WO1998013417A1 - Acrylic sheet having uniformly distributed coloring and filler - Google Patents
Acrylic sheet having uniformly distributed coloring and filler Download PDFInfo
- Publication number
- WO1998013417A1 WO1998013417A1 PCT/US1997/007798 US9707798W WO9813417A1 WO 1998013417 A1 WO1998013417 A1 WO 1998013417A1 US 9707798 W US9707798 W US 9707798W WO 9813417 A1 WO9813417 A1 WO 9813417A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- syrup
- weight
- composition
- sheet
- microns
- Prior art date
Links
- 238000004040 coloring Methods 0.000 title abstract description 3
- 239000000945 filler Substances 0.000 title description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 title description 2
- 239000006188 syrup Substances 0.000 claims abstract description 21
- 235000020357 syrup Nutrition 0.000 claims abstract description 21
- 239000012764 mineral filler Substances 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims description 25
- 239000003431 cross linking reagent Substances 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 11
- 239000007787 solid Substances 0.000 claims description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 7
- 150000004684 trihydrates Chemical class 0.000 claims description 7
- 238000005452 bending Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 5
- 230000000379 polymerizing effect Effects 0.000 claims description 3
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 abstract description 20
- 239000003795 chemical substances by application Substances 0.000 abstract description 7
- 238000003856 thermoforming Methods 0.000 abstract description 7
- 239000013008 thixotropic agent Substances 0.000 abstract description 5
- 238000010438 heat treatment Methods 0.000 abstract 1
- 238000013508 migration Methods 0.000 abstract 1
- 230000005012 migration Effects 0.000 abstract 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 17
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 17
- 239000004926 polymethyl methacrylate Substances 0.000 description 17
- 239000002245 particle Substances 0.000 description 16
- 238000012360 testing method Methods 0.000 description 15
- 239000000463 material Substances 0.000 description 13
- 229910021485 fumed silica Inorganic materials 0.000 description 12
- 239000000178 monomer Substances 0.000 description 10
- 239000004971 Cross linker Substances 0.000 description 9
- 239000004615 ingredient Substances 0.000 description 9
- 229910052500 inorganic mineral Inorganic materials 0.000 description 9
- 239000011707 mineral Substances 0.000 description 9
- 239000000047 product Substances 0.000 description 9
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 6
- 239000012986 chain transfer agent Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 239000003063 flame retardant Substances 0.000 description 5
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 4
- -1 for example Substances 0.000 description 4
- 239000010438 granite Substances 0.000 description 4
- 239000000049 pigment Substances 0.000 description 4
- 238000006116 polymerization reaction Methods 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 230000000717 retained effect Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- DBCAQXHNJOFNGC-UHFFFAOYSA-N 4-bromo-1,1,1-trifluorobutane Chemical compound FC(F)(F)CCCBr DBCAQXHNJOFNGC-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- LSDPWZHWYPCBBB-UHFFFAOYSA-N Methanethiol Chemical compound SC LSDPWZHWYPCBBB-UHFFFAOYSA-N 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229920006037 cross link polymer Polymers 0.000 description 2
- HBGGXOJOCNVPFY-UHFFFAOYSA-N diisononyl phthalate Chemical compound CC(C)CCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCC(C)C HBGGXOJOCNVPFY-UHFFFAOYSA-N 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- WNAHIZMDSQCWRP-UHFFFAOYSA-N dodecane-1-thiol Chemical compound CCCCCCCCCCCCS WNAHIZMDSQCWRP-UHFFFAOYSA-N 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- STVZJERGLQHEKB-UHFFFAOYSA-N ethylene glycol dimethacrylate Substances CC(=C)C(=O)OCCOC(=O)C(C)=C STVZJERGLQHEKB-UHFFFAOYSA-N 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 229920002818 (Hydroxyethyl)methacrylate Polymers 0.000 description 1
- WDZGTNIUZZMDIA-UHFFFAOYSA-N 2-(hydroxymethyl)-2-methylpropane-1,3-diol 2-sulfanylacetic acid Chemical compound OC(=O)CS.OC(=O)CS.OC(=O)CS.OCC(C)(CO)CO WDZGTNIUZZMDIA-UHFFFAOYSA-N 0.000 description 1
- ICBJBNAUJWZPBY-UHFFFAOYSA-N 2-hydroxyethyl 3-methylbut-2-enoate Chemical compound CC(=CC(=O)OCCO)C ICBJBNAUJWZPBY-UHFFFAOYSA-N 0.000 description 1
- SUNXFMPZAFGPFW-UHFFFAOYSA-N 2-methyl-5-(1-sulfanylpropan-2-yl)cyclohexane-1-thiol Chemical compound SCC(C)C1CCC(C)C(S)C1 SUNXFMPZAFGPFW-UHFFFAOYSA-N 0.000 description 1
- 125000003903 2-propenyl group Chemical group [H]C([*])([H])C([H])=C([H])[H] 0.000 description 1
- YYPNJNDODFVZLE-UHFFFAOYSA-N 3-methylbut-2-enoic acid Chemical compound CC(C)=CC(O)=O YYPNJNDODFVZLE-UHFFFAOYSA-N 0.000 description 1
