Abstract: The present invention is a process for producing an injection-molded thermoplastic work piece having a thermoset coating bonded thereto, comprising the steps of introducing into a closed mold a thermoplastic material, such as a polyolefin, heated to a temperature above its melting point and molding said material to form a work piece; followed by introducing a thermoset coating composition capable of generating free radicals into the closed mold to contact at least a portion of a surface of the work piece, the temperature of which is at or above the temperature at which free radicals contained in the coating composition are generated. The mold is then opened and the work piece is removed after the coating composition has at least partially cured. The present invention is also directed to a molded article made by the described process.

Abstract: The present invention is a process for producing an injection-molded thermoplastic workpiece having a thermoset coating bonded thereto, comprising the steps of introducing in three stages into a closed mold a thermoplastic material, such as a polyolefin, heated to a temperature above its melting point and molding said material to form a workpiece; cooling the workpiece to a temperature less than its melt temperature introducing a thermoset coating composition into the closed mold to cover at least a portion of a surface of the workpiece. The mold is then opened and the workpiece is removed after the coating composition has at least partially cured. The invention is also directed to a molded article made by the described process.

Abstract: An in-mold coating composition for a fiber reinforced plastic comprises an aliphatic resin such as a saturated aliphatic ester intermediate polyurethane having terminal acrylate end groups, a saturated (cyclo)aliphatic (meth)acrylate such as isobornyl acrylate, a hydroxyl alkyl (meth)acrylate, a polyacrylate ester of an alkylene polyol, and a vinyl substituted aromatic. The in-mold coating compositions have good end use weather-resistant properties so that there is no need for a subsequent paint coat thereon which heretofore has been required. The paint-free coating compositions can be either clear or pigmented and can contain various additives such as lubricants, adhesion aids, hardeners, and the like.

Abstract: Hydroxy-terminated telechelic rubber polymers and block copolymers of flexible polymers with unsaturated polyester resins improve the elongation and flexural elongation of in-mold coating compositions for fiber reinforced plastics (FRP). An FRP in-mold coating composition based upon vinyl ester resin, ethylenically unsaturated monomers, and at least one of telechelic hydroxy terminated flexible polymers and the block copolymers of functionally terminated flexible polymers with unsaturated polyester polymers are described.

Abstract: A composite material having a coated fiber structure dispersed in a polyester matrix. The coating is a block copolymer having an elastomer block bonded to an ester block. The coating provides a flexible barrier between the fiber structure and the polyester matrix which results in a strong fiber reinforced composite having better crack resistance and improved toughness. The composite is particularly suited for use as a molding compound for use in the production of automotive body panels and structural components, aircraft components, sporting goods, housings for electrical and various other consumer goods, etc.

Abstract: ABA block copolymers having saturated polyester midblocks "B" and unsaturated polyester condensation end blocks A of molecular weight from about 100 to 500 or 600 are described which increase the flexural strain to failure of unsaturated polyester or vinyl ester resins. These ABA block copolymers are generally compatible with unsaturated polyester resins and increase flexural strain by a different mechanism than used by incompatible rubbery polymers. These ABA block copolymers are compatible with the unsaturated polyester compositions and do not phase separate.

Abstract: This invention relates to a thermosetting unsaturated polyester or vinyl ester resin compositions modified with AB or ABA block copolymers. The A blocks are unsaturated polyester while the B blocks are flexible poller having a Tg of 0.degree. C. or lower. The blocks are generally separately prepared having a variety of terminal groups such as hydroxyl, carboxyl, amine, or isocyanate groups, but low molecular weight A blocks can be prepared in situ on the B blocks, The functionality of the blocks can be controlled to get AB or ABA diblocks and polyblocks, These modified unsaturated polyester or vinyl ester resin compositions have higher flexural strain to failure and are generally tougher than standard resins without modification. Control of the reaction conditions and the functionality of the blocks prior to coupling minimizes the formation of A(BA).sub.n where n is an integer above 1.

Abstract: Hydroxy-terminated telechelic rubber polymers and block copolymers of flexible polymers with unsaturated polyester resins improve the elongation and flexural elongation of in-mold coating compositions for fiber reinforced plastics (FRP). An FRP in-mold coating composition based upon vinyl ester resin, ethylenically unsaturated monomers, and at least one of telechelic hydroxy terminated flexible polymers and the block copolymers of functionally terminated flexible polymers with unsaturated polyester polymers are described.

