CA1106744A - Flexible foam board - Google Patents
Flexible foam boardInfo
- Publication number
- CA1106744A CA1106744A CA316,957A CA316957A CA1106744A CA 1106744 A CA1106744 A CA 1106744A CA 316957 A CA316957 A CA 316957A CA 1106744 A CA1106744 A CA 1106744A
- Authority
- CA
- Canada
- Prior art keywords
- laminate
- sheet
- foam
- weight
- styrene
- 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
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
FLEXIBLE FOAM BOARD
ABSTRACT
A foamed styrene-maleic anhydride copolymer sheet having a coating on both sides of solid styrene-maleic anhydride resin. A principal use for said sheet is as a component of automobile headliners.
ABSTRACT
A foamed styrene-maleic anhydride copolymer sheet having a coating on both sides of solid styrene-maleic anhydride resin. A principal use for said sheet is as a component of automobile headliners.
Description
Backs,~round of the Invention ~
Field of the Invention ~ ;
... ..
This invention relates to a coated foam sheet in which the resin in ~ -each of the layers is at least predominantly a styrene-maleic anhydride 10 copolymer. A process of producing such a sheet is disclosed.
Prior Art - Related to the process and product disclosed herein is the process s~.
and product disclosed in Whelan et al IJ.S. Patent 3,616,020.
An object of this invention is to provide a thermoformable coated --15 foam sheet of improved properties. A furt:her object is to provide such a sheet which uill remain flat for use as is or which can be thermoformed and thereafter retQin the new shape.` A further object is to provide a sheet which can be laminated to other materials to provide stiffness to the ~J~
. `'." ' . ~
resulting composite if the material to which it is laminated is flexible. ;`-The product of our invention can be used m automobile headliners, ` -as aluminum siding backerboard, in the production of disposable pallets, , .. ..
as display board, etc. ' ~.
Summary of the Invention ,. .
Broadly our invention comprises an essentially flat plastic laminate ~ .:
25 ~ which is flexible and thermoformable having an intermediate foam layer : -; formed by extruding a foamable resin mixture comprising, on a weight ! - . : . ::
'i basis, at least 60% of a styrene-maleic anhydrlde copolymer, up to 20% of -l~ reclaim resin from said sheet, up to 20~ of crystal polystyrene\, and a ,j. ~ , .
~, . i - . : :
'' ~`''' :
film coating on each side of a resin comprising at least 90% of a styrene maleic-anhydride copolymer, said sheet having~ a total thickness 0. 7 to ;
7mm, with each film having a thickness of 0 . 03 to 4mm, the weight . ~ .
oî said laminate being 200 to 1,500 g/m2 with the foam weight being -;
150 to 600 g/m2, the adhesion of film to foam being an average of at least 30 newtons/meter with no value less than 20 newtons/meter when -~testing both sides in machine and transverse directions at an angle of 90 at a test rate of 300 mm/minutes, said laminate having a flatness factor of 5 cnl for a sheet having dimensions of 1. 5 by 3 meters . The balance of each resin layer can be crystal polystyrene. The styrene-maleic anhydride copolymer contains from 5 to 20% by weight of bound maleic anhydride . The solid resin coating preferably contains 1. 5 to 10% by weight of a rubbery polymer such as high cis-polybutadiene.
Drawing ~`
The drawing includes: ~ ~
Figure 1, a cross section of a final product of our invention; 1;
Figure 2, a perspective view of apparatus suitable for producing foam coated with film; ~.
Figure 3, a top view of the foam extrusion and slitting system;
and ,~.
Figure 4, a side view of the system of Figure 3.
Preferred Embodiment ~ ;~
Referring to Figure 1, we have illustrated in cross section the , product produced according~ to our invention as it is incorporated in an automobile heaclliner. This Figure shows the foam layer 10 with solid resin layers 11 and 12 fused to the foam layer 10. 13onded to solid resin layer 12- is a rubbery foam layer 13 and bonded to layer 13 is a cloth layer 14. For its ultimate use, this composite structure of l:igure 1 is thermoformed to form an automobile headliner.
lf ,! !
67~L
.:
The process of the invention can be used to produce such a composite structure containing layers 10, 11, and 12. For the head-.. . . .
liner application, it is preferred that the laminate have a weight of :~
Field of the Invention ~ ;
... ..