- VXEGSRKPIUDPQT-UHFFFAOYSA-N 4-[4-(4-methoxyphenyl)piperazin-1-yl]aniline Chemical compound C1=CC(OC)=CC=C1N1CCN(C=2C=CC(N)=CC=2)CC1 VXEGSRKPIUDPQT-UHFFFAOYSA-N 0.000 description 1
- 238000012935 Averaging Methods 0.000 description 1
- SYVZQBJPZFJHJZ-UHFFFAOYSA-N CC(=CC(=O)O)C.C=CC Chemical compound CC(=CC(=O)O)C.C=CC SYVZQBJPZFJHJZ-UHFFFAOYSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- OKKRPWIIYQTPQF-UHFFFAOYSA-N Trimethylolpropane trimethacrylate Chemical compound CC(=C)C(=O)OCC(CC)(COC(=O)C(C)=C)COC(=O)C(C)=C OKKRPWIIYQTPQF-UHFFFAOYSA-N 0.000 description 1
- RUDUCNPHDIMQCY-UHFFFAOYSA-N [3-(2-sulfanylacetyl)oxy-2,2-bis[(2-sulfanylacetyl)oxymethyl]propyl] 2-sulfanylacetate Chemical compound SCC(=O)OCC(COC(=O)CS)(COC(=O)CS)COC(=O)CS RUDUCNPHDIMQCY-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 244000309464 bull Species 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000779 depleting effect Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000001034 iron oxide pigment Substances 0.000 description 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 1
- CDOSHBSSFJOMGT-UHFFFAOYSA-N linalool Chemical compound CC(C)=CCCC(C)(O)C=C CDOSHBSSFJOMGT-UHFFFAOYSA-N 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 1
- KZCOBXFFBQJQHH-UHFFFAOYSA-N octane-1-thiol Chemical compound CCCCCCCCS KZCOBXFFBQJQHH-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000013031 physical testing Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000003505 polymerization initiator Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- FBCQUCJYYPMKRO-UHFFFAOYSA-N prop-2-enyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC=C FBCQUCJYYPMKRO-UHFFFAOYSA-N 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000005049 silicon tetrachloride Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 238000013112 stability test Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/003—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/06—Acrylates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
- C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
- C08F265/06—Polymerisation of acrylate or methacrylate esters on to polymers thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00965—Uses not provided for elsewhere in C04B2111/00 for household applications, e.g. use of materials as cooking ware
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/54—Substitutes for natural stone, artistic materials or the like
Definitions
- This invention relates to the manufacture of acrylic sheet or slabs, that is sheets or slabs
- PMMA polymethylmethacrylate
- flame retardant minerals typically alumina trihydrate.
- This invention describes a sheet that can be heated and bent at a sharp 90° angle and/or that can
- the sheets or slabs of this invention display specific physical and other properties, like low flammability and minimal color changes after thermoforming; the uniform
- the sheet is heated and then pulled by vacuum into a concave cavity (or convex) mold,
- Such a mold can be shaped as a vanity top
- the part After forming, cooling and trimming, the part can be installed directly in place, without
- ATH alumina trihydrate
- mold release agents such as aliphatic acids.
- MMA methyl methacrylate
- iron oxide pigment of 10 microns or less is uniformly distributed in a syrup of MMA/PMMA
- a material destined for use as a kitchen countertop should have a surface which is easily repairable and restored to
- FIG. 1 A is a more or less hypothetical illustration of a prior art bending of a sheet of
- FIG. IB is a similar idealized illustration of the bending of a sheet of the present
- the present invention addresses the making of mineral filled PMMA sheets that:
- thermoformed into shaped articles without losing the uniform appearance without losing the uniform appearance and properties of the top surface
- thermoforming temperature low enough to avoid any significant loss of
- thermoplastic materials have a Flame Spread Index, by the ASTM E-84 Tunnel Test, lower than 75 and a
- Our invention provides for the stability of the suspension of alumina trihydrate, or other
- ATH in the entire composition 20-60% by weight, preferably 25-40%).
- Thixotropic agent preferably fumed silica
- Crosslinking agent as % weight of the total monomers content: > 1 % when using ethylene glycol dimethacrylate.
- Chain-transfer agent as % weight of the total monomers content: Less than (1.07 x
- crosslinker in parts per hundred of the total monomers content. This amount may be
- n-dodecyl mercaptan A convenient way to compare the effects of chain-transfer agents is to compare molecular weights obtained by polymerizing MMA in the presence of the chain-transfer agent and the absence of crosslinkers.
- the MW W The MW W
- MW n should be similar to that obtained by n-dodecyl mercaptan.
- dyes and pigments may be present,
- compositions and colors ranging from about 150 to 500 microns — that is, they will pass through
- function-mineral flame retardants such as ATH, for example, or synthetic resin or other fillers.
