DE2915136A1 - METHOD OF MANUFACTURING A WEB FROM A RESINY COMPOSITION WITH A STRUCTURED SURFACE - Google Patents

Description

MANNINGTON MILLS, INC.
Salem, New Jersey / USA

Method of making a sheet from a resinous Composition with a textured surface

The invention relates to a method for the production of elongated, continuous sheets of a resinous composition with a structured surface.

Resin-containing cushions or foamed coverings, in particular for floors and walls, with an embossed or structured Surface are known. Such a material can also be used to cover tables, as a book cover, for production of containers, as a seat cushion cover, for covering the interior of an automobile and the like. More can be used. In the US-PSs 35 74 659, 29 20 977, 39 14 485 and 39 31 429 various techniques for the production of such coverings are described. The method described in US Pat. No. 2,920,977 comes closest to the present invention.

After the method according to US-PS 29 20 977 several Polyvinyl halide compositions or so-called plastisols printed on a substrate in a pattern, with at least one of the compositions is heat foamable. Thereafter, the entire structure is supported by the substrate heated to give the foamable composition a assumes greater thickness than that of the other compositions of the structure. In this way an embossed or structured Surface generated. From this US-PS it is also

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knows several plastisols with different thermal expansion properties, achieved by using different amounts of blowing agent or different types of blowing agent printed separately in different patterns. That Applying a thin, transparent, non-foaming Wear layer is also disclosed.

However, the US-PS 29 20 977 does not specify a method with which the plastisol structure in accordance with its pattern in different colors would be dyed exactly, especially not using the squeegee intaglio printing technique (rotogravure printing technique). Rather, it is suggested there to add a pigment to the plastisol before it is applied, whereby the fineness possible with the doctor blade gravure printing technique cannot be achieved.

The US-PS 39 14 485 and 39 31 429, which disclose a process similar to that of US-PS 29 20 977, teach the addition a pigment to the plastisol before printing.

The main reason for including pigments in the plastisol before printing is because it is difficult to produce a acceptable coverage or correspondence between the printed plastisol pattern and the subsequent multicolored overprinting to be achieved with the help of rotogravure presses or similar printing presses. In fact, they are supposed to be chemical Bossiertechniken according to the US-PS 32 92 094 and 32 93 108 the resulting problems with such an alignment Avoid by using chemical foam inhibitors in connection with the color drawdown. First and foremost is the The reason for the problems arising with the required agreement is that the carrier substrate for which in the As a rule, impregnated asbestos felt is used because its dimensions are not stable enough. Such substrates

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expand and shrink in length when tensioned or pulled or shorten as the tension eases. In addition, the degree of longitudinal expansion or shrinkage changes along the continuous web due to a variety of factors including changes in thickness or composition Belong to the BaIm. Furthermore, the moisture content, which is both temporally and spatially over the Web change can have an impact on the stability of the dimensions. The resin layer applied to the web works does not counteract this instability, but rather increases it.

In practice, the plastisol is applied to the substrate and gelled in a production line, at the end of which the Web is rolled up. If on the surface of the gelled-n Plastisol's color is to be printed on, this is done in a separate color line, which is a multitude of colors one after the other having rotogravure presses arranged in a row. If the plastisol is to be puffed up, the web mostly will fed from the printer into the blowing ovens, inflated, cooled and wound up at the end of the street. It is impractical ^ if not at all impossible to carry out the entire process in a single line without rolling up the web in between, which leads to a decrease in web tension.

Due to the relaxation of the web between the imprints of the Plastisol pattern and overprinting with color result in great problems with regard to the correspondence between the Plastisol pattern and the coloring tailored to the plastisol pattern. Therefore, the methods according to the US patents 29 20 977, 39 14 485 and 39 31 429 have not yet found much acceptance in practice.

If the plastisol, for example in the rotary screen printing process, is printed, the input voltage of the sub-

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strats are maintained, causing some longitudinal stretch results. The rotary screen prints a pattern with a period which is equal to the circumference of the printing drum. The period length is equal to the circumference of the drum. However is the length of the periodically repeating plastisol image on the web is reduced or enlarged, because the tension is compared to the tension at the Feed to the plastisol printer changes.

