AU639992B2 - Process for the production of a sheet of a composite material comprising a cast poly (methyl methacrylate) panel combined with a thermoplastic support layer and products obtained - Google Patents

Process for the production of a sheet of a composite material comprising a cast poly (methyl methacrylate) panel combined with a thermoplastic support layer and products obtained Download PDF

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Publication number
AU639992B2
AU639992B2 AU74054/91A AU7405491A AU639992B2 AU 639992 B2 AU639992 B2 AU 639992B2 AU 74054/91 A AU74054/91 A AU 74054/91A AU 7405491 A AU7405491 A AU 7405491A AU 639992 B2 AU639992 B2 AU 639992B2
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AU
Australia
Prior art keywords
poly
sheet
methyl methacrylate
thermoplastic material
panels
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.)
Ceased
Application number
AU74054/91A
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AU7405491A (en
Inventor
Joel Queirel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TECHNOPLAST SA
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TECHNOPLAST SA
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Filing date
Publication date
Application filed by TECHNOPLAST SA filed Critical TECHNOPLAST SA
Publication of AU7405491A publication Critical patent/AU7405491A/en
Application granted granted Critical
Publication of AU639992B2 publication Critical patent/AU639992B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/30Making multilayered or multicoloured articles
    • B29C43/305Making multilayered articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04Polymers of esters
    • B29K2033/12Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2055/00Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
    • B29K2055/02ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/769Sanitary equipment
    • B29L2031/7692Baths

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Bathtubs, Showers, And Their Attachments (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

Process for the manufacture of a composite material comprising a cast polymethyl methacrylate sheet bonded to a supporting layer of a thermoplastic material such as ABS. In accordance with the invention the adhesion of the two materials is obtained by applying the polymethyl methacrylate sheet (7, 8, 9) by calendering onto the sheet of thermoplastic material which is formed continuously (6) as soon as it leaves the extruder (1) when the thermoplastic material is still fluid, whereas the polymethyl methacrylate sheet is at room temperature. The invention applies especially to the preparation of a composite material which can be employed for moulding various articles and especially baths. <IMAGE>

