CA1240248A - Multi-layer composite structure having a plastic coated ceramic enamel layer on a metal substrate - Google Patents
Multi-layer composite structure having a plastic coated ceramic enamel layer on a metal substrateInfo
- Publication number
- CA1240248A CA1240248A CA000451446A CA451446A CA1240248A CA 1240248 A CA1240248 A CA 1240248A CA 000451446 A CA000451446 A CA 000451446A CA 451446 A CA451446 A CA 451446A CA 1240248 A CA1240248 A CA 1240248A
- Authority
- CA
- Canada
- Prior art keywords
- composite structure
- layer
- plastic
- accordance
- ceramic
- 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.)
- Expired
Links
Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
-
- 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
- A47K1/00—Wash-stands; Appurtenances therefor
- A47K1/04—Basins; Jugs; Holding devices therefor
Landscapes
- Health & Medical Sciences (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- General Health & Medical Sciences (AREA)
- Laminated Bodies (AREA)
Abstract
A MULTI-LAYER COMPOSITE STRUCTURE
ABSTRACT
A composite structure, e.g., a plastic-backed enamel steel product having high impact and thermal shock resistance is disclosed. The composite structure is formed having bonded thereto, a finished layer on one side thereof, and on the other side a layer of reinforced plastic to form a laminated structure. The plastic layer has a thickness of at least 1/8 in., and a density of between about 20 lbs. per cu.ft. and about 125 lbs per cu.ft. The finished layer is resistant to delamination when subjected to relatively high impact applied directly to the finished and/or plastic layer surface and to delamination when the composite structure is subjected to a sudden temperature change of about 180°F.
ABSTRACT
A composite structure, e.g., a plastic-backed enamel steel product having high impact and thermal shock resistance is disclosed. The composite structure is formed having bonded thereto, a finished layer on one side thereof, and on the other side a layer of reinforced plastic to form a laminated structure. The plastic layer has a thickness of at least 1/8 in., and a density of between about 20 lbs. per cu.ft. and about 125 lbs per cu.ft. The finished layer is resistant to delamination when subjected to relatively high impact applied directly to the finished and/or plastic layer surface and to delamination when the composite structure is subjected to a sudden temperature change of about 180°F.
Description
I Z~:8 MULTI-LAY~R COMPOSITE STRUCTURE
HAVING A PLASTIC COAXED CERAMIC
ENAMEL LAYER ON A METAL SUBSTRATE
BACKGROUND OF THE INVENTION
.
This invention relates to a multi-layer composite structure, and in particular, to a composite structure having a plastic chemically bonded to the substrate of the composite structure to impart resistance to delamination when subjected to impact and/or thermal shock.
any attempts have been made by industry to make a multi-layer composite structure including at least a substrate of appreciable strength and stiffness, wherein the layers are resistant to delamination when subjected to high impact or when subjected to thermal shock. When subjected to high impact from either side of the structure, one of the layers, the finished layer, may deform, crack, craze, or chip, and another layer, i.e., a plastic layer, may delaminate from the substrate. Delamination may also occur when the composite structure is subjected to thermal shock.
U. S. Patent No. 3,172,775 discloses a structure of ceramic-coated asbestos fibers impregnated with a thermoplastic or thermosetting resin. The ceramic material, in the form of a Fritz is fused to the asbestos fibers. The resin is allowed to impregnate the ceramic fibers to form a bond. In U. S.
Patent No. 3,496,058, a semi-elastic layer, containing particulate material such as sand, is applied to one side of an aluminum sheet, and to this layer, a plastic foam is applied.
Jo , , Lo PZ~8 1 1 .1 1 i If the semi-elastic layer were not used, the aluminum would be dented if subjected to impact by a one-pound metal ball dropped through a distance of 3 feet. In US. Patent No. 4,053,545, a thermoplastic sheet is reinforced by injecting S a plastic foam into a mold. Bonding is achieved through melting of the thermoplastic sheet, or an adhesive coating is applied to the thermoplastic sheet to firmly bond the sheet to the foam. In US. Patent No. 4,216,294, a rigid or semi-rigid structure, such as a fiberglass-reinforced polyester panel, for example in the form of a boat, has applied thereto a polyester foam. The polyester foam is used because of its excellent adhesion to a like material. U. S. Patents j,Nos. 3,823,099 and 4,358,548 describe polyester-foam-resin ll~systems which form both rigid and flexible open-or-closed-cell foam products. The foams can be employed in operations such was spxay-up, hand-layup, press molding, expansion casting RIM or RIM, and resin-transfer molding.
