GB2144141A - Synthetic resin materials containing micro-sphere filler - Google Patents
Synthetic resin materials containing micro-sphere filler Download PDFInfo
- Publication number
- GB2144141A GB2144141A GB08419377A GB8419377A GB2144141A GB 2144141 A GB2144141 A GB 2144141A GB 08419377 A GB08419377 A GB 08419377A GB 8419377 A GB8419377 A GB 8419377A GB 2144141 A GB2144141 A GB 2144141A
- Authority
- GB
- United Kingdom
- Prior art keywords
- synthetic material
- material according
- filler
- resin
- synthetic
- 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
- 239000000463 material Substances 0.000 title claims abstract description 31
- 239000000945 filler Substances 0.000 title claims abstract description 20
- 239000004005 microsphere Substances 0.000 title claims abstract description 8
- 229920003002 synthetic resin Polymers 0.000 title claims description 3
- 239000000057 synthetic resin Substances 0.000 title claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims abstract description 21
- 229920005989 resin Polymers 0.000 claims abstract description 15
- 239000011347 resin Substances 0.000 claims abstract description 15
- 239000004593 Epoxy Substances 0.000 claims abstract description 3
- 229920000728 polyester Polymers 0.000 claims abstract description 3
- 239000004567 concrete Substances 0.000 claims description 7
- 239000003054 catalyst Substances 0.000 claims description 6
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 abstract description 4
- 239000000049 pigment Substances 0.000 abstract description 2
- 239000000654 additive Substances 0.000 abstract 1
- 239000000203 mixture Substances 0.000 description 11
- 239000002253 acid Substances 0.000 description 5
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000002386 leaching Methods 0.000 description 2
- 229920001225 polyester resin Polymers 0.000 description 2
- 239000004645 polyester resin Substances 0.000 description 2
- 239000011253 protective coating Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- -1 27-33% Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 229940062187 carbon dioxide 70 % Drugs 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000010485 coping Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000007706 flame test Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229940120480 nitrogen 30 % Drugs 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
Synthetic material comprises a curable resin e.g. polyester or epoxy type and a filler, which material provides, on curing, a rigid product which can be moulded to form a variety of articles, notably for use in the building trade. The filler comprises microspheres which contribute to thermal and mechanical properties of the material in conjunction with the resin. Pigments, reinforcement and other additives can be included.
Description
SPECIFICATION
Synthetic material
This invention relates to synthetic materials and to articles made therefrom.
Conventional materials such as concrete and timber have long been used in the building trade, and have found a wide range of applications. For example concrete slipsills at windows provide a weatherproof surface for allowing rainwater to run off the building. It has been found, however, that rainwater causes acid to leach out of the concrete, and this acid attacks the bottom portions of timber window frames mounted on the concrete slipsills.
A new synthetic material has now been discovered in the terms of this invention which can provide building materials such as slipsills which are impervious and inert to rainwater and which can therefore be used as a substitute for concrete in such applications. Embodiments of the material also have use in many other areas, for example as a substitute for timber, plasterboard and other materials, and as protective coatings for wood, metal and the like.
According to the present invention there is provided synthetic material comprising a synthetic resin which on setting produces a rigid material, and a micro-sphere filler.
The filler is preferably Fillite or similar type, which has surprisingly been found to combine with the resin to produce a rigid and very tough synthetic material. The filler may be particulate in its raw state, and preferably contains silicate.
Fillite' '-type fillers contain lightweight hollow microspheres which assist in maintaining low weight, excellent thermal and electrical properties and good thermal insulation.
Fillite itself contains alumina, 27-33%, silica 55-65% and iron 4% maximum, as well as nitrogen 30% and carbon dioxide 70%. Its melting temperature is 1200-1 350 C, it has a thermal conductivity of 0.09 Wm-1 K-' and a thermal expansion coefficient of 8 X 10-6 (or).
The microspheres are generally larger than 5 microns.
Fillite's physical properties are as follows: density range 0.3 - 0.82 bulk density 0.18 - 0.45 packing factor 60 - 62% hardness Moh's scale 5 average wall thickness 1/10 sphere diameter permutivity 2.2 at 50 Hz loss tangent 0.024 at 50 Hz
The resin is preferably a polyester, epoxy or lightweight concrete resin, most preferably of the type which is conventionally used in making glass-reinforced plastics materials. A viscosity of around 600 centipoise produces good results.
In preparing the material of the invention a catalyst is preferably included in the mix, generally in an amount of loz per 31b mix, to assist in curing of the resin. Most preferably the catalyst is methyl ethyl ketone peroxide (MEKP). An accelerator may also be included, preferably in an amount of 1/2 oz per 31b mix.
The resin and filler are preferably present in the mix in a ratio of 65-75 : 35-25. The higher the content of filler the greater the viscosity of the mix, so the relative proportions can be selected in accordance with the use and application of the material.