This invention relates to a coated foam sheet in which the resin in ~ -each of the layers is at least predominantly a styrene-maleic anhydride 10 copolymer. A process of producing such a sheet is disclosed.
Prior Art - Related to the process and product disclosed herein is the process s~.
and product disclosed in Whelan et al IJ.S. Patent 3,616,020.
An object of this invention is to provide a thermoformable coated --15 foam sheet of improved properties. A furt:her object is to provide such a sheet which uill remain flat for use as is or which can be thermoformed and thereafter retQin the new shape.` A further object is to provide a sheet which can be laminated to other materials to provide stiffness to the ~J~
. `'." ' . ~
resulting composite if the material to which it is laminated is flexible. ;`-The product of our invention can be used m automobile headliners, ` -as aluminum siding backerboard, in the production of disposable pallets, , .. ..
as display board, etc. ' ~.
Summary of the Invention ,. .
Broadly our invention comprises an essentially flat plastic laminate ~ .:
25 ~ which is flexible and thermoformable having an intermediate foam layer : -; formed by extruding a foamable resin mixture comprising, on a weight ! - . : . ::
'i basis, at least 60% of a styrene-maleic anhydrlde copolymer, up to 20% of -l~ reclaim resin from said sheet, up to 20~ of crystal polystyrene\, and a ,j. ~ , .
~, . i - . : :
'' ~`''' :
film coating on each side of a resin comprising at least 90% of a styrene maleic-anhydride copolymer, said sheet having~ a total thickness 0. 7 to ;
7mm, with each film having a thickness of 0 . 03 to 4mm, the weight . ~ .
oî said laminate being 200 to 1,500 g/m2 with the foam weight being -;
150 to 600 g/m2, the adhesion of film to foam being an average of at least 30 newtons/meter with no value less than 20 newtons/meter when -~testing both sides in machine and transverse directions at an angle of 90 at a test rate of 300 mm/minutes, said laminate having a flatness factor of 5 cnl for a sheet having dimensions of 1. 5 by 3 meters . The balance of each resin layer can be crystal polystyrene. The styrene-maleic anhydride copolymer contains from 5 to 20% by weight of bound maleic anhydride . The solid resin coating preferably contains 1. 5 to 10% by weight of a rubbery polymer such as high cis-polybutadiene.
Drawing ~`
The drawing includes: ~ ~
Figure 1, a cross section of a final product of our invention; 1;
Figure 2, a perspective view of apparatus suitable for producing foam coated with film; ~.
Figure 3, a top view of the foam extrusion and slitting system;
and ,~.
Figure 4, a side view of the system of Figure 3.
Preferred Embodiment ~ ;~
Referring to Figure 1, we have illustrated in cross section the , product produced according~ to our invention as it is incorporated in an automobile heaclliner. This Figure shows the foam layer 10 with solid resin layers 11 and 12 fused to the foam layer 10. 13onded to solid resin layer 12- is a rubbery foam layer 13 and bonded to layer 13 is a cloth layer 14. For its ultimate use, this composite structure of l:igure 1 is thermoformed to form an automobile headliner.
lf ,! !
67~L
.:
The process of the invention can be used to produce such a composite structure containing layers 10, 11, and 12. For the head-.. . . .
liner application, it is preferred that the laminate have a weight of :~
2 2 640 g/m with the foam having a weight of 210 g/m . The solid resin layers 11 and 12 have a thickness of 0. 2mm and the laminate have a thickness of 3 . 8mm maximum .
The resulting sheet containing layers 10, 11, and 12 should have a flatness factor of not over 5cm. The flatness factor is a measurement of the amount of upward bowing in a sheet having dimensions of 1. 5 by
The resulting sheet containing layers 10, 11, and 12 should have a flatness factor of not over 5cm. The flatness factor is a measurement of the amount of upward bowing in a sheet having dimensions of 1. 5 by
3 meters.
The thickness of rubbery foam sheet 13 is generally substantially thicker than the composite coated foam sheet but this is dependent upon !: ,,. ,~' . . 'i, .
the amount of padding desired in the final product. The cloth layer 14 :
is any suitable material having decorating properties for use in an " : `~
15 automobile headliner.
.. .