- PMMA as used herein is polymethylmethacrylate having a (weight average) molecular
- MMA is methyl methacrylate.
- the syrup is described herein as comprising PMMA
- monomers comprising at least about 60% MMA, and preferably at least about 80%
- Alumina trihydrate is well known in the art of synthetic mineral manufacture. In the
- the ATH may vary from about 20% to about 60% weight (preferably 25% to 50%) of
- Our invention contemplates a solid surface material in which may be seen the effects of the particulates no greater than 90 microns across.
- Our material is not simulative of granite, in
- particulates in our material can be discerned at all, it may be described as substantially fine ⁇
- grained (which we define specifically as having grains or particles less than 90 microns — that is, having no individually visibly discernable particles greater than 90 microns). We intend for the term "substantially fine-grained" to include materials in which no grains or particles are
- crosslinking agents Di-fiinctional or tri-functional, may be used.
- crosslinkers examples include ethylene glycol dimethylacrylate, propylene
- butanediolmethacrylate 1 ,4-butane ethylene glycol dimethacrylate or neopentyl glycol
- dimethacrylate as Di-functional crosslinkers and trimethylol propane trimethacrylate, triallyl
- hydroxypropylmethacr late as tri-functional crosslinkers.
- ethylene glycol ethylene glycol
- the crosslinking agents are maintained in concentrations preferably
- crosslinking agent and chain termination in the appropriate amounts assures the appropriate
- Chain terminators or chain-transfer agents such as octyl mercaptan, iso-dodecyl
- pentaerythritol tetrathioglycolate normally serve the function of regulating the molecular weight of the polymerizing MMA, which in turn is known to affect the plastic behavior of polymerized
- chain terminators or chain-transfer agents are used to
- thixotropic agents we use are shown herein to be particularly suited for present purposes. They
- fumed silica we identify the product formed by
- CAB-O-Sil M5 which has a surface area of
- fumed silica is hydrophilic since it has an abundance of hydroxyl groups
- the fumed silica and/or the ATH are dried to eliminate the absorbed moisture, the final
- the amount of fumed silica is selected so that the preferred viscosity is obtained, regardless of variations in the other ingredients.
- the preferred method of obtaining a desired viscosity is the following:
- step B Repeat step A including an amount of fumed silica and measure the viscosity.
- step B Repeat step B to bring the viscosity to a level between 1 ,000 and 10,000 centipoise,
- PMMA prepolymer are important in stabilizing the ATH and/or other solids contributing to an
- the flow of ingredients has a tendency to distort the visual or decorative pattern
- radius for the curvature e.g. 3 inches.
- Figure IB illustrates the achievable curvature of a sheet of the present invention, wherein
- the radius of the curve is one-half inch rather than the three inches of the section of Figure 1 A.
- the theoretical circumference of the outside of the curved section CD is 100%
- the present invention overcomes a more severe displacement of material in relatively less
- thermoformability which is a primary object of the
- the test consists of clamping a flat test specimen 4-7/8" square having the
- a load cell generates a signal representing the
- TP-0085 specimens of each sample is recommended. This test may be referred to herein as TP-0085.
- a syrup was made by partial polymerization of MMA to obtain a viscosity of 3 Poise and a
- the mixture of ingredients was first agitated under vacuum for 15 minutes, to eliminate the dissolved gases and avoid bubbles in the resulting sheet. It was then used to fill a cell cast
- Table 2 shows the combinations of chain transfer agent and crosslinker used and the test
- the first group of data (PL-8, PL-1 1 , PL-12, PL-14, PL-16, PL-19, PL-24, PL-25, PL-28
- compositions from the known art were also thermally stable to provide
- the second group of data (PL-10, PL-13, PL-20. PL-23) represents compositions that
- the third group of data (PL- 12, PL-22, PL-27) represents formulations that provide
- V mold forming test referred to in Table 2 was developed to determine what type of composition would yield a sheet that was an improvement over the prior art. For example, a 12
- a sheet of the present invention is an improvement over
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
Ranges of chain-transfer agents, thixotropic agents, and mineral filler content are balanced to minimize migration or maldistribution of coloring matter and mineral filler during curing of methyl methacrylate in a syrup and also during subsequent heating and deformation in thermoforming, to achieve constancy of impact resistance and improve stability of patterns even in deformed portions of formed sheets.
Description
ACRYLIC SHEET HAVING UNIFORMLY DISTRIBUTED COLORING AND FILLER
Related Application
This application is a continuation-in-part of our co-pending application of the same title, Serial No. 720,164, filed September 25, 1996, which is a continuation-in-part of Serial No.
620,510 filed March 22, 1996, Patent No. 5,567,745, which is a Divisional of Application Serial
No. 392,650, filed February 23, 1995, Patent No. 5.521,243. which is a continuation-in-part of
Serial No. 157,253, filed November 26, 1993, now abandoned.
