DE2121220A1 - Process for making a decorative plastic-coated sheet material - Google Patents

Description

Process for the production of a decorative, plastic-coated Sheet material

The invention relates to a sheet material consisting of a substrate and on one of its surfaces has a decorative pattern. The decorative sheet material of the present invention can be used for a variety of purposes are used, for example, as a material for covering walls, ceilings, blackboards, floors, furniture, upholstery and books .

In recent years, a decorative sheet material, which consists of a paper sheet, has become popular which is provided on one of its surfaces with a continuous coating of a compound based on polyvinyl chloride.

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Often the coated surface was covered with a single or multi-colored, decorative print provided. The appearance of such a material has also been enhanced by printing on it Surface of the sheet material has given a profile embossing. The cost of producing a material of this Art, are high because of the number of proficiency levels. This was particularly true when the surface of the material is provided with a multicolored print, because the printing each color requires a separate printing unit, which is equipped with expensive pattern rollers.

Efforts have been made to produce two or more differently pigmented plastic masses at the same time to be applied to the surface of a textile product, the plastic masses being inside by mechanical devices be mixed together in a bank, which is kept on the estate. A considerable amount is made according to this method Mixing the masses and in the formed coating, very little individuality of coloring is maintained. aside from that it is not possible with this method to create a decorative pattern that runs along the length of the textile is reproducible.

According to the invention, a decorative sheet material consists of a substrate which on one of its surfaces »

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for the purpose of creating a decoration, has a coating, which consists of two or more plastic masses with different Coloring exists whereby the masses have been allowed to blend with one another and become a continuous one To form coating on the surface of the substrate. Desirable is the decorative surface of the material also imprinted a profile.

Dei invention further includes a method for producing a decorative, plastic-coated sheet material _r which is characterized indicates that two or more pigmented plastic compositions having different colors is applied to the surface of a substrate at the same time that it allows the plastic compositions to mix with each other and forming a continuous coating on the surface of the substrate and heating the coating to cause it to gel and fuse.

To ensure that the different pigmented Plastic masses mix together around on the To form a uniform coating on the substrate is a suitable fixed distance measuring device such as one rotating roller, provided in the path of the coated substrate. The ideal is the arrangement where there is a narrow bank of plastic masses on the coated substrate by the measuring device

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is withheld and this ensures that on the Substrate forms a uniform coating.

Preferably the decorative surface of the sheet material is conventional by means of a pattern roller provided with profile embossing »

If desired, the different plastics compositions may be different in practicing the invention Amounts of the same pigment incorporated / so that the decorative surface of the sheet material two or more Has shades of the same color. However, what is more preferred, each plastic compound can also be different Incorporated pigment included, so that a variable color effect is produced on the substrate. Even each plastic compound can, if desired, have more than one pigment incorporated therein.

In general, the plastic compounds are grounded on the Substrate applied at the same time and that by means of suitable application devices, while the substrate is in relation on the applicators, which are arranged across the width of the substrate, moved longitudinally. The order presentation

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directions can be fixed, but they can also be movable transversely to the substrate while the substrate is in motion. Furthermore, one or all of the order

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Devices are used to apply the plastic compound continuously or intermittently.

It must be realized that the pattern formed is a combined effect that is created by the movement of the substrate, the speed with which the plastic mass on the surface of the substrate applied v / ground and the relative movement of the applicators with respect to the substrate. Another The factor that influences the effects that can be produced consists in the viscosities of the plastic masses, because this is the determine mutual mixing. A great variety of coloring effects can be produced, some of them more abstract Type or simulations of wood grain or marbling could be.

The plastic compounds can be applied to the substrate by a variety of methods.

In one embodiment of the invention, a number of pigmented plastic compounds are allowed to flow down laterally next to one another over a surface onto the substrate surface. If desired, the individual masses can be allowed to partially mix by gravity as they flow down over the surface, and diverse patterns can be produced by the interaction of the application devices used. The surface that you use can

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either an inclined plate, or the surface of a rotating or non-rotating roller. Further the surface used can either be flat or also grooved or profiled in some other way.

Although the opposite mixing of the different pig-. mented plastic mass occurs when flowing down over the surface, the mutual mixing is in this embodiment of the invention caused only by gravity and not by mechanical devices.

