GB2264083A - Composite foam-filled articles - Google Patents
Composite foam-filled articles Download PDFInfo
- Publication number
- GB2264083A GB2264083A GB9300289A GB9300289A GB2264083A GB 2264083 A GB2264083 A GB 2264083A GB 9300289 A GB9300289 A GB 9300289A GB 9300289 A GB9300289 A GB 9300289A GB 2264083 A GB2264083 A GB 2264083A
- Authority
- GB
- United Kingdom
- Prior art keywords
- isocyanate
- composite material
- article
- composite
- void
- 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.)
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- 239000002131 composite material Substances 0.000 title claims description 42
- 239000006260 foam Substances 0.000 title abstract description 13
- 239000012948 isocyanate Substances 0.000 claims abstract description 31
- 150000002513 isocyanates Chemical group 0.000 claims abstract description 30
- 239000000945 filler Substances 0.000 claims abstract description 26
- 229920005862 polyol Polymers 0.000 claims abstract description 15
- 150000003077 polyols Chemical class 0.000 claims abstract description 15
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract description 7
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229920000570 polyether Polymers 0.000 claims abstract description 7
- 239000011496 polyurethane foam Substances 0.000 claims abstract description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 6
- 239000004721 Polyphenylene oxide Substances 0.000 claims abstract description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229920002635 polyurethane Polymers 0.000 claims abstract description 5
- 239000004814 polyurethane Substances 0.000 claims abstract description 5
- ICLCCFKUSALICQ-UHFFFAOYSA-N 1-isocyanato-4-(4-isocyanato-3-methylphenyl)-2-methylbenzene Chemical compound C1=C(N=C=O)C(C)=CC(C=2C=C(C)C(N=C=O)=CC=2)=C1 ICLCCFKUSALICQ-UHFFFAOYSA-N 0.000 claims abstract description 4
- 229910021532 Calcite Inorganic materials 0.000 claims abstract description 3
- 239000002202 Polyethylene glycol Substances 0.000 claims abstract description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 3
- 229910000323 aluminium silicate Inorganic materials 0.000 claims abstract description 3
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims abstract description 3
- 239000011324 bead Substances 0.000 claims abstract description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 3
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims abstract description 3
- 239000010459 dolomite Substances 0.000 claims abstract description 3
- 229910000514 dolomite Inorganic materials 0.000 claims abstract description 3
- 239000010436 fluorite Substances 0.000 claims abstract description 3
- 239000011521 glass Substances 0.000 claims abstract description 3
- 239000010440 gypsum Substances 0.000 claims abstract description 3
- 229910052602 gypsum Inorganic materials 0.000 claims abstract description 3
- 229910052652 orthoclase Inorganic materials 0.000 claims abstract description 3
- 229920001223 polyethylene glycol Polymers 0.000 claims abstract description 3
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 3
- 239000000463 material Substances 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 21
- 239000011800 void material Substances 0.000 claims description 19
- 239000000203 mixture Substances 0.000 claims description 11
- 125000003118 aryl group Chemical group 0.000 claims description 9
- 125000003342 alkenyl group Chemical group 0.000 claims description 8
- 125000003545 alkoxy group Chemical group 0.000 claims description 8
- 125000000217 alkyl group Chemical group 0.000 claims description 8
- 125000003710 aryl alkyl group Chemical group 0.000 claims description 8
- 125000004104 aryloxy group Chemical group 0.000 claims description 8
- 238000006243 chemical reaction Methods 0.000 claims description 7
- 229910052736 halogen Inorganic materials 0.000 claims description 6
- 150000002367 halogens Chemical class 0.000 claims description 6
- 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 claims description 4
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims description 4
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical group CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 claims description 3
- SBJCUZQNHOLYMD-UHFFFAOYSA-N 1,5-Naphthalene diisocyanate Chemical group C1=CC=C2C(N=C=O)=CC=CC2=C1N=C=O SBJCUZQNHOLYMD-UHFFFAOYSA-N 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 125000002837 carbocyclic group Chemical group 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- 235000013312 flour Nutrition 0.000 claims description 2
- 239000010881 fly ash Substances 0.000 claims description 2
- 125000000623 heterocyclic group Chemical group 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
- 229910052618 mica group Inorganic materials 0.000 claims description 2
