Abstract: A cast, composite countertop is prepared by spraying a castable, curable organic resin composition which includes over 20% by weight of an inorganic, particulate material therein, into a mold cavity corresponding to a top surface and side wall of a countertop so as to produce a continuous coating therein. This coating is at least partially cured, and a hardenable, liquid substrate composition introduced into the mold cavity, and the resultant composite is fully cured to produce a countertop. In some instances, an additional casting step may be employed to build up the edge thickness. Also disclosed are dual spray techniques for enhancing the surface quality of the composite, and techniques for enhancing the thermal stability thereof. Also disclosed are countertops made by the disclosed methods.

Abstract: Polymer composite products, including products made of polymer concrete, reinforced polymer concrete and reinforced plastics, such as bulk molding compound, sheet molding compound, mineral molding compound and advanced molding compound systems, are produced by the simultaneous application of vibration, heat and pressure to a mixture of filler and polymeric binder. The simultaneous application of vibration, heat and pressure provides a protective layer of polymerized binder that protects the surfaces of the mold and provides products that are substantially free of curling, cracking or voids. The process of the present invention substantially reduces the time required to cure polymer composite products.

Abstract: In a fiber composite plastic composed of plastic composition and fibers, the fibers have a pronounced fiber length distribution, in particular more than 50% by weight of the fibers have a length outside the range from 0.8.times.L to 1.2.times.L, where L is the mean (weight average) fiber length, and the mean fiber length is greater than the critical fiber length of the plastic composition/fiber system.

Abstract: A method of moulding, notably injection or compression moulding, of a composite product from an impregnation paste based upon thermosetting resin or resins and a reinforcement of glass threads, by supplying the moulds with an impregnation paste and reinforcement in the form of coated chopped direct rovings incorporated into the paste, the coating material of which includes an adhesive agent based upon polyurethane or polyurethanes.

Abstract: An energy absorbing roadway barrier for dissipating kinetic energy upon impact by a moving vehicle includes an elongated core of reinforced high density concrete having barrier anchor members attached from the elongated core to a position for anchoring the barrier. An elongated barrier portion is formed around the elongated core and around the core anchor members to form a road barrier.

Abstract: Thin-walled molded articles (i.e., molded articles where at least 70% of the wall thickness is 0.8 mm or less) are formed of a polybutylene terephthalate (PBT) molding composition having improved fluidity characteristics and desirable mechanical strength properties. The PBT molding composition includes (A) 100 parts by weight of a polybutylene terephthalate base resin having a melt index of between 40 and 200 as measured at 235.degree. C. under a load of 2160 grams according to ASTM D-1238; (B) between 1 to 60 parts by weight of plate-like glass flakes having an average flake dimension of between 10 to 200 .mu.m; and (C) between 0.01 to 5 parts by weight of a fatty acid metal salt.

Abstract: A process for producing fiberglass reinforced molded articles of superior surface quality involves preparation of a mat of glass fiber comprised of a majority of fibers having a diameter of less than one micron and a minority of fibers having a diameter greater than one micron. A sizing is applied to the fibers. The sizing includes a coupling agent preselected to be compatible with the moldable material, e.g. nylon. The glass fiber mat is comminuted into pieces shaped and dimensioned for combination with the moldable material to form a composite having a range of to 50% of glass fiber by weight. The composite is then molded by a conventional process to yield a fiberglass reinforced article with superior surface quality.

Abstract: A process for using shredded scrap or virgin fiber glass in combination with starch, water and other components to make ceiling tiles. The tiles are made by initially preparing a mixture of water, starch, boric acid and fire clay. That initial mixture is then heated to form a gel. Fiber glass is then added to the gel to form a pulp. The pulp is fed into trays to form slabs. The slabs are dried and finished into tiles.

Abstract: A method of manufacturing a cabinet for use with a display, the cabinet having a sandwiched structure at portions requiring extra strength such as the picture tube or display screen setting portion, the sandwiched structure including a flat outer surface including a resin and a core including a fiber-reinforced resin mixture. Other portions of the cabinet can be formed relatively thin-walled.

Abstract: A method for manufacturing a substantially rigid water-dispersible article includes the step of mixing together an ionic water-soluble film-forming polymer, a non-ionic water-soluble film-forming polymer, a chemically purified finely divided highly bleached cellulose, and glass fiber wool. Water is added to the dry mixture to form a dough which is subsequently molded into the desired form and dried while being maintained in the molded form. A filler or extender such as talc or paper pulp may be added prior to the molding step. In addition, a wetting agent may be added to accelerate rewetting and dispersal of the article upon disposal thereof, while a hydrophobic composition may be added to the dough to form a water repellant surface layer or film during drying of the molded article.

Abstract: Laminated composites including method for the preparation thereof comprising forming in combination in a mold at least one layer of a rigid polyurethane modified polyisocyanurate by reacting in said mold, a reaction mixture of an organic di- or polyisocyanate, a cyclic alkylene carbonate and a polyether polyol in the presence of a soluble adduct aminecarbonate catalyst, and at least one layer of material selected from metal, plastic, cellulose, glass and ceramic or combinations thereof. The electrically conductive "metal clad" laminates are especially usefual as printed circuit boards.

Abstract: A method for adding intact fiber reinforcing material into thermoplastic resin compositions for toughening purposes without breakage of the fibers, including blending a polymeric solution and chopped fibers in a mixture at low to medium shear, injecting the resulting mixture into an extruder with a resin to be reinforced at an entry point positioned very near a vacuum point, and then removing the solvent for recycle while the reinforcing glass fiber and polymer blend is extruded.

