Process for Making Objects From Mineral Fillers Bonded With a Thermosetting Resin

The invention relates to a process for making three-dimensionally shaped objects by moulding a material, in which a moulding material consisting of mineral fillers and a thermosetting resin with a hardener is first evenly distributed outside the mould, the assembly (sheet) that has been pretreated in this way and is still pliable is transferred to the mould and subsequently subjected to pressure at an elevated temperature.

The shaping of objects by hot moulding of a mixture of thermosetting resin and mineral fillers (so-called bulk, dough or sheet moulding compounds) is known. After moulding, the objects are further finished and, preferably while still warm, provided with a decorative layer. In the next moulding pass the mould is still hot. A relative process and moulding, as well as the finishing of such are described in Netherlands Patent Application No. 7,706,997, by which objects are made by causing unsaturated polyester resin, mineral filler and magnesium oxide to be mixed and to thicken in the presence of glass fibre to a moulding material that is virtually free of air and by moulding parts of the thickened material at an elevated temperature, after whicht the objects are given a finish outside the mould. This known method is cumbersome and therefore costly because much manual work is required to apply a sound and attractive finish.

Application of a finish to a three-dimensional object while this is being shaped in a mould is known. The objects concerned are however made from foam compounds. The finish applied to the mould wall, which finish is bonded to the object in the mould during moulding or shaping, is not then subjected to shearing forces by the moulding material and thus allowed to retain its integrity. In the case of a finish being applied in an analogous way to an object made from another material, e.g. wood, resin-bonded mineral substances, only flare or slightly curved shapes can be processed. In addition, with this process the hazard of damage to the finish by development of gas or vapour remains. To avoid this, extra provisions are then needed on the mould or in the practices performed on the moulding material, e.g. provision of vent ports.

The purpose of the invention is to apply to the face of a three-dimensional object to be shaped moulding, such as the aforementioned, a smooth, decorative and/or protective finish. Another purpose is to realize this finish by only a few cumbersome means during moulding, so that after moulding the object is completely finished.

According to the invention this is achieved if the wall of the mould is wholly or partly provided, at the elevated temperature, with at least one layer of a powdery, thermosetting resin with catalyst either with or without a pigment, which resin is made to melt and polymerize, whereupon the pretreated moulding material is placed in the mould and subjected to pressure.

By the procedures of the invention the envisaged purpose can be achieved by applying the finish in powdery form or in quasi-liquid form to the hot mould wall, powdery resin components and a liquid catalyst being mixed in a cylinder head and subsequently sprayed onto the mould wall. In both cases it is ensured that no components are present that boil or evaporate at the operating temperature. Rapid polymerization of the resin components applied to the mould wall is enhanced by the mould wall not cooling off significantly below the operating temperature after a moulding pass. The mould wall is also taken to mean the male mould if the decorative layer is to be applied on that side.

The essence of the invention is that, before introduction of the moulding material, the finish at least polymerizes to a thermoflexible state at the prevailing temperature, after which the moulding material is distributed evenly in the mould as a pliable assembly (preferably in the form of a sheet) and moulded. Any shearing forces still acting can be absorbed by the finish without damage.

It is still sometimes advisable to provide the pretreated, still pliable moulding material assembly on at least one side with a glass-fibre fleece before introducing this material as a sheet into the mould. This has several advantages: the pliable sheed is easier to handle, the eventually hardened material is strengthened on the outside, whilst, as an extra provision, any shearing forces still acting (on highly curved parts, for instance) are taken up.

The glass-fibre fleece that may be present on one or both sides of the material may or may not be pre-impregnated with resin and catalyst, but is preferably dry.

For moulding large areas, it may be necessary to apply substances to give air trapped between the mould wall and the pretreated pliable assembly an opportunity to escape during moulding. This is achieved by dusting on glass fibres while the layer or thermosetting resin applied to the wall of the mould is melting. Glass fibre in the form of a mat, fleece or fabric may also be laid on the polymerized resin layer before the moulding material is applied.

The powdery, thermosetting resin applied to the hot mould may consist of a polycondensation product of multivalent alcohols and multivalent, unsaturated acids or acid-forming anhydrides. Propylene glycol, ethylene glycol, pentane diol, butane diol, butylene glycol, dipropylene glycol are representatives of the alcohols. Among the acids and acid-forming anhydrides, maleic acid (anhydride), phthalic acid (anhydride), isophthalic acid (anhydride), adipinic acid and the like are usual. Normally, this unsaturated polyester resin is linked. Suitable for this purpose are unsaturated compounds, such as triallyl(iso)cyanurate, a prepolymer of polydiallylphthalate, and other dry monomers and prepolymers. As catalyst for this linkage the usual peroxides may be used, e.g. benzoyl peroxide in powder form. An internal release agent, e.g. zinc stearate, as well as an anti-blocking agent, is also taken up in the powdery resin. The preparation of a powdery, thermosetting resin is not restricted to unsaturated polyester resins. In an analogous manner, a powdery, thermosetting resin on the basis of epoxy resins can be applied successfully. However, other known moulding materials are not excluded hereby.

For pigment, preference is given to the use of coloured, inorganic substances, such as particles of metal oxide or metal. A decorative effect can also be achieved by replacing said pigments wholly or partly by particles of thermoplastics which are fully, partly or not soluble in one or more of the components of the thermosetting resin, as described in British Patent Specification 1,459,230.