- 229920001451 polypropylene glycol Polymers 0.000 claims description 2
- 239000010454 slate Substances 0.000 claims description 2
- 239000000454 talc Substances 0.000 claims description 2
- 229910052623 talc Inorganic materials 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 7
- 239000006261 foam material Substances 0.000 description 7
- 229920001225 polyester resin Polymers 0.000 description 6
- 239000004645 polyester resin Substances 0.000 description 6
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 229920001730 Moisture cure polyurethane Polymers 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 4
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 4
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 4
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 4
- WOZVHXUHUFLZGK-UHFFFAOYSA-N dimethyl terephthalate Chemical compound COC(=O)C1=CC=C(C(=O)OC)C=C1 WOZVHXUHUFLZGK-UHFFFAOYSA-N 0.000 description 4
- 230000002787 reinforcement Effects 0.000 description 4
- 239000004793 Polystyrene Substances 0.000 description 3
- -1 aromatic isocyanate Chemical class 0.000 description 3
- 238000005187 foaming Methods 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920003051 synthetic elastomer Polymers 0.000 description 2
- 239000005061 synthetic rubber Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- ZXHZWRZAWJVPIC-UHFFFAOYSA-N 1,2-diisocyanatonaphthalene Chemical compound C1=CC=CC2=C(N=C=O)C(N=C=O)=CC=C21 ZXHZWRZAWJVPIC-UHFFFAOYSA-N 0.000 description 1
- 208000013201 Stress fracture Diseases 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 125000005442 diisocyanate group Chemical class 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010944 pre-mature reactiony Methods 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 239000011369 resultant mixture Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 230000000007 visual effect Effects 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
- C08J9/32—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof from compositions containing microballoons, e.g. syntactic foams
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K3/00—Baths; Douches; Appurtenances therefor
- A47K3/28—Showers or bathing douches
- A47K3/40—Pans or trays
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
-
- 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
- C08J9/0066—Use of inorganic 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
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Polymers & Plastics (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Organic Chemistry (AREA)
- Public Health (AREA)
- General Health & Medical Sciences (AREA)
- Epidemiology (AREA)
- Inorganic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Laminated Bodies (AREA)
Abstract
High density polyurethane moulded articles are produced by including filler in polyurethane foam. The polyurethane foam is obtained by reacting an isocyanate bearing at least two isocyanate groups with a polyol. The isocyanate may be selected from MDI, TDI, TODI and NDI, and the polyol may be a polyether such as polyethylene glycol. Suitable fillers are calcium carbonate, silica, alumina, aluminosilicates, gypsum, fluorite, calcite, dolomite, orthoclase, and glass beads. The foam/filler may be used to fill an outer skin to form a shower tray.
Description
Improvements in or relating to Composite Foam
Filled Articles
The present invention relates to rigid articles having a composite-material-filled void, such articles including, for example, sanitary ware and more particularly, but not exclusively, shower trays.
Articles such as shower trays have conventionally been produced by forming, for example in a mould, a skin most commonly from a polymeric material, which skin defines the outer surface of the article, and subsequently filling the cavity thereby formed at reverse of the article with a suitable material formed, for example, by a foaming process. A substantially rigid structure is thus formed on hardening of the material. If necessary, the material can be applied under pressure to achieve the required high density.
Polyester-resin based foam materials have commonly been used, in which case, the polymeric skin into which the foam is applied may be formed from a gel-coat material which is applied to the inner surface of a mould before the mould is filled with foam. Polyurethane based foam materials have also been used (see, for example,
British patent No. 1 339 902) in which case the polymeric skin is commonly vacuum formed from a material such as polystyrene or an ABS-backed acrylic laminate. Vacuum formed outer skins of polystyrene,
ABS-backed acrylic laminate and the like are, however, unsuitable for use with polyester-resin based foam materials, due to the excessive generation of heat when the polyester-resin based foam is formed. Other skinforming techniques are also known.