Abstract: ABA block copolymers having saturated polyester midblocks "B" and unsaturated polyester condensation end blocks A of molecular weight from about 100 to 500 or 600 are described which increase the flexural strain to failure of unsaturated polyester or vinyl ester resins. These ABA block copolymers are generally compatible with unsaturated polyester resins and increase flexural strain by a different mechanism than used by incompatible rubbery polymers. These ABA block copolymers are compatible with the unsaturated polyester compositions and do not phase separate.

Abstract: A block copolymer of generally an AB, ABA, or A(BA).sub.n structure, or mixtures thereof where the A block is an unsaturated polyester, the B block is a flexible polymer having a Tg of 0.degree. C. or lower, and n is 2 to 5. The various block components are generally first separately prepared as polymers with the flexible polymer generally having 1 or 2 functional end groups such as an amine group, a carboxyl group, or a hydroxyl group with the later being preferred. Alternatively, for low molecular weight unsaturated polyester blocks, the block can be made in situ. The preferred reaction route is to react a mono or dihydroxy terminated flexible polymer with a diisocyanate which subsequently can be readily reacted with the polyester. The block copolymers can be utilized as toughening agents.

Abstract: Vinyl-terminated polyesters and vinyl-terminated aliphatic polycarbonates are described which improve the flexibility and elongation at failure of cured samples of unsaturated polyesters or vinyl ester resins both at room temperature and at high temperatures, and without significant loss of surface quality or other mechanical properties. Further, these polymers do not phase separate from uncured polyester resin/styrene solutions, do not significantly increase the initial viscosity of molding compositions in which they have been incorporated, and do not negate the effect of low shrinkage additives during cure.

Abstract: A composite material having a coated fiber structure dispersed in a polyester matrix. The coating is a block copolymer having an elastomer block bonded to an ester block. The coating provides a flexible barrier between the fiber structure and the polyester matrix which results in a strong fiber reinforced composite having better crack resistance and improved toughness. The composite is particularly suited for use as a molding compound for use in the production of automotive body panels and structural components, aircraft components, sporting goods, housings for electrical and various other consumer goods, etc.

Abstract: A photochromic article having improved pohotochromic equilibrium response is described. In particular, a phtochromic compound is incorporation into or applied to an article, e.g., matrix, of a synthetic organic resin prepared from a composition comprising from about 55 to about 90 weight percent of a polyol(allyl carbonate), e.g., diethylene glycol bis(allyl carbonate), from about 10 to about 40 weight percent of an aliphatic polyurethane having terminal ethylenic unsaturation, e.g., an aliphatic polyesterurethane diacrylate, and from about 0 to about 5 weight percent of a difunctional monomer selected from the group consisting of allyl methacrylate and allyl acrylate. Such photochromic articles have an improved photochromic equilibrium response at ambient temperatures compared to the response of a comparable photochromic article prepared from a polyol(allyl carbonate) homopolymer, e.g., homopolymers of diethylene glycol bis(allyl carbonate), at the same ambient temperatures.

Abstract: A photochromic article having improved photochromic equilibrium response is described. In particular, a photochromic compound is incorporated into or applied to an article, e.g., matrix, of a synthetic organic resin prepared from a composition comprising from about 55 to about 90 weight percent of a polyol(allyl carbonate), e.g., diethylene glycol bis(allyl carbonate), from about 10 to about 40 weight percent of an aliphatic polyurethan having terminal ethylenic unsaturation, e.g., an aliphatic polyesterurethan diacrylate, and from about 0 to about 5 weight percent of a difunctional monomer selected from the group consisting of allyl methacrylate and allyl acrylate. Such photochromic articles have an improved photochromic equilibrium response at ambient temperatures compared to the response of a comparable photochromic article prepared from a polyol(allyl carbonate) homopolymer, e.g., homopolymers of diethylene glycol bis(allyl carbonate), at the same ambient temperatures.

Abstract: Spiro(indoline)-type photochromic compounds are prepared by admixing a solution of the Fischer's Base reactant in non-polar solvent with a mixture of the pyran- or oxazine-forming reactant, e.g., 5-nitroso-6-hydroxy quinoline, in polar solvent and heating the resulting reaction medium at temperatures sufficient to form the corresponding spiro(indoline)-type compound while simultaneously removing co-product water.