GB2469317A - Method of making a composite body comprising holder filled with mixture of a foamable resin and filler - Google Patents
Method of making a composite body comprising holder filled with mixture of a foamable resin and filler Download PDFInfo
- Publication number
- GB2469317A GB2469317A GB0906163A GB0906163A GB2469317A GB 2469317 A GB2469317 A GB 2469317A GB 0906163 A GB0906163 A GB 0906163A GB 0906163 A GB0906163 A GB 0906163A GB 2469317 A GB2469317 A GB 2469317A
- Authority
- GB
- United Kingdom
- Prior art keywords
- providing
- filler
- holder
- mixture
- skin
- 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.)
- Granted
Links
- 239000000945 filler Substances 0.000 title claims abstract description 29
- 239000000203 mixture Substances 0.000 title claims abstract description 25
- 239000002131 composite material Substances 0.000 title claims abstract description 17
- 229920005989 resin Polymers 0.000 title claims abstract description 12
- 239000011347 resin Substances 0.000 title claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 239000000463 material Substances 0.000 claims abstract description 20
- 238000000034 method Methods 0.000 claims abstract description 18
- 239000010455 vermiculite Substances 0.000 claims abstract description 14
- 229910052902 vermiculite Inorganic materials 0.000 claims abstract description 14
- 235000019354 vermiculite Nutrition 0.000 claims abstract description 14
- 239000010451 perlite Substances 0.000 claims abstract description 13
- 235000019362 perlite Nutrition 0.000 claims abstract description 13
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 10
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 8
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 4
- 229920005749 polyurethane resin Polymers 0.000 claims abstract description 4
- 159000000007 calcium salts Chemical class 0.000 claims abstract description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 5
- 239000011575 calcium Substances 0.000 claims description 5
- 229910052791 calcium Inorganic materials 0.000 claims description 5
- 239000011324 bead Substances 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- 238000005266 casting Methods 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 230000036571 hydration Effects 0.000 description 2
- 238000006703 hydration reaction Methods 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 238000005341 cation exchange Methods 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 239000010423 industrial mineral Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000005332 obsidian Substances 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000005335 volcanic glass Substances 0.000 description 1
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
- A47K3/28—Showers or bathing douches
- A47K3/40—Pans or trays
-
- 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
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
-
- 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
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
Landscapes
- Health & Medical Sciences (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- General Health & Medical Sciences (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A method of making a composite body 1, such as a shower tray, comprising providing a holder 3 which is substantially hollow, providing a foamable resin material, providing a filler, mixing the resin material and filler, and then providing the step of filling the mixture 4 directly into the holder to provide a composite body. The filler may comprise Perlite, Vermiculite or a mixture thereof. Preferably, the holder is an ABS capped acrylic skin. An additional filler comprising calcium carbonate or a calcium salt may be provided and the foamable resin may be a non-blown polyurethane resin. A composite body formed by the method, preferably a shower tray, is also disclosed. The mixture when set being adapted to retain a screw element of a leg to support the body.
Description
I
A METHOD OF MAKING A COMPOSITE BODY, AND A COMPOSITE BODY
MADE BY THE METHOD
The invention relates to a method of making a composite body, and a composite body made by the method, and particularly to a shower tray and a method of making same.
Shower trays are often made of an outer skin which is substantially hollow, and which forms a holder, or mould, into which a filling mixture is introduced to form the complete shower tray, the mixture providing a base.
Shower trays, whilst usually installed on a substrate such as a bathroom or shower room floor, are often required to be supported on support elements such as legs. Often these are screwed into the base. However, this is usually not strong enough to take a screw-in fixture, so screw-threaded inserts or bosses have had to be provided.
These inserts or bosses are relatively heavy and expensive. Moreover, the base itself is usually of a material which is heavy, to provide strength. This again adds to the cost and also increases time of installation whilst reducing ease of installation.
It is an object of the invention to seek to mitigate these disadvantages.
According to a first aspect, the invention provides a method of making a composite body, comprising providing a holder which is substantially hollow, a foamable resin material, providing a filler, mixing the resin material and filler, and then providing the step of filling the mixture directly into the holder to provide a composite body.
The filler may comprise Perlite, or Vermiculite, and/or a mixture of Perlite and Vermiculite.
In a preferred embodiment, the holder may be provided as an a acrylic skin, suitably as an ABS capped acrylic skin.
For ease of use, the step of filling the mixture directly into the holder may comprise pouring the mixture directly into the holder.
The method may be enhanced by providing an additional filler material as an additional step.
The step of providing an additional filler material may comprise a material which itself may comprise calcium and/or a calcium salt.
Preferably the additional filler may be provided as calcium carbonate and calcium beads.
The step of providing the holder may comprise a flat casting step.
The step of providing a foaniable resin may comprise providing a non-blown polyurethane resin system.
According to a second aspect, the invention provides a composite body, comprising a substantially hollow holder and a foamable mixture substantially filling same which comprises a resin material and a filler material.
The body may comprise a shower tray, though it will be understood that it may comprise a bath, sink or the like bathroom or kitchen equipment.
The holder may comprise a skin of the shower tray.
The filler material may comprise Perlite, or Vermiculite, and/or a mixture of Perlite and Vermiculite.
Suitably the skin may comprise an acrylic skin, suitably an ABS capped acrylic skin.
The mixture when set may be adapted to retain a screw device by direct screwing thereto.
The screw device may comprise a screw element of a leg on which the body is supportable on a substrate.
The use of the filler as hereinbefore defined provides a relatively low density filler which in turn provides light weight, strength, and the ability to receive a screwed-in element directly without the need for an insert or boss in the base of the shower tray.
A method and product embodying the invention are hereinafter described, by way of example, with reference to the accompanying drawings.
Fig. 1 is a schematic drawing showing a step in a method according to the invention; and Fig. 2 is a schematic perspective view of a shower tray according to the invention.
Referring to the drawings, Fig. 2 shows a perspective view of a shower tray 1, having a foot well 2, and an initially hollow ABS capped acrylic skin 3, which forms a holder for a mixture 4 which is poured directly thereinto (arrow X, Fig. 1) when the skin 3 is inverted. The mixture 4 provides a light weight yet strong base 4' which is flush at 5 with the lower edge of the skin 3 and which can receive screw threaded elements such as support legs 6 which can be screwed directly into the base 4' via threaded spigots 7 without the intervention of screwed-threaded bosses or inserts.
The base 4' comprises a mixture of a non-blown polyurethane resin system which has in the preferred embodiment, a Perlite filler. There is also in the embodiment an additional filler in the form of calcium carbonate and calcium beads.
It will be understood that Perlite is an amorphous volcanic glass that has a relatively high water content, typically formed by the hydration of obsidian. It occurs naturally and has the unusual property of greatly expanding when heated sufficiently. It is an industrial mineral and a commercial product useful for its light weight after processing.
It has a typical analysis of * 70-75% silicon dioxide: Si02 * 12-15% aluminium oxide: Al203 * 3-4% sodium oxide: Na20 * 3-5% potassium oxide: 1(20 * 0.5-2% iron oxide: Fe203 * 0.2-0.7% magnesium oxide: MgO * 0.5-1.5% calcium oxide: CaO * 3-5% loss on ignition (chemical/combined water) Expanded Perlite is a brilliant white in colour and has typically in bulk density of 30 -kg/rn3.
In use to make a tray, the skin or holder 3 to form the boundary of the tray is inverted and the mixture 4 of polystyene, Perlite and additional filler (if used) is poured directly into the back of the (i.e. inverted) skin 3. The mixture 4 fills the entire channel and base area to form the base 4 and to provide a "flat back" appearance. The system is thus an open pour system, which provides for zero shrinkage, is 20% lighter than prior trays, and provides for screw retention so that, as described above, leg sets 6, 7 from a riser kit can be screwed directly into the back of the tray 1 (Fig. 2).
Vermiculite can also be used as a filler. This is a natural mineral that also expands with the application of heat. The expansion process is called exfoliation and it is routinely accomplished in purpose-designed commercial furnaces. Vermiculite is formed by hydration of certain basaltic minerals. Vermiculite is a 2:1 clay, meaning it has 2 tetrahedral sheets for every one octahedral sheet. It is a limited expansion clay with a medium shrink-swell capacity. Vermiculite has a high cation exchange capacity at 100-meq/1 00g. Vermiculite clays are weathered micas in which the K ions between the molecular sheets are replaced by Mg2 and Fe2 cations.
Using the invention as described herein with reference to the drawings, it is possible to provide a composite product such as a shower tray which is formed by an open pour method with a foamed material interior bonded to a pre-formed skin and which is light in weight and has the capacity to receive screw-in elements directly without the need for the intervention of a screw-threaded boss or insert.
Claims (22)
- CLAIMS1. A method of making a composite body, comprising providing a holder which is substantially hollow, providing a foamable resin material, providing a filler, mixing the resin material and filler, and then providing the step of filling the mixture directly into the holder to provide a composite body.
- 2. A method according to Claim 1, the filler comprising Perlite.
- 3. A method according to Claim 1, the filler comprising Vermiculite.
- 4. A method according to Claim 1, the filler comprising a mixture of Perlite and Vermiculite.
- 5. A method according to any preceding claim, comprising providing the holder as an acrylic skin.
- 6. A method according to Claim 5, comprising the step of providing an ABS capped acrylic skin.
- 7. A method according to any preceding claim, the step of filling the mixture directly into the holder comprising pouring the mixture directly into the holder.
- 8. A method according to any preceding claim, comprising the step of providing an additional filler material as an additional step.
- 9. A method according to Claim 8, the step of providing an additional filler material comprising providing a material comprising calcium and/or a calcium salt.
- 10. A method according to Claim 9, the additional filler comprising calcium carbonate and calcium beads.
- 11. A method according to any preceding claim, the step of providing the holder comprising a flat casting step.
- 12. A method according to any preceding claim, the step of providing a foamable resin comprising providing a non-blown polyurethane resin system.
- 13. A method of making a composite body, substantially as hereinbefore described with reference to the accompanying drawings.
- 14. A composite body, comprising a substantially hollow holder and a foamable mixture substantially filling same which comprises a resin material and filler material.
- 15. A body according to Claim 14, comprising a shower tray.
- 16. A body according to Claim 15, the holder comprising a skin of the shower tray.
- 17. A body according to Claim 16, the filler material comprising Perlite, or Vermiculite, and/or a mixture of Perlite and Vermiculite.
- 18. A body according to Claim 17, the skin comprising an acrylic skin.
- 19. A body according to Claim 18, the skin comprising an ABS capped acrylic skin.
- 20. A body according to any preceding claim, the mixture when set being adapted to retain a screw device by direct screwing thereto.
- 21. A body according to Claim 20, the screw device comprising a screw element of a leg on which the body is supportable on a substrate.
- 22. A composite body, substantially as hereinbefore described with reference to the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0906163.1A GB2469317B (en) | 2009-04-08 | 2009-04-08 | A method of making a composite body, and a composite body made by the method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0906163.1A GB2469317B (en) | 2009-04-08 | 2009-04-08 | A method of making a composite body, and a composite body made by the method |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB0906163D0 GB0906163D0 (en) | 2009-05-20 |
| GB2469317A true GB2469317A (en) | 2010-10-13 |
| GB2469317B GB2469317B (en) | 2012-12-12 |
Family
ID=40750364
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0906163.1A Active GB2469317B (en) | 2009-04-08 | 2009-04-08 | A method of making a composite body, and a composite body made by the method |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2469317B (en) |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3405026A (en) * | 1965-05-14 | 1968-10-08 | Arthur H. Roberts | Impact resistant article and method of manufacture |
| GB2264083A (en) * | 1992-01-10 | 1993-08-18 | Cavalier Bemis Limited | Composite foam-filled articles |
| GB2306495A (en) * | 1993-11-16 | 1997-05-07 | Filtec Limited | Composite materials |
| GB2332206A (en) * | 1997-12-12 | 1999-06-16 | Airbath International | Filler |
| WO2007067903A1 (en) * | 2005-12-09 | 2007-06-14 | Masco Corporation | Lightweight shower tray |
| EP2048172A1 (en) * | 2007-10-09 | 2009-04-15 | Cray Valley Ltd | Crosslinkable and foaming polyester-polyurethane (hybrid) resin moulding compositions, with foaming characteristics for closed mould applications |
| GB2466309A (en) * | 2008-12-22 | 2010-06-23 | Cavalier Marketing Ltd | A bath |
-
2009
- 2009-04-08 GB GB0906163.1A patent/GB2469317B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3405026A (en) * | 1965-05-14 | 1968-10-08 | Arthur H. Roberts | Impact resistant article and method of manufacture |
| GB2264083A (en) * | 1992-01-10 | 1993-08-18 | Cavalier Bemis Limited | Composite foam-filled articles |
| GB2306495A (en) * | 1993-11-16 | 1997-05-07 | Filtec Limited | Composite materials |
| GB2332206A (en) * | 1997-12-12 | 1999-06-16 | Airbath International | Filler |
| WO2007067903A1 (en) * | 2005-12-09 | 2007-06-14 | Masco Corporation | Lightweight shower tray |
| EP2048172A1 (en) * | 2007-10-09 | 2009-04-15 | Cray Valley Ltd | Crosslinkable and foaming polyester-polyurethane (hybrid) resin moulding compositions, with foaming characteristics for closed mould applications |
| GB2466309A (en) * | 2008-12-22 | 2010-06-23 | Cavalier Marketing Ltd | A bath |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0906163D0 (en) | 2009-05-20 |
| GB2469317B (en) | 2012-12-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) |
Free format text: REGISTERED BETWEEN 20101007 AND 20101013 |