GB2038347A - Producing shaped parts - Google Patents
Producing shaped parts Download PDFInfo
- Publication number
- GB2038347A GB2038347A GB7942196A GB7942196A GB2038347A GB 2038347 A GB2038347 A GB 2038347A GB 7942196 A GB7942196 A GB 7942196A GB 7942196 A GB7942196 A GB 7942196A GB 2038347 A GB2038347 A GB 2038347A
- Authority
- GB
- United Kingdom
- Prior art keywords
- ester
- reaction
- process according
- mixture
- reaction mixture
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 claims abstract description 22
- 150000002148 esters Chemical class 0.000 claims abstract description 18
- 239000011541 reaction mixture Substances 0.000 claims abstract description 15
- 238000006243 chemical reaction Methods 0.000 claims abstract description 12
- 238000009835 boiling Methods 0.000 claims abstract description 8
- 239000000203 mixture Substances 0.000 claims abstract description 8
- 238000005187 foaming Methods 0.000 claims abstract description 4
- 239000012948 isocyanate Substances 0.000 claims abstract description 4
- 150000002513 isocyanates Chemical class 0.000 claims abstract description 4
- 150000005846 sugar alcohols Polymers 0.000 claims abstract description 4
- 239000006260 foam Substances 0.000 claims description 10
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid Chemical compound OC(=O)C1=CC=CC=C1C(O)=O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 claims description 8
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 claims description 7
- 239000004593 Epoxy Substances 0.000 claims description 6
- KBPLFHHGFOOTCA-UHFFFAOYSA-N 1-Octanol Chemical compound CCCCCCCCO KBPLFHHGFOOTCA-UHFFFAOYSA-N 0.000 claims description 2
- 235000021355 Stearic acid Nutrition 0.000 claims description 2
- 125000001797 benzyl group Chemical group [H]C1=C([H])C([H])=C(C([H])=C1[H])C([H])([H])* 0.000 claims description 2
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 claims description 2
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 claims description 2
- 239000008117 stearic acid Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 description 8
- 239000000835 fiber Substances 0.000 description 6
- 238000000465 moulding Methods 0.000 description 6
- 239000003365 glass fiber Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- -1 hydrocarbyl alcohol Chemical compound 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 239000000470 constituent Substances 0.000 description 3
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 2
- 239000004721 Polyphenylene oxide Substances 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 229920000570 polyether Polymers 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- HIFVAOIJYDXIJG-UHFFFAOYSA-N benzylbenzene;isocyanic acid Chemical class N=C=O.N=C=O.C=1C=CC=CC=1CC1=CC=CC=C1 HIFVAOIJYDXIJG-UHFFFAOYSA-N 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 125000001183 hydrocarbyl group Chemical group 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0085—Use of fibrous compounding ingredients
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0014—Use of organic additives
- C08J9/0023—Use of organic additives containing oxygen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Emergency Medicine (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A process for producing a fibre- reinforced foamed shaped part, in which the foaming is caused by the reaction of a mixture of a polyhydric alcohol and an isocyanate, in which the reaction mixture additionally comprises from 5 to 30%, by weight of the mixture, of an inert ester whose boiling point is above the reaction temperature of the reaction mixture.
Description
SPECIFICATION
Producing shaped parts
It is known to produce shaped foamed plastics parts by introducing a mixture of an isocyanate, a polyhydric alcohol and an activator into a moulding tool so that the constituents react and expand to take the form of the mould. The mechanical properties of the shaped products can largely be determined in advance by the choice of the nature and quantity of the constituents. It is generally true that, with increasing density per unit volume, improved strength properties are obtained.
Attempts have been made to improve the strength properties of shaped foam parts having low weight per unit volume by adding fibres or fibre mattings which, following the reaction, are firmly held within the foamed plastics product. However, this technique has not been successful in practice, particularly in the production of large shaped parts, because adequate penetration is possible only over short distances and because adequate wetting is possible only when using very coarsely structured mattings or very short fibres.
However, the use of such fibres and mattings has little or no strengthening effect.
It has been proposed, with a view to improving the flow distances achieved, to use only reactive constituents which react slowly with one another. A procedure of this kind, however, inevitably leads to longer hardening and mould residence times, and is therefore uneconomic.
According to the present invention, in a process of the type described above for producing foamed shaped plastics products, from 5 to 30%, and preferably from 10 to 20%, by weight of an inert ester with a boiling point above the reaction temperature of the reaction mixture is added thereto.
