CA1177741A - Foam composite material impregnated with resin - Google Patents
Foam composite material impregnated with resinInfo
- Publication number
- CA1177741A CA1177741A CA000386323A CA386323A CA1177741A CA 1177741 A CA1177741 A CA 1177741A CA 000386323 A CA000386323 A CA 000386323A CA 386323 A CA386323 A CA 386323A CA 1177741 A CA1177741 A CA 1177741A
- Authority
- CA
- Canada
- Prior art keywords
- resin
- foam composite
- composite material
- web
- microspheres
- 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.)
- Expired
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Abstract
Abstract The invention relates to a foam composite material which comprises a material in web form impregnated with a curable resin. The resin in the foam composite mate-rial is in the B-stage. The foam composite material furth-er contains expanded thermoplastic particles which are essentially uniformly distributed in the resin and in the web material. The invention also relates to laminates pre-pared by use of the foam composite material and a method for the manufacture of such laminates.
Description
1~771~
A foam composite material impregnated with resin The present invention concerns a foam composite material which is impregnated with resin, a laminate containing that mat-erial and a method for manufacture of such a laminate. Specifi-cally, the invention concerns a foam composite material comprising a web, which is impregnated with a thermosetting resin and which contains expanded thermoplastic particles. The foam composite material according to the invention is preferably used for modi-fying surfaces.
Thus in a first aspect this invention provides a laminate which comprises:
(i) at least one foam composite material including a material in the form of a web, a cured resin and expanded thermo-plastic particles essentially uniformly distributed in the resin and in the web material, and (ii) at least one further such a material of another mater-ial, wherein the materials are bonded by the resin in the foam composite material, whereby the expanded thermoplastic particles constitute between 70 and 95 percent by volume of the foam compo-site material parts of the laminate.
In a second aspect this invention provides a method forthe manufacture of a laminate, which method comprises:
(a) preparing a foam composite material containing a mat-erial in the form of a web, a curable resin in -the B-stage and expanded thermoplastic particles essentially uniformly distributed in the resin and in the material, . ~
.
la ll 7 7~1 (b) assembling the foam composite material with at least one further such material or another material and, (c) bonding the materials to each other by finally curing the resin.
The foam composite material may for instance be prepared in the following way. A pre-condensate of a water based thermo-setting resin is prepared conventionally and the amount of water is adjusted in order to obtain 30 to 75 percent by weight dry substance. I'o the solution obtained is added non-expanded thermo-plastic particles, known as microspheres, in an amount such thatthe weight ratio microspheres:resin varies between 4:1 and 1:50 in the finished foam composite material. In the expanded condi-tion, the microspheres preferably constitute 70-95, specifically 85-95, percent by volume of the foam composite material. A
material in the form of a web is impregnated with the mixture of resin and microspheres in a conventional way, e.g. by immersing the web in a bath of the mixture, by spraying the mixture on the web or by adding the mixture in connection with the formation of the web. The impregnated web, the degree of impregnation of which can be adjusted e.g by rolls, is then treated thermally, suitably with circulating hot air having a temperature of 80-150C so that the resin sets to the B-stage and the microspheres expand. It should he noted in this context that a thermosetting resin in the A-stage is meltable, poorly cross-linked and soluble in acetone and other solvents. A C-stage resin is not meltable, completely cross-linked and insoluble. The B-stage is a stage between the ~77~
lb A-stage and the C~stage.
Thermosetting resins that may be used according to the present invention are resins based on formaldehyde with urea, phenol, resorcinol or melamine.
The web material may consist of woven or non-woven ~1777~ , organic or inorganic material and specifically glass fib- I
re, mineral fibre, cellulose fibre and polyester may be f mentioned. It is also important that the web material has sufficien~porosity so that it can be impregnated with the 5. mixture ~ resin and microspheres in a satisfying manner.
Further, the web material must not be taken too thick and suitably the thickness may vary between 0.1 and 5 mm. The reason why the web material must be thin is that otherwise there may be a non-uniform expansion of microspheres owing 10. to the fact that, at the thermal treatment, superficially situated microspheres expand first and these expanded mic-rospheres form a thermally, insulating layer preventing those microspheres which are situated more deeply or more central from expanding and if this happens a product of 15. inferior quality, which is not homogenous, will be obtain-ed.
It is also possible to add the resin and/or the mic-rospheres in connection with the formation of the web, e.g. f by the direct manufacture of the web by depositing a fibre 20. suspension also containing resin and/or microspheres. Al-ternatively the resin and/or microspheres can be added in connection with deposition of fibres from air into a web.
