GB1389446A - Abrasion resistant cellular articles - Google Patents

Abstract

1389446 Moulding cellular articles; laminates IMPERIAL CHEMICAL INDUSTRIES Ltd 28 March 1972 [8 April 1971] 9044/71 Headings B5A and B5N [Also in Division B2] Cellular articles of increased abrasion resistance are prepared by curing the oil phase of a curable water-in-oil emulsion in a surface layer of which is embedded a layer of abrasionresistant particles. The particles may be laid, preferably as a monolayer, in a mould, in which they may be held by a releasable adhesive or the article may be made in a continuous process by applying the particles to a sloping belt to form a monolayer over which the emulsion is poured and cured as the belt travels horizontally. Alternatively, where there is a sufficient density difference, a mixture of particles and emulsion may be added to a mould or a centrifugal casting apparatus. Pipes may also be produced in which the inner surface contains low density hollow glass spheres whilst the outer surface contains solid glass ballotini. The largest particle may be less than twice the diameter of the smallest, at least 0À5 mm. particles being preferred and particles up to 15 mm. being specified. A laminate may be formed by bonding two articles together with their particle-bearing faces outermost. Further laminae may be incorporated. The oil phase of the emulsion may comprise a liquid or liquefied monomer such as styrene, methyl, ethyl- and butyl-methacrylate or acrylate, vinyl acetate, vinyl chloride, vinylidene chloride or butadiene. The emulsifier may be a polymer such as an unsaturated polyester and polymers of styrene, methyl-, ethyl- and butyl-methacrylate, vinyl acetate, acrylamide and acrylonitrile. Further polymers, preferably polymers of the monomers used, may be added. The emulsion may be prepared by adding water (which may contain a dyestuff, a lower alcohol, a saccharide or formamide), to a solution of the emulsifier in the monomer which forms the oil phase and adding a polymerization catalyst. The invention may be used to produce tiles or cladding panels, or articles of furniture such as chair legs or arms.