METHOD OF MAKING AN ARTICLE FROM AN ACRYLIC MATERIAL

Abstract: A method of making an article such as an article of sanitary ware from an acrylic material and a backing material, includes the steps of forming the acrylic material into a desired shape, applying to a side of the acrylic material a layer of a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures but which caused delamination of the backing material from the acrylic material at elevated temperatures, and applying to the resulting product the backing material with the layer of the bonding material between the acrylic material and the backing material, so that the backing material adheres to the acrylic material to form the article. The article so formed may easily be subjected to a process of delamination so that the acrylic material may be recovered for recycling.

Description: METHOD OF MAKING AN ARTICLE FROM AN ACRYLIC MATERIAL BACKGROUND OF THE INVENTION This invention relates to a method of making an article from an acrylic material and a backing material, and to a process of recovering an acrylic material from an article made by this method. Many articles, such as sanitary ware, are presently made from acrylic sheet material backed with a backing material such as a glass reinforced plastics material. The backing material is applied in order to reinforce the acrylic sheet material to enable the article, for example a bath or a sink or a shower tray, to conform to the specified requirements in respect of dimensional and heat stability in normal service. The backing material, for example a glass reinforced plastic material, adheres strongly to the acrylic sheet material and is extremely difficult to separate therefrom. However, an acrylic material is a material which is readily recycled by depolymerisation back to its monomer, at high leveis of efficiency, via the application of heat at approximately 500°C. In order to carry out such recycling, the backing material must be removed from the acrylic material, as the components of the backing material, for example the plastics material and the glass fibre, would contaminate the depolymerisation plant rendering it inoperative. However, due to the difficulty of separating backing materials from acrylic sheet materials, much of such acrylic sheet material is rendered unavailable for depolymerisation recycling. There is thus a need for a method by which an article made from an acrylic material and a backing material can later be separated into its component parts so that the acrylic material may be recycled. SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided a method of making an article from an acrylic material and a backing material, which method includes the steps of: ( 1 ) forming the acrylic material into a desired shape; (2) applying to a side of the acrylic material a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures but which causes delamination of the backing material from the acrylic material at elevated temperatures; and (3) applying to the product of steps (1) and (2). the backing material with the layer of the bonding material between the acrylic material * and the backing material so that the backing material adheres to the acrylic material to form the article. By acrylic material there is meant a thermoplastic polymer or co-polymer of acrylic acid, methacrylic acid, esters of these acids or acrylonitrile. Step (2) may be carried out before or after step (1). j According to a second aspect of the invention there is provided an article made by the method described above. According to a third aspect of the invention there is provided a process of recovering an acrylic material from an article made by the method described above which process includes the steps of: (a) heating the article to an elevated temperature, for example in the thermo-elastic forming range of the acrylic material, so that the backing material delaminates from the acrylic material; and (b) recovering the acrylic material. In step (1), the acrylic material is preferably an acrylic sheet material. In step (1), the acrylic material may be formed into the desired shape by vacuum and/or heat forming. In step (2) the layer of a bonding material made be applied to a side of the acrylic material by: (i) applying the layer of a bonding material to a surface of a mould for the acrylic material; and (ii) introducing the acrylic material into the mould and moulding the : acrylic material to a desired shape with the layer of the bonding material thereon. The layer of the bonding material may be formed from a composition of a suitable polymeric material in a suitable solvent therefor, or the layer of the bonding material may be formed from a film of a suitable polymeric material. A preferred polymeric material is a polyurethane polymer. At temperatures in the thermo-forming range of the acrylic material, i.e. in the range 140°C to 170°C inclusive, polyurethane loses a substantial part of its strength. Further, the acrylic material generally has a strong elastic memory, and at a temperature in the thermo-forming range, exeπs strong forces on the layer of the polyurethane, which yields, enabling the acrylic material to revert to its original form and thus to delaminate the backing material therefrom. Other polymeric materials which may be used to form the bonding layer include high impact polystyrene (HIPS), polystyrene, acrylonitrile-styrene- butadiene (ABS), poiymethyl methacrylate (PMMA). styrene acrylonitrile (SAN), crystal polystyrene, high molecular weight polystyrene, polyvinyl chloride (PVC), acrylic-styrene-acrylonitrile (ASA), and styrene butadiene, each used either alone or in combination with each other or in combination with a polyurethane polymer. As stated above, the layer of the bonding material bonds to the acrylic material and to the backing material at ambient temperatures but causes delamination of the backing material from the acrylic material at elevated temperatures. These elevated temperatures may be in the thermoelastic forming range of the acrylic material or may be below this temperature. The layer of the bonding material may be applied in any suitable manner. For example, when the layer of the bonding material is formed from a liquid composition, the layer may be applied by brushing or spraying. Alternatively, when the layer of the bonding material is formed from a film of a polymeric material, then the film may be placed on the acrylic material or placed on a surface of a mould for the acrylic material. For example, where the bonding material is a composition of a polyurethane polymer, the polyurethane polymer is preferably dissolved in a suitable solvent and the combination is then applied to the acrylic material by brushing or spraying. Thereafter, the solvent evaporates leaving a layer of polyurethane bonded to the acrylic material. Another preferred bonding material is high molecular weight polystyrene, for example Dow Styron 648. This bonding material is preferably applied by dissolving it in a suitable solvent carrier such as for example methyl ethyl ketone optionally in conjunction with a higher boiling point solvent. The composition so formed may then be applied brushing or spraying or the like. In step (3), the backing material may be any suitable backing material, for example a glassfibre reinforced plastics material (GRP), a plastics material reinforced with fibres other than glass fibres, for example hessian, or a polyurethane foam material. The backing material may be applied to a part or pans or to the whole of the shaped acrylic material. DESCRIPTION OF EMBODIMENTS The crux of the invention is that an article made from an acrylic material and a backing material, includes a layer between the acrylic material and the backing material of a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures, but which causes delamination of the backing material from the acrylic material at elevated temperatures and particularly at temperatures in the thermo-elastic forming range of the acrylic material. This means that the acrylic material may be recovered from the article for recycling. In step ( 1 ) of the method of the invention, the acrylic material, generally an acrylic sheet material, is formed into a desired shape for example by vacuum or heat forming. Examples of suitable acrylic materials are: (a) Sanitaryware grade cell cast acrylic sheet based on polymerised methyl methacryate and chemically cross-linked with glycol dimethacrylate, of thickness typically 4 or 5mm; (b) Uncross-linked polymerised methyl methacrylate cell cast sheet: (c) Extruded poly methyl methacrylate sheet. Thereafter the acrylic material is optionally sanded to provide a suitable surface for the application of the composition of step (2). In step (2) of the method of the invention, there is then applied to the shaped acrylic material a bonding material which bonds to the acrylic material and the backing material at ambient temperatures but which causes delamination of the backing material from the acrylic material at elevated temperatures. Alternatively, step (2) may be carried out before step (1) i.e. the bonding material may be applied to the acrylic material before it is shaped. Further alternatively, step (2) may be carried out by applying the layer of a bonding material to a surface of mould for the acrylic material and then introducing the acrylic material into the mould and moulding the acrylic material to a desired shape with the layer of the bonding material thereon. For example, a thin extruded film of a polymeric material may be placed against a glass sheet which comprises a mould in which cell-cast acrylic material is polymerised. The film is held in place by a PVC gasket and clips normally used in a cell-casting process. An acrylic syrup is then introduced into the mould and polymerised in the normal way. the film of polymeric material being incorporated into a surface of the acrylic sheet thus formed to form a surface layer which subsequently is able to bond to the backing material. Alternatively, a composition of a polymeric material dissolved in a solvent or in a monomer for the polymeric material may be applied to a glass sheet which comprises a mould in which cell-cast acrylic material is polymerised, for example by means of a roller, spray, brush or the ' like. The viscosity of this composition is such that the layer thereof is not "washed" off when the acrylic syrup is introduced into the mould. On polymerisation of the acrylic material, the bonding material is incorporated into the surface of the acrylic sheet such that the backing material may subsequently be bonded thereto. The composition of step (2) must not only bond to the acrylic material and the backing material at ambient temperatures, but also under normal service and test temperatures and conditions. For example, articles of the invention have been subjected to the following tests: a) Continuous boiling of water in an article of the invention, being a sink unit bowl, using an electric immersion heater over a period of time of several weeks. b) Subjecting an article of the invention alternatively to