SUMMARY OF THE INVENTION ~~- l -The present invention is directed to a multi-layer composite structure including at least a substrate of ¦ appreciable strength and stiffness. The composite structure is formed having at least one surface to which a layer of plastic is chemically bonded, whereby the composite structure is characterized by high resistance to impact and delamination of the plats a and finish layers from the substrate. The
HAVING A PLASTIC COAXED CERAMIC
ENAMEL LAYER ON A METAL SUBSTRATE
BACKGROUND OF THE INVENTION
.
This invention relates to a multi-layer composite structure, and in particular, to a composite structure having a plastic chemically bonded to the substrate of the composite structure to impart resistance to delamination when subjected to impact and/or thermal shock.
any attempts have been made by industry to make a multi-layer composite structure including at least a substrate of appreciable strength and stiffness, wherein the layers are resistant to delamination when subjected to high impact or when subjected to thermal shock. When subjected to high impact from either side of the structure, one of the layers, the finished layer, may deform, crack, craze, or chip, and another layer, i.e., a plastic layer, may delaminate from the substrate. Delamination may also occur when the composite structure is subjected to thermal shock.
U. S. Patent No. 3,172,775 discloses a structure of ceramic-coated asbestos fibers impregnated with a thermoplastic or thermosetting resin. The ceramic material, in the form of a Fritz is fused to the asbestos fibers. The resin is allowed to impregnate the ceramic fibers to form a bond. In U. S.
Patent No. 3,496,058, a semi-elastic layer, containing particulate material such as sand, is applied to one side of an aluminum sheet, and to this layer, a plastic foam is applied.
Jo , , Lo PZ~8 1 1 .1 1 i If the semi-elastic layer were not used, the aluminum would be dented if subjected to impact by a one-pound metal ball dropped through a distance of 3 feet. In US. Patent No. 4,053,545, a thermoplastic sheet is reinforced by injecting S a plastic foam into a mold. Bonding is achieved through melting of the thermoplastic sheet, or an adhesive coating is applied to the thermoplastic sheet to firmly bond the sheet to the foam. In US. Patent No. 4,216,294, a rigid or semi-rigid structure, such as a fiberglass-reinforced polyester panel, for example in the form of a boat, has applied thereto a polyester foam. The polyester foam is used because of its excellent adhesion to a like material. U. S. Patents j,Nos. 3,823,099 and 4,358,548 describe polyester-foam-resin ll~systems which form both rigid and flexible open-or-closed-cell foam products. The foams can be employed in operations such was spxay-up, hand-layup, press molding, expansion casting RIM or RIM, and resin-transfer molding.
SUMMARY OF THE INVENTION ~~- l -The present invention is directed to a multi-layer composite structure including at least a substrate of ¦ appreciable strength and stiffness. The composite structure is formed having at least one surface to which a layer of plastic is chemically bonded, whereby the composite structure is characterized by high resistance to impact and delamination of the plats a and finish layers from the substrate. The
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, composite structure also has high resistance to thermal Schick. Unexpectedly, it has been found that the invention is I particularly useful where the substrate is a plumbing fixture Such as an enameled-steel bathtub, shower receptor, lavatory, llkitchen sink, or a wall panel. In such a structure, the Impact . I and delamination properties are equal to or better than for cast iron, enameled steel, or fiberglass-reinforced polyester with either an acrylic or gel-coat-finished product of the same configuration.
An object of the present invention is to provide a plastic-backed enameled-steel plumbing fixture thaw is . resistant to chipping, cracking, crazing, delamination or I deformation when subjected to high impact from either the ¦ finished or the reverse side, as when compared to presently lo I available porcelainized cast-iron or enameled-steel plumbing ' products.
