WO2002040593A2 - Process for the manufacture of a flat or shaped sheet product - Google Patents
Process for the manufacture of a flat or shaped sheet product Download PDFInfo
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- WO2002040593A2 WO2002040593A2 PCT/IB2001/002109 IB0102109W WO0240593A2 WO 2002040593 A2 WO2002040593 A2 WO 2002040593A2 IB 0102109 W IB0102109 W IB 0102109W WO 0240593 A2 WO0240593 A2 WO 0240593A2
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- paste
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- particulate filler
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
Abstract
A process for manufacturing a flat or shaped sheet product or a moulding is disclosed. The first step is to prepare a paste from a thermoplastic elastomer, a thermoplastic polymer, a particulate filler which may be an inorganic particulate filler, an organic particulate filler or a mixture of the two, and an amount of a solvent to dissolve the thermoplastic elastomer and the thermoplastic polymer and to wet the particulate to form the paste. The paste may be placed on a carrier and allowed to dry to form the sheet product, whereafter it is removed from the carrier. Alternatively the paste may be applied to a substrate, shaped into a desired shape and allowed to dry so that it adheres to the substrate to form the mouding.
Description
PROCESS FOR THE MANUFACTURE OF A FLAT OR SHAPED SHEET
PRODUCT
BACKGROUND OF THE INVENTION
THIS invention relates to a process for the manufacture of a flat or shaped sheet product, to a paste for use in this process and similar processes, and to products so manufactured.
In International Patent Application No PCT/IB 99/01332 there is disclosed a process for the manufacture of a moulding including the steps of (a) providing a substrate; (b) providing a paste comprising (i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer; (ii) 70% to 98% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive of the combined mass of components (i) and (ii) of an inorganic particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste; (c) applying to the substrate a layer of the paste; (d) during or after step (c) shaping the paste to a desired shape; and (e) allowing the paste to dry so that it adheres to the substrate to form the moulding.
The term "moulding" includes any ornamental edging or band and includes architectural mouldings such as skirting boards, cornices and door edgings, and also includes picture and photo frames and elements for the manufacture thereof.
It has now been found that a paste of this type, and similar pastes may be used for the manufacture of other products.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a process for manufacturing a flat or shaped sheet product including the steps of:
(a) forming a paste comprising:
(i) 2% to 30% inclusive, preferably 5% to 23% inclusive, more preferably 8% to 18% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer;
(ii) 70% to 98% inclusive, preferably 77% to 95% inclusive, more preferably 82% to 92% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer;
(iii) 250% to 450% inclusive, preferably 290% to 400% inclusive, more preferably 310% to 380% inclusive of the combined mass of components (i) and (ii) of a particulate filler; and
(iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
(b) placing an amount of the paste on a carrier;
(c) shaping the paste into a desired shape on the carrier;
(d) allowing the paste to dry to form the sheet product; and
(e) removing the sheet product from the carrier.
The particulate filler may comprise an inorganic particulate filler, an organic particulate filler, or a mixture of the two.
According to a second aspect of the invention there is provided a process for manufacturing a moulding, including the steps of:
(a) providing a substrate;
(b) providing a paste comprising:
(i) 2% to 30% inclusive, preferably 5% to 23% inclusive, more preferably 8%> to 18% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer;
(ii) 70% to 98% inclusive, preferably 77% to 95% inclusive, more preferably 82% to 92% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive, preferably 290% to 400% inclusive, more preferably 310% to 380% inclusive of the combined mass of components (i) and (ii) of a particulate filler comprising from 1 % to 25% inclusive by mass of an organic particulate filler and from 75% to 99% inclusive by mass of an inorganic particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
(c) applying to the substrate a layer of the paste;
(d) during or after step (c) shaping the paste to a desired shape; and
(e) allowing the paste to dry so that it adheres to the substrate to form the moulding.
According to a third aspect of the invention there is provided a paste for use in the manufacture of a flat or shaped sheet product as described above. According to a fourth aspect of the invention there is provided a paste for use in the manufacture of a moulding as described above.
According to a fifth aspect of the invention there is provided a flat or shaped sheet product formed as described above.
According to a sixth aspect of the invention there is provided a moulding formed from a substrate to which is applied a layer of a paste as described above.
