DE2104254A1 - Imitation products and processes for their manufacture - Google Patents

Description

Priority: 2.2.197oi V.St.A .; No. 7724

The invention relates to imitation products, in particular wood, marble or gold leaf imitations, which are made from a plastic foam connected patterned film exist, as well as a process for the production of such imitation products.

It is already known to foam a foam substrate in one form. After foaming, the mold is opened and over A vacuum is applied to the openings in the foam so that a film is laminated with the help of this negative pressure can be. The fact that the foam has openings therethrough increases the strength of the substrate very deteriorated. In addition, it is not always advantageous to open the mold before lamination or lamination (US patent 2 8o6 812).

It is also known to use a male mold for vacuum forming a thin plastic film, which is then attached to a preformed, metal insert provided with holes is attached. After that, a foamable liquid plastic is used around it

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poured. ' During foaming, the plastic fills the space in the molded film (US Pat. No. 3,088,539). This The method has the disadvantage that a preform and separate handling of the film as well as a reinforcement insert are required is.

Finally, the use of a pre-embossed surface as an imitation product is known on its upper side Plastic foam is deposited (US Patent 3 4o2 52o) With this product it is necessary to provide additional work steps, which are required by the pre-stamping.

The object of the present invention is to create an imitation product of the type mentioned at the outset which has sufficient strength, a desired, very real-looking pattern or color, and in a simple manner is to be established.

In the case of the imitation product, this task becomes the one described at the beginning Art solved in that the plastic foam substrate, no openings or breakthroughs or perforations and the shape or shape of the painful film is only fixed by the plastic foam substrate. The film can at least be partially transparent and arranged over a color layer forming a contrast to the pattern, the Contrasting color contained throughout the substrate, painted on the bottom of the film or laminated as a second colored film can be.

Such an imitation product can be used very inexpensively as part of furniture, as a beam and the like, wherein Raised or recessed embossments can be provided, the shape of which is retained by the foam and the film is granted.

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The method for producing the imitation according to the invention products is characterized by the fact that a relatively thin, thermally deformable thermoplastic film is heated until it is limp and easy to pull, this film is held in a form pressed against a molded part and the form with liquid foamable plastic is at least partially filled, which exerts a pressure when foaming in the closed mold, after closing the mold with a preferably gas-permeable mold bottom, foaming and then curing take place, with Film and foam are adhesively connected, and that the product formed is ejected from the mold.

If necessary, the product can pass through after being ejected a cooling fluid can be quenched. The film is expedient to about 65 to 2o5 C for a time of about 5 to 609SC is heated and pressed against the mold by vacuum or overpressure held down.

With reference to the accompanying drawings, the invention is exemplified in more detail.

Fig. 1 shows a film with wood grain.

Fig. 2 shows in perspective a mold and a mold frame.

Fig. 3 shows the vacuum bed in perspective.

Fig. 4 shows the mold and mold frame arranged in the vacuum bed.

Fig. 5 shows in perspective the holding frame and film in the form before applying the vacuum.

FIG. 6 shows, in a view like FIG. 5, that under vacuum foil drawn against the mold.

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Fig. 7 shows the filling of the dex * form with foamable plastic.

Fig. 8 shows in perspective the shape and frame, holding frame and the pressure plates during foaming.

9 schematically shows an optionally executable blocking of the product produced after removal of the film protruding from the edges.

Fig. Io and loa show from above or in cross section a according to furniture part manufactured according to the invention.

In FIG. 1, the film or film made of plastic has an imitated grain 2.

In Fig. 2 the mold frame 3 and in the frame a flexible mold k is shown, which preferably consists of an elastomer. A pattern 5 is arranged in the mold 4, and holes 6 are also provided for applying a vacuum.

In Fig. 3, a vacuum bed 7 has vacuum openings 8 in the top. A conventional device, not shown, for creating the vacuum is via a connection to the openings 8 connected.

In FIG. K , a vacuum bed 7 ″ vacuum openings 8 and a mold frame 31 containing the mold are again shown. The holding or clamping frame for the film can be moved in and out of a heating furnace, not shown, on rails Io, the rails Io only being shown in FIG. 3 for the sake of simplicity

are shown. A press plate 11 can by a not shown herk «!".? ». liche device raised on rods 12 or be lowered.

In Fig. 5, a film 13 is clamped in the clamping frame 9 by conventional means not shown. The clamping frame is in position above the shape k and the

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Mold frame 3> for pulling the film against the mold is ready when vacuum is applied.

FIG. 6 shows, like FIG. 5, the one drawn against the mold under vacuum Film 13

In the same view as FIG. 6, FIG. 7 shows the pouring of the foamable plastic 1k from the pipe 15 into the vacuum-held film 13.

