WO2001032385A2 - Improved plastic system and articles - Google Patents
Improved plastic system and articles Download PDFInfo
- Publication number
- WO2001032385A2 WO2001032385A2 PCT/US2000/041588 US0041588W WO0132385A2 WO 2001032385 A2 WO2001032385 A2 WO 2001032385A2 US 0041588 W US0041588 W US 0041588W WO 0132385 A2 WO0132385 A2 WO 0132385A2
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- WO
- WIPO (PCT)
- Prior art keywords
- composition according
- polyol
- paint
- polyurethane
- sediment
- Prior art date
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Classifications
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- 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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
- B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
- C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
- C08G18/6666—Compounds of group C08G18/48 or C08G18/52
- C08G18/667—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38
- C08G18/6681—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/32 or C08G18/3271 and/or polyamines of C08G18/38
- C08G18/6685—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/32 or C08G18/3271 and/or polyamines of C08G18/38 with compounds of group C08G18/3225 or polyamines of C08G18/38
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/26—Scrap or recycled material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
Definitions
- the present invention relates generally to molded plastic systems and articles, and more particularly, to improved molded polyurethane systems and articles.
- Plastic systems such as molded plastic systems and articles, possess numerous advantages over many previous systems. Ease and flexibility in manufacture and the ability to form complex shaped articles are among the many benefits often cited in favor of plastics, such as molded plastics.
- One family of molded plastics is the crosslinkable molded plastic. Ordinarily the starting materials are placed in a mold and are activated to react. Upon curing, articles produced thereby often are relatively near net shape and require little additional processing. Systems such as these permit for the manufacture of composite materials or other combination of dissimilar materials.
- materials such as acoustic foams do not bond well to other materials, making efficient in-mold processing of articles extremely difficult using ordinary processing parameters.
- polyurethane systems generally are well known in the art and typically involve the reaction of a polyol and a polyisocyanate. Examples of polyurethane systems and their constituent ingredients can be found in, without limitation, U.S. Patent Nos. 5,422,380; 5,417,161 ; 4.866,102; and 4,714,575 all of which are expressly incorporated by reference. Summary of the Invention
- the present invention overcomes the shortcomings of the prior art by providing an improved molded plastic system and articles.
- the improved system includes a polyurethane that has been reacted in the presence of a filler that includes particulated by-products from the solids of reclaimed paint sludge.
- system contemplates bonding at least a portion of one surface of a first article with a second article to form a composite or laminate.
- the system and articles of the present invention offer improved capability for the manufacture of molded plastic articles and particularly molded polyurethane foam structures.
- the ability to incorporate reclaimed paint sediment or sludge into the foam offers attractive economic and environmental advantages, and permits for the manufacture of relatively rigid foamed articles, capable of withstanding structural stresses encountered in many construction applications.
- laminate or composite articles made with or without the filler, as disclosed offer high integrity mating between materials of two articles, particularly when such materials are dissimilar. Though optional, no additional layer of adhesive is needed nor other labor or cost-intensive processing steps.
- Fig. 1 is a schematic of an exemplary apparatus for making one type of article of the present invention. Detailed Description of the Preferred Embodiment
- the present invention generally includes a plastic system that is based on a polyurethane system, a reinforcement material (e.g., glass) and is capable of exhibiting at least the following approximate ranges of properties and characteristics in Table I, when used by itself.
- a reinforcement material e.g., glass
- An article exhibiting gradients of these properties across a section of the article may also be made in accordance with the present invention. Higher and lower ranges of course may be achieved by variations in the amounts and nature of ingredients.
- Compressive Strength 20 - 130 ksi 30 - 75 ksi
- the compressive strength is at least about 20 ksi, and more preferably at least about 50 ksi. In some applications it is at least about 70 ksi, and more preferably at least about 100 ksi.
- the polyurethane is prepared from a reaction of polyisocyanate and polyol starting materials, wherein the polyol includes a noncyclic aliphatic polyactive amine-containing polyol.
