Note: Descriptions are shown in the official language in which they were submitted.
-- 1 --
The present invention relates to a glass fiber
reinforced polyvinyl chloride composition made up of polyvinyl
chloride resin, glass fibers, and inorganic fillers differing
from the glass fibers and optionally customary additives, such
as mold release agents, stabilizers, processing aids, colorants,
or the like.
me present invention also relates to a profile strip,
especially suitable for the production of frames for windows
or for doors, having an optionally hollow core profile of a
reinforced synthetic resin and a shell of a synthetic resin
surrounding the core profile.
Efforts have been made in the art of synthetic
resins to broaden the spectrum of materials offered by com-
bining inactive or active fillers and reinforcing agents with
classical thermoplastics. In this connection, raising of the
strength and rigidity levels is desirable, on the one hand,
while attempts are also made, on the other hand, to make such
materials less expensive. Inactive fillers are understood to
mean, in general, additives in the solid form differing with
respect to their composition and structure from the synthetic
resin matrix; in most cases, inorganic materials are involved
here which are also called extender fillers, such as, for
example, calcium carbonate, hydrated aluminas, and aluminosili-
cates. Active fillers are understood to mean those which, in
a controlled fashion, improve certain mechanical or physical
properties of the synthetic resin; they are in most cases
also called reinforcing fillers or agents. The best reinforcing
agents are, in general, of a fibrous structure; the most
frequently employed reinforcing material is constituted by
glass fibers. While the inactive fillers in most instances
have, rather, a lowering effect on tensile strength and
toughness of the synthetic resin and are chemically inactive,
and inexpensive, reinforcing fillers such as glass fibers
impart a rigidifying effect and a satisfactory force application
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with low shrinkage with chemical inactivity. Disadvantages
in the reinforcing fillers, such as glass fibers, are anisot-
ropy, as well as orientation of the glass fibers when pro-
cessing the synthetic resin composition.
Hollow profiles for the manufacturing of window or
door frames are known which consist of a core profile of steel
or the like coated with a synthetic resin layer, especially
a layer of plasticized polyvinyl chloride (PVC). Furthermore,
inherently rigid hollow profiles of a synthetic resin, espe-
cially nonplasticized PVC, have been known for a long time for
the production of window or door frames; however these profiles,
in case of very large dimensions of window and door openings,
must additionally be rigidified in the hollow portion, i.e.,
internal cavity by the insertion of reinforcing profiles of
steel or aluminum.
Attempts have also been made to provide mechani-
cally more rigid and stronger plastic hollow profiles for win-
dow and door frames and are described, for example, in German
Patent No. 1,086,032 wherein the hollow profiles formed into
a frame are subsequently filled with a liquid or plastic-flow
filling material, thereby, after the hardening process, the
individual frame sections are simultaneously bonded together.
An example for such a filling material is a phenolic resin or
plastic wood, in the frame for windows or doors disclosed in
Swiss Pat. No. 411,301, hollow profiles of an elastic synthetic
resin, especially based on polyvinyl chloride are likewise
filled with a hardening filling material based on plastic
cement, for example, expanded polystyrene with an addition of
cement or epoxy resin with additives of grainy materials, such
as sand, aluminum scrap, vermiculites, or the like, to increase
strength. The profile strip for building components known
from German Utility Model No. 1,994,127 uses a core of cheap
materials, such as low-quality synthetic resins, slag stones,
pressed wood scrap, or the like; this core is encompassed by
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a shell extending all the way around and made of a high-quality
synthetic resin. Also, efforts have been made, according to
DOS (German Unexamined Laid-Open ~pplication) No. 2,326,911, to
produce window frame profiles encased by synthetic resin where-
in a core of expanded (i.e., foamed) plastic is surrounded bya compact (non-foamed) plastic shell; to increase the rigidity,
the core can contain reinforcing inser.s of light-metal pipes
or plastic pipe. Another example for a compact, multilayer
profile strip is described in DOS No. 2,827,851 wherein a hol-
low synthetic resin profile, especially one of PVC, is filledwith a synthetic resin filling of a matrix of methyl methacry-
late with hollow silicate spheres, and wherein additionally
glass filaments are embedded to extend in the longitudinal
direction of the profile strip to increase rigidity. In all
of these solid, multilayer profile strips, difficulties are
encountered in each case ln establishing perfect, tight
connections at corners and butt joints of the profile strips
which are watertight and provide full wind protection and
exhibit a sufficiently high strength, and which are to be
readily producible by conventional methods.
Moreover, French Pat. No. 1,602,375 describes a
hollow profile strip made up of two layers, consisting of a
hollow profile of glass-reinforced polyester, forming the core,
the latter being encased on the outside by another glass fiber
impregnated with a synthetic resin. Difficulties are a~so
encountered in connection with this pro-Eile in establishing
perfect, firm connections at corners and butt joints of the
profiles.
