GB2342614A - Moulding process - Google Patents

Moulding process Download PDF

Info

Publication number
GB2342614A
GB2342614A GB9821822A GB9821822A GB2342614A GB 2342614 A GB2342614 A GB 2342614A GB 9821822 A GB9821822 A GB 9821822A GB 9821822 A GB9821822 A GB 9821822A GB 2342614 A GB2342614 A GB 2342614A
Authority
GB
Grant status
Application
Patent type
Prior art keywords
lt
rti
resin
wood
process
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.)
Withdrawn
Application number
GB9821822A
Other versions
GB9821822D0 (en )
Inventor
Joseph Roukin
Original Assignee
Joseph Roukin
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

Links

Classifications

    • 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
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/58Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/06Unsaturated polyesters
    • 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
    • B29K2705/00Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • 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
    • B29K2711/00Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/14Wood, e.g. woodboard, fibreboard

Abstract

A composition to be used in a moulding process comprises a resin, a catalyst, and sawdust and/or wood shavings and/or metal filings. The composition is pre-mixed prior to adding it to a mould and then allowing it to cure. The composition may optionally also include at least one ink dye for the sawdust/wood shavings. The resin may be a thixotropic orthophalic polyester resin or a phenolic resin. The catalyst may be methyl ethyl ketone peroxide. The moulding process is preferably compression moulding.

Description

PROCESS FOR THE MANUFACTURE OF A PRODUCT The present invention relates to a process for the manufacture of a product. More particularly, the present invention relates to a process for the manufacture of a product which can be used to construct floor coverings, room fittings, work surfaces, furniture, boats, canoes, jewellery, i. e. any product, the shape of which is determined by a mould.

The present invention also provides a product when made by the process of the present invention, as well as the product per se.

Brazilian Patent No. P 18952137-OA discloses a process for the manufacture of a product for the construction of floor coverings, slabs etc., made from a mixture of wood shavings, sawdust and phenolic resin.

Such process comprises the steps of selecting the wood shavings by their colour, <RTI>solidness</RTI> and content of natural resin, and mixing the wood shavings with sawdust at a ratio of 65%: 35% respectively. The resultant mixture is then homogenised and impregnated with a natural phenolic resin in the ratio of 60%: 75% to 25%: 40% respectively. The impregnated mixture is then allowed to dry for approximately 24 hours, and the dried impregnated mixture is then moulded and heated to a temperature of approximately <RTI>120 </RTI> to <RTI>140 C</RTI> for 4 to 7 minutes. The resultant product is then removed from the mould and ready for use.

The problem associated with such a process is that it is extremely time consuming and moreover, and since the application of heat is required, consumes a lot of energy.

According to the present invention there is provided a process for the manufacture of a product comprising the steps of: preparing a composition comprising a selected amount of resin, catalyst and sawdust <RTI>and/or</RTI> wood shavings <RTI>and/or</RTI> metal filings; adding the composition to a mould ; and leaving same to cure.

It is an object of the present invention to provide a process that is believed to overcome, or at least address, the problems outlined above. In particular, the process of the present invention is less time consuming and hence, more efficient, and moreover, does not require the external application of heat during moulding.

The present invention will now be exemplified in a non-limiting manner, with reference to the following examples: Example 1 <RTI>a)</RTI> A particular type and grade of sawdust <RTI>and/or</RTI> wood shavings were selected.

Different grades and textures can be obtained by using different types of machinery, for example, a sanding machine will produce fine sawdust, whereas, a plane, lathe or drill will produce wood shavings at different grades depending upon the different heights, shapes and sizes of the cutting tools used. Furthermore, different types of wood will affect the grades and textures of the sawdust and/or wood shavings produced.

In a preferred embodiment, the sawdust and/or wood shavings are produced from chipboard, MDF, plywood, ash, apple, beech, jellutong, mahogany, pine, red wood and yew. It is to be understood that the sawdust and/or wood shavings can be produced from a single type of wood, or a combination of wood types. b) Preferably the sawdust <RTI>and/or</RTI> wood shavings selected were then dyed to a desired colour using ink dyes, preferably, permanent ink dyes.