Gel coats have been used with polyester-resin based foam materials due to their ability to withstand the heat evolved on foam production. However, the use of gel coats is disadvantageous due to the low adherence of outer surfaces of the article, formed by the gel coat, to the polyester-resin derived filling material. Gel coats are, furthermore, not sufficiently resistant to mechanical deformation or thermal shock and have insufficient impact resistance and accordingly may become separated in use from the supporting polyester-resin derived filling material, detracting significantly from the utility and visual attractiveness of the article.
It is conventional to reduce the amount of filling material required by including reinforcement means which also serve to provide additional strength where necessary. A foam material filled shower tray must, for example, be able to withstand the weight of a person standing in the shower tray and is conventionally reinforced by a metal and/or wooden substructure. For example, composite wooden boards comprising resin-bonded compressed woodshavings are commonly adhered to the lower surface of the tray to provide additional strength and rigidity whilst also serving as a means to which support means such as, for example, adjustable legs or spacers, may be attached by fixing means.However, the susceptibility of such substructures to corrosion and rot in a damp environment are well known, and the reinforcement means are also disadvantageous due to their different rates of thermal expansion with respect of the filling material In particular, in the case of shower trays, the action of hot water on the shower tray causes the filling material to expand to a much greater extent than that of the reinforcement means, leading to stress fractures and premature failure.
The present invention seeks to provide articles of the above type wherein a composite material is of a nature suitable for retaining fixing means directly, such as, for example, screws which may be driven into the material to secure the article to another article or surface. Furthermore, the articles provided can advantageously be free standing without the need for any additional supporting means. The present invention further seeks to provide such an article having high mechanical strength, high impact resistance, excellent heat resistance and scratch resistance.
Conventionally formed shower trays are usually very lightweight and, whilst this undoubtedly has advantages in the ease of transporting and manoeuvring the trays for fitting, excessive lightness in weight is perceived by the consumer to represent an article of lower quality and is therefore disadvantageous. The present invention also seeks to provide articles comprising voids substantially filled with a compositefilling material such as a foam-derived material having a greater specific weight.
According to one aspect of the present invention there is provided a process for producing a composite material-filled article by the steps of
a) forming an outer skin of the article into a desired shape to define a void in at least a part thereof,
b) introducing the composite material into the void and,
c) hardening the material,
wherein the composite material comprises a mixture of a filler and a polyurethane foam formed by the reaction of a polyol with an isocyanate, said isocyanate comprising two or more isocyanate groups.
In an embodiment of the present invention the isocyanate is an aromatic isocyanate and preferably a derivative of the following general formula:
where R may be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen; a commonly available example is toluene diisocyanate (TDI). Alternative isocyanates which find utility in the present invention are of the general formula:
wherein at least two of X1, X2, Y1 and Y2 are isocyanate groups, P1 and P2 are carbocyclic groups or heterocyclic groups and may be the same or different and A is alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or carbon 4,4' diphenyl methyldiisocyanate (MDI) is a well known example of this class of diisocyanate.
The isocyanate may alternatively be of the type represented by the general formula:
where R1 and R2 may independently be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen. This class of isocyanates is exemplified by bitolylene diisocyanate (TODI). Further isocyanates which may be used in the present invention include those of the general formula:
where R1 and R2 may independently be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen. Such a class of isocyanates is exemplified by 1,5 naphthalene diisocyanate (NDI).
In another embodiment the polyol may be a polyether (such as a polyethylene glycol, a polypropylene glycol, or aromatic polyester polyols obtained from residues of terephthalic acid production or by transesterification of dimethyl terephthalate (DMT) or poly(ethylene terephthalate) (PET) scrap with glycols), ethylene glycol, propane glycol or butane glycol. When the polyol is a polyether it is preferable that the polyether is a medium viscosity blend of polyethers.
In yet another embodiment of the present invention the filler is a powder or granulate material.