DAS 2,540,639 discloses a pulverulent, glass fiber-
reinforced extrusion composition based on polyvinyl chloride,made up on the basis of 15-30 parts by weight of mineral fillers
having an average particle size of below 50 ~m, 1.5-3 of at
least one mold release agent and 15-30 parts by weight of
glass fibers per 100 parts by weight of polyvinyl chloride~
~2~6~
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This composition makes it possible to manufacture reinforced
articles with a smooth surface and a homogeneous structure by
the extrusion method.
As can be seen from DAS 2,540,639, and also from
other literature references, considerable difficulties are
encountered in homogeneously incorporating larger amounts
of glass fibers into thermoplastic synthetic resins, especially
also into polyvinyl chloride resin. In this procedure, there
is not only a high amount of wear and tear on the processing
machines, such as masticators, mixers, extruders, but there
are also problems with respect to homogenization, i.e., the
uniform distribution of the glass fibers within the thermo-
plastic, as well as regarding adhesion between glass fiber
and thermoplastic. Thus, it has been known to subject glass
fibers to a surface treatment; the best well-known of such
treatments is silanizing in order to increase adhesion to the
synthetic resin. In this connection, attention is invited,
for example, to the article by B.W. Lipinsky, "Silane loesen
~aftprobleme" ~ilanes Solve Adhesion Problems~ in defazet,
28th year, No. 5, 1974, pp. 207-211. British Pat No. 1,345,841
describes a glass-reinforced thermoplastic composition to which
are added, per 100 parts by weight of thermoplastic synthetic
resin, 5-150 parts by weight of glass fibers and additionally
0.5-1.5 parts by weight of a special adhesion promoter based
on metallocenes.
According to the present invention, there is provided
an extrudable glass fiber-reinforced polyvinyl chloride compo-
sition made up of polyvinyl chloride resin having a K value
between 55 and 75, glass fibers, and inorganic fillers different
from the glass flbers, and conventional additives, including
mold release agents, stabilizers, processing aids, and colorants
for the production of extruded articles, said composition con-
taining, per 100 parts by weight of a polyvinyl chloride resin,
50-100 parts by weight of glass fibers having a diameter of
~67~2;2
between 5 and 25 )um with a length up to 12 mm, and 5-25 parts
by weight of a mineral filler having an average particle
diameter of below 50 Jum and exhibiting a modulus of elasticity
in the extrusion direction of an extruded product of at least
S 8,000N/mm at 23C.
According to the present invention, there is also
provided a profile strip for the manufacture of frames for
windows or doors comprising a core profile formed of reinforced
synthetic resin shell surrounding at least a part of the core
profile; said core profile being formed of a glass fiber-
reinforced polyvinyl chloride resin-containing composition,
additionally containing per 100 parts by weight of a polyvinyl
chloride resin having a K value between 55 and 75,40 to 100
parts by weight of glass fibers having a diameter of between
5 and 25 Jum with a length of up to 12 mm, and 0 to 25 parts by
weight of a mineral filler with an average particle diameter
of below 50 ~m; said core profile exhibiting a microporous,
slightly roughened surface, and said core profile being bonded
to the shell; said shell being free of glass fibers, being
formed of a synthetic resin that is compatible with polyvinyl
chloride resin and exceeding the impact resistance of the core
profile and said strip exhibiting, in the extrusion direction,
a modulus of elasticity of at least 8000N/mm at 23C.
By the use of a hollow core profile based on glass
fiber-reinforced PVC according to this invention, a rigid,
firm structure is obtained exhibiting a high modulus of
elasticity and being highly stable dimensionally, i.eO, the
stresses built in during processing of the composition into
the profile strip are not triggered, even at high temperatures
of up to 100C. (Distortion of the profile is thereby
avoided). Since the core profile does not lend itself readily
to dyeing due to the high glass fiber proportion, i.e., it
exhibits essentially a grey-yellow coloring, determined by the
glass fiber, the shell not only takes over the task of forming
a smooth surface, but also of imparting color to the composite
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or combined profile. Moreover, a substantial feature of the
invention resides in that the impact strength of the combined
profile, the core of which is relatively brittle on account
of the glass fiber proportion, is increased by an appropriate
selection of a high-impact-strength material, for the shell
which is free of glass-fibers. It proves to be especially
advantageous that the core profile, due to the high glass fiber
proportion, exhibits a slightly rough surface with a micro-
porous structure, whereby the synthetic resin shell finds
especially good anchorage,and a particularly good adhesion or
high adhesive strength is achieved between core profile and
shell, directly and without additional adhesion-promoting
means.
The glass fiber-reinforced polyvinyl chloride compo-
sition selected, according to this invention for the core
profile, shows a very good processability by extrusion and a
balanced spectrum of physical properties, even with the use
of relatively minor proportions of mineral powdery fillers
together with a relatively high proportion of glass fibers.
