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: A method of making a fiber reinforced part by compression molding under heat and pressure a glass fiber reinforced thermosetting resin composition at an initial high pressure for a short period of time and then substantially reducing the pressure for a longer period of time to form an almost cured FRP part at which time there is applied to the exterior or outer surface of the FRP part an in-mold coating composition and heat and pressure are continued to cure the in-mold coating composition and to complete the cure of the FRP part. During the molding process the temperature gradient across, or the temperature non-uniformities of, the molding or working surfaces of the mold halves is less than about 5.degree. C.

Abstract: An FRP molding can be in-mold coated using a free radical peroxide initiated thermosetting composition of at least one polymerizable epoxy based oligomer having at least two acrylate groups, at least one copolymerizable ethylenically unsaturated monomer, at least one copolymerizable monoethylenically unsaturated compound having a --CO-- group and a --NH.sub.2, --NH-- and/or --OH group, polyvinyl acetate, at least one zinc salt of a fatty acid having at least 10 carbon atoms, at least one accelerator for a peroxide initiator, conductive carbon black, a filler such as talc and a copolymerizable or cocurable compound selected from the group consisting of(I) at least one polyoxyalkylene glycol oligomer having two acrylate groups and(II) at least one polyurethane oligomer having two acrylate groups and mixtures of (I) and (II).Optionally and desirably, there additionally can be added to the foregoing composition at least one calcium salt of a fatty acid.

Abstract: An FRP molding can be in-mold coated using a free radical peroxide initiated thermosetting composition of at least one polymerizable epoxy based oligomer having at least two acrylate groups, at least one copolymerizable ethylenically unsaturated monomer, at least one copolymerizable monoethylenically unsaturated compound having a --CO-- group and a --NH.sub.2, --NH-- and/or --OH group, polyvinyl acetate, at least one zinc salt of a fatty acid having at least 10 carbon atoms, at least one accelerator for a peroxide initiator, conductive carbon black, a filler such as talc and a copolymerizable or cocurable compound selected from the group consisting of(I) at least one polyoxyalkylene glycol oligomer having two acrylate groups and(II) at least one polyurethane oligomer having two acrylate groups and mixtures of (I) and (II).Optionally and desirably, there additionally can be added to the foregoing composition at least one calcium salt of a fatty acid.

Abstract: An SMC (FRP) molding is coated with a minimum amount of an IMC composition by skewing one of the mold halves during the initial IMC molding cycle to effect a scissoring action, the fulcrum being at or about the IMC injection point or placement to spread or wipe the IMC over the surface of the SMC part and then effecting at least substantial parallelism of the mold halves during the remaining IMC cycle of coating and curing the IMC.

Abstract: An FRP molding can be in-mold coated using a free radical peroxide initiated thermosetting composition of at least one polymerizable epoxy based oligomer having at least two acrylate groups, at least one copolymerizable ethylenically unsaturated monomer, at least one copolymerizable monoethylenically unsaturated compound having a --CO-- group and a --NH.sub.2, --NH-- and/or --OH group, polyvinyl acetate, at least one zinc salt of a fatty acid having at least 10 carbon atoms, at least one accelerator for a peroxide initiator, conductive carbon black, a filler such as talc and a copolymerizable or cocurable compound selected from the group consisting of(I) at least one polyoxyalkylene glycol oligomer having two acrylate groups and(II) at least one polyurethane oligomer having two acrylate groups and mixtures of (I) and (II).Optionally and desirably, there additionally can be added to the foregoing composition at least one calcium salt of a fatty acid.

Abstract: An FRP molding can be in-mold coated using a one-component peroxide initiated composition of (a) a liquid crosslinkable composition having an average molecular weight of up to about 5,000, having a plurality of polymerizable ethylenic double bonds, being essentially free of active hydrogen atoms and being essentially free of isocyanate groups and (b) a material selected from the group consisting of (I) a polyisocyanate and (II) the reaction product of an excess of equivalents of a polyisocyanate and an ethylenically unsaturated compound having --NH.sub.2, --NH-- and/or OH groups, said reaction product being free of active hydrogen atoms.