The material mix may be of suitable viscosity for coating or moulding articles such as slipsills, ceiling tiles, coping, oversills, fencing, lintels, partitioning and steps, or for spraying or painting the mix as a protective coating on, for example, wood or metal.
Waterproofing material can also be included in the material of the invention, and it has been found that Gellcote is especially effective, for example in resisting attack by rainwater.
For increased strength fibrous material can be incorporated, for example asbestos or glass fibres. This provides reinforcement for the material of the invention in situations where the material is under stress. Glass powder, preferably in a ratio of around 50:50 with the filler can also be incorporated.
Steel or other metal mesh wire may also be included for greater strength and reinforcement.
Further components, for example colourants, can be used in the material, and if colourants are included at the stage of forming the material a permanent and durable colour can be imparted throughout the thickness of the entire material; thus in the event of the material having its surface chipped the colour remains constant at the damaged portion.
An embodiment of this invention will now be described by way of illustration in the following
Example.
EXAMPLE
The following components were mixed together in the proportions stated: tillite (ilicate filler material) 1 lb.
Polyester Resin (conventional
resin in GRP) 6 oz.
Gellcote (waterproof material) 6 oz.
Catalyst (MEKP) 0.5 - 1 oz.
Cclourant as required
Fibreglass needles }
Steel mesh wire }(reinforcement) as required
When the components were thoroughly mixed together, 0.5-1 oz. of a conventional accelerator for curing the resin was added, and the resultant mass poured into a mould to produce a profile of a slipsill of required length and extent. The mass was then allowed to cure in the mould, and the result was a slipsill which was hard, rigid, tough, wear-resistant and inert to attack by water.
The slipsill was then installed below a wooden window frame which was not then subject to rotting through acid leaching from the slipsill.
The form of the mould is entirely optional, so that a very wide range of articles can be produced from the material of the invention. For example, in the building trade a combined slipsill and window frame can be produced without using wood at all, the frame also being moulded from the material of this invention. The material also finds use in many areas other than the building trade.
When subject to a spread of flame test to BS476:Part 7:1971 on rigid insulation boards the material was designated Class 0 and exhibited nil travel of the flame.
A mechanical evaluation of panels of the material gave the results shown in the accompanying
Table.
The material is non-porous, impervious and inert to rainwater, lighter than cement but equally strong, is not susceptible to acid leaching, has minimal thermal expansion and contraction, can be machined, cut and drilled, is sound-proof and is easily cleaned.
Alteration of the content of Fillite and resin provides a change in the viscosity of the mix, and the proportions can thus be adjusted as required, for example to provide a mix which can be painted onto an existing structure. Once cured the material provides a hard, water-impervious and acid-resistant coat for the structure.
Modifications and improvements may be made without departing from the scope of the invention.
A further example is as follows:
EXAMPLE 2
The following components were mixed together in the proportions stated:
Fillite 1 lb
Polyester Resin 6 oz
Mekp Catalyst 8 cc per 1 Ib mix
Pigment 1 oz per 1 Ib mix
The components were thoroughly mixed together and then treated in the same manner as those in the foregoing example to produce a slipsill.
The relative proportions of resin:filler in the material of this invention are preferably from 65-75 : 35-25.
CONDITION (1) CONDITION (2) CONDITION (3)
ROOM TEMPERATURE ROOM TEMPERATURE ROOM TEMPERATURE
CURE ONLY CURE PLUS 2 HOURS CURE PLUS 2 HOURS # # 80 C POSTCURE 80 C PLUS 24 HOURS
IMMERSION IN WATER
PLUS 24 HOURS AT
ROOM TEMPERATURE
Specific Gravity g/cc 1.034 1.013 0.999
Flexural Strength Mpa 15.47 16.07 17.59
Flexural Modulus GPa 1.79 1.92 2.08
Claims (14)
1. Synthetic material comprising a synthetic resin which on setting produces a rigid material, and a micro-sphere filler.
2. Synthetic material according to Claim 1, wherein the resin is selected from polyester, epoxy and lightweight concrete resins.
3. Synthetic material according to Claim 1 or 2, wherein the filler is particulate.
4. Synthetic material according to Claim 1, 2 or 3, wherein the filler contains silicate.
5. Synthetic material according to any one of the preceding Claims, wherein the filler comprises gas-filled microspheres.
6. Synthetic material according to any one of the preceding Claims, wherein the filler wall material contains alumina and silica.
7. Synthetic material according to any one of the preceding Claims, wherein the microspheres of the filler are larger than 5mm.
8. Synthetic material according to any one of the preceding Claims, wherein the filler has a bulk density within the range from 0.18 to 0.45.
6. Synthetic material according to any one of the preceding Claims, wherein the ratio of resin:filler is within the range from 25:75 to 35:65.