Description

4 fL COMMONWEALTH OF AUSTRALIA Patents Act 1952 TECHNOPLAST (SOCIETE ANONYME) (French Patent No. 90 05381) COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED:- "PROCESS FOR THE PRODUCTION OF A SHEET OF A COMPOSITE MATERIAL COMPRISING A CAST POLY (METHYL METHACRYLATE) PANEL COMBINED WITH A THERMOPLASTIC SUPPORT LAYER AND PRODUCTS OBTAINED" The following statement is full description of this invention, including the best method of performing it know to me/us:la Poly(methyl methacrylate), commonly known by the abbreviation PMMA, enables panels of a noble material, such as the panels marketed under the trade names "Plexiglass, Altuglass, to be produced when the technique of casting between glass panels followed by a polymerisation lasting several hours is used. These panels have the appearance of glass, without, however, having the hardness; however, they have a flexibility which allows them to be used for numerous applications in which glass cannot conveniently be used.
In particular, bathtubs manufactured from plastic material must necessarily comprise a shaped panel of cast PMMA as the outer layer.
Given that this material is very expensive, and 15 on the other hand does not have all of the characteristics required for use of this type of product, in particular in respect of the rigidity and the mass, the suitably shaped PMMA panel must be dressed using reinforcing and stiffening products, such as glass fibres suitably projected and glued on the underside of the o sheet with the addition of reinforcements, frequently of 1 wood, agglomerated or laminated in particular under the upper girdle of the bathtub and under the base.
Of course, all of these finishing operations which are essentially of the type carried out by craftsmen impose a considerable burden on the price of the So final product, without this product having the finish characteristics which are desirable and readily reproducible.
Of course, attempts have been made to assemble the noble panel of PMMA on panels or sheets of plastic materials which are less noble and have satisfactory complementary rigidity or mass characteristics. However, these experiments have been abandoned because they have not given any satisfactory results, more particularly in respect of a join between the two materials PMMA and the other plastic material, which do not appear to be compatible and separate at the slightest provocation. Gluing experiments have also proved disappointing and, of 2 course, the co-extrusion of PMMA and the thermoplastic material cannot be envisaged because, in this case, it is impossible to obtain the quality of the sheet cast and polymerised under glass panels, which have been considered above.
The aim of the invention is to resolve these difficulties.
To this end, according to the invention, the production i of a sheet of a composite material comprising a panel of a PMMA [poly(methyl methacrylate)] prefabricated by casting, which will form an outer layer of the composite material, and a support layer of a thermoplastic material, is carried out, the process ibeing characterised in that, with a view to obtaining a perfect I cohesion and join of the two layers to one another, a machine comprising calendering rolls is fed by an extruder so as to form a continuous extruded sheet of the thermoplastic material, the said PMMA panels are supplied regularly to the inlet of the machine on one side of the sheet of thermoplastic material formed, which PMMA panels are calendered simultaneously with the S 20 sheet of thermoplastic material between the calendering rolls of the machine, and the sheets of composite material are obtained, consisting of the abovementioned PMMA panels assembled on an Sabovementioned support layer of thermoplastic material are cut off at the outlet from the calendering machine.
So as to obtain perfect cohesion of the two sheets, the PMMA panels are preferably calendered against the extruded sheet S of thermoplastic material from its exit from the extruder, the t €4 f S first calendering action ensuring an application of the still fluid thermoplastic material against the non-fluid PMMA panel.
2a For example, if the thermoplastic material is to be of the ABS (polyacrylonitrile-butadiene-styrene) type, the temperature at which the ABS sheet is fed at the first set of calendering rolls will be close to 240 0 C, while the poly(methyl methacrylate) panels, for example having a thickness of 3 mm, will be supplied one by one at i i i-ruitrt 3 ambient temperature and calendered with the ABS sheet from its exit from the extruder.
The invention also relates to the sheets of composite material obtained by the process of the invention and to the finished products formed from these sheets.
Other characteristics, subjects and advantages of the invention will become more clearly apparent with the aid of the description which follows, which is given with reference to the appended drawings, which are given solely by way of example and in which: Figure 1 shows diagrammatically the process for the production of sheets of composite material according to the invention.
.15 Figure 2 is a sectional view in the plane II-II of Figure i.
Figure 3, like Figure 2, shows a sectional view of a composite sheet of variable thickness which may be obtained.
Referring first to Figures 1 and 2, the process for the production of the composite material according to the invention will be explained in more detail.
The figures are not to scale, in particular the Sthicknesses of the sheets have been considerably exaggerated so as to facilitate reading of the drawings, the Vi lengths of the sheets, on the other hand, having been i proportionally reduced.
