EP1011957A1 - Rigid coloured article - Google Patents
Rigid coloured articleInfo
- Publication number
- EP1011957A1 EP1011957A1 EP98900097A EP98900097A EP1011957A1 EP 1011957 A1 EP1011957 A1 EP 1011957A1 EP 98900097 A EP98900097 A EP 98900097A EP 98900097 A EP98900097 A EP 98900097A EP 1011957 A1 EP1011957 A1 EP 1011957A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- article
- layer
- sheet
- mould
- skin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
Links
- 238000007666 vacuum forming Methods 0.000 claims abstract description 3
- 238000000034 method Methods 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 15
- 239000011342 resin composition Substances 0.000 claims description 13
- 229920003023 plastic Polymers 0.000 claims description 11
- 239000004033 plastic Substances 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- 229920001169 thermoplastic Polymers 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 239000006260 foam Substances 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- 239000000835 fiber Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 239000002243 precursor Substances 0.000 claims description 3
- 239000011230 binding agent Substances 0.000 claims description 2
- 238000001125 extrusion Methods 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims description 2
- 229920005830 Polyurethane Foam Polymers 0.000 claims 1
- 239000004411 aluminium Substances 0.000 claims 1
- 229910052782 aluminium Inorganic materials 0.000 claims 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims 1
- 239000011496 polyurethane foam Substances 0.000 claims 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 7
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 6
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 6
- 229920002635 polyurethane Polymers 0.000 description 5
- 239000004814 polyurethane Substances 0.000 description 5
- 229920000058 polyacrylate Polymers 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 229920005669 high impact polystyrene Polymers 0.000 description 2
- 239000004797 high-impact polystyrene Substances 0.000 description 2
- 239000012948 isocyanate Substances 0.000 description 2
- 150000002513 isocyanates Chemical class 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920005862 polyol Polymers 0.000 description 2
- 150000003077 polyols Chemical class 0.000 description 2
- 239000004800 polyvinyl chloride Substances 0.000 description 2
- 229920000915 polyvinyl chloride Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004150 EU approved colour Substances 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 241000237983 Trochidae Species 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 150000002843 nonmetals Chemical class 0.000 description 1
- 229940006093 opthalmologic coloring agent diagnostic Drugs 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 229920000193 polymethacrylate Polymers 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
- B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
-
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
-
- 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
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
-
- 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
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
-
- 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 invention relates to a method of making coloured rigid articles and to the articles
- the vehicles can have metal panels as an exterior covering it would
- A-0266107 discloses an article said to be useful as an automobile body panel and comprising a cast weatherable polymer film made up of a pigmented acrylic layer
- the invention provides a method of making a coloured rigid article
- thermoplastic polymer to form the precursor of the skin
- the skin should be capable of being thermoformed (i.e. under vacuum) and have a
- the skin should be weather and impact resistant and have
- the thermoplastic layer may be acrylonitrilebutadienestyrene (ABS); an ester of acrylonitrilestyreneacrylic(ASA); polycarbonate and derivatives thereof;
- thermoplastic polymer is
- ABS and the pigmented layer is a glossy pigmented layer in a plastics carrier, e.g. a
- the sheet and layer are a coextrusion which is available under the trade mark "IRIDON".
- the formed article will need to be secured to a frame or companion articles and it is an
- the shell may be shaped to engage the free end
- the sheet is preferably formed of ABS, i.e. acrylonitrilebutadienestyrene, and the polyacrylate carrier for the pigment is preferably polymethylmethacrylate.
- ABS i.e. acrylonitrilebutadienestyrene
- polyacrylate carrier for the pigment is preferably polymethylmethacrylate.
- a high impact form having the following combination of properties: an Izod impact of 380-420 J/m at 23°C; a tensile strength of 30-40 MPa; a density of about 1.1
- the coextrusion sheet is first vacuum formed, i.e. thermoformed, in a male mould to
- the resin composition is cured in the mould.
- the shell comprises shell halves of cured epoxy GRP (which can be made to particularly tight tolerances).
- the shell halves are located in a mould which is then held in a pressure
- the shaped sheet is laid in the shell half with the acrylate layer face down, so that the
- the fibres Preferably have tensile and ductile properties.