The color printer working with the doctor blade gravure printing process must have a Have image period equal to the period of the plastisol image printer when matched should be achieved. The plastisol image on the web must be Imprint the color the same length as when imprinting the plastisol. However, the web shrinks when the Tension after the plastisol pattern is printed so that the plastisol image is compressed. If the plastisol picture If it is not stretched again in the longitudinal direction until it is the same length as when the plastisol was applied, a coincidence can be achieved or an exact alignment cannot be achieved with the color printer. In addition, if there are several Color printers the color match under the respective Color printers are maintained.

The invention is therefore based on the object of specifying a method with which the color impression and the plastisol image in Consistency can be maintained even though the web tension between the application of the plastisol images and the im Rotational printing process wears off color. Further it should be possible to produce resin-like sheets that are printed, structured or embossed using the rotary printing process, by printing patterns of foamable plastisols and then printing these patterns with color in accordance with the plastisol patterns can be overprinted using a relatively simple control technique.

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The features of claim 1 and the further claims serve to solve this task area.

Further advantages, details and features of the invention emerge from the following, with reference to the enclosed Description of a preferred embodiment of the method according to the invention and some modifications, taking place in the drawing of this.

In the drawing show:

Figure 1 is a schematic view of a plastisol printing line,

Figure 2 is a schematic view of a portion of a

Rotary printing line, inbes. a rotogravure printing line,

Figure 3 is a cross-sectional view of the web with a foamable one and a non-foamable plastisol and a wear layer before foaming takes place,

FIG. 4 shows a cross-sectional view corresponding to FIG. 3 after foaming and

FIG. 5 is a plan view of the web to illustrate the periodically repeating plastisol image and the reference marks on the edge of the web.

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It is assumed that a continuous path or curve is to be created, which can be used as a floor or wall covering suitable. The product then comprises several layers, namely a substrate 11, preferably an impregnated asbestos felt, a resin layer 12, preferably polyvinyl chloride, and a transparent wear layer 13, which in turn is preferably is composed of a polyvinyl chloride (see. Also Fig. 3 and 4).

In the resin layer, two or more patterns each aligned with each other are preferably contained at least one of which is a pattern of a heat-expandable resin 14 and the other is a pattern of a non-through Heat foamable resin 15 is constructed. Alternatively to this Both resin patterns 14 and 15 may be composed of heat-expandable resins, but the degree of expansion with the same heat treatment due to the use of larger amounts of blowing agents or different types of blowing agents fluctuates.

Before the expansion and before the wear layer 13 is applied, the colors, preferably using the doctor blade gravure printing process (Rotogravure printing process) on the surfaces of the resin compositions formed patterns are printed. After the puff, there are sections in the overall pattern that have a have greater thickness than other sections of the overall pattern, as shown in Figure 4, whereby a structured, surface provided with elevations and depressions is created.

The substrates which can be used for a variety of purposes in terms of their nature and their properties are well known. In general, an impregnated asbestos felt with a thickness of 0.6 to 1.2 mm is used as the substrate for floor coverings is used, with a thickness of 0.76 mm being preferred. A

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Such asbestos felt is available in the form of rolls with a width of 1.8 to 4 m for use as a floor covering. The asbestos felt webs of such rolls often have a length of 600 to 1,200 m.

According to the invention, the surface of the resinous sheet is now printed with a multicolored pattern, the tiles or bricks or stones made of another material, for example can be separated from each other by cement joints, can pretend. In the case of simulated bricks or In the finished product, tiles are thicker than the "stone areas" than the "joint areas", which creates a bossy surface.

By changing the thickness of the resin layer either in a random manner or in accordance with a regular geometric Changing the pattern or using any combination of the two can produce a variety of effects achieve. In addition, according to the present invention, a resin layer can be used that is post-inflated has three or more clearly different thicknesses and thus different surface heights, see above that a variety of interesting effects can be created.

In practice, the desired pattern is used for identification analyzed all areas in which either no expansion or expansion up to a given thickness is desired will. This can be two or more different pattern distributions lock in.