A so prepared web can be treated in the same way as an im-pregnated ready web, i.e. being heated afterwards to ex-25. pand the microspheres and to transform the resin into the B stage. It is, however, also possible in these cases to add already expanded particles to the web at deposition of this since no impregnation step is required. This can be done with special simplicity at deposition of the web from 30. air since then the buoyancy of the expanded particles cau-ses no problems. When the microspheres are expanded before or during the deposition of the web it is possible to make the web thicker than when the expansion is made by heating the impregnated web since no heat transfer problems will 35. arise in this connection. The manufacture of a thicker layer without the need for laminating together several thin sheets is of value in certain connections, especially when the strength demands are lower. It is also possible to pro-f 3 ~ 774~
duce in this way first a very porous web, which by pressing can be given a variable density or a more complicated final shape. The product can otherwise be used in the same way as a foam composite material prepared by impregnation of a rea-5. dy web.
The microspheres which are used when preparing thefoam composite material according to the present invention have shells which may be made up of copolymers of vinyl chloride and vinylidene chloride, copolymers of vinylidene 10. chloride and acrylonitrile, copolymers of vinyl chloride and acrylonitrile and copolymers of styrene and acrylonitrile.
Further, copolymers of methyl metacrylate containing up to 20 percent by weight styrene, copolymers of methyl metacry-late and up to 50 percent by weight of combined monomers of 15. ethyl metacrylate, copolymers of meth~l m~acryl~te and up to about 70 percent by weight of ort~o~b~Co~r/ost Sro~c~m~aey be mentioned. The particle size of the non-expanded particles and, accordingly, the expanded particles may vary within broad limits and is selected with respect to the properties 20. desired for the finished product. Examples of particle si-zes for the non-expanded spheres are l)um to 1 mm, prefer-ably 2 ~m to 0.5 mm and specifically 5)um to 50 ~m. At the expansion the diameter of the microspheres increases by a factor 2-5. The non-expanded microspheres contain volatile, 25. liquid blowing agents which are vaporized at the applica-tion of heat. The blowing agents may consist of freones, hydrocarbons, such as n-pentane, isopentane, neopentane, butane, isobutane or other blowing agents, that are used conventionally in microspheres of the type specified above.
30. Suitably 5-30 percent by weight of the microspheres may consist of blowing agent. The microspheres may be added to the resin solution in the form of dried particles or in the form of a suspension, for instance in an alcohol such as methanol.
35. As mentioned previously, the ratio resin to micro-spheres in the impregnating solution may vary within broad limits and this ratio affects the properties of the final product. Correspondingly, starting from certain fields of 4 ~1777~1 employment and certain desired properties of the final pro-duct it is also possible to select a suitable ratio resin to microspheres in the mixture. This ratio can easily be determined by preparatory experiments in the laboratory.
5. Different additives such as stabilizers, coupling agents, fillers, flame retarding agents and/or pigments may be added to the mixture of resin and the microspheres if desired or required.
The foam composite materials according to the inven-10. tion may be used in combination with substrates or support-ing layers, preferably wood bades supporting layers, for preparing laminates and these laminates are called hetero- I
genous laminates in the following text. It is also possib- !
le to laminate several layers of the foam composite mate-15. rial according to the invention for the preparation of multilaminates and these laminates will be called homogen-ous laminates in the following text. It is certainly also possible to produce mixed laminates containing at least one homogenous laminate together with at least one other 20. material.
In the preparation of the heterogenous laminates the foam composite material according to the invention is com-bined with an optional supporting layer and the combina-tion of the foam composite material and the supporting 25. layer is compressed at an elevated temperature. In this process time, temperature and pressure are chosen mainly with consideration taken to the type of resin used. Often the time for the pressing may vary between 20 seconds and 20 minutes. The temperature may vary between 100 and 180C
30. and the pressure between 0.1 and 3 MPa. If the supporting layer has a rough and uneven surface especially attractive effects may be attained by the foam composite material penetrating the cavities and filling these up, while the "free" surface of the foam composite material, i.e. the 35. surface that is facing the press plate, becomes complete-ly smooth, as the microspheres adjacent to the press pla-te collapses by the pressure while expanded microspheres adjacent the rough surface of the supporting layer penet-i ~ P7741 rates into the cavities filling these up. Accordingly~ alevelling out of the surface is effected. In practice this effect of levelling out can be achieved for example in con-nection with the peparation of plywood. In conventional ply-5. wood preparation si~ed veeners are prepared first and theveneers are compacted to plywood. In order to get a satis-fying surface the rough surface is then ground and a sur-face coating is then pressed onto the plywood surface. Us-ing the foam composite material according to the present ~0. invention it is possible to press together several veneer sheets and a thin sheet of a foam composite material in one single step and, after pressing, there is obtained a hard completely smooth surface layer consisting of a foam composite material according to the invention, in which ma-15. terial the resin is completely cured and the microsphereshave col]apsed partly. Other properties which can be obtain-ed in heterogenous laminates containing a foam composite ma~
terial according to the invention are improved flame retard-ing properties. It is possible to get a laminate surface 20. suitable for painting and (wall) paper covering, to get a higher flexural modulus and a surface that is water repell-ant and thermal insulating. In sheet material a decrease of the skew of the plate, may be achieved.
