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filingDate 1970-09-23-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationDate 1974-07-17-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber GB-1360397-A
titleOfInvention Method for the production of an integral skin
abstract 1360397 Cellular article with a non-cellular skin IMPERIAL CHEMICAL INDUSTRIES Ltd 13 Sept 1971 [23 Sept 1970] 45289/70 Heading C3C [Also in Division B6] A method for making a cellular article having an integral skin of substantially non-cellular material over at least part of its surface comprises emulsifying water with a water-immiscible liquid monomer polymerizable to a thermoplastic material in the presence of an emulsifier therefor to form an emulsion having an aqueous disperse phase, polymerizing the liquid monomer to form a cellular polymer, drying the outer layer of said polymer over at least part of its surface, applying heat and pressure to said layer to raise its temperature above the softening point of the polymer and fuse said layer, and cooling the fused layer to form a non-cellular skin. The cellular product may have at least 95% of the cells of a diameter less than 7 Ám. and at least 90% less than 2 Ám. The liquid monomer preferably comprises at least 50% by weight of methyl methacrylate, whilst the emulsifier preferably comprises an unsaturated polyester of a bisphenol A epoxy-modified glycol and one or more ethylenically unsaturated dicarboxylic acids, the quantity of polyester lying within the range 0À3-5% by weight of the monomer. Polymeric materials may also be added to the mixture, e.g. a polymethyl methacrylate for use with methyl methacrylate. Ease of glazing is affected by the number of free radicals available for initiating the reaction. The polymerization may be initiated at a temperature within the range 10-50‹ C. in the presence of sufficient free radicals. The ability to form a skin may also be improved by copolymerizing the monomer with monoethylenically unsaturated comonomers which provide internal plasticization, e.g. 2-ethyl-hexyl acrylate, in an amount 5-20% by weight. The applied pressure should be less than that required to crush the cellular core and may be between 0À5 and 70 bar. The cellular polymer obtained from the polymerization reaction may be cut into smaller pieces which are subsequently provided with an integral skin by fusion. The cellular sheets having integral non-cellular skins may be moulded, in which moulding process at a temperature above its softening at least part of the surface is stretched. The surface of the cellular article may be patterned or ornamented, e.g. by transfer techniques. The polymeric material may also contain fillers, e.g. glass fibres. The examples refer to cellular materials formed from methyl methacrylate, polymethylmethacrylate and as emulsifier:-a polysiloxane (1); propoxylated bisphenol A unsaturated polyester (2), (3), (4), (5).
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