AU2017228727B2 - An article and a method of forming an article - Google Patents
An article and a method of forming an article Download PDFInfo
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- AU2017228727B2 AU2017228727B2 AU2017228727A AU2017228727A AU2017228727B2 AU 2017228727 B2 AU2017228727 B2 AU 2017228727B2 AU 2017228727 A AU2017228727 A AU 2017228727A AU 2017228727 A AU2017228727 A AU 2017228727A AU 2017228727 B2 AU2017228727 B2 AU 2017228727B2
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Abstract
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Description
(elcome to Family Member Analyser, Jordan. 4 Family Member Analyser IF
APPLICATION NUMBER PROGRESS No family members were identified
AU2017228727 Compare Family Members IP OFFICES Found 2 Independent Claims for AU2017228727A1 - 1, 10 AU WO Office Application Number Publication Number Publication Date Relevance FER Documents
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This invention relates to an article and a method of forming an article. More particularly, the invention relates to an article and a method of forming an article made from one or more polymers.
The discussion of any prior art documents, techniques, methods or apparatus is not to be taken to constitute any admission or evidence that such prior art forms, or ever formed, part of the common general knowledge.
Polymers such as polyurethanes are commonly used for moulding articles with high strength characteristics. One of the many reasons polyurethanes, in particular are used is their excellent wear resistance, outperforming steel at times as high as 8 to 1. As a result, polyurethane is commonly used for moulding articles used in the mining industry, the transportation industry, in processing equipment as well as in many other industries.
Despite the wide ranging use of polyurethanes, articles moulded with polyurethanes often have problems particularly in relation to wear and tear during prolonged use. Although there are many causes of wear, including erosion oxidation, UV degradation, fatigue, and abrasion; it is desirable to at least improve abrasion resistance of articles moulded with polyurethanes.
Another issue with articles moulded with polyurethane relates to providing a gripping surface on these articles. Articles moulded with polyurethane can often be slippery. Therefore, there is also a need for providing an articles that includes an improved gripping surface.
In a first aspect, the invention provides an article comprising a polymeric substrate and a coating containing discrete particles wherein at least a first portion of a substantial number of the discrete particles is embedded in the matrix of said polymeric substrate and wherein at least a second portion of the substantial number of the discrete particles is not embedded in the matrix of the polymeric substrate, thereby forming the coating.
In an embodiment, thickness of the coating is less than 10mm, preferably less than 8mm and more preferably in the range of 1mm and 4mm.
In an embodiment, each of said discrete particles comprises particles having a mean particle size of less than 8mm, preferably less than 6mm and more preferably less than 5mm.
In an embodiment, the discrete particles comprise one or more of the following: glass particles, ceramic particles, rubber particles, silicon carbide particles, titanium carbide particles, metal particles, alloy particles.
In an embodiment, the polymeric substrate comprises at least a first polymeric base layer and second polymeric supporting layer for supporting the discrete particles of the coating. Preferably, at least a first portion of the substantial number of the discrete particles is embedded in the matrix of the second polymeric supporting layer.
In an embodiment, durometer hardness of the first polymeric base layer is greater than or equal to hardness of the second polymeric supporting layer.
In an embodiment, the article comprises a plurality of outwardly facing surfaces wherein at least one of said faces comprises the coating. Preferably, the coating forms a gripping surface on the article.
In a second aspect, the invention provides a method of forming article, the method comprising the steps of: providing a curable polymer precursor in a mould; decreasing the viscosity of the polymer precursor to form a partially cured polymer precursor; adding discrete particles to the partially cured polymer precursor and allowing further curing of the partially cured polymer precursor thereby forming a cured polymer matrix; wherein at least a first portion of a substantial number of the discrete particles is embedded in cured polymer matrix and wherein at least a second portion of the substantial number of the discrete particles is not embedded in the cured polymer matrix, thereby forming an exposed coating.