Lamination with wood gives a material with the sur-25. face properties of wood but with a reduced density, which is usable for example in packings, coachworks or interior fittings. Lamination with metals, especially aluminium sheets or aluminium foils, gives a material with good and lasting surface properties and high stiffness but with re-30. duced density, which can be used for example in packings,coachworks, building frontages, signboards or travel requi-sites. Lamination with papers, impregnated with formalde-hyde-based resins, gives materials with resistant and/or decorative surfaces, high stiffness and low density suited 35. for example in interior fittings, panels and signboards.
In order to improve the adhesion between the impregnated paper and the foam composite material and to reduce the effects of the brittleness of the material it is in these 6 ~77~
cases advantageous to arrange a middle sheet of for examp-le cardboard. Lam;nation of materials with thermoplastic surfaces can give light decorative products suitable in interior fittings and for panels. A coating of nylon 5. flocks on the foam composite material gives a decorative and durable surface allowing pin attachments, which pro-duct is usable for example in notice-boards, interior fittings and signboards. Similar properties and uses flows from laminates with textiles. Numerous other hetero-10. genous laminates are of course possible. It is also possib-le to adhere the foam composite material of the invention against non-solid materials at the formation of these, for example to foam polyuretane against the foam composite ma-terial, preferably between two sheets of these, whereby not 15. only a light and in relation to the weight stiff product is obtained but also is achieved a more uniform foaming of the polyuretane material due to the low heat conduction and heat capacity of the foam composite material. The covering sheets also gives a fire resistant effect reactive to the polyure-20. tane foam. The mentioned properties are of special valuewhen using the product as building elements. It is general-ly possible in heterogenous laminates to introduce a middle sheet between the different materials in order to improve stiffness, adhesion and dent resistance. A suitably select-25. ed middle layer can be bonded against the foam compositematerial by use of the remaining bonding capacity of the resin in the material in accordance with a general purpose of the invention and at the same time, on its other side, allow glueing to materials normally not bondable by the re-30. sin of the foam composite material. For example paper or a fiber web can be used for this purpose and it is especial-ly advantageous that t~le sheet is impregnated with a cur-able resin, preferably the same as in the foam composite material or a resin compatible with this.
35. The homogenous laminates are prepared with pressure times varying between 1 minute and 30 minutes. The pressu-re may suitably vary between 0.01 and 0.5 MPa and the tem-peratures between 100 and 150C. Preferably such conditions are chosen that the expanded microspheres do not collapse.
:11777~1 A lig~t weigilt and strong material which for example may be used in the building trade is obtained if the micro-spheres do not collapse. Furthermore, it should be noted that the ~ly4~ can be laminated by g]ueing without the 5. application of heat.
The foam composite material is heat mouldable in non-cured condition, which for example allows formation of double-bent surfaces in connection with lamination.
Such a moulding can take place both at manufacture of 10. homogenous laminates and at manufacture of heterogenous laminates wherein the other materials are preformed or allows deformation under the lamination procedure.
The invention will be illustrated more in detail in the following non limiting examples.
15. Example 1 . _ A 50 g/m~ felt of glass fibre was impregnated with a dispersion of VDC/ACN microspheres from KemaNord AB and a phenol resin solution 9916 from AB Casco having dry sub-stances of 60 %,wherein the ratio of the dry substances 20. MS:PF is 2:1 (VDC = vinylidene chloride, ACN = acrylonitri-le, MS = microspheres, PF = phenol formadelhyde resin).
When the felt has been immersed in the impregnating bath excessive dispersion is pressed away by rolls. Then the felt is treated with air (120C) causing the water to 25. leave until 7 percent by weight remain and simultaneously the microspheres expand. A homogenous larninate was prepar-ed by superimposing four layers and pressing at 0.25 MPa, 125C for 10 minutes.