In particular, the composition exhibits, in the extrusion
direction, a modulus of elasticity of at least ~,OOON/mm2 at
23C., measured according to DIN (German Industrial Standard)
53457.
The term"polyvinyl chloride resin" as used herein
is meant to include polyvinyl chloride (i.e., homopolymer)
produced by bulk, suspension, or emulsion polymerization with
a K value of between 55 and 75 whereby the K-value refers to
the homopolymer content of vinyl chloride as well as poly-
vinylidene chloride; post-chlorinated polyvinyl chloride;
and modified polyvinyl chloride; i.e., the copolymers obtained
from a chlorinated vinyl monomer and at least one monomer co-
polymerizable therewith, for example, a homopolymer, or co-
polymer and/or graft polymer of vinyl chloride with, for
example, ethylene-vinyl acetate, methyl acrylate, vinyl acetate,
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chlorinated polyethylene, butadiene, polyolefins, or the like,
as the co- or graft component, as well as mixtures of these
materials wherein the vinyl chloride or the polyvinyl chloride
constitutes at least about 75% by weight of the total weight
of the polymeric material.
The mineral fillers additonal to the galss fibres
because of their small amounts hardly serve to achieve a
reduction in costs of the composition but essentially for
improvement of the wording properties, the mechanical prop-
erties of the material only being slightly influenced. Toohigh a mineral filler content negatively influences the
improvement in the mechanical properties required just by the
use of glass fibres. Mineral fillers, such as for example
natural or precipitated chalk, finely divided silica, colloidal
silicic acid, aluminosilicates ox hydrated clays without or
with corresponding surface treatment, alone or in admixture
with one another are usable as fillers. The particle size
of the fillers should not as far as possible essentially
exceed the fibre diameter of the glass fibres, that is the
maximum particle diameter of the filler should be smaller
than 50 ~m, preferably less than 20 ~
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Either continuous or chopped glass fibres with a
preferred filament diameter between 5 and 25 pm serve as
starting material for the glass fibres in the
preparative process. With chopped fibres, the starting
length should amount to at least 0.5 mm, preferably
between 3 and 12 mm. As a result of preparation and
working, the starting length is in any case broken to a
final length between about 0.3 to 1.5 mm, for example in
the extrusion moulds. Basically all kinds of glass
fibres which are compatible with PVC are usable for the
invention. However preferably those fibres are used
which are pre-treated by corresponding surface
treatment, with addition of bonding agents such as for
example vinyl silane and substituted alkyl silanes, for
example chloroalkyl-, aminoal~yl-, diaminoalkyl silanes
etc. This pre-treatment takes place as a rule, however,
in the production process ~or the glass fibres and not
in the working of the PVC materials. As a result of the
use according to the invenkion of 40 to 100 parts by
2 weight of glass fibres to 100 parts by weight of PVC, a
Youngs modulus of at least 8000 N/mm2 is achieved in the
products which are obtained.
Unmodified polyvinyl chloride exhibits, in
addition to a good impact strength, only a moderate
notched bar impact strength. Indeed, as a result of the
additional glass fibres, the notched bar impact strength
is only slightly influenced, the good impact strength
being decreased however to the level of the notched bar
impact strength. For this reason, according to the
invention, the composition contains modifiers such as
for example ethylene vinylacetate, acrylates,
chlorinated polyethylene, acrylic-butadiene-styrene,
methacryl-butadiene-styrene or the like in up to 30
parts by weight related to 100 parts by weiqht of PVC.
In contrast to the usual amounts of lubricants in
the working of PVC, with the compositions according to
the invention, a lubricant addition essentially
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1 increased with respect to known compositions is
attained. With the composition according to the
invention, this preferably lies between 2.5 to 5.5 parts
by weight of lubricant to 100 parts by weight of
polyvinyl chloride, with the lubricant amount increasing
with increasing glass fibre and filler content. To be
used are the lubricants known in the working of PVC and
PVC containing moulding materials, that is, as a rule,
mixtures of so-called internal lubricants, that is
showing good compatibility with PVC, and so-called
external lubricants, that is products less well
compatible with PVC. Belonging to the group of
internal lubricants are for example glycerine, mono-,
di- and tri esters of natural or oxidised carboxylic
lS acids with chain lengths of C12 to C40, fatty alcohols
of thè above-indicated chain lengths! neutral and basic
metal soaps, preferably stearates, of the metals lead,
calcium, barium, magnesium, cadmium etc, C10 to
C40-alcohols esterified with C12 to C36 acids, phthalic
acid esters of long-chain alcohols etc. Belonging to
the group of external lubricants are for example C12 to
C40 fatty acids or substituted (oxidised) fatty acids,
paraEfin oils and hard paraffins, polyethylene or
oxidised polyethylene, fatty acid amines, silicone oils
and the like.
