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Details
Inventors: Iseler, Kenneth A.; Duffield, Phoebe; Yen, Robert C.;
Assignee: The Budd Company (Troy, MI)
Primary Examiner: Michl; Paul R.
Assistant Examiner: Cain; Edward J.
Attorney, Agent or Firm: Harness, Dickey & Pierce

Molded articles prepared from flexible sheet molding compounds, and method of making the same. A flexibility modifying agent is incorporated into a thermoset resin composition (e.g. sheet molding compound) to improve the flexibility characteristics of the thermoset resin composition by lowering the flexural modulus. The thermoset resin composition also contains therein an isocyanate terminated urethane prepolymer; a thickening agent; a catalyst; a fibrous reinforcing material; and an inert filler.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT "Flexibility modifying agent", as used herein, refers to an additive that when used in a resin system will result in a resin system that shows a significant and reproducible improvement in one or more of the mechanical or aesthetic properties of the resin system as compared to a resin system without a flexibility modifying agent.
Examples of such properties include, without limitation, toughness, flexural modulus, and chip resistance.
Materials modified using a flexibility modifying agent also exhibit good surface finish characteristics and a desirable specific gravity and thermal expansion coefficient.
The flexibility modifying agents of the present invention are preferably a polymer of the type including elastomeric or flexible polymers.
For instance, it is contemplated that the preferred flexibility modifying agents include one or more polymers based on systems such as butadienes, polybutadienes, styrenes, polystyrenes, polyolefins (e.
g.
poly/ethylene/propylenes), styrene-butadienes, acrylonitriles, methacrylates (e.
g.
methyl methacrylate) or the like.
More preferably, the polymer is one selected from the group consisting of polystyrene-polybutadiene-polystyrene ("S-B-S") polystyrene-polyisoprene-polystyrene ("S-I-S"), polystyrene-ethylene/butylene-polystyrene ("S-EB-S), and mixtures thereof.
As can be appreciated such copolymers may be linear, branched, or may include varying ratios of both.
However, in the present preferred embodiment, the S-B-S copolymer is linear, the S-I-S copolymer is branched, and the S-EB-S copolymer is branched.
Such materials may be prepared according to known methods.
A highly preferred flexibility modifying agent includes a two-component admixture.
The first component includes S-B-S admixed with S-I-S, wherein the first component is present in an amount of about 10 to about 40 percent by weight of the total admixture.
The second component includes S-EB-S, present in an amount of about 60 to about 90 percent by weight of the total admixture



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