FIG. 8 shows, similar to FIG. 4, the Klenimrahmen 9 in its Position over the mold and the press plate 11 over the clamping frame in the arrangement in which the foaming of the plastic he follows.

9j Io and loA show the composite product l6. In Fig. 9 it is quenched in a fluid 17, for example water, in order to avoid warping or warping. The deterrent can be done optionally and is often not necessary. With 5 'is corresponding to the reference number 5 in Fig. 2 that in the product trained pattern called.

As shown in FIG. 10A, the film, which is shown reinforced for the sake of clarity, is firmly connected to the foamed plastic 14 'which has been formed by foaming from the liquid 1k according to FIG.

For simplification, the pattern is on the film, bexspxelswexse the wood grain 2 in Fig. 1, shown only stylized in this figure.

The following explanations are provided for further illustration the invention.

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The plastic film chosen should be a thermoplastic material that is capable of pulling itself when appropriate Manufacturing temperatures, for example at about 65 ° C to 2o5 C thermoforming. The particular temperature used can of course depend on the thickness of the film, in particular the type of film used and the vacuum applied change.

For practical purposes, the films used should generally have the following physical and technical properties:

A) Physical properties

1) Thickness 0.5 mm or less, preferably 0.05 to o, 25 mm

2) Tensile strength (ASTM D882-61T)> 0.7 kg / mm ²

3) Elongation (ASTM d882-61T)> Io %

4) burst strength at _f o o25 mm strength (ASTM D774-63T)

^, Io Mullen points

5) Tear strength (ASTM Dloo4-6l)> o, ol8 kg / mm ² (l, o lb / inch)

B) Technical characteristics

1) Printable, thermoformable, dimensionally stable with normal Environmental conditions of temperature, pressure and humidity.

2) Handleable rolled or as a sheet

Examples of suitable film materials are cellulose acetate, cellulose triacetate, cellulose acetate butyrate, cellulose propionate, ethyl cellulose, FEP-fluoro-plastic, Polytrifluoi'chloräthylenmischpolymerisate, Polytetrafluoräthylenpolymerisate, PoIyvinylfluoride, polyethylene of low, medium and high density ethylene-vinyl acetate copolymers, polycarbonates, polyamides, such as nylon 6, nylon 6/6 and nylon 12, polypropylene,

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Polyesters such as polyethylene terephthalate, polyvinyl chloride, Vinyl chloride-acetate copolymers, vinylidene chloride-vinyl chloride copolymers, Vinyl nitrile rubber products, polystyrene, ABS, ionomers, polyimides, polyurethane elastomers, expanded polystyrene foam, rubber hydrochloride and polyester films.

The properties of these films are described in the reference "Modern Plastics Encyclopedia", 1968-1969, pages 52k to 528 «

The selection of the foamable liquid plastic for the production of the substrate depends on the fact that it is foamed exerts pressure. For example, foamable materials as described in Handbook of Foamed Plastics, - Bender, Lake Publishing Corp., 1965, pp Io and 11, are described. Such substances are, for example, cellulose acetate, styrene copolymer, epoxy, phenol, Polystyrene, polyurethane, polyvinyl chloride, polyester, silicone and urea-formaldehyde foams.

Foam is the preferred substrate for imitation wood, which has a density that is close to "wood", especially hard furniture wood. To achieve this, the amount of regulates the propellant used in the foam. In certain circumstances it may be desirable in the foam as well Bring filler.

According to the invention, preferred films are plasticized or non-plasticized vinyl films, for example rigid polyvinyl chloride films, flexible polyvinyl chloride films and vinyl chloride / acetate mixed polymer films, furthermore cellulose acetobutyrate films, acrylic films, for example a Korad A polymethyl methacrylate film, polyester Films such as Mylar (polyethylene terephthalate) and other glycol terephthalate derivative films and cellulose acetate films.

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Polyurethane foam, which is the reaction product of a polyether polyol having a hydroxyl group number in the range, is preferred from about 25o to 5oo, preferably 3 ° o to 4oo, with one Is isocyanate. Examples of suitable polyols are the reaction products of sucrose, sorbitol or methyl glucoside with Ethylene and / or propylene oxide. The isocyanate can either be monomeric, such as tolylene diisocyanate, or polymeric, such as metaphenylene diisocyanate be. Numerous other common diisocyanates can also be used to form foam. Normally is used to initiate the foaming reaction a tertiary amine catalyst, although other known catalysts for example tin-II-octoate and other tin catalysts can be used. To create the bubbles in water or a fluorocarbon blowing agent such as Freon II is conventionally used in the foam. Under certain Surface treatment agents are sometimes used as additives to, for example, a silicone such as Dow-Corning DC 193> to achieve even bubbles. If so desired, give conventional modifiers such as Unioncarbide PPG 2o25 or Monsanto Phosgard C22R. To achieve special foam properties, to achieve elasticity and flame retardancy,

A preferred temperature range when using a plasticized ' Vinyl film, for example a polyvinyl chloride film 0.05 mm thick, extends from about 100 ° C. to about 115 ° C.