Taking into account the reaction mixtures usually employed, the ester used in the process of this invention should generally have a boiling point of more than 200"C. The use of esters having a sufficiently high boiling point is important because the addition of substances with a low vaporisation point would lead to absorption of the liberated heat and thereby to an undesirable cooling effect during the chemical reaction of the mixture.
The consequence of this would be incomplete hardening. Suitable esters are those of hydrocarbyl mono- or di- carboxylic acids having from 6, more preferably 8, to 25, more preferably 20, carbon atoms with a hydrocarbyl alcohol of up to 12, and preferably from 3 to 10, carbon atoms. Particularly suitable esters are the esters of phthalic or stearic acid with butyl, benzyl or octyl alcohol. Mixtures of such esters can be used.
The ester should not react with the other components.
The flow behaviour of the reaction mixture, which is particularly important as regards good penetration and wetting of the fibres or fibre matting, can be improved, in addition to the improvement caused by the presence of the ester, of an epoxy stearate, in an amount of up to 25%. When both an ester and an epoxy stearate are added to the reaction mixture, a distinct improvement of the flow behaviour can be observed in each case, and flow distances of more than 0.5 m through a compressed fibre matting are readily obtained.
The reaction behaviour of the reaction mixture employed does not change recognisably when the ester and any epoxy stearate are added. Therefore, conventional methods of production of shaped foamed parts, using known metering equipment, can be employed.
A film, e.g. a prefabricated film, may be inserted into the mould in which the process is conducted, the film being forced against the wall of the mould during blowing of the reaction mixture and forming a strong bond with the foam in the process. The mechanical properties of a film-reinforced shaped part are the result of the sandwich bond with the film or films covering the surface and which, if necessary, may also consist of a hard material, and of the position and the mutual anchoring of the fibres arranged in the interior of the foam.
Optimum strength properties are obtained when there is, in the interior of the foam, a non-woven fabric of very fine continuous fibres, the orientation of which is fixed so that they can satisfactorily absorb the stresses subsequently exerted on the product. Strength properties completely independent of orientation are obtained by employing a non-woven fabric of tangled fibres, the fibre structure of which does not allow any preferred orientation to be recognised.
The mould residence times necessary when carrying the process according to the invention into effect are similar to those used in known processes for the production of hard polyurethane foams having satisfactory flow characteristics. For products having a minimum dimension of about 1600 mm, the residence time should be of the order of 4 to 5 minutes.
The process according to the invention permits the embedding of very finely-structured fibre mattings, for example non-woven glass fibre mattings with a weight per unit area of 600 g/m2, an average fibre thickness of 20 lim and a total thickness of the workpiece obtained of less than 3 mm. In general, the fibres used in this invention preferably have a maximum cross-sectional dimension of 200cm, more preferably 1 001lem.
Owing to the high surface area of the very fine fibres which can be used in the invention, a good bond with the foam is obtained. Consequently, when the process according to the invention is conducted, this bond effects a considerably better support of the individual fibres than would be the case with the use of relatively coarse-structured fibres.
By way of example, the process of this invention can be used to produce a shaped product from a commercial integral hard foam system consisting of polyether polyhydric alcohol and liquid crude diphenylmethane diisocyanate, which may be provided with catalysts and blowing agent and which, in this stage, attains flow distances of only a few centimetres through a matting of glass fibres, by the addition of a neutral ester of, for example, phthalic acid with butyl alcohol, whose boiling point is about the reaction temperature of the reaction mixture, optionally in admixture with an epoxy stearate.
The process according to the invention permits the production of workpieces of large size and complicated shape for which particularly high strength properties for a low specific gravity and a thin wall thickness are desired. Typical examples of application consist in the manufacture of suitacase shells or in the manufacture of facings or coverings for the interior spaces of motor vehicles, for example the manufacture of instrument panels.
The process according to the invention allows up to 40% by weight of very fine fibres to be embedded in the foam and the mechanical properties, in particular the impact resistace and bending resistance, of the workpiece obtained can thereby be controlled within side limits. The gross density of parts which are produced by the process according to the invention may be 0.5 for a wall thickness of 3 - 4 mm, in spite of the embedding of the glass fibres.
The following Example of the production of a half shell, for a travelling case, which has a depth of 100 mm, external dimensions of 700 x 500 mm, and a total thickness of 4 mm which includes an external coating of an
ABS film with a thickness of 0.8 mm. illustrates the invention.