In the preferred embodiment of the invention, the Resin composition known as plastisol applied with a rotating, stenciled cylinder. The plastisol compositions that are suitable for use as floor or wall coverings are generally

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knows and do not need to be explained in more detail. Depending on the desired thickness of the resin for a given section of the overall pattern, the plastisol is applied with or without blowing agent or different blowing agent concentrations are used or types of blowing agent are used, so that different expansion ratios are used for the same heat treatment appear.

The company Stork Brabant in Holland, the company Peter Zimmer in Kufstein, Austria, the company Johannes Zimmer in Klagenfurt, Austria, and the company Mitter & Co. in Schist Nuerholte, Germany, produce rotating screen printing machines that are used for applying the plastisols in question according to the present invention are suitable.

The line for applying the plastisols has one or more rotary printing stations with interposed gelling ovens on.

For example, there can be two stations, the first of which is the plastisol with a certain amount of blowing agent and applying activator agent in a predetermined pattern. The plastisol contains, for example, so much blowing agent and activator, that the plastisol in the foamed state is three times thicker than when it was applied, i.e. in the non-foamed state State, is. This pattern is then gelled as it passes through an oven. The second station applies a plastisol that contains no blowing agent, this application being carried out in a pattern that is opposite to the pattern produced with the first print is aligned or adapted to this. The web then goes through another oven to gel the second plastisol. The pattern formed by the first plastisol then forms the raised areas, for example the tile surfaces, while the pattern formed by the second plastisol forms the recessed areas, for example the joints.

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If three distinctly different thicknesses are to appear in the finished sample, a third plastisol sample must be used with a higher or lower concentration of blowing agent than the first sample or with a different kind of Blowing agents can be printed in the same way as above. The expansion of the third pattern is then greater or smaller than that of the first sample.

The plastisols can be essentially colorless or have slightly masked pigmentation. After applying and the gelation of the respective, coordinated patterns can use the colors on the respective sections of the pattern of the web to simulate tiles, bricks or other patterns are applied. The colors are preferably printed using the rotogravure printing process. upset. In general, the line for applying the plastisols differs from the rotary color printing line and is separate from it. Consequently, the web is wound up at the end of the line for the application of the plastisols and then handed over to the end of the printing line. Furthermore, the printing line generally also has a device for applying the wear layer and blowing ovens. Therefore, the one in Plastisolstrasse usually leaves the train generated tension at the end of the street. To find a match between the squeegee presses and the plastisol patterns To achieve which the paint is to be optionally applied, it is necessary to adjust the length of the plastisol pattern or the image to be returned to its original length. In the present invention is a device provided that now not only for a match between the printing press and the image length of the plastisol pattern ensures, but also for a mutual coordination of the individual produced by the various printing presses Color ranges.

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Reference is now made to FIG. A roll of asbestos felt 11 is at an unwinding station of a plastisol printing line, which is shown schematically arranged. The web or asbestos felt substrate 11 then passes through a mechanical one Tensioning device 16, which the web 11 with a constant Provides loading tension or exerts a pull on the railway, whereupon the web passes through rotary printing stations 17 and 18 for the application of the plastisols. The path 11 runs through after the rotary screen printers 17 and 18 each have a gelling oven 19 and 20 respectively. Kühltrommelη 21, 22 are each downstream of the respective gelling ovens 19, 20 arranged.

With a constant feed tension of the web 11, that in the tensioning device 16 is generated, the applied plastisol patterns at the rotary printing stations 17 and 18 can be in precise alignment are held to each other. Leg Release of tension the web 11 at the end of the plastisol printing line, however, results in a considerable shrinkage of the web, whereby the Plastisol sample images can be compressed. Since the period lengths the plastisol images are equal to the period lengths of the color printer when applied, must be the original length the plastisol image can be restored in the printing line.

According to the invention, reference marks 23 are used for the coordination the seam or the edge of the web 11 in accordance with the Plastisol images printed on. Preferably the reference marks 23 printed in the first rotary screen printing station 17 for the application of plastisol and are in a fixed relationship to the first plastisol images.

In practice, any repetitive plastisol image " tion assigned three reference marks 23, wherein the devices for printing the reference marks on the plastisol printing drum are offset from one another by 120 °.

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The rotogravure printing line for applying the inks is shown schematically in Figure 2 and has an unwinding station for for a web roll 11, on whose path the one into the other plastisol patterns joined together and aligned with one another have been printed and then gelled. The web 11 passes through a tensioning device 25 and runs from there the first rotogravure station 26. The number of rotogravure stations depends on the desired color scheme in the final sample. In Figure 2, four color printing stations 26, " 27, 28 and 29, ovens 30, 31, 32 and 33 are shown for drying are immediately downstream of the printing stations 26, 27, 28 and 29. The ovens 30, 31, 32 and 33 dry the pigmented Printing fluid that has been applied in the aforementioned printing stations.

Two spatially separated optical sensors 34 and 35 are near the first printing station 26, preferably downstream, and on opposite sides

a compensation device 36 to compensate for the web path, which will be described in detail later intended. The optical sensors 34 and 35 control the tensioning device 25, which controls the feed tension of the web 11 to the first printing station 26 controls.

An optical sensor 37 is provided in the vicinity of the printing station 27. The optical sensor 37 takes the same here relative position to the printing station 27 as the optical sensor 34 to the printing station 26. In a similar way is an optical Sensor 38 arranged in the vicinity of the printing station 28, and an optical sensor 39 in the vicinity of the printing station 29. If additional printing stations are used, there are additional optical sensors in the same way as the optical ones Sensors 37, 38, 39 in connection with the additional printing stations.

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The printing drum of the first printing station 26 is in the printing line arranged in such a way that their rotation is as close as possible to the beginning of the first plastisol imprint of the repetitive Imprint begins. The angular position of the following Rotary printer 27, 28, 29 etc. is chosen with regard to the length of the web in between that in general a match with the repeating plastisol images consists. However, it is due to the fact that the tension in the web 11 after the application of the plastisols has subsided, it is almost inevitable that the length of the repeating plastisol images will be slightly shorter than when applying the plastisol images in the plastisol printing line.

The sensors connected to the first printing station 26 34 and 35 should be the reference marks 23 at the same time detect when the path distance between sensors 34 and 3 is equal to an integral multiple of the length of the plastisol image period is. However, if the image period is now shorter than when applying in the plastisol printing line, the sensor 35 does not scan a reference mark at the same time as the sensor 34.

If there is a lack of synchronization between the sensors 34 and 35, a signal from a suitable, known electronic Device delivered to the tensioning device 25, whereupon the tension exerted on the web 11 for elongation the web is increased until the sensors 34 and 35 detect the reference marks 23 at the same time, which indicates that the required plastisol image length has been restored by stretching the web 11.

The sensors 34 and 35 continuously monitor the reference marks on the edge of the web 11 so that even the slightest deviations

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genes can be recorded in the length of the plastisol images. For example, the property of the asbestos felt can change after correct coordination between the first printing station 26 and the plastisol map still change from point to point in such a way that either a greater or lesser tension used up * to maintain the originally applied plastisol image length. The sensors 34 and 35 give then a signal for controlling the voltage device 25 in order to increase the input voltage for the purpose of compensation or to decrease so that a continuous correspondence between the first printing station 26 and the plastisol images is ensured.

The voltage device controlled by sensors 3, 4 and 35 is sufficient 25 off to maintain the alignment between the plastisol images and the first printing station 26, however, additional facilities must be provided to ensure color synchronization among the subsequent printing stations 27, 28, 29 etc. and the first printing station 26 to maintain. The same reference marks 23 are used for this. The sensors 37, 38 and 39 are in the vicinity of the printing stations 27, 28 and 29 are arranged in the same way as the sensor 34 with respect to the printing station 26. The initial one Adjustment for the congruence of the colors must be made visually by an operator who has the Printing stations 27, 28, 29 manually synchronized so that the colors applied in these stations are congruent with the color image are. Nevertheless, the synchronization between the printing stations 26, 27, 28 and 29 are lost, as a result of which readjustment is necessary between the respective printing stations.