DESCRIPTION OF EMBODIMENTS
The first aspect of the invention is a process for manufacturing a flat or shaped sheet product, such as for example a door or wall panel, a panel for a vehicle or a train carriage, or the like.
The first step of the process is to form a paste.
Component (i) of the paste is a thermoplastic elastomer, also known as a thermoplastic rubber. Examples of suitable thermoplastic elastomers are those having styrene end blocks, and an elastomeric mid block such as for example butadiene, isoprene, ethylene and the like, i.e. those that have two different polymers in each molecule. Thus for example the thermoplastic elastomer may be a styrene-butadiene-styrene polymer, or a styrene-isoprene polymer, or an acrylonitrile-butadiene-styrene polymer, and the like.
Specific examples of suitable thermoplastic elastomers are the Kraton grades by Shell Chemicals. The D series are unsaturated and suitable for interior applications, and are comprised of styrene-butadiene-styrene block copolymers which are linear, styrene-isoprene-styrene block copolymers which are linear, and styrene-butadiene radial copolymers .
The G series are fully hydrogenated grades for exterior applications and include styrene-ethylene/butylene-styrene block copolymers which are linear, and styrene-ethylene/propylene di block. The Kraton G range elastomers possess excellent resistance to oxygen, ozone and UV light degradation.
It is optional to formulate the thermoplastic elastomer with a small proportion of a mineral oil as a plasticizer, for example a paraffinic mineral oil such as Shell Flex 371 , 451 or 270 added in an amount of from 1 % to 4% of the combined mass of components (i) and (ii). The addition of an amount of a mineral oil improves the flexibility of the elastomer and promotes softness, and minimises stickiness of the paste.
Other optional additives to the thermoplastic elastomer include:
An anti oxidant such as Shell 330 in an amount of from 0,005% to 0,2% of the combined mass of components (i) and (ii).
A stabilizer in an amount of from 0,1% to 1 % of the combined mass of components (il) and (ii), such as a hindered phenol type, e.g. Irganox 1010 by
Ciba-Geigy.
A silane in an amount of from 0,1 % to 1 % of the combined mass of components (i) and (ii) for adhesion promotion, an example being Silane A-189 by Union Carbide.
A UV inhibitor such as Tinuvin 770 or P by Ciba-Geigy, in an amount of from
0,1% to 1%) of the combined mass of components (i) and (ii) when the product is intended for exterior use.
Component (ii) of the paste is a thermoplastic polymer such as for example polystyrene or polyvinyl chloride.
The thermoplastic polymer provides the paste with cohesion, stability, and strength.
The paste comprises 2% to 30% inclusive, preferably 5% to 23% inclusive, more preferably 8% to 18% inclusive of the combined mass of components (i) and (ii) of the thermoplastic elastomer, and 70% to 98% inclusive, preferably 77% to 95% inclusive, more preferably 82% to 92% inclusive of the combined mass of components (i) and (ii) of the thermoplastic polymer. In other words the paste contains from 2 parts of thermoplastic elastomer to 98 parts of thermoplastic polymer, to 30 parts of thermoplastic elastomer to 70 parts of thermoplastic polymer, and so on.
Component (iv) of the paste is an amount of a solvent to dissolve components (i) and (ii) (and to wet component (iii) as described hereinafter) to form the paste. The solvent must have a solubility parameter suitable for both of components (i) and (ii). In this regard, the Hildebrand solubility parameters for various elastomeric mid blocks are approximately 7,9 for polyethylene/butylene, 8,1 for polyisoprene and 8,4 for polybutadiene. Thus, solvents with a solubility parameter between 6,9 and 9,4 are suitable for the dissolution of the thermoplastic elastomer. Solvents with a solubility parameter of 9,1 are best suited for polystyrene, when polystyrene is used as the thermoplastic polymer. Thus, overall, solvents with a solubility parameter between 6,9 and 10,1 are most suited for the paste of the invention.
The solvent may be an aliphatic, aromatic or chlorinated hydrocarbon, ketone or ester.
Examples of suitable solvents are dichloromethane, ethyl acetate, butyl acetate, toluene, acetone, methyl ethyl ketone, xylene, turpentine, and blends of solvents such as for example a blend of methyl ethyl ketone and hexane.