¦ Another object of the invention is to provide a ,¦ composite structure having bonded thereto a finished r on _ 111 one side thereof and on the other side a layer of plastic 20 Al which is resistant to delamination when subjected to thermal 11l shock.
A further objector the invention is to provide a plastic having a Solon coupling agent to bond it to an enameled-steel surface.
25 ¦ gill another object of the invention is to provide . I
it 1.
. .
12~248 an enam~led-steel composite structure having a reinforced-plastic layer chemically bonded to one side of the enameled-steel structure.
A still further object of the inversion is to provide a relatively inexpensive method for bonding a resin layer to ah enameled-steel plumbing fixture.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a top plan view of an enameled-steel bathtub constructed in accordance with the invention I Fix. 2 is an elevation Al view of one end of the bathtub of Fig. l;
Fig 3 is a top plan view of an enameled-steel vapory constructed in accordance with the invention;
¦ L Fig. 4 is an elevation Al view of the lavatory of g. 3;
if Fig. S is a top plan view of an enameled-ste ¦ _ shower receptor constructed in accordance with the invention;
Fugue is an elevation Al view of the shower receptor OF Fir s;
I¦ Fig. 7 is an isometric view of an enameled-steel I not constructed in accordance with the invention; and of Fig. 8 is a greatly enlarged sectional view taken Tom within the broken line circles of Figs. 2, 4, 6 and 7 which illustrates the composite structure of the invention.
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DETAILED DESCRIPTION OF THE INVENTION
In Figs. 1-6, enameled-steel plumber fixtures and an enameled-steel wall panel such as is used for bathtub surrounds or shower stalls are constructed in accordance with the present invention. Bathtub 10, Figs. 1 and 2, lavatory 12, Figs. 3 and 4, shower receptor 14, Figs. 5 and 6, and wall panel 16, Fig. 7 are all formed having the composite structure 20 shown in Fig. 8. Composite structure 20 includes a substrate 22 yin the form of steel to which enamel layers 24, 26 are bonded ion either side thereof. As generally practiced in the menu-l~facture of ~nam~led-steel plumbing fixtures, the enamel layers 24, 26 have a thickness in the range of about 1/64 to 1/32 ¦
of an inch. The enamel consists of inorganic oxides with a thigh concentration of silicon dioxide, forming a glassy layer Lyon fused to the steel substrate 22. after the plumbing fixture or wall panel has been enameled, a plastic layer I
us bonded to the enamel layer 26. The plastic may be applied or example, by spray-up, hand lay-up, RIM, RIM, or RUM. The thickness of the plastic layer 28 may vary. For example, in Tithe bathtub shown in Fig. 2, the side walls thereof may have a thickness of plastic as little as 1/8 of an inch and the base or sup as little as 1/4 inch. Such thicknesses are adequate lo provide an effective amount of plastic on bathtub 10 so that Kit is resistant to chipping, cracking, crazing, deformation and Z5 Illelamination when subjected to impact forces of energy levels l! l s 1245,';~9~8 to which an unreinforced product would not be resistant. Also, the plastic layer resists delamination when subjected to thermal shock.
, various resins may be used in practicing the preset , invention, for example, unsaturated polyester containing vinyl monomer, epoxy, polyurethane, isocyanurate, nylon and others.
The resin may be either foamed or unframed, with or without a filler suck as glass fibers and/or aluminum trihydrate when Bonded to an enameled-steel structure. When using unsaturated lipolyester resin containing a vinyl monomer, the bonding materials 'Ire couplers found suitable are the Solon coupling agents such as a vinyl Solon, for example, vinyl benzylamino) ethyl amino llpropyltrimethoxy Solon.
Al The resin can be filled to provide reinforcement by 15 l¦ any suitable material, for example: glass spheres, fibers and weaves; ceramic spheres and fibers; boron; carbon fibers;
graphite; wollastonite; an aromatic polyamide pharaoh - _ Dupont Co., and others.
I¦ The enameled-steel fixture is incorporated into 'if the composite structure by means of insert-molding techniques.
Al The resin mixture is introduced into the mold to provide a ¦¦ packing factor of from about 20% to 100%. The packing factor ¦¦ it the ratio of the volume of resin mixture to the volume of the mold.