Moreover the usual special additives in the
working of PVC-containing mixtures are employed,
especially stabilisers such as for example complex
barium cadmium soaps, lead salts or lead soaps r complex
- 30 calcium-zinc soaps, alkyltin merGapto compounds or
alkyltin carboxylates, with in addition organic
stabilisers such as expoxidised oils or esters,
diphenylthiourea, phenylindole, aryl or alkyl or
aryl-alkyl mixed phosphites singly or in admixtures.
Furthermore, there may also be added to the composition,
especially for stabilisation, the modifying or co- or
graft components such as for example sterically hindered
phenols or bisphenol or the like. Preferred amounts
lie between 1 and 5 parts by weight of stabilisers to
100 parts by weight of PVC. Further known additives
are working auxiliaries, plasticisers and plasticising
auxiliaries and colourants.
A preferred composition according to the invention
contains, related to 100 parts by weight of PVC which
possesses a R-value between 55 and 75, 40 to 80 parts by
weight of glass fibres with a diameter between 5 and 25
~m with a length of 0.5 to 12 mm, 1 to 15 parts by
weight of a pulverous mineral filler with a mean
particle diameter below 15 pm and 2.5 to 5.0 parts ~y
weight of lubricant and up to 30 parts by weight of
modifier.
The present invention possesses significant
advantages which make the use of the glass fibre
reinforced polyvinyl chloride composition suited to the
production of shaped bodies, in particular by extrusion
moulding, the shaped bodies possessing a Youngs modulus
of at least 8000 N/mm2 at 23, in the extrusion
direction. The shaped bodies which are produced
exhibit, according to their glass content and filler
content, a very fine microporous surface, whereby the
bonding to subsequent coverings, for example based on
PVC or another thermoplastic is essentially improved.
~ The composition according to the invention can serve for
the production of shaped bodies with high mechanical
stiffness and strength, which subsequently or
simultaneously are clad with an unreinforced
~~~ thermoplastic material of like or different basis, for
example by extrusion, lamination or immersion. The
cladding can also be provided over only a part of the
surface of the shaped body. Of particular consideration
for the surface finishing are materials compatible with
PVC which are preferably or especially
weather-resistant, such as for example acrylates,
polyesters, polymethacrylates, acrylate-containing
7~2
g
polymers or the like, or multiple layerings with different
materials.
The composition according to the invention makes
possible the production of shaped bodies with mechanical
properties essentially improved with respect to the unre-
inforced plastic, so that the shaped bodies can be made use
of as supporting constructions, and for example enable one
to dispense with metallic reinforcements frequently employed
in specifically shaped constructions in the use of plastics,
or enable one to reduce the wall strengths of the shaped
constructions.
A preferred area of use for the invention relates
to production of a shaped moulding in particular for frames
for windows or doors with an optionally hollow core moulding
formed from reinforced plastics and a covering formed of
plastics surrounding the core moulding. With this, in par-.
ticular, the object is to be solved of producing a shaped
moulding for the production of window or door frames which
meets the requirements with respect to weathering resistance,
the requirements with respect to mechanical strength and
stiffness which makes possible the use of a connecting tech-
nique for the mouldings to produce frames in particular by
welding which is as simple as possible, which makes possible,
by employment of inexpensive materials, economic production
of the product and which excels in its capacity for being
carried out as simply as possible.
The invention solves the states object by a shaped
moulding in which the core profile is built up from a glass
fibre-reinforced polyvinyl chloride composition containing,
based on 100 parts by weight of polyvinyl chloride which
possesses a K-value between 55 and 75, 40 to 100 parts by
weight of glass fibres with a diameter between 5 and 25 ~m
in a length of up to 12 mm and 0.25 parts by weight of
mineral fillers with an average particle diameter below 50
~m and possesses a microporous easily roughened surface,
and is bound to a covering formed
`` ~2~167~2
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from a plastics material compatible with the polyvinyl
chloride which possesses an impact strength superior to
that of the core moulding.
As a result of the use according to the invention
of a hollow core moulding based on glass
fibre-reinforced PVC, a stiff solid construction is
obtained which possesses a high Youngs modulus and is
very stable dimensionally, that is the tensions
incorporated in the material when it is worked to form
the shaped moulding are not lost even at high
temperatures up to 100C. Since the core moulding is,
because of the high glass fibre proportion, poorly
colou~able, that is into essentially a grey yellow
colour, determined by the glass fibres, the covering
takes over not only the colouring of the moulding, but
at the same time also the formation of a smooth surface.
Moreover an essential feature of the invention is that
the impact strength of the combined moulding whose core,
on account of the glass fibre content is reIatively
brittle, is increased by a corresponding choice of
impact resistant material for the covering. It has
proved to be particularly advantageous that the core
moulding, as a result of the high ylass fibre content,
possesses an easily roughened surface with microporous
structure, whereby the covering with plastics material
can be anchored particularly well and an especially good
bonding or high bond strength between core moulding and
covering is achieved directly without additional means.
