DE1704483A1 - Plastic product - Google Patents

Description

Plastic product The invention relates to plastic products, such as building panels, table tops, floors, roof coverings, furniture, window sills, walls etc., which consist of a carrier core which is encased by plastic.

The invention also provides a light-formable carrier core sur which is built in such a way that it fits into the plastic body of the product surrounding it intervenes.

The invention also relates to a casting method for molding objects made of layered plastics, the objects having any shape can and equipped with simple surfaces or decorative surfaces and / or can be given away with simple storage or decorative storage.

According to the invention, a core material is encased in such a way that a product is created that has bulk but not excessive weight and has full strength. The invention also provides a cast laminate available with an extremely smooth or embossed, relatively hard surface having.

For the production of the cast laminates and for wrapping the Any thermosetting or thermoplastic resin can be used such as epoxy resins, polyester, polystyrene, methyl polymethacrylate, and others.

The plastic layer body cast according to the invention is suitable; themselves for many purposes, e.g. for table tops, and has considerable mass or as much wetness as you want without adding any extra weight than the plastic itself. The wetness is increased to the desired extent by a Inlay or a core achieved that is embedded in the plastic surrounding it and is so welded to it that it is made of a single piece with the plastic The cores can consist of the most varied of substances and so easily or be as severe as it gets right.

The manufacturing process is such that the laminate produced regardless of whether or not it has a core or filler, whole or to be partially born or Any combination you want or Mixture of colors may have. Through suitable storage either for yourself alone or in addition to the grain or filler body you can create beautiful patterns and decorations achieve.

The invention also provides objects in which a bound by self-binding to the core and with it by mutual intervention Locked plastic body has a seamless plastic edge that is made of one piece with any external surface as well as a striking, three-dimensional decorative effect having the branch visible through the plastic, the core being Erseugnie Rigidity, light weight, acoustic properties, shock resistance, insulation properties etc. confers.

Finally, the invention relates to articles of manufacture in the form of panels or plates consisting of a core and a surrounding core Plastic bodies are made.

To further explain the invention, reference is made to the drawings taken.

Figs. 1 and 2 are cross-sections through shapes used in the implementation the invention can be used.

Figures 3 to 8 are cross-sectional views showing the main process steps explain the wrapping of a core.

Fig. 9 is a cross section through a product according to the invention.

Figures 10 to 16 are cross-sectional views showing the process steps explain after which the liquid resin is provided with ornaments and the core under Forming a product with a flat surface is enveloped.

Figs. 17 to 23 are cross-sectional views showing the process steps explain the manufacture of a product with a finished surface.

24 is a cross-section through a product with bevelled plastic edges; which is produced in the form shown in FIG.

Figures 26, 27 and 28 are top plan views of a core located in FIG Shape is in different positions to produce square products with a, make two or three integral edges on the respective sides.

Fig. 29 is a cross-section through a product with a particular one Soitenumriee.

Figures 30 through 34 are cross-sectional views illustrating the procedures # ~ stages in the manufacture of a product with at least one finished product Explain the surface.

35 is a cross section through one produced according to FIGS. 30 to 34 Product that corresponds to the product shown in FIG. 9, but in reverse Position.

36 to 46 are cross-sections through various shaped cores, which can be easily enveloped and possibly have different surfaces.

Fig. 1 shows a form consisting of a flat base 1, a Press cushion 2 made of metal foil, a mold base 3 and mold winches 4. The mold walls and the bottom of the mold are firmly pressed together by the clamping bracket 5, so that they form the open shape 6. Under certain circumstances, the open form 6 can be replaced by the in Fig. 2 shown one-piece form can be replaced when products with standardized Sizes can be produced.

The simple molded parts shown in FIGS. 1 to 4 are melamine molded parts (made of Formica-coated plywood) that can be easily adapted to suit everyone you want Let the shape of the side wall shape deform.

The mold bottom 9 (Fig. 1) is a glass or melamine floor, and for The mold base and the mold walls must be a mold coating. If the The bottom of the mold or the walls of the mold are made of polyester film required, because the material to be cast is made of polyester film easily peeled off.

The one-piece shape according to FIG. 2 can be made of rubber, metal, glass or plastic. If it is a rigid material, form the end of the mold with the bottom of the mold make an angle of more than 900 so that the product can be can be removed from the mold. with reference to Fig. 3 is the method of production a table top with a diameter of 122 cm explained step by step.