EXAMPLE
In a moulding tool, a preshaped ABS film is placed. The film completely covers the inner surface of one part of the two-parttool.
A blank of non-woven glass fibre fabric consisting of continuous fibres and having a weight per unit area of 450 g/m2 is placed on top of the ABS film. In this state, the non-woven blank is completely uncompressed and unconsolidated and it has a total thickness of about 8 to 10 mm.
Afoamable reaction mixture comprising (in parts by weight):
Polyether polyol (OH number > 500) 100 parts
Tertiary amine 2 parts
Phthalic acid ester 46 parts
Fluorohydrocarbon 10 parts
Modified diphenylmethanediisocyanate 120 parts is poured, the isocyanate being added last, to initiate foaming, approximately into the centre of the moulding tool, in an amount such that while ensuring complete filling of all the spaces of the mould, the desired foam structure will be obtained. The foam structure is dependent in particular on the specific final pressure which is set up in the moulding tool during the reaction. This pressure can be measured and altered as desired by varying the amount fed in at any particular time.
Immediately after the reaction mixture has been poured in, the mould is closed and the initially very non-woven glass fibre fabric is compressed to a total thickness of about 3 mm. As a consequence of the chemical reaction occurring in the reaction mixture, the foaming process now begins and the foamed plastics material being formed fills all of the remaining empty spaces within the moulding tool, the ABS film being pressed hard against the inner wall of the mould as the final shape is achieved.
After a hardening time of 4 to 5 times, the chemical reaction is substantially complete and the moulding tool is opened. The finished half suitcase shell is removed from the mould and subjected to further processing as desired.
A high boiling epoxy fatty acid ester can be added to the phthalic acid ester, with similar results.
Claims (6)
1. A process for producing a fibre-reinforced foam shaped part, in which the foaming is caused by the reaction of a mixture of a polyhydric alcohol and an isocyanate, in which the reaction mixture additionally comprises from 5 to 30%, by weight of the mixture, of an inert ester whose boiling point is above the reaction temperature of the reaction mixture.
2. A process according to claim 1 in which thereaction mixture comprises from 10 to 20% by weight of the ester.
3. A process according to claim 1 or claim 2 in which the ester has a boiling point of more than 200"C.
4. A process according to any preceding claim in which the ester is of phthalic or stearic acid with butyl, benzyl and/or octyl alcohol.
5. A process according to any preceding claim in which the reaction mixture additionally comprises an epoxy stearate, in an amount of up to 25% by weight, based on the weight of the ester.
6. A process according to claim 1 substantially as described in the Example.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB7942196A GB2038347B (en) | 1979-12-06 | 1979-12-06 | Producing shaped parts |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB7942196A GB2038347B (en) | 1979-12-06 | 1979-12-06 | Producing shaped parts |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2038347A true GB2038347A (en) | 1980-07-23 |
| GB2038347B GB2038347B (en) | 1982-10-20 |
Family
ID=10509676
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB7942196A Expired GB2038347B (en) | 1979-12-06 | 1979-12-06 | Producing shaped parts |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2038347B (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2141722A (en) * | 1983-06-20 | 1985-01-03 | Secretary Industry Brit | Urethane composites |
| EP0714929A1 (en) * | 1994-11-30 | 1996-06-05 | Inoac Corporation | Waterproof plastic foam |
| EP4501998A1 (en) * | 2023-08-01 | 2025-02-05 | W.AG GmbH | Method for producing a luggage case with a foam insert made of rigid foam |
| EP4501999A1 (en) * | 2023-08-01 | 2025-02-05 | W.AG GmbH | Method for producing a shell case with a foam insert made of soft foam |
-
1979
- 1979-12-06 GB GB7942196A patent/GB2038347B/en not_active Expired
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2141722A (en) * | 1983-06-20 | 1985-01-03 | Secretary Industry Brit | Urethane composites |
| EP0714929A1 (en) * | 1994-11-30 | 1996-06-05 | Inoac Corporation | Waterproof plastic foam |
| EP4501998A1 (en) * | 2023-08-01 | 2025-02-05 | W.AG GmbH | Method for producing a luggage case with a foam insert made of rigid foam |
| EP4501999A1 (en) * | 2023-08-01 | 2025-02-05 | W.AG GmbH | Method for producing a shell case with a foam insert made of soft foam |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2038347B (en) | 1982-10-20 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |