Abstract: A wet fiber based composition that includes wet glass fibers, a water dispersible polymeric resin, and gypsum is provided. Components including melamine formaldehyde, a filler material, coupling agents, acetic acid, an accelerator, and/or a hardener may also be added to the composition. The gypsum may be a-gypsum, B-gypsum, or combinations thereof. The wet glass fibers are wet chopped glass fibers or a wet continuous roving. The combination of the wet glass fibers, the water dispersible polymeric resin, and the gypsum have a synergistic effect that creates a composite product that is water resistant, fire resistant, and has improved mechanical properties. In one exemplary embodiment, the wet fiber based composition is used to form a gypsum board that can be molded into various composite products. In other exemplary embodiments, thin multi-ply gypsum boards may be formed by alternately layering glass mats with layers of a gypsum/polymer slurry.

Abstract: A composite material containing wet chopped strand fibers, gypsum, and a polymer material is provided. The wet fibers are filamentized within the polymer material. In exemplary embodiments, the wet chopped strand fibers are wet-used chopped strand glass fibers. The gypsum may be ?-gypsum, ?-gypsum, or combinations thereof. In at least one embodiment, the polymer is a urea-formaldehyde resin. The composite material may contain a facing layer on at least one exposed major surface of the composite material. A method of forming a composite material that includes mixing gypsum with a polymer material to form a substantially homogeneous matrix and adding a sufficient quantity of wet-used chopped strand fibers to form the composite material is also provided.

Abstract: A roofing product is disclosed including a structural layer of composite material and a gel coat cover layer. The structural layer of composite material is formed by (a) a substantially homogeneous matrix of gypsum material and a polymer resin material and (b) wet-used chopped strand fibers. The wet-used chopped strand fibers are substantially filamentized with the substantially homogeneous matrix. In addition, a method for making a roofing product is disclosed.

Abstract: A composite material containing substantially homogeneous matrix of a gypsum material and a urea-formaldehyde material where wet-used chopped strand fibers are filamentized within the substantially homogeneous matrix.

Abstract: A size composition for reinforcement fibers used to form non-woven mats that contain variable amounts of individual filaments dispersed from chopped reinforcement fiber bundles is provided. The size composition contains a polyvinylamine film former, one or more silane coupling agents, and, optionally a lubricant. The size composition works in conjunction with the whitewater components in a wet-laid mat forming process to disperse individual filaments from the bundles of chopped fibers. The whitewater contains an anionic polyacrylamide viscosity modifier and/or a cationic or non-ionic amine dispersant (e.g., ethoxylated amine). The presence of a cationic or non-ionic amine in the whitewater disperses individual filaments from the chopped glass fiber bundles. The greater the amount of cationic or non-ionic amine present in the whitewater, the greater the amount of fiber dispersion.

Abstract: A thin drywall board that includes a gel coat, at least one polymer/gypsum layer, and a wet glass fiber layer is provided. The gel coat is formed of a gel coat composition that includes a water dispersible polymer, gypsum, and optionally a crosslinking agent and/or a coupling agent. The polymer/gypsum layer is formed of a matrix composition that includes a water dispersible polymeric resin and gypsum. Components including melamine formaldehyde, a filler material, coupling agents, acetic acid, an accelerator, and/or a hardener may also be added to the matrix composition. The wet glass fiber layer is preferably a glass fiber mat. The combination of the water dispersible polymeric resin and the gypsum in the matrix composition have a synergistic effect that creates a thin drywall board that is water resistant, fire resistant, and has improved mechanical properties. A method of forming the inventive thin drywall boards is also provided.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The fibrous material is introduced as a veil layer adjacent a paste layer, the veil flows well during the molding process. The improved flow and surface characteristics of a composite part are attributed to the elongation of the veil during molding and to the improved filling capabilities.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The fibrous material is introduced as a veil layer adjacent a paste layer, the veil flows well during the molding process. The improved flow and surface characteristics of a composite part are attributed to the elongation of the veil during molding and to the improved filling capabilities.

Abstract: A sheet molding composition is provided which exhibits controllable thickening. The composition includes a low molecular weight polyester in which some of the chain ends have been endcapped with functional groups which are unable to react with the thickeners employed in the sheet molding composition. The sheet molding composition has a low viscosity of from about 6 to about 20 million centipoise which allows molding at low pressures of from about 100 to about 300 psi.

Abstract: This development relates to elastomer modified polyester for sheet molding compound (SMC). This development copolymerizes the rubber with the polyester. The reaction provides copolymers with extended storage times without phase separation. It also enhances impact resistance of the molded part.

Abstract: This development provides glycidyl-acrylates that, when copolymerized with unsaturated polyesters, provide high performance, structural SMC products. The acrylates increase the reactivity of the polyesters. One result has been "zero shrinkage" parts with good heat distortion, pigmentability and excellent mechanical and physical properties.

Abstract: A process for making a composite article having improved mechanical properties such as fatigue life, which process comprises contacting at least one continuous filament with a mixture comprising a resin and a strain relieving polymer.

Abstract: A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components comprising at least one compound containing one or more polyoxyethane substituents. The compatible component remains compatible when the polyester and monomer cure and imparts improved surface characteristics when added to low-profile resin systems.

Abstract: Citrate ester compositions which are useful as compatible components in a resinous system for sheet molding compositions and have a general formula ##STR1## wherein X is selected from the group consisting of --OC.sub.3 H.sub.6).sub.3 --OCH.sub.3 and OH are disclosed. Also disclosed is a sheet molding composition which includes a four component resinous system comprising (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile thermoplastic polymer additives which cause phase separation and internal voids during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerize with the unsaturated polyester; and, (d) one or more compatible components which remain compatible when the polyester and monomer cure and impart improved surface characteristics when added to typical low-profile resin systems.

Abstract: A sheet molding composition is disclosed which includes a four component resinous system which comprises (a) an unsaturated polyester comprising a polycondensation product of one or more dihydric alcohols and one or more ethylenically unsaturated polycarboxylic acids; (b) one or more low-profile additives which are thermoplastic polymers which cause phase separation and porosity during the curing reaction; (c) one or more olefinically unsaturated monomers which copolymerizes with the unsaturated polyester; and, (d) one or more compatible components containing one or more polyoxyethane substituents. The compatible components remain compatible when the polyester and monomer cure and impart improved surface characteristics when added to typical low-profile resin systems.