In another embodiment, the plastic compounds can be applied to the substrate by means of nozzles or sprays, whereby the plastic compounds are thrown onto the substrate. In a particularly desirable embodiment of the method according to the invention, one or more pigmented plastic compounds are applied to the substrate over separate areas, using one or more suitable application devices as described above Width of the coated substrate is applied using an applicator consisting of a spreader such as a knife or roller, Preferably a bank of mass is maintained behind the spreader.

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The distance between the spreader and the substrate surface is such that the separate areas of the compounds which have previously been applied are not unduly disturbed while the further plastic compound is being applied will. In certain cases it has been found desirable to maintain a constant supply of plastic mass to the bank, a serious change in color of the mass in the bank as a result of mixing with the previously applied masses to avoid.

The plastic compounds can be applied to the moving substrate be applied by means of fixed applicators. In this case, the decorative material produced shows a general, longitudinal strip-like effect. However, one can also use moving application devices achieve a wide variety of pleasant pattern effects. The applicators can be made to move in one direction reciprocate transverse to the movement of the substrate, or they can be made to move in a circular path or a similar closed circular path to move. V? O nozzles or sprayers are used, you can either use them move together as a single unit, or you can have individual nozzles or groups of nozzles both relative to the others Move nozzles as well as relative to the substrate.

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Any suitable substrate can be used in accordance with the invention including fiber sheet, metal sheet / metal gauze or mesh, or plastic sheet.

A typical fiber sheet is knitted, bent or not bent textile material, felt material or paper sheet. The usable paper sheet can only contain paper fibers,

"but it can also be a mixture of paper fibers, if desired with man-made fibers such as nylon, rayon or acrylic fibers. Furthermore, the paper sheet with a be provided with a coating of a polymer or other suitable material, which may optionally be pigmented. That Paper sheet should be strong enough to provide decorative sheet material with adequate tear strength and dimensional stability to surrender. In the case of wall covering or wallpapering, it is expedient to use a sheet of paper with a thickness of up to 0.635 mm, for example from 0.152 mm to 0.635 mm, and preferably from 0.152 mm to 0.305 mm. The paper itself can be made from chemical wood pulp or it may be desirable for economic reasons to make the paper from a To produce a mixture of mechanical and chemical wood pulp, for example up to 85% by weight of mechanical Used wood pulp.

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The invention is generally suitable for the use of the usual plastic compositions, in particular those on

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based on vinyl chloride polymer The polymeric material can be in divided form in a suitable plasticizer, for example in a mixture of dialkyl phthalates, so that a plastic of such a consistency is formed, that it mixes with the other plastics masses after it has been applied to the fibrous sheet.

In general, pastes with a viscosity in the range from 1 to 10,000 poise are suitable.

A solution of a polymeric material in a solvent can also be used. Typically, the Solution has a viscosity in the range of 20 to 400 centipoise.

The plastic compound can also contain other conventional constituents. In particular, it generally includes one Heat stabilizer. Other ingredients that may be present in the mass are lubricants, fillers, ultraviolet stabilizers, dispersants, and organic solvents. *

It was found that wallpapers can be produced on paper sheet base by azo incorporating in one or all ver used plastic compounds, a chemical blowing agent as dicarbonimid. When the coated paper is heated, the chemical blowing agent decomposes and surrenders

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at least one gaseous decomposition product soft within those areas of the coating which contain the blowing agent contained, held back and caused their expansion. If one or more of the plastic compounds is a blowing agent and the remaining haters do not contain any blowing agent, the coating will only stretch over selected areas the end. A product is therefore obtained which has relief areas of one color and other areas of different color Has coloring. It is ideal if the proportion of blowing agent in the plastic compound is chosen so that when heated, the Mass this expands to three or more times the original thickness.

Decorative sheet material according to the invention can be prepared with any suitable coating depth. However are generally with most of the usual plastic compounds, especially those based on polyvinyl chloride, Depths up to 1.52 mm, and more often up to 0.331 mm, will be satisfactory for most purposes.

The invention is illustrated by the following exemplary embodiments:

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Example 1

There are two pigmented plastic masses in shape 109847/1283

of pastes, which have the following ingredients:

Components w eight parts

PVC polymer 100

Plasticizer 50

Pigment and filler 50

Stabilizer 1

Turpentine oil substitute 20

The masses are identical with the exception of the pigment used, with one mass containing a beige pigment and a brown pigment is incorporated in the other. The viscosity each mass is about 6 poise.

