DE202018006061U1 - Device for the after-treatment of a homogeneous floor covering - Google Patents

Abstract

Plastisol applicator for the after-treatment of a homogeneous floor covering (1), for example a PVC or vinyl flooring, the plastisol applicator being adapted to carry out the following steps:
- Providing (100) of a homogeneous floor covering (1), at an upper side (2), in particular on a decorative side, at least one defect (3);
- Post-treatment (200) of the provided floor covering (1) with a flowable plastisol (4), wherein a plastisol layer (5) on the top (2) of the floor covering (1), in particular on the decorative side of the floor covering (1) is applied (210 ), wherein the at least one defect (3) is filled with the plastisol (4) and leveled (220) with respect to the top (2);
- hardening (300) the plastisol layer (5).

Description

The invention relates to a device for the aftertreatment of a homogeneous floor covering, for example a PVC or vinyl floor covering.

The EP 0 899 372 B1 describes a method of making a floor covering in which a flooring substrate is printed and subsequently coated with a PVC plastisol layer which, after a gelling and curing step, forms a transparent and durable surface coating of the printed flooring. A similar procedure also describes the EP 0 522 064 B1

Homogenous floor coverings, however, particularly when they have been produced with the aid of double belt presses, on their upper side, and thus on their intended side for printing, defects due to the production process using the double belt press. These imperfections may be pinholes, tape marks of a top belt of the double belt press or defects due to poor agglomeration of a plastic granulate used for the production of the homogeneous floor covering. If a finely divided printing of the top of the homogeneous floor covering is provided, the defects can also attract attention visually negative in addition to their haptic disadvantages and are therefore generally undesirable.

It is therefore an object of the invention to propose a device relating to this, which allows the production-related defects of homogeneous floor coverings to conceal so far that they appear optically and haptically less prominent.

This object is achieved by a device having the features of claim 1. Dependent claims 2 to 15 each relate to advantageous embodiments of the invention.

• - Bereitstellen eines homogenen Bodenbelags, der beispielsweise mit einer Doppelbandpresse hergestellt worden ist und der an einer Oberseite, insbesondere auf einer Dekorseite, mindestens eine Fehlstelle aufweist;
• - Nachbehandeln des bereitgestellten Bodenbelags mit einem fließfähigen Plastisol, wobei eine Plastisolschicht auf der Oberseite des Bodenbelags, insbesondere auf die Dekorseite des Bodenbelags aufgetragen wird, wobei die mindestens eine Fehlstelle mit dem Plastisol gefüllt und in Bezug auf die Oberseite eingeebnet wird; und
• - Härten der Plastisolschicht.

A device for the after-treatment of a homogeneous floor covering ( 1 ), for example a PVC or vinyl floor covering, is accordingly set up in such a way that the following steps are carried out:

• - Providing a homogeneous floor covering, which has been prepared for example with a double belt press and which has at least one defect on an upper side, in particular on a decorative side;
• Aftertreating the provided floor covering with a flowable plastisol, wherein a plastisol layer is applied to the top of the floor covering, in particular to the decorative side of the floor covering, wherein the at least one defect is filled with the plastisol and leveled with respect to the upper side; and
• - hardening of the plastisol layer.

After curing, the printing of the cured plastisol layer can take place. The printing may in particular comprise or be embossing of the plastisol layer and may optionally, but not necessarily have a paint application. After curing and before printing, the plastisol layer can be plasticized for printing. The plasticizing can be carried out contactlessly by thermal irradiation of the plastisol layer.

The curing may include gelling or precuring the plastisol layer. Furthermore, curing after gelling or precuring may include curing the plastisol layer. The curing of the flowable plastisol layer can be carried out in particular in a single step, wherein a cured plastisol layer is produced. If the plastisol layer is to be printed after curing, it is preferably cured in the previous curing. However, the plastisol layer can also be printed in a precured state, for example in a gelled state, and cured only after printing.

The application of the plastisol layer to the top of the floor covering may involve the application of a plastisol comprising at least one powdered thermoplastic polymer, for example polyvinyl chloride (PVC), and at least one plasticizer.