Preferred fillers include one or more of the following materials calcium carbonate, silica, alumina, slate, gypsum, fluorite, calcite, dolomite, orthoclase, alumino silicates, mica, talc, wood flour, fly ash and glass beads.
In a further embodiment of the present invention the filler comprises from not less than 20% to not more than 60% by weight of the mixture, and more preferably is in the range of from not less than 42% to not exceeding 50% by weight.
In a further embodiment of the present invention a key coat is applied to the reverse of the outer skin before the application of the composite material; the key coat may comprise a synthetic rubber adhesive.
In a still further embodiment of the present invention the outer skin is disposed in an outer mould prior to the introduction of the composite material.
Preferably a closure is applied to the mould prior to the introduction of the composite material and particularly preferably the mould in constructed such that it is able to withstand internal pressure.
According to a second aspect of the present invention there is provided an article comprising an outer skin, wherein at least part of said skin defines an internal void which is substantially filled with a composite material comprising an admixture of
a) a polyurethane foam formed by the reaction of a polyol with an isocyanate, said isocyanate comprising at least two isocyanate groups, and
b) one or more fillers.
In an embodiment of this second aspect of the present invention the core density of the finished article is in the range 75-350 kgm#3, more preferably in the range 100-225 kgm~3.
The composite-material-filled articles of the present invention are preferably prepared by mixing the filler and polyol in desired amounts and then admixing the same with the desired amount of isocyanate. The resultant mixture is then introduced into the void.
The reaction between the isocyanate and polyol results in the evolution of carbon dioxide which provides a foaming action. In addition, the resulting pressure causes the foam structure to collapse into a dense solid material. The void of the skin is thus filled by the foamed composite material. Typically, the time required to form the foam is of the order of 90 seconds, and foaming is complete in approximately 15 minutes. The composite material is then allowed to harden for between approximately 30 and 60 minutes, depending on the relative quantities of the initial ingredients.
Alternatively, the polyol-filler mixture and the isocyanate may be separately pumped into the void. If necessary the pump for the polyol-filler mixture can include a liner sufficient to resist any abrasion caused by the filler. Depending on the nature of the filler it may be necessary to warm the polyol-filler mixture.
In an example, the composite material used in the present invention may be produced by the admixture of chalk (as filler) with the reaction product of a polyol and a low to medium molecular weight 4,4' diphenyl methyl diisocyanate pre-polymer. The preferred molecular weight of the pre-polymer is in the range 400 to 10000. A polyurethane foam based composite material thereby results. The pre-polymer is advantageously supplied in 100% solids form. The use of the above pre-polymer is also particularly advantageous due to its ability to form a more dense foam than conventional materials. The relative quantities of polyol and 4,4' diphenyl methyl diisocyanate are dependent on the nature of the desired final composite material and are thus not particularly limited.
For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example only to the following drawings, in which:
Figure 1 is a cross-section along the line X-X in
Figure 2 of a shower tray of the present invention,
Figure 2 is a plan view of the shower tray,
Figures 3a and 3b are respectively a sectional and an underneath view of another shower tray according to the invention,
Figures 4a and 4b are respectively a sectional and an underneath view of a further shower tray according to the invention, and
Figure 5 is a schematic view of the shower tray of
Figures 4a and 4b disposed in a mould suitable for forming and hardening the composite material; the inlet for the components of the composite material has been omitted for clarity.
Referring now to the drawings, in which the thickness of the outer skin has been exaggerated for clarity, there is shown a shower tray 1 comprising an outer skin 2 and a composite filling material 3. Outer skin 2 defines at least that part of the finished article which, in use, is visible to the user. As is particularly apparent from Figure 1, outer skin 2 can terminate at edges 5, resting on plane 4, which plane may, for example be the floor on which the shower tray is located. In conjunction with plane 4, outer skin 2 defines a void 6 at least part of which is filled with composite material 3. [ In an alternative form, outer skin 2 continues from edges 5, and forms an additional surface, substantially parallel to plane 4.Void 6 is thereby entirely defined by outer skin 2. ] The shower tray may be formed in any desired shape, provided that reverse side 10 of the outer skin, and inside surface of mould 11 define void 6 which can be filled with composite material as illustrated in Figure 5. Drain hole 7 (Figure 1) is incorporated into the shower tray in any suitable location.