- the polyurethane includes a filler that includes particulated reclaimed paint sediment by-product.
- a first polyurethane article is bonded to a second article, and more preferably forms a laminate structure having two dissimilar materials bonded together over at least a portion of the interface between the articles.
- the preferred polyurethane is described in the following by reference to a detailed description of its starting materials, which generally include polyisocyanate and polyol.
- the preferred starting materials also include a catalyst, a blowing agent, and a reinforcement material, and may further include a filler and one or more ingredients selected from the group consisting of a chain extender, crosslinking agent, flame retardant, surfactant, mold release agent, or a mixture thereof. Other ingredients likewise are possible.
- Blowing Agent 0.025 to about 5 parts
- Table III illustrates another preferred example of relative approximate proportions of starting materials when employed:
- the polyisocyanates used in the invention may be selected from aliphatic, aromatic compounds having two or more isocyanate groups or mixtures thereof.
- the polyisocyanate may include a cycloaliphatic isocyanate. Combinations of the above polyisocyanates may also be employed.
- Polyisocyanates also may have more than two isocyanate groups present.
- polyisocyanates are available. The skilled artisan will appreciate, in the absence of a commercially available polyisocyanate, one may be prepared by reacting an appropriate excess of a diisocyanate with a polyhydric compound. Polyisocyanates may also be prepared by a self- condensation reaction of the isocyanate group, i.e., three isocyanate groups may condense to form an isocyanurate ring. Crude polyisocyanates may also be used.
- Suitable aliphatic diisocyanates preferably contain 2 to about 36 carbon atoms (excepting the carbon atom in the isocyanate groups), and include cyclic and non-cyclic aliphatic groups.
- difunctional aliphatic polyisocyanates recognized by those skilled in the art include, but are not limited to, ethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate (HDI), isomers of cyclohexane diisocyanate including trans- cyclohexane-l,4-diisocyanate (CHDI), 4,4'-methylene-bis(cyclohexyliso- cyanate) (hydrogenated MDI), dodecamethylene diisocyanate, dimeryl diisocyanate (DDI), isophorone diisocyanate (IPDI), 2,2,4-trimethylhexa- methylene-l,6-diisocyanate, isomers of te
- Examples of familiar suitable aromatic diisocyanates are those that generally contain from about 6 to about 25 carbon atoms (excepting the carbon atoms in the isocyanate groups).
- Specific examples of representative difunctional aromatic polyisocyanates include, but are not limited to, isomers of toluene diisocyanate (TDI) (e.g., toluene-2,4-diisocyanate, toluene-2,6- diisocyanate), isomers of tetramethyl-xylene diisocyanate (TMXDI) (e.g., the meta and para isomers), isomers of phenylene diisocyanates (e.g., meta and para (PPDI) isomers, 4,4'-methylene-bis(phenylisocyanate) (also known as diphenylmethane-4,4'-diisocyanate (4,4'-MDI or as MDI), diphenylmethane- 2,4-diisocyan
- isocyanates useful in this invention are dimers and trimers of isocyanates and diisocyanates and polymeric diisocyanates such as those having the general formula:
- R is a monofunctional or polyfunctional atom or radical.
- the relative amounts of the isocyanate can be varied to increase or decrease the hardness of the foam.
- the polyisocyanate is an aromatic diisocyanate, and more preferably it is the well-known MDI.
- the polyol reactants employed in the present invention preferably include carbon, hydrogen and oxygen.
- the polyols may also include compounds which contain these elements in combination with other elements familiar to those skilled in the art, such as phosphorus, halogen, nitrogen or mixtures thereof.
- suitable classes of organic polyol reactants for use in otherwise this invention are polyester polyols and polyether polyols, but they may include polyactone polyols, nitrogen-containing polyols, phosphorus- containing polyols, phenolic-based polyols, and polymer/polyols known in the art.
- the polyol is a polyether polyol, a polyester polyol or a mixture thereof.