The vacuum applied in the process according to the invention is from 38 ° to 760 Torr, preferably from 560 to 660 Torr.

If desired, certain films by use of fluid pressure, such as air, are heated pre-stretched, wherein the fluid pressure for a few seconds before applying the vacuum to said holes, acts by Vakuumöffmingen. Sometimes it may also be desirable to have a print

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is applied on the side of the film opposite the vacuum to make the film tightly against the mold. The inventive The device is then adapted accordingly. In each of these cases the pressure used is between O and 3.5 kg / cm.

The temperature ranges described above are obtained by heating the film for about 5 to 6oSec suspends. However, any conventional type of heating and residence time can be used if they are of the desired type. Production speed corresponds.

Although the film and foam of the composite product already work well together In many cases it is desirable to use an adhesive between the film and the foam. This glue can be applied to the inner surface of the film before the foam is deposited either during film production or during the Film is held in the mold by vacuum, for example applied by spraying or coating before filling the mold will.

Examples of suitable adhesives are heat-activated adhesives M such as a linear polyurethane elastomer which is modified with vinyl and chlorinated rubber copolymers (Inraont Corporation, No. 31o ^ 3) »pressure-sensitive adhesives such as a styrene-butadiene block polymer which is made with an isoprene and a glycerol ester a hydrogenated resin (Inmont Corporation No. 31209), two-part adhesives such as a bisphenol--type epoxy resin (SW Chemical Co. Epon 828) which is cured with tridimethylaminomethylphenol (Shell DMP-30), and Hot melt adhesive, such as tall oil resin (Inmont Corporation No. F-153-63A) modified with an ethylene-vinyl acetate copolymer.

Instead of an adhesive painted or sprayed onto the inner surface of the film held by vacuum, the

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Foil can be covered with a layer during its manufacture, which reacts with the expanding foam. Uin respond too this layer should contain reaction groups, for example a component with active hydrogen sites. For example, such a layer contains a hydroxyl-modified one Vinyl chloroacetate material (Vinylite VAGII, Union Carbide Corporation).

The wood grain initiation can be printed on the foils or applied by the silk screen method. Other possible patterns are, for example, marble or gold sheet.

The patterned foils should be conventional furniture polishes accept directly or after applying an intermediate layer. Examples of such preferred films are films from Korad A and from cellulose acetobutyrate.

To be able to imitate wood or other patterned products, it is necessary to have a contrast between the grain or to have a different pattern and background of the grain. Such contrast can be achieved in several different ways be achieved.

For example, a printed film is transparent with the exception of the areas covered by the printed grain are. The foam substrate can be colored so that it contrasts with the grain on the film. This method has the advantage that different types of wood can be imitated using the same type of film by merely using the color of the foam is changed. Suitable dyes are, for example, carbon black and iron oxide.

However, a coating of contrasting color can also be sprayed or sprayed onto the inside of the transparent printed film

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otherwise applied before the foam is deposited, either during film manufacture or during Foil is held in place by vacuum before filling. Of the The aforementioned reactive coating can be used if desired be colored with a contrasting surface color.

Finally, a second film with a contrasting color can also be used behind the transparent film on which the grain appears, be used. The two foils are expediently produced as a laminate.

It is preferred to use an elastomeric form in which the process according to the invention can be carried out particularly advantageously leaves, since the printed film protects the surface of the form and thus serves as a pull-off device, whereby such a additional setup is not required. Since elastomeric forms generally have a relatively short lifespan, such protection is a clear advantage.

Another advantage of the method according to the invention results by the fact that carvings or reliefs, which are made in the form of elastomeric material, in a simple way can be produced in large numbers.

The following examples serve to further illustrate the invention.

example 1

An elastomeric form is made by first building a wooden container open at the top and then inside it with the front an original of a furniture part to be copied is arranged upwards. This part is held in place by that it is attached to the bottom of the container with screws.

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Both the inside of the container and the furniture part are then coated with wax, which serves as a release agent. A conventional two-part cast urethane elastomer (Conap. TU-75) compound 5 is then mixed, vented and poured over the model so that the container is completely filled. The elastomer is then allowed to cure for 2k hours at room conditions and then removed from the original part. After drilling vacuum holes in the key places, the mold is ready to use.