The following product was obtained:
Thickness 7.10 mm Density 162 kg m 3 Flexural modulus248 N/mm2 Flexural strength4.68 N/mm2 E modulus pressure15.66 N/mm2 Compression strength, 10 % 2 deformation 0.78 N/mm Smoke 2.8 % KemaNord PM 227 Smoke develop- ¦
ment according to Arapahoe Oxygen index 45 ASTM 2863 ~ a~7~7~l T~lis product can preferably be used as a core or surface material in sandwich structures. The homogenous laminate can be moulded at a temperature of about 120C.
Example 2 5. The process according to example 1 was repeated but the ratio MS:PF was 1:1 (calculated on the dry substances).
The following product was obtained:
Thickness 4.09 mm Density 264 kg m 3 Flexural modulus 574 N/mm2 Flexural strength 12.22 N/mm2 E modulus pressure 31.11 N/mm2 Compression strength, 10 %
deformation 1.89 N/mm2 Smoke 2.4 % KemaNord PM 227 Smoke develop-ment according to Arapahoe Oxygen index 45 ASTM 2863 This product can be used in sandwich struc~ures.
Example 3 10. The process according to example 1 was repeated but the ratio MS:PF was 1:2 (calculated on the dry substances).
The following product was obtained:
Thickness 3.1 mm Density 306 kg/m 3 Flexural modulus 799 N/mm2 Flexural strength 20.16 N/mm2 ! E modulus pressure 40.19 N/mm2 Compression strength, 10 %
deformation 3.85 N/mm2 Smoke 1.8 % KemaNord PM 227 Smoke develop-ment according to Arapahoe Oxygen index 42 ASTM 2863 Flame-proof surface layer class 3 NT 004 Average smoke density 9 %
, The product can be used in sandwich structures.
9 ~3.7774~
Example 4 A foam fibre layer was prepared according to examp-le 1 but the ratio MS:PF was 1:2, calculated on the dry substance. This sheet was pressed onto a plasterboard at 5. a pressure of 0.4 MPa and a temperature of 120C for 10 minutes, and a decorative surface suitable for embossing was obtained. At fire testing NT 004 class 1 is obtained on the surface and no smoke is developed.
Example 5 10. Example 4 was repeated but a 10 mm unground spruce plywood was used as a supporting layer.
A levelling out of the surface was obtained and the surface was waterproof and suitable for painting and covering with wall paper.
15. The surface can further be decorative and suitable for embossing. The products have improved stiffness and are as far as fire is concerned classified as flame-proof surface layer class 3, average smoke density 13 %.
A foam composite material impregnated with resin The present invention concerns a foam composite material which is impregnated with resin, a laminate containing that mat-erial and a method for manufacture of such a laminate. Specifi-cally, the invention concerns a foam composite material comprising a web, which is impregnated with a thermosetting resin and which contains expanded thermoplastic particles. The foam composite material according to the invention is preferably used for modi-fying surfaces.
Thus in a first aspect this invention provides a laminate which comprises:
(i) at least one foam composite material including a material in the form of a web, a cured resin and expanded thermo-plastic particles essentially uniformly distributed in the resin and in the web material, and (ii) at least one further such a material of another mater-ial, wherein the materials are bonded by the resin in the foam composite material, whereby the expanded thermoplastic particles constitute between 70 and 95 percent by volume of the foam compo-site material parts of the laminate.
In a second aspect this invention provides a method forthe manufacture of a laminate, which method comprises:
(a) preparing a foam composite material containing a mat-erial in the form of a web, a curable resin in -the B-stage and expanded thermoplastic particles essentially uniformly distributed in the resin and in the material, . ~
.
la ll 7 7~1 (b) assembling the foam composite material with at least one further such material or another material and, (c) bonding the materials to each other by finally curing the resin.
The foam composite material may for instance be prepared in the following way. A pre-condensate of a water based thermo-setting resin is prepared conventionally and the amount of water is adjusted in order to obtain 30 to 75 percent by weight dry substance. I'o the solution obtained is added non-expanded thermo-plastic particles, known as microspheres, in an amount such thatthe weight ratio microspheres:resin varies between 4:1 and 1:50 in the finished foam composite material. In the expanded condi-tion, the microspheres preferably constitute 70-95, specifically 85-95, percent by volume of the foam composite material. A
material in the form of a web is impregnated with the mixture of resin and microspheres in a conventional way, e.g. by immersing the web in a bath of the mixture, by spraying the mixture on the web or by adding the mixture in connection with the formation of the web. The impregnated web, the degree of impregnation of which can be adjusted e.g by rolls, is then treated thermally, suitably with circulating hot air having a temperature of 80-150C so that the resin sets to the B-stage and the microspheres expand. It should he noted in this context that a thermosetting resin in the A-stage is meltable, poorly cross-linked and soluble in acetone and other solvents. A C-stage resin is not meltable, completely cross-linked and insoluble. The B-stage is a stage between the ~77~
lb A-stage and the C~stage.