Due to the fact that even before the printing on the floor covering any imperfections of the floor covering are filled by means of the plastisol and thereby leveled, an optimal, especially over its entire surface flat top of the floor covering is provided for the subsequent printing of the flooring, so that the generated with the printing Motif on the top of the flooring is not affected by imperfections visually and / or haptically.

It may be provided that the plastisol layer is applied ungelled on the top of the floor covering, in particular on the decorative side of the floor covering and gelled before curing. In the ungelled state, the plastisol may already penetrate the voids and fill them at least to the level of a surface of the top of the homogeneous floor covering. Preferably, the ungelled plastisol layer is applied to the top with a layer thickness such that, after curing of the plastisol layer, the weight per unit area of the plastisol layer is less than less than 40 g / m ² .

The plastisol layer of dilutable plastisol applied to the top of the flooring may be gelled or precured with a tempered gelling roll, which preferably has a shell surface of a chromium alloy and a temperature of about 160 ° C.

Post-cure printing may include embossing or engraving the hardened plastisol layer coated top of the homogeneous flooring. The embossing or engraving can be done by applying an embossing roller to the top.

It can be embossed or engraved in the homogeneous floor covering in the embossing or engraving of the coated with the hardened plastisol layer top of the homogeneous floor covering through the plastisol layer.

For embossing or engraving, in particular immediately preceding this, at least the upper side of the homogeneous floor covering may be at a temperature between 140 ° C and 180 ° C, preferably at a temperature between 150 ° C and 170 ° C and more preferably at a temperature of approximately 160 ° C are heated. For this purpose, at least the top of the homogeneous floor covering can be heated without contact and preferably with infrared radiation.

After curing, the plastisol layer may have a weight per unit area between 20 and 60 g / m ² , preferably between 30 g / m ² and 50 g / m ² and more preferably less than 40 g / m ² . The plastisol layer can be made so thin that on the one hand it is sufficiently thick enough to fill in the imperfections and level with respect to the top, and on the other hand does not change the structure of the homogeneous floor covering so much that the homogeneous floor covering is damaged by the coating Plastisol according to the relevant definitions would have to qualify as a heterogeneous flooring.

It can be provided that in the after-treatment, the plastisol layer is applied only to the at least one defect, wherein the at least one defect is filled with the plastisol and leveled with respect to the top. This also contributes to the fact that the material composition of the homogeneous floor covering is changed only as slightly as possible by the post-treatment with the plastisol and the aftertreated flooring does not lose its quality as a homogeneous floor covering.

The plastisol layer may be transparent at least after curing.

The flaw may be a local damage to the top, in particular a recess in the top of the floor covering. This damage may be, for example, a pinhole, a tape imprint of a top belt of the double belt press or a defect due to poor agglomeration of a granulate used for the production of the homogeneous floor covering.

The plastisol layer can be applied to the top of the flooring with a reverse roll coater, also known as reverse roll coater, with a nip between a reverse roll coater applicator roll and a reverse roll coater meter roll at least 50 microns is.

The plastisol layer can be applied with a gravure roller indirectly via a rubber roller on the top of the floor covering. The rubber roller can have a hardness of 50 Shore-A. The gravure roll and the rubber roll may be part of a gravure coater which further comprises a platen roller over which the homogeneous flooring is unwound from a supply spool.

A layer thickness of the plastisol layer outside the at least one defect can be 0.1 to 0.15 mm after curing.

The curing may be carried out at a temperature between 100 ° C and 140 ° C, preferably at a temperature between 110 ° C and 130 ° C, and more preferably at a temperature of 120 ° C.

With the device according to the invention it is achieved that the quality of the final product no longer depends exclusively on the quality of the homogeneous starting floor covering produced before printing using the double belt press. Quality deficiencies due to the manufacturing process using a double belt press can be masked by coating the initial flooring with the plastisol layer prior to printing the homogeneous flooring.

It has also been found that even with basis weights of the plastisol layer of less than 40 g / m ^2, the plastisol layer is resistant to the printing of the cured plastisol layer, in particular even if the printing comprises embossing of the plastisol layer. It has proven to be advantageous if the plastisol layer is plasticized before embossing.

It could be stated that the use of embossing rollers is also the case Plastisolschicht resistant to chipping due to the embossing process is. This applies both to embossing processes in which the plastisol layer is broken through and to embossing processes in which the plastisol layer is not broken.

According to another aspect of the invention, the device is also described for eliminating at least one defect on a top surface of a homogeneous floor covering.

• 1 ein Ablaufdiagramm eines Verfahrens der erfindungsgemäßen Vorrichtung;
• 2 eine schematische Darstellung einer ersten Ausführungsform einer erfindungsgemäßen Vorrichtung zur Durchführung des Verfahrens;
• 3 eine schematische Darstellung einer zweiten Ausführungsform einer erfindungsgemäßen Vorrichtung zur Durchführung des Verfahrens; und
• 4 einen schematischen Querschnitt durch einen von der erfindungsgemäßen Vorrichtung nachbehandelten homogenen Bodenbelag.

Further details will be explained with reference to the following figures. Showing:

• 1 a flow diagram of a method of the device according to the invention;
• 2 a schematic representation of a first embodiment of a device according to the invention for carrying out the method;
• 3 a schematic representation of a second embodiment of a device according to the invention for carrying out the method; and
• 4 a schematic cross section through a post-treated by the device according to the invention homogeneous flooring.

This in 1 shown method of the device according to the invention comprises in a first step 100 the provision of a homogeneous floor covering made with a double belt press. In the production of homogeneous floor coverings with the aid of double belt presses, defects occur in the form of local damage on the upper side of the homogeneous floor covering. The flaws can be formed for example as a recess in the top of the floor covering. These may be, for example, pinholes, tape impressions of a top band of the double belt press or defects due to poor agglomeration of a granulate used for the production of the homogeneous floor covering. The floor covering thus has on its upper side, which may be in particular a decorative side of the floor covering, a plurality of defects, which may be visually and haptically disturbing.

A step 200 includes the post-treatment of the provided flooring with a plastisol, wherein a plastisol layer is applied to the top of the floor covering, in particular on the decorative side of the floor covering. In this case, we filled the at least one defect with the plastisol and leveled in relation to the top. The aftertreatment 200 can the application 210 the plastisol layer in ungelled form on the top of the flooring cover. The ungelled plastisol penetrates into the defects and levels the imperfections against the top of the floor covering in one step 220 one.

In a following step 230 the plastisol layer forming the plastisol layer is gelled, whereby the plastisol layer becomes a homogeneous and viscoelastic mass with a defect-free and even surface. After gelling 230 can the plastisol layer in a further step 300 be hardened. While gelling may be accomplished by means of a gelling roller having a temperature of about 160 ° C, curing may be carried out without contact in an oven having, for example, a temperature of 120 ° C.

After hardening 300 of the plastisol can do this in one step 400 be heated to a temperature between 140 ° C to 180 ° C, and more preferably to a temperature of about 160 ° C, so that the plastisol layer is plasticized and thus plastically deformable to in one step 500 to obtain an embossing that corresponds to a desired decor on the top of the homogeneous floor covering.

After embossing 500 The floor covering can be cooled down with the embossed plastisol layer and wound up on a rewinder for further processing.

The plastisol layer can after hardening 300 have a basis weight of less than 40 g / m ² , with a layer thickness of the plastisol layer outside the defects, which is between 0.1 and 0.15 mm. Accordingly, even after the aftertreatment according to the invention, the homogeneous floor covering retains the properties which qualify it as a homogeneous floor covering in terms of its material composition.

