Patent GB-910195-A (GB)
Title: Plastic surfaced, thermoset cellular structures and a method for the production thereof
IPC: C08J9/34
Filed: 1960-02-22
Abstract: A thermoset cellular structure to which is integrally bonded a continuous plastic covering is made by heating a vinyl chloride resin plastisol to form a skin, charging a foamable thermosetting composition on to the skin, allowing the thermosetting composition to foam, and heating the resulting structure to fuse the vinyl chloride resin skin.  In one example, a plastisol composition comprising polyvinyl chloride resin, 50 parts by weight; vinyl chloride-vinylidene chloride resin, 50; di-2-ethyl hexyl hexahydrophthalate, 25,5; high boiling petroleum residue, 4,5; calcium carbonate, 10; titanium dioxide, 10; a mixture of barium octyl phenolate, cadmium 2-ethyl hexoate and trioctyl phosphate (weight relationship 3:1:1), 2; a mixture of zinc soap and trioctyl phosphate, 1; and an adduct produced by reacting 7 mols. of ethylene oxide per mol. of nonyl phenol, 2, was charged into a mould, a skin allowed to form, excess plastisol removed, and a foamable polyurethane resin charged into the mould and allowed to foam in place.  The foamable polyurethane resin composition comprised polyurethane resin, 200 grams; dimethyl silicone oil, 1; distilled water, 4,6; N-methyl morpholine, 2; and triethylamine, 0,4.  In a second example, the plastisol composition comprised polyvinyl chloride resin, 100 parts by weight; di-2-ethyl hexyl phthalate, 21; an aryl alkyl hydrocarbon extender, 4; a mixture of barium octyl phenolate, cadmium 2-ethyl hexoate and trioctyl phosphate (weight relationship 3:1:1), 2; a mixture of zinc soap and trioctyl phosphate, 1; a composition comprising a diglycidyl ether of 2,2,-bis(p-hydroxyphenyl) propane, 88% by weight, and butyl glycidyl ether, 12% by weight, 2; and titanium dioxide, 1. The foamable composition was made up of the following: phenol-formaldehyde resin, 200 grams; a polyoxyethylene sorbitan monopalmitate surfactant, 2; diisopropyl ether, 12; sodium sulphite, 15; hydrated lime, 15; and hydrochloric acid, 26.  In a third example, a plastisol composition of the following formulation was used with the polyurethane resin composition of the first example; polyvinyl chloride resin, 100 parts by weight; di-2-ethyl hexyl phthalate, 20; dipropylene glycol dibenzoate, 40; 2-ethyl hexyl diphenyl phosphate, 40; a chlorinated diphenyl containing 54% by weight of chlorine, 20; epoxidized soya bean oil, 6; calcium carbonate, 60; calcined clay, 7,5; titanium dioxide, 3; and barium-cadmium ricinoleate, 2.ALSO:A thermoset cellular structure to which is integrally bonded a continuous plastic covering is made by charging a vinyl chloride resin plastisol into a mould cavity and heating it sufficiently for it to gel forming a plastic skin whose interior surfaces are wet to the touch, the excess plastisol removed, a thermosetting foamable resin composition charged into the mould cavity and allowed to foam in place, and the entire assembly then heated at a temperature sufficiently high to fuse the vinyl chloride resin skin.  The vinyl chloride resin may be polyvinyl chloride, a copolymer of vinyl chloride with another ethylenically unsaturated compound, or a mixture of polyvinyl chloride and such a copolymer. Any foamable thermosetting resin composition can be used, examples of suitable resins being phenol-aldehyde, e.g. phenolformaldehyde resins, epoxy resins, polyurethane resins, urea-aldehyde resins and melamine-aldehyde resins.  The blowing or foaming agent is selected so that the resin composition into which it is incorporated is expanded at a temperature such that the vinyl chloride resin plastisol is not fused.  In some cases, the blowing or foaming agent can be generated in situ as, for example, in the preparation of polyurethane foams by reacting a polyglycol with a diisocyanate.  Examples of suitable blowing or foaming agents are pentane, hexane, heptane, petroleum ether, cyclopentane, cyclopentadiene, acetone, methanol, methyl acetate, ethyl acetate, methyl formate, ethyl formate, dichloroethylene, isopropyl chloride, methylene chloride, diisopropyl ether, carbon dioxide, nitrogen, air, dichlorodifluoromethane, and compositions which release gases on decomposition such as sodium bicarbonate.