- the polyol includes polyester polyol.
- it is difunctional aromatic polyester polyol.
- it is difunctional aromatic polyester polyol.
- it has a hydroxyl value ranging from about 175 to about 315.
- it has a viscosity of about 200 to about 25000 (cPs, 25°C).
- lower hydroxyl values are operative (e.g., as low as about 110).
- the polyol is characterized as having an average molecular weight at room temperature of at least about 700 and preferably ranging from about 1000 to about 8000, and more preferably about 1500 to 3000. Upon heating to about 90°F, the molecular weight will be reduced to a range of about 700 to about
- polystyrene resin 1200.
- Commercially available polyols are available from Stepan Company (e.g., under the trade designation STEPANPOL®), or ICI America (e.g., under the trade designation 423), or BASF (ELASTOPOR® product series).
- An example of one suitable polyol is, without limitation, tearate. It is well known to the polyurethane art that the particular polyol reactant or combination of polyols employed is a function of the desired end- product.
- suitable organic polyols useful in the present invention include, without limitation, glycerol, trimethylol propane, butylene glycol, polyalkylene glycols, such as polyethylene glycol, polypropylene glycol, and polybutylene glycol, polyhydroxy polyesters, lactic acid, esters of hydroxy carboxylic acids, such as castor oil, polyhydroxy amino alcohols, such as, N,N,N',N'-tetrakis-(2-hydroxypropyl) ethylene aliamine, triethanolamine, and the like.
- the starting materials include a noncyclic aliphatic polyactive amine-containing polyol.
- the polyol is reacted with one or more other polyols.
- one preferred starting ingredient is an oxide adduct (e.g. alkylene) of a polyactive amine.
- the ingredient includes a propylene oxide adduct of ethylenediamine.
- a very specific example without limitation is N, N, N', N',
- a first polyol is employed in combination with a second polyol, such as, for instance, a noncyclic aliphatic polyactive amine-containing polyol, the ratio of the first polyol to the second polyol will range from about 1 to about 0.02 parts by weight.
- the ratio of polyisocyanate to polyol is about 1 part polyisocyanate to about 1 part polyol, and more preferably about
- the polyol mixture includes about 75 parts of polyol (e.g., 231 by ICI Americas), about 25 parts sucrose amine (e.g. F180 by ICI Americas), about 0.1% lead octoate (about 36% purity); and up to about 3 parts QUADROL®.
- catalysts are used in the process according to the invention.
- the catalysts used are known and include, by way of example, without limitation, tertiary amines, silamines, bases containing nitrogen, organometallic compounds, or the like.
- nitrogen-containing hydroxides include, for instance, sodium hydroxide, alkali metal phenolates such as sodium phenolate or alkali metal alcoholates such as sodium ethylene. Hexahydrotriazines may also be used as catalysts.
- Organic metal compounds may also be used as catalysts according to the invention, especially organic tin compounds.
- the catalysts may be tin (II) salts of carboxylic acids such as tin (I ⁇ )-acetate, tin (II) octoate, tin (II)- ethylhexonoate and tin (I ⁇ )-laurate and the dialkyl tin salts of carboxylic acids such as dibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin maleate, dibutyl tin oxide, tributyl tin methacrylate or dioctyl tin diacetate.
- carboxylic acids such as tin (I ⁇ )-acetate, tin (II) octoate, tin (II)- ethylhexonoate and tin (I ⁇ )-laurate
- blowing agent water, volatile organic substances or both may be used as blowing agents in the process according to the invention.
- suitable organic blowing agents include, for instance, butane, hexane, heptane or the like.
- a blowing effect can also be obtained by adding compounds, such as those which decompose at temperatures above room temperature to liberate gases.
- blowing agents may be illustrated by azo-bis- isobutyro-nitrile, sodium carbonate, bicarbonate, or the like.
- a reinforcement material is used in combination with the starting materials for forming a polyurethane.