Technical Field
This invention relates to the manufacture of acrylic sheet or slabs, that is sheets or slabs
of polymethylmethacrylate ("PMMA"), of the type usable in or designed for architectural uses
such as kitchen countertops and more complex shapes. The sheets or slabs contain significant
amounts of flame retardant minerals, typically alumina trihydrate. and almost always have
colorants in them, frequently in imitation of natural minerals such as onyx, marble or similar
synthetic appearing solid color or patterned types having no visibly distinguishable particles.
This invention describes a sheet that can be heated and bent at a sharp 90° angle and/or that can
be heated and vacuum formed into shapes like sinks and bowls without a significant esthetic
sacrifice. In addition, the sheets or slabs of this invention display specific physical and other properties, like low flammability and minimal color changes after thermoforming; the uniform
distribution of flame retardant significantly improves the consistency of impact resistance.
Background of the Invention
Sheets and slabs of synthetic mineral appearing material are now commonly used as
kitchen countertops and interior and exterior decorative coverings of all kinds for buildings such
as banks, air terminals, stores, and the like. Such applications frequently require that the material
be fabricated to fit custom designed areas, requiring in turn that the slabs or sheets be butted
together or otherwise joined in ways that juxtapose a cross section with a normal surface at 90°.
The fabrication process requires extensive time and specially trained craftsmen to be
completed successfully, since special tools and procedures are necessary. If a shaped, one piece
part of continuous or monolithic material is desired, such a part can only be produced by casting it in a mold cavity under special conditions. In addition to the high costs of such a process and
for the installation of the parts (fitting, gluing it in place to a flat sheet, and/or finishing, for
example,) there are often color differences between the cast bowl, for example, and the flat slab
of the same material.
The sheet (the terms "sheet'* and "slab" will be used interchangeably herein) of our
invention can provide a relatively complex finished part by a simple thermoforming operation —
that is, the sheet is heated and then pulled by vacuum into a concave cavity (or convex) mold,
where it is allowed to cool, to retain its new shape. Such a mold can be shaped as a vanity top,
with one 90° back splash wall, with a front end bull nose of 1.0 inch radius and a vanity type
bowl. After forming, cooling and trimming, the part can be installed directly in place, without
additional fabrication required.
Only one contemporary commercial product (Corian ® by DuPont) is said to be capable
of being heat bent. However, its performance is not suitable, for example, to make 90° angle
back splash wall, since the minimum radius of curvature specified by the Corian literature of
which we are aware is 3.0 inches.
So far as we are aware, the use of alumina trihydrate in polymethylmethacrylate
("PMMA") articles was first proposed by Stevens et al in U.S. Patent 3,563,939 (col. 4, lines 28-
29) and Duggins in Canadian Patent 916,337. Its flame retardant properties are now well known
and accepted, and alumina trihydrate ("ATH") is now widely used as a filler in various resinuous
products. Somewhat more detail for the construction of synthetic mineral products is provided
by Duggins in U.S. Patent 3,847,865; crosslinking agents are mentioned, for example. Also
proposed are mold release agents, and viscosity reducers such as aliphatic acids.
Buser et al, in U.S. Patents 4,085,246 and 4,159,301 address the problem of the settling
rates of various particles used in making a simulated granite having a matrix of polymerizable
methyl methacrylate ("MMA") having PMMA dissolved in it. See column 7, lines 42-62 of the
4301 patent. They use the PMMA to adjust viscosity, which in turn controls the settling rates of
the larger particles ~ see the Examples, particularly Example 5 of U.S. Patent 4,159,301. lines
31-34. They also use chain-transfer agents as accelerators for the polymerization ~ col. 8, lines
58-68 of the same patent.
Uniformity of color is mentioned as a goal in Gavin et al U.S. Patent 4,413,089, wherein
iron oxide pigment of 10 microns or less is uniformly distributed in a syrup of MMA/PMMA
which is then cured; prolonged storage of the syrup is not recommended (col. 2, lines 50-64).
In addition to meeting the above-described challenges, a material destined for use as a kitchen countertop, for example, should have a surface which is easily repairable and restored to
its original appearance, such as by sanding and polishing, be protected against flammability, and
have good temperature resistance in spite of being thermoformable.
The prior art has more or less neglected the goal of thermoformability or thermobending
of solid surface sheets, since the prior art products were generally designed for reproducing the look of flat, natural, mineral based sheets.
Brief Description of the Drawings
FIG. 1 A is a more or less hypothetical illustration of a prior art bending of a sheet of
"Corian" one-half inch thick.
FIG. IBis a similar idealized illustration of the bending of a sheet of the present
invention.