In order to dye 250 grams of wood shavings, preferably fine wood shavings, 250 grams of wood shavings, produced from beech, were placed into a container, preferably a clean plastic container, and 400 millilitres of water and 100 millilitres of permanent ink were placed in a separate container and were mixed using a stirring apparatus, for example, a stainless steel or plastic spoon.

The mixture of water and ink were then placed into the container containing the wood shavings, and mixed using a stirring apparats. It was observed that the wood shavings would absorb most of the liquid added. Excess liquid was then removed from said container and the contents of the container were then placed onto a baking tray and spread evenly. The baking tray was then placed into an oven, for approximately 45 minutes, at a temperature of approximately <RTI>350 C.</RTI> This dried the dyed wood shavings.

The skilled person would realise that the temperature required is dependent on the size of the oven, the type of wood to be dyed and the size of the wood shavings to be dyed. c) A desired type and grade of metal was then selected.

Different grades of metal can be obtained by using industrial machinery, for example, a milling machine or engineering lathe. The skilled person will realise that the speed of such a machine and the sharpness of the cutter provided on said machine, will determine the grade. For example, a machine run at high speed having a sharp cutter will produce a fine grade of metal. Additionally, the skilled person will realise that the type of metal used will also affect the grade, since some metals are harder than others.

For example, brass is harder than silver and aluminium. In a preferred embodiment, the metal selected was aluminium, brass or silver. It is to be understood that either a single type of metal may be selected, or a combination of metals may be selected. d) A mould, was selected, the shape of which determines the shape of the object to be made. The male part of said mould was covered with a releasing agent. In a preferred embodiment, the releasing agent is beeswax or liquid PVC. e) A layer of white petroleum jelly was then spread over, or applied to, the releasing agent.

An amount, enough to cover the surface of the male mould, of resin was then placed into a container.

In a preferred embodiment, the resin is a pre-accelerated low viscosity, <RTI>thixot, zpic,</RTI> orthophalic polyester laminating resin. Further preferably, the resin is Beetle General Purpose Polyester Resin 864E.

A suitable catalyst, preferably, methyl ethyl ketone peroxide (MEKP), was then <RTI>acded</RTI> and mixed with the resin, preferably, utilising a non-plastic implement, for example, a wooden stick. Further preferably, 1-2.5wt% of MEKP was added to the resin. g) A thin layer of the resin and catalyst composition was then applied to the surface of the male mould.

In a preferred embodiment, the thin layer of the resin and catalyst composition is applied utilising a paintbrush having PVC bristles. h) The selected sawdust and/or wood shavings, and/or metal filings were then sprinkled onto the male mould, that is, until such time as the surface thereof is completely or partially or substantially covered with said wood shavings and/or sawdust <RTI>and/or</RTI> metal filings. The amount added depends on the desired look of the finished product.

If sawdust is used, then the sawdust must be completely saturated with the resin. i) The resin was then left to cure.

This took approximately 15-50 minutes and is dependent on the percentage of the catalyst used, as well as on the catalytic properties of the catalyst used. j) Whilst the mixture of resin, catalyst and wood shavings <RTI>and/or</RTI> sawdust <RTI>and/or</RTI> metal filings on the male mould was curing, a female mould was then prepared in accordance with steps b) to e), as outlined above. k) An amount of resin, that is, enough to completely saturate the metal and/or wood shavings <RTI>and/or</RTI> sawdust utilised was then poured into a container, preferably a PVC container.