- fibres may be loose but preferably take the form of a mat. While the fibres may be
- metals selected from a wide range of materials, e.g. metals, non-metals, composites such as
- the fibre material is preferably
- the resin composition should be selected to have mechanical properties according to
- the composition may be selected for sound attenuation, flowability (to allow the moulding of complex shapes); and be capable of being pigmented and colour matched.
- the resin composition may be selected from a range of curable materials such as PVC,
- composition is a mixture of acrylic polymer, polyethylene, polyester, polyurethane and the like.
- the composition is a mixture of acrylic polymer, polyethylene, polyester, polyurethane and the like.
- composition is selected to form a formed
- polyurethane in which case it comprises a polyol component, an isocyanate component
- ingredients may be present such as fillers, blowing agents,
- the polyol may be based on a polyester,
- the isocyanate may be methyldiisocyanate
- the curable resin composition is a polyurethane because
- Such element may be a threaded bolt the head of
- Curing is then initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation. Foaming may be initiated chemically or by temperature or other radiation.
- the invention provides a method of making a coloured rigid article comprising the steps of placing a shaped skin having a pigmented surface in a shaped shell in a pressure and temperature resistant mould with the pigmented surface
- the skin is a vacuum formed co-extrusion of a layer of an impact resistant
- the invention provides a rigid shaped article comprising an outer layer
- the article includes fibre
- Figure 1 is a side elevation of a coextrusion
- Figure 2 is a vertical section through a mould containing shell halves and before
- a coextrusion 1 comprising an acrylonitrile butadiene styrene 1A and a layer of
- pigmented impact modified polymethacrylate IB is thermo or vacuum formed in a
- suitable vacuum mould (not shown) at about 160° to 170°C to a required profile P of the skin of the intended article.
- the coextrusion is selected according to the properties required for the end use; in a preferred case the coextrusion has a density of about 1.1
- the coextrusion will have a Vicat softening temperature of about
- a rigid foam backing B is applied to the profile P in a mould shown in Figure 1.
- mould comprises a base 2 and a lid 3; and has side walls 4.
- the sidewalls are in
- bottom and top halves 4A, 4B respective shaped to hold the free edges of the profile P.
- a paste of a self setting filler composition 5, e.g. a filled plastics is placed in the lower
- the lower shelf half HI has a shaped upper wall against which
- the shell half is made of glass reinforced epoxy plastics or the like to tight tolerances, so that the profile is an accurate fit, and
- uncured polyurethane composition 7 is poured on to the upper, i.e.
- a top shell half H2 is placed at one end.
- the panel has been made with a glossy paint finish and at low cost.
- the shell halves are
- the invention is not limited to the embodiment shown.
- the coextrusion may have a shaped face to key to the foam layer.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Glass Compositions (AREA)
- Diaphragms For Electromechanical Transducers (AREA)
- Graft Or Block Polymers (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
A coloured rigid article is made by vacuum forming a layered sheet shaped to form the skin of the article.
Description
RIGID COLOURED ARTICLE
The invention relates to a method of making coloured rigid articles and to the articles
themselves. While the invention can be applied to a wide range of articles it is seen to
particular advantage in making panels for motorised machines/vehicles and so it will be described in relation to such items, with the reminder that the invention is of wider applicability.
Some vehicles, especially heavy use industrial vehicles such as earth diggers are prone
to damage. While the vehicles can have metal panels as an exterior covering it would
be more economic if the panels were made of a less expensive more robust material.
Plastics are obvious candidate materials but these do not have an attractive colour. EP-
A-0266107 discloses an article said to be useful as an automobile body panel and comprising a cast weatherable polymer film made up of a pigmented acrylic layer
joined by adhesive to a pvc film and supported on a polymer layer. The article is made
by injecting curable polymer behind the film placed in a mould with the pvc film facing
innermost. There is a need for a method of making a rigid impact resistant panel which
has an attractive bright colour.
In one aspect the invention provides a method of making a coloured rigid article, the
method comprising:
i) applying a layer of impact resistant pigmented material to a sheet of
impact resistant thermoplastic polymer to form the precursor of the skin
of the article;
ii) vacuum forming the layered sheet to a predetermined shape appropriate to the skin of the article.
iii) contacting the shaped layered sheet with a shaped shell in a pressure
and temperature resistant mould with the pigmented layer contacting a wall of the shell;
iv) supplying a curable resin composition to contact the exposed face of the
sheet, closing the mould and allowing or causing the composition to
cure, whereby the cured composition has the same shape as the sheet,
and
v) removing the formed coloured rigid article.