SUE . I
I ' ` 1, lZ4~Z48 A typical resin mixture is formulated of the i , following compounds and materials:
, , , l Parts Unsaturated Polyester Resin Containing 100 ¦ Vinyl Monomer (Pioneer 236)~
ll~luminum Trihydrate 10 I Chopped Fiberglass OF 832-FC) 5 ¦ no Hydroperoxide 0.5 ¦~imethylèthanolamine 3.5 Polyethylene Polyphenylis~ocyanate 10 (Upjohn Pap 901)~
silicone Surfactant Dow Corning 193) 0.3 pigment 0.5 Water 0.25 In practicing the invention, it is preferred that eye RIM or ROY process be employed although other means for plying the resin, whether it is foamed or unframed, may be use. For example, an en~neled-steel plumbing fixture~R~r-as t bathtub is placed in a mold in which a resin, such as an unsaturated polyester containing a vinyl monomer, with or without a filler, a reinforcement, a surfactant, a catalyst, blowing agent and a vinyl Solon coupler which can be part of the mixture or can be applied to the fixture as a primer are mixed under high pressure, injected into the mold, and allowed to cure. The mold cycle is at least 1 minute for particulate composite structures or about 3 minutes for a bathtub. The ~lnameled-steel bathtub is removed from the mold. The resulting ; I -7-1!
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. I, ,, . . .
; I/
lZ~,'Z~8 plastic-backed bathtub has bonded thereto a resin foam layer of an unsaturated polyester-polyureth~ne copolymer which is resistant to delamination when subjected either to high impact forces or thermal shock. Further, the finished enamel surface 24 is resistant to chipping, cracking, or crazing when subjected to direct impact forces and resists deformation and pop-off of the finished layer when subjected to reverse forces such juicy are encountered during installation or shipping Al - The physical properties and characteristics of the llplastic-backed enameled-steel composite structure are equal to 'o'er better than most of the physical properties or characteristics of existing state-of-the-art saunterer products. The improved product performance is exemplified by the impact latest results shown in the following tables Table I shows Lithe impact that is required to cause damage to the finished llsurface when the impact is applied to the finished surface of Thea saunterer and is the type of damage that may result after wits installation. Tale II shows the results of the reverse-impact test, that is, when the load is applied to the plastic-lacked surface of the saunterer and is the type of damage caused by handling, trucking, and installation.
I Testing procedure followed is that of American National , Standard Z 124.1-1980 4.3 Impact Loads except that the test area has a 3" unsupported diameter.
I -U-1' .
.
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124~Z~3 TALE I
Direct Impact Jo Impact To Cause Damage Saunterer To Finished Surface(Ft-L~?
ilFiberglass-Reinforced Polyester/Gel Coat 1.50 i),Fiberglass-Reinforced Polyester/Acrylic 2 00(3) Enameled Steel 1.25 Enameled Cast Iron 1.75 jIPlastic-Backed Enameled Steel I of the Present Invention 2.50 If TABLE II
induct Impact . Impact To Cause D~mage(21 ¦ISanitaryware To Finished surfac~F~t.-Lb) Fiberglass Reinforced Polyester/Gel Coat 1.0 Fiberglass-Reinforced Polyester Acrylic 2.5 If enameled Steel 1 - 2- .. _ Enameled Cast Iron 1 - 2 Plastic-backed Enameled Steel of the Present Invention S
I Damage is defined as a craze, dent or material delamination I ¦ of the finished surface layer.
I (3) ! Incipient structural damage with surface cracking observed et on impact energy level of 4.0 ft-lbs.
-' 'i '.
48` ,1 , ' Another physical property of the plastic-backed enameled steel structure of the eye invention is its ability to resist thermal shock. A product such as a wall panel is subjected to temperatures of approximately 180F, thereafter the panel is removed from the temperature source and pleased in a temperature environment of zero degrees or below, for example, a freezer. Tube change in temperature of 180F
does not cause delamination of the plastic layer from the enwomb led-steel panel.
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Al !
, . ' 124~48 ., , !
