2 ) and (a 3 ) being used in proportions satisfying the following equation: (a 2 +a 3 ) / (a 1 +a 2 +a 3 )x100 = 1 to 15 wt%, preferably 5 to 10 wt %, (2) the polymerizable vinyl monomer component (B) comprises 5 to 40 % by weight, preferably 10 to 25 % by weight, of methyl methacrylate, and (3) the polyisocyanate compound (C) is a liquid compound having a terminal group of and a viscosity, at 25°C, of 10 to 2,000 cps, preferably of 30 to 1,500 cps, particularly preferably of 35 to 200 cps, the process being carried out under the following conditions (i), (ii) and (iii) ; (i) the amount of (B) is 20 to 50 % by weight, preferably 35 to 50 % by weight, based on the total amount of (A) and (B), (ii) the molar amount of isocyanate groups in (C) is 0.75 to 1.2 times, preferably 0.85 to 1.1 times, the amount of hydroxyl groups in (A), and (iii) the amount of (D) is 30 to 75 % by weight, preferably 30 to 60 % by weight, based on the total amount of (A), (B), (C) and (D). Further, according to this invention, there is provided a mixture of the active hydrogen compound (A) with the polymerizable vinyl monomers (B) which satisfies the condition that the amount of polymerizable vinyl monomers (B) is 20 to 50 % by weight, preferably 35 to 50 % by weight, based on the total amount of the active hydrogen compound (A) and the polymerizable vinyl monomers (B). Furthermore, according to this invention, there is provided a thermosetting resin composition for moulding an article , which is a combination of the mixture consisting of the active hydrogen compound (A) and the polymerizable vinyl monomers (B) with the polyisocyanate compound (C) and satisfies the conditions that the amount of polymerizable vinyl monomers (B) is 20 to 50 % by weight, preferably 35 to 50 % by weight, based on the total amount of the active hydrogen compound (A) and the polymerizable vinyl monomers (B) and that the polyisocyanate compound (C) provides isocyanate groups in an amount which is 0.75 to 1.2 times, preferably 0.85 to 1.1 times, by mole, the amount of the hydroxyl groups of (A). The unsaturated polyester (a 1 ) is a polycondensate produced by carrying out, according to a known method, a dehydration-polycondensation reaction between a mixture of 40 to 100 mole % of an unsaturated dicarboxylic acid or an anhydride thereof with not more than 60 mole % of a saturated dicarboxylic acid or an anhydride thereof, as an acid component, and a polyhydric alcohol having primary hydroxyl groups as an alcohol component. The unsaturated polyester (a 1 ) used in the present composition has an acid value of not more than 5 mgKOH/g and a hydroxyl value of 110 to 280 mgKOH/g, preferably 150 to 250 mgKOH/g. When the unsaturated polyester has an acid value of over 5 mgKOH/g, the resultant fiber-reinforced molded article is liable to foam when molding and suffers a reduction in strength. An unsaturated polyester having a hydroxyl value of less than 110 mgKOH/g has a molecular weight of greater than 1,000 (according to a terminal groups method), which results in reduction in impregnatability. An unsaturated polyester having a hydroxyl value of more than 280 mgKOH/g has a molecular weight below 500 , which results in insufficient impact resistance, although impregnatability into a : glass fiber, etc., would be good. Examples of the unsaturated dicarboxylic acid or anhydride thereof are maleic acid, maleic anhydride and fumaric acid. Examples of the saturated dicarboxylic acids or anhydrides thereof are phthalic acid, phthalic anhydride, isophthalic acid, terephthalic acid, HET acid and tetrahydro-phthalic anhydride. Examples of polyhydric alcohols having primary hydroxyl groups are ethylene glycol, diethylene glycol, 1,4-butanediol and neopentyl glycol. Polyhydric alcohols having a secondary hydroxyl group such as propylene glycol, dipropylene glycol or an adduct of bisphenol