In order to achieve the desired high density of composite material, composite material 3 can be introduced into void 6 under pressure. However, in practice, introduction of the composite material under pressure is unnecessary since the reaction between the isocyanate and the polyol produces carbon dioxide gas, which generates sufficient pressure within the mould to ensure uniform and complete filling of the void. In the case of the embodiment shown in Figure 1, in order to effect the filling, the skin is applied to mould 11 (Figure 5) having interior dimensions which are slightly greater than those of the outer skin but such that the mould and outer skin are just in contact, and a closure is applied along plane 4, which closure may be removed after the hardening of the composite material.It is not essential for foam material 3 to completely fill void 6 in the region adjacent to plane 4. Provided that a sufficient degree of rigidity is achieved, the amount of foam and filler required may be reduced by forming reinforcement ribs or pockets in the foam. Examples of such ribs 8 and pockets 9 are illustrated in Figures 3 and 4 respectively. Ribs 8 and pockets 9 may, for example be formed by a suitable moulding on the closure applied along plane 4.
Outer skin 2 may be formed from any suitable material by any appropriate means. Injection moulding and vacuum forming are particularly useful in this respect. Preferred materials for outer skin 2 are polymeric materials, for example polystyrene or ABS backed acrylic (ABS backed acrylic is a laminate of an acrylic polymer and an acrylonitrile-butadiene-styrene co-polymer). Such polymers can be pigmented to provide a range of desired colours for the finished product.
If the adhesion between the outer skin and the composite material is insufficient, the adhesion may be improved by means of a key-coat. The key-coat may, for example, be applied to reverse side 10 of outer skin 2 prior to the application of the composite material.
The choice of materials for the key coat is not limited, but synthetic rubber adhesives, for example elastomer based compositions in non-flammable solvents, are preferred.
The choice of the filler used in the present invention is not limited although it is preferable that the filler is of high density since this results in an increased weight of the finished article. A wide range of grades of filler can be used, although the use of a particle size which is too small will result in increased costs since a greater amount of composite material will be required to coat the larger surface area of the fine particles. The filler should be dry to ensure that there is no premature reaction with the isocyanate and it is preferable that the filler is inert to chemical reaction under the conditions used and does not chemically react with water.
The scope of the present invention is such that it may be applied to any article which includes a void suitable for filling with a foam material. Moreover, it is not restricted to the use of ABS skins but may be carried out using any polymeric or other skin.
Claims (22)
1. A process for producing a composite materialfilled article by the steps of a) forming an outer skin of the article into a
desired shape to define a void in at least a part
thereof, b) introducing the composite material into the void
and, c) hardening the material, wherein the composite material comprises a mixture of a filler and a polyurethane foam formed by the reaction of a polyol with an isocyanate, said isocyanate comprising two or more isocyanate groups.
2. A process as claimed in claim 1 wherein the isocyanate has the general formula
where R may be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen.
3. A process as claimed in claim 2 wherein the isocyanate is toluene diisocyanate.
4. A process as claimed in claim 1 wherein the isocyanate has the general formula
wherein at least two of X1, X2, Y1 and Y2 are isocyanate groups, P1 and P2 are carbocyclic groups or heterocyclic groups and may be the same or different and A is alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or carbon.
5. A process as claimed in claim 4 wherein the isocyanate is 4,4' diphenyl methyl diisocyanate
6. A process as claimed in claim 1 wherein the isocyanate has the general formula
where R1 and R2 may independently be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen.
7. A process as claimed in claim 6 wherein the isocyanate is bitolylene diisocyanate.
8. A process as claimed in claim 1 wherein the isocyanate has the general formula
where R1 and R2 may independently be H, alkyl, alkenyl, alkoxy, aryl, aryloxy, aralkyl or halogen.