, composite structure also has high resistance to thermal Schick. Unexpectedly, it has been found that the invention is I particularly useful where the substrate is a plumbing fixture Such as an enameled-steel bathtub, shower receptor, lavatory, llkitchen sink, or a wall panel. In such a structure, the Impact . I and delamination properties are equal to or better than for cast iron, enameled steel, or fiberglass-reinforced polyester with either an acrylic or gel-coat-finished product of the same configuration.
An object of the present invention is to provide a plastic-backed enameled-steel plumbing fixture thaw is . resistant to chipping, cracking, crazing, delamination or I deformation when subjected to high impact from either the ¦ finished or the reverse side, as when compared to presently lo I available porcelainized cast-iron or enameled-steel plumbing ' products.
¦ Another object of the invention is to provide a ,¦ composite structure having bonded thereto a finished r on _ 111 one side thereof and on the other side a layer of plastic 20 Al which is resistant to delamination when subjected to thermal 11l shock.
A further objector the invention is to provide a plastic having a Solon coupling agent to bond it to an enameled-steel surface.
25 ¦ gill another object of the invention is to provide . I
it 1.
. .
12~248 an enam~led-steel composite structure having a reinforced-plastic layer chemically bonded to one side of the enameled-steel structure.
A still further object of the inversion is to provide a relatively inexpensive method for bonding a resin layer to ah enameled-steel plumbing fixture.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a top plan view of an enameled-steel bathtub constructed in accordance with the invention I Fix. 2 is an elevation Al view of one end of the bathtub of Fig. l;
Fig 3 is a top plan view of an enameled-steel vapory constructed in accordance with the invention;
¦ L Fig. 4 is an elevation Al view of the lavatory of g. 3;
if Fig. S is a top plan view of an enameled-ste ¦ _ shower receptor constructed in accordance with the invention;
Fugue is an elevation Al view of the shower receptor OF Fir s;
I¦ Fig. 7 is an isometric view of an enameled-steel I not constructed in accordance with the invention; and of Fig. 8 is a greatly enlarged sectional view taken Tom within the broken line circles of Figs. 2, 4, 6 and 7 which illustrates the composite structure of the invention.
Al I I
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``'' 1,, .: - , ` . . _ lZ45~Z48 'i.
DETAILED DESCRIPTION OF THE INVENTION
In Figs. 1-6, enameled-steel plumber fixtures and an enameled-steel wall panel such as is used for bathtub surrounds or shower stalls are constructed in accordance with the present invention. Bathtub 10, Figs. 1 and 2, lavatory 12, Figs. 3 and 4, shower receptor 14, Figs. 5 and 6, and wall panel 16, Fig. 7 are all formed having the composite structure 20 shown in Fig. 8. Composite structure 20 includes a substrate 22 yin the form of steel to which enamel layers 24, 26 are bonded ion either side thereof. As generally practiced in the menu-l~facture of ~nam~led-steel plumbing fixtures, the enamel layers 24, 26 have a thickness in the range of about 1/64 to 1/32 ¦
of an inch. The enamel consists of inorganic oxides with a thigh concentration of silicon dioxide, forming a glassy layer Lyon fused to the steel substrate 22. after the plumbing fixture or wall panel has been enameled, a plastic layer I
us bonded to the enamel layer 26. The plastic may be applied or example, by spray-up, hand lay-up, RIM, RIM, or RUM. The thickness of the plastic layer 28 may vary. For example, in Tithe bathtub shown in Fig. 2, the side walls thereof may have a thickness of plastic as little as 1/8 of an inch and the base or sup as little as 1/4 inch. Such thicknesses are adequate lo provide an effective amount of plastic on bathtub 10 so that Kit is resistant to chipping, cracking, crazing, deformation and Z5 Illelamination when subjected to impact forces of energy levels l! l s 1245,';~9~8 to which an unreinforced product would not be resistant. Also, the plastic layer resists delamination when subjected to thermal shock.
, various resins may be used in practicing the preset , invention, for example, unsaturated polyester containing vinyl monomer, epoxy, polyurethane, isocyanurate, nylon and others.
The resin may be either foamed or unframed, with or without a filler suck as glass fibers and/or aluminum trihydrate when Bonded to an enameled-steel structure. When using unsaturated lipolyester resin containing a vinyl monomer, the bonding materials 'Ire couplers found suitable are the Solon coupling agents such as a vinyl Solon, for example, vinyl benzylamino) ethyl amino llpropyltrimethoxy Solon.