The skin should be capable of being thermoformed (i.e. under vacuum) and have a
suitable colour and gloss. The skin should be weather and impact resistant and have
stability to ultraviolet light. If required, the skin should be capable of bonding to the resin substrate. The thermoplastic layer may be acrylonitrilebutadienestyrene (ABS);
an ester of acrylonitrilestyreneacrylic(ASA); polycarbonate and derivatives thereof;
impact modified unplasticised polyvinylchloride (PVC-u); and uv-resistant high impact polystyrene (HIPS). Most preferably the impact resistant thermoplastic polymer is
ABS and the pigmented layer is a glossy pigmented layer in a plastics carrier, e.g. a
polyacrylate. Most preferably the sheet and layer are a coextrusion which is available under the trade mark "IRIDON".
The formed article will need to be secured to a frame or companion articles and it is an
advantageous feature of the invention that for this purpose a fixing element may be
anchored in the curable composition. The shell may be shaped to engage the free end
of the fixing elements.
The sheet is preferably formed of ABS, i.e. acrylonitrilebutadienestyrene, and the polyacrylate carrier for the pigment is preferably polymethylmethacrylate. The ABS is
preferably a high impact form having the following combination of properties: an Izod impact of 380-420 J/m at 23°C; a tensile strength of 30-40 MPa; a density of about 1.1
gms/cc.
The coextrusion sheet is first vacuum formed, i.e. thermoformed, in a male mould to
have the desired profile. This is then placed in a shell which most preferably is
distortion resistant, i.e. resistant to the pressure and temperatures arising when the
resin composition is cured in the mould. Most preferably the shell comprises shell halves of cured epoxy GRP (which can be made to particularly tight tolerances).
Advantageously the shell halves are located in a mould which is then held in a pressure
resistant press.
The shaped sheet is laid in the shell half with the acrylate layer face down, so that the
shaped ABS sheet then acts as a former for the curable resin composition. Because the
shaped sheet contacts the inner layer of the mould a mould release agent is not needed.
It is a much preferred feature of the invention that fibres are present to reinforce the
curable composition. Preferably the fibres have tensile and ductile properties. Such
fibres may be loose but preferably take the form of a mat. While the fibres may be
selected from a wide range of materials, e.g. metals, non-metals, composites such as
titanium, carbon, aluminosilicate, plastics such as polypropylene, it is preferred to use glass fibres. They may be bonded together in the mat in an emulsion binder, selected
to be compatible with the curable composition. The fibre material is preferably
VETROTEX M5 available from Vetrotex (UK) Ltd.
The resin composition should be selected to have mechanical properties according to
the intended end use of the article. A high strength to weight ratio is preferred, together with compatibility with the other components. Optionally the resin
composition may be selected for sound attenuation, flowability (to allow the moulding of complex shapes); and be capable of being pigmented and colour matched.
The resin composition may be selected from a range of curable materials such as PVC,
acrylic polymer, polyethylene, polyester, polyurethane and the like. The composition is
preferably adapted to form a rigid form, the strengths of which are selected appropriate
to the intended end use. Most preferably the composition is selected to form a formed
polyurethane in which case it comprises a polyol component, an isocyanate component
and a catalyst. Other ingredients may be present such as fillers, blowing agents,
extenders, colouring agents; and the like. The polyol may be based on a polyester,
polyepoxy, polyethers, polybutadiene; the isocyanate may be methyldiisocyanate,
napthalene diisocyanate, tolylene diisocyanate or the like. It is a much preferred feature of the invention that the curable resin composition is a polyurethane because
that will provide a rigid article in a short time period, e.g. less than five minutes and
typically from 1.5 to about three minutes. As a result the articles may be made quickly
and on a mass production basis.
It is a much preferred feature of the invention that a fixing element is anchored in the
resin composition before curing. Such element may be a threaded bolt the head of
which is anchored in the composition. Several such elements may be included.
Curing is then initiated chemically or by temperature or other radiation. Foaming may
be caused in known manner.