The 2 shows a device for carrying out the method of the device according to the invention. From a supply roll 19 becomes the homogeneous flooring 1 a reverse roll coater 8th supplied and via a counter-pressure roller 14 from the supply roll 19 settled. Reverse roll coaters are also known as reverse roll coaters of the prior art. The reverse roll coater 8th also has an applicator roll 10 and a metering roller 11 on, with a nip 9 between the applicator roll 10 and the metering roller 11 at least 50 microns. Using the counter-rotating applicator roller 10 and metering roller 11 becomes the plastisol 4 as a physical mixture of at least one powdery thermoplastic polymer, for example PVC, and at least one plasticizer and optionally fillers, blowing agents and additives on the top 2 of homogeneous flooring 1 as a plastisol layer 5 applied.

The one with the plastisol layer 5 coated flooring 1 becomes a gelling roller 6 fed, which may for example have a temperature of 160 ° C. Upon gelling, the plasticizer dissolves out of the thermoplastic polymer to give the gelled plastisol 4 a flat polymer layer on top 2 of the flooring 1 forms. The flooring 1 with the gelled plastisol layer 5 is a stove 15 fed to the plastisol layer 5 to harden. The curing can be carried out, for example, at a temperature of 120 ° C.

After leaving the oven 15 becomes the flooring 1 with the hardened plastisol layer 5 infrared radiation 7 exposed, causing the plastisol layer 5 is plasticized. This is how the flooring is prepared 1 with the plastified plastisol layer 5 a stamping calender with an embossing roller 18 fed, with the help of which on the top 2 of the flooring 1 a surface structure is introduced. It has been found that the plastisol layer 5 the treatment by the embossing roller 18 unscathed survived and in particular by the embossing not from the flooring 1 peel. After embossing with the help of the embossing roller 18 becomes the flooring 1 a chill roll arrangement 16 fed and then a rewinder 17 be supplied.

The 3 shows an alternative device for carrying out the method according to the invention, which is characterized by the device according to 2 differentiates that instead of a reverse roll coater 8th ( 2 ) a gravure coater 20 ( 3 ) for the application of Plastisolmischung 4 on top 2 of the flooring 1 is provided. The gravure coater 20 has a gravure roll 12 put in a reservoir for the Plastisolmischung 4 protrudes and so the plastisol 4 receives. About a rubber roller 13 becomes the plastisol 4 indirectly from the gravure roll 12 on top 2 of the flooring 1 applied. After the plastisol layer 5 on top 2 of the flooring 1 is applied, the with the plastisol layer 5 coated flooring 1 analogous to the embodiment according to FIG 2 first a gelling roller 6 , then a stove 15 , then source of infrared radiation 7 , then the embossing roll 18 , then the chill roll assembly 16 and finally the rewinder 17 fed.

The 4 shows a schematic cross-sectional view of a floor covering according to the invention 1 the one with a plastisol layer 5 is coated. As you can see, the flooring shows 1 at its top 2 defects 3 completely filled with plastisol. The plastisol layer 5 may in particular be transparent at least after curing and a thickness d have the outside of the defects 3 is only 0.1 to 0.15 mm and thus neither haptic nor visually noticeable and incidentally also contributes, due to their low basis weight of, for example, less than 40 g / m ² that the homogeneous floor covering also taking into account the coating 5 still be qualified as a homogeneous floor covering.

The features of the invention disclosed in the foregoing description, in the drawings and in the claims may be essential to the realization of the invention both individually and in any combination.

LIST OF REFERENCE NUMBERS

1

Flooring

2

top

3

void

4

plastisol

5

plastisol

6

Gelierwalze

7

infrared radiation

8th

Reverse roll coater

9

nip

10

applicator roll

11

metering

12

engraved roll

13

squeegee

14

Backing roll

15

oven

16

chill rolls

17

rewinder

18

embossing roller

19

supply roll

20

gravure

100

Provide

200

aftertreatment

210

Instruct

220

level out

230

Gel

300

hardening

400

Heat

500

print on

d

layer thickness

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0899372 B1 [0002]
• EP 0522064 B1 [0002]

Claims (15)