- One example is the use of continuous strand glass fibers (e.g., having a small diameter, such as about 9 ⁇ ).
- Other reinforcements are also possible, illustratively including synthetics, organic, inorganic or ceramic materials.
- the form of the reinforcement is not critical. Popular forms include without limitation, continuous fiber, chopped fiber, woven, matte, lofted, particulated or the like.
- the reinforcement can be provided as a preform (i.e., having a pre-configured shape). Preferably e-glass is used, but a-glass likewise may be employed.
- powders that can be used as fillers include talc, aluminum, zinc, mono ammonium phosphate fatty acids (including tall oil fatty acids or tall oil per se, which, if desired, may be halogenated for example, with chlorine or bromine), vermiculite, saw dust, cork, synthetic plastics including vinyl polymers such as, polyvinyl chloride, polystyrene and the like.
- the average particle size of the filler material may vary from about 325 mesh (Tyler) to about 16 mesh (Tyler), with about 200 mesh (Tyler) being an average particle size.
- the filler is a particulated by- product of paint sludge that has been reclaimed.
- overspray or excess paint found in an industrial paint spray booth can be collected and separated so that a remaining sediment or sludge by-product is dried by a sludge dryer and particulated into relatively ultrafme or fine particles, e.g., having an average particle size of about 50 mesh. Higher or lower particle sizes may be used.
- the particles thus will be composed of resinous-based material, such as an acrylic, a urethane, or a mixture thereof, and other residual paint ingredients.
- the present filler also may be employed advantageously in other plastic systems such as without limitation, vinyl esters, polyesters, epoxies or others.
- additives include one or more or softness control additives, chain extenders, cross-linkers, surfactants, coloring agents (e.g. carbon black, titanium dioxide, methyl blue, chromium red and the like), flame retardants, a conventional mold release or the like.
- the softness of the polyurethane foam optionally may be increased by increasing the amount of chain-extenders.
- suitable compounds containing active hydrogen (for reacting with isocyanate groups) include compounds containing hydroxyl or amine groups.
- suitable chain extenders are water, hydrazine, primary and secondary diamines, amino alcohols, amino acids, hydroxy diols such as ethane diol; butane- 1, 2- diol, butane- 1, 3-diol, butane-1, 4-diol, hexanediol, di ethylene glycol, triethylene glycol, tetraethylene glycol and higher polyglycols preferably having molecular weights in the range 2000 to 3000, ethylene glycol, glycerine, trimethylolpropane, 1 ,4-butanediol and primary and secondary diamines such as phenylene diamine, l,4-cyclohexane-bis-(methylamine), ethylene
- cross-linkers preferably are compounds containing more than 2 active hydrogen atoms per molecule, preferably more than 3. Examples of such cross-linkers are diethanolamine, triethanolamine, N,N,N',N'-tetrakis-(2-hydroxypropyl)ethylene diamine, and phenol/formaldehyde/aniline condensation products. It is possible to use a cross-linker in the polyol formulation giving softer foam, provided that the formulation giving harder foam contains an increased quantity of cross linker and/or contains an isocyanate giving a harder foam. Similarly it is possible to use a chain extender in the polyol giving a harder foam if the formulation giving softer foam contains an increased quantity of chain extender or an isocyanate giving softer foam.
- a surface-active agent may be desirable for production of high grade molded polyurethane foam according to the present invention, to help the foams so they do not collapse or contain very large uneven cells. While other surfactants may be employed, nonionic surface active agents (e.g. silicones) are preferred.
- flame retardants which optionally may be employed in any suitable amount are pentabromodiphenyl oxide, antimony oxide, dibromopropanol, tris(-chloropropyl)phosphate, 2,2-bis
- (2,3-dibromopropyl)phosphate tris(-chloroethyl)-phosphate, tris(l ,2-dichloro- propyl)phosphate, bis-(2-chloro-ethyl) 2-chloroethylphosphonate, molybdenum trioxide, ammonium molybdate, ammonium phosphate, penta- bromodiphenyloxide, tricresyl phosphate, triphenyl phosphate, hexabromo- cyclododecane and dibromoethyl- dibromocyclohexane. It is appreciated that flame retardant is incorporated into an article of the present invention either as a surface covering or alternatively impregnated throughout the article.