Thermosetting resins that may be used according to the present invention are resins based on formaldehyde with urea, phenol, resorcinol or melamine.
The web material may consist of woven or non-woven ~1777~ , organic or inorganic material and specifically glass fib- I
re, mineral fibre, cellulose fibre and polyester may be f mentioned. It is also important that the web material has sufficien~porosity so that it can be impregnated with the 5. mixture ~ resin and microspheres in a satisfying manner.
Further, the web material must not be taken too thick and suitably the thickness may vary between 0.1 and 5 mm. The reason why the web material must be thin is that otherwise there may be a non-uniform expansion of microspheres owing 10. to the fact that, at the thermal treatment, superficially situated microspheres expand first and these expanded mic-rospheres form a thermally, insulating layer preventing those microspheres which are situated more deeply or more central from expanding and if this happens a product of 15. inferior quality, which is not homogenous, will be obtain-ed.
It is also possible to add the resin and/or the mic-rospheres in connection with the formation of the web, e.g. f by the direct manufacture of the web by depositing a fibre 20. suspension also containing resin and/or microspheres. Al-ternatively the resin and/or microspheres can be added in connection with deposition of fibres from air into a web.
A so prepared web can be treated in the same way as an im-pregnated ready web, i.e. being heated afterwards to ex-25. pand the microspheres and to transform the resin into the B stage. It is, however, also possible in these cases to add already expanded particles to the web at deposition of this since no impregnation step is required. This can be done with special simplicity at deposition of the web from 30. air since then the buoyancy of the expanded particles cau-ses no problems. When the microspheres are expanded before or during the deposition of the web it is possible to make the web thicker than when the expansion is made by heating the impregnated web since no heat transfer problems will 35. arise in this connection. The manufacture of a thicker layer without the need for laminating together several thin sheets is of value in certain connections, especially when the strength demands are lower. It is also possible to pro-f 3 ~ 774~
duce in this way first a very porous web, which by pressing can be given a variable density or a more complicated final shape. The product can otherwise be used in the same way as a foam composite material prepared by impregnation of a rea-5. dy web.
The microspheres which are used when preparing thefoam composite material according to the present invention have shells which may be made up of copolymers of vinyl chloride and vinylidene chloride, copolymers of vinylidene 10. chloride and acrylonitrile, copolymers of vinyl chloride and acrylonitrile and copolymers of styrene and acrylonitrile.
Further, copolymers of methyl metacrylate containing up to 20 percent by weight styrene, copolymers of methyl metacry-late and up to 50 percent by weight of combined monomers of 15. ethyl metacrylate, copolymers of meth~l m~acryl~te and up to about 70 percent by weight of ort~o~b~Co~r/ost Sro~c~m~aey be mentioned. The particle size of the non-expanded particles and, accordingly, the expanded particles may vary within broad limits and is selected with respect to the properties 20. desired for the finished product. Examples of particle si-zes for the non-expanded spheres are l)um to 1 mm, prefer-ably 2 ~m to 0.5 mm and specifically 5)um to 50 ~m. At the expansion the diameter of the microspheres increases by a factor 2-5. The non-expanded microspheres contain volatile, 25. liquid blowing agents which are vaporized at the applica-tion of heat. The blowing agents may consist of freones, hydrocarbons, such as n-pentane, isopentane, neopentane, butane, isobutane or other blowing agents, that are used conventionally in microspheres of the type specified above.
30. Suitably 5-30 percent by weight of the microspheres may consist of blowing agent. The microspheres may be added to the resin solution in the form of dried particles or in the form of a suspension, for instance in an alcohol such as methanol.
35. As mentioned previously, the ratio resin to micro-spheres in the impregnating solution may vary within broad limits and this ratio affects the properties of the final product. Correspondingly, starting from certain fields of 4 ~1777~1 employment and certain desired properties of the final pro-duct it is also possible to select a suitable ratio resin to microspheres in the mixture. This ratio can easily be determined by preparatory experiments in the laboratory.
5. Different additives such as stabilizers, coupling agents, fillers, flame retarding agents and/or pigments may be added to the mixture of resin and the microspheres if desired or required.
The foam composite materials according to the inven-10. tion may be used in combination with substrates or support-ing layers, preferably wood bades supporting layers, for preparing laminates and these laminates are called hetero- I
genous laminates in the following text. It is also possib- !
le to laminate several layers of the foam composite mate-15. rial according to the invention for the preparation of multilaminates and these laminates will be called homogen-ous laminates in the following text. It is certainly also possible to produce mixed laminates containing at least one homogenous laminate together with at least one other 20. material.
In the preparation of the heterogenous laminates the foam composite material according to the invention is com-bined with an optional supporting layer and the combina-tion of the foam composite material and the supporting 25. layer is compressed at an elevated temperature. In this process time, temperature and pressure are chosen mainly with consideration taken to the type of resin used. Often the time for the pressing may vary between 20 seconds and 20 minutes. The temperature may vary between 100 and 180C
30. and the pressure between 0.1 and 3 MPa. If the supporting layer has a rough and uneven surface especially attractive effects may be attained by the foam composite material penetrating the cavities and filling these up, while the "free" surface of the foam composite material, i.e. the 35. surface that is facing the press plate, becomes complete-ly smooth, as the microspheres adjacent to the press pla-te collapses by the pressure while expanded microspheres adjacent the rough surface of the supporting layer penet-i ~ P7741 rates into the cavities filling these up. Accordingly~ alevelling out of the surface is effected. In practice this effect of levelling out can be achieved for example in con-nection with the peparation of plywood. In conventional ply-5. wood preparation si~ed veeners are prepared first and theveneers are compacted to plywood. In order to get a satis-fying surface the rough surface is then ground and a sur-face coating is then pressed onto the plywood surface. Us-ing the foam composite material according to the present ~0. invention it is possible to press together several veneer sheets and a thin sheet of a foam composite material in one single step and, after pressing, there is obtained a hard completely smooth surface layer consisting of a foam composite material according to the invention, in which ma-15. terial the resin is completely cured and the microsphereshave col]apsed partly. Other properties which can be obtain-ed in heterogenous laminates containing a foam composite ma~
terial according to the invention are improved flame retard-ing properties. It is possible to get a laminate surface 20. suitable for painting and (wall) paper covering, to get a higher flexural modulus and a surface that is water repell-ant and thermal insulating. In sheet material a decrease of the skew of the plate, may be achieved.
Lamination with wood gives a material with the sur-25. face properties of wood but with a reduced density, which is usable for example in packings, coachworks or interior fittings. Lamination with metals, especially aluminium sheets or aluminium foils, gives a material with good and lasting surface properties and high stiffness but with re-30. duced density, which can be used for example in packings,coachworks, building frontages, signboards or travel requi-sites. Lamination with papers, impregnated with formalde-hyde-based resins, gives materials with resistant and/or decorative surfaces, high stiffness and low density suited 35. for example in interior fittings, panels and signboards.
In order to improve the adhesion between the impregnated paper and the foam composite material and to reduce the effects of the brittleness of the material it is in these 6 ~77~
cases advantageous to arrange a middle sheet of for examp-le cardboard. Lam;nation of materials with thermoplastic surfaces can give light decorative products suitable in interior fittings and for panels. A coating of nylon 5. flocks on the foam composite material gives a decorative and durable surface allowing pin attachments, which pro-duct is usable for example in notice-boards, interior fittings and signboards. Similar properties and uses flows from laminates with textiles. Numerous other hetero-10. genous laminates are of course possible. It is also possib-le to adhere the foam composite material of the invention against non-solid materials at the formation of these, for example to foam polyuretane against the foam composite ma-terial, preferably between two sheets of these, whereby not 15. only a light and in relation to the weight stiff product is obtained but also is achieved a more uniform foaming of the polyuretane material due to the low heat conduction and heat capacity of the foam composite material. The covering sheets also gives a fire resistant effect reactive to the polyure-20. tane foam. The mentioned properties are of special valuewhen using the product as building elements. It is general-ly possible in heterogenous laminates to introduce a middle sheet between the different materials in order to improve stiffness, adhesion and dent resistance. A suitably select-25. ed middle layer can be bonded against the foam compositematerial by use of the remaining bonding capacity of the resin in the material in accordance with a general purpose of the invention and at the same time, on its other side, allow glueing to materials normally not bondable by the re-30. sin of the foam composite material. For example paper or a fiber web can be used for this purpose and it is especial-ly advantageous that t~le sheet is impregnated with a cur-able resin, preferably the same as in the foam composite material or a resin compatible with this.
35. The homogenous laminates are prepared with pressure times varying between 1 minute and 30 minutes. The pressu-re may suitably vary between 0.01 and 0.5 MPa and the tem-peratures between 100 and 150C. Preferably such conditions are chosen that the expanded microspheres do not collapse.