According to the implementation example illustrated in Figure i, the sheet of thermoplastic material, such as ABS, forms at 2 at the outlet of an extruder 1 to be fed to a calendering machine comprising, in the example illustrated, three calendering rolls having reference numerals 3, 4 and 5. The thermoplastic material leaves the extruder, for example, at about 240°C, a temperature at which it is fluid.
From the inlet to the first set of calendering rolls, consisting of rolls 3 and 4, single cast panels of poly(methyl methacrylate), such as indicated by the reference numerals 7, 8 and 9, are fed from above the
P
i
I
:i 4 extruded continuous sheet 6 of thermoplastic material.
The PMMA sheets have a thickness of a few millimetres, generally of between 2.5 and 4 mm, which may, if appropriate, be reduced down to a thickness of 1 mm or, on the contrary, increased up to 7 or even 10 mm. The PMMA panels are supplied at ambient temperature and a shoulder, as shown diagrammatically at 10, forms at the inlet to the set of calendering rolls, at the join with the still fluid ABS material.
In practice, it appears that it is the choice of bringing the PM4A sheet at ambient temperature into contact with the still fluid thermoplastic material and the immediate calendering of the composite material thus 0 0 formed which ensures an excellent adhesion and join of 15 the two materials, then preventing their separation.
In an implementation example which has proved satisfactory, the panels 7 had a thickness of 3 mm, the ABS sheet 6 also had a thickness 'of 3 mm, the diameter of the calendering rolls was 300 mm and the temperatures of the rolls 3, 4 and 5 were, respectively, 80 0 C, 900C and 900C. A composite material of excellent quality resisting any separation of the two layers was obtained at a strip speed of 0.75 m/min, the composite material leaving the outlet of the third calendering roll at a temperature close to 50 to Of course, it is possible, at the initiative of theoperator, to modify the strip speed of the laminating train, to modify the laminating pressure by modifying the gap between the rolls, also to modify the number of calendering rolls and the relative thickness of the materials, or even to modify a certain speed differential between the calendering rolls 3, 4 and The PMMA panels may be translucent or transparent and in this case the apparent colour of the material will be that of the support layer 6.
If this colour is satisfactory, for example if black panels are desired, it would be possible to use conventional ABS of black colour. If it is desired to obtain another colour, the layer of thermoplastic S- material 6 could be cast using the known technique of multi-layer extrusion reserving the crude material for the thicker underlying layer and the desired colour for Sthe surface layer.
According to another technique, the PMMA panels i could be painted and decorated in any desired manner, and prior to their use, on that side which adjoins the thermoplastic material. It has actually been found that in this case the paint, which probably migrates into the PMMA panel, has no effect on the quality of the join between the two layers of composite material, in the ABS/PMMA species.
According to the implementation variant shown diagrammatically in Figure 3, it has been assumed that the PMMA panel having reference numeral 11 was combined i with a panel of thermoplastic material 12, which was of variable thickness being thinner at the edges and thicker at the centre. A sheet of this type having this type of structure may be obtained simply by providing, for example, a corresponding section of the calendering rolls i which will have a slightly larger diameter towards the edges and a smaller diameter towards the centre. This may be advantageous, for example, if, using the composite material as the starting material, it is desired to shape a bathtub for which it will generally be advantageous to obtain a greater thickness on the bottom, or even on the Ssides of the bathtub and, on the other hand, a lesser I thickness at the top and in particular at the two lateral edges. It would thus be possible to dispense with the installation of base or girdle reinforcements.
Surprisingly, the quality of the composite material obtained is excellent, combining the excellence of the surface appearance of the poly(methyl methacrylate) panel and its hardness with the rigidity of the thermoplastic material used, such as ABS, for the sublayer, the composite material being free from the defects inherent to PMMA, which is relatively sensitive to shocks and which when treated in this way acquires an exceptional resistance to such shocks.
6 In place of ABS, which has already been mentioned, numerous other thermoplastic materials could be used and the following will be mentioned in particular: PE (polyethylene), PS (polystyrene), and PP (polypropylene), which materials may or may not contain fillers.
The choice of materials and the choice of the relative thicknesses of the layers will depend on the product which must be shaped by thermoforming in a mould from the composite sheet and must be so shaped in a manner known per se. It will be mentioned only, in I general, that the poly(methyl methacrylate) sheet will be 0 able to be thinner than was necessary with the application of the known reinforcing techniques, to the extent that the composite material has an exceptional hold, in particular not being subject to any possible delamination. And in such a material, PMMA would be able, even in a thin layer, to provide the required characteristics of smooth appearance and intrinsic surface finish and hardness which it possesses.