- WATER The cell structure is obtained by the interaction of any blowing agent, preferably water, which interacts with the prepolymers to produce carbon dioxide gas.
- the water added may be added as a separate component, or it can at least in part comprise water added in conjunction with another component of the system. The person skilled in the art will be able to readily select the amount of water depending upon the desired result.
- the materials may be prepared either by a single step process or a multi-step process.
- the preparation of the prepolymer of the multi-step process is omitted and all of the reactive active hydrogen compounds are combined essentially simultaneously with the polyisocyanate.
- Additives can be added to the individual reactive components prior to or during the final mixing step.
- the two-step process includes first preparing a polyurethane prepolymer having free isocyanate groups by reacting an excess of a polyisocyanate, with a high molecular weight polyol. All or a portion of the additives may be added to the prepolymer or their remaining portions may be added later together with a chain extender.
- the chain extender (when used), is mixed into the prepolymer.
- the catalyst if employed, may also be added to the prepolymer but preferably to the chain extender component.
- the ingredients are combined in a mixer. Mixing is continued at any suitable pressure for any suitable time to assure a substantially homogenous mixture. The mixture is then placed into a mold and cured.
- More complex multi-step process embodiments of the present invention afford increased control of catalyst activity, when a catalyst is present and otherwise generally afford more efficient component mixing.
- a multi-step process according to the present invention three or more separated component streams are charged into an injection head or mixing vessel prior to injection into the mold.
- a catalyst when present, is supplied in a component stream compatible with long term catalyst stability thereby increasing component shelf life.
- a catalyst reactive towards isocyanates is mixed with a portion of the reactive polyol in a first component stream containing various inert additives therein.
- a second component stream includes the remaining portion of the reactive polyol and fillers or other additives as detailed herein.
- a third component stream includes the reactive isocyanates.
- the stoichiometric quantity of polyol necessary to reaction with isocyanate to form a polyurethane is apportioned between a catalyst containing first component stream and a second component stream such that the majority of the total polyol charged into the injection head or mixing vessel is present within the second component stream.
- a first product stream containing 20% of the reactive polyol and the catalyst, a second component stream including 80% of the reactive polyol and filler upon mixing with a third component stream containing polyisocyanate yields an article having comparable properties to an article formed through a single step process yet with component streams having shelf lives of greater than six months at room temperature.
- a multi-step process according to the present invention presupposes that the polyol and polyisocyanate components being charged into an injection head are flowable.
- the reactive polyols and polyisocyanates operative in multi-step process embodiments of the present invention have viscosities of less than 500 centipoise. It is appreciated that a fourth component stream or even a fifth component stream are readily coupled to an injection head according to the present invention in order to avoid not only increased catalyst shelf life but also to afford more precise process control thereby allowing different composition articles to be produced through a single injection head. Thus, articles varying in color, density or other properties are readily formed.
- an article 10 is prepared by providing a mold 12 having a cavity generally defining the shape of the desired article. Resin and reinforcement is introduced into the cavity. Particularly when a laminate article is manufactured with vacuum assistance. It is appreciated that the present invention is operative absent application of vacuum.
- the mold includes platens 14 and 16 having one or more channels 18, associated with a vacuum source 20, defined therein to help create a negative pressure in the mold cavity when a vacuum is employed. The platens preferably are maintained at an elevated temperature (e.g.
- the cavity is closed and one or more pressures are applied as needed to maintain the desired interior dimensions of the cavity. It should be noted that temperature, pressure or both can be applied to the material in the mold cavity to vary the density at preselected locations across its section.
- a vacuum is applied to draw the acoustical foam material securely against the platen (to help avoid wrinkles).