Abstract: A method of manufacturing a blank for a light-weight mirror. Graphite molding bodies are positioned at regular intervals on a base that functions as a mirror plate or backing plate. The base is surrounded up to the top of the molding bodies with a graphite wall. The interstices between the molding bodies and between the wall and the molding bodies are filled with granular quartz. The assembly is heated in an evacuated furnace to approximately 1730.degree. C. into a honeycomb-shaped supporting structure that is securely fastened to the base. The graphite molding bodies and wall are removed after cooling. Either a backing plate or a mirror plate in the form of another plate is applied to the resulting supporting structure.

Abstract: Mechanical properties, especially tensile and flexural properties and impact strength, of glass fiber reinforced oxymethylene polymer molding compositions can be enhanced by incorporating into the molding composition an effective amount of a prepolymeric amino resin, whereby the glass fiber reinforcing agent and the oxymethylene polymer are coupled. The amino resin can be a condensation product of formaldehyde and melamine, urea, guanidine, guanamine or a substituted guanamine. An acid catalyst is preferably employed to promote the cross-linking of the prepolymeric amino resin.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

Abstract: A process for the manufacture of glass fiber-reinforced polyester products is disclosed. A ready-to-mold resin and reinforcement composite is prepared using an initiator which has been microencapsulated in order to prevent initiator-induced cross-linking of the resin reactants. The initiator is released during the molding of the composite by rupture of the microcapsules due to internal vapor pressure developed at a preselected molding temperature. The encapsulation of the initiator provides improved homogeneity and increased flowability of the composites during molding, and enables the provision of molded polyester products having higher degrees of cure and more defect-free finish surfaces.

Abstract: Seal rings are molded from an injection moldable elastomeric material, with the rings being designed to have an axially thick body, a rib at the outer periphery for mounting engagement within the outer race ring groove, and a flexible sealing lip at the inner periphery for engagement with the inner race ring. To provide a rigid support body for the ring, particles are dispersed within the moldable material to be injected into the molds, the filler particles having a minimum dimension substantially larger than the maximum dimension of the sealing lip so that, during molding, the filler particles are excluded from the lip but are embedded in the body portion to make that portion more rigid.

Abstract: This invention provides a method for producing porous elastomeric sheet material, wherein ungelled elastomer liquid material is admixed with hollow spherical filler particles and then spread to form a sheet, which is then dried and gelled. The dried and gelled sheet of filled elastomer is subjected to rigorous biaxial stretching, wherein the elastomeric material surrounding at least some of the particles is stretched and ultimately broken by the rigorous stretching, to form a porous sheet material.

Abstract: Overpolymer rubbers comprised of a hard, predominantly acrylonitrile core, a rubbery shell, and a hard overcoat are prepared which have utility as tougheners for thermoset or thermoplastic resin molding compounds.

Abstract: A resinous product has high resistance to flame spread, good heat release and exhibits a low smoke-developed rating when exposed to flame or to indirect or radiant heat, and is flexible, tough and resistant to cracking and embrittlement upon curing. Such a product is the condensation product of resorcinol with or without included phenol, and an admixture of paraformaldehyde and furfural or furfuryl alcohol or both. The resorcinol starting material of this invention can also suitably be used in the form of a B-stage or partially cured resin of resorcinol-phenol-formaldehyde which is then condensed with the aforesaid aldehydes or such aldehyde substance and furfuryl alcohol. The product is useful in making castings or moldings which are resistant to embrittlement or cracking upon curing, and in making tough fiberglass parts, and it can contain fillers or the like. A method of making the product and articles is provided.

Abstract: A method for preparing reinforcer-incorporated plastic molded articles by rotational molding which includes moving a reinforcer and a binder of an amount smaller than the amount of reinforcer along the inner wall of a rotary mold to thereby form in advance a layer of reinforcer which is fixed on the inner side of the mold and having a large number of fine voids, feeding a liquid matrix into the rotary mold and impregnating the liquid matrix into the layer of reinforcer, and solidifying the matrix impregnated in the reinforcer in the rotary mold.

Abstract: A method of fabricating a reinforced plastic tubular article. A mandrel is positioned within a mold in spaced relation to the inner surface of the mold. Dry reinforcing material, in the form of fibrous or particulate material or a combination of both, is located in the annular space between the mandrel and the mold. The interior of the mold is evacuated to remove gas from the mold as well as from the voids within the reinforcing material. An uncured thermosetting resin system, which was mixed under vacuum conditions to remove gas from the system, is introduced into the mold. Pressure is applied to the resin to thoroughly impregnate the reinforcing material with the resin. The resin is then cured by heating while the pressure is maintained on the resin. The resulting cured product has a smooth outer surface which facilitates the attachment of coupling members and has improved mechanical properties.

Abstract: A process for producing fiberglass reinforced molded articles of superior surface quality involves preparation of a mat of glass fiber comprised of a majority of fibers having a diameter of less than one micron and a minority of fibers having a diameter greater than one micron. A sizing is applied to the fibers. The sizing includes a coupling agent preselected to be compatible with the moldable material, e.g. nylon. The glass fiber mat is comminuted into pieces shaped and dimensioned for combination with the moldable material to form a composite having a range of to 50% of glass fiber by weight. The composite is then molded by a conventional process to yield a fiberglass reinforced article with superior surface quality.