:11777~1 A lig~t weigilt and strong material which for example may be used in the building trade is obtained if the micro-spheres do not collapse. Furthermore, it should be noted that the ~ly4~ can be laminated by g]ueing without the 5. application of heat.
The foam composite material is heat mouldable in non-cured condition, which for example allows formation of double-bent surfaces in connection with lamination.
Such a moulding can take place both at manufacture of 10. homogenous laminates and at manufacture of heterogenous laminates wherein the other materials are preformed or allows deformation under the lamination procedure.
The invention will be illustrated more in detail in the following non limiting examples.
15. Example 1 . _ A 50 g/m~ felt of glass fibre was impregnated with a dispersion of VDC/ACN microspheres from KemaNord AB and a phenol resin solution 9916 from AB Casco having dry sub-stances of 60 %,wherein the ratio of the dry substances 20. MS:PF is 2:1 (VDC = vinylidene chloride, ACN = acrylonitri-le, MS = microspheres, PF = phenol formadelhyde resin).
When the felt has been immersed in the impregnating bath excessive dispersion is pressed away by rolls. Then the felt is treated with air (120C) causing the water to 25. leave until 7 percent by weight remain and simultaneously the microspheres expand. A homogenous larninate was prepar-ed by superimposing four layers and pressing at 0.25 MPa, 125C for 10 minutes.
The following product was obtained:
Thickness 7.10 mm Density 162 kg m 3 Flexural modulus248 N/mm2 Flexural strength4.68 N/mm2 E modulus pressure15.66 N/mm2 Compression strength, 10 % 2 deformation 0.78 N/mm Smoke 2.8 % KemaNord PM 227 Smoke develop- ¦
ment according to Arapahoe Oxygen index 45 ASTM 2863 ~ a~7~7~l T~lis product can preferably be used as a core or surface material in sandwich structures. The homogenous laminate can be moulded at a temperature of about 120C.
Example 2 5. The process according to example 1 was repeated but the ratio MS:PF was 1:1 (calculated on the dry substances).
The following product was obtained:
Thickness 4.09 mm Density 264 kg m 3 Flexural modulus 574 N/mm2 Flexural strength 12.22 N/mm2 E modulus pressure 31.11 N/mm2 Compression strength, 10 %
deformation 1.89 N/mm2 Smoke 2.4 % KemaNord PM 227 Smoke develop-ment according to Arapahoe Oxygen index 45 ASTM 2863 This product can be used in sandwich struc~ures.
Example 3 10. The process according to example 1 was repeated but the ratio MS:PF was 1:2 (calculated on the dry substances).
The following product was obtained:
Thickness 3.1 mm Density 306 kg/m 3 Flexural modulus 799 N/mm2 Flexural strength 20.16 N/mm2 ! E modulus pressure 40.19 N/mm2 Compression strength, 10 %
deformation 3.85 N/mm2 Smoke 1.8 % KemaNord PM 227 Smoke develop-ment according to Arapahoe Oxygen index 42 ASTM 2863 Flame-proof surface layer class 3 NT 004 Average smoke density 9 %
, The product can be used in sandwich structures.
9 ~3.7774~
Example 4 A foam fibre layer was prepared according to examp-le 1 but the ratio MS:PF was 1:2, calculated on the dry substance. This sheet was pressed onto a plasterboard at 5. a pressure of 0.4 MPa and a temperature of 120C for 10 minutes, and a decorative surface suitable for embossing was obtained. At fire testing NT 004 class 1 is obtained on the surface and no smoke is developed.
Example 5 10. Example 4 was repeated but a 10 mm unground spruce plywood was used as a supporting layer.
A levelling out of the surface was obtained and the surface was waterproof and suitable for painting and covering with wall paper.
15. The surface can further be decorative and suitable for embossing. The products have improved stiffness and are as far as fire is concerned classified as flame-proof surface layer class 3, average smoke density 13 %.
Claims (19)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A laminate which comprises:
(i) at least one foam composite material including a material in the form of a web, a cured resin and expanded thermoplastic particles essentially uniformly distributed in the resin and in the web material, and (ii) at least one further such a material of another material, wherein the materials are bonded by the resin in the foam composite material, whereby the expanded thermoplastic particles constitute between 70 and 95 percent by volume of the foam composite material parts of the laminate.
(i) at least one foam composite material including a material in the form of a web, a cured resin and expanded thermoplastic particles essentially uniformly distributed in the resin and in the web material, and (ii) at least one further such a material of another material, wherein the materials are bonded by the resin in the foam composite material, whereby the expanded thermoplastic particles constitute between 70 and 95 percent by volume of the foam composite material parts of the laminate.