In another aspect the invention provides a method of making a coloured rigid article comprising the steps of placing a shaped skin having a pigmented surface in a shaped
shell in a pressure and temperature resistant mould with the pigmented surface
contacting a wall of the shell followed by a curing resin behind the skin characterised
in that the skin is a vacuum formed co-extrusion of a layer of an impact resistant
pigmented layer and a sheet of impact resistant thermoplastic polymer
In other aspects the invention provides a rigid shaped article comprising an outer layer
of pigmented impact resistant material, a sheet of impact resistant thermoplastic
polymer and an inner layer of foamed plastics; preferably the article includes fibre
reinforcement in the foamed plastics layer and preferably the article including a fixing element anchored in the foamed plastics layer.
In order that the invention may be well understood it will now be described by way of
example only, with reference to the accompanying diagrammatic drawings, in which:
Figure 1 is a side elevation of a coextrusion; and
Figure 2 is a vertical section through a mould containing shell halves and before
curing of the resin composition.
A coextrusion 1 comprising an acrylonitrile butadiene styrene 1A and a layer of
pigmented impact modified polymethacrylate IB is thermo or vacuum formed in a
suitable vacuum mould (not shown) at about 160° to 170°C to a required profile P of the skin of the intended article. The coextrusion is selected according to the properties
required for the end use; in a preferred case the coextrusion has a density of about 1.1
gms/cc and a thickness of about 2 mm; a tensile strength of about 30 to about 40 MPa
and a flexural strength of about 50 to about 55 MPa, and a flexural modulus of about
2.2 Gpa. Typically the coextrusion will have a Vicat softening temperature of about
97 to about l01°C.
A rigid foam backing B is applied to the profile P in a mould shown in Figure 1. The
mould comprises a base 2 and a lid 3; and has side walls 4. The sidewalls are in
bottom and top halves 4A, 4B respective shaped to hold the free edges of the profile P. A paste of a self setting filler composition 5, e.g. a filled plastics is placed in the lower
half of the mould box to form the intended shape M. A lower shell half HI is placed
on the setting paste. The lower shelf half HI has a shaped upper wall against which
the profile P is placed (with the layer IB facing downwards), and pipes 6 at the rear
through which a heating medium flows. The shell half is made of glass reinforced epoxy plastics or the like to tight tolerances, so that the profile is an accurate fit, and
will not move during the moulding step. A mat of VETROTEX material (not shown)
is placed and then uncured polyurethane composition 7 is poured on to the upper, i.e.
backing face 1A of the profile P. An insert 8 is placed at one end. A top shell half H2
is placed on top followed by more of the paste 5, and then the lid 3 is placed in position. The whole is put in a hydraulic press, not shown. Hot water is passed
through the pipes 6, to provide heat to cause the polyurethane composition to foam
and cure. This takes about two minutes. The water supply is shut off, and the mould M removed from the press and dismantled. The profile P with its high density rigid
foam backing is removed and trimmed to size and shape. In this way a highly rigid
panel has been made with a glossy paint finish and at low cost. The shell halves are
reusable.
The invention is not limited to the embodiment shown. The coextrusion may have a shaped face to key to the foam layer.
Claims
1. A method of making a coloured rigid article, the method comprising:
i) applying a layer of impact resistant pigmented material to a sheet of impact resistant thermoplastic polymer to form the precursor of the skin of the article;
ii) vacuum forming the layer sheet to a predetermined shape appropriate to the skin of the article;
iϋ) placing the shaped skin precursor in a shaped shell in a pressure and temperature resistant mould with the pigmented layer contacting a wall of the shell;
iv) supplying a curable resin composition to the exposed face of the sheet, closing the mould and allowing or causing the composition to cure whereby the cured composition has the same shape as the sheet; and
v) removing the formed coloured rigid article from the mould.
2. A method according to Claim 1, wherein the layer and the sheet are formed as a coextrusion.
3. A method according to Claim 1 or 2, including adding at least one fixing element to the curable composition whereby the fixing element is anchored in the formed article.