Claims (8)

1. Ic-- r~ 7 1. Process for the production of a sheet of a composite material comprising an outer layer of a prefabricated cast panel of a poly(methyl methacrylate) and a support layer of a thermoplastic material, characterised in that, with a view to obtaining a perfect cohesion and join of the two layers to one another, it comprises: a. forming a continuous extruded sheet of said thermoplastic material employing an extruder feeding a machine comprising calendering rolls; b. supply said poly(methyl methacrylate) panels regularly to the inlet of said machine on one side of the sheet of thermoplastic material as it is formed, which poly(methyl methacrylate) panels are calendered simultaneously with the sheet of thermoplastic material between the calendering rolls of the machine, and c. cutting off sheets of composite material obtained from step that consist of the poly(methyl methacrylate) panels assembled on said support layer of thermoplastic material at the outlet of the machine having calendering rolls.
2. Process according to Claim 1, characterised in that the poly(methyl methacrylate) panels are calendered against the extruded sheet of thermoplastic material at the exit of the extruder, the first calendering action ensuring the application of the thermoplastic material while it is still fluid against the non-fluid poly(methyl methacrylate) panels.
3. Process according to Claim 1 or Claim 2, characterised in that at the inlet of the calendering machine the thermoplastic material is at its fluidity temperature at which is exits from the extruder, while the poly(methyl methacrylate) panels are at ambient temperature. A 8 8
4. Process according to any one of the preceding claims, characterised in that the thermoplastic material is ABS (polyacrylonitrile-butadiene-styrene) or PE (polyethylene), PS (polystyrene), PP (polypropylene). Process according to any one of the preceding claims, characterised in that the thermoplastic material being ABS, the temperature at which the ABS sheet is fed at the first set of calendering rolls is close to 240 0 C.
6. Process according to any one of the preceding claims, characterised in that the thickness of the poly(methyl methacrylate) panels is of the order of 1 to 7 mm and advantageously between 2.5 and 4 mm.
7. Process according to any one the preceding claims, characterised in that the poly(methyl methacrylate) panels are translucent of transparent and decorated on that side which adjoins the thermoplastic material prior to being supplied to the inlet of said machine.
8. Process according to any one of Claims 1 to 6, characterised in that the poly(methyl methacrylate) panels are translucent or transparent and which comprises forming said thermoplastic sheet by a multilayer extrusion technique with a base support layer and a coloured surface layer adjoining the poly(methyl methacrylate) panels.
9. A product consisting of a sheet of a composite material obtained according to the process of any one of the preceding claims, characterised in that it comprises an upper poly(methyl methacrylate) panel obtained by casting, joined in an inseparable manner to a support sheet of thermoplastic material. A producc according to Claim 9, characterised in that said sheet of thermoplastic material has lc-ally different thicknesses depending on the requirements for use of the finished article which will be formed by thermoforming in a mould from the sheet of composite material. DATED THIS Third DAY OF June, 1993 TECHNOPLAST (Societe Anonyme) BY SPIZZEY COMPANY PATENT ATTORNEYS PROCESS FOR THE PRODUCTION OF A SHEET OF A COMPOSITE MATERIAL COMPRISING A CAST POLY(METHYL METHACRYLATE) PANEL COMBINED WITH A THERMOPLASTIC SUPPORT LAYER AND PRODUCTS OBTAINED In the name of the company called TECHNOPLAST (Societ6 Anonyme) ABSTRACT The inventica relates to a process for the production of a composite material comprising a cast Sao poly(methyl methacrylate) panel combined with a support layer of a thermoplastic material such as ABS. According to the invention, the adhesion of the two materials is obtained by applying the poly(methyl methacrylate) panel 8, 9) by calendering to the sheet Sof continuously formed thermoplastic material from its exit from the extruder when the thermoplastic material is still fluid, while the poly(methyl meth- acrylate) panel is at ambient temperature. The invention applies in particular to the preparation of a composite material which may be used for moulding diverse articles and in particular bathtubs. Figure 1.
AU74054/91A 1990-04-27 1991-04-03 Process for the production of a sheet of a composite material comprising a cast poly (methyl methacrylate) panel combined with a thermoplastic support layer and products obtained Ceased AU639992B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9005381A FR2661364B1 (en) 1990-04-27 1990-04-27 PROCESS FOR PRODUCING A SHEET OF A COMPOSITE MATERIAL COMPRISING A PLATE OF MOLTEN METHYL POLYMETHACRYLATE JOINED WITH A THERMOPLASTIC SUPPORT LAYER AND PRODUCTS OBTAINED.
FR9005381 1990-04-27

Publications (2)