A with propylene oxide may be used. One or more such polyhydric alcohols may be used in an amount of not more than 5 mole %. When the unsaturated polyester is produced using over 5 mole% of a polyhydric alcohol, all of the resultant molded articles exhibit low impact resistance. The unsaturated polyester (a 1 ) used according to this invention may contain an ordinary polymerization inhibitor such as hydroquinone, p-benzoquinone or methylhydroquinone. The unsaturated epoxy ester (a 2 ) used in this invention is a product produced from an epoxy compound having at least one epoxy group in the molecule and an epoxy equivalent of 70 to 200, preferably 140 to 200 and a polymerizable unsaturated monobasic acid. When an unsaturated epoxy ester produced from an epoxy compound having an epoxy equivalent of greater than 200 and a polymerizable unsaturated monobasic acid is used according to this invention, it is impossible to achieve a low viscosity of the resin and to keep viscosity low by controlling the reaction rate during injection. Examples of the unsaturated epoxy ester (a 2 ) are vinyl ester resins obtained from bisphenol-type epoxy and novolak-type epoxy resins. The acrylic compound (a 3 ) is a compound having an acryloyl group and a hydroxyl group in the molecule. Examples of the acrylic compound are 2-hydroxyethyl (meth)acrylate and 2-hydroxypropyl (meth)acrylate. The mixing ratio of these components satisfies the equation of (a 2 +a 3 ) / (a 1 +a 2 +a 3 ) x 100 = 1 to 15 wt%, preferably 5 to 10 wt%. When this mixing ratio exceeds 15 wt%, the viscosity of the moulding material increases too sharply to mold the molding material into a large sized article adequately. Preferably, the polymerizable vinyl monomer component (B) comprises 5 to 40 % by weight of methyl methacrylate and at least one of styrene, chlorostyrene, vinyl toluene, (meth)acrylic acid, ethyl(meth)acrylate, propyl(meth)acrylate, butyl (meth)acrylate, and derivatives of these. When the active hydrogen compound (A) and the polymerizable vinyl monomer (B) are mixed with each other according to this invention, the amount of the active hydrogen compound (A) is in the range of from 50 to 80 % by weight, preferably 50 to 65 % by weight, and the amount of the polymerizable vinyl monomers (B) is in the range of from 20 to 50 % by weight, preferably 35 to 50 % by weight. When the amount of component (A) exceeds 80 % by weight, the resultant mixture has a high viscosity and the object of this invention cannot be attained. When the amount of component (A) is less than 50 % by weight, the resultant moulded article is fragile, and cannot be used in fields requiring the moulding of large-sized articles such as automobile industry and construction industry. The polymerizable vinyl monomers (B) contain 5 to 40 % by weight, preferably 10 to 25 % by weight, of methyl methacrylate. When the methyl methacrylate proportion exceeds 40 % by weight, curing of the resultant moulded article takes a longer time. When this proportion is less than 5 % by weight, it is more difficult to achieve low initial viscosity of the resins and it is more difficult to maintain the viscosity increase which is caused by a reaction during injection, at a low level, as intended by this invention. The polyisocyanate compound (C) used in the composition of this invention is a liquid compound having a terminal group and a viscosity, at 25 °C, of 10 to 2,000 cps, preferably 30 to 1,500 cps, more preferably 30 to 200 cps. Examples of the polyisocyanate compound (C) include liquid diphenylmethane diisocyanate (e.g. supplied by Dow Mitsubishi Kasei Co., Ltd., under the tradename of "Isonate 134L"), polyether prepolymers of diphenylmethane-4,4'-diisocyanate (e.g. supplied by Dow Mitsubishi Kasei Co., Ltd., under the tradename of "Isonate 181"), and polyester prepolymers of diphenylmethane-4,4'-diisocyanate (e.g. supplied by Dow Mitsubishi Kasei Co., Ltd., under the tradename of "Isonate 240"). The amount of polyisocyanate compound (C) is selected such that the amount of isocyanate groups is 0.75 to 1.20 times, preferably 0.85 to 1.1 times, by mole, as large as the amount of hydroxyl groups of the active hydrogen compound (A). When the amount of isocyanate groups is less than 0.75 times by mole, the amount of the hydroxyl groups or more than 1.20 times by mole, the amount of the hydroxyl groups, the resultant moulded article is fragile and cannot be used in fields requiring the moulding of large-sized articles, such as automobile industry and construction industry. Preferred examples of the fiber (D) are glass fibers, carbon fibers and aramid fibers, in view of their strength, affinity with the resins, price, etc., Glass fibers are particularly preferable. The present resins may be used in the following mode, whereby a moulded article of a fiber-reinforced thermosetting resin composition can be obtained. The polyol side of a RIM machine is charged with the active hydrogen compound (A) and the polymerizable vinyl monomers (B) into which an ordinary cure promotor such as dimethyl aniline or cobalt naphthenate and an ordinary urethanating catalyst such as cobalt octenate or di-n-butyltin dilaurate are added. The isocyanate side of the RIM machine is charged with polyisocyanate compound (C) into which an ordinary curing catalyst having no active hydrogen, such as t-butyl perbenzoate, t-butyl peroctoate or benzoyl peroxide is added. Further, fiber (D) is preliminarily charged into a mold, and then the above two liquid resins are injected into the mold, while being uniformly mixed, by using the above RIM machine, whereby a urethanation reaction and radical reaction are effected nearly simultaneously. A molded article of a fiber-reinforced thermosetting resin composition can thus be obtained. The moulding material according to the invention exhibits a low viscosity. It is particularly useful as the resin for a resin transfer moulding process. Furthermore, the resin compositions prepared by mixing the active hydrogen compound (A) with the polymerizable vinyl monomers (B) have short moulding times. The combination of active hydrogen compound (A) polymerizable vinyl monomers (B) and polyisocyanate compound (C) leads to excellent impact resistance of the resultant moulded article. The components (A), (B), (C) and (D) specified in this invention are mixed in the specified ratio, whereby the viscosity of the resultant mixture is low, the initial thickening is comparatively moderate, and it is possible to effect a reaction in which curing is completed in a short period of time. Therefore, large-sized moulded articles can be obtained from the fiber-reinforced thermosetting resin composition. EXAMPLES The following Examples will illustrate this invention more in detail. However, this invention shall not be limited to these Examples. SYNTHESIS EXAMPLE 1 Synthesis of unsaturated polyester and preparation of unsaturated polyester resin (α):- A reactor having a stirrer, a thermometer, a nitrogen-introducing tube and a partial refluxer with a thermometer on its column portion was charged with 1,034 g of isophthalic acid, 1,687 g of neopentyl glycol and 1,006 g of ethylene glycol. In a flow of nitrogen gas, the mixture was heated up to 200 °C to carry out a conventional dehydration-condensation reaction. In the partial refluxer, using steam having a temperature of 100°C, the glycols were refluxed to distil condensation water off from the reactor system. When the acid value of the resultant reaction mixture reached 4.5 mgKOH/g, heating was stopped, and the reaction mixture was cooled to 120°C. Then, 2,169 g of fumaric acid was added. The resultant mixture was again heated to carry out a dehydration-condensation reaction with taking care that the reaction temperature did not exceed 220°C, whereby 5,000 g of an unsaturated polyester having an acid value of 4.5 mgKOH/g and a hydroxyl value of 151.6 mgKOH/g was obtained. Then, the unsaturated polyester was cooled to 170°C, and 1.5 g of hydroquinone was added and fully mixed. Part of the unsaturated polyester was dissolved in styrene to give an unsaturated polyester resin (α) containing 35 % of styrene. SYNTHESIS EXAMPLE 2 Synthesis of unsaturated polyester and preparation of unsaturated polyester resin (β) :- The same reactor as that used in Synthesis Example 1 was charged with 989 g of isophthalic acid, 1,751 g of neopentyl glycol, 1,044 g of ethylene glycol and 2,073 g of fumaric acid, and the mixture was reacted in the same way as in Synthesis Example 1 to synthesize an unsaturated polyester, having an acid value of 2.3 mgKOH/g and a hydroxyl value of 232.3 mgKOH/g. The unsaturated polyester was dissolved in styrene to give an unsaturated polyester resin (β) containing 35 % of styrene. SYNTHESIS EXAMPLE 3 Synthesis of unsaturated epoxy ester resin (γ):- A three-necked flask having a refluxer was charged with 700 g of a novolak-type epoxy resin (DEN 438, supplied by Dow Chemical, epoxy equivalent = 179), 340 g of methacrylic acid, 693 g of styrene, 2.08 g of triethylamine and 0.4 g of hydroquinone, and while the mixture was stirred, it was heated up to 120°C to allow it to react until its acid value reached 15 mgKOH/g,whereby an unsaturated epoxy ester resin (γ) was obtained. Table 1 shows the physical properties of the above unsaturated polyester resins (α) and (β) and the above unsaturated epoxy ester resin (γ). EXAMPLE 1 Di-n-butyltin dilaurate (10 g) as a urethanation catalyst and 80 g of 6 % cobalt naphthenate as a radical reaction promotor were added to a mixture consisting of 8.5 kg of the unsaturated polyester resin (α) prepared in Synthesis Example 1, 0.5 kg of the unsaturated epoxy ester prepared in Synthesis Example 3 and 1.0 kg of methyl methacrylate. The resultant mixture was charged into the A side raw material tank of a RIM machine. 200 g of t-butyl peroctoate as a radical reaction catalyst was added to 10 kg of ISONATE 143 (supplied by Dow Mitsubishi Kasei Co., Ltd., 4,4'-diphenylmethane diisocyanate, NCO equivalent = 143) as a polyisocyanate component, and the resultant mixture was charged into the B side raw material tank of the RIM machine. The A side/B side material mixing ratio was calculated such that the amount of the isocyanate group in the B side tank was 0.93 times, by mole, as large as the amount of the hydroxyl group in the A side tank, and it was found that the A side/B side ratio was 4.275 (g/g). The injection rates (flow rates) of the A side and B side were adjusted to meet this ratio. Then, the RIM machine conditioned as above was operated to inject the resins into a poly cup for 1 second, and 2 cm 3 of the injected mixture liquid was measured for a viscosity change by using a rheometer (RM-1, supplied by Shimadzu Corporation). The time when the injection was finished was taken as 0 time. The measurement showed a viscosity of 25 cps after 10 seconds and a viscosity of 100 cps after 60 seconds. This resin composition had a very low viscosity for 60 seconds from the initial time. Then, a mold, which had a cavity size of 400 x 500 x 3 (mm) and a fan gate in one of short sides of its rectangular form and which was designed to allow a resin to overflow the other short side when the resin was injected, was heated to 60°C, and charged with a continuous strand mat. The mold was closed and positioned perpendicularly, and the above-prepared RIM machine was operated to inject the resins through the lower portion of the mold until the resins overflowed the mold top portion. Then, the mold was closed and left to stand for 2 minutes, and the mold was then opened and removed to give a molded article