- a suitable pressure is applied to the polyurethane reactants while the mixture is reacting to help assure the mold remains shut and the desired article density is achieved.
- Further layers can be added to the article by adding additional material to at least a partially reacted article or by removing at least partially the reacted article and placing such additional material in the mold cavity, turning the at least partially reacted article over and again placing it in the mold cavity for processing as discussed in the above.
- Laminates are also possible.
- one or more polyurethanes may be bonded to one or more layers of high pressure laminate (e.g. melamine) sheet, a second foam, wood, metal, plastic, fiber based material, paperboard, cork, textiles or other dissimilar material.
- laminates may be made, such as (without limitation), a combination of a first layer and a second layer; such as first material/polyurethane, first material/polyurethane/first material, first material/polyurethane/second material, polyurethane/first material/ polyurethane, polyurethane/first material/polyurethane/second material, etc.
- "sandwich" laminate combinations can be made such as acoustic foam/ polyurethane/high pressure laminate (e.g. melamine); high pressure laminate (e.g. melamine)/polyurethane/ high pressure laminate (e.g. melamine); acoustic foam/polyurethane/acoustic foam; polyurethane/acoustic foam/polyurethane. Laminate or other surfaces may be employed on either or both sides of the outer "sandwich” layers. It is recognized that polyurethane as used in the above description encompasses the preferred reinforced polyurethane foam of the present invention.
- one of the advantageous features of the invention is that it permits a high integrity bond to form between layers of materials having dissimilar properties or characteristics.
- the bond primarily is a mechanical bond with potentially incidental chemical bonding. Without intending to be bound by theory, it is believed that reactants from the polyurethane system penetrate porous surfaces of opposing layers and upon curing will effectively form an
- the first layer is a glass- reinforced polyurethane in accordance with the present invention.
- Such first layer is bonded to a second layer that is a second polyurethane foam, which may be lower density than the first layer (e.g., in a ratio of about 1 to about 5:1 density ratio between the first polyurethane and the second polyurethane).
- a second polyurethane foam which may be lower density than the first layer (e.g., in a ratio of about 1 to about 5:1 density ratio between the first polyurethane and the second polyurethane).
- RubinateTM IV- 1 available through CGR or Hutsman ICI Chemicals, LLC.
- An example of a suitable density range for the material is about 3 to about 10 pounds per cubic foot (pcf).
- Such material is an open cell foam, but a closed cell foam can also be employed.
- the density of the second layer is higher than the first.
- Another particularly preferred embodiment includes a glass web embedded within polyurethane in accordance with the present invention.
- the glass web includes woven roving or lofted glass layers.
- a woven roving glass operative herein typically has a density of 10 to 45 ounces per square yard. Woven roving glass is obtained from Fiber Glass, Inc. (Amsterdam, New York, USA).
- a woven roving glass having a chopped glass applied to a surface thereof is also operative herein having a similar density and is available from Fiber Glass as FABMAT®.
- a facing glass mat is embedded within the polyurethane foam proximal to or on the surface of the article. The facing glass mat is typically located at between 0 and 10 millimeters from the article surface.
- a still stronger reinforced polyurethane has a second glass mat embedded proximal to or defining the opposing article surface.
- forces exerted upon a facing glass mat are distributed throughout the article volume through the glass web.
- Impregnating the interior glass web with fire retardant affords a fire resistant barrier to an article fashioned according to the present invention.
- the interior glass web is readily utilized to entrain various substances as detailed herein in order to modify article properties.
- a web reinforced article according to the present invention is formed using a reactant polyol component having a viscosity of greater than about 200 centipoises. More preferably, the reactive polyol component has a viscosity of between 400 and
- Compression molding techniques may be suitably employed also. It will be appreciated also that the invention is not limited to molded articles. Articles may be prepared from any of a number of processes such as hand lay- up, spray techniques, cast in place, or the like. One or more layers of polyurethane sheet stock may also be employed and bonded to another layer of material. Resulting articles from the present invention find utility in a number of applications, including but not limited to building panels such as ceiling tiles, wallboard, ornamental paneling, insulation panels, acoustic panels, boat hulls, flooring, transport vehicle structural materials, cabinetry, instrumentation housings, or the like.
