Product made of synthetic plastic material of good mechanical strength and good thermal insulating and soundproofing characteristics, and relative manufacturing method

Abstract: A product made of synthetic plastic material composed of a thermoplastic polymer resin including at least one polymer or copolymer or a mixture of polymers or copolymers, and an inert filler dispersed uniformly in the resin, wherein the material is a foam material including a number of open or closed cells distributed substantially uniformly, and wherein the resin is cross-linked three-dimensionally. A resin, selected from the group including polyolefin and polystyrene resins and mixtures thereof, is mixed with a natural or synthetic inert filler, such as calcium carbonate, barium sulfate, etc., and with appropriate additives, is injection molded or extruded after adding chemical or physical foaming agents (inert gases), and is cross-linked, wholly or in part, by adding chemical cross-linking agents or by radiation by an electron beam.

Description: The present invention relates to a product made of synthetic plastic material of good mechanical strength, low density, and good thermal insulating and soundproofing characteristics. The product may be injection molded or extruded into any form, typically a pipe, panel or section, but also a seal or industrial coating or film; and the present invention also relates to a method of manufacturing such a product. Numerous applications, particularly the manufacture of sanitary fittings, require elements, such as pipes, sections, panels, etc., of good mechanical strength, good thermal insulating and soundproofing characteristics, and good flame resistance, and which, in particular, are self-extinguishing and give off little or no toxic or irritating fumes. At present, no one single material is available incorporating all the above characteristics. Thermosetting resin materials are normally difficult and expensive to manufacture, may give off toxic fumes, and are normally somewhat fragile and therefore unsuited to the above applications. Thermoplastic materials, on the other hand, are cheaper and easier to work, e.g. by injection molding or extrusion, but, even though a satisfactory degree of flame resistance may be achieved using suitable additives, they nevertheless present the drawback of softening when subjected to heat, and, in certain conditions, may give off red-hot spray. Moreover, the mechanical strength of thermoplastic resins is not very good, particularly in applications involving fatigue, such as that induced by cyclic thermal deformation, and normally gets worse in time due to "aging" of the material, which is even further accelerated if the product is exposed to weather and/or sunlight. Thermal insulation and soundproofing require the use of foam materials, such as those described in GB-A-2 070 021, US-A-4 353 997, JP-A-03 269 028, JP-A-04 055 440 and JP-A-05 025 308, of even poorer mechanical strength, which is why recourse is normally made to multilayer products featuring a supporting structure of compact material, and an insulating or soundproof covering of foam material. Such products, however, are expensive and difficult to produce. It is an object of the present invention to provide a product made of synthetic thermoplastic material, which is cheap and easy to mold or extrude into pipes, sections or similar, and which at the same time presents good mechanical strength and good thermal insulating and soundproofing characteristics with no need for a multilayer structure. According to the present invention, there is provided a pipe and/or a pipe fitting made of synthetic plastic material comprising a thermoplastic polymer resin in turn comprising at least one thermoplastic polymer or copolymer selected from the group comprising polyolefins, polystyrenes and mixtures thereof, and an inert filler dispersed uniformly in the resin as defined in claim 1. Pipes and relative fittings may thus be made which are low-cost, lightweight, flame resistant by adding appropriate nonhalogenated, nontoxic agents, of good soundproofing and thermal insulating properties, and of good mechanical strength which remains unchanged with time. According to the present invention, there is also provided a method of manufacturing the above pipes and/or pipe fittings as claimed in claim 5. In other words, underlying the present invention is the idea of combining in the same pipe/fitting i.e. in the same manufacturing process, two known processes formerly used separately: cross-linking; and foaming, either chemically (by adding reagents capable of producing gaseous substances) or physically (by adding inert gases under pressure). Moreover, the two processes are applied for the first time to saturated thermoplastic resins, which in themselves are unsuited to intermolecular cross-linking, and are hot normally used for manufacturing foam materials (with the exception of polystyrene used for packing materials and insulating panels). Foaming and the use of inert fillers also provide for considerable saving of valuable raw material, i.e. thermoplastic resin, and for enabling the manufacture of low-density, hence lightweight, products which are therefore easy to handle and transport. Three-dimensional cross-linking of the resin, on the other hand, has surprisingly been found to also result in products