Preferably, a first solvent is used to dissolve the thermoplastic elastomer, and a second solvent is used to dissolve the thermoplastic polymer. Thus, for example, the thermoplastic elastomer is dissolved in the first solvent, and the
thermoplastic polymer is dissolved in the second solvent. Thereafter, these two solutions are combined and mixed. At this stage, the particulate filler component (iii) may be added, either in dry form, or already wetted with the first or the second or a further solvent. As a specific example, the thermoplastic elastomer is preferably dissolved in toluene, the thermoplastic polymer, when it is polyvinyl chloride, is preferably dissolved in methyl ethyl ketone, and when it is polystyrene, is preferably dissolved in acetone, and the particulate filler is wetted with acetone.
At the conclusion of mixing of the total composition, a small proportion, in the range of from 1 % to 5% of the total composition by mass, of an alcohol, preferably a low carbon alcohol, more preferably ethanol is added and mixed, to minimise the tendency of the composition to stick or adhere to forming tools or moulds.
Preferably, the solvent or solvents used to dissolve components (i) and (ii) are present in an amount of from 75% to 200%, more preferably from 85% to 160%) inclusive of the mass of components (i) and (ii). However, generally, the quantity of solvent or solvents used must be sufficient to form the paste, and this will obviously vary with the nature of the components (i) to (iii) and the quantities thereof present.
Component (iii) of the paste is an amount of a particulate filler. The term "particulate" is intended to include short fibrous elements.
The particulate filler may be an inorganic particulate filler. Alternatively, up to and including 25% by mass of the inorganic particulate filler may be replaced with an organic particulate filler.
Examples of suitable inorganic fillers are calcium sulphate alpha-or beta- hemidrate or hydrated gypsum, talc, bentonite, diatomaceous earth, fine
particle size milled exfoliated vermiculite, barytes, calcium carbonate, hollow glass microballoons, wollastonite, milled rockwool, milled ceramic fibres, milled glass fibres or the like, or fly ash or the like.
Preferred inorganic particulate fillers include calcium sulphate alpha-or beta- hemidrate or hydrated gypsum, talc and fly ash.
The most preferred inorganic filler is calcium sulphate alpha-or beta-hemidrate or hydrated gypsum, most preferably calcium sulphate beta-hemidrate, for reasons of cost, propagation of drying and its non-abrasive nature, most preferably in combination with hollow glass microballoons such as Fillite of particle size in the range of from 50 to 300 microns inclusive.
Specific examples of these materials will now be given.
As stated above, the calcium sulphate may be alpha-or beta-hemidrate or may be in the form of hydrated gypsum. The expanded vermiculite may be for example the Zonolites or FPSV grades of W R Grace which have a small particle size, typically of less than 250 micron diameter. The hollow glass microballoons may be Fillite by Fillite Runcorn Limited or Cenfill or Cenolite by Ash Resources. The fibrous type materials, e.g wollastonite, milled rockwool, ceramic fibre or milled glass fibre preferably have a fibre length of below 1 mm.
The organic particulate filler may be for example saw dust from the manufacture of MDF and other engineered wood products, paper waste, ground nut shells, cork particles and the like, preferably with a particle size of less than 0,25 mm in diameter.
The advantage of replacing part of the inorganic filler material with an organic filler material is to promote evaporation or removal of the solvent or solvents in step (d) and to modify the density of the finished product.
The paste comprises 250% to 450% inclusive, preferably 290% to 400%. inclusive, more preferably 310% to 380% inclusive of the combined mass of components (i) and (ii) of the particulate filler. In other words the paste contains from 250 parts of the filler to 100 parts of components (i) and (ii) to 450 parts of the filler to 100 parts of components (i) and (ii), and so on.
It is to be noted that the components (i), (ii) and (iii) together constitute at least 90%), preferably at least 95% of the mass of the paste (excluding the solvent or solvents). In other words, any optional components may constitute only 10%, preferably only 5% of the mass of the paste (excluding the solvent or solvents).
The paste must have the following characteristics: it must dry quickly (which is a function of the particulate filler and the choice of solvent); it must not shrink or crack on drying (which is a function of the particulate filler), it must provide a product which is able to be cut or guillotined; it must not be sticky (which is a function of the particulate filler and the oil, if present, and the addition of an alcohol); it must allow for the rapid release of the solvent or solvents in order to minimise the time taken for the process (which is a function of the particulate filler and the solvent choice); it must have a good impact resistance (which is a function of the thermoplastic elastomer); it must be capable of exhibiting fine detail (which is a function of the particulate filler and its particle size).