When the operator adjusted the mutual position of the colors sensors. 37, 38 and 39 are used for operational

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massively connected storage devices switched on, so that Now each sensor should detect a reference mark 23 at a predetermined point in time when the mutual color alignment should be maintained.

If the alignment of the colors to one another changes, then each sensor 37, 38 and 39 detects the lack of synchronization at the respective printing station. A signal from the corresponding sensor 37, 38 or 39 then acts on a device to adjust the length of the web path between adjacent printers, the feed tension on the out of sync Printer or the speed of rotation of the mis-synchronized printer to re-establish synchronization. Since several sensors are provided, these adjustments can also be made at several points.

A compensation device 36 for the path length of the web is shown schematically in FIG. 2 and is located between the printers 26 and 27. If the sensor 37 detects a lack of synchronization when the colors are applied by the printer 27, the compensation device 36 changes the path length of the web between the printing stations 26 and 27 to re-establish synchronization. The compensation device 36 acts as a sheet-collecting device, the web of the Aufgäbespannung changes at least immediately following printing station in case of change of the path length at the _χ η direction of movement of the web.

As an alternative to this, a sensor, for example the sensor 39, which detects the dissynchronization, can be sent to the Printing station 29 upstream voltage device 40 emit a signal to restore synchronization .

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According to a further embodiment, it is possible to switch the printing cylinder or its speed of rotation to change, which can be done by the sensor 38 in the present case.

Depending on your requirements, one or a combination of the three options mentioned above can be used to synchronize the color prints be applied.

A control device which can be used in connection with the sensors 34 and 35 to control the voltage device 25 is from Hurletron Altair in Danville, Illinois, or from Crossfield Electronics, Great Britain, available.

The control device described above not only ensures a comparison between the plastisol image and the color printer, but also for a comparison between the color printers themselves and constantly compensates for changes in the image lengths due to an uneven stretching of the web 11.

In addition, this control system compensates for a lack of synchronization between the color printers, which is due to the mechanical processes in the printers, the drive systems and the transport mechanism between adjacent printers.

After applying the colors with the help of the doctor blade gravure printing machine a wear layer is applied in a known manner, e.g. with the aid of a reversing roller, after which the web is then passed through an expansion furnace to expand the foamable plastisols.

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Plastisols of the Newtonian type (4/14/78) with viscosities between 2 up to 7.5 Pa-s (the conversion is based on: 1 Pa * s = 1,000 cps, cps is used in the American system of measurement), the with a 20 RPM Brookfield No. 4 spindles have been measured, proved to be favorable. Dilatant plastisols, on the other hand have proven to be unfavorable to this day.

Mesh sizes of 18 for the raised areas and 32 for the recessed areas have been found in the rotary screens, preferably of the galvanic type, well proven. It seems best for the recessed areas or joint areas to be when the viscosity is between 1 Pa · s between 2.5 Pa.s. is chosen, the upper range being preferred.

When printing the plastisol patterns, it is desirable to first "capture" the plastisol from the second station, i.e. that if the grout lines are, for example, 1.3 cm, when applied to a previously printed pattern to form the Raised areas on one side should be made larger by about 0.5 mm. This creates an overlap of the on top of the surrounding raised surfaces.

It was also found that the surface then tends to be irregular at the boundaries between the patterns of different plastisols when the plastisol patterns are well adjusted to each other when printing. This will degrade printing performance, with low areas be passed over.

This problem can be solved by using a rotary sieve after applying the plastisol pattern to apply a layer of plastisol that covers the entire web and does not contain any blowing agent. This was done with a

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SAD ORIDSNAL

40-iger Stork application sieve carried out that the uneven surfaces between the raised and recessed areas has filled satisfactorily and only about 1.5 to 2 ιβη * above the Surface of the raised areas has been applied. A plastisol with a low viscosity, about 0.5 Pa-s, yielded highly satisfactory results. Alternatively, the surface of the raised and recessed areas by applying a relatively low viscosity plastisol using reverse roll coaters or one Scraper knife or a combination of the two. If a smooth surface is not in a single one Passage is achieved, multiple passages can be provided.