- building panels such as ceiling tiles, wallboard, ornamental paneling, insulation panels, acoustic panels, boat hulls, flooring, transport vehicle structural materials, cabinetry, instrumentation housings, or the like.
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- Medicinal Chemistry (AREA)
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- Polyurethanes Or Polyureas (AREA)
Abstract
Description
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Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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AU37904/01A AU3790401A (en) | 1999-10-26 | 2000-10-26 | Improved plastic system and articles |
CA002389890A CA2389890A1 (en) | 1999-10-26 | 2000-10-26 | Improved plastic system and articles |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US42735799A | 1999-10-26 | 1999-10-26 | |
US09/427,357 | 1999-10-26 | ||
US52805900A | 2000-03-17 | 2000-03-17 | |
US52834400A | 2000-03-17 | 2000-03-17 | |
US09/528,344 | 2000-03-17 | ||
US09/528,059 | 2000-03-17 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2001032385A2 true WO2001032385A2 (en) | 2001-05-10 |
WO2001032385A3 WO2001032385A3 (en) | 2002-01-24 |
Family
ID=27411547
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/041588 WO2001032385A2 (en) | 1999-10-26 | 2000-10-26 | Improved plastic system and articles |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU3790401A (en) |
CA (1) | CA2389890A1 (en) |
WO (1) | WO2001032385A2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1502726A1 (en) * | 2003-07-29 | 2005-02-02 | Behr GmbH & Co. KG | Materials for moldings |
WO2017161207A1 (en) * | 2016-03-16 | 2017-09-21 | Rco Engineering Inc. | Improved system and process for the manufacture of polymer foam with additives |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4714575A (en) * | 1986-05-27 | 1987-12-22 | Ex-Cell-O Corporation | Method for manufacturing RIM composites |
US4866102A (en) * | 1987-11-20 | 1989-09-12 | Pray Edward R | Moldable energy absorbing rigid polyurethane foams |
US5417161A (en) * | 1993-02-23 | 1995-05-23 | Sri International | Fabrication of molded block of dilute high explosive foamed polyurethane |
US5422380A (en) * | 1994-06-07 | 1995-06-06 | Westinghouse Electric Corporation | Sound absorbing and decoupling syntactic foam |
-
2000
- 2000-10-26 CA CA002389890A patent/CA2389890A1/en not_active Abandoned
- 2000-10-26 WO PCT/US2000/041588 patent/WO2001032385A2/en active Application Filing
- 2000-10-26 AU AU37904/01A patent/AU3790401A/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4714575A (en) * | 1986-05-27 | 1987-12-22 | Ex-Cell-O Corporation | Method for manufacturing RIM composites |
US4866102A (en) * | 1987-11-20 | 1989-09-12 | Pray Edward R | Moldable energy absorbing rigid polyurethane foams |
US5417161A (en) * | 1993-02-23 | 1995-05-23 | Sri International | Fabrication of molded block of dilute high explosive foamed polyurethane |
US5422380A (en) * | 1994-06-07 | 1995-06-06 | Westinghouse Electric Corporation | Sound absorbing and decoupling syntactic foam |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1502726A1 (en) * | 2003-07-29 | 2005-02-02 | Behr GmbH & Co. KG | Materials for moldings |
WO2017161207A1 (en) * | 2016-03-16 | 2017-09-21 | Rco Engineering Inc. | Improved system and process for the manufacture of polymer foam with additives |
Also Published As
Publication number | Publication date |
---|---|
WO2001032385A3 (en) | 2002-01-24 |
CA2389890A1 (en) | 2001-05-10 |
AU3790401A (en) | 2001-05-14 |
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