The particulate filler also acts as an extender and allows variation of the density of the paste and thus the final product.
The paste may include various optional components as follows.
Th e first optional component of the paste is a suitable pigment or dye to colour the paste to a desired colour. For example, if it is desired that the product be given a natural wood appearance, the paste may be coloured yellow and the pigment of choice is then yellow oxide such as Bayferox 920 by Bayer.
A second optional component of the paste is an amount of organic or inorganic reinforcing fibres, the fibres preferably having a length of less than 1 mm. For example, the fibres may be polyester, polyvinyl alcohol, carbon, glass, ceramic or lignocellulosic fibres, used in an amount of up to 10% by mass of the total composition.
The second step of the process is to place an amount of the paste on a carrier.
The carrier may be, for example, a platen of a press.
The paste may be placed on the carrier in a lump or, more preferably, may be extruded or otherwise formed into a sheet and then placed on the carrier in sheet form.
Optionally, a reinforcing sheet may be placed on the carrier before the paste is placed thereon, i.e the paste is placed on the reinforcing sheet on the carrier. The reinforcing sheet may be for example a woven or non-woven natural or synthetic fibrous material, for example a sheet of a polyester material, an acrylic material or glass fibre or a crinett, or paper The reinforcing sheet may also be a rigid reinforcing sheet such as a board. In this case, in step (c), the paste adheres to the reinforcing sheet so as to provide the finished sheet product with reinforcing.
The third step of the process is to shape the paste into a desired shape on the carrier.
For example, when the carrier is a platen, the carrier platen with the paste thereon may be placed into a press containing a fixed platen, and the paste may be shaped between the two platens under suitable conditions of temperature and pressure.
The pressure applied need only be sufficient to shape the paste into the desired shape, for example a pressure of up to 5 kg/cm2. The temperature is preferably ambient temperature.
In this step, the sheet product is formed with the required shaping. For example, if the sheet product is intended as a decorative sheet product, e.g for the outside of a door, then the shaping may comprise embossed detail on a generally flat surface. Alternatively, when the sheet product is intended as a panel for a vehicle or a train carriage or the like, the shaping may include forming curved and other shapes, or apertures or provisions for mechanical securement, into the sheet product.
In this step, the paste is preferably formed into a sheet product having a thickness of from 2,5 mm to 12 mm inclusive, more preferably of 3 mm to 9 mm inclusive.
The fourth step of the process is to allow the paste to dry to form the sheet product.
The fifth step of the process is to remove the sheet product from the carrier. In other words, the carrier does not form part of the finished sheet product.
Examples of the process of the invention will now be given.
Example 1
A paste is formed from:
A
Acetone 160 pbw
Polyester foam regrind 200 pbw
B
Dichloromethane 60 pbw
Kraton D 1102 polymer, (Shell Chemicals) SBS linear 24 pbw
Kraton DO 1102 polymer, oil modified, (Shell Chemicals) 16 pbw
C
Acetone 100 pbw
Calcium sulphate hemi-hydrate 400 pbw
Fly ash - Plastfill 45/110 by Ash Resources 200 pbw
D
Ethanoi 20 pbw
(pbw = parts by weight)
The components A were mixed. The components B were then mixed and added to components A. The components C were then mixed and added to the mixture of components A and B. The component D was then mixed with the mixture of components A, B and C to give the paste.
The paste was extruded into a sheet form and this sheet was then placed on a fibre glass mould or former. The paste was allowed to dry and the finished shaped panel was then removed from the mould.
Example 2
A paste is formed from:
A
Acetone 160 pbw
Polyester foam regrind 200 pbw
B
Toluene 60 pbw
Kraton D 1102 polymer, (Shell Chemicals) SBS linear 32 pbw
C
Acetone 100 pbw
Calcium sulphate hemi-hydrate 600 pbw
MDF sawdust 75 pbw
D
Ethanol 20 pbw
(pbw = parts by weight)
The components A were mixed. The components B were then mixed and added to components A. The components C were then mixed and added to the mixture of components A and B. The component D was then mixed with the mixture of components A, B and C to give the paste. The paste was extruded into a sheet form and this sheet was then placed on a fibreglass mould or former. The paste was allowed to dry and the finished shaped panel was then removed from the mould.