of good mechanical strength, both absolute and in terms of resistance to fatigue, and highly resistant to aging and softening when subjected to heat. Finally, the products maintain good thermal insulating and soundproofing characteristics, the latter being particularly evident in the case of products such as the drain pipes of sanitary installations. The thermoplastic resin used according to the invention is a resin comprising a thermoplastic polymer or copolymer, or a mixture of thermoplastic polymers or copolymers selected from the group comprising: polyethylene, polypropylene, polyethylvinyl acetate, polystyrene, acrylonitrile butadiene styrene (ABS), and relative copolymers. The inert filler, on the other hand, is a natural (e.g. mineral) or synthetic inorganic material, and is preferably selected, for example, from the group comprising: calcium carbonate, barium sulfate, and other mineral substances of similar chemical characteristics, weight, particle size and mechanical resistance. Depending on the resin and filler used, and particularly on the degree of foaming, the density of the material from which the product according to the invention is made may range between 1.000 and 1.500 gr/cm3; and, to get the full benefit of the present invention, the thermoplastic resin from which the products are made must present, when the product is finished, a cross-linking rate of 80 to 100%. In addition to the above characteristics, the material from which the product according to the invention is made obviously also includes the usual additives to plastic materials, such as stabilizers, lubricants and plasticizers, as well as nonhalogenated, nontoxic flame extinguishing substances, e.g. Ba SO 4 Blanc Fixe made by Industria Chimica Subalpina S.p.A. - Italy, or BLANC ROC Micro made by MINERALS GIRONA S.A. - Spain, in quantities ranging from 100 to 280 parts by weight per 100 parts of resin. The products according to the invention are made using substantially conventional processes comprising the steps of: mixing the selected thermoplastic polymer resin (or mixture of resins) with the appropriate quantity of inert filler, until the resin is dispersed uniformly in the inert filler or vice versa; rendering the thermoplastic resin fluid by heating to a suitable temperature, e.g. 160-220°C; and forming the product to the required shape and size from the above mixture, in which the resin is still in the fluid state, using a standard method, e.g. injection molding or extrusion; and solidifying the thermoplastic resin by cooling at ambient temperature. Unlike known processes, however, according to the present invention, the thermoplastic resin is three-dimensionally cross-linked to form carbon-carbon bonds between atoms of different polymer chains; and, before or during cross-linking and while the resin is still fluid, the entire resin and inert filler mixture is subjected to the action of gaseous substances in expansion to form a solid end material comprising a number of cells uniformly dispersed in the material; which cells are open or closed, depending on the application of the product, and are empty or, in general, filled with air or the foaming gas, e.g. carbon dioxide or nitrogen. Foaming may be effected in known manner by adding chemical foaming agents, e.g. azodicarbonamide A.D.C.M, to the mixture at the mixing stage, or by adding a cylinder-stored compressed gas, e.g. CO 2 or N 2 , to the mixture, even at the final forming and cross-linking stage. Particularly in the case of polyolefin resins which are saturated, cross-linking is normally effected by adding appropriate quantities of chemical cross-linking agents, particularly organic peroxides, to the mixture. Alternatively, cross-linking of the thermoplastic resin may even be effected on the finished product, at any rate on the foamed solid material, by subjecting the product or material to radiation by a high-power electron beam. Finally, polyfunctional chemical compounds, particularly organosiloxane compounds, may be grafted beforehand in known manner to the polymer chains of the selected resin. More specifically, the content of such agents in the chain ranges from 0.500 to 3.000%. A number of embodiments of the invention will now be described by way of example. EXAMPLE 1 Mixes are prepared with the compositions shown in Tables 1 and 2, and are used to extrude pipes of 40 to 315 mm in diameter and 2 to 10 mm thickness, and to injection mold elements such as bends, Y branches, branch pipes and fittings, also of 40 to 315 mm in diameter and 2 to 10 mm thickness. Cross-linking is effected by adding, at the mixing stage, 1.500 parts per 100 parts of the mixture of organosiloxane compounds, such as silane or UCARSIL™ by Union Carbide - USA. Foaming is effected by adding, at the mixing stage, 0.500 parts per 100 parts of the mixture of chemical foaming agents, such as Genitron AC4™ by Schering Polymer Additives - Great Britain. The finished products present a density of 1.350 gr/cm 3 and a weight per unit area of 7 kg/m 2 . When tested to ASTM D792 (specific weight), D2240 (Shore hardness), D638 (tensile strength and extensibility) and D2863 (oxygen index), the finished products present a mechanical strength fully comparable with that of similar products with no foaming or cross-linking, and all present good thermal insulating and soundproofing properties.