9. A process as claimed in claim 8 wherein the isocyanate is 1,5 naphthalene diisocyanate.
10. A process as claimed in any preceding claim wherein the polyol is a polyether.
11. A process as claimed in claim 10 wherein the polyether is a polyethylene glycol, a polypropylene glycol, or is derived from terephthalic acid.
12. A process as claimed in any preceding claim wherein the filler is selected from; calcium carbonate, silica, alumina, slate, gypsum, fluorite, calcite, dolomite, orthoclase, alumino silicates, mica, talc, wood flour, fly ash and glass beads.
13. A process as claimed in any preceding claim
14. A process as claimed in claim 13 wherein the filler comprises from not less than 42% to not more than 50% by weight of the mixture.
15. A process as claimed in any preceding claim wherein the composite material is formed by admixing the polyol and the filler to form a mixture and subsequently combining the mixture with the isocyanate immediately prior to introduction into the void.
16. A process as claimed in any preceding claim including the additional step of applying a key coat to the reverse side of the formed outer skin prior to applying the composite material into the void.
17. A composite polyurethane article comprising an outer skin, wherein at least part of said skin defines an internal void which is substantially filled with a composite material comprising an admixture of a) a polyurethane foam formed by the reaction of a
polyol with an isocyanate, said isocyanate
comprising at least two isocyanate groups, and b) one or more fillers.
18. A composite polyurethane article as claimed in claim 17 wherein the core density is from not less than 75 kgm'3 to not more than 350 kgm#3.
19. A composite polyurethane article as claimed in claim 18 wherein the core density is from not less than 100 kgm-3 to not more than 225 kgm#3.
20. A composite material-filled article produced by the process of any one of claims 1 to 16.
21. A process for producing a composite materialfilled article as claimed in claim 1 substantially as hereinbefore described.
22. A composite material-filled article as claimed in claim 17 substantially as hereinbefore described.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB929200495A GB9200495D0 (en) | 1992-01-10 | 1992-01-10 | Improvements in or relating to foam-filled articles having composite-material filled voids |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9300289D0 GB9300289D0 (en) | 1993-03-03 |
| GB2264083A true GB2264083A (en) | 1993-08-18 |
Family
ID=10708401
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB929200495A Pending GB9200495D0 (en) | 1992-01-10 | 1992-01-10 | Improvements in or relating to foam-filled articles having composite-material filled voids |
| GB9300289A Withdrawn GB2264083A (en) | 1992-01-10 | 1993-01-08 | Composite foam-filled articles |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB929200495A Pending GB9200495D0 (en) | 1992-01-10 | 1992-01-10 | Improvements in or relating to foam-filled articles having composite-material filled voids |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB9200495D0 (en) |
Cited By (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2304069A (en) * | 1995-08-11 | 1997-03-12 | Advance Enterprises Ltd | A process for manufacturing organic and inorganic compositions, moulded flat or extruded or injection moulded |
| GB2308374A (en) * | 1995-12-19 | 1997-06-25 | Nat Starch Chem Corp | Fillers for strengthening structures |
| EP0728574A3 (en) * | 1995-02-23 | 1998-06-03 | Bayer Ag | Sandwich type structural polyurethane element and method for its manufacture |