One paste is applied over separate areas to the surface of a continuously moving sheet of paper applied by means of a number of nozzles which are reciprocated across the moving sheet. The other Paste is then applied across the width of the sheet using an applicator which has a Has squeegee. A bank of this paste is maintained behind the spreader. The bank is ongoing padded to ensure color uniformity.

The coated paper is left through at about Oven held at 200 C to cause the coating to gel and fuse. The coating is by means of

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a pattern roller provided with profile embossing, while the coating is still hot. The coating has the appearance of a wood grain.

Example 2

In this example a basic composition is used, which is similar to that of Example 1 except that both pastes are between 2 and 5 parts by weight contain a chemical blowing agent »The example is identical to Example 1 with the exception that when heated of the coated paper an expansion of the coating takes place.

Example 3

This example uses matrices which are similar to those of Example 1, with the exception that between 2 and 5 parts by weight of a chemical blowing agent is incorporated into one of the pastes. The example is with identical to Example 1 except that when the coated paper is heated, one of the pastes in the coating expands, which causes parts of the coating to rise relative to the other parts of the coating.

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Example 4

Three pigmented plastic pastes are prepared in the form of plasticized pastes, which have the following ingredients exhibit:

Components weight point

PVC polymer 100

Plasticizer 50

Pigment and filler 5O

Stabilizer 1

Thinner 20

The masses are identical with the exception of the pigment used. The viscosity of each hat is about 6 poise. The masses are applied by means of a number of nozzles to the surface of a flat plate which is inclined against a moving sheet of paper. The streams of paste run down the plate and onto the surface of the paper sheet. The nozzles are reciprocated in a direction perpendicular to the direction of travel of the sheet of paper and this causes partial mixing of the streams as they descend under gravity on the plate. The coated sheet of paper passes between two rotating rollers, the top roller maintaining a bank of coating composition on the sheet of paper and ensuring that a uniform coating is formed on the sheet of paper. The coated paper passes through "inen oven at about 200 ⁰ C through to a

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To cause the coating to gel and melt together. The hot coating is provided with a profile embossing using a pattern roller.

Example 5

In this example nan uses matrices which are similar to those of Example 4 except that two of the pastes up to 5 parts by weight of a blowing agent (including grants) included. The method of forming the coating is the same as in Example 4, however When the coating is heated, certain parts of the coating expand.

Example 6

In this example bases similar to those of Example 4 are used, except that equal parts by weight of a ketone / hydrocarbon solvent are substituted for the plasticizer. The same method of formation of the coating ends. However, a much lower temperature is required to remove the solvent from the coating.

Example 7

In this example, compounds are used which correspond to the 1098A7 / 1283

used in Example 6 are similar. The masses are allowed to flow down an inclined plate, with a partial. Mix he follows. No measuring device is used and a non-uniform coating forms, which is not provided with a profile embossing. The coating is as in example 6 dried.

Example 8

The pastes described in Example 4 are applied by reciprocating nozzles to the upper roller of two pinch rollers, between which a sheet of paper passes. The pastes are partially mixed by gravity before they flow onto the paper sheet. Another paste of the same composition but with a different color is held as a bench on the sheet of paper in front of the upper roll. The bank of paste is continually replaced to ensure a uniform background color. A uniform coating is obtained by letting the coated sheet pass between two spaced rollers which rotate in the opposite direction to the direction of movement of the sheet, excess paste is removed from the upper of the two rollers by means of a rake. The coated paper passes through an oven at about 20O ⁰ C and there is a gelling and melting together of the. Coating.

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Claims (5)

Claims Process for the production of a decorative, plastic-coated sheet material, characterized in that you have two or more differently pigmented plastic compounds simultaneously applied to the surface of a substrate that one for the purpose of forming a continuous coating the wet can be mixed with each other, and that one then the continuous coating to bring about a gelation heated and fused together. 2. The method according to claim 1, characterized in that the coated substrate under a measuring device can pass through which a narrow bank of plastic masses retains to form a uniform coating on the substrate. 3. The method according to any one of the preceding claims, characterized in that the differently pigmented Plastic masses side by side before the surface and can flow down onto the substrate. 4. The method according to claim 3, characterized in that an inclined plate is used as the surface. 5. The method according to claim 3, characterized in that 109847/1283 that the surface is a rotating or a non-rotating one Roller used. ORIGINAL INSPECTED 10 9847/1283