A 19 mm thick carrier core 7 (Fig. 3) is equipped with feet 9, which keep the core at a distance from the bottom of the mold and for a specific cavity worry under the core. This see can be organs on the opposite side of the mold bottom Surface of the core are attached, such as nails, screws, dowels, plugs, etc. Damlt the core is level, these rivers must be of the same length and correct be ordered, and their number must be at least 3. As soon as the grain 7 with the must 9 has been centered on the bottom of the mold, measures are taken to around the core in one position and the feet 9 in close contact with the bottom of the mold keep. The cavity 8 is covered by the edge and that not by the feet Part of the bottom of the core, feet, and corresponding mold sections limited.

The holding of the core in its position can be done from above by means of the rod 10 shown in FIG. 4 or from below by means of the one shown in FIG Screws 11 are made through corresponding holes 12 in the mold bottom 3 in the feet 9 are screwed in. These holding organs can be removed at any time as desired.

Enveloping the core can be done in two different ways, which are shown in Figs.

To produce a table top with a diameter of 122 cm, the first step is a mixture of 3.785 l polyester resin, 316 ml styrene, 1.77 g cobalt naphthenate (6 * Cobalt) and 85 g of black polyester paste.

Done according to the first method. enveloping the core in two stages: Half of the mixture is placed in a special container with 1% methyl ethyl ketone peroxide (60%) stirred and then poured onto the core in the mold, so that the catalyst-containing Mixture, as shown in Fig. 6, partially fills the mold and forms part of the edges of the core.

When this first layer has hardened to a certain extent, the other half of the mixture is stirred with 1% methyl ethyl ketone peroxide (60%), poured onto the first layer 13 and straightened at the edges, so that it completely surrounds the edges and surface of the core, as in 7 is shown at 14.

When this mixture has hardened, the product can be removed from the mold be taken out; it then has the following properties: the edges and the Surface of the plastic consist of one piece, the self-bond between both layers is perfect, the plastic has set with itself, and there is no seam at the edges, because both layers are related The pigmentation and other composition are completely the same. This product is shown in cross section in FIG.

The second method of enveloping the core is illustrated by FIG. According to this method, the whole mixture is stirred in with 1% methyl ethyl ketone peroxide (60%) poured into the mold at once and straightened at the edges so that ea completely covers the core and fills the shape, as shown at 150 after the Hardening and removal as the mold is again obtained as shown in FIG. 9 Product.

In order to avoid any air pockets under the core, the synthetic resin must from one side directly into those formed by the edges of the core and the mold walls To be poured into comfort, eo that it is free on two different ones Flow paths flows into the mold cavity, displacing all air until it the shape is completely created up to the desired height.

The product made by these methods has a single color Plastic surface (which is black in this example).

If a decorative effect is desired, use the plastic surface is visible through, this can be achieved by the following methods: a) The decorative effect can be created in the liquid synthetic resin mixture that the Core completely enveloped. b) The decorative effect can be in at least one additional Liquid synthetic resin layer is generated, which completely covers the surface of the core enveloping plastic is applied.

The decorative effect can be achieved in the liquid synthetic resin surrounding the core can be generated according to the following examples: The first example is illustrated by Fig. 10 explained. To a certain amount of liquid, catalyst-containing synthetic resin Pearl essence pigment is added with stirring and the mixture is made as on hand of Fig0 8 described, poured into the mold.

As soon as the liquid resin mixture covers the surface of the core, it is moved by hand to distribute the pearl essence pigment and to orient and create the desired pattern, this "combing" by hand is terminated when the viscosity of the synthetic resin has risen to such an extent that a gel has formed and the pattern created is fixed in the synthetic resin.

The second example is illustrated by FIG. According to FIG. 8 first the liquid, catalyst-containing synthetic resin poured into the mold, and once the surface of the core is covered, nacre scales are hand in the desired pattern is introduced into the resin before the resin solidifies to form a gel. The duration of the tent until it solidifies can be selected as required the ratio of accelerator to catalyst to synthetic resin and the working temperature being controlled.

The third example is illustrated by FIG. Been here with one pointed factory, which was previously soaked at the top with black polyester resin paste or has been provided, black veins in the catalyst-containing and pearl essence pigment mixed liquid synthetic resin drawn to mimic a marble surface.

If a three-dimensional depth effect is desired, the method be modified by placing on the enveloping the core plastic additional layers are generated.

One of these modifications is the one covering the core surface liquid mixture a first decorative layer, as described above, produced this Layer is cured, then more liquid resin is added, and in each of these further layers the desired effect or the desired one becomes Patterns are generated using the decorative means explained with reference to FIGS. 10 to 12 introduces into the resin mixture.

You just have to make sure that every single layer is already there is hardened to a certain extent when the next liquid resin layer is applied. This is shown in Figs. Here is the first decorative effect in the mixture 15 covering the surface of the core and the second decorative effect in the further liquid sent 16 is generated.