Al The resin can be filled to provide reinforcement by 15 l¦ any suitable material, for example: glass spheres, fibers and weaves; ceramic spheres and fibers; boron; carbon fibers;
graphite; wollastonite; an aromatic polyamide pharaoh - _ Dupont Co., and others.
I¦ The enameled-steel fixture is incorporated into 'if the composite structure by means of insert-molding techniques.
Al The resin mixture is introduced into the mold to provide a ¦¦ packing factor of from about 20% to 100%. The packing factor ¦¦ it the ratio of the volume of resin mixture to the volume of the mold.
SUE . I
I ' ` 1, lZ4~Z48 A typical resin mixture is formulated of the i , following compounds and materials:
, , , l Parts Unsaturated Polyester Resin Containing 100 ¦ Vinyl Monomer (Pioneer 236)~
ll~luminum Trihydrate 10 I Chopped Fiberglass OF 832-FC) 5 ¦ no Hydroperoxide 0.5 ¦~imethylèthanolamine 3.5 Polyethylene Polyphenylis~ocyanate 10 (Upjohn Pap 901)~
silicone Surfactant Dow Corning 193) 0.3 pigment 0.5 Water 0.25 In practicing the invention, it is preferred that eye RIM or ROY process be employed although other means for plying the resin, whether it is foamed or unframed, may be use. For example, an en~neled-steel plumbing fixture~R~r-as t bathtub is placed in a mold in which a resin, such as an unsaturated polyester containing a vinyl monomer, with or without a filler, a reinforcement, a surfactant, a catalyst, blowing agent and a vinyl Solon coupler which can be part of the mixture or can be applied to the fixture as a primer are mixed under high pressure, injected into the mold, and allowed to cure. The mold cycle is at least 1 minute for particulate composite structures or about 3 minutes for a bathtub. The ~lnameled-steel bathtub is removed from the mold. The resulting ; I -7-1!
" . I
. I, ,, . . .
; I/
lZ~,'Z~8 plastic-backed bathtub has bonded thereto a resin foam layer of an unsaturated polyester-polyureth~ne copolymer which is resistant to delamination when subjected either to high impact forces or thermal shock. Further, the finished enamel surface 24 is resistant to chipping, cracking, or crazing when subjected to direct impact forces and resists deformation and pop-off of the finished layer when subjected to reverse forces such juicy are encountered during installation or shipping Al - The physical properties and characteristics of the llplastic-backed enameled-steel composite structure are equal to 'o'er better than most of the physical properties or characteristics of existing state-of-the-art saunterer products. The improved product performance is exemplified by the impact latest results shown in the following tables Table I shows Lithe impact that is required to cause damage to the finished llsurface when the impact is applied to the finished surface of Thea saunterer and is the type of damage that may result after wits installation. Tale II shows the results of the reverse-impact test, that is, when the load is applied to the plastic-lacked surface of the saunterer and is the type of damage caused by handling, trucking, and installation.
I Testing procedure followed is that of American National , Standard Z 124.1-1980 4.3 Impact Loads except that the test area has a 3" unsupported diameter.
I -U-1' .
.
, l ': !
124~Z~3 TALE I
Direct Impact Jo Impact To Cause Damage Saunterer To Finished Surface(Ft-L~?
ilFiberglass-Reinforced Polyester/Gel Coat 1.50 i),Fiberglass-Reinforced Polyester/Acrylic 2 00(3) Enameled Steel 1.25 Enameled Cast Iron 1.75 jIPlastic-Backed Enameled Steel I of the Present Invention 2.50 If TABLE II
induct Impact . Impact To Cause D~mage(21 ¦ISanitaryware To Finished surfac~F~t.-Lb) Fiberglass Reinforced Polyester/Gel Coat 1.0 Fiberglass-Reinforced Polyester Acrylic 2.5 If enameled Steel 1 - 2- .. _ Enameled Cast Iron 1 - 2 Plastic-backed Enameled Steel of the Present Invention S
I Damage is defined as a craze, dent or material delamination I ¦ of the finished surface layer.