10. Synthetic material according to any one of the preceding Claims, containing also an accelerator.
11. Synthetic material according to any one of the preceding Claims, containing also a catalyst for curing of the resin.
1 2. Synthetic material according to Claim 11, wherein the catalyst comprises methyl ethyl ketone peroxide.
1 3. Synthetic material substantially as hereinbefore described in the Example.
14. A moulded product containing the synthetic material according to any one of the preceding Claims.
1 5. A slipsill manufactured from the synthetic material according to any one of the preceding Claims.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB838320616A GB8320616D0 (en) | 1983-07-30 | 1983-07-30 | Synthetic material |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8419377D0 GB8419377D0 (en) | 1984-09-05 |
| GB2144141A true GB2144141A (en) | 1985-02-27 |
| GB2144141B GB2144141B (en) | 1987-08-26 |
Family
ID=10546569
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB838320616A Pending GB8320616D0 (en) | 1983-07-30 | 1983-07-30 | Synthetic material |
| GB08419377A Expired GB2144141B (en) | 1983-07-30 | 1984-07-30 | Synthetic resin materials containing micro-sphere filler |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB838320616A Pending GB8320616D0 (en) | 1983-07-30 | 1983-07-30 | Synthetic material |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB8320616D0 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4689358A (en) * | 1985-08-06 | 1987-08-25 | The Brooklyn Union Gas Company | Insulating polymer concrete |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1033237A (en) * | 1963-10-17 | 1966-06-22 | Shell Int Research | Synthetic resin based terrazzo surfacing compositions |
| GB1271298A (en) * | 1968-11-13 | 1972-04-19 | Ciba Geigy | Carveable epoxy resin compositions |
| GB1272973A (en) * | 1968-05-22 | 1972-05-03 | Rech Des Nouveaux Agglomerants | Agglomerating composition for preparing materials intended particularly for building purposes |
| GB1464243A (en) * | 1974-07-31 | 1977-02-09 | Ici Ltd | Composite materials |
| US4087401A (en) * | 1976-07-12 | 1978-05-02 | Stayner Vance A | Silica flour containing reinforced resin compositions and articles formed thereof |
| GB2028344A (en) * | 1978-08-17 | 1980-03-05 | Toray Silicone Co | Heat-curable filled moulding composition |
| GB1579208A (en) * | 1977-03-10 | 1980-11-12 | Hinterwaldner Rudolf | One component storage stable composition |
| GB2063269A (en) * | 1979-11-23 | 1981-06-03 | British Leyland Cars Ltd | Adhesives |
| GB2115799A (en) * | 1981-12-23 | 1983-09-14 | Tokuyama Soda Kk | Amorphous, spherical particles of an inorganic compound for use in dentistry |
| EP0097225A1 (en) * | 1982-06-22 | 1984-01-04 | International Business Machines Corporation | Radiation sensitive adhesive |
-
1983
- 1983-07-30 GB GB838320616A patent/GB8320616D0/en active Pending
-
1984
- 1984-07-30 GB GB08419377A patent/GB2144141B/en not_active Expired
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1033237A (en) * | 1963-10-17 | 1966-06-22 | Shell Int Research | Synthetic resin based terrazzo surfacing compositions |
| GB1272973A (en) * | 1968-05-22 | 1972-05-03 | Rech Des Nouveaux Agglomerants | Agglomerating composition for preparing materials intended particularly for building purposes |
| GB1271298A (en) * | 1968-11-13 | 1972-04-19 | Ciba Geigy | Carveable epoxy resin compositions |
| GB1464243A (en) * | 1974-07-31 | 1977-02-09 | Ici Ltd | Composite materials |
| US4087401A (en) * | 1976-07-12 | 1978-05-02 | Stayner Vance A | Silica flour containing reinforced resin compositions and articles formed thereof |
| GB1579208A (en) * | 1977-03-10 | 1980-11-12 | Hinterwaldner Rudolf | One component storage stable composition |
| GB2028344A (en) * | 1978-08-17 | 1980-03-05 | Toray Silicone Co | Heat-curable filled moulding composition |
| GB2063269A (en) * | 1979-11-23 | 1981-06-03 | British Leyland Cars Ltd | Adhesives |
| GB2115799A (en) * | 1981-12-23 | 1983-09-14 | Tokuyama Soda Kk | Amorphous, spherical particles of an inorganic compound for use in dentistry |
| EP0097225A1 (en) * | 1982-06-22 | 1984-01-04 | International Business Machines Corporation | Radiation sensitive adhesive |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4689358A (en) * | 1985-08-06 | 1987-08-25 | The Brooklyn Union Gas Company | Insulating polymer concrete |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2144141B (en) | 1987-08-26 |
| GB8320616D0 (en) | 1983-09-01 |
| GB8419377D0 (en) | 1984-09-05 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |