NON-PROVISIONAL PATENT APPLICATION

POWDER-COATABLE MOLDING COMPOSITIONS

This application claims the benefit of U.S. Provisional Application Serial No.

60/688,659, filed June 8, 2005.

TECHNICAL FIELD

The present invention relates to powder-coatable molding compositions. In a

more specific aspect, this invention relates to such molding compositions which provide

products with a Class A surface after powder coating. This invention also relates to a

process for the manufacture of these powder-coatable molding compositions.

BACKGROUND OF THE INVENTION

Molding compositions have been manufactured and used for many years in

forming various articles. Examples of these compositions include sheet molding

compositions (SMC) and bulk molding compositions (BMC).

Automotive painting operations are typically carried out on a body-in-white,

which is the unpainted unitary body structure comprising body panels and structural

components. The body structure is usually formed mostly of steel panels but may include

polymer composite panels. The paint shop practice is well known for the steel portion of

the body structure, as the steel portion is electrically conductive and, therefore, receives

several coating layers for corrosion resistance, paint adhesion and painted surface finish

quality.

The polymer composite panels do not respond to the coating procedure in the

same way as the steel panels. For example, automotive painting operations often involve

the separate application of a zinc phosphate base layer, an electrocoated liquid prime coat

using water or an organic solvent, a liquid or powder primer surfacer layer, a liquid base

color coat and a liquid or powder clear top coat.

Following each of the prime coat, primer surfacer and clear top coat applications,

a baking step at temperatures of 250° F or higher is generally used to cure or dry the new

layer and to promote flow of the top coat films to a commercially acceptable finish for a

vehicle. Such aggressive heating of the painted composites typically leads to "out-

gassing", which is the release of entrapped air, solvent, moisture, uncured chemicals and

uncured polymer precursor materials from the somewhat porous composite substrate. Too

often the result is an unsightly and unacceptable rough surface. Out-gassing was initially

experienced with liquid primer surfacer paints at their 250° F bake temperature. The

occurrence of surface roughness with such paint systems has been reduced in some

instances by the use of a specially formulated, electrically conductive polymer prime coat

as a barrier coat after molding. This polymer prime coat on the composite surface may

reduce out-gassing at that location.

However, the prior art molding compositions often experience problems with

achieving excellent surfaces with powder primers on parts molded from sheet molding or

bulk molding compositions. These problems can be attributed to the kind and amount of

components contained in the SMC or BMC compositions.

Examples of prior art efforts to improve the surface of molding compositions after

powder prime include U.S. Patents No. 6,872,294 and 6,875,471, which describe that the

quality of painted surfaces of polymeric articles is improved by depositing a coating of a

metal such as zinc or zinc alloy on the surface of the article to be painted. The metal

coated polymeric surface provides a good base for electrostatic deposition of either liquid

or powder paint, and the metal surface prevents the formation of defects in the painted

surface during heating of the article to dry or cure the paint film.

U.S. Patent No. 6,843,945 describes in-mold coating of polymer composite parts

for metallization and painting.

U.S. Patent No. 4,039,714 describes pre-treatment of plastic materials for metal

plating by conditioning their surface by a treatment with sulfur trioxide vapor or a

material which contains sulfur trioxide.

All the processes mentioned above require some kind of pre-treatment of the

composite surface before powder-painting to result in a Class A surface, which increases

cycle-time and adds cost. Therefore, there is a need in the industry for molding

compositions which will provide an excellent surface to the molded products and painted

parts without pre-treatment steps.

SUMMARY OF THE INVENTION

The present invention provides powder-coatable molding compositions for the

manufacture of sheet molded products and bulk molded products which surprisingly have

an excellent surface after powder prime and paint. The present invention also provides a

process for the manufacture of these powder-coatable molding compositions.

Accordingly, an object of this invention is to provide powder-coatable molding

compositions.

Another object of this invention is to provide powder-coatable molding

compositions for sheet molded products and bulk molded products.

Another object of this invention is to provide powder-coatable molding

compositions which, when molded and powder-primed, provide products with an

excellent surface.

Still another object of this invention is to provide a process for the manufacture of

powder-coatable molding compositions.

Still another object of this invention is to provide a process for the manufacture of

powder-coatable molding compositions for sheet molded products and bulk molded

products.

Still another object of this invention is to provide a process for the manufacture of

molding compositions which, when molded and powder-primed, provide products with

an excellent surface.

These and other objects, features and advantages of this invention will become

apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a digital image of the reflection of a fluorescent ceiling light on a

powder primed panel made from a sheet molding composition of the prior art.

Fig. 2 shows a digital image of the reflection of a fluorescent ceiling light on a

powder primed panel made from a sheet molding composition of this invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a new and unique thermosetting, powder-coatable

molding composition which comprises the following components: an unsaturated,

uncured, curable polyester and/or vinyl ester; a monomer which will copolymerize with

the unsaturated polyester and/or vinyl ester; at least two thermoplastic polymers; a filler;

and a reinforcing agent.

The present invention also provides a process for the manufacture of these new

and unique powder-coatable molding compositions.

As used in this application, the term "new and unique" will be understood as

referring to the resulting excellent surface of sheet and bulk molded products made from

the compositions of this invention after powder coating, and the term "excellent surface"

will be understood as referring to either a Class A surface which has a Loria less than

about 85 or a near Class A surface which has a Loria less than about 150. (The Loria

values are measured on a Loria™ surface analyzer from Ashland Chemical Company).

Of course, depending upon the intended use, the molding compositions of this

invention may optionally contain other additives, such as dyes, pigments, thickening

agents, viscosity reducers, inhibitors, peroxides, mold release agents, catalysts, etc.

The molding compositions of this invention can be molded into various products,

including sheet and bulk parts, such as automotive hoods, fenders, truck beds, bumpers,

etc.

The unsaturated, uncured, curable polyesters and/or vinyl esters useful in this

invention are commercially available products. These polyesters (sometimes referred to

as polyester alkyds) are a class of soluble, linear, low molecular weight materials which

contain both carboxylic ester groups and carbon-carbon double bonds as recurring units

along the main polymer chain. These polyesters may be prepared by condensation of

long chain polyols, diols, ethylenically unsaturated dicarboxylic acids or anhydrides to

impart the unsaturation and saturated dicarboxylic acids to modify the polymer.

Suitable unsaturated polyesters are the usual condensation products of polybasic

acids, in particular dibasic carboxylic acids and their esterifiable derivatives such as their

anhydrides, with polyhydric alcohols. Preferred unsaturated polyesters are those formed

from maleic anhydride and propylene glycol; I ₃ 3 -propanediol; I ₅ 4-butanediol; neopentyl

glycol; ethylene glycol; diethylene glycol; dipropylene glycol and/or dicyclopentadiene.

Suitable vinyl ester resins, also known as epoxy (meth) acrylates, that may be used

in the composition of this invention are addition products of polyepoxides and

unsaturated carboxylic acids, preferably acrylic acid and methacrylic acid. Suitable

polyepoxides are epoxy novolac resins and, in particular, polyepoxides based on

bisphenol A. Another suitable class of vinyl ester resins is the esterifϊcation products of

alkoxylated bisphenol A and (meth) acrylic acid.

The monomer used in this invention can be mono-or poly-functional but must be

copolymerizable with the unsaturated polyester and/or vinyl ester. Preferred monomers

are styrene, alpha-methyl styrene, chlorostyrene, vinyl toluene, divinyl benzene, methyl

methacrylate and mixtures thereof.

A third essential part of the molding compositions of this invention is a blend (i.e.,

at least two) of thermoplastic polymers (also referred to as low profile additives). As

with the unsaturated polyester, these thermoplastic polymers are commercially available

products and are especially useful in producing molded articles having a Class A surface

which is essential for molded automotive parts. Many thermoplastic polymers can be

used in this invention, including saturated polyester alkyds, vinyl polymers,

polymethacrylates, acrylic polymers and mixtures thereof. For purposes of this

invention, rubber-containing homopolymers and copolymers shall be considered as

thermoplastic polymers. Preferred thermoplastic polymers are poly(methylmethacrylate),

styrene-butadiene-copolymers, saturated polyester alkyds and mixtures thereof.

In this invention, the thermoplastic polymer component is present in amount of

from about 10 to about 25 percent by weight, based on the total weight of the unsaturated

polyester and/or vinyl ester component, the monomer component and the thermoplastic

polymer component.

The low profile additive most commonly used in the industry, a vinyl acetate

containing polymer, is not a preferred thermoplastic polymer to make the compositions of

this invention. However, a low amount of a vinyl acetate containing polymer, such as no

more than about 5.0 percent by weight, may be used to increase surface smoothness of

the molded part.

The molding compositions of this invention also contain a reinforcing agent.

Specific suitable reinforcing agents are made from glass, carbon and synthetic organic

fibers such as polyethylene, polycarboxylic esters, polycarbonates and mixtures thereof.

Our molding compositions also contain a filler. Preferred fillers are alumina

trihydrate, alumina powder, aluminosilicate, baruim sulfate, calcium carbonate, calcium

silicate, calcium sulfate, clay, dolomite, glass spheres, limestone dust, mica, quartz

powder, crushed silica, talc and mixtures thereof.

Other additives may also be used in formulating the curable resin composition of

the present invention. The additives and their functions are well known in the industry,

examples of which are tougheners, release agents, inhibitors, leveling agents, wetting

agents and adhesion promoters.

Examples of suitable compatibilizers are leveling agents (such as acrylic resins,

fluorocarbons, fluoropolymers and silicones) and wetting agents (such as boric acid

esters, phosphate esters, fatty acid salts and polyethers).

The composition may also contain conventional toughening agents such as core

shell rubbers or liquid rubbers having reactive groups.

Suitable inhibitors are phenolic compounds such as (substituted) hydroquinone,

pyrocatechol, t-butylpyrocatechol and ring-substituted pyrocatechols; quinones such as

benzoquinone, naphthoquinone and chloranil; nitrobenzenes such as m-dinitrobenzene

and thiodiphenylamine; N-nitroso compounds such as N-nitrosodiphenylamine; salts of

N-nitroso-N-cyclohexylhydroxylamine; and mixtures thereof.

Suitable thickeners include oxides or hydroxides of lithium, magnesium, calcium,

aluminium or titantium. Preferred thickeners include magnesium oxide and magnesium

hydroxide.

The resin compositions of this invention may be cured by a number of free- radical

initiators, such as organic peroxide and azo-type initiators. Peroxide initiators include

diacylperoxides, hydroperoxides, ketone peroxides, peroxyesters, peroxyketals, dialkyl

peroxides, alkyl peresters and percarbonates. Azo-type initiators include

azobisisobutyronitrile and related compounds. These initiators are preferably used in the

range of from about 1 to about 3 percent by weight.

Other optional additives are mold release agents, such as zinc stearate, magnesium

stearate and calcium stearate; curing accelerants such as octoates or naphthenates of

copper, lead, calcium, magnesium, cerium, manganese and cobalt; and thickening

accelerants such as water and polyols.

The composition of this invention can be used to mold various parts which, after

cure, exhibit a change of from about 0.02 percent shrinkage to about 0.07 percent

expansion, as compared to cold mold dimensions.

The present invention is further illustrated by the following example which is

illustrative of certain embodiments designed to teach those of ordinary skill in the art how

to practice this invention and to represent the best mode contemplated for carrying out

this invention.

EXAMPLE

A process for making a SMC is described as follows. All ingredients, except for

the glass, fiber strands are mixed together to form a resin paste. The paste is transferred

to a doctor box and then deposited onto a moving carrier film passing directly beneath.

At the same time, glass fiber strands are fed into a cutting apparatus above the resin paste

coated carrier film. The fibers are chopped to 1 inch length and dropped onto the resin

paste. The amount of glass is controlled by the speeds of the cutter and the carrier film.

After the glass deposition, a second resin paste coated carrier film is laid on top, paste

side down. The paste-glass-paste sandwich is subsequently sent through a series of

compaction rollers where the fibers are wet out with the paste and excess trapped air is

squeezed out of the sheet. At the end of the compaction rollers, the SMC sheet is bi-

folded into a bin which is covered tightly to avoid the evaporation of styrene and other

ingredients.

Before used for molding, the SMC must mature. The maturation is required to

allow the relatively low-viscosity resin to thicken chemically and also increase

significantly in viscosity. The thickened SMC is easier to handle and prevents the resin

paste from being squeezed out of the glass fiber bed. SMC typically requires 3 to 5 days

to reach the desired molding viscosity (~ 40 to 100 million mPa.s). ■

When the SMC is ready for molding, the sheet is cut into pieces of a

predetermined size and shape, and the carrier film on both sides removed. The pieces are

then placed on the hot mold surface in a pattern that was established earlier for optimum

flow and mold coverage during compression. Under heat and pressure, the SMC flows to

fill the mold cavity. The cure time of the SMC varies from 30 to 150 seconds, depending

mostly on the material formulation and the thickness of the molded part.

After curing, the mold is opened, and the part is ejected from the bottom mold

surface with the use of ejector pins. Care must be used during removal of the part from

the press to avoid stressing of the part.

The molded parts are then sent to the painting operation where the parts are

powder primed to customer specifications.

The following Tables 1-3 are used for comparison purposes. Table 1 illustrates a

standard Tough Class A ("TCA") SMC formulation (as described in U.S. Patent No.

6,759,466) which is widely used in the industry for the manufacture of composite

automotive body panels because of the ability of this formulation to significantly reduce

paint pops. Table 2 illustrates a Class A SMC formulation with a low profile additive

package containing poly (vinyl acetate). Table 3 illustrates a Class A SMC formulation

according to this invention which uses a for powder-prime surface optimized low profile

additive package.

All 3 SMC formulations contain 27.5 % by weight 1 inch glass fibers as a

reinforcing agent, and all 3 SMC formulations show a Class A capable surface (30 - 85

Loiϊa), after demolding from the press before powder prime.

Figs. 1 and 2 show digital images of sections of panels of the formulations of

Tables 1 and 3 after powder prime. Both images cover the same area on the respective

panels and are of identical resolution. The composition described in Table 3 (Fig. 2)

clearly outperformed the standard TCA system (Fig. 1). The term PHR refers to parts per

hundred resin, and the term resin refers to the sum of all polymers, polyester alkyds and

reactive monomers in the composition.

In terms of grades, the powder primed parts from the composition in Table 3

would be considered an A (highest grade), the parts from the composition in Table 2

would be a D and the parts from the composition in Table 1 would be an F.

Table 1

Table 2

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Table 3

This invention has been described in detail with particular reference to certain

embodiments, but variations and modifications can be made without departing from the

spirit and scope of the invention as defined in the following claims.