Drawing attention to Figure 2, the principal steps of the process -~
can be seen. The process comprises mixing the resin with a nucleating agent and feeding this mixture to extruder 20 wherein a blowing agent is added. Those skilled in the art will recognize that a number of systems can be used for nucleating and blo~,ving. We prefer to use, on "~
a weight basis based on the resin, O.1 to ll~o sodium bicarbonate, O.1 to ~ ~-1% citric acid, and 2 to 3% isopentane. This mixture is extruded through circular die 21 and the tube foams and expands over a sizing mandrel ~. ,,~., (now shown) to produce a tubular foam structure 22. Tension is maintained on tube 22 in S ~rrap rollers 23, 24, and 26 after passing over roller 27. Figures 3 and 4 show top ~md side views of the system.
;
I
~6~74L~
., .
The tube is slit at the top by knife 25 after it lcaves the cooling mundrel.
Therenfter~ the sheet passes over rollers 28 and 29 before entering a polish roll stack comprising rolls 30, 31, and 32. Into the nip between rolls 30 and 31, a sheet of unfoamed resin 33 extruded from the extruder 39, 5 is fused to the sheet 31 by the pressure at said nip. This foam sheet, now coated on one side, is passed over rolls 42, 43, 44, and 46 and into a second polish roll stack comprising rolls 47, 48, and 49. From die 50, a sheet 51 is extruded into the nip by the rolls ~7 and 48, this applying a second i solid resin coating~ to the foam. This coated foam now having solid resin 10 on both sides thereof, and shown at 52 passes over roll 55 and into tension control roll system comprising rolls 53 and 54. The proper tension ~ ¦
is adjusted to produce a flat wrinkle-free sheet without snapping the web.
Obviously, the sheet at this stage has the first coating as the top layer.
Thereafter, the sheets are cut to length in shear means 58 and passed 15 into the finish stack 59.
The resins use~ in the production of the preferred article prepared -according to this invention are styrene-maleic anhydride copolymers containing approximately 10 percent of bound maleic anhydride. For the foam, we prefer to use a resin having the following properties: -;
ASTM Typical Properties MethodValues -.:
Tensile Strength, psi D-638 7,800 Tensile Elongation, % D-638 2.0 Tensil Modulus, 105 psi D-638 4. 5 Flexural Strength, psi D-790 13,50û
llexural Modulus, 105 psi D-790 4.7 Izod Impact Strength, D-255 o. 4 Ft . I.bs . /In .
' Dcflection Temperature D-618 237 Under Load, F., 264 psi Annealed at 90C.
,, (1/2" x 1/2" x 5" Bar) 30 l, -4-.. ..
,,, ~ .: ` `:
! ASTMTypical ' Properties Me~hodValues , . . . .
Vicat, C. D-1525 120 F. 248 Specific Gravity, D-792 1.08 23/23C. ~:
Water ~bsorption, Wt . ~6 D-57Q 0.11 . .:
Mold Shrinkag~e, In . /In . D-955 0.005 :: .~.....
Rockwell Hardness, D-785 108 -"L" Scale -, For the coating, we also use a styrene-maletic anhydride copolymer containing approximately 10 percent bound maleic anhydride . .
and approximately 3 percent of a rubbery modifier, high cis-polybutadiene being most commonly used. The following properties describe a suitable material:
ASTM Typical Properties MethodValues Tensile Strength, psi D-638 5,000 Utlimate Elongation, % D-638 25 ;~
Tensile Modulus, 10 psi D-638 3.2 Flexural Strength, psi D-790 8,900 Flexural Modulus, 105 psi D-790 3.4 ` ~
I~od Impact Strength D-256 3.4 ' Ft. Lbs . /Inch Deflection Temperature D-618 239 Under Load, F. 264 psi Annealed at 90C.
(1/2" x 1/2" x 5" Bar) i - ~ .~.