Summary of the Invention
The present invention addresses the making of mineral filled PMMA sheets that:
can be heat bent at relatively sharp angles,
can be thermoformed into shaped articles without losing the uniform appearance without losing the uniform appearance and properties of the top surface,
can be thermoformed by vacuum into a single-profile mold, concave or convex,
and do not require two matching molds,
have only minor and tolerable color changes across the whole finished part, either
less than Delta E = 2.0 by Cielab or not easily discernible by the human eye,
have a thermoforming temperature low enough to avoid any significant loss of
water from ATH filler during thermoforming, as is often the case for other
thermoplastic materials,
have a Flame Spread Index, by the ASTM E-84 Tunnel Test, lower than 75 and a
Smoke Index of 350 or less,
have the same impact resistance, by a falling weight method, measured from both
the top side and the bottom side.
Our invention provides for the stability of the suspension of alumina trihydrate, or other
mineral filler, in a syrup of methyl methacrylate having polymethylmethacrylate dissolved in it
by maintaining the following ingredients within the indicated ranges (by weight):
Content of PMMA dissolved in MMA/other monomers: 0-30% weight, preferably
10-25%.
ATH in the entire composition: 20-60% by weight, preferably 25-40%).
Thixotropic agent (preferably fumed silica) in the monomer/syrup fraction of the mixture:
.10-3.5%) or as much as necessary to obtain a viscosity of 1 ,000-10,000 centipoise
(preferably about 2,000-5,000 centipoise) after mixing and measured by
Brookfield Viscometer Model RVTDV-II, Spindle No. 2, 10 RPM.
Crosslinking agent as % weight of the total monomers content: > 1 % when using ethylene glycol dimethacrylate.
Chain-transfer agent as % weight of the total monomers content: Less than (1.07 x
+ 0.3) and more than the greater of 0.01 and (0.545 x -3.23), where x is the
crosslinker in parts per hundred of the total monomers content. This amount may
be adjusted to somewhat more or less when using chain-transfer agents other than
n-dodecyl mercaptan. A convenient way to compare the effects of chain-transfer
agents is to compare molecular weights obtained by polymerizing MMA in the presence of the chain-transfer agent and the absence of crosslinkers. The MWW
and MWn should be similar to that obtained by n-dodecyl mercaptan.
In addition to the above-identified ingredients, dyes and pigments may be present,
polymerization initiators will be necessary, and other conventional ingredients may be used as
are known in the art.
However, we do not employ particulates which are visibly distinguishable in the finished
product. Most synthetic granites contain visibly distinguishable particles of various
compositions and colors ranging from about 150 to 500 microns — that is, they will pass through
a sieve having openings of 500 microns and be retained on one having openings of 150 microns
(although larger particles are not uncommon in the synthetic mineral art). We have found that
our objective of even distribution of particles can be frustrated through the use of such larger particles of various compositions, and accordingly, we restrict our particle size to particles
smaller than those which will be retained on a sieve having openings of 90 microns, and
preferably smaller than those which will be retained on a sieve having openings of 60 microns.
These specifications for particle size apply in our invention to particulates of any composition of
function-mineral flame retardants such as ATH, for example, or synthetic resin or other fillers.
The above-listed ingredients may be further described as follows:
PMMA as used herein is polymethylmethacrylate having a (weight average) molecular
weight range of about 30,000 to about 600,000 having no crosslinked polymer chains, in order to
remain soluble in MMA. It is typically made in situ by partial polymerization of methyl
methacrylate, but can be pre-polymerized and dissolved in the MMA.
MMA is methyl methacrylate. The syrup is described herein as comprising PMMA
dissolved in monomers comprising at least about 60% MMA, and preferably at least about 80%
MMA, but of course the crosslinking agent, chain terminator, initiator, and thixotropic agent are
also present in the amounts indicated herein as well as variable amounts of dyes and/or pigments;
in addition, amounts of other, optional, copolymerizable monomers, notably butyl acrylate, may
be present in the syrup as is known in the art. We prefer to use a syrup which contains about 15% to about 25%) PMMA. References to syrup herein and to MMA should be understood possibly to include such additional materials.
Alumina trihydrate is well known in the art of synthetic mineral manufacture. In the
examples, we used it in a particulate size range of about 9 microns average, but the particulate
size may vary widely. As noted above, the ATH as well as any other particles which are
potentially visually distinguishable (if large enough) in the finished product should be able to
pass through a sieve having openings of 90 microns, and preferably will pass through a sieve
having openings of 60 microns, in order to assure that they will not be visually distinguishable.
In quantity, the ATH may vary from about 20% to about 60% weight (preferably 25% to 50%) of
the finished product.
Our invention contemplates a solid surface material in which may be seen the effects of the particulates no greater than 90 microns across. Our material is not simulative of granite, in
that it is not coarse-grained, as granite is sometimes described. Rather, if the effects of the
particulates in our material can be discerned at all, it may be described as substantially fine¬
grained (which we define specifically as having grains or particles less than 90 microns — that is, having no individually visibly discernable particles greater than 90 microns). We intend for the
term "substantially fine-grained" to include materials in which no grains or particles are
individually visibly discernable.
Any number of crosslinking agents, Di-fiinctional or tri-functional, may be used.