| WO1998058994A1 (en) * | 1997-06-23 | 1998-12-30 | Peter Silbernagel | Method for producing tiles or shaped parts, and tile-shaped semi-finished products and interior decorating items made according to said method |
| GB2332206A (en) * | 1997-12-12 | 1999-06-16 | Airbath International | Filler |
| EP0965611A1 (en) * | 1998-06-19 | 1999-12-22 | Schwanekamp GmbH | Polyurethane moulded parts, process for their preparation as well as panel shaped semi-finished product and tub-shaped objects obtainable using the polyurethane moulded parts produced in this way |
| US6204312B1 (en) | 1995-08-11 | 2001-03-20 | Advance Enterprises Ltd. | Process for manufacturing organic and inorganic compositions, moulded flat or extruded to give complex formation, dimensional stability, added strength, biological resistance, using non toxic resin formulations |
| EP1240862A3 (en) * | 2001-03-15 | 2003-11-05 | REXPOL S.r.l. | Assembled shower tray in plastic material with polystyrene foam sintered onto it |
| EP1413236A3 (en) * | 2002-10-25 | 2005-01-12 | Polypipe Building Products Ltd. | Sanitary apparatus |
| GB2428567A (en) * | 2005-07-23 | 2007-02-07 | Matki Plc | Manufacture of sanitary ware |
| GB2450694A (en) * | 2007-07-02 | 2009-01-07 | Impey | Shower base assembly |
| GB2466309A (en) * | 2008-12-22 | 2010-06-23 | Cavalier Marketing Ltd | A bath |
| GB2469317A (en) * | 2009-04-08 | 2010-10-13 | Trayco Inc | Method of making a composite body comprising holder filled with mixture of a foamable resin and filler |
| ES2348904A1 (en) * | 2010-09-16 | 2010-12-16 | Anguiano Poliuretano S.L. | IMPROVED SHOWER TRAY DUE TO INCORPORATION IN ITS MANUFACTURE OF FLEXIBLE LOADS FROM RECYCLING OF CAR TIRES. |
| EP3255084A1 (en) * | 2016-06-10 | 2017-12-13 | New Bath | Method for preparing a reinforced structure |
| GB2569871A (en) * | 2017-11-15 | 2019-07-03 | World Elastomers Trade Sl | Decorative panel for shower trays |
| WO2019145687A1 (en) * | 2018-01-25 | 2019-08-01 | Kohler Mira Limited | An article of sanitary ware comprising a hollow shell and a filler material which is disposed in] the shell |
Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1152724A (en) * | 1966-05-13 | 1969-05-21 | Arthur Hugh Roberts | Method of Moulding Rigid Composite Articles. |
| GB1159080A (en) * | 1967-03-22 | 1969-07-23 | Gen Motors Corp | An Automobile Bumper. |
| GB1339902A (en) * | 1972-02-15 | 1973-12-05 | Porta Showers Ltd | Shower base |
| GB1392119A (en) * | 1971-12-18 | 1975-04-30 | Sanyo Chemical Ind Ltd | Skin polyurethane foam |
| US4502234A (en) * | 1981-07-29 | 1985-03-05 | Secans Ag | Synthetic-resin body support material |
| GB2148786A (en) * | 1983-10-28 | 1985-06-05 | Armitage Shanks Ltd | Manufacturing laminated articles |
| EP0211495A2 (en) * | 1985-07-01 | 1987-02-25 | Imperial Chemical Industries Plc | Reinforced shaped article and method for producing the same |
| US4916173A (en) * | 1988-05-06 | 1990-04-10 | Ciba-Geigy Corporation | Polyurethane syntactic foam modeling stock |
-
1992
- 1992-01-10 GB GB929200495A patent/GB9200495D0/en active Pending
-
1993
- 1993-01-08 GB GB9300289A patent/GB2264083A/en not_active Withdrawn
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1152724A (en) * | 1966-05-13 | 1969-05-21 | Arthur Hugh Roberts | Method of Moulding Rigid Composite Articles. |
| GB1159080A (en) * | 1967-03-22 | 1969-07-23 | Gen Motors Corp | An Automobile Bumper. |
| GB1392119A (en) * | 1971-12-18 | 1975-04-30 | Sanyo Chemical Ind Ltd | Skin polyurethane foam |
| GB1339902A (en) * | 1972-02-15 | 1973-12-05 | Porta Showers Ltd | Shower base |
| US4502234A (en) * | 1981-07-29 | 1985-03-05 | Secans Ag | Synthetic-resin body support material |
| GB2148786A (en) * | 1983-10-28 | 1985-06-05 | Armitage Shanks Ltd | Manufacturing laminated articles |