The polyvinyl chloride material reinforced with
glass fibre selectively according to the invention
shows, with use of relatively small amounts o mineral
pulverous fillers together with the relatively high
proportions of glass fibres, a very good capacity for
working by extrusion and a balanced physical property
profile. In particular it possesses a Youngs modulus in
the extrusion direction of at least 8000 N/mm2 at 23C
measured according to DIN 53457.
1 A preferred covering is based on plastics material
of the likes of polyvinyl chloride, polyvinylidene
chloride, post-chlorinated polvyinyl chloride,
copolymers obtained from a chlorinated monomer and at
least one monomer polymerisable therewith such as homo-
or co- or graft polymers with for example ethylenevinyl
acetate, acrylate, vinylacetate, chlorinated poly-
ethylene, butadiene, polyolefins or others and mixturesthereof which can additionally contain additives such as
stabilisers, lubricants, pigments, UV-absorbers, working
auxiliaries and modifiers. Another group advantageous
for the enveloping of suitable thermoplastic plastics
are those based on acrylates or polymethyl meth-
acrylates, acrylic-butadiene-styrene or methacrylic-
-butadiene-styrene or polyesters or polyvinyl fluoride
or polyvinylidene fluoride or mixtures thereof.
For minimisation of the material employed, it is
proposed according to the invention to form the core
moulding as a hollow moulding wherein wall thicknesses
between 1.0 to 10 mm, preferably 2.0 to 4 mm are
provided. The covering which has essentially the object
of surface cladding and if necessary contributes to the
increasing of the impact strength and increases the
weather resistance, possesses preferably wall thick-
nesses of 0.2 to 4 mm, in particular 0.3 to 1.5 mm. Itis also possible to produce the covering in part from
two materials different from one another, for example a
visible side of the profile with a covering of material
~ A and the remaining side of the profile with a covering
~~ 30 formed from a material B, or to cover differently in
individual regions.
In a further embodiment of the invention, it can
be moreover of advantage to form the covering at least
partially in multilayer form from different materials.
Here it is possible to combine advantageously different
properties of the individual materials and accordingly
`! ~2~6~722
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1 to pay proper regard to the different requirements of
the product, which are not achievable with only one
individual material. A preferred variant of the
invention provides that the covering is preferably to be
S provided with a partially shielding surface layer formed
from a weather resistant plastics which is also readily
colourable, especially based on acrylate, in a thickness
of 0.1 to 1.2 mm. When operating in this way, this
additional surface layer can be applied by extrusion,
but also by lamination with a foil or by painting.
Since the core moulding with high glass fibre
content is relatively brittle, although of small shrink
age with high stiffness and strength, it can be of
advantage to improve the impact strength of the multiple
lS layer moulding by a corresponding equipping of the
covering. In this connection it is proposed that the
covering contains in addition to the plastics material
up to 20~ by weight of impact strength modifiers such as
ethylene vinylacetate, chlorinated polyethylene, meth-
acrylic-butadiene-styrene, polybutylacrylate, acrylates
or the like.
The core moulding formed of glass fibre-reinforced
polyvinyl chloride should take oYer the function of
stiffening corset for the shaped moulding. A preferred
embodiment of the invention provides that the covering
is formed with profilings of the shaped mouldings such
as grooves, projections, webs, undercuts and the-like.
The multilayer shaped moulding according to the
invention is preferab~y produced by co-extrusion, being
externally calibrated and possessing a residual
shrinkage below 0.5%, in particular below 0.3%. The
multilayer product according to the invention possesses~
in contrast to pure plastic~ mouldings formed from hard
PVC, an essentially increased Youngs modulus and
accordingly a greater stiffness and torsional
resistance, greater strength and accordingly higher
safety against breaking and an almost complete reduction
~ ~2~%2
-13-
1 in prevailing thermally releasable shrinkage. In
particular when employed in climates with high
temperature differences, the moulding deformation by
thermal radiation is avoided and an essential reduction
in the thermal expansion coefficient is achieved, as a
result of which the tolerance problems in the productioh
of the frames and the accompanying working problems are
significantly reduced.
In the production of multilayer shaped mouldings
according to the invention, there is achieved above all
the advantage that the core moulding based on glass
fibre reinforced PVC need be thermally stabilised merely
with respect to the PVC, while the covering may also be
provided with additional stabilisers relating to weather
resistance, W -absorbers as well as pigments. With this
there is however achievable overall a cost reduction for
the product by the reduced employment of dearer
materials with simultaneous essential increase in the
mechanical properties in particular.