The second aspect of the invention is a process for manufacturing a moulding. This process is substantially similar to the process disclosed in PCT/IB 99/01332, except for the composition of the particulate filler.
According to the present invention, the particulate filler comprises from 1 % to 25%) inclusive by mass of the filler of an organic particulate filler, and from 75% to 99% inclusive by mass of the filler of an inorganic particulate filler.
In other words, a proportion of the inorganic particulate filler as disclosed in PCT/IB 00/01332 is replaced with an organic particulate filler, to promote the removal of the solvent from the paste in step (d) and to modify the density of the finished product.
The substrate may be a plastics substrate. For example, the substrate may be a polymeric extrusion, preferably a cellular extusion.
Preferably, the plastics material of the plastics substrate is a thermoplastic polymer which is the same as the thermoplastic polymer in the paste. For example, where the substrate is a polystyrene extrusion, then the thermoplastic polymer in the paste is preferably polystyrene, and when the substrate is a polyvinyl chloride extrusion, then the thermoplastic polymer in the paste is preferably polyvinyl chloride, so as to match expansion coefficients and to compatibilize the solvents.
Alternatively, the substrate may be a wood or other lignocellulosic material composite, for example a length of wood or a length of medium density fibre board.
In this case, the length of wood or medium density fibre board or the like is preferably surface impregnated and coated with a thermoplastic polymer to assist in achieving a good bond between the paste and the substrate.
For example, when the substrate is a length of medium density fibre board, the length of medium density fibre board may be treated with a composition comprising a thermoplastic polymer dissolved in a suitable solvent therefor.
Thereafter, the solvent is evaporated off, leaving behind a coating of the thermoplastic polymer. The thermoplastic polymer in the paste is preferably the same as the thermoplastic polymer coating the length of medium density fibre board.
The second step of the process is to provide a paste. This is described above.
An example of a suitable particulate filler for use in a paste /to form a moulding is set out below.
The third step of the process is to apply the paste to the substrate in any suitable manner, for example by extrusion of the paste onto the substrate.
In step (d) of the process of the invention, during or after step (c), the paste is shaped to a desired shape. The shaping may be achieved by moulding, profiling or embossing the paste, while it is still soft. As indicated, this shaping may take place while the paste is being applied to the substrate or once it has been applied to the substrate.
In step (e) of the process of the invention, the paste is allowed to dry so that it adheres to the substrate to form the moulding.
The paste may be applied to the moulding at a thickness of from 0,5mm to 15mm, depending on the end use of the moulding.
Example 3
Inorganic filler:
Plasfill 45/110, which is a fly ash composed of alumina silicate of spherical particle size; 54%Si02, 34% Al203, Ca and Fe oxides; bottom cut - 20% passing a 45 micron screen; top cut - 400 micron; bulk density 1000g/l;
specific surface area 400 cm /g; oil absorption % m/m -20; pH 11-12 (in water) - 40% by mass;
Talc (300 mesh) 40% by mass
Organic filler:
Pulp fibre of typical fibre length of 3 mm 20% by mass
Claims
A process for manufacturing a flat or shaped sheet product including the steps of:
(a) forming a paste comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer; (ii) 70% to 98% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive of the combined mass of components
(i) and (ii) of a particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
(b) placing an amount of the paste on a carrier;
(c) shaping the paste into a desired shape on the carrier;
(d) allowing the paste to dry to form the sheet product; and
(e) removing the sheet product from the carrier.
A process according to claim 1 wherein the paste comprises:
(i) 8% to 18% inclusive of the combined mass of components (i) and (ii) of the thermoplastic elastomer; (ii) 82% to 92% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic polymer; and (iii) 310% to 380% inclusive of the combined mass of components (i) and
(ii) of the particulate filler.
A process according to claim 1 or claim 2 wherein the particulate filler is selected from the group consisting of an inorganic particulate filler, an organic particulate filler and a mixture of the two.
A process according to any one of claims 1 to 3 wherein in step (a) the thermoplastic elastomer is dissolved in a first solvent, the thermoplastic polymer is dissolved in a second solvent, the two solutions are mixed, and then there is added thereto the particulate filler, optionally wetted with a solvent, to form the paste.