I (3) ! Incipient structural damage with surface cracking observed et on impact energy level of 4.0 ft-lbs.
-' 'i '.
48` ,1 , ' Another physical property of the plastic-backed enameled steel structure of the eye invention is its ability to resist thermal shock. A product such as a wall panel is subjected to temperatures of approximately 180F, thereafter the panel is removed from the temperature source and pleased in a temperature environment of zero degrees or below, for example, a freezer. Tube change in temperature of 180F
does not cause delamination of the plastic layer from the enwomb led-steel panel.
I, I . ` ' it , 1! `
Claims (17)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A thermal-shock resistant composite structure comprising:
a metal substrate having a ceramic enamel layer on at least one side thereof;
said ceramic enamel layer having bonded thereto a layer of plastic including a silane coupler to form a reinforced laminate;
said plastic layer having a thickness of at least 1/8 in. and having a density between about 20 lbs. per cu. ft. to about 125 lbs. per cu. ft. whereby said plastic layer is resistant to delamination when subjected to a sudden temperature change of at least about 180°F.
a metal substrate having a ceramic enamel layer on at least one side thereof;
said ceramic enamel layer having bonded thereto a layer of plastic including a silane coupler to form a reinforced laminate;
said plastic layer having a thickness of at least 1/8 in. and having a density between about 20 lbs. per cu. ft. to about 125 lbs. per cu. ft. whereby said plastic layer is resistant to delamination when subjected to a sudden temperature change of at least about 180°F.
2. The composite structure in accordance with claim 1 in which said plastic layer has a thickness of at least about 1/8 inch.
3. The composite structure in accordance with claim 1 in which the structure has the configuration of a plumbing fixture.
4. The composite structure in accordance with claim 1 in which said plastic is a foam having a packing factor between about 20% and about 100% by volume.
5. A high-impact composite structure comprising:
a metal substrate having a ceramic enamel layer on at least one side thereof;
said ceramic enamel layer having bonded thereto a layer of plastic to form a high-impact-resistant laminate and a finished layer on the other side of said substrate;
said plastic layer including a silane coupler and having a thickness of at least 1/8 in. and a density of about 20 lbs. per cu. ft. to about 125 lbs. per cu. ft.
whereby said plastic layer of said composite structure is resistant to delamination when subjected to an impact of at least about 2.0-lbs. applied to the finished layer and when an impact of at least about 3.0 ft.-lbs. is applied to the surface of said plastic layer.
a metal substrate having a ceramic enamel layer on at least one side thereof;
said ceramic enamel layer having bonded thereto a layer of plastic to form a high-impact-resistant laminate and a finished layer on the other side of said substrate;
said plastic layer including a silane coupler and having a thickness of at least 1/8 in. and a density of about 20 lbs. per cu. ft. to about 125 lbs. per cu. ft.
whereby said plastic layer of said composite structure is resistant to delamination when subjected to an impact of at least about 2.0-lbs. applied to the finished layer and when an impact of at least about 3.0 ft.-lbs. is applied to the surface of said plastic layer.
6. The composite structure in accordance with claim 5 in which said composite structure has the configuration of a plumbing fixture.
7. The composite structure in accordance with claim 5 in which said substrate is a ceramic enameled-steel bathtub.
8. The composite structure in accordance with claim 5 in which said substrate is a ceramic enameled-steel sink.
9. The composite structure in accordance with claim 5 in which said substrate is a ceramic enameled-steel shower receptor.
10. The composite structure in accordance with claim 5 in which said substrate is a ceramic enameled wall panel.
11. The composite structure in accordance with claim 5 in which said plastic is an unsaturated polyester-polyurethane copolymer.
12. The composite structure in accordance with claim 5 in which said plastic is reinforced by a material selected from the group consisting of glass spheres, glass fibers, glass weaves, ceramic fibers, ceramic spheres, boron, carbon and graphite fibers, wollastonite and aromatic polyamide fiber.
13. The composite structure in accordance with claim 12 in which said plastic is a glass-reinforced unsaturated polyester-polyurethane copolymer.
14. The composite structure in accordance with claim 5 in which said plastic is an unsaturated polyester-poly-urethane copolymer foam and may be porous or nonporous or combinations thereof.