4. A method according to any preceding Claim, including the step of including fibres in the curable resin composition.
5. A method according to Claim 4, wherein the fibres are coated with a binder.
6. A method according to Claim 4 or 5, wherein the fibres are of glass, metal or the like.
7. A method according to Claim 6, wherein the fibres are in the form a of a mat.
8. A method accordmg to any preceding Claim, wherein the curable resin composition is adapted to form a foam.
9. A method accordmg to Claim 8, wherein the curable resin is adapted to form a polyurethane foam.
10. A method according to any preceding Claim, wherein the curable resin
composition is adapted to cure and foam in less than five minutes.
1 1. A method according to Claim 10, wherein the resin composition is adapted to
cure in from about one minute to about three minutes.
12. A method according to any preceding Claim wherein the shell is formed of
GRP or the like.
13. A method according to any preceding Claim, wherein the shell located in a
pressure resistant mould.
14. A method according to Claim 13, wherein the mould is made of is cast aluminium.
15. A method of making a coloured rigid article comprising the steps of placing a
shaped skin having a pigmented surface in a shaped shell in a pressure and
temperature resistant mould with the pigmented surface contacting a wall of the
shell followed by a curing resin behind the skin characterised in that the skin is a vacuum formed co-extrusion of a layer of an impact resistant pigmented
layer and a sheet of impact resistant thermoplastic polymer.
16. A rigid shaped article comprising an outer layer of pigmented impact resistant material, a sheet of impact resistant thermoplastic polymer and an inner layer of foamed plastics.
17. An article accordmg to Claim 16, including fibre reinforcement in the foamed plastics layer.
18. An article according to Claim 16 or 17, including a fixing element anchored in the foamed plastics layer.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9700071 | 1997-01-03 | ||
| GB9700071A GB2320908B (en) | 1997-01-03 | 1997-01-03 | Rigid coloured article |
| PCT/GB1998/000009 WO1998029233A1 (en) | 1997-01-03 | 1998-01-05 | Rigid coloured article |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP1011957A1 true EP1011957A1 (en) | 2000-06-28 |
Family
ID=10805524
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP98900097A Ceased EP1011957A1 (en) | 1997-01-03 | 1998-01-05 | Rigid coloured article |
Country Status (14)
| Country | Link |
|---|---|
| EP (1) | EP1011957A1 (en) |
| JP (1) | JP2001507298A (en) |
| CN (1) | CN1243472A (en) |
| AU (1) | AU721660B2 (en) |
| BR (1) | BR9806830A (en) |
| CA (1) | CA2276663A1 (en) |
| CZ (1) | CZ238599A3 (en) |
| GB (1) | GB2320908B (en) |
| HU (1) | HUP0000864A2 (en) |
| IL (1) | IL130699A0 (en) |
| PL (1) | PL334441A1 (en) |
| SK (1) | SK91299A3 (en) |
| TR (1) | TR199901970T2 (en) |
| WO (1) | WO1998029233A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102371683A (en) * | 2010-08-19 | 2012-03-14 | 李启文 | Polyurethane composite material and preparation method thereof |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10120912A1 (en) | 2001-04-27 | 2002-10-31 | Basf Ag | Composite components made of polyurethane and their use in exterior body parts |
| DE10161155B4 (en) * | 2001-12-12 | 2007-08-09 | Basf Ag | Deposit containing polyurethane composite components |
Family Cites Families (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2708288A (en) * | 1950-05-26 | 1955-05-17 | Frank W Fuller | Method and apparatus for molding plastic |
| US4065337A (en) * | 1973-04-18 | 1977-12-27 | Coast Catamaran Corporation | Molding process |
| DE2548318A1 (en) * | 1975-10-29 | 1977-05-05 | Theysohn Friedrich Fa | METHOD AND DEVICE FOR COATING FILM MATERIAL |