hot and cold water (90°C/20°C) for a period of time. c) Applying a pan containing hot oil at 180°C. to an article of the invention, being a sink unit draining board and bowl, and allowing the oil to cool to 120°C, and then repeating the procedure several times. The articles of the invention showed no deformation or delamination after these tests. The bonding material may be a composition of a polyurethane polymer, which may be dissolved in a suitable solvent for application. The polyurethane polymer is preferably a mainly linear polyurethane polymer with a low level (about 0,1 %) hydroxyl content. This polymer exhibits a very low thermoplasticity and an extremely high rate of crystallisation. The polyurethane polymer may be dissolved in a solvent such as methyl ethyl ketone, at a level of approximately 15%, although this may be varied to give a greater or lesser viscosity. In order to give the required heat resistance, the polyurethane polymer is preferably cross linked chemically with the addition of MDI (diphenylmethane-4,4'-diisocyanate), preferably with a functionality of 2,7 minimum, more preferably with a functionality in the range of 2,85 to 3. The MDI may be added as is, or in a solvent, to the solution of the polyurethane in the solvent, at levels of 1 to 3% solids, prior to applying the composition to the acrylic material. The solution may be applied by brushing or by spraying or any other suitable means. The solvent rapidly evaporates leaving a bonded film of cross-linked polyurethane on the acrylic material. Suitable polyurethanes include Desmocoll 540 from Bayer; and Irostic P9820 from Marton International. MDI is also available from Bayer and Marton International and as Suprasec 5005 and Suprasec 20885 from ICI. Various other polymeric materials are also suitable to form the layer of the bonding material. These polymeric materials include high impact polystyrene, polystyrene, ABS, polymethyl methacrylate, SAN, crystal polystyrene, high molecular weight polystyrene, PVC, ASA and styrene butadiene, either alone or in combination with each other or in combination with a polyurethane polymer. The vicat softening and heat distortion temperature of different grades of the polymeric materials have been found greatly to affect the bonding and delamination properties of the article formed from the acrylic material and the backing material. Thus, articles may be made to have a range of delamination temperatures and resistance to delamination. For example, a low heat distortion temperature (HDT)/low vicat material such as high impact polystyrene (HIPS) will give an excellent bond at temperatures below 100°C but readily separates at temperatures lower than the thermoforming temperatures, i.e. less than 165°C. On the other hand, high molecular weight polystyrene will give a much stronger bond at higher temperatures which enables it to be used where the article must pass, for example, hot oil resistance tests, for example at temperatures of 230°C for short periods of time, or long term boiling tests. A preferred bonding material is high molecular weight polystyrene such as for example Dow Styron 648 as it is cost effective, bonds very well under test procedures and releases very cleanly and easily when required. The preferred method of application of high molecular weight polystyrene is by dissolving it in a suitable solvent carrier such as for example methyl ethyl ketone. The composition so formed may be applied before or after vacuum forming of the acrylic material. When the composition is applied as a spray, a higher boiling point solvent such as toluene, xylene and white spirit, may be used in conjunction with the methyl ethyl ketone to prevent stringing. An optimal composition comprises a 15% by mass solution of high molecular weight polystyrene in methyl ethyl ketone. Another suitable solvent carrier for the high molecular weight polystyrene is an acrylic monomer. In step (3), the backing material is applied to the product of steps (1) and (2) in a conventional manner so that the backing material adheres to the acrylic material . For example, when the backing material is a glass reinforced plastics material, the fibreglass and resin may be sprayed on to the product of steps (1) and (2) with a chopper gun. The articles produced by this method are suitable for use in the normal manner, without any delamination of the backing material from the acrylic material occurring duπng use The invention also covers a process of recovering an acrylic mateπal from an article made by the method descnbed above by heating the article to a elevated temperature for example in the thermo-elastic forming range of the acrylic material so that the backing mateπal delaminates from the acrylic mateπal, and recovering the acrylic material The mechanism whereby the delamination of the backing mateπal from the acrylic mateπal occurs, is that the layer between the acrylic mateπal and the backing material loses a substantial part of its strength at elevated temperatures e g temperatures in the thermo-elastic forming range of the acrylic matenal, i.e. at temperatures between 140°C and 170°C inclusive. Further, the acrylic material has a strong elastic memory and at 140°C to 170°C, exerts strong forces on the intermediate layer, which yields, enabling the acrylic material to revert to its original flat form and thus causing delamination of the backing material from the acrylic mateπal. For certain bonding materials, temperatures lower than 140°C may be sufficient for delamination, i.e. temperatures in the range of 90°C