of the fiber-reinforced thermosetting resin composition. That is, molded articles having a glass content of 42 wt%, 56 wt% or 69 wt% were prepared. These molded articles all showed that the resin impregnatability into the glass fiber was excellent and the resin impregnation was perfect. EXAMPLES 2 to 4 Example 1 was repeated except that the kind and amount of the components for the active hydrogen compound (A) in the A side tank, the methyl methacrylate amount, the styrene amount and the A side/B side mixing ratio were changed as shown in Table 2. The viscosity change in the mixed resins and the glass content and moldability were evaluated. The Table shows the results together with the results of the molded article of Example 1. COMPARATIVE EXAMPLES 1 to 7 Example 1 was repeated except that the kind and amount of the components for the active hydrogen compound (A) in the A side tank, the methyl methacrylate amount and the A side/B side mixing ratio were changed as shown in Table 3 or 4. The viscosity change in the mixed resins and the glass content and moldability were evaluated. Tables 3 and 4 show the results. In all of Comparative Examples 1 to 7, the resins after being mixed showed a steep viscosity increase, and when the glass content exceeded 56 wt%, the resins exhibited a very high back pressure and leaked through a connection portion between the mixing head of the RIM machine and the mold. Thus, it was impossible to obtain a completely filled, molded article. COMPARATIVE EXAMPLE 8 Example 1 was repeated except that the kind and amount of the components for the active hydrogen compound (A), the methyl methacrylate amount and the A side/B side mixing ratio were changed as shown in Table 4. The viscosity change in the mixed resins and the glass content and moldability were evaluated. Tables 4 show the results. The resin composition showed a low increase in viscosity during the period of 60 seconds after the resins were mixed, and could be completely filled up to a glass content of 69 wt%. However, while the time required from the injection to removal of the mold was as short as 246 seconds in Example 1, the time required in this Comparative Example 8 was as long as 398 seconds. Thus, it was impossible to obtain a resin combination exhibiting the short cure time that is an object of this invention. RESIN SYNTHESIS EXAMPLE UNSATURATED POLYESTER RESIN UNSATURATED EPOXY ESTER RESIN NAME OF RESIN (α) (β) (γ) SYNTHESIS EXAMPLE 1 2 3 COMPOSITION Isophthalic acid 1034 g Isophthalic acid 989 g DEN-438 700 g Fumaric acid 2169 g Fumaric acid 2073 g Methacrylic acid 340 g Ethylene glycol 1006 g Ethylene glycol 1044 g Styrene 693 g Neopentyl glycol 1687 g Neopentyl glycol 1751 g Triethylamine 2.08 g Hydroquinone 0.40 g ANALYSIS (1) Unsaturated polyester Acid value (mgKOH/g) 4.5 2.3 Hydroxy value (mgKOH/g) 151.6 232.3 DILUTION Styrene 2000 g Styrene 2000 g Hydroquinone 1.5 g Hydroquinone 1.5 g ANALYSIS (2) Unsaturated polyester resin Unsaturated epoxy ester resin Styrene content (wt%) 35.0 35.0 40.0 Acid value (mgKOH/g) 2.9 1.5 15.0 Hydroxy value (mgKOH/g) 98.5 151.0 127.0 EXAMPLE 1 2 3 4 COMPOSITION Unsaturated polyester Kind α α β β resin (a 1 )+SM (part of (B)) Amount (part) 85.0 82.5 85.0 83.1 Unsaturated epoxy Kind γ γ γ ester (a 2 )+SM(part of (B)) Amount (part) 5.0 5.0 5.0 - Acrylic compound having Kind 2-HEMA 2-HEMA a hydroxyl group Amount - 2.5 - 5.0 SM (part of (B)) Amount (part) - - - 6.9 MMA (part of (B)) Amount (part) 10.0 10.0 10.0 5.0 Polyisocyanate Kind 143L 143L 143L 143L compound (C) Amount (part) 21.6 23.7 33.1 37.1 MIXING RATIO IN RIM MACHINE (A SIDE/B SIDE) 4.275 3.926 2.875 2.581 ANALYSIS [(a 2 )+(a 3 )]/[(a 1 )+(a 2 )+(a 3 )]x100 (wt%) 5.15 9.30 5.15 8.47 (B)/[(a 1 )+(a 2 )+(a 3 )+(B)]x100 (wt%) 41.8 40.9 41.8 41.0 Methylmethacrylate/(B)x100 (wt%) 24.0 24.5 24.0 12.2 NCO group of polyisocyanate compound (C)/OH group of [(a 1 )+(a 2 )+(a 3 )] (by mole) 0.93 0.93 0.95 1.00 VISCOSITY 10 seconds after mixed (cps) 25 25 25 20 60 seconds after mixed (cps) 100 85 84 50 MOLDABILITY EVALUATION Glass fiber (D) Glass content 42 wt% 0 0 0 0 Glass content 56 wt% 0 0 0 0 Glass content 69 wt% 0 0 0 0 Molding time (sec) 246 241 293 295 COMPARATIVE EXAMPLE 1 2 3 4 COMPOSITION Unsaturated polyester Kind α β α β resin (a 1 )+SM (part of (B)) Amount (part) 100.0 100.0 95.0 95.0 Unsaturated epoxy Kind γ ester (a 2 )+SM (part of (B)) Amount (part) - - 5.0 - Acrylic compound having Kind 2-HEMA a hydroxyl group Amount - - - 5.0 SM (part of (B)) Amount (part) - - - - MMA (part of (B)) Amount (part) 0.0 0.0 0.0 0.0 Polyisocyanate Kind 143L 143L 143L 143L compound (C) Amount (part) 25.4 39.0 24.1 38.7 MIXING RATIO IN RIM MACHINE (A SIDE/B SIDE) 3.682 2.461 3.866 2.479 ANALYSIS [(a 2 )+(a 3 )]/[(a 1 )+(a 2 )+(a 3 )]x100 (wt%) 0.0 0.0 4.63 7.49 (B)/[(a 1 )+(a 2 )+(a 3 )+(B)]x100 (wt%) 35.0 35.0 35.2 33.3 Methyl methacrylate/(B)x100 (wt%) 0.0 0.0 0.0 0.0 NCO group of polyisocyanate compound (C)/OH group of [(a 1 )+(a 2 )+(a 3 )] (by mole) 1.00 1.00 0.96 1.00 VISCOSITY 10 seconds after mixed (cps) 50 56 59 56 60 seconds after mixed (cps) 590 420 353 1,350 MOLDABILITY EVALUATION Glass fiber (D) Glass content 42 wt% 0 0 0 0 Glass content 56 wt% Δ Δ Δ X Glass content 69 wt% X X X X Cure time (sec) 265 305 205 253 COMPARATIVE EXAMPLE 5 6 7 8 COMPOSITION Unsaturated polyester Kind α β α β resin (a 1 )+SM (part of (B)) Amount (part) 95.0 95.0 75.0 75.0 Unsaturated epoxy Kind γ γ ester (a 2 )+SM (part of (B)) Amount (part) - - 10.0 5.0 Acrylic compound having Kind 2-HEMA a hydroxyl group (a 3 ) Amount - - 5.0 - SM (part of (B)) Amount (part) - - - - MMA (part of (B)) Amount (part) 5.0 5.0 10.0 20.0 Polyisocyanate Kind 143L 143L 143L 143L compound (C) Amount (part) 24.1 37.0 24.3 18.8 MIXING RATIO IN RIM MACHINE (A SIDE/B SIDE) 3.866 2.587 3.565 4.425 ANALYSIS [(a 2 )+(a 3 )]/[(a 1 )+(a 2 )+(a 3 )]x100 (wt%) 0.0 0.0 18.4 5.8 (B)/[(a 1 )+(a 2 )+(a 3 )+(B)]x100 (wt%) 38.3 38.3 40.3 48.3 Methyl methacrylate/(B)x100 (wt%) 13.1 13.1 24.8 41.5 NCO group of polyisocyanate compound (C)/OH group of [(a 1 )+(a 2 )+(a 3 )] (by mole) 1.00 1.00 0.88 0.92 VISCOSITY 10 seconds after mixed (cps) 42 47 21 12 60 seconds after mixed (cps) 277 260 840 64 MOLDABILITY EVALUATION Glass fiber (D) Glass content 42 wt% 0 0 0 0 Glass content 56 wt% Δ Δ Δ 0 Glass content 69 wt% X X X 0 Cure time (sec) 301 336 227 398

Claims: A moulding material which is a mixture of (A) an active hydrogen compound (A) obtainable by mixing (a 1 ) an unsaturated polyester having a hydroxyl value of 110 to 280 mgKOH/g and an acid value of not more than 5 mgKOH/g and derived from a dicarboxylic acid component containing 40 to 100 mole% of an unsaturated dicarboxylic acid or an anhydride thereof and a polyhydric alcohol containing primary hydroxyl groups with at least one of (a 2 ) an unsaturated epoxy ester derived from an epoxy compound having at least one epoxy group in the molecule and an epoxy equivalent of 70 to 200 and a polymerizable unsaturated monobasic acid and (a 3 ) an acrylic compound having an acryloyl group and a hydroxyl group in the molecule, the amounts of (a 1 ), (a 2 ) and (a 3 ) satisfying the equation; (a 2 +a 3 ) / (a 1 +a 2 +a 3 ) x 100 = 1 to 15 wt%, and (B) a mixture of polymerizable vinyl monomers (B) other than (a 1 ), (a 2 ) and (a 3 ), said mixture containing 5 to 40% by weight of methyl methacrylate; the amount of polymerizable vinyl monomers (B) being 20 to 50% by weight of the total amount of the active hydrogen compound (A) and the polymerizable vinyl monomers (B). A moulding material according to claim 1, wherein the unsaturated dicarboxylic acid or anhydride thereof is at least one of maleic acid, maleic anhydride and fumaric acid. A moulding material according to claim 