Vicat Softening Point, C. D-1525 121 ~ -, F. 250 Specific Gravity, 23/23 C D-792 1.06 Wntcr Absorption, Wt. g; D-570 0.12 ` Mold Shrinkage, In./In. D-955 0.006 - 0.007 Rockwell Hardness, "L" Scale D-785 80 30 ~, -5-~ I , 1, , ., o~
j~ ~xample . .
jl Using a 6" extruder with a 3. 75 inch diameter die opening, a mixture of the styrene-maleic acid copolymer containing, on a weight basis, 0. 5 percent citric acid and 0 . 5 percent sodium carbonate as a nucleating agent and 4 percent isopentane ns a blowing agent was extruded . The circumference of the tube of the blown material expanded ~ ~ ~
to 52 inches. This tube was then slit and opened up. It has a weight 1~, ,`
of 210 grams per square meters. The average pore size in the foam was approximately 0 . 2mm in diameter, this diameter providing maximum 10 bond strength to the coating subsequently added without excessive brittleness which would result from larger cell size. This sheet was passed between rolls 30, 31, and 32 which were supplied with cooling water at 115, 175, and 175F. from top to bottom. The coating 38 was ~ , ~
supplied to the nip between rolls 30 and 31 with a 0.100 inch gap at the coating sizes. Thereafter, the foam sheet having a coating on one side ~vas passed to roll stack containing rolls 47, 48, 49, these rolls being supplied with coolant at a temperature of 205F, 140F, and 205F from top to bottom . The nip between rolls 47 and 48 was 0 . 060 inch . The two ~, ,.
nip gaps set forth were determined by experimentation to provide mlaximum bond strength without sacrificing thickness. ~s excessive gap ~-diminishes bond strength and as the gap decreases, bond strength -:
increases to a point limited by the cell structure although more and more foam is destroyed by the hot melt. The roll stack temperatures are -selected to achieve a good bond on the first coat and sheet flexibility 25 ~ ancl, on the second stack, the temperatures control the coating temperature on both sides as the coated foam leaves the stack which, in turn, affects sheet flatness.
' , 3 0 ~ 6 For the foam, we hnve referred to specific styrene-malcic anhydride copolymers and these are preferred. ~lowever, it is possible to operate using up to 20 percent of crystal polystyrene and up to 20 percent reclaim, all on a weight basis in the -foam without 5 adversely affecting the properties of the final product. Further, reclaim sheet can be used with the virgin resin in an amount up to 20 percent by weight.
While we have described our invention in specific terms, it is apparent that modifications in the sheet can be made without departing 10 from the invention.
The thickness of rubbery foam sheet 13 is generally substantially thicker than the composite coated foam sheet but this is dependent upon !: ,,. ,~' . . 'i, .
the amount of padding desired in the final product. The cloth layer 14 :
is any suitable material having decorating properties for use in an " : `~
15 automobile headliner.
.. .
Drawing attention to Figure 2, the principal steps of the process -~
can be seen. The process comprises mixing the resin with a nucleating agent and feeding this mixture to extruder 20 wherein a blowing agent is added. Those skilled in the art will recognize that a number of systems can be used for nucleating and blo~,ving. We prefer to use, on "~
a weight basis based on the resin, O.1 to ll~o sodium bicarbonate, O.1 to ~ ~-1% citric acid, and 2 to 3% isopentane. This mixture is extruded through circular die 21 and the tube foams and expands over a sizing mandrel ~. ,,~., (now shown) to produce a tubular foam structure 22. Tension is maintained on tube 22 in S ~rrap rollers 23, 24, and 26 after passing over roller 27. Figures 3 and 4 show top ~md side views of the system.
;
I
~6~74L~
., .
The tube is slit at the top by knife 25 after it lcaves the cooling mundrel.
Therenfter~ the sheet passes over rollers 28 and 29 before entering a polish roll stack comprising rolls 30, 31, and 32. Into the nip between rolls 30 and 31, a sheet of unfoamed resin 33 extruded from the extruder 39, 5 is fused to the sheet 31 by the pressure at said nip. This foam sheet, now coated on one side, is passed over rolls 42, 43, 44, and 46 and into a second polish roll stack comprising rolls 47, 48, and 49. From die 50, a sheet 51 is extruded into the nip by the rolls ~7 and 48, this applying a second i solid resin coating~ to the foam. This coated foam now having solid resin 10 on both sides thereof, and shown at 52 passes over roll 55 and into tension control roll system comprising rolls 53 and 54. The proper tension ~ ¦
is adjusted to produce a flat wrinkle-free sheet without snapping the web.
Obviously, the sheet at this stage has the first coating as the top layer.
Thereafter, the sheets are cut to length in shear means 58 and passed 15 into the finish stack 59.
The resins use~ in the production of the preferred article prepared -according to this invention are styrene-maleic anhydride copolymers containing approximately 10 percent of bound maleic anhydride. For the foam, we prefer to use a resin having the following properties: -;
ASTM Typical Properties MethodValues -.:
Tensile Strength, psi D-638 7,800 Tensile Elongation, % D-638 2.0 Tensil Modulus, 105 psi D-638 4. 5 Flexural Strength, psi D-790 13,50û
llexural Modulus, 105 psi D-790 4.7 Izod Impact Strength, D-255 o. 4 Ft . I.bs . /In .
' Dcflection Temperature D-618 237 Under Load, F., 264 psi Annealed at 90C.
,, (1/2" x 1/2" x 5" Bar) 30 l, -4-.. ..
,,, ~ .: ` `:
! ASTMTypical ' Properties Me~hodValues , . . . .
Vicat, C. D-1525 120 F. 248 Specific Gravity, D-792 1.08 23/23C. ~:
Water ~bsorption, Wt . ~6 D-57Q 0.11 . .:
Mold Shrinkag~e, In . /In . D-955 0.005 :: .~.....
Rockwell Hardness, D-785 108 -"L" Scale -, For the coating, we also use a styrene-maletic anhydride copolymer containing approximately 10 percent bound maleic anhydride . .
and approximately 3 percent of a rubbery modifier, high cis-polybutadiene being most commonly used. The following properties describe a suitable material:
ASTM Typical Properties MethodValues Tensile Strength, psi D-638 5,000 Utlimate Elongation, % D-638 25 ;~
Tensile Modulus, 10 psi D-638 3.2 Flexural Strength, psi D-790 8,900 Flexural Modulus, 105 psi D-790 3.4 ` ~
I~od Impact Strength D-256 3.4 ' Ft. Lbs . /Inch Deflection Temperature D-618 239 Under Load, F. 264 psi Annealed at 90C.
(1/2" x 1/2" x 5" Bar) i - ~ .~.
Vicat Softening Point, C. D-1525 121 ~ -, F. 250 Specific Gravity, 23/23 C D-792 1.06 Wntcr Absorption, Wt. g; D-570 0.12 ` Mold Shrinkage, In./In. D-955 0.006 - 0.007 Rockwell Hardness, "L" Scale D-785 80 30 ~, -5-~ I , 1, , ., o~
j~ ~xample . .
jl Using a 6" extruder with a 3. 75 inch diameter die opening, a mixture of the styrene-maleic acid copolymer containing, on a weight basis, 0. 5 percent citric acid and 0 . 5 percent sodium carbonate as a nucleating agent and 4 percent isopentane ns a blowing agent was extruded . The circumference of the tube of the blown material expanded ~ ~ ~
to 52 inches. This tube was then slit and opened up. It has a weight 1~, ,`
of 210 grams per square meters. The average pore size in the foam was approximately 0 . 2mm in diameter, this diameter providing maximum 10 bond strength to the coating subsequently added without excessive brittleness which would result from larger cell size. This sheet was passed between rolls 30, 31, and 32 which were supplied with cooling water at 115, 175, and 175F. from top to bottom. The coating 38 was ~ , ~
supplied to the nip between rolls 30 and 31 with a 0.100 inch gap at the coating sizes. Thereafter, the foam sheet having a coating on one side ~vas passed to roll stack containing rolls 47, 48, 49, these rolls being supplied with coolant at a temperature of 205F, 140F, and 205F from top to bottom . The nip between rolls 47 and 48 was 0 . 060 inch . The two ~, ,.
nip gaps set forth were determined by experimentation to provide mlaximum bond strength without sacrificing thickness. ~s excessive gap ~-diminishes bond strength and as the gap decreases, bond strength -:
increases to a point limited by the cell structure although more and more foam is destroyed by the hot melt. The roll stack temperatures are -selected to achieve a good bond on the first coat and sheet flexibility 25 ~ ancl, on the second stack, the temperatures control the coating temperature on both sides as the coated foam leaves the stack which, in turn, affects sheet flatness.
' , 3 0 ~ 6 For the foam, we hnve referred to specific styrene-malcic anhydride copolymers and these are preferred. ~lowever, it is possible to operate using up to 20 percent of crystal polystyrene and up to 20 percent reclaim, all on a weight basis in the -foam without 5 adversely affecting the properties of the final product. Further, reclaim sheet can be used with the virgin resin in an amount up to 20 percent by weight.
