GB1585106A - Shaped composite articles of polyurethane foam - Google Patents

Shaped composite articles of polyurethane foam Download PDF

Info

Publication number
GB1585106A
GB1585106A GB19741/76A GB1974176A GB1585106A GB 1585106 A GB1585106 A GB 1585106A GB 19741/76 A GB19741/76 A GB 19741/76A GB 1974176 A GB1974176 A GB 1974176A GB 1585106 A GB1585106 A GB 1585106A
Authority
GB
United Kingdom
Prior art keywords
foam
parts
shaped composite
uncured
sheet material
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
Application number
GB19741/76A
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.)
Imperial Chemical Industries Ltd
Original Assignee
Imperial Chemical Industries Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Imperial Chemical Industries Ltd filed Critical Imperial Chemical Industries Ltd
Priority to GB19741/76A priority Critical patent/GB1585106A/en
Priority to FR7714570A priority patent/FR2350954A1/en
Priority to BE177529A priority patent/BE854572A/en
Priority to DE19772721745 priority patent/DE2721745A1/en
Priority to IT23554/77A priority patent/IT1125747B/en
Publication of GB1585106A publication Critical patent/GB1585106A/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5636—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching with the addition of heat
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Polyurethanes Or Polyureas (AREA)

Description

(54) SHAPED COMPOSITE ARTICLES OF POLYURETHANE FOAM ~ (71) We, IMPERIAL INDUSTRIES LIMITED, Imperial Chemical House, Millbank, London SW1P 3JF, a British Company do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to shaped composite articles containing polyurethane foam and method for their fabrication.
Methods are already known for producing shaped articles comprising a shaped body of polyurethane foam and an adherent facing material.
One method of producing such articles is to prepare a shaped body of polyurethane foam either by cutting or moulding and then to bring about adhesion between the foam and a facing material either by using an adhesive or by melting the foam. This method involves several operations and is time-consuming. Another method is to apply a polyurethane foam-forming liquid reaction mixture to a facing material in a suitable mould so that the foam is formed in contact with the facing material. This method can be unsatisfactory when the facing material is a permeable material such as a textile fabric because the liquid reaction mixture can sometimes penetrate the fabric giving a product having an unsatisfactory appearance.
It has now been found that shaped composite articles of the kind referred to can be produced in a single operation without the aforesaid disadvantages.
Thus, according to the invention, there is provided a process for the manufacture of a shaped composite article which comprises contacting a flexible facing material which is a fabric made from natural or synthetic fibres or a plastics sheet material with a freshly made polyurethane foam as hereinafter defined, still in the uncured state, said foam having been made under free rise conditions, applying pressure to permanently deform the uncured foam to the required shape and effect adhesion between the foam and the facing material, the foam.
Methods for the preparation of polyurethane foams have been fully described in the literature and are carried out commerically on a large scale. lie methods employed generally involve preparing a liquid mixture containing the foam-forming ingredients which then react and cause the mixture to expand.
For a short time after completion of expansion, the freshly made foam may have a tacky surface and, because of the still plastic nature of the polymer, can readily be permanently deformed by the application of pressure. Eventually, the polymerisation reactions taking place in the foam reach such a stage that it can be handled without suffering any change in shape.
When this stage has been reached it is regarded as cured although a further elapse of time at normal or elevated temperatures may be required before the full physical properties of the foam have been attained. For the purpose of the present invention, a freshly made foam still in the uncured state means a foam made from a liquid mixture as described above that has expanded substantially completely but it is still in a sufficiently plastic state to be permanently deformable. The period of time for which the foam is in this state will depend upon the composition of the reaction mixture from which the foam is made, particularly upon the reactivity of the components and the nature and concentration of the catalyst but these factors will be fully appreciated by persons skilled in the art.
The polyurethane foam used in the manufacture of the composite article may be of the flexible, semi-flexible or rigid type according to the use to which the composite article is to be put and the components of the foam-forming reaction mixture are selected in known manner to produce foam of the required type.
The flexible facing material is a fabric made from natural or synthetic fibres such as welded nylon fibres or woven fibres, or a plastics sheet material such as polyvinyl chloride sheet.
The deforming of the uncured foam to the required shape may be carried out using methods and equipment, for example compression moulding, conventionally used for the shaping of plastics materials. By using suitably profiled equipment, local variations in thickness will be produced in the finished product and, if desired, sufficient pressure can be applied locally to collapse the cells of the foam in selected parts of the composite article so as to form regions of unfoamed polymer which give structural strength to the composite article. Normal or elevated temperatures may be used for deforming the uncured foam.
After deforming, curing of the foam may be carried out at normal or elevated temperatures in conventional manner.
The shaped composite articles made by the process of the invention may be used for a variety of purposes but particularly in domestic and industrial furnishings and as trims, headlinings, crash pads and insulated panels in motor cars and other vehicles.
The invention is illustrated but not limited by the following Example in which all parts and percentages are by weight.
EXAMPLE The following materials are mixed together: Polyether polyol 100 parts Triethanolamine 10 parts N,N-Dimethylcyclohexylamine 0.85 parts Oxyethylated p-octylphenol 1.0 parts Oxypropylated glycerol (molecular weight 310) 40 parts Water 3.5 parts Crude diisocyanatodiphenylmethane 155 parts Between 3 and 5 minutes after commencement of mixing, the resulting foam is pressformed in contact with a polyvinyl chloride sheet material to form a roof-lining for a motor car. A pressure of 3 bars at a temperature of 50" C for a period of 1 minute is employed.
After press-forming, the foam is allowed to cure in the normal way.
Other impermeable plastics sheet materials can be used in place of the polyvinyl chloride sheet material or, if desired, permeable fabrics of a woven, knitted or melded type can be used.
The polyether polyol used in this Example is an ethylene oxide tipped oxypropylated glycerol having an oxyethylene content of 14% and amolecular weight of 5,300.
The and e crude dllsocyanatodiphenylmethane used in the Example contains approximately 55% of diisocyanatodiphenylmethane isomers and has an NCO content of 30%.
WHAT WE CLAIM IS: 1. A process for the manufacture of a shaped composite article which comprises contacting a flexible facing material which is a fabric made from natural or synthetic fibres or a plastics sheet material with a freshly made polyurethane foam still in the uncured state, as hereinbefore defined, said foam having been made under pre-rise conditions, applying pressure to permanently deform the uncured foam to the required shape and effect adhesive between the foam and the facing material, and airing the foam.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (1)