Publication Number Publication Date
AU7405491A AU7405491A (en) 1991-11-07
AU639992B2 true AU639992B2 (en) 1993-08-12

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AU74054/91A Ceased AU639992B2 (en) 1990-04-27 1991-04-03 Process for the production of a sheet of a composite material comprising a cast poly (methyl methacrylate) panel combined with a thermoplastic support layer and products obtained

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EP (1) EP0454520B1 (en)
JP (1) JPH05131559A (en)
AT (1) ATE105766T1 (en)
AU (1) AU639992B2 (en)
CA (1) CA2041138A1 (en)
DE (1) DE69102014T2 (en)
DK (1) DK0454520T3 (en)
ES (1) ES2053292T3 (en)
FR (1) FR2661364B1 (en)
LT (1) LT3566B (en)
LV (1) LV5427A3 (en)
RU (1) RU1814615C (en)
UA (1) UA19870A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103879033A (en) * 2014-04-16 2014-06-25 昆山市耐光包装材料有限公司 High-strength plastic packaging box

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US5069851A (en) * 1990-07-09 1991-12-03 Aristech Chemical Corporation ABS/Acrylic lamination process
DE9210508U1 (en) * 1992-08-06 1992-11-26 Targor GmbH, 55116 Mainz Composite panel
DE4436381A1 (en) 1994-10-12 1996-04-18 Roehm Gmbh Composites of thermoplastic layers for sanitary articles
KR100316364B1 (en) * 1997-11-04 2002-07-02 사공수영 Multilayer sheet improved with impact resistance and weatherability
ES2184329T3 (en) * 1997-11-06 2003-04-01 Lucite Int Uk Ltd METHOD FOR MANUFACTURING AN ACRYLIC ARTICLE.
PL191976B1 (en) 1997-12-05 2006-07-31 Roehm Gmbh Method of obtaining superficially hardened pmma films, suitable for use in the film-insert-moulding process, brigtened on both sides, free of gel lumps
NZ504028A (en) * 1999-04-27 2001-03-30 Sumitomo Chemical Co Method for producing multi-layer resin molded article by heat molding a multi-layer thermoplastic resin plate comprising a first surface and a second surface
FR2989616B1 (en) * 2012-04-20 2014-05-09 New Bath METHOD FOR MANUFACTURING A SHEET OF A COMPOSITE MATERIAL
CN104354426A (en) * 2014-11-19 2015-02-18 科勒(中国)投资有限公司 Filler enhanced type acrylic plate
CN107738486A (en) * 2017-10-20 2018-02-27 深圳市捷创新材料有限公司 A kind of multi-layer co-extruded high polymer material and preparation method thereof
CN112476866B (en) * 2020-10-28 2022-09-06 龙南新涛亚克力科技有限公司 Material filling equipment for mixing acrylic plates

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IT1132231B (en) * 1980-07-24 1986-06-25 Montedison Spa THERMOPLASTIC LAMINAR PRODUCT AND ITEMS OBTAINED FROM IT
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Publication number Priority date Publication date Assignee Title
CN103879033A (en) * 2014-04-16 2014-06-25 昆山市耐光包装材料有限公司 High-strength plastic packaging box

Also Published As

Publication number Publication date
AU7405491A (en) 1991-11-07
DE69102014D1 (en) 1994-06-23
DE69102014T2 (en) 1994-09-01
LT3566B (en) 1995-12-27
EP0454520B1 (en) 1994-05-18
FR2661364A1 (en) 1991-10-31
FR2661364B1 (en) 1992-07-24
RU1814615C (en) 1993-05-07
CA2041138A1 (en) 1991-10-28
LTIP1434A (en) 1995-05-25
LV5427A3 (en) 1994-03-10
DK0454520T3 (en) 1994-09-19
EP0454520A1 (en) 1991-10-30
ES2053292T3 (en) 1994-07-16
UA19870A (en) 1997-12-25
JPH05131559A (en) 1993-05-28
ATE105766T1 (en) 1994-06-15

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