While we have described our invention in specific terms, it is apparent that modifications in the sheet can be made without departing 10 from the invention.
Claims (5)
1. An essentially flat plastic laminate which is flexible and thermoformable having an intermediate form layer formed by extruding a foamable resin mixture comprising, on a weight basis, at least 60%
of a styrene-maleic anhydride copolymer, up to 20% of reclaim resin from said sheet, up to 20% of crystal polystyrenes, and a film coating on each side of a resin comprising at least 90% of a styrene maleic-anhydride copolymer, said sheet having a total thickness 0.7 to 7mm, with each film having a thickness of 0.03 to 4mm, the weight of said laminate being 200 to 1,500 g/m2 with the foam weight being 150 to 600 g/m2, the adhesion of film to foam being an average of at least 30 newtons/meter with no value less than 20 newtons/meter when testing both sides in machine and transverse directions at an angle of 90° at a test of 300 mm/minutes, said laminate having a flatness factor of 5 cm for a sheet having dimensions of 1.5 by 3 meters.
of a styrene-maleic anhydride copolymer, up to 20% of reclaim resin from said sheet, up to 20% of crystal polystyrenes, and a film coating on each side of a resin comprising at least 90% of a styrene maleic-anhydride copolymer, said sheet having a total thickness 0.7 to 7mm, with each film having a thickness of 0.03 to 4mm, the weight of said laminate being 200 to 1,500 g/m2 with the foam weight being 150 to 600 g/m2, the adhesion of film to foam being an average of at least 30 newtons/meter with no value less than 20 newtons/meter when testing both sides in machine and transverse directions at an angle of 90° at a test of 300 mm/minutes, said laminate having a flatness factor of 5 cm for a sheet having dimensions of 1.5 by 3 meters.
2. The laminate of claim 1 wherein said foamable resin mixture contains from 0.1 to 1% of sodium bicarbonate, 0.1 to 1% of citric acid, and 2 to 8% isopentane.
3. The laminate of claim 1 which upon heating for 60 minutes at 115°C expands in an amount not to exceed 150%.
4. The laminate of claim 1 having bonded thereto a rubbery foamed sheet of a thickness equal to or greater than said laminate of claim 1 and a cloth layer attached to said rubbery foamed sheet opposite said laminate of claim 1.
5. An automobile headliner made by thermoforming the product of claim 4.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA316,957A CA1106744A (en) | 1978-11-27 | 1978-11-27 | Flexible foam board |
| DE7935750U DE7935750U1 (en) | 1978-11-27 | 1979-10-23 | Automotive disadvantage |
| DE19797929987U DE7929987U1 (en) | 1978-11-27 | 1979-10-23 | PRACTICALLY FLAT, FLEXIBLE AND THERMOFORMABLE PLASTIC MADE OF PLASTIC |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA316,957A CA1106744A (en) | 1978-11-27 | 1978-11-27 | Flexible foam board |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1106744A true CA1106744A (en) | 1981-08-11 |
Family
ID=4113031
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA316,957A Expired CA1106744A (en) | 1978-11-27 | 1978-11-27 | Flexible foam board |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA1106744A (en) |
| DE (2) | DE7935750U1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11613604B2 (en) | 2021-06-28 | 2023-03-28 | Covestro Llc | Isocyanate-reactive compositions, polyurethane foams formed therefrom, multi-layer composite articles that include such foams, and methods for their preparation |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GR1004968B (en) * | 2004-09-23 | 2005-09-08 | Weply Limited | Inflated polystyrene with the ability to absorb moisture internally, of a single-layer structure, without surface cover with membranes (non-laminated); products and method |
-
1978
- 1978-11-27 CA CA316,957A patent/CA1106744A/en not_active Expired
-
1979
- 1979-10-23 DE DE7935750U patent/DE7935750U1/en not_active Expired
- 1979-10-23 DE DE19797929987U patent/DE7929987U1/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11613604B2 (en) | 2021-06-28 | 2023-03-28 | Covestro Llc | Isocyanate-reactive compositions, polyurethane foams formed therefrom, multi-layer composite articles that include such foams, and methods for their preparation |
Also Published As
| Publication number | Publication date |
|---|---|
| DE7935750U1 (en) | 1980-04-17 |
| DE7929987U1 (en) | 1980-04-17 |
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