1 or 2, wherein the dicarboxylic acid component, in addition to the unsaturated dicarboxylic acid, comprises at least one of phthalic acid, phthalic anhydride, isophthalic acid, terephthalic acid, Het acid and tetrahydrophthalic anhydride. A moulding material according to claim 1, 2 or 3 wherein the polyhydric alcohol having primary hydroxyl groups is at least one of ethylene glycol, diethylene glycol, 1,4-butanediol and neopentyl glycol. A moulding material according to any one of the preceding claims wherein the acrylic compound (a 3 ) is 2-hydroxyethyl (meth)acrylate and/or 2-hydroxypropyl (meth)acrylate. A moulding material according to any one of the preceding claims, wherein the polymerizable vinyl monomers (B) comprise 5 to 40% by weight of methyl methacrylate and at least one of styrene, chlorostyrene, vinyl toluene, (meth)acrylic acid, ethyl (meth)acrylate, propyl (meth)acrylate and butyl (meth)acrylate. A moulding material according to any one of the preceding claims wherein the unsaturated polyester (a 1 ) has a hydroxyl value of 150 to 250 mgKOH/g. A moulding material according to any one of the preceding claims wherein the unsaturated epoxy ester (a 2 ) is derived from an epoxy compound having at least one epoxy group in the molecule and an epoxy equivalent of 140 to 200 and a polymerizable monobasic acid. A moulding material according to any one of the preceding claims, wherein the amount of polymerizable vinyl monomers (B) is 30 to 50% by weight of the total amount of the active hydrogen compound (A) and the polymerizable vinyl monomers (B). A combined material for use in moulding an article which comprises a moulding material as claimed in any one of the preceding claims and (C) a polyisocyanate compound (C) having a terminal group of the formula and a viscosity, at 25°C of 0.01 to 2 Pas (10 to 2,000 cps) and an isocyanate group content which is 0.75 to 1.2 times, by mole. the hydroxyl group content of (A). A process for the production of a moulded article by a RIM process, which comprises the reaction injection of a moulding material (A) + (B) as claimed in any one of claims 1 to 9 and a component containing a polyisocyanate compound (C) which is a liquid compound having a terminal group of the formula and a viscosity, at 25°C, of 0.01 to 2 Pas (10 to 2,000 cps) and an isocyanate group content which is 0.75 to 1.2 times, by mole, the hydroxyl group content of (A), into a mould containing a fiber (D) in an amount of 30 to 75% by weight based on the total weight of (A), (B), (C) and (D), and curing of a reaction product in the mould. A process according to claim 11 wherein (C) has an isocyanate group content which is 0.85 to 1.1 times, by mole, the hydroxyl group content of (A). A process according to claim 11 or 12, wherein (C) is at least one of liquid diphenylmethane diisocyanate, a polyether prepolymer of diphenylmethane-4,4'-diisocyanate and a polyester prepolymer of diphenylmethane-4,4'-diisocyanate. A process according to claim 11 or 12, wherein (D) is at least one of a glass fiber, a carbon fiber and an aramid fiber. A process according to claim 11, 12, 13 or 14, wherein (C) has a viscosity, at 25°C of 0.03 to 1.5 Pas (30 to 1,500 cps). A process according to claim 15, wherein (C) has a viscosity, at 25°C, of 0.03 to 0.2 Pas (30 to 200 cps). A process according to any one of claims 11 to 16, wherein the amount of (D) is 30 to 60% by weight based on the total amount of (A), (B), (C) and (D).

Inventors: KUROKAWA MASASHI, NAMIKAWA AKIRA, OKUMURA HIROYUKI, TANISAKE HIROKA, KUROKAWA, MASASHI, NAMIKAWA, AKIRA, OKUMURA, HIROYUKI, TANISAKE, HIROKA
Applicants: INT CHEMICAL COMPANY INC AG, TOYOTA MOTOR CO LTD, A. G. INTERNATIONAL CHEMICAL COMPANY, INC., TOYOTA JIDOSHA KABUSHIKI KAISHA
Application year: 1990
Main classification: C08L67
IPC codes: B29C45, C08F299, C08L67, C08L75, C08G18, C08F283, C08J5, C08K7