A process according to any one of claims 1 to 4 wherein in step (b) the carrier is a platen of a press.
A method according to any one of claims 1 to 5 when in step (b) a reinforcing sheet is placed on the carrier and the paste is placed on the reinforcing sheet on the carrier.
A paste for use in the manufacture of a flat or shaped sheet product comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer; (ii) 70% to 98% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive of the combined mass of components
(i) and (ii) of a particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
A paste according to claim 7 comprising:
'(i) 8% to 18% inclusive of the combined mass of components (i) and (ii) of the thermoplastic elastomer; (ii) 82%o to 92% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic polymer; and (iii) 310%) to 380% inclusive of the combined mass of components (i) and
(ii) of the particulate filler.
A paste according to claim 7 or claim 8 wherein the particulate filler is selected from the group consisting of an inorganic particulate filler, an organic particulate filler and a mixture of the two.
A paste according to any one of claims 7 to 9 wherein the thermoplastic elastomer is dissolved in a first solvent, the thermoplastic polymer is dissolved in a second solvent, the two solutions are mixed, and then there is added thereto the particulate filler, optionally wetted with a solvent, to form the paste.
A process for manufacturing a moulding including the steps of:
(a) providing a substrate;
(b) providing a paste comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer; (ii) 70% to 98% inclusive of the combined mass of components
(i) and (ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive of the combined mass of components (i) and (ii) of a particulate filler comprising from
1 % to 25% inclusive by mass of an organic particulate filler and from 75% to 99% inclusive by mass of an inorganic particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
(c) applying to the substrate a layer of the paste;
(d) during or after step (c) shaping the paste to a desired shape; and
(e) allowing the paste to dry so that it adheres to the substrate to form the moulding.
A process according to claim 11 wherein the inorganic particulate filler is selected from the group consisting of calcium sulphate alpha-or beta-
hemihydrate, hydrated gypsum, talc, bentonite, diatomaceous earth, fine particle size milled exfoliated vermiculite, barytes, calcium carbonate, hollow glass microballoons, wollastonite, milled rockwool, milled ceramic fibres, milled glass fibres, fly ash, and a mixture of two or more thereof.
A process according to claim 11 or claim 12 wherein the organic particulate filler is selected from the group consisting of sawdust, paper waste, ground nut shells, and cork particles, with a particle size of less than 0,25mm in diameter.
A process according to any one of claims 1 1 to 13 wherein the paste comprises:
(i) 8% to 18% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic elastomer; (ii) 82% to 92% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic polymer; and (iii) 310%) to 380% inclusive of the combined mass of components (i) and (ii) of the particulate filler.
A process according to any one of claims 11 to 14 wherein in step (b) the thermoplastic elastomer is dissolved in a first solvent, the thermoplastic polymer is dissolved in a second solvent, the two solutions are mixed, and then there is added thereto the particulate filler, optionally wetted with a solvent, to form the paste.
A paste for use in the manufacture of a moulding comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer; (ii) 70% to 98% inclusive of the combined mass of components
(i) and (ii) of a thermoplastic polymer;
(iii) 250% to 450% inclusive of the combined mass of components (i) and (ii) of a particulate filler comprising from 1% to 25% inclusive by mass of an organic particulate filler and from 75% to 99% inclusive by mass of an inorganic particulate filler; and
(iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste;
A paste according to claim 16 wherein the inorganic particulate filler is selected from the group consisting of calcium sulphate alpha-or beta- hemihydrate, hydrated gypsum, talc, bentonite, diatomaceous earth, fine particle size milled exfoliated vermiculite, barytes, calcium carbonate, hollow glass microballoons, wollastonite, milled rockwool, milled ceramic fibres, milled glass fibres, fly ash, and a mixture of two or more thereof.
A paste according to claim 16 or claim 17 wherein the organic particulate filler is selected from the group consisting of sawdust, paper waste, ground nut shells, and cork particles, with a particle size of less than 0,25mm in diameter.
A paste according to any one of claims 16 to 18 comprising:
(i) 8% to 18% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic elastomer; (ii) 82% to 92% inclusive of the combined mass of components (i) and
(ii) of the thermoplastic polymer; and (iii) 310%) to 380% inclusive of the combined mass of components (i) and (ii) of the particulate filler.