15. The composite structure in accordance with claim 5 in which said plastic contains a surfactant.
16. The composite structure in accordance with claim 1 wherein said coupler is a 3[2(vinyl benzylamino)ethylamino]
propyltrimethoxy silane.
propyltrimethoxy silane.
17. The composite structure in accordance with claim 5 wherein said coupler is a 3[2(vinyl benzylamino)ethylamino]
propyltrimethoxy silane.
propyltrimethoxy silane.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US51438383A | 1983-07-15 | 1983-07-15 | |
| US514,383 | 1983-07-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1240248A true CA1240248A (en) | 1988-08-09 |
Family
ID=24046911
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000451446A Expired CA1240248A (en) | 1983-07-15 | 1984-04-06 | Multi-layer composite structure having a plastic coated ceramic enamel layer on a metal substrate |
Country Status (9)
| Country | Link |
|---|---|
| JP (1) | JPS6038147A (en) |
| KR (1) | KR910008869B1 (en) |
| BR (1) | BR8402924A (en) |
| CA (1) | CA1240248A (en) |
| GB (1) | GB2146266B (en) |
| HK (1) | HK81389A (en) |
| MX (1) | MX170101B (en) |
| SG (1) | SG6888G (en) |
| ZA (1) | ZA842638B (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5167706A (en) * | 1990-12-04 | 1992-12-01 | American Standard Inc. | Silane primer composition |
| EP0517974A1 (en) * | 1991-06-12 | 1992-12-16 | Hosny Henry Mady | Process for lining metal or plastic surface to support pre-shaped products and products produced therewith |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL271840A (en) * | 1961-03-23 | 1900-01-01 | ||
| GB1092473A (en) * | 1965-01-23 | 1967-11-22 | W R Midwinter Ltd | Improvements relating to ceramic ware |
| GB1239217A (en) * | 1967-07-28 | 1971-07-14 | ||
| FR2289583A1 (en) * | 1974-10-29 | 1976-05-28 | Ugine Kuhlmann | COATING COMPOSITIONS BASED ON POLYTETRAFLUORETHYLENE |
| WO1979000716A1 (en) * | 1978-03-06 | 1979-10-04 | Glacier Metal Co Ltd | Improvements in or relating to bonding plastics materials to steel |
| GB2111861B (en) * | 1981-12-22 | 1985-05-01 | Armourcote Surface Treatments | Improvements in methods of coating surfaces to render them abrasion resistant |
| GB2120956B (en) * | 1982-05-26 | 1985-12-04 | Setsco Private Limited | Process for decorative surface colouring and frosting |
-
1984
- 1984-04-06 CA CA000451446A patent/CA1240248A/en not_active Expired
- 1984-04-10 ZA ZA842638A patent/ZA842638B/en unknown
- 1984-05-08 MX MX0201275A patent/MX170101B/en unknown
- 1984-06-15 BR BR8402924A patent/BR8402924A/en not_active IP Right Cessation
- 1984-07-11 GB GB08417701A patent/GB2146266B/en not_active Expired
- 1984-07-13 JP JP59144554A patent/JPS6038147A/en active Granted
- 1984-07-14 KR KR1019840004166A patent/KR910008869B1/en not_active IP Right Cessation
-
1988
- 1988-02-02 SG SG68/88A patent/SG6888G/en unknown
-
1989
- 1989-10-12 HK HK813/89A patent/HK81389A/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| ZA842638B (en) | 1984-11-28 |
| JPS6038147A (en) | 1985-02-27 |
| GB2146266B (en) | 1987-07-01 |
| SG6888G (en) | 1988-06-17 |
| HK81389A (en) | 1989-10-20 |
| MX170101B (en) | 1993-08-06 |
| GB8417701D0 (en) | 1984-08-15 |
| KR910008869B1 (en) | 1991-10-24 |
| KR850001080A (en) | 1985-03-14 |
| BR8402924A (en) | 1985-05-14 |
| GB2146266A (en) | 1985-04-17 |
| JPH0419933B2 (en) | 1992-03-31 |
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Legal Events
| Date | Code | Title | Description |
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| MKEX | Expiry |