CARBON FIBER REINFORCED MOLDING COMPOSITION SUITABLE FOR ELECTROPHORETIC COATING
A cured article includes a cured thermoset resin matrix defining an article surface. Hollow glass microspheroids are dispersed in the cured thermoset resin matrix. A low profile additive package is dispersed in the cured thermoset resin matrix. A plurality of carbon fiber bundles are present and wet by the cured thermoset resin matrix. The matrix formed from a prepolymer and styrenic monomer. A free radical initiator is provided to cure the thermoset resin matrix and having limited decomposition products with a boiling point of between 160-210° C.; wherein the article emits less than 250 parts per million (ppm) of volatiles as measured after heating to 185° C. at a rate of 14° C./min and held for 1 minute.
1 . A cured article comprising:
a cured thermoset resin matrix defining an article surface;
hollow glass microspheroids dispersed in said cured thermoset resin matrix;
a low profile additive package dispersed in said cured thermoset resin matrix; and
a plurality of carbon fiber bundles wet by said cured thermoset resin matrix;
styrenic monomer cured into and part of said cured thermoset resin matrix; and
free radical initiator curing said cured thermoset resin matrix and having limited decomposition products with a boiling point of between 160-210° C.; wherein the article emits less than 250 parts per million (ppm) of volatiles as measured after heating to 185° C. at a rate of 14° C./min and held for 1 minute.
2 . The article of claim 1 , wherein said cured thermoset resin matrix is a polyester.
3 . The article of claim 1 wherein said hollow glass microspheroids further comprise a silane surface derivative bonded to said matrix.
4 . The article of claim 1 wherein said hollow glass microspheroids are present from 5 to 15 total weight percent.
5 . The article of claim 1 wherein said low profile additive package further comprises at least one of polystyrene, styrene-butadiene rubber, polyvinyl acetate, or polyethylene.
6 . The article of claim 1 wherein said styrenic monomer is styrene present in an amount that contributes less than 200 ppm of the volatiles.
7 . The article of claim 1 further comprising a thickener, said thickener being an alkaline earth oxide, an alkaline earth hydroxide, or a combination thereof.
8 . The article of claim 7 wherein said thickener and the article are devoid of polyurea interpenetrating network.
9 . The article of claim 7 further comprising an e-coating applied to the article surface, said e-coating being free of blisters visible to an unaided, normal human eye.
10 . The article of claim 1 further comprising an e-coating applied to the article surface, said e-coating being free of blisters visible to an unaided, normal human eye.
11 . The article of claim 8 further comprising an e-coating applied to the article surface, said e-coating being free of blisters visible to an unaided, normal human eye.