Plastisol applicator for the after-treatment of a homogeneous floor covering (1), for example a PVC or vinyl flooring, the plastisol applicator being adapted to carry out the following steps: - Providing (100) of a homogeneous floor covering (1), at an upper side (2), in particular on a decorative side, at least one defect (3); - Post-treatment (200) of the provided floor covering (1) with a flowable plastisol (4), wherein a plastisol layer (5) on the top (2) of the floor covering (1), in particular on the decorative side of the floor covering (1) is applied (210 ), wherein the at least one defect (3) is filled with the plastisol (4) and leveled (220) with respect to the top (2); - hardening (300) the plastisol layer (5). Plastisol applicator after Claim 1 comprising, after curing (300), printing (500) the cured plastisol layer (5). Plastisol applicator after Claim 1 or 2 in which the plastisol layer (5) of flowable plastisol (4) applied to the upper side (2) of the floor covering (1) is gelled or precured (230) with a tempered gelling roller (6), which preferably has a jacket surface of a chromium alloy and a Temperature of about 160 ° C. Plastisol applicator according to one of the preceding claims, in which the printing (500) after hardening (300) comprises embossing or engraving the top (2) of the homogeneous floor covering (1) coated with the hardened plastisol layer (5). Plastisol applicator after Claim 4 in which embossing or engraving of the top side (2) of the homogeneous floor covering (1) coated with the hardened plastisol layer (5) is embossed or engraved through the plastisol layer (5) into the homogeneous floor covering (1). Plastisol applicator after Claim 4 or 5 in which, for embossing or engraving, at least the upper side (2) of the homogeneous floor covering (1) is at a temperature between 140 ° C and 180 ° C, preferably at a temperature between 150 ° C and 170 ° C and more preferably at a temperature of 160 ° C is heated (400). Plastisol commissioned after one of Claims 4 to 6 in which, for embossing or engraving, at least the upper side (2) of the homogeneous floor covering (1) is contactless and preferably with infrared radiation (7) to a temperature between 140 ° C to 180 ° C, preferably to a temperature between 150 ° C to 170 ° ° C and particularly preferably to a temperature of 160 ° C is heated (400). Plastisol applicator according to one of the preceding claims, wherein the plastisol layer (5) after curing (300) has a basis weight between 20 and 60 g / m ² , preferably between 30 g / m ² and 50 g / m ² and more preferably of less than 40 g / m ² . Plastisol applicator according to one of the preceding claims, wherein in the after-treatment (200) the plastisol layer (5) is applied only to the at least one defect (3) (210), wherein the at least one defect (3) with the plastisol (4 ) is filled (200). Plastisol applicator according to one of the preceding claims, wherein the defect (3) in the production of the homogeneous floor covering (1) has been produced with a double belt press and, for example, a pinhole, a tape imprint of a top band of the double belt press or a defect (3) due to a deficient Agglomeration of a granulate used for the production of the homogeneous floor covering (1). Plastisol applicator according to one of the preceding claims, wherein the defect (3) is a local damage to the top (2) of the homogeneous floor covering (1), in particular a recess in the top (2) of the homogeneous floor covering (1). Plastisol applicator according to one of the preceding claims, in which the plastisol layer (5) is applied to the upper side (2) of the floor covering (1) with a reverse roll coater (8), a nip (9) being arranged between an applicator roll (8). 10) of the reverse roll coater (8) and a metering roll (11) of the reverse roll coater (8) at least 50 microns and a layer thickness (d) of the plastisol layer (5) outside the at least one defect (3) after the Hardness (300) is 0.1 to 0.15 mm. Plastisol commissioned after one of Claims 1 to 11 in which the plastisol layer (5) is applied with a gravure roller (12) indirectly via a rubber roller (13) to the top (2) of the floor covering (1), wherein the rubber roller (13) has a hardness of 50 Shore A. Plastisol applicator according to one of the preceding claims, wherein the curing (300) at a temperature between 100 ° C and 140 ° C, preferably at a temperature between 110 ° C and 130 ° C and particularly preferably at a temperature of 120 ° C. is carried out. Plastisol applicator according to one of the preceding claims for eliminating at least one defect (3) on an upper side (2) of a homogeneous floor covering (1).

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