Abstract:
A process for manufacturing a flat or shaped sheet product or a moulding is disclosed. The first step is to prepare a paste from a thermoplastic elastomer, a thermoplastic polymer, a particulate filler which may be an inorganic particulate filler, an organic particulate filler or a mixture of the two, and an amount of a solvent to dissolve the thermoplastic elastomer and the thermoplastic polymer and to wet the particulate to form the paste. The paste may be placed on a carrier and allowed to dry to form the sheet product, whereafter it is removed from the carrier. Alternatively the paste may be applied to a substrate, shaped into a desired shape and allowed to dry so that it adheres to the substrate to form the mouding.
Abstract:
A method for manufacturing an hydraulic binder or thermoplastic binder containing product including the steps of impregnating the binder into a flexible open cell polymeric foam element by compressing the foam element to exclude air from the open cells and then releasing the compression with the foam elements whilst in contact with the binder so that the binder penetrates and becomes contained in the open cells of the foam elements as it regains its shape. Alternatively impregnating the binder into the foam element from one side under pressure so that the binder penetrates and becomes contained in the open cells of the foam and then allowing the binder to set or hardened and dry to form the product. The product is particularly suitable as a building element.
Abstract:
A method of making a finished product includes the steps of (a) providing a dry feedstock selected from the group consisting of particles or fibres of a lignocellulosic material; particles of an expanded mineral; particles of a foamed set hydraulic binder; particles of an undensified silica fume or a mixture of two or more thereof; (b) mixing the feedstock with: (i) a suitable amount of a thermosetting resin in finely divided dry powder form; (ii) a suitable amount of a first binding agent selected from the group consisting of an alkaline earth metal oxide or hydroxide; or a mixture of two or more thereof, in finely divided dry powder form; and (iii) a second binding agent such as a pozzolan in finely divided dry powder form; to give a starting material; (c) subjecting the starting material of step (b) to suitable conditions of temperature and pressure to cause the thermosetting resin to set to form a cohesive product; (d) providing to the cohesive product of step (c) water in an amount sufficient to permit the reaction of the first and second binding agents to form a binder; and (e) allowing the binder to set to form the finished product. The finished product may, for example, be a board.
Abstract:
A method for the production of a hydraulic binder foam which may subsequently be used to make a finished product such as a thermal insulation product, includes the steps of preparing a paste or a slurry from a hydraulic binder and a foaming agent; feeding the paste or the slurry to a foam generator and introducing compressed air into the foam generator to produce an aerated product; and pumping the aerated product and additional compressed air from the foam generator through a length of piping thus causing turbulence of the aerated product and the compressed air so as to produce a hydraulic binder foam exiting the length of piping. The hydraulic binder foam exiting the length of piping is air saturated and thus of a consistent density as a function of the liquid to hydraulic binder ratio rather than as a function of the method of production.
Abstract:
A method of making a composite panel from two substantially similar panel skins (40, 42) and an edging (48), is disclosed. The first panel skin (40), is made in a mould from a first composition comprising a thermosetting resin, a catalyst for the thermosetting resin and inorganic filler particles. On this layer is placed a layer of a fibrous reinforcing material wetted with a second composition comprising a thermosetting resin and a catalyst for the thermosetting resin. Before the thermosetting resin in the second composition has set, the edging (48) is placed all around the edge of the first panel skin (40). The thermosetting resin in the second composition then sets to form a combination of the first panel skin (40) with the edging (48) attached thereto. The second panel skin (42) is then formed in the same manner as the first panel skin (40) and before the thermosetting resin in the second composition is set, the combination of the first panel skin (40) and the edging (48) is placed on the second panel skin (42) with the edging (48) in contact with the second panel skin (42). The thermosetting resin is then allowed to set to form an intermediate panel from the second panel skin (42) and the combination. The intermediate panel includes a cavity defined by the first and second panel skins (40, 42) separated by the edging (48), and this cavity is filled with a polyurethane foam (50) to form the composite panel.
Abstract:
A method of applying a powder coating to a non-metallic substrate such as a length of a lignocellulosic material, e.g a length of wood, is disclosed. The substrate is impregnated or has applied to the surface thereof, a composition containing a pre-accelerated, unsaturated polyester resin containing a latent catalyst therefor, either dissolved in a suitable non-aqueous solvent or mixed or dispersed in water. Thereafter the non-aqueous solvent or water is removed, and the substrate is placed in an electrostatic field or in a fluidised bed and a powder coating composition is applied thereto. The substrate is then subjected to an elevated temperature to polymerise and/or cross-link the polyester resin in or on the substrate and to cure the powder coating composition to form the powder coating. The result is a product with a decorative powder coating which may be used for many purposes.
Abstract:
A process for manufacturing a moulding such as an architectural moulding or a picture or photo frame, includes the steps of providing a substrate such as a polymeric extrusion; providing a paste comprising a thermoplastic elastomer, a thermoplastic polymer, an inorganic particulate filler and an amount of a solvent to dissolve or wet the various components to form the paste; applying to the substrate a layer of the paste; shaping the paste to a desired shape; and allowing the paste to dry so that it adheres to the substrate to form the moulding.