In an embodiment, the step of providing the curable polymer precursor in the mould is carried out an initial elevated temperature and the step of decreasing the viscosity of the polymer precursor to form the partially cured polymer precursor at an intermediate lowered temperature followed by allowing further curing of the partially cured polymer precursor by lowering the temperature of the partially cured polymer precursor.
In an alternative embodiment, the step of decreasing the viscosity of the polymer precursor may be carried out without necessarily lowering the temperature.
In an embodiment, the step of adding the discrete particles to the partially cured polymer precursor is undertaken such that the reduced viscosity prevents the discrete particles from being completely embedded in the polymer matrix upon curing.
In an embodiment, the method comprises an initial step of forming an initial polymeric base layer to support the cured polymer matrix. Preferably, the step of forming the first polymeric base layer comprises introducing an initial base layer polymer precursor and allowing the initial base layer polymer precursor to cure partially thereby forming the polymeric base layer.
In an embodiment, the initial base layer polymer precursor is allowed to at least become partially cured before the step of providing the curable polymer precursor in the mould. Preferably, upon being cured, durometer hardness of the first polymeric base layer is greater than or equal to the durometer hardness of the cured polymer matrix comprising the embedded discrete particles.
In an embodiment, the polymer precursor may be allowed to cool to the intermediate temperature for a pre-determined time period before adding the discrete particles.
The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:
Figure 1 is a sectional view of an article 100 in accordance with a first embodiment of the invention.
Figure 2 is a sectional view of an article 200 in accordance with a second embodiment of the invention.
Figure 3 is a perspective view of a supporting pad 300 in accordance with a third embodiment of the invention.
Figure 4 is a sectional view of the supporting pad 300 in accordance with a third embodiment of the invention.
Figure 5 is a perspective view of a supporting plate 400 in accordance with a fourth embodiment of the invention.
Figure 6 is a sectional view of the supporting plate 400 in accordance with a third embodiment of the invention.
Referring to Figure 1, an article 100 formed in accordance with an embodiment of the present invention is illustrated.
The invention in the first embodiment is directed to an article 100 with a textured surface coating 20 provided in the article. The textured coating 20 is provided by embedding discrete coating particles into the cured polymer matrix of the body 50 of the article. Specifically, at least a first portion of a substantial number of the discrete particles in the surface coating 20 is embedded in the matrix of said polymeric substrate. A second portion of the substantial number of the discrete particles is not embedded in the matrix of the polymeric substrate, thereby forming the coating 20.
The discrete particles used include, but are not limited to, crumbed rubber particles, various salts, including sodium chloride, potassium chloride, calcium chloride, magnesium chloride, zinc chloride, calcium nitrate, zinc nitrate. Amorphous particles such as discrete glass particles may also be used for forming the coating 20. Alternatively or additionally, crystalline sand particles may also be used for forming the coating 20.
Polymers, particularly polyurethanes of the type suitable for moulding articles in accordance with the present invention, i.e., high-modulus elastomers, are well known in the art. Synthesis of such polyurethanes is carried out by the reaction of compounds containing isocyanate groups (either monomers, oligomers, or prepolymers) with hydroxy-containing compounds, or "polyols" (either monomers, oligomers, or prepolymers).
The precise compounds suitable for use in the preparation of polyurethanes used for moulding the article 100 in accordance with some embodiments are numerous, and may vary, depending on the characteristics desired in the finished molded article. Suitable hydroxy-containing compounds for example include polyesters, polyethers, polythioethers, polyacetals and polycarbonates. Suitable compounds containing isocyanate groups include the aliphatic, cycloaliphatic, aromatic and heterocyclic polyisocyanates. Isocyanate-containing compounds are also known, and are disclosed with further specificity in the art.
In order to form the base layer of the main body portion 50, the curing reaction for a high-modulus elastomer polyurethane for use in moulding or forming processes may be carried out using the "one-shot" approach. All ingredients (isocyanates, polyols with short-chain diol or amino chain extender and/or polyamines) may be mixed simultaneously (in "one shot"), together with any other desired additives, such as fillers, catalysts, colorants, or plasticizers. The mixture may then be placed in an open mould or other form and allowed to remain for at least a first time period that results in an increase in the viscosity of the poured mixture resulting in the formation of a partially cured mixture. The discrete particles, such as rubber particles maybe added into the mixture after the first time period has elapsed but preferably before the polyurethane has completely set.