| DE3127253A1 (en) * | 1980-07-16 | 1982-06-16 | Comind S.p.A. Azienda Stars, Villastellone, Torino | SELF-SUPPORTING ELEMENT FOR THE EQUIPMENT OF THE INTERIOR OF MOTOR VEHICLES, IN PARTICULAR INSTRUMENT COVER, AND METHOD FOR THE PRODUCTION THEREOF |
| JPS60176740A (en) * | 1984-02-22 | 1985-09-10 | Hitachi Chem Co Ltd | Method of forming pattern on vacuum-formed item |
| JPS6131214A (en) * | 1984-07-23 | 1986-02-13 | Toyota Motor Corp | Manufacture of vehicle decorating lace |
| JPS62181114A (en) * | 1986-02-06 | 1987-08-08 | Meiwa Sangyo Kk | Manufacture of composite molded form |
| CA1292603C (en) * | 1986-10-28 | 1991-12-03 | Thomas M. Ellison | Injection molded plastic article with integral weatherable pigmented film surface |
| US4698277A (en) * | 1986-11-12 | 1987-10-06 | General Electric Company | High-temperature laminated insulating member |
| ATE129664T1 (en) * | 1988-12-22 | 1995-11-15 | Basf Corp | METHOD FOR PRODUCING A COATED, LAMINATED AUTOMOTIVE OR VEHICLE PART. |
| US4983247A (en) * | 1989-08-07 | 1991-01-08 | General Electric Company | Method for producing resin rich surface layer on composite thermoplastic material |
| KR930702144A (en) * | 1991-07-18 | 1993-09-08 | 모리히데오 | Manufacturing method of multilayer molded article |
| JPH05147170A (en) * | 1991-12-02 | 1993-06-15 | Toppan Printing Co Ltd | Multilayer plastic molded article and method for producing the same |
| TW224443B (en) * | 1992-07-31 | 1994-06-01 | Minnesota Mining & Mfg | |
| JPH06144123A (en) * | 1992-11-10 | 1994-05-24 | Kasai Kogyo Co Ltd | Internal component for automobile and its manufacture |
| JPH06287323A (en) * | 1993-04-05 | 1994-10-11 | Mitsui Petrochem Ind Ltd | Skin sheet highly resistant to piercing and laminate made by using the sheet |
| TW300227B (en) * | 1993-12-20 | 1997-03-11 | Sumitomo Chemical Co | |
| US5514320A (en) * | 1995-04-25 | 1996-05-07 | Akemi, Inc. | Method of making a hollow tool |
-
1997
- 1997-01-03 GB GB9700071A patent/GB2320908B/en not_active Expired - Fee Related
-
1998
- 1998-01-05 SK SK912-99A patent/SK91299A3/en unknown
- 1998-01-05 TR TR1999/01970T patent/TR199901970T2/en unknown
- 1998-01-05 CN CN98801681A patent/CN1243472A/en active Pending
- 1998-01-05 EP EP98900097A patent/EP1011957A1/en not_active Ceased
- 1998-01-05 CZ CZ992385A patent/CZ238599A3/en unknown
- 1998-01-05 PL PL98334441A patent/PL334441A1/en unknown
- 1998-01-05 AU AU53347/98A patent/AU721660B2/en not_active Ceased
- 1998-01-05 BR BR9806830-0A patent/BR9806830A/en not_active IP Right Cessation
- 1998-01-05 JP JP52975798A patent/JP2001507298A/en active Pending
- 1998-01-05 IL IL13069998A patent/IL130699A0/en unknown
- 1998-01-05 WO PCT/GB1998/000009 patent/WO1998029233A1/en not_active Ceased
- 1998-01-05 HU HU0000864A patent/HUP0000864A2/en unknown
- 1998-01-05 CA CA002276663A patent/CA2276663A1/en not_active Abandoned
Non-Patent Citations (1)
| Title |
|---|
| See references of WO9829233A1 * |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102371683A (en) * | 2010-08-19 | 2012-03-14 | 李启文 | Polyurethane composite material and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| AU721660B2 (en) | 2000-07-13 |
| AU5334798A (en) | 1998-07-31 |
| WO1998029233A1 (en) | 1998-07-09 |
| SK91299A3 (en) | 2000-03-13 |
| CN1243472A (en) | 2000-02-02 |
| GB2320908B (en) | 1999-04-28 |
| TR199901970T2 (en) | 2000-08-21 |
| GB9700071D0 (en) | 1997-02-19 |
| CA2276663A1 (en) | 1998-07-09 |
| GB2320908A (en) | 1998-07-08 |
| BR9806830A (en) | 2002-01-02 |
| JP2001507298A (en) | 2001-06-05 |
| PL334441A1 (en) | 2000-02-28 |
| CZ238599A3 (en) | 1999-12-15 |
| IL130699A0 (en) | 2000-06-01 |
| HUP0000864A2 (en) | 2000-08-28 |
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