Example 2

The elastomeric mold made by the procedure of Example 1 is attached to a vacuum bed similar to that shown in FIG. The vacuum pressure is adjusted to 760 Torr and the heating furnace output so that a film temperature of II3 to II8 C is obtained after 60 seconds in the furnace. A piece of 0.1 mm thick, semi-rigid vinyl film printed with a wood grain pattern in a conventional manner is clamped in a clamp frame as shown in FIG. 5 prior to heating and vacuum formed in the manner shown in FIG . A liquid polyurethane foaming in place is applied to the vacuum held film. After foaming, the polyurethane composition has a density of 0.2 g / cm. The polyurethane is made from the following materials:

Polyglycol derivative of sucrose

(Dow Voranol RB - 3 ^ o) 9o parts by weight

Trichlorofluoromethane as propellant 5 " " active additive triethylenediamine

(DABCO 80/20 catalyst,

Houdry Process and Chemical Co.) o.5 ""

Silicon (Dow Corning DC 193) 1.5 ""

Water ο, 2 "»

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These substances are mixed and then mixed with 79 parts of a polymeric isocyanate based on methylenediphenyl diisocyanate (Mondur MR) mixed, whereby the foamable mixture is formed. The mixture is poured into the mold, a gas-permeable lid, in the present case wrapping paper under a plate, placed on the mold. The foam is then allowed to expand for 15 minutes. The product obtained will be removed and excess foil cut off. In this way you have a piece of furniture made of foil and foam that looks like the front wall of a wooden chest of drawers.

Example 3

-A 0.14 mm thick printed acrylic film (Korad A) is included with coated with a heat activated urethane adhesive, heat deformed and foamed in the same manner as in the previous example, except that the foam is prepared as follows:

70 parts by weight of polyester, which are made from Il6 parts of fumaric acid and Io6 parts of diethylene glycol, are mixed with 30 parts of styrene and 12.5 parts of NaIICO, to which k parts of benzoyl peroxide (as a 50% paste in dimethyl phthalate) and 0.75 parts of myristyl alcohol are added will. A separately prepared solution of 6.9 parts of HCOOH, 2.5 parts of water and 0.5 parts of dimethyl-p-toluidine is quickly added to the above mixture.

The furniture parts produced in this way have a good look in the details protruding pattern, for example an excellent grain, bubble and empty space-free surfaces and look not like plastic. Such furniture parts are particularly suitable for the use of television housings, for imitiex'te Gold leaf mirrors and picture frames as well as for smooth or carved chests of drawers and doors.

10983A / 0228 " ^Claims "

Claims (12)

~ i4 - Protection claims rl.J imitation product, especially wood, marble or Gold leaf imitations, consisting of one with plastic foam-bonded grained film, characterized in that the plastic Schaunisubstrat no Has openings and the shape of the Feirifolie only through the plastic foam substrate is fixed. 2. Imitation product according to claim 1, characterized in that the film is at least partially transparent and is arranged over a ^{color layer forming a contrast to the Mi * s J} -T ~ ung. 3. Imitation product according to claim 1 or 2, characterized in that that the contrast color is present throughout the substrate. 4. Imitation product according to claim 1 or 2, characterized in that that a second thermally deformable thermoplastic film to the first as a contrasting color layer Film is laminated. 5. Imitation product according to one of the preceding claims, characterized in that the film is a vinyl, Cellulose acetate butyrate, cellulose acetate ·, acrylic or Polyester film and the plastic foam a polyurethane or Polyester foam is. 6. Imitation product according to one of the preceding claims, characterized in that the substrate has a raised or lowered embossing. 7. Imitation product according to one of the preceding claims, dadux'ch characterized in that the adhesive for connecting the film and substrate is contained in the color layer. 10983A / 0228 BATH ORIGINAL 8. A method for producing Imxtationsprodukte according to any one of the preceding claims, characterized in that a relatively thin, thermally deformable, thermoplastic film is heated until it is slack and easy to pull, this film is held pressed in a Foi-m against a molded part and the Shape with liquid
foamable plastic at least partially filled
becomes, the foaming in the closed form a pressure; exerts, after closing the mold with a preferably gas-permeable mold bottom, the foaming and then curing takes place, the film and foam adhering
connected and the formed product is ejected from the mold. 9. The method according to claim 8, characterized in that the product is quenched by a cooling fluid after expulsion will. 10. The method according to claim 8 or 9 »characterized in that that. the slide to about 65 to 2o5 C during one Time of about 5 to 60 seconds is heated. 11. The method according to any one of claims 8 to Io, characterized
characterized in that the film is held pressed against the mold by vacuum and / or overpressure. 12. The method according to any one of claims 8 to 11, characterized
characterized in that the film held in the mold before the mold is filled with schäunibarera plastic - Coated at least one layer of a contrasting color will. 109834/0228 Blank page