Since the multilayer mouldings according to the
invention with their glass fibre-reinforced polyvinyl
chloride core moulding possess very little shrinkage,
they are also capable of higher thermal loading and
weathering, that is, they can also be heated up to a
greater extent by the suns rays, without inadmissible
stresses which could lead to an inadmissible shrinking
of the moulding, being releasedO It is therefore however
possible to colour multilayer profiles according to the
invention externally in the covering or in t~.~e surface
3 layer even in dark colours such as brown, black, dark
green, as are required on many occasions by architects
on aesthetic grounds. Such a dark colouration is not
possible for example with hard PVC mouldings since they
so shrink on exceeding specific heating temperatures by
3 release of stresses that the frames crack.
Surprisingly, it has been established that the
shaped mculdings according to the invention with their
~Z~.672%
- 14 -
glass fibre reinforced core moulding, may be welded in
trouble free manner and good weld strengths be obtained in
spite of the high glass fibre content, as may be established
for example in the production of frames for windows or doors.
Preferred embodiments of the present invention will
now be described, as examples only, without limitative
manner, having reference the attached drawings, wherein
FIGURES 1 to 6 show sections of different multi-
layer shaped mouldings according
to the invention.
In Figure 1 there is shown schematically a hollow core
moulding 1 formed of glass fibre-reinforced polyvinyl
chloride which is covered externally with a thin covering 2
formed from a thermoplastic plastics, such as for example
hard PVC or ABS. In addition a part of the extent of the
covering is bound directly to a surface layer 3 formed from
a plastics material different from that of the covering 2,
for example a weather resistant plastics material such as
polymethylmethacrylate. It is also possible here for example
to laminate a very thin polyvinylidene fluoride or polyvinyl
fluoride foil by means of a bonding layer.
In Figure 2 th~re is shown schematically a glass
fibre-reinforced hollow core moulding 1 which is provided
externally with a covering 2 which is composed of different
materials or like materials in different colours in the
regions 2a and 2b.
~n Figure 3 there is shown a shaped moulding which
contains two core mouldings la, lb formed of glass fibre
reinforced polyvinyl chloride as stiffening in a corset and
a stable thermoplastic shape-imparting covering 2, formed
for example of hard PVC. The shape imparting covering 2
here gives the profile the external form inclusive of pro-
jections 21.
In Figure 4 is shown a T-form shaped moulding which
possesses a multichamber hollow core moulding 1 formed of
glass fibre-reinforced PVC which imparts to
~Z~i722
-15-
1 the moulding the necessary stiffness, strength,
torsional resistance and Youngs modulus. This core
moulding 1 is provided with a covering 2 formed of a
thermoplastic plastics material, with the covering
containing additional shape imparting formations in the
form of projections 21 e~c. In addition, this moulding
can be provided furthermore for example with a surface
layer 3 on the weathering side, which is especially
weather resistant and which can be coloured different to
the covering 3. Preferably such a profile is produced
according to Figure 4 by combined extrusion with the
bonding of the Iayers 1,~,3 taking place without bonding
means and the multilayer moulding 1,2,3 obtaining its
final form in a single calibrating tool, provided that
thermoplastic materials compatible with one another are
provided.
In Figure 5 there is shown a further possibility
for formation and use of the inventionj wherein a core
mouldihg 1 formed very simply in a right angled hollow
moulding mould is provided with a covering 2 formed from
a suitable plastics material realising a complicated
moulding shape. Such a moulding is also preferably
producible by co-extrusion.
In Figure 6 it is shown in a further development
Of the invention that it is possible to form the c~re
moulding 1 formed of glass fibre-reinforced PVC with a
complicated shaping and plurality of hollow chambers,
with the covering then following the shaping of the core
moulding 1. Also here a further surface cladding layer
can still be additionally provided which can extend over
a part of the periphery or however also over the entire
periphery of the moulding.
From the above-indicated descriptions of the
figures, it follows that in each case the supporting
moulding, the core moulding 1, is formed of glass
fibre-reinforced polyvinyl chloride. The covering
formed of unreinEorced glass fibre~free thermoplastic
;72;~
-16-
1 plastics material, such as for example hard PVC or
acrylate and optionally a still further surface layer
formed of a further material and optionally also
coloured differently to the covering, improves the
S properties of the core moulding. The multilayer
moulding is preferably extruded, with the thicknesses of
the individual layers being the same or even different.
this being adjusted too according to the statistical
requirements under optimal use for the properties of the
material layers. Since the core mouldiny formed of
glass fibre-reinforced PVC possesses very good
mechanical properties, it can be produced, in contrast
to pure hard-PVC mouldings, in simplified cross-section.
The covering layer has not only the object of
lS smoothing the possibly porous and rough surface of the
core moulding and sealing it, but also of increasing of
the appearance and weather resistance. Moreover as a
result of the thinner plastics covering layer, on
callibration of the multilayer profile, the calibration
tool makes less demands on the walls than if a glass
fibre-reinforced material must be directly calibrated.
In this way, as a result of the covering, the welding in
the production of the mouldings in metal tools is also
reduced.
In Figure 7 there is shown schematically an
extrusion apparatus for the production of the multilayer
moulding layer according to the invention by
co-extrusion. At 10 there is shown the main extruder
for extrusion of the glass fibre-reinforced polyvinyl
~-- 30 chloride for the core moulding to which the extrusion
tool 12 for shaping of the core moulding is connected.
Adjoining it i5 the extrusion tool 13 for the shaping of
the covering 2, with the plastics material for the
covering being supplied by the extruder 14. Finally,
there is connected, for a third layer, the extrusion
tool 15 to which the surface layer material is supplied
by the ext~uder 16. The multilayer moulding 11 leaving
2Z
1 -17-
the extrusion tool is then supplied to the calibrating
tools 17, with the final external dimensioning of the
profile moulding and cooling thereof taking place during
passage through these calibrating tools. The withdrawal
takes place at the withdrawal arrangement 1~. In
addition, the moulding can also be cooled internally by
means of for example water.
The different components of the composition
according to the invention can be homogenised with one
another for the production of extrudable mixtures and
then be extruded.
The following ~xamples 1 to 19 serve for the
clarification and explanation of the invention. Of
these, Examples 1 to 5, 8 and 19 are to be regarded as
Compa~rative Examples or Examples lying outside the
invention, whilst the other examples serve for the
explanation of the invention. The Examples are
reproduced in the following Tables. For obtaining the
composition, the proportions can be mixed in dry
pulverous form and plasticised, after which plates of a
thickness of about 4 mm and a width of about 500 mm are
extruded by means oE for example a single spinder-screw
extruder. The extrusion takes place at cylinder
temperatures increasing from 160 to 190C with a tool
te.~perature of 195C. The test bodies were produced
from these plates according to standard test
specifications.
The components of the composition are expressed in
the Examples in parts by weight, a suspension-PVC with
K-value 64 being employed for Examples 1 to 13 and 19
and, for Examples 14 to 18, a suspension PVC with a
K-value of 57 being employed. The different modifiers
employed in Examples 10 to 19 are indicated by their
abbreviation.
The properties with respect of the extruded plates
have been measured both in the longitudinal and
transverse direction. The Youngs modulus is d~termined
-18-
according to DIN 53457, the notched bar impact strength
according to Izod ASTM D 256, the tear strength
according to DIN 5345$, the elongation at break
accordlng to DIN 53455 and the dimensional stability A
in C according to ISO ~ 75.
Example 1 contains an unreinforced PVC-material
without further fillers as comparative example.
Examples 3 and 6 show an unreinforced material with 30
or 50 parts by weight of glass fibres without further
fillers. From this it is apparent that, by the addition
of glass fibres, the Youngs modulus is increased, while
the tear resistance is already somewhat decreased. By
the addition of small amounts of mineral filler, here
calcium carbonate, according to Example 7, in contrast
to Example 6 without mineral filler, both the Youngs
modulus and also the special mechanical properties
predominantly relating to the elongation are improved.
Example 19 shows the properties with an impact
strength modified PVC material without any fillers.
Examples 2, 5 and 9 show in a comparative series
how, with continuous addition of glass fibres to
unreinforced PVC and constant amount of mineral filler,
here calcium carbonate, the property picture with
respect to mechanical properties is changed. In
particular, from a comparison of Examples 7 and 9, it is
clear that an~ increasing addition of mineral filler does
not impart to the glass fibres any essential improvement
of the properties, with the relationships chosen
according to the invention in fact approach equilibrium,
that i5 with slightly decreasing Youngs modulus and
notched bar impact strength and still increasing tear
resistance in comparison with products without mineral
fillers, see Example S, good properties are achieved.
The comparison of Examples 4 and 8 shows that at too
small amounts of ~lass fibres, the desired high
stiffening effect of the shaped bodies based on
reinforced PVC materials is not yet achieved.
67%;~
-19 - .
1 Example 10 shows a composition which contains an
impact resisting modifying material in order to increase
the notched bar impact strength, this working to the
detriment especially of the Youngs modulus and tear
resistance. This can then, according to Example 11
already be increased further by small additions of
mineral filler such as calcium carbonate. Examples 12
and 13 show the further addition of modifying means in
higher amounts which, however, in spite of the
increasing of the notched bar impact strength, in
particular do not improve the mechanical properties but
reduce themO Examples 14 to 18 show the addition of
small amounts of modifying means for increasing the
notched bar impact strength, with addition of small
amounts of calcium carbonate being maintained at a
constant level with in~reasing proportion of glass
fibres. From these Examples one can see the improvement
in Youngs modulus with increasing glass fibre proportion
while maintaining at the same time the notched bar
impact strength and the tear resis~ance in the desired
range. Both the notched bar impact strength and the
impact strength of these compositions is improved.