In the event that the smoothing plastisol layer is using to be applied by rollers, the floating rollers from the Küsters company in Krefeld, Germany, Proven useful.

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Claims (11)

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JX-5 Company MANNINGTON MILLS, INC, Salem, New Jersey / USA Patent claims: A method of making elongated, continuous sheets of a resinous composition having a structured surface, characterized a) that with the help of heat foamed, resinous Composition in the form of a pattern is printed on a substrate, b) that a large number of reference marks on the substrate is applied in accordance with the pattern, c) that the resinous composition is gelled, d) that in accordance with the pattern above color is printed, e) that the correspondence between the pattern of the resinous composition and that printed on it Color is continuously maintained by reducing the stress applied to the substrate during the Color pressure is continuously set or readjusted, depending on the detection of the momentary Location of the separated reference marks in the vicinity of the color printing station, and 09843/0891 f) that the foamable composition by application is foamed by heat. 2. The method according to claim 1, characterized in that the reference marks by the resinous composition applied Printer applied. 3. The method according to claim 1 or 2, characterized in that a plurality of separate patterns formed from a resinous composition are printed on the substrate, the resinous composition of at least one of the patterns being heat-expandable _{to expand to a thickness} that is larger than that of at least one of the other patterns formed from the resinous composition, and that the patterns are printed in mutual alignment with one another. 4. The method according to any one of claims 1 to 3, characterized in that that the reference marks are applied at substantially the same distances from one another, wherein a plurality of marks are provided for each repetition of the pattern. 5. The method according to claim 3 or 4, characterized in that a) that a plurality of colors sequentially across the patterns formed by the resinous composition, and in accordance with these, are printed, b) that the mutual matching arrangement of the colors is continuous is maintained by placing the current location of the fiducial marks in the vicinity of each on which first color printing station with the following color printing station the current location of the reference marks at the first printing station is compared, and 909843/0881 _m J c) that the feed tension of the web at each printing station is varied continuously as a function of this comparison. 6. The method according to claim 3 or 4, characterized in that a) that a plurality of colors sequentially across the patterns formed by the resinous composition, and in accordance with these, are printed, b) that ^the mutual matching arrangement of the colors is continuously maintained by the current location of the reference marks in the vicinity of each color printing station following the first color printing station is compared with the current location of the reference marks at the first printing station, and c) the path length of the web between adjacent printing stations in function of this comparison continuously ariiert \ ^r. 7. The method according to claim 3 or 4, characterized in that a) that a plurality of colors sequentially across the patterns formed by the resinous composition are printed in accordance with them, b) that the mutual fitting arrangement of the colors is continuous is maintained by placing the current location of the fiducial marks in the vicinity of each on which first color printing station following color printing station with the current location of the reference marks at the first Printing station is compared, and c) that the angular velocity of each printing station following the first printing station during the Rotation is continuously varied depending on this comparison. 909843/0891 8. The method according to any one of claims 3 to 7, characterized in that that the current location of the fiducial marks in the vicinity of each printing station is at the same relative Position in relation to each plastisol pattern repeat is determined. 9. The method according to any one of the preceding claims, characterized characterized in that the tension between printing and gelling of the resinous composition and overprinting is significantly reduced with color. 10. A method for making elongated, continuous sheets of a resinous composition having a structured surface, characterized a) that a pattern of a heat-foamable resinous composition on a substrate is printed b) that the resinous composition is gelled, c) that color is printed over it in accordance with the pattern, and d) that the foamable composition by application is foamed by heat. 11. The method according to claim 10, characterized in that a) that a plurality of separate patterns formed from a resinous composition on the substrate is printed, wherein the resinous composition of at least one of the patterns is heat-foamable is to expand to a thickness greater than that of at least one of the rest of the resinous ones Composition formed patterns, and that, the patterns are printed in mutual alignment to each other be, and 909843/089 b) that at least one pattern conforms therewith is overprinted with color. 909843/0 8-91