MOLDING OF UNSATURATED POLYESTER

摘要

The method of curing unsaturated polyester with a hydroperoxide-based curing agent in improved by employing isocyanate and at least one isocyanate-reactive accelerator that is exothermically reactive with the isocyanate to generate heat to accelerate the gellation and curing reaction (26) between the polyester and its curing agent. Dilution of the polyester with a monomer cross-linking agent, especially styrene, enables impingement mixing under high pressure and rapid filling of mold cavities (58) and (88). Preferably an excess of isocyanate reacts, commencing prior to gellation of the resin, with a component of the mixture, preferably the hydroperoxide, to cause formation of small gas bubbles to prevent shrinkage and, where desired, to expand the mixture. An improved curing agent for the unsaturated polyester comprises a buffered equilibrium system of a limited quantity of un-ionized hydroperoxide and a salt of the hydroperoxide that is soluble in the resin, preferably formed by reacting hydroperoxide with an amine that serves as a weak base. By selection of an amine that is also reactive with isocyanate, the amine can perform in both a buffering and polyester cure accelerating actions. A thixotropic additive enables use of a high level of reinforcement fibres (126) in the fluid resin and a heat conductive additive permits molding of thick sections while achieving good surface finish.