Examples for suitable crosslinkers are ethylene glycol dimethylacrylate, propylene
dimethylacrylate, polethylene-glycol diemethylacrylate, propylene dimethylacrylate,
polyethyiene-glycol dimethylacryalate, divinyl benzene, diallyl phthalate, 1,3-
butanediolmethacrylate, 1 ,4-butane ethylene glycol dimethacrylate or neopentyl glycol
dimethacrylate as Di-functional crosslinkers and trimethylol propane trimethacrylate, triallyl
cyanurate, pentaerythritol tetramethacrylate, allylmethacrylate, hydroxyethylmethacrylate or
hydroxypropylmethacr late as tri-functional crosslinkers. Most suitably, ethylene glycol
dimethacrylate is preferred. The crosslinking agents are maintained in concentrations preferably
of up to about 12.0 pph of Di-functional crosslinkers based on the MMA in the syrup, or, as a
component of the finished product, based on the crosslinked polymer. The combination of
crosslinking agent and chain termination in the appropriate amounts assures the appropriate
polymeric network most amenable to thermoformability.
Chain terminators or chain-transfer agents, such as octyl mercaptan, iso-dodecyl
mercaptan, thiurams, dithiocarbarumates, dipentene dimercaptan, 2-mercapts ethanol, allyl
mercapts-acetates, ethylene glycol dimercapts-acetate, trimethylolethane trithioglycolate,
pentaerythritol tetrathioglycolate, normally serve the function of regulating the molecular weight of the polymerizing MMA, which in turn is known to affect the plastic behavior of polymerized
mixture. In accordance with our method, chain terminators or chain-transfer agents are used to
regulate the length of the polymer chains and thus to obtain the most suitable polymer matrix for
thermoformability, as will be seen by the data in Example 3. They should be used in preferred
amounts from .01 to about 7.0 pph of the total monomers present when using n-dodecyl
mercaptan.
While we may use a conventional thickening agent as well as a thixotropic agent, the
thixotropic agents we use are shown herein to be particularly suited for present purposes. They
appear to enhance the inertial tendency of a particle to remain stationary in the matrix
suspension. We prefer to use fumed silica. By fumed silica we identify the product formed by
the hydrolysis of silicon tetrachloride vapor in a flame of hydrogen and oxygen, to produce solid
particles in the range 7-30 millimicrons. Many different types of fumed silica are available. To
conduct the bulk of our experimentation, we selected CAB-O-Sil M5, which has a surface area of
200 sq.meter/gram. However, any conventional fumed silica will have a beneficial effect in our
invention.
The surface of fumed silica is hydrophilic since it has an abundance of hydroxyl groups,
which makes it capable of hydrogen bonding with suitable molecules. Absorbed moisture in the
silica or in the other components has a gross effect on the final viscosity of suspensions
containing fumed silica and normally it lowers it. The same effect is given by other substances
which may be more or less capable of developing hydrogen bonding.
If the fumed silica and/or the ATH are dried to eliminate the absorbed moisture, the final
viscosity of the suspension will be higher than when using the commercial products directly from the containers in which they are sold. Drying of the ATH above 200 °F may defeat its primary
utility as a flame retardant by depleting its water content.
In our preferred compositions, the amount of fumed silica is selected so that the preferred
viscosity is obtained, regardless of variations in the other ingredients.
The preferred method of obtaining a desired viscosity is the following:
A. Mix all the ingredients (MMA, PMMA, ATH, pigments, other additives, catalysts,
chain-transfer agent, and crosslinking agent) of the formulation except the fumed silica and
measure the viscosity as indicated below. If necessary, adjust the MMA (monomer) content of
the syrup to obtain a viscosity of 800 to 1,500 centipoise.
B. Repeat step A including an amount of fumed silica and measure the viscosity.
C. Repeat step B to bring the viscosity to a level between 1 ,000 and 10,000 centipoise,
preferably between 2,000 and 5,000 centipoise.
As indicated previously, the stability of our syrup is considered important, and this is
especially so where the sheet or slab is formed in a continuous steel belt forming machine such
as described in Hellsund's U.S. Patent 3,371 ,383 and Opel's U.S. Patent 3,376,371 , both of
which are incorporated herein by reference in their entireties, as these references represent our preferred procedure. While the forming of sheets or slabs between two moving continuous steel
belts is the preferred procedure, it is important to realize that such machines are necessarily prone
to vibration and microadjustments which tend to result in an almost unavoidable jostling of the
particulates in the syrup; the concentrations of crosslinker, chain terminator, fumed silica, and
PMMA prepolymer are important in stabilizing the ATH and/or other solids contributing to an
evenly distributed fine-grained appearance.