Introducing the discrete particles after the first initial time period when the polyurethane mixture has been partially cured, as described above has two advantages. Firstly, the increased viscosity of the partially cured polyurethane prevents the discrete particles from sinking to a lower portion of the open mould and maintains the discrete particles at or along an upper portion of the poured mixture. It is desirable to prevent the discrete particles from being completely embedded in the cured matrix of the polyurethane in order to form the exposed coating of the discrete particles. Secondly, partial embedding of the discrete particles followed by further curing of the polyurethane surrounding the discrete particles improves bonding in between the discrete particles and polyurethane.
It is important to appreciate that the time duration available for the addition of the discrete particles to the partially cured polyurethane matrix may be limited because the polyurethane continues to cure progressively with the passage of time. Therefore, there is a limited period available for applying the discrete particles to an exposed surface of the partially cured polyurethane matrix. The extent of curing may be determined by way of measuring viscosity of the polyurethane matrix continuously during the curing process.
Polyurethane chemistry is very versatile, as seen by the multitude of uses from bowling balls to flexible foam and windmill adhesives. By changing the polyol and isocyanate components, the final properties of the polyurethane resin may be varied significantly. The invention is not limited by the final properties of the polyurethane resin.
Referring to Figure 2, an article 200 in accordance with the present invention is illustrated. Like reference numerals denote like features that have been previously described.
One of the main differences between the previously described article 100 and the article 200 of the second preferred embodiment is that unlike the previously described embodiment, a supporting layer 260 comprising another polymeric material is provided for supporting the discrete particles. Specifically, the article 200 comprises a first polymeric base layer 250 and second polymeric supporting layer 260 for supporting the discrete particles of the coating 220.
Both the first polymeric base layer 250 and the second supporting layer 260 may be moulded using different blends of polyurethane having differing characteristics.
In order to form the base layer 250 of the article body, the curing reaction for the first high-modulus elastomer polyurethane may be carried out using the "one-shot" approach. Once again, all ingredients (isocyanates, polyols with short-chain diol or amino chain extender and/or polyamines) may be mixed simultaneously (in "one shot"), together with any other desired additives, such as fillers, catalysts, colorants, or plasticizers. The base layer 250 is allowed to cure at least partially before all ingredients for the second layer 260, are poured above the supporting layer 260. The ingredients for the second layer 260 are poured only after an initial curing time period for the initial base layer
250 has elapsed I order to ensure that a small portion of the second layer 260 is embedded into the partially cured matrix of the base layer 250.
The discrete particles may be added after an initial curing time period has elapsed and the polyurethane in the supporting layer 260 has partially cured. The addition of the discrete particles after partial curing of the supporting layer 260 has two advantages. Firstly, the increased viscosity of the partially cured polyurethane in the supporting layer 260 prevents the discrete particles from sinking to a lower portion of the open mould and maintains the discrete particles at or along an upper portion of the poured mixture. It is desirable to prevent the discrete particles from being completely embedded in the cured matrix of the polyurethane in order to form the exposed coating of the discrete particles. Secondly, partial embedding of the discrete particles followed by further curing of the polyurethane surrounding the discrete particles also improves bonding in between the discrete particles and polyurethane.
It is preferably desirable that the hardness of the supporting polyurethane layer 260 is lower than the hardness of the base polyurethane layer 250. Providing the supporting layer 260 with a polyurethane blend having a relatively lower hardness in comparison with the hardness of the base layer 250 provides several advantages. Firstly, at least some polyurethane blends with relatively lower durometer hardness levels may be used for forming the supporting layer 260. Polyurethane blends with relatively higher durometer hardness levels may be used for forming the base layer 250. Providing a supporting layer 260 with a relatively lower hardness is advantageous because such a layer is expected to provide greater flexibility particularly when the exposed coating formed by the discrete particles is subjected to directional abrasive forces.