According to a further modification, the surface of the core is covered with a opaque pigmented liquid resin that covers the background for forms the decorative effect and hides the core. Then with the help of further quantities liquid sunstarse, which are successively applied to the surface of the core opaque layer can be poured, a three-dimensional decorative effect generated. This modification is shown in FIGS. This is where the decorative layer becomes 16 by distributing pearls mixed in the synthetic resin bens pigment or made by inserting mother-of-pearl scales into the synthetic resin. Here too each layer has to be allowed to harden to a certain extent before the next liquid synthetic resin layer applies.

The finished product obtained by the process described above has a flat surface after removal from the porm, the evenness of the viscosity of the synthetic resin or the amount of monomer used or Depends on the diluent.

A nooh smoother surface can be obtained under certain circumstances by that one adds a little molten paraffin to the styrene. Leave such surfaces work on, polish or grind with the sandblasting fan.

To stockings with any perfectly finished sewing To obtain, one makes use of the additional process stages shown in FIGS. 17 to 23.

After removing the clamps, a cover plate is placed on the mold. whose underside exactly matches the desired outer surface of the finished product corresponds, put on together with a sealing ring, so that the mold is closed will.

In Fig. 17, the cover plate 17 and the seals 18 are in the sum of putting on the shown in Fig. 1 open Shape suitable Position. In Fig. 18 the mold is already closed and the clamps 5 are firmly sucked in, eo that the cover plate 17 and the seals 18 against the mold walls 4 to be pressed and the cavity: 21 from the surface of the last hardened Plastic layer 20, the fori walls 4, the seals 18 and the underside of the Cover plate 17 is limited. The slot 19 has previously been worked out from the fori wall 4 to be able to introduce further liquid synthetic resin into the cavity and to let the air escape.

Then the whole mold is tilted so that the liquid, catalyst containing Synthetic resin 22 can be poured into the cavity 21 from above or below, as shown in FIGS. 19-22. To the escape of the trapped To facilitate air from the cavity, the slot 19 must be properly shaped and are in the correct position; you can also use the whole form in Offset rotation.

When the cavity is filled and no longer contains air bubbles, you can hold the mold in any position to allow the resin to cure, in Fig. 22 the shape is vertical; Preferably, however, the curing takes place horizontally Position as shown in Fig. 29 to make sure that the liquid resin remains in contact with the inner surface of the cover plate, with the slot through the plug 24 is closed. This lag gives better results because these last layer of plastic that works in reverse as the previous layers has been formed, the product has isotropic properties after curing @ Opposite tensions and extremely hard plastic surfaces.

Another variation of the process, in which the whole lot of the catalyst-containing polyester resin is poured into the mold at once for production of products with at least one desired surface is shown at the edge of Fig.

30 to 54 explained. As shown in FIG. 30, the carrier core is first 7 attached to the mold bottom 30 Then the cover plate 17, the bottom of the finished outer surface corresponds to the desired product, with the seals 18 placed on the mold (Fig. 31). Fig. 32 shows the closed form; the clamps 5 are tightened and hold the cover plate 17, the seals 18 and the mold walls 4 close together, ao that the cavity 26 of the core 7, the mold walls 4, the Seals 18 and the underside of the cover plate 17 is limited. The slots 19 and 23 have previously been incorporated into the mold base 3 in order to make the liquid. Synthetic resin Introduce ru in the cavity and the air through one or both openings to escape.

Then the whole form is put into the one in Ptg. 33 reversed position, so that the catalyst-containing liquid synthetic resin into the cavity 26 can be filled. Fig. 34 shows how the liquid resin 27 by the Slot 19 is poured in, the air escapes through a slot 23.

When the cavity is filled and the air bubbles have escaped, will Let the mold stand until the resin has hardened, whereupon the brseugnis from the Porn: is taken out.

The Erseugnie has at least one finished surface, and the core 7 is practically completely surrounded by the plastic 27 (FIG. 35), according to when removed from the mold, the product shows a completely finished one (e.g. polished, matted, embossed, raised, engraved, etched or irregular) Surface.

The decorative effect is visible through the plastic surface and the three-dimensional depth decorating effect depends on the number of layers, who have done this decorative effect.

The pigmented plastic part that covers the core can also be completely or partially visible or invisible through the plastic surface seir., but is very clear on the edge and on part of the back of the product visible, with the edge in one piece on the plastic surface without any nant is bound.

The back of the product can always be seen, namely the one Plastic part that surrounds the feet of the core on this side and its width, Thickness and shape of the size and length of the feet, the outline of the bottom of the mold and depends on the mold walls and the outline of the back of the core, and that part the feet that were in contact with the bottom of the mold and not of plastic has been covered.

Ut: can improve the appearance of the back of the product the feet can be removed if they have previously been coated with a plain are, or they can optionally be used to make plates or other Attach fastening devices to it in this way. You can also see the part of your feet with catalyst-containing liquid synthetic resin, paint or other Cover fabric.