2. The laminate of claim 1, in which the web material has a thickness between 0.1 and 5 mm.
3. The laminate of claim 1, which comprises at least two sheets of the foam composite material.
4. The laminate of claim 1, in which the resin in the foam composite material consists of a formaldehyde-based resin with phenol, resorcinol, urea and/or melamine.
5. A method for the manufacture of a laminate, which method comprises:
(a) preparing a foam composite material containing a material in the form of a web, a curable resin in the B-stage and expanded thermoplastic particles essentially uniformly distributed in the resin and in the material, (b) assembling the foam composite material with at least one further such material or another material and, (c) bonding the materials to each other by finally curing the resin.
(a) preparing a foam composite material containing a material in the form of a web, a curable resin in the B-stage and expanded thermoplastic particles essentially uniformly distributed in the resin and in the material, (b) assembling the foam composite material with at least one further such material or another material and, (c) bonding the materials to each other by finally curing the resin.
6. The method of claim 5, in which the final curing of the resin takes place under influence of heat and pressure.
7. The method of claim 5, in which the foam composite material is prepared by impregnation of the web material with expandable thermoplastic particles and a solution of the resin and then heating the impregnated material to expand the thermoplastic particles and to transform the resin into the B-stage.
8. A dry foam composite material which comprises a material in the form of a web, impregnated with a curable resin which is in the B-stage, and expanded thermoplastic particles which are essentially uniformly distributed in the resin and in the web material.
9. A foam composite material according to claim 8, in which the curable resin is based on formaldehyde with phenol, resorcinol, carbamide or melamine.
10. A foam composite material according to claims 8 or 9, in which the expanded thermoplastic particles have a shell made up from a copolymer of vinylidene chloride and acrylonitrile.
11. A foam composite material according to claim 8 or 9, in which the expanded thermoplastic particles are present in an amount of 70-95, preferably 85-95, per cent by volume.
12. A method for the manufacture of a foam composite material, which method comprises:
(a) homogeneously impregnating a web material with a precondensate of a curable resin and thermoplastic microspheres, (b) heating the so impregnated web material to a temperature sufficient to expand unexpanded thermoplastic microspheres and to cure the resin into the B-stage but not into the C-stage and, (c) drying the web material with expanded microspheres and B-stage resin.
(a) homogeneously impregnating a web material with a precondensate of a curable resin and thermoplastic microspheres, (b) heating the so impregnated web material to a temperature sufficient to expand unexpanded thermoplastic microspheres and to cure the resin into the B-stage but not into the C-stage and, (c) drying the web material with expanded microspheres and B-stage resin.
13. The method of claim 12, in which the resin and the unexpanded microspheres are mixed before impregnation of the web material.
14. The method of claim 12, in which the impregnation takes place simultaneously with the formation of the web material from discrete fibres.
15. The method of claim 12, in which the resin is a solution of a formaldehyde-based resin with urea, melamine resorcinol or preferably phenol.
16. The method of claim 15, in which the resin solution has a dry content between 30 and 75 percent by weight.
17. The method of claim 12, in which enough thermoplastic microspheres are incorporated in the web material to after expansion constitute between 70 and 95 percent by volume of the dry foam composite material.
18. The method of claim 12, in which the thermoplastic microspheres are expanded 2 to 5 times their initial diameter during the heating operation.
19. The method of claim 12, in which a web material of a thickness between 0.1 and 5 mm is impregnated.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000386323A CA1177741A (en) | 1981-09-21 | 1981-09-21 | Foam composite material impregnated with resin |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000386323A CA1177741A (en) | 1981-09-21 | 1981-09-21 | Foam composite material impregnated with resin |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1177741A true CA1177741A (en) | 1984-11-13 |
Family
ID=4120999
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000386323A Expired CA1177741A (en) | 1981-09-21 | 1981-09-21 | Foam composite material impregnated with resin |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1177741A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108215363A (en) * | 2017-12-28 | 2018-06-29 | 江阴市沪澄绝缘材料有限公司 | The production line and its production technology of brominated epoxy glass fabric insulation board |
-
1981
- 1981-09-21 CA CA000386323A patent/CA1177741A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108215363A (en) * | 2017-12-28 | 2018-06-29 | 江阴市沪澄绝缘材料有限公司 | The production line and its production technology of brominated epoxy glass fabric insulation board |
| CN108215363B (en) * | 2017-12-28 | 2023-07-14 | 江阴市沪澄绝缘材料有限公司 | Production line and production process of brominated epoxy glass fiber cloth insulating board |
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