Referring to Figures 3 and 4 another embodiment of the article 300 is illustrated. Article 300 is a supporting pad with a non-slip coating 20 provided upon a polyurethane base 60 that is adapted for supporting a plurality of supporting blocks (not shown). Like reference numerals denote like features that have been previously described.
Article 300 is formed by way of the same process as described for article 100. The non-slip textured coating 20 is provided by embedding discrete rubber particles (having a mean particle size in the range oflmm-4mm) into the cured polymer matrix of the body 50 of the article. Specifically, at least, a first portion of a substantial number of the discrete particles in the surface coating 20 is embedded in the matrix of said polymeric substrate. A second portion of the substantial number of the discrete particles is not embedded in the matrix of the polymeric substrate, thereby forming the non-slip coating 20. During use, the supporting blocks (not shown) are positioned upon the non-slip coating 20 of the supporting pad 300 to prevent slipping of the supporting blocks during use, particularly when the supporting blocks are supporting heavy loads such as heavy machinery and equipment.
Referring to Figures 5 to 6, another embodiment of the article in the form of supporting base plate 400 is illustrated. The supporting base plate 400 includes a non-slip coating 20 provided upon a polyurethane base 60. During use, the non-slip coating 20 is provided along an underside of the supporting plate in order provide additional traction in between the base plate 400 and the supporting surface. The supporting plate 400 is provided with a plurality of apertures that are adapted for providing drainage holes or fastener receiving holes. Like reference numerals denote like features that have been previously described.
Article 400 is formed by the same process as described for article 100. The non-slip textured coating 20 is provided by embedding discrete rubber particles (having a mean particle size in the range oflmm-4mm) into the cured polymer matrix of the body 50 of the article. Specifically, at least, a first portion of a substantial number of the discrete particles in the surface coating 20 is embedded in the matrix of said polymeric substrate. A second portion of the substantial number of the discrete particles is not embedded in the matrix of the polymeric substrate, thereby forming the non-slip coating 20. During use, the supporting blocks (not shown) are positioned upon the non-slip coating 20 of the supporting pad 400 to prevent slipping of the supporting blocks during use, particularly when the supporting blocks are supporting heavy loads such as heavy machinery and equipment.
In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any additional features.
It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.
The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.
Claims (18)
1. An article comprising a polyurethane substrate substantially comprising polyurethane and a coating containing discrete particles wherein at least a first portion of a substantial number of the discrete particles is embedded in the matrix of said polyurethane substrate and wherein at least a second portion of the substantial number of the discrete particles is not embedded in the matrix of the polyurethane substrate, thereby forming the coating.
2. An article in accordance with claim 1 wherein thickness of the coating is less than 10mm, preferably less than 8mm and more preferably in the range of 1mm and 4mm.
3. An article in accordance with any one of claim 1 or claim 2 wherein embodiment, each of said discrete particles comprises particles having a mean particle size of less than 8mm, preferably less than 6mm and more preferably less than 5mm.
4. An article in accordance with any one of the preceding claims wherein the discrete particles comprise one or more of the following: glass particles, ceramic particles, rubber particles, silicon carbide particles, titanium carbide particles, metal particles, alloy particles.
5. An article in accordance with any one of the preceding claims wherein the polyurethane substrate comprises at least a first polyurethane base layer and second polyurethane supporting layer for supporting the discrete particles of the coating.
6. An article in accordance with claim 5 wherein at least a first portion of the substantial number of the discrete particles is embedded in the matrix of the second polyurethane supporting layer.
7. An article in accordance with claim 5 or claim 6 wherein durometer hardness of the first polyurethane base layer is greater than or equal to hardness of the second polyurethane supporting layer.
8. An article in accordance with any one of the preceding claims wherein the article comprises a plurality of outwardly facing surfaces wherein at least one of said faces comprises the coating.