  1. **WARNING** start of CLMS field may overlap end of DESC **.
    regions of unfoamed polymer which give structural strength to the composite article. Normal or elevated temperatures may be used for deforming the uncured foam.
    After deforming, curing of the foam may be carried out at normal or elevated temperatures in conventional manner.
    The shaped composite articles made by the process of the invention may be used for a variety of purposes but particularly in domestic and industrial furnishings and as trims, headlinings, crash pads and insulated panels in motor cars and other vehicles.
    The invention is illustrated but not limited by the following Example in which all parts and percentages are by weight.
    EXAMPLE The following materials are mixed together: Polyether polyol 100 parts Triethanolamine 10 parts N,N-Dimethylcyclohexylamine 0.85 parts Oxyethylated p-octylphenol 1.0 parts Oxypropylated glycerol (molecular weight 310) 40 parts Water 3.5 parts Crude diisocyanatodiphenylmethane 155 parts Between 3 and 5 minutes after commencement of mixing, the resulting foam is pressformed in contact with a polyvinyl chloride sheet material to form a roof-lining for a motor car. A pressure of 3 bars at a temperature of 50" C for a period of 1 minute is employed.
    After press-forming, the foam is allowed to cure in the normal way.
    Other impermeable plastics sheet materials can be used in place of the polyvinyl chloride sheet material or, if desired, permeable fabrics of a woven, knitted or melded type can be used.
    The polyether polyol used in this Example is an ethylene oxide tipped oxypropylated glycerol having an oxyethylene content of 14% and amolecular weight of 5,300.
    The and e crude dllsocyanatodiphenylmethane used in the Example contains approximately 55% of diisocyanatodiphenylmethane isomers and has an NCO content of 30%.
    WHAT WE CLAIM IS:
    1. A process for the manufacture of a shaped composite article which comprises contacting a flexible facing material which is a fabric made from natural or synthetic fibres or a plastics sheet material with a freshly made polyurethane foam still in the uncured state, as hereinbefore defined, said foam having been made under pre-rise conditions, applying pressure to permanently deform the uncured foam to the required shape and effect adhesive between the foam and the facing material, and airing the foam.
GB19741/76A 1976-05-13 1976-05-13 Shaped composite articles of polyurethane foam Expired GB1585106A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
GB19741/76A GB1585106A (en) 1976-05-13 1976-05-13 Shaped composite articles of polyurethane foam
FR7714570A FR2350954A1 (en) 1976-05-13 1977-05-12 PROCESS FOR THE REALIZATION OF COMPOSITE OBJECTS INCLUDING A FOAM
BE177529A BE854572A (en) 1976-05-13 1977-05-12 MANUFACTURES
DE19772721745 DE2721745A1 (en) 1976-05-13 1977-05-13 METHOD OF MANUFACTURING A COMPOSITE MOLDED ARTICLE
IT23554/77A IT1125747B (en) 1976-05-13 1977-05-13 FORMING COMPOSITE MANUFACTURES, CONTAINING POLYURETHANE FOAMS AND METHODS FOR THEIR PREPARATION

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB19741/76A GB1585106A (en) 1976-05-13 1976-05-13 Shaped composite articles of polyurethane foam

Publications (1)

Publication Number Publication Date
GB1585106A true GB1585106A (en) 1981-02-25

Family

ID=10134434

Family Applications (1)

Application Number Title Priority Date Filing Date
GB19741/76A Expired GB1585106A (en) 1976-05-13 1976-05-13 Shaped composite articles of polyurethane foam

Country Status (5)

Country Link
BE (1) BE854572A (en)
DE (1) DE2721745A1 (en)
FR (1) FR2350954A1 (en)
GB (1) GB1585106A (en)
IT (1) IT1125747B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2475460A1 (en) * 1980-02-13 1981-08-14 Rhone Poulenc Textile Pre-fabricated moulded construction - of synthetic continuous filament non-woven fabric, needled and singed, then pressed with plastic support in mould
DE3612834A1 (en) * 1986-04-16 1987-10-22 Krall & Roth Weberei Gmbh & Co Textile composite material and manufacture thereof

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1518134A (en) * 1966-04-06 1968-03-22 Dunlop Co Ltd Flexible sheet materials
FR1510857A (en) * 1966-08-31 1968-01-26 Naphtachimie Sa Application of polyurethane foams in the manufacture of floor coverings and wall coverings
NL6913229A (en) * 1968-09-13 1970-03-17
BE728672A (en) * 1969-02-20 1969-08-01
JPS5018601A (en) * 1973-06-16 1975-02-27

Also Published As

Publication number Publication date
IT1125747B (en) 1986-05-14
BE854572A (en) 1977-11-14
FR2350954B1 (en) 1983-04-01
DE2721745A1 (en) 1977-12-01
FR2350954A1 (en) 1977-12-09

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Legal Events

Date Code Title Description
PS Patent sealed
PCNP Patent ceased through non-payment of renewal fee