| EP0211495A2 (en) * | 1985-07-01 | 1987-02-25 | Imperial Chemical Industries Plc | Reinforced shaped article and method for producing the same |
| US4916173A (en) * | 1988-05-06 | 1990-04-10 | Ciba-Geigy Corporation | Polyurethane syntactic foam modeling stock |
Cited By (22)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0728574A3 (en) * | 1995-02-23 | 1998-06-03 | Bayer Ag | Sandwich type structural polyurethane element and method for its manufacture |
| US5856371A (en) * | 1995-02-23 | 1999-01-05 | Bayer Aktiengesellschaft | Polyurethane sandwich structure element and process for production thereof |
| GB2304069A (en) * | 1995-08-11 | 1997-03-12 | Advance Enterprises Ltd | A process for manufacturing organic and inorganic compositions, moulded flat or extruded or injection moulded |
| GB2304069B (en) * | 1995-08-11 | 2000-03-15 | Advance Enterprises Ltd | A process for manufacturing, by moulding non resinous organic and inorganic compositions |
| US6204312B1 (en) | 1995-08-11 | 2001-03-20 | Advance Enterprises Ltd. | Process for manufacturing organic and inorganic compositions, moulded flat or extruded to give complex formation, dimensional stability, added strength, biological resistance, using non toxic resin formulations |
| GB2308374A (en) * | 1995-12-19 | 1997-06-25 | Nat Starch Chem Corp | Fillers for strengthening structures |
| WO1998058994A1 (en) * | 1997-06-23 | 1998-12-30 | Peter Silbernagel | Method for producing tiles or shaped parts, and tile-shaped semi-finished products and interior decorating items made according to said method |
| GB2332206A (en) * | 1997-12-12 | 1999-06-16 | Airbath International | Filler |
| GB2332206B (en) * | 1997-12-12 | 2001-09-19 | Airbath Internat | A shower tray moulding incorporating a filler |
| EP0965611A1 (en) * | 1998-06-19 | 1999-12-22 | Schwanekamp GmbH | Polyurethane moulded parts, process for their preparation as well as panel shaped semi-finished product and tub-shaped objects obtainable using the polyurethane moulded parts produced in this way |
| EP1240862A3 (en) * | 2001-03-15 | 2003-11-05 | REXPOL S.r.l. | Assembled shower tray in plastic material with polystyrene foam sintered onto it |
| EP1413236A3 (en) * | 2002-10-25 | 2005-01-12 | Polypipe Building Products Ltd. | Sanitary apparatus |
| GB2428567A (en) * | 2005-07-23 | 2007-02-07 | Matki Plc | Manufacture of sanitary ware |
| GB2450694A (en) * | 2007-07-02 | 2009-01-07 | Impey | Shower base assembly |
| GB2466309A (en) * | 2008-12-22 | 2010-06-23 | Cavalier Marketing Ltd | A bath |
| GB2469317A (en) * | 2009-04-08 | 2010-10-13 | Trayco Inc | Method of making a composite body comprising holder filled with mixture of a foamable resin and filler |
| GB2469317B (en) * | 2009-04-08 | 2012-12-12 | Trayco Ltd | A method of making a composite body, and a composite body made by the method |
| ES2348904A1 (en) * | 2010-09-16 | 2010-12-16 | Anguiano Poliuretano S.L. | IMPROVED SHOWER TRAY DUE TO INCORPORATION IN ITS MANUFACTURE OF FLEXIBLE LOADS FROM RECYCLING OF CAR TIRES. |
| EP3255084A1 (en) * | 2016-06-10 | 2017-12-13 | New Bath | Method for preparing a reinforced structure |
| GB2569871A (en) * | 2017-11-15 | 2019-07-03 | World Elastomers Trade Sl | Decorative panel for shower trays |
| GB2569871B (en) * | 2017-11-15 | 2022-12-07 | World Elastomers Trade Sl | Decorative panel for shower trays |
| WO2019145687A1 (en) * | 2018-01-25 | 2019-08-01 | Kohler Mira Limited | An article of sanitary ware comprising a hollow shell and a filler material which is disposed in] the shell |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9200495D0 (en) | 1992-02-26 |
| GB9300289D0 (en) | 1993-03-03 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |