LONG-FIBER THERMOSET COMPOSITE WITH LOW ORANGE PEEL

1 . A reinforced polymer composite comprising:

a polymeric barrier layer comprising:

a barrier layer first surface;

a barrier layer second surface; and

a plurality of hard segment domains;

a reinforced polymeric layer covering at least a portion of the barrier layer first surface;

wherein the barrier layer second surface exhibits a Class A quality; and

wherein the plurality of hard segment domains substantially suppress deformation of the polymeric barrier layer at a molding temperature of the reinforced polymer composite.

2 . The composite of claim 1 , wherein the polymeric barrier layer and the reinforced barrier layer comprise a polyurethane.

3 . The composite of claim 2 , wherein the polymeric barrier layer comprises a thermosetting polyurethane.

4 . The composite of claim 2 , wherein the polymeric barrier layer comprises an aliphatic urethane.

5 . The composite of claim 2 , wherein the plurality of hard segments has a glass transition temperature of at least 100° C.

6 . The composite of claim 2 , wherein the plurality of hard segments has a domain size ranging from 5 nm to 20 nm.

7 . The composite of claim 2 , wherein the barrier layer has a root mean square roughness of 1 or less.

8 . The composite of claim 2 , wherein the reinforced polymeric layer comprises a plurality of fibers.

9 . The composite of claim 8 , wherein the plurality of fibers comprises one or more of a glass fiber, a carbon fiber, or an aramid fiber.

10 . The composite of claim 8 , wherein the plurality of fibers comprises glass fibers.

11 . The composite of claim 1 , further comprising a paint layer covering at least a portion of the barrier layer second surface, wherein the paint layer exhibits a Class A quality.

12 . The composite of claim 2 , further comprising a paint layer covering at least a portion of the barrier layer second surface, wherein the paint layer exhibits a Class A quality.

13 . The composite of claim 12 , wherein the paint layer comprises an in-mold paint layer.

14 . The composite of claim 12 , wherein the paint layer comprises an aliphatic polyurethane.

15 . The composite of claim 12 , wherein the composite comprises an article of manufacture selected from the group consisting of a vehicular panel, a water craft hull, a window, and a door.

16 . A method of preparing a reinforced polymer composite to a mold surface, the mold surface having a degree of finish suitable for the manufacture of a Class A quality cured polymer surface, comprising:

applying a polymeric barrier layer to at least a portion of the mold surface;

wherein the polymeric barrier layer comprises:

a barrier layer first surface;

a barrier layer second surface; and

a plurality of hard segments;

applying a reinforced polymeric layer to cover at least a portion of the barrier layer first surface;

molding the polymeric barrier layer and the reinforced barrier layer at a polymer composite molding temperature;

wherein the plurality of hard segments substantially suppress deformation of the polymeric barrier layer at the polymeric composite molding temperature; and

demolding the polymeric barrier layer and the reinforced barrier layer;

wherein the barrier layer second surface comprises the Class A quality cured polymer surface.

17 . The method of claim 16 , wherein the applying the polymeric barrier layer and the applying the reinforced barrier layer comprise applying a polyurethane.

18 . The method of claim 17 , wherein the applying the polymeric barrier layer comprises applying a thermosetting polyurethane.

19 . The method of claim 17 , wherein the applying the polymeric barrier layer comprises applying an aliphatic urethane.

20 . The method of claim 17 , wherein applying the polymeric barrier layer comprises applying a barrier layer wherein the plurality of hard segments has a glass transition temperature of at least 100° C.

21 . The method of claim 17 , wherein after the demolding the plurality of hard segments has a domain size from 5 nm to 20 nm.

22 . The method of claim 17 , wherein after the demolding the barrier layer has a root mean square roughness of 1 or less.

23 . The method of claim 16 , wherein the reinforced polymeric layer comprises a plurality of fibers.

24 . The method of claim 23 , wherein the plurality of fibers comprises one or more of a glass fiber, a carbon fiber, or an aramid fiber.

25 . The method of claim 23 , wherein the plurality of fibers comprises glass fibers.

26 . The method of claim 16 , further comprising applying an in-mold paint layer to at least a portion of the mold prior to applying a polymeric barrier layer, wherein the applying the barrier layer comprises covering the in-mold paint layer, and wherein the in-mold paint layer exhibits the Class A quality after the demolding.

27 . The method of claim 17 , further comprising applying an in-mold paint layer to at least a portion of the mold prior to applying a polymeric barrier layer, wherein the applying the barrier layer comprises covering the in-mold paint layer, and wherein the in-mold paint layer exhibits the Class A quality after demolding.

28 . The method of claim 27 , wherein the applying the in-mold paint layer comprises applying an aliphatic polyurethane.

29 . The method of claim 16 , wherein the reinforced polymer composite is selected from the group consisting of a vehicular panel, a water craft hull, a window, and a door.

30 . A reinforced polymer composite article of manufacture comprising:

a polyurethane barrier layer comprising:

a barrier layer first surface;

a barrier layer second surface; and

a plurality of hard segments;

wherein the plurality of hard segments has a glass transition temperature of at least 100° C.; and

wherein the plurality of hard segments substantially suppress deformation of the polymeric barrier layer at a polymer composite molding temperature;

a reinforced polyurethane layer covering at least a portion of the barrier layer first surface;

wherein the reinforced polyurethane layer comprises a plurality of glass fibers;

wherein the barrier layer second surface exhibits a Class A quality.

31 . The article of manufacture of claim 30 , further comprising an in-mold paint layer covering at least a portion of the barrier layer second surface, wherein the in-mold paint layer exhibits the Class A quality.

32 . The article of manufacture of claim 31 , wherein the in-mold paint layer comprises an aliphatic polyurethane.

33 . The article of manufacture of claim 30 , wherein the article is selected from the group consisting of a vehicular panel, a water craft hull, a window, and a door.