A flat or shaped sheet product formed from a paste comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer;
(ii) 70%) to 98% inclusive of the combined mass of components (i) and
(ii) of a thermoplastic polymer; (iii) 250% to 450% inclusive of the combined mass of components (i) and
(ii) of a particulate filler; and (iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste; the paste having been shaped to a desired shape on a carrier and allowed to dry and then removed from the carrier to form the flat or shaped sheet product.
A moulding formed from a substrate to which is applied a layer of a paste comprising:
(i) 2% to 30% inclusive of the combined mass of components (i) and (ii) of a thermoplastic elastomer;
(ii) 70%) to 98% inclusive of the combined mass of components (i) and (ii) of a thermoplastic polymer;
(iii) 250%) to 450% inclusive of the combined mass of components (i) and (ii) of a particulate filler comprising from 1% to 25% inclusive by mass of an organic particulate filler and from 75% to 99% inclusive by mass of an inorganic particulate filler; and
(iv) an amount of a solvent to dissolve components (i) and (ii) and to wet component (iii) to form the paste; the paste having been shaped to a desired shape and allowed to dry so that it adheres to the substrate to form the moulding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2002214184A AU2002214184A1 (en) | 2000-11-14 | 2001-11-09 | Process for the manufacture of a flat or shaped sheet product |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ZA200006599 | 2000-11-14 | ||
| ZA2000/6599 | 2000-11-14 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2002040593A2 true WO2002040593A2 (en) | 2002-05-23 |
| WO2002040593A3 WO2002040593A3 (en) | 2002-08-01 |
Family
ID=25588977
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/IB2001/002109 WO2002040593A2 (en) | 2000-11-14 | 2001-11-09 | Process for the manufacture of a flat or shaped sheet product |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU2002214184A1 (en) |
| WO (1) | WO2002040593A2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2008068606A1 (en) * | 2006-12-07 | 2008-06-12 | Garlock Sealing Technologies, Llc | Process for making high-pressure sheet gasketing materials |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1998040435A1 (en) * | 1997-03-11 | 1998-09-17 | Nippon Zeon Co., Ltd. | Conductive elastomer film, method for production thereof, and conductive elastomer composition |
| WO2000007791A1 (en) * | 1998-08-04 | 2000-02-17 | Windsor Technologies Limited | Process for the manufacture of a moulding |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH11263909A (en) * | 1998-03-18 | 1999-09-28 | Hitachi Chem Co Ltd | Resin paste having film peelable with water and release of film formed from resin paste |
-
2001
- 2001-11-09 WO PCT/IB2001/002109 patent/WO2002040593A2/en not_active Application Discontinuation
- 2001-11-09 AU AU2002214184A patent/AU2002214184A1/en not_active Abandoned
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1998040435A1 (en) * | 1997-03-11 | 1998-09-17 | Nippon Zeon Co., Ltd. | Conductive elastomer film, method for production thereof, and conductive elastomer composition |
| WO2000007791A1 (en) * | 1998-08-04 | 2000-02-17 | Windsor Technologies Limited | Process for the manufacture of a moulding |
Non-Patent Citations (1)
| Title |
|---|
| PATENT ABSTRACTS OF JAPAN vol. 1999, no. 14, 22 December 1999 (1999-12-22) & JP 11 263909 A (HITACHI CHEM CO LTD), 28 September 1999 (1999-09-28) * |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2008068606A1 (en) * | 2006-12-07 | 2008-06-12 | Garlock Sealing Technologies, Llc | Process for making high-pressure sheet gasketing materials |
| US20120095137A1 (en) * | 2006-12-07 | 2012-04-19 | Garlock Sealing Technologies, Llc | Process for making high-pressure sheet gasketing materials |
| CN101528880B (en) * | 2006-12-07 | 2013-12-04 | 卡罗克密封技术公司 | Process for making high-pressure sheet gasketing materials |
| US8871841B2 (en) | 2006-12-07 | 2014-10-28 | Garlock Sealing Technologies, Llc | Process for making high-pressure sheet gasketing materials |
| KR101476657B1 (en) * | 2006-12-07 | 2014-12-24 | 갈록 실링 테크놀로지스 엘엘씨 | Process for making high-pressure sheet gasketing materials |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2002214184A1 (en) | 2002-05-27 |
| WO2002040593A3 (en) | 2002-08-01 |
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