9. An article in accordance with any one of the preceding claims wherein the coating forms a gripping surface on the article.
10. A method of forming an article, the method comprising the steps of: providing a curable polyurethane precursor in a mould; decreasing the viscosity of the polyurethane precursor to form a partially cured polyurethane precursor; adding discrete particles to the partially cured polyurethane precursor and allowing further curing of the partially cured polyurethane precursor thereby forming a cured polyurethane matrix; wherein at least a first portion of a substantial number of the discrete particles is embedded in cured polyurethane matrix and wherein at least a second portion of the substantial number of the discrete particles is not embedded in the cured polyurethane matrix, thereby forming an exposed coating.
11. A method in accordance with claim 10 wherein the step of providing the curable polyurethane precursor in the mould is carried out an initial elevated temperature and the step of decreasing the viscosity of the polyurethane precursor to form the partially cured polyurethane precursor at an intermediate lowered temperature followed by allowing further curing of the partially cured polyurethane precursor by lowering the temperature of the partially cured polyurethane precursor.
12. A method in accordance with claim 10 wherein the step of decreasing the viscosity of the polyurethane precursor may be carried out without necessarily lowering the temperature.
13. A method in accordance with any one of claims 10 to 12 wherein the step of adding the discrete particles to the partially cured polyurethane precursor is undertaken such that the reduced viscosity prevents the discrete particles from being completely embedded in the polyurethane matrix upon curing.
14. A method in accordance with any one of claims 10 to 13 the method comprises an initial step of forming an initial polyurethane base layer to support the cured polyurethane matrix.
15. A method in accordance with claim 14 wherein the step of forming the first polyurethane base layer comprises introducing an initial base layer polyurethane precursor and allowing the initial base layer polyurethane precursor to cure partially thereby forming the polyurethane base layer.
16. A method in accordance with claim 15 wherein the initial base layer polyurethane precursor is allowed to at least become partially cured before the step of providing the curable polyurethane precursor in the mould.
17. A method in accordance with claim 15 or 16 comprising the step of controlling the durometer hardness of the first polyurethane base layer to ensure that the durometer hardness of the first polyurethane base layer is greater than or equal to the durometer hardness of the cured polyurethane matrix comprising the embedded discrete particles.
18. A method in accordance with any one of claims 10 to 17 comprising the step of cooling the polyurethane precursor to the intermediate temperature for a pre determined time period before the step of adding the discrete particles.
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Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2016903810 | 2016-09-21 | ||
| AU2016903810A AU2016903810A0 (en) | 2016-09-21 | An Article and a Method of Forming an Article |
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| AU2017228727A1 AU2017228727A1 (en) | 2018-04-05 |
| AU2017228727B2 true AU2017228727B2 (en) | 2022-03-03 |
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| AU2017228727A Active AU2017228727B2 (en) | 2016-09-21 | 2017-09-18 | An article and a method of forming an article |
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6362302B1 (en) * | 1999-11-29 | 2002-03-26 | Carl E. Boddie | Method and compositions for spray molding polyurethane three dimensional objects |
| EP1242702B1 (en) * | 1999-12-23 | 2004-11-03 | Pergo (Europe) AB | A process for the manufacturing of surface elements |
| US20050183871A1 (en) * | 2003-07-29 | 2005-08-25 | Pon-Wei Hou | Shielding material for preventing from outleakage and penetration of electromagnetic waves |
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- 2017-09-18 AU AU2017228727A patent/AU2017228727B2/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6362302B1 (en) * | 1999-11-29 | 2002-03-26 | Carl E. Boddie | Method and compositions for spray molding polyurethane three dimensional objects |
| EP1242702B1 (en) * | 1999-12-23 | 2004-11-03 | Pergo (Europe) AB | A process for the manufacturing of surface elements |
| US20050183871A1 (en) * | 2003-07-29 | 2005-08-25 | Pon-Wei Hou | Shielding material for preventing from outleakage and penetration of electromagnetic waves |
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| AU2017228727A1 (en) | 2018-04-05 |
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