By preference, two or even more layers are applied to the mould or parts thereof (including the male mould). First a transparent layer is applied, next a second, pigmented one. In the finished product, the first layer then forms the outermost (transparent) layer.

Depending on the visible part, the mould and/or the male mould or parts thereof is/are provided with the thermosetting powder. Preferably, the powder is spread by dusting. This may take place in any suitable manner, preferably however by electrostatic dusting. Decorations may be applied to the finished product by covering certain parts during the dusting. It is advisable to apply two layers, of which the outermost layer of the finished product and, hence, the first layer to be dusted, is a transparent layer. With these two layers a true enamel effect is obtained.

By way of example, powdery mixtures of the following compositions (expressed in parts by weight) may be made by grinding.

For the first (transparant) layer a mixture of equal parts of components A and B is used; for the second, pigmented layer a mixture of equal parts of components A and C.

In this way, also other mixtures may be applied, for instance:

For the first (transparant) layer a mixture of equal parts of components D and E is used; for the second (pigmented) layer a mixture of equal parts of components E and F.

Yet another composition of the mixtures is as follows:

For the first (transparant) layer a mixture of 100 parts of component G and 10 parts of component K is used; for the second (pigmented) layer a mixture of 100 parts of component G, 20 parts of component H, and 10 parts of component K.

The examples mentioned do not exclude other formulations, such as the use of other resins and of other monomers, prepolymers and polymers, precopolymers and copolymers.

For instance, the thermosetting powder may be obtained by grinding--together with a total of 30 parts by weight of triallyl cyanurate, 30 parts by weight of a prepolymer of polydiallylphthalate, 4.5 parts by weight of zinc stearate--240 parts by weight of the polycondensation product of 1.5 moles of hydrated bisphenol A, 1.5 moles of propylene glycol, 0.5 phthalic acid anhydride, 1 mole of maleic acid anhydride, 1 mole of fumaric acid anhydride, whereupon 6.75 parts by weight of benzoyl peroxide powder and 6 parts by weight of finely divided silicon dioxide (trade name Aerosil) are added.

The thermosetting powder may also be obtained as an epoxy resin by mixing 100 parts by weight of an unmodified condensation product of bisphenol A and epichlorohydrine with an equivalent quantity of hardener (amine, amide, acid anhydride), 2 parts by weight of zinc stearate for internal release agent. This mixture is heated at 130.degree.-140.degree. C. for a few minutes, to be rapidly cooled thereupon. The solidified mixture is pulverized to the powder to be dusted on.

All constituent, powdery resin components are preferably ground to a fineness lying between 30 and 80 microns, although other graduations may also be used. During the application of the mixtures the temperature of the mould and/or male mould should be approximately 90.degree. to approximately 150.degree. C. As a rule, this temperature is still present after the preceding moulding operation.

It is noted that the application of a coloured layer to an object by dusting with a powder is known, for instance from the Netherlands Patent Application No. 6,906,356. What is particular about the decoration according to the present invention was already described when setting forth the purpose aimed at.

An example of quasi-liquid components that may be atomized (again expressed in parts by weight):

For the first (transparant) layer a mixture of 100 parts of component P and 1 to 6 parts of component R is used; for the second (pigmented) layer a mixture of 100 parts of component Q and 1 to 6 parts of component R. The mixed components may be atomized with a special, if necessary heated, spray nozzle. As a rule, the constituent components are not mixed until they have entered the spray nozzle.

For moulding material, a material is highly suitable which, for instance, has been composed as follows:

A polycondensation product is started from of:

1.5 moles of hydrated bisphenol A,

1.5 moles of propylene glycol,

0.5 moles of phthalic acid anhydride,

1 mole of maleic acid anhydride,

1 mole of fumaric acid anhydride,

of which 650 parts are combined with:

235 parts by weight of styrene monomer,

100 parts by weight of diallyl phthalate,

10 parts by weight of tertiary butyl perbenzoate

5 parts by weight of water.

Finally, about 1 wt.% of magnesium oxide is added to this resin composition.

Next, starting from this resin mixture, a mixture, is composed which, referred to the total mass, contains 85 wt.% of calcium-magnesium carbonate of 0-200 microns, or another inorganic powder, such as calcium carbonate, silicon dioxide, talc and the like, and 1.5 wt.% of glass fibres having a length of, mainly, 6 to 9 mm. Of this self-levelling material a sheet is made--if desired between two glass fleeces--and allowed to thicken. The sheet, which has thus become pliable, is suitable to be placed in the pretreated mould. For that matter, the moulding material may already in a more pasty condition be placed on one or between two glass fleeces.

The finished products, particularly those in which glass fibre has been used, have a very good scratch resistance, which has been measured with the aid of the Erichsen apparatus, type 413, for the testing of hardness. As a measure of the scratch resistance weights are stated in grams at which a certain diamond penetrator does just not, and does just, bring about a scratch on the surface to be tested. In the case of stainless steel the load of the diamond penetrator is zero. For the finished products according to the invention 230-250. Further, the surface proved to be highly heat-resistant and resistant to household chemicals.

Objects made according to the process described can replace enamelled ceramic products very well, especially those for sanitary use, such as wash-basins, shower-basins, baths and the like, but also serve as kitchen slabs, drip trays for cooking-appliances, etc. Even highly complex shapes may be prepared in one pass. The thickness of the composed material may be very different, depending on the application. Thicknesses of between 5 and 15 mm are applied the most.