Detailed Description of the Invention
Referring to Figure 1A, the recommended (DuPont Corian Technical Bulletin CTDC-
1 10, October, 1987) minimum bending radius of three inches for a prior art one-half inch thick
flat sheet is illustrated as the radius of the bend in the inside curve from vertical extension point
A to horizontal extension point B. Applying the simple formula C=IID, the circumference of a
hypothetical three-inch circle would be 18.8496 inches, and the quarter circle AB would measure
4.7124 inches. Applying the same formula to the outside curve for a sheet 0.5 inch thick, i.e.
using a radius of 3.5, yields a quarter circle of 5.4953, a difference of 16.6% from the inside
curvature. Such a distortion will tend to cause a flow of heated ingredients from the compressed
inside curve to the expanded outside, and lengthwise toward points A and B from the curved
portion. The flow of ingredients has a tendency to distort the visual or decorative pattern;
accordingly, the prior art has minimized the disruptions of the material by using a relatively large
radius for the curvature, e.g. 3 inches.
Figure IB illustrates the achievable curvature of a sheet of the present invention, wherein
the radius of the curve is one-half inch rather than the three inches of the section of Figure 1 A. In this case, the theoretical circumference of the outside of the curved section CD is 100%)
greater than that of the inside of the curve. It is readily seen that by enabling such a forming
ability, the present invention overcomes a more severe displacement of material in relatively less
volume. The relatively more severe displacement of material means a greater potential for
distortion of the esthetic pattern, but we avoid or neutralize such distortion and so achieve a
continuity of pattern heretofore not achievable under the stress of thermoforming.
A test has been devised to evaluate thermoformability, which is a primary object of the
present invention. The test consists of clamping a flat test specimen 4-7/8" square having the
desired thickness onto a steel plate in which has been drilled a 3-inch diameter hole; then a
polished stainless steel plunger having a one-inch radius is lowered at a rate of five inches per
minute regardless of the resistance. The apparatus and sample are heated prior to the test to the
desired temperature. As the plunger moves, a load cell generates a signal representing the
amount of resistance in pounds, which may be recorded. At the moment the specimen ruptures,
the plunger is stopped and the distance it has traveled is measured. Averaging of tests from four
specimens of each sample is recommended. This test may be referred to herein as TP-0085.
Example 1
A syrup was made by partial polymerization of MMA to obtain a viscosity of 3 Poise and a
PMMA content about of 20% weight. Butyl Acrylate, Cab-O-Sil M5, Aluminum Trihydrate
(ATH) were added to the syrup under agitation. Their proportions are indicated below, together
with the chemicals necessary to obtain a complete polymerization and a good release from the
call casting plates:
TABLE 1
% Weieht
1-3 syrup (80% MMA) 57.20
Butyl Acrylate 2.00
Cab-O-Sil M5 0.53
ATH 39.92
Wetting Agents 0.35
Ehr
Pigment Paste As needed
Release Agents As needed
Catalysts As needed
Chain Transfer Agent See Table 1
Plasticizer See Table 1
The mixture of ingredients was first agitated under vacuum for 15 minutes, to eliminate the
dissolved gases and avoid bubbles in the resulting sheet. It was then used to fill a cell cast
assembly, large enough to produce a sheet of approximately 12 x 12 x 0.5 inches. The curing
was obtained by dipping the cell cast assembly into a 180 °F water bath for one hour, followed by one hour of post cure im an air circulated oven at 250°F. After cooling to room temperature, the cell cast assembly was opened to remove the plastic sheet, and the physical testing described in the text was performed after conditioning at room temperature.
Table 2 shows the combinations of chain transfer agent and crosslinker used and the test
results.
The first group of data (PL-8, PL-1 1 , PL-12, PL-14, PL-16, PL-19, PL-24, PL-25, PL-28
listed in Table 2 represents compositions that were thermoformed under vacuum to a much
greater extent than compositions from the known art. They were also thermally stable to provide
formed shapes without defects.
The second group of data (PL-10, PL-13, PL-20. PL-23) represents compositions that
failed the thermal stability test at 340°F. Sample PL-23 did not show a visible evidence of
failing the blister test, but specimens broken during the H.D.T. test and its stability were judged
to be not completely satisfactory.
The third group of data (PL- 12, PL-22, PL-27) represents formulations that provide
sheets with a borderline thermoformability. PL-22 and PL-27 represent the demarcation between
good formability above them and poor formability below them.
The V mold forming test referred to in Table 2 was developed to determine what type of composition would yield a sheet that was an improvement over the prior art. For example, a 12
inch x 12 inch Corian sheet does not draw to any significant extent under vacuum.
(Approximately 0.2 inches). Therefore, a sheet of the present invention is an improvement over
the prior art if the observed draw is greater than 0.2 inches.
TABLE 2
Sample # x<» yd) Plast.(2> HDT<3) TP-0085< ) V Mold(5) Blister*6'
*F in./lbs. in. Temp°F
PL-8 1.44 1.44 5.2/1 12 2.5 P PL- 11 2.88 2.88 3.6/110 P PL- 12 4.80 4.32 2.4/125 2.4 P PL- 14 2.88 1.20 2.0/187 P PL- 16 2.16 0.48 2.1/192 P PL- 19 4.80 2.40 1.88 P PL-24 6.72 5.76 157 2.3/71 P PL-25 8.64 3.84 178 1.1/90 P PL-28 1 1.50 3.00 171 0.7/38 P
PL- 10 1.44 2.40 6.9/23 F PL- 13 2.88 3.60 Blistered F PL-20 4.80 5.28 2.7/55 F PL-23 7.68 6.72 F P
PL- 18 4.80 0.48 197 1.5/148 0.8 P
PL-22 6.72 0.96 0.55 P PL-27 11.50 3.00 187 .54/68 P
(1) Phr. of crosslinker & and chain transfer agent y per 100 parts of monomers in Ex. 1 formulation.
(2) Phr. of plasticizer DINP (Di-isononyl phthalate) used. (3) Heat distortion temperature, at 264 psi; per ASTM D-648. (4) Thermoforming test described in U.S. Patent No. 5,521,243. Samples are heated for 40 minutes in an oven at 340 °F before the test is initiated.
(5) V mold forming test. (6) Aristech test method; visual observations to determine if blisters were developed in a 4" x
4" sample after 40 minutes in an oven at 340°F; P = indicates passing the test; F indicates failure.
Claims
1.0 parts by weight crosslinking agent and wherein is the amount of crosslinking agent and y is
no more than about 1.07 x 0.13 and y is no less than the greater of about 0.01 and 0.54 x - 3.23,
and;
(b) solid particulates which will pass through a sieve having openings of 90 microns,
said solid particulates comprising about 20% to about 60%, based on the weight of the final
composition, of a mineral filler, and wherein a one-half inch thick, flat thermoformable sheet or
slab made from said composition will have a minimum bending radius of less than three inches.
2. A composition according to claim 1 wherein x is about 1.0 to about 12.0.
3. A composition according to claim 1 wherein said particulates will pass through a sieve
having an opening of 60 microns.
4. A composition according to claim 1 wherein said mineral filler is alumina trihydrate.
5. A method of making a thermoformable sheet comprising the steps of:
(a) making a prepolymerized composition comprising:
(i) syrup comprising a methyl metharcrylate said syrup having dispersed within it y
parts by weight chain terminator per hundred parts by weight of methyl metharcylate and least
1.0 parts by weight crosslinking agent where x is the amount of crosslinking agent and y is no
more than about 1.07 x 0.13 and y is no less than the greater of about 0.01 and 0.54 x - 3.23, and;
(ii) solid particulates which will pass through a sieve having openings of 90
microns, said solid particulates comprising about 20%> to about 60%, based on the weight of the
final composition, of a mineral filler, and wherein a one-half inch thick, flat thermoformable
sheet or slab made from said composition will have a minimum bending radius of less than three
inches.
(b) putting said prepolymerized syrup between at least two surfaces, said surfaces
defining a space being in the shape of a sheet;
(c) polymerizing said prepolymerized composition; and
(d) removing said sheet from said space.
6. A method according to claim 5 wherein x is about 1.0 to about 12.0.
7. A method according to claim 5 wherein said particulates will pass through a sieve
having an opening of 60 microns.
8. A method according to claim 5 wherein said mineral filler is alumina trihydrate.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/720,164 | 1996-09-25 | ||
US08/720,164 US5705552A (en) | 1993-11-26 | 1996-09-25 | Thermoformable acrylic sheet having uniform distribution of color and mineral filler |
US74083096A | 1996-11-04 | 1996-11-04 | |
US08/740,830 | 1996-11-04 |
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Publication Number | Publication Date |
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WO1998013417A1 true WO1998013417A1 (en) | 1998-04-02 |
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ID=27110209
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Application Number | Title | Priority Date | Filing Date |
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PCT/US1997/007798 WO1998013417A1 (en) | 1996-09-25 | 1997-05-08 | Acrylic sheet having uniformly distributed coloring and filler |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2797634A1 (en) * | 1999-08-20 | 2001-02-23 | Sumitomo Chemical Co | Resin panel for use in manufacture of sanitary ware, has high break elongation and low flow and relaxation indices |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5521243A (en) * | 1993-11-26 | 1996-05-28 | Aristech Chemical Corporation | Acrylic sheet having uniform distribution of coloring and mineral filler before and after thermoforming |
-
1997
- 1997-05-08 WO PCT/US1997/007798 patent/WO1998013417A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5521243A (en) * | 1993-11-26 | 1996-05-28 | Aristech Chemical Corporation | Acrylic sheet having uniform distribution of coloring and mineral filler before and after thermoforming |
US5567745A (en) * | 1993-11-26 | 1996-10-22 | Aristech Chemical Corporation | Acrylic sheet having uniform distribution of coloring and mineral filler before and after thermoforming |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2797634A1 (en) * | 1999-08-20 | 2001-02-23 | Sumitomo Chemical Co | Resin panel for use in manufacture of sanitary ware, has high break elongation and low flow and relaxation indices |
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