In Figure 8, the Youngs modulus is shown in its
relationship with the glass fibre content and the
mineral filler in the composition. Curves la and lb
show the progress of the Youngs modulus according to
Examples 1, 3, 6, in the longitudinal and ~ransverse
direction of the plate a~ 0 parts by weight of calcium
carbonate, Curves 2a, 2b tpe Youngs modulus at 15 parts
by weight of calcium carbonate according to Examples 4,
8 and Curves 3a, 3b at 25 parts by weight calcium
carbonate according to Examples 2, 5, 9.
The dependence of tear resistance on the glass
fibre content and mineral filler content is shown in
Figure 9, corresponding to Examples 1, 3, 6 in Curves
la, b,to Examples 4, 8 in Curves 2a, b and to Examples
2, 5, 9 in Curves 3a, b. From this it can be seen that
-20-
1 the small amounts of mineral filler additional to the
giass f.ibres which are preferred according to the
invention improve on the one hand the workability of the
material, but work negatively against the mechanical
properties only to a small extent and essentially
reinforcing properties are obtained by the addition of
the glass fibres.
What is surprising is the good workability of the
composition according to the invention which, in spite
of the high glass fibre content, leads to a homogeneous
product which excels as a result of very good mechanical
properties and lack of shrinkage ~approaching 0).
A lack of shrinkage means herein that the tensions
which become locked in during the working of the
material according to the invention to profiles or tubes
are not lost later during use of the products even at
higher temperatures, this being observable for example
by a warm storing experiment at 100C.
_~ 30
~2~72~
--21 --
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~LZ~722
The essentially improved properties achievable with
the shaped mouldings constructed according to the
invention, in contrast to known mouldings formed of
plastics material for the prod~ction of windows or
doors were tested by production of mouldings by
co-extrusion according to Figure 6, however without
surface layer 3. For this purpose there was used a core
moulding formed of glass fibre~reinforced PVC having the
composition according to Example 14, with the core
moulding possessing a wall thickness of 3 mm. In
addition, a covering with profiling formed from a hard
PVC was according to Example 19, co-extruded with a
cross-sectioned wall thickness of 0.5 mm. Moreover, the
moulding according to Figure 6 was only extruded from
the h~ard PVC composition according to Example 19.
The essential properties were measured on the
profiles and are set out together in the accompanying
Table A. In this way the outstanding properties of the
moulding according to the invention with a glass fibre
reinforced PVC core moulding and hard PVC covering for
example with respect to a pure hard PVC moulding become
very clearly recognisable. The significant Youngs
modulus for the bending and torsional stiffness of the
moulding achieves the more than three times value with
the moulding construction according to the inven~ion in
contrast to the hard PVC moulding. In this way~ wi h
the shaped mouldings accPrding to the invention windows
and door frames stiffer with respect to bending can be
produced which are able to cope with higher loads and do
not require additional metal reinforcements. This good
property is also significant on comparison of the
tensile strengths and also in the load deflection
experiment. The load deflection experiment was carried
out with a span of 100 cm with a more than double as
great a force being required for the moulding according
to the present invention. The impact strength of the
moulding according to the present invention is merely
%Z
decreased on account of the brittle glass fibre
reinforced PVC core moulding with respect to a pure
thermoplastics material. Of especial value are the
small shrinkage values of ~he moulding according to the
invention which suggest a high dimensional stability and
is apparent especially advantageously on heating of the
moulding when incorporated in window and door frames
with solar irradiation on one side. As a result of the
reduced shrinkage of the mouldings according to the
invention and the high Youngs modulus thereof, a concave
flexing of the frames or frame mouldings on heating on
one side is reduced to a minimal value which does not
influence the unctional efficiency of the frames.
Also surprising however is the welding strength
achievable on welding of the mouldings according to the
invention under like conditions to normal hard PVC
mouldings, that is so-called corner strength values.
These are of practically unchanged value.
,~
~6~Z
- 27 -
T a b 1 e A
Properties Dimension Moulding Moulding
according with core
to Com- according
position to com-
of Example position
19 of Example
8 and
covering
according
to com-
position
of Example
19
-
Tensile strength N/mm. 47 75
_ _
Elongation at break % 35 5
Youngs modulus 23C N/mm2 2800 9000
__ _
Ball drop experimentKJ/m not broken not broken
1 m K, 1 Kp, 23C
laccording to RAL) C
_
Shrinkage
1 hour at 100C in air ~ 1.7 Q.12
Force for 3.3 mm bending
in a span of 100 cm N 175 440
Welded corner strength N 7200 7200
_
Bending according to
heat exchange loadingmm/n -3.0 -0.1
Impact strength 23C XJ/m not broken 26
-20C " " 30
_