<RTI>I)</RTI> A suitable amount of catalyst was then added to said resin. In a preferred embodiment, <RTI>2wt%</RTI> of MEKP was added to the resin. Once again the mixture of resin and catalyst is then mixed, preferably, using a non-plastic implement, for example, a wooden stick. m) A thin layer of the resin solution was then applied to the surface of the male mould using a paintbrush, preferably having PVC bristles. n) The sawdust <RTI>and/or</RTI> wood shavings <RTI>and/or</RTI> metal filings was then poured into the rest of the resin solution and stirred with a non-plastic implement, that is, until the sawdust <RTI>and/or</RTI> wood shavings and/or metal filings was completely saturated and mixed. The resultant composition was then poured into the female mould and the male mould was then firmly pressed into the female mould, that is, with a view to removing any air pockets therefrom. Additionally, the mould could be agitated with a view to removing any air-pockets. The male mould was then secured into position using locators and held under pressure by, for example, a 10Kg weight. o) The composition within the mould was then left to cure for approximately 50 minutes. The time being dependent on the amount of catalyst added, as well as the catalytic properties of the catalyst used. p) After curing, the moulded product was removed from the mould and then left to cure completely and cool for approximately 3 to 4 hours. q) The resultant moulded product was solid and was ready for finishing.

Finishing The moulded product can be finished in several ways depending upon the surface texture desired.

If a texture finish is desired, then, and because a chemical reaction occurs between the resin solution and the white petroleum jelly which produces a wrinkled, textured surface, all that is required is to simply brush the moulded product utilising a wire brush, preferably a stiff wire brush.

If a polished finish is desired, then various grades of abrasive paper (commonly known as wet and dry) can be used. The grades are 180,240,320,400,600,800 and 1200.

Once all these grades have been used, the material can be polished using a polishing machine. Finally, a soft cloth-polishing mop is used with polish to produce a glass-like finish. In a preferred embodiment, the polishes used are Brasso (RTM), Carborax (RTM)or Tripoli (RTM).

Regardless of the finishing treatment used, the finished moulded product is then preferably cleaned using an anti-bacterial agent, for example, Fairy Liquid (RTM) to remove all traces of polish therefrom.

Different ratios of sawdust <RTI>and/or</RTI> wood shavings and/or metal filings to resin can be used to determine different surface qualities. Preferably, the ratios are 55-75% sawdust <RTI>and/or</RTI> wood shavings <RTI>and/or</RTI> metal filings to 45-25% resin.

Example 2 A polished flat tile 250 mm by 200 mm by 10 mm was made by utilising 250 grams of sawdust <RTI>and/or</RTI> wood shavings, preferably dyed as outlined above, 600 <RTI>ml</RTI> of resin, 612 ml of catalyst, preferably MEKP, and a wax-releasing agent. The same method as described above was used, except that a flat mould was used and that the step including the application of white petroleum jelly was not utilised.

It is to be understood that the present invention can be utilised to produce any product or object and that it really depends on the shape of the mould used.

In a second aspect of the present invention there is provided. a product when made by the process of the present invention.

In a third aspect of the present invention, there is provided any object when made by the process of the present invention.

In a further aspect of the present invention there is provided a moulded product comprising wood shavings <RTI>and/or</RTI> sawdust and metal filings and a resin.

In a preferred embodiment the resin is a phenolic resin.

Claims (1)

  1. CLAIMS <RTI>1.</RTI> A process for the manufacture of a product comprising the steps <RTI>of :</RTI> preparing a composition comprising a selected amount of resin, catalyst and sawdust and/or wood shavings <RTI>and/or</RTI> metal filings ; adding the composition to a mould ; and leaving same to cure.
    2. The process of claim 1, wherein the sawdust <RTI>and/or</RTI> wood shavings are produced from at least one of the following types of wood selected from the group consisting of chipboard, MDF, plywood, ash, apple, beech, jellutong, mahogany, pine, red wood and yew.
    3. The process of any one of the preceding claims, wherein the sawdust and/or wood shavings are dyed before preparing the composition using at least one ink dye.
    4. The process of claim 4, wherein the ink dye is a permanent ink dye.
    5. The process of any one of the preceding claims, wherein the metal filings are produced from at least one metal selected from the group consisting of aluminium, brass or silver.
    6. The process of any one of the preceding claims, wherein prior to adding the composition to the mould, the mould is covered with a releasing agent.
    7. The process of claim 6, wherein the releasing agent is beeswax or liquid PVC. 8. The process of any one of the preceding claims, wherein the resin is a pre-accelerated low viscosity, thixotropic, orthophalic polyester laminating resin.
    10. The process of claim 8, wherein the resin is Beetle General Purpose Polyester Resin 864E.
    11. The process of any one of the preceding claims, wherein the catalyst is methyl ethyl ketone peroxide.
    12. The process of claim 11, wherein 1-2.5% wt. of methyl ethyl ketone peroxide was added to the resin.
    13. The process of claim 12, wherein 2% wt. of methyl ethyl ketone peroxide was added to the resin.
    14. The process of any one of the preceding claims, wherein once the composition was placed in the mould, the mould was agitated such that any air pockets within the composition were removed.
    15. The process of any one of the preceding claims, wherein once added to the mould, the composition was left to cure for 50 minutes.
    16. The process of any one of the preceding claims, wherein after curing, the product was removed from the mould and allowed to cool for approximately 3 to 4 hours.
    17. The process of any one of the preceding claims, further including the step of finishing the product.
    18. The process of claim 17, wherein finishing of the product is effected by brushing the product with a wire brush.
    19. The process of claim 18, wherein the wire brush is a stiff wire brush.
    20. The process of claim 17, wherein finishing of the product is effected by rubbing the product with an abrasive paper and then polishing the product.
    21. The process of claim 20, wherein the product is first polished by a polishing machine and then with a soft cloth-polishing mop.
    22. The process of any one of claims 17 to 21, wherein subsequent to finishing, the product is cleaned with an antibacterial agent.
    23. The process of any one of the preceding claims, wherein the ratio of sawdust <RTI>and/or</RTI> wood shavings <RTI>and/or</RTI> metal filings to resin is 55-75% to 4525%.
    24. The process of any one of the preceding claims, wherein the resin is a phenolic resin.
    25. A process for the manufacture of a product as claimed in any one of the preceding claims substantially as hereinbefore described and exemplified.
GB9821822A 1998-10-05 1998-10-05 Process for the manufacture of a product Withdrawn GB9821822D0 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9821822A GB9821822D0 (en) 1998-10-05 1998-10-05 Process for the manufacture of a product

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9821822A GB9821822D0 (en) 1998-10-05 1998-10-05 Process for the manufacture of a product

Publications (2)

Publication Number Publication Date
GB9821822D0 GB9821822D0 (en) 1998-12-02
GB2342614A true true GB2342614A (en) 2000-04-19

Family

ID=10840126

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9821822A Withdrawn GB9821822D0 (en) 1998-10-05 1998-10-05 Process for the manufacture of a product

Country Status (1)

Country Link
GB (1) GB9821822D0 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105754447A (en) * 2014-12-17 2016-07-13 常熟东达红木家具有限公司 Redwood furniture paint
CN105754446A (en) * 2014-12-17 2016-07-13 常熟东达红木家具有限公司 Redwood furniture paint

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB791256A (en) * 1955-10-20 1958-02-26 Hakon Gisle A method of manufacturing slabs, blocks or similar products of wooden particles or other fibrous material
GB836431A (en) * 1955-10-05 1960-06-01 American Cyanamid Co Improvements in aminoplast resinous compositions and method of making same
GB937606A (en) * 1959-05-18 1963-09-25 Borden Co Improvements in or relating to urea-formaldehyde resin compositions
JPS5641246A (en) * 1979-09-10 1981-04-17 Nippon Carbide Ind Co Ltd Thermosetting amino resin molding material
JPS59103723A (en) * 1982-12-06 1984-06-15 Ain Eng Kk Forming process for reinforced resin formed product like wood
US4882112A (en) * 1985-07-08 1989-11-21 Dai-Ichi Kogyo Seiyaku Co., Ltd. Process for producing shaped articles from vegetable particulate materials
JPH0485028A (en) * 1990-07-30 1992-03-18 Dainippon Printing Co Ltd Manufacture of polyester decorative laminated sheet
US5130072A (en) * 1989-06-16 1992-07-14 Hoechst Aktiengesellschaft Process for the production of a molded body comprising pressed particles and a phenolic resin
US5151230A (en) * 1990-10-01 1992-09-29 Dinoflex Manufacturing Ltd. Process for production of products formed of polymer bonded and granulated particles

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB836431A (en) * 1955-10-05 1960-06-01 American Cyanamid Co Improvements in aminoplast resinous compositions and method of making same
GB791256A (en) * 1955-10-20 1958-02-26 Hakon Gisle A method of manufacturing slabs, blocks or similar products of wooden particles or other fibrous material
GB937606A (en) * 1959-05-18 1963-09-25 Borden Co Improvements in or relating to urea-formaldehyde resin compositions
JPS5641246A (en) * 1979-09-10 1981-04-17 Nippon Carbide Ind Co Ltd Thermosetting amino resin molding material
JPS59103723A (en) * 1982-12-06 1984-06-15 Ain Eng Kk Forming process for reinforced resin formed product like wood
US4882112A (en) * 1985-07-08 1989-11-21 Dai-Ichi Kogyo Seiyaku Co., Ltd. Process for producing shaped articles from vegetable particulate materials
US5130072A (en) * 1989-06-16 1992-07-14 Hoechst Aktiengesellschaft Process for the production of a molded body comprising pressed particles and a phenolic resin
JPH0485028A (en) * 1990-07-30 1992-03-18 Dainippon Printing Co Ltd Manufacture of polyester decorative laminated sheet
US5151230A (en) * 1990-10-01 1992-09-29 Dinoflex Manufacturing Ltd. Process for production of products formed of polymer bonded and granulated particles

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105754447A (en) * 2014-12-17 2016-07-13 常熟东达红木家具有限公司 Redwood furniture paint
CN105754446A (en) * 2014-12-17 2016-07-13 常熟东达红木家具有限公司 Redwood furniture paint

Also Published As

Publication number Publication date Type
GB9821822D0 (en) 1998-12-02 grant

Similar Documents

Publication Publication Date Title
US4400423A (en) Abrasion-resistant laminate
US1596482A (en) Method of producing cement tiles, slabs, and like products
Van Doren Industrial design
US3736221A (en) Structural shape based on waste paper and method of providing the same
US6660333B2 (en) Apparatus and methods for producing artificially distressed plank flooring
US4948443A (en) Plastic laminate repair
US5658379A (en) Wood filler
US2763105A (en) Burnishing wheel
US2067012A (en) Composite building material
US20100310893A1 (en) Engineered wood product
US6772748B2 (en) Method of forming stone inlays in wood and article of manufacture
EP0152491A1 (en) Composite foamed articles and process for their production
US2634534A (en) Ornamented wood and method of manufacture
US6063444A (en) Bas-relief process
CN1792584A (en) Method for producing single plate laminated floor board by middle and small diameter grade rotation cutted wood material
US4779386A (en) Scouring block for cleaning rubber and the like
US20010002412A1 (en) Decorative structurally enhanced impregnated porous stone product
US4238438A (en) Hardboard with smooth, dense surface and method
JPH06293008A (en) Manufacture of particle board made of bamboo
CN1177533A (en) Embossed decorative plate frame of polyurethane and method for making mould thereof
JPH02220838A (en) Laminate and support material of member to be polished and polishing cloth used therewith
Truax The gluing of wood
US2062671A (en) Process and compound for polishing plastics
US5830536A (en) Cream crystallizer stone floor maintenance composition and method
US3305499A (en) Article of pressed wood and process for making same

Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)