to 140°C inclusive, but temperatures of 130°C and above are preferred, for speed of delamination Various examples of the invention will now be given Example 1 Reinforcing of a polyurethane polymer with an acrylic polymer A composition for forming a layer of a bonding material is comprised of 15% Desmocoll 540 in methyl ethyl ketone 100 parts 15%) Suprasec 2085 (MDI) in methyl ethyl ketone 100 parts 15% Perspex C.P.80 (Polymethyl methacrylate) in methylene chloride 100 parts 300 parts All percentages are by mass. When applied to a flat sheet of acrylic material, such as 4mm sanitary ware grade 'Perspex', the acrylic material is able to be vacuum formed, subsequently reinforced with GRP and perform acceptably in normal usage and testing without delamination. When subsequently heated to 165°C, the acrylic sheet delaminates to give a substantially intact sheet and a GRP shell, which may both then be further processed for recycling by existing means. The above composition enables the bonding layer to withstand hot oil at 230°C/min whereas a non reinforced purely polyurethane bonding layer would fail such a test in the context of a sink or sink bowl unit for instance. Similarly, the polyurethane may be also reinforced with polystyrene based resins, e.g general purpose crystal polystyrene, high molecular weight polystyrene, and ABS. Example 2 Bonding layer using high impact polystyrene. A composition for forming a layer of a bonding layer is comprised of: Dow Styron 472 10-20 parts by mass Methyl ethyl ketone 90-80 parts by mass When applied to an acrylic sheet either before or after vacuum forming, this composition gives a satisfactory bond to subsequently applied GRP and will withstand normal service and tests such as SABS 1402 thermal cycling (90°C/15°C - cycles) but readily delaminate at relatively low temperatures (e.g 130-140°C). Whilst such a bonding layer composition will not support acrylic/GRP adhesion against 230°C hot oil, it delaminates so easily at the relatively low temperatures quoted above that there are economic advantages opposite delamination costs in terms of energy use. Note that other carrier solvents may be used as solvents for styrene based resins, for example methylene chloride and other ketones. Example 3 Bonding layer using a general purpose polystyrene. A composition for forming a layer of a bonding material is comprised of: Dow Styron 678E 10 parts by weight Methyl ethyl ketone/dichloromethane 50/50 90 parts by weight Here, due to higher heat distortion properties, the bond strength is better than HIPS at elevated temperatures and is able to resist the long term effects of for instance, boiling water in a sink bowl without delamination, yet will readily separate at 165°C in an oven. Example 4 Bonding layer using high molecular weight polystyrene. A composition for forming a bonding layer is comprised of: Dow Styron 648 (which is a high molecular weight polystyrene) 15 parts by weight Methyl ethyl ketone 85 parts by weight This composition may be applied to an acrylic sheet both before or after vacuum forming. Due to the nature of the high heat, high molecular weight composition it is able to be vacuum formed without difficulty using standard ovens commonly used for sanitary ware without sticking to either the oven interior surface or vacuum forming mould. In addition it is more resistant to the styrene monomer present in GRP polyester resins. Such a bonding laver is able to resist all common tests including long term boiling water inside the bowl or bath and hot oil at 230°C/ min contact, yet delaminate effectively on placing in an oven at 165°C. Example 5 Non-solvent formation of a bonding layer. As the use of organic solvents in any process may be considered environmentally undesirable, there are advantages in the use of a non-solvent based bonding layer. Two such methods of obtaining such a layer are described: - 1 A thin extruded film (up to 2mm thick, but normally 0,1 - 1 ,0mm thick) of a polymeric material mentioned above may be placed against a glass sheet which comprises a mould in which cell-cast acrylic is polymerised. This film is held in place by the PVC gasket and clips normally used in a cell-casting process. When an acrylic syrup is introduced into the mould cell and polymerised in the normal way, the polymeric film is incorporated into the surface of the acrylic sheet thus formed, and forms a surface layer which subsequently is able to bond to GRP reinforcement and also delaminate on heating to thermoforming temperatures. 2 Alternatively, the polymeric material may be predissolved in methyl methacrylate monomer and the solution applied to a glass cell surface by roller, spray, brush or other convenient means. The viscosity of this solution is such that the applied wet film is not 'washed' off when the main body of the acrylic syrup is introduced into the cell. On polymerisation the monomer carrier is converted into PMMA and the polymeric material (e.g polystyrene) is incorporated into the surface of the acrylic sheet. This enables the GRP subsequently applied to bond and thermo-release for recycling. The various polymeric materials mentioned above all have various advantages such as cost, ease of use, bond strength and temperature at which delamination occurs, and the like. The method of the invention has the advantage that, articles such as sanitary ware made by the method may now be recycled at the end of their life, or articles rejected during manufacture or damaged during distribution may also be recycled, which has economic and ecological advantages.

Claims: CLAIMS A method of making an article from an acrylic material and a backing material, includes the steps of: (1) forming the acrylic material into a desired shape; (2) applying to a side of the acrylic material a layer of a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures but which causes delamination of the backing material from the acrylic material at eievated temperatures; and (3) applying to the product of steps (1 ) and (2), the backing material with the layer of the bonding material between the acrylic material and the backing material so that the backing material adheres to the acrylic material to form the article. A method according to claim 1 wherein step ( 1) is carried out before step (2). A method according to claim 1 wherein step (2) is carried out before step (1). -A method according to any one of claims 1 to 3 wherein the acrylic material is an acrylic sheet material. A method according to any one of claims 1 to 4 wherein in step (1) the acrylic material is formed into the desired shape by vacuum forming or heat forming. A method according to any one of claims 1 to 5 wherein step (2) is carried out by: (i) applying the layer of a bonding material to a surface of a mould for the acrylic material; and (ii) introducing the acrylic material into the mould and moulding the acrylic material to a desired shape with the layer of the bonding material thereon. A method according to any one of claims 1 to 6 wherein the bonding material is selected from the group comprising: (A) a composition of a polymeric material in a solvent therefor; and (B) a film of a polymeric material. A method according to claim 7 wherein the polymeric material is a polyurethane polymer. A method according to claim 7 wherein the polymeric material is selected from the group consisting of high impact polystyrene, polystyrene, acrylonitrile-styrene-butadiene,polymethylmethacrylate, styrene acrylonitrile, crystal polystyrene, high molecular weight polystyrene, polyvinyl chloride, acrylic-styrene-acrylonitrile, and styrene butadiene, each used either alone or in combination with each " -other or in combination with a polyurethane polymer. A method according to claim 9 wherein the polymeric material is high molecular weight polystyrene dissolved in a suitable solvent carrier. A method according to claim 10 wherein the suitable solvent carrier is methyl ethyl ketone. A method according to any one of claims 1 to 1 1 wherein in step (3) the backing material is selected from the group consisting of a glassfibre reinforced plastics material, a plastics material reinforced with fibres other than glassfibres, and a polyurethane foam material. A method according to any one of claims 1 to 12 wherein the backing material is applied to a part or pans or to the whole of the shaped acrylic material. An article made from an acrylic material and a backing material by a method which includes the steps of: (1) forming the acrylic material into a desired shape; (2) applying to a side of the acrylic material a layer of a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures but which causes delamination of the backing material from the acrylic material at elevated temperatures; and (3) applying to the product of steps (1) and (2), the backing material with the layer of the bonding material between the acrylic material and the backing material so that the backing material adheres to the acrylic material to form the article. A process of recovering an acrylic material from an article made from an acrylic material and a backing material by a method which includes the steps of: (1) forming the acrylic material into a desired shape; (2) applying to a side of the acrylic material a layer of a bonding material which bonds to the acrylic material and to the backing material at ambient temperatures but which causes delamination of the backing material from the acrylic material at elevated temperatures; and (3) applying to the product of steps ( 1 ) and (2), the backing material with the layer of the bonding material between the acrylic material and the backing material so that the backing material adheres to the acrylic material to form the article; which process includes the steps of: (a) heating the article to an elevated temperature so that the backing material delaminates from the acrylic material; and (b) recovering the acrylic material A process according to claim 15 wherein in step (a) the elevated temperature is in the thermo-elastic forming range of the acrylic material. A method according to claim 16 wherein in step (a) the temperature is from 140°C to 170°C inclusive. A process according to claim 15 wherein in step (a) the elevated temperature is from 130°C to 140°C inclusive.

Inventors: TINKER PAUL, TINKER, PAUL
Applicants: AECI LTD, TINKER PAUL, AECI LIMITED, TINKER, PAUL
Application year: 1997
Main classification: C08J5
IPC codes: C08J5