Claims: A plastic pipe and/or pipe fitting being made of synthetic plastic material and comprising a thermoplastic polymer resin in turn comprising at least one thermoplastic polymer or copolymer selected from the group comprising polyolefins, polystyrenes and mixtures thereof, and an inert filler dispersed uniformly in the resin, wherein (a) - said material is a foam material comprising a number of open or closed cells distributed substantially uniformly in the material, and (b) - the resin is cross-linked three-dimensionally; characterized in that , in combination, the density of said material ranges from 1.000 to 1.500 gr/cm 3 and said resin presents a cross-linking rate of 80 to 100%. A plastic component as claimed in Claim 1, characterized in that said resin comprises a polymer selected from the group comprising: polyethylene, polypropylene, polyethylvinyl acetate, polystyrene and ABS. A plastic component as claimed in Claim 1 or 2, characterized in that said inert filler is of natural or synthetic origin, and is preferably selected from the group comprising: calcium carbonate and barium sulfate. A plastic component as claimed in one of the foregoing Claims, characterized in that said material includes stabilizing, lubricating, plasticizing and nonhalogenated self-extinguishing additives. A method of manufacturing pipes and/or pipe fittings as defined in one of the foregoing claims, the method comprising the steps of: (a) - mixing a thermoplastic polymer resin, comprising at least one thermoplastic polymer or copolymer selected from the group comprising polyolefins, polystyrenes and mixtures thereof, with an inert filler until the resin is dispersed uniformly in the inert filler or vice versa; (b) - rendering the thermoplastic resin fluid; and (c) - forming said product from said mixture, and solidifying said thermoplastic resin; (d) - three-dimensionally cross-linking said thermoplastic polymer resin to form carbon-carbon bonds between atoms of different polymer chains; and (e) - subjecting said mixture, while the resin is still fluid, to the action of gaseous substances in expansion, to form a solid end material comprising a number of cells uniformly dispersed in the material; characterized in that said three dimensionally cross-linking step is carried out in such a way that said resin presents a cross-linking rate of 80 to 100% and said expansion step is carried out in such a way that the density of said material ranges from 1.000 to 1.500 gr/cm 3 . A method as claimed in Claim 5, characterized in that said forming step comprises injection molding. A method as claimed in Claim 5, characterized in that said forming step comprises extrusion. A method as claimed in one of the foregoing Claims from 5 to 7, characterized by comprising the step of foaming the mixture, while the resin is still fluid, by adding chemical foaming agents to the mixture. A method as claimed in one of the foregoing Claims from 5 to 7, characterized by comprising the step of foaming the mixture, while the resin is still fluid, by adding a compressed gas to the mixture. A method as claimed in one of the foregoing Claims from 5 to 9, characterized in that said cross-linking step is performed by adding chemical cross-linking agents, in particular organic peroxides, to said mixture. A method as claimed in one of the foregoing Claims from 5 to 9, characterized in that said cross-linking step is performed by subjecting the product to radiation by an electron beam following completion of the foaming step and following solidification of said resin. A method as claimed in one of the foregoing Claims from 5 to 9, characterized in that said cross-linking step is performed using polyfunctional chemical compounds, in particular organosiloxane compounds, grafted beforehand to the polymer chains of said resin.

Inventors: ABEVILLI FULVIO, ABEVILLI, FULVIO
Applicants: VALSIR SPA, VALSIR S.P.A.
Application year: 1996
Main classification: C08L23
IPC codes: C08J9, C08L23, C08K3