Processes for in-mold coating systems for molding, and products formed therefrom

Abstract

Disclosed are processes for In-Mold coating of a substrate. The processes include: introducing a curable composition to a mixhead at a first elevated pressure, the curable composition comprising a first polymeric component and a second polymeric component, the introducing of the curable composition to the mixhead comprising mixing the first and second polymeric components by impingement to form an intermediate composition; introducing the intermediate composition to a secondary mixer, the introducing of the intermediate composition to the secondary mixer comprising mixing the intermediate composition to form a coating composition; and introducing the coating composition into a mold containing a substrate to form a curable coating on a surface of the substrate.

1 . A process for In-Mold coating, comprising:
 introducing a curable composition to a mixhead at a first elevated pressure, the curable composition comprising a first polymeric component and a second polymeric component, the introducing of the curable composition to the mixhead comprising mixing the first and second polymeric components by impingement to form an intermediate composition;   introducing the intermediate composition to a secondary mixer, the introducing of the intermediate composition to the secondary mixer comprising mixing the intermediate composition to form a coating composition; and   introducing the coating composition into a mold containing a substrate to form a curable coating on a surface of the substrate.   
     
     
         2 . The process according to  claim 1 , wherein the secondary mixer is a peanut mixer, wherein the mixing of the intermediate composition to form the coating composition is a kinetic mixing. 
     
     
         3 . The process according to  claim 1 , wherein the secondary mixer is partially formed in the mold and partially formed in the substrate. 
     
     
         4 . The process according to  claim 1 , wherein introducing the coating composition into the mold containing the substrate further comprises introducing at least one of the intermediate composition and the coating composition into a dump well in communication with the mold, and further comprising:
 limiting a flow of the curable composition wherein the introducing of the curable composition to the mixhead is decreased to a second pressure less than the first elevated pressure to form a non-homogenous mixture of the first and second polymeric components; and   limiting entry of the non-homogenous mixture into the mold by a volume of the dump well.   
     
     
         5 . The process according to  claim 4 , wherein the dump well comprises the secondary mixer. 
     
     
         6 . The process according to  claim 4 , wherein the dump well comprises at least two channels. 
     
     
         7 . The process according to  claim 4 , further comprising positioning the dump well between the mixhead and the secondary mixer. 
     
     
         8 . The process according to  claim 4 , further comprising positioning the secondary mixer between the dump well and the mixhead. 
     
     
         9 . (canceled) 
     
     
         10 . A process for In-Mold coating comprising:
 introducing a curable composition to a mixhead at a first elevated pressure, the curable composition comprising a first polymeric component and a second polymeric component, the introducing of the curable composition to the mixhead comprising mixing the first and second polymeric components by impingement to form a coating composition; and   introducing the coating composition into a mold containing a substrate via at least two channels to form a curable coating on a surface of the substrate.   
     
     
         11 . The process according to  claim 1 , where the first polymeric component comprises an isocyanate-reactive group and the second polymeric component comprises a polyisocyanate. 
     
     
         12 . The process according to  claim 11 , wherein the isocyanate-reactive group comprises a polyol. 
     
     
         13 . The process according to  claim 1 , wherein the first elevated pressure is at least 1600 psi. 
     
     
         14 . The process according to  claim 1 , wherein the coating composition is homogeneous. 
     
     
         15 . The process according to  claim 1 , further comprising curing the curable coating to form a cured coating on the substrate, the cured coating having a thickness between 50 micrometers and 100 micrometers. 
     
     
         16 . The process according to  claim 15 , wherein the cured coating thickness is between 80 micrometers and 100 micrometers. 
     
     
         17 . The process according to  claim 15 , wherein the cured coating is substantially free of defects. 
     
     
         18 . The process according to  claim 15 , wherein the curable coating composition is cured:
 at a mold temperature of 75° C. to 105° C.; and   for a period between 10 and 90 seconds.   
     
     
         19 . The process according to  claim 1 , further comprising introducing the coating composition into the mold via at least two channels. 
     
     
         20 - 46 . (canceled)