Abstract: An FRP molding can be in-mold coated using a one-component peroxide initiated composition of (a) a liquid crosslinkable composition having an average molecular weight of up to about 5,000, having a plurality of polymerizable ethylenic double bonds, being essentially free of active hydrogen atoms or being essentially free of isocyanate groups and (b) a material selected from the group consisting of (I) a polyisocyanate and (II) the reaction product of an excess of equivalents of a polyisocyanate and an ethylenically unsaturated compound having --NH.sub.2, --NH-- and/or OH groups, said reaction product being free of active hydrogen atoms.

Abstract: A method comprises in-mold coating on a molded thermoset polyester glass fiber substrate an in-mold coating composition at a pressure of from about 25 to 50 p.s.i. and at a temperature not in excess of about 150.degree. F. for from about 2 to 12 minutes, said in-mold coating composition comprising the reaction product of an unsaturated aliphatic fumarate polyester diol, a saturated polyester diol flexibilizer, a cross-linking aliphatic polyol having from 3 to 6 OH groups, a diisocyanate in an amount by weight sufficient to provide from about 50 to 120%, preferably from about 80 to 103%, of the stoichiometric amount of --NCO groups required to react with all of the active hydrogen atoms in the coating composition and an ethylenically unsaturated monomer sufficient to polymerize with and crosslink the unsaturated polyester in admixture with a free radical peroxide initiator, an accelerator for said peroxide initiator and a polyurethane tin catalyst.

Abstract: A method is disclosed comprising in-mold coating a structural foam part made from a thermoplastic aromatic polycarbonate resin or a thermoplastic ABS polymer resin with a thermosetting in-mold coating composition at a pressure of from about 25 to 50 p.s.i. and at a temperature not in excess of about 200.degree. F. for from about 1 to 10 minutes, preferably for from about 1 to 3 minutes, to provide hard, smooth and adherent coatings, said thermosetting in-mold coating composition comprising an ethylenically unsaturated polyester resin and an ethylenically unsaturated monomer(s) catalyzed with an organic perioxide initiator including an accelerator for the initiator.

Abstract: A laminate comprises an adherent in-mold thermoset coating composition on a thermoset polyester glass fiber substrate, the coating composition comprising essentially the reaction product of an unsaturated aliphatic fumarate polyester diol, a saturated polyester diol flexibilizer, a cross-linking aliphatic polyol having from 3 to 6 OH groups, a diisocyanate in an amount by weight sufficient to provide from about 50 to 120%, preferably from about 80 to 99%, of the stoichiometric amount of --NCO groups required to react with all of the active hydrogen atoms in the coating composition and an ethylenically unsaturated monomer sufficient to polymerize with and crosslink the unsaturated polyester in admixture with a minor amount by weight of polyvinyl acetate which serves to reduce or eliminate shrinkage of the coating composition.

Abstract: A laminate comprises an adherent in-mold thermoset coating composition on a thermoset polyester glass fiber substrate, the coating composition comprising essentially the reaction product of an unsaturated aliphatic fumarate polyester diol, a saturated polyester diol flexibilizer, a cross-linking aliphatic polyol having from 3 to 6 OH groups, a diisocyanate in an amount by weight sufficient to provide from about 50 to 120%, preferably from about 80 to 99%, of the stoichiometric amount of --NCO groups required to react with all of the active hydrogen atoms in the coating composition and an ethylenically unsaturated monomer sufficient to polymerize with and crosslink the unsaturated polyester in admixture with a minor amount by weight of polyvinyl acetate which serves to reduce or eliminate shrinkage of the coating composition.

Abstract: An in-mold coating composition is disclosed which includes (a) an isocyanate-terminated material containing an excess of reactive isocyanate groups and (b) a material selected from the group consisting of a composition containing reactive hydrogen atoms, generally hydroxyl groups, and a catalyst capable of trimerizing the terminal isocyanate groups. The coating composition is applied to a molded substrate, such as an FRP part, by placing a charge of the composition in the mold on the substrate, the charge being sufficient to provide a coating having a thickness less than about 20 mils. Appropriate pressure is then applied to the charge, such as by closing the mold, so that the coating composition is forced to cover substantially the entire surface area of the substrate, filling any surface defects. The composition is cured to yield a crosslinked, isocyanate-based coating which adheres tightly to the substrate.