Fig. 24 illustrates a beveled-edged product used in the The shape shown in Fig. 25 is manufactured.

Figures 26, 27 and 28 show three top views in different positions of the panel core, which is made of wood, plywood, synthetic wood, honeycomb plastic, foam plastic or any other filler. The core is so in that Form used that a square product with one, two or three edges that is suitable for applications where four edges are not required are.

In these cases, the cavity is only selected from among those in each case Sides 25 of the core formed.

Fig. 29 shows a product formed in a shape with correspondingly Walls has been built.

36 to 46 illustrate various examples of the invention coated cores and methods of making the same.

Examples are given in Figs. 36, 37, 39, 41, 42 and 44 polished, matt or patterned surface. 38 shows a Product with a raised surface. 40 shows a product with an engraved surface.

43 and 45 show products with convex or concave surface. Fig. 46 shows a product with irregular surfaces and edges as well as irregular ones Split the back.

The covered cores shown in FIGS. 36 to 46 can be various Have shapes.

From U.S. Patent 3,072,973 there is a method of manufacture known from plastic moldings with a layered structure. With this well-known The procedure resulted in rigid plate cores encased in plastic on all sides, by placing it in an open-topped mold, the bottom of which is shaped like the surface of the molded body to be produced, first a plastic layer by adding a liquid synthetic resin forms and this plastic then hardens. On the hardened one The first layer of plastic is then given a further amount of a polymerizable liquid resin containing a polymerization catalyst in which a pigment and optionally also a decorative medium is included. Any existing Ornamental media are distributed by swirling or vortex-like movement and for fixing the resin containing the polymerization catalyst is hardened in the decorative media. Then you put more liquid resin in the mold and a plate core that is narrower than the edge of the mold, causing the liquid resin to disperse and rise around the core and these completely, optionally after the addition of further liquid polymerizable Resin, surrounds. After curing, a molded plastic body is then obtained with layers Structure whose surface corresponds to the shape of the bottom of the mold.

The present invention represents a further development of these shaped bodies The invention relates essentially to the feature that the plate core by means of the spacer in the Form is held. When pouring out of the shape you get a smooth surface on the underside, while on the The upper side has a slightly rougher surface in accordance with the liquid, This somewhat rougher hardened surface can be removed by further pouring on resin can be modified in such a way that one recovers a surface in the desired shape.

The new process enables a lockable core that made of wood or plastic or of some other material, in one Hollow form 80 is enclosed so that a feathered, evenly thick, Coating the core achieved. The spacers remain on the molded body and can serve as a starting point for attaching table legs etc.

Claims (7)

P a t o n t a n s p r ü @ h e Cast, isotropic decorative building board material for surfaces, characterized by a plastic body (13, 14, 15), the cinen the core (7) imparting Starrh @ it essentially surrounds and consists of a hardened synthetic resin decorative layer that engages in the core and is bound to him by self-binding and the surface, the sides and one Forms part of the back of the product, while the core (7) is on one surface completely covered by the plastic corresponding to the surface of the product is, characterized in that the core (7) on the opposite surface is equipped with spacers (9), which extend up to the surface on the back the plastic casing extend with the core (7) centered and in the plastic body is arranged parallel to the surface of the product, the plastic side edges consist seamlessly from one piece with the plastic surfaces of the product and, measured from the edge of the core to the Musseren surface of the plastic edge, have the same thickness, and that the product has an extremely hard plastic surface having and a decorative effect is visible through the plastic. 2. Building board material according to claim 1, characterized in that the plastic body surrounding the core is made up of several layers, of at least one of which contains a decorative agent, and that the core (7) with at least three Abatandhalter (9) is equipped. 3. Building board material according to claim 1 or 2, characterized in that that the plastic body surrounding the core consists of two parts, which are in opposite directions Directions perpendicular to the surface of the product are shaped such that the Entire product has isotropic properties. 4. Building board material according to claim 1 to 3 in the form of a table top. 5. Building board material according to claim +, characterized in that the spacers are removable. 6. Building board material according to claim 1 to 5, characterized in that because .. the surface of the plastic .. is coated with a film. 7. Process for the production of building panels with a layered structure, which contain a rigid plate core enclosed on all sides by plastic, characterized in that one has a plate core (7) with at least three of the same length Provides feet (9), the core with the feet (9) centered on a mold bottom, on the core a catalyst-containing mixture of a polymerizable plastic pours so that the form is partially filled and at least part of the round of the core, this first layer is hard and to a certain extent then another catalyst-containing polymerizable mixture is poured on, so that the rounder and the surface of the core are completely surrounded and the mixture hardened.