Stock material or miscellaneous articles – Structurally defined web or sheet – Including components having same physical characteristic in...
Patent
1987-06-25
1990-09-11
Lusignan, Michael
Stock material or miscellaneous articles
Structurally defined web or sheet
Including components having same physical characteristic in...
156285, 264510, 264516, 264547, 428214, B32B 702
Patent
active
049562240
DESCRIPTION:
BRIEF SUMMARY
The assembly of one or more layers of thermoplastic resin with one or more layers of reinforced thermosetting resin to form a laminate material has always presented a technical problem which is difficult to solve.
One of the first proposed solutions consisted, according to GB Pat. No. 1,210,268 relating to coldformed laminates in which the thermoplastic layer consists of polyvinyl chloride or chlorinated polyethylene, in improving the adhesion of this layer to the thermosetting layer occasionally reinforced with fibres by carrying out the assembly in the presence of 0.1 to 20% by weight (based on the thermoplastic) of a bonding agent preferably consisting of polybutadiene or of butadiene-acrylonitrile rubber. GB Pat. No. 1,301,023 subsequently described a process consisting in (a) forming laminate comprising a sheet of thermoplastic material and at least one sheet of fibrous material impregnated with thermosetting resin, the sheet of thermoplastic material being at least as thick as the impregnated fibrous material, and (b) pressing the said laminate hot under a pressure of up to 35 bars and under time, temperature and pressure conditions which cause the thermosetting resin to cure without destroying the thermoplastic material.
GB Pat. A-2,087,307 describes a product comprising a substrate of thermoplastic material to which a decorative surface layer comprising a thermosetting material is bonded by means of a so-called "hot-melt" elastomer. This product may be obtaine by a process consisting:
either in manufacturing the thermoplastic substrate by continuous hot extrusion and, while it is still hot after the extrusion stage, placing it in contact with the face of the decorative surface layer which is coated with hot-melt elastomer,
or in arranging at least one sheet of the decorative surface layer, coated with hot-melt elastomer, in a mould forming part of a moulding or injection-moulding apparatus, introducing the thermoplastic material into the said mould at elevated temperature and, lastly, moulding the said material to form the substrate. fibre-reinforced. Lastly, GB Pat. B-2,043,532 describes a hot-mouldable laminate comprising at least one thermoplastic resin layer, at least one fibre-reinforced and cured thermosetting resin layer and at least one adhesive layer intermediate between the resin layers, the said adhesive layer comprising a thermoplastic resina and being able of existing in the molten state at a temperature below the moulding temperature, and the thickness of the thermoplastic resin layer being from 1 to 100 times the thickness of the reinforced and cured thermosetting resin layer.
The common feature of the various processes referred to above, whether they do or do not involve bonding fo thermoplastic and thermosetting layers by means of an adhesive layer, and whatever the respective thicknesses of the said layers, is the production of laminates by means of compression moulding techniques. In general, these techniques are suited to the manufacture of articles having a planar or virtually planar shape. On the contrary, they are poorly suited to the manufacture of articles having a complex, (convex or concave)shape, such as sanitaryware (baths, washbasins, sinks, and the like), motorcyclists' helmets, and the like. To manufacture such articles, particularly when the thermoplastic resin is polymethyl methyacrylate, use is generally made of the technique known as skelton forming, the latter being defined (according to A. F. Dorian, Six-Language Dictionary of Plastics and Rubber Technology (1965) page 535) as a process in which a plastic sheet is drawn partially into a vacuum chamber and then snapped back into a skelton mould in which the pressure is controlled by air admission.
In this context, there is already known, namely by FR Pat. A-2,325,505 a laminate material based on a skelton substrate of acrylic resin joined to a reinforced polyester, characterized by a sheet of polymethyl methacrylate to at least one face of which a polyester/reinforcing fibre and/or filler composite adheres direc
REFERENCES:
patent: 3896069 (1975-07-01), Kosaka et al.
patent: 4443507 (1984-04-01), Yamada et al.
patent: 4634140 (1987-01-01), Stroi
International Search Report, PCT/FR 86/00373, Feb. 19, 1987.
Lusignan Michael
Societe Chimique Des Charbonnages S.A.
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