GB2108426A - Method of making decorative laminated products such as tiles, panels or webs - Google Patents

Method of making decorative laminated products such as tiles, panels or webs Download PDF

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Publication number
GB2108426A
GB2108426A GB08212782A GB8212782A GB2108426A GB 2108426 A GB2108426 A GB 2108426A GB 08212782 A GB08212782 A GB 08212782A GB 8212782 A GB8212782 A GB 8212782A GB 2108426 A GB2108426 A GB 2108426A
Authority
GB
United Kingdom
Prior art keywords
plastics
cork
layer
cellulosic material
tile
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB08212782A
Inventor
Ulf Lennart Ahlstedt
Sven Arvid Ryden
Eduard Lussi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarkett AB
Original Assignee
Tarkett AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tarkett AB filed Critical Tarkett AB
Publication of GB2108426A publication Critical patent/GB2108426A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/14—Layered products comprising a layer of synthetic resin next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/06—Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B32B2264/067—Wood particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/02—Cork
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Floor Finish (AREA)
  • Laminated Bodies (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Finishing Walls (AREA)

Abstract

A laminated decorative tile for flooring purposes, is made by forming a base layer of granulated cellulosic material e.g. cork in a matrix of fusible plastics, and placing on the base layer a thin decorative layer of cellulosic material e.g. cork with natural holes and recesses therein. A film of fusible plastic is applied to the decorative layer and the laminate hot pressed and immediately cooled in a cold press to force granules of the base layer, in the hot pressing, into and to fill the holes and recesses of the decorative layer.

Description

SPECIFICATION Method of making decorative laminated products such as tiles, panels or webs This invention relates to a method of making decorative laminated products in tile, panel or web form.
Decorative coating or covering materials are produced in a multitude of embodiments and may consist for instance of synthetic or natural materials or combinations thereof. The materials may present a smooth or relief wear resisting surface. Mostly, the latter alternative is preferred for both practical and aesthetical reasons. Relief materials have a threedimensional appearance rich in contrasts, but to produce this appearance the pattern and relief must be perfectly synchronized. An ordinary relief embossing to which the plastics surface is subjected and which is not in good register with the printing pattern does not bring about the above-mentioned effect.
Apart from all wood imitations in plastics, excellent cork imitations with relief surfacing have been made during the last few years. Like all pure natural materials, such limitations are usable for both wall covering and flooring purposes. As for coating and covering materials comprising a combination of natural and synthetic materials in the form of a relatively thick plastics sheeting covering the natural material, conditions are slightly different in that these coating and covering materials are only available with a smooth wear resisting surface since one has not succeeded in developing any method of securing a thick wear resisting plastics layer on, for instance, cork without neutralizing the relief effect at the same time.
Such smooth cork flooring tiles, which have been manufactured for a great many years, are composed of a wear resisting layer of plastics, a decorative layer, a resilient layer and a base layer. The wear resisting layer preferably consists of a calendered or coated plastisol of transparent softened PVC of high resistance to wear and stain repellency. The resilient layer consists of a sheet made by lathe-turning or splitting blocks of cork granules. This sheet is, if necessary, refined by prelamination with a thin decorative cork veneer. The base layer serves as a mechanical stress relieving means and said layer or a further layer complementary of the wear resisting layer counteracts dishing of the tiles and delays diffusion of moisture from the sub-floor.For the last-mentioned layer use is made of a softened PVC film which has the same modulus of strength as the wear resisting layer or a higher modulus than said layer. This will result in a balance of forces in the finished floor structure and ensures that the tiles remain planar.
Cork is a material which is excellently suited for the purpose concerned, but its enormous porosity and air content give rise to problems at the tile manufacture. Being a natural product, cork besides suffers from numerous defects which appear as big or small holes and recesses that are not acceptable in the finished tiles. This necessitates a severe selection and implies expensive waste in the production. Especially thin cork veneers of but little compression are usually strewn with holes which must be stopped up before the sheets can be provided with laminates.
The wear resisting layer is usually united with the underlying layers by pressure gluing. One has also tried to manufacture cork webs continuously including varnishing and roll gluing, but these experiments have not met with any great success.
Summarizing, it may be established that natural materials combined with a wear resisting layer of plastics film occur only in the form of cork tiles with a smooth covering film layer.
The object of the present invention is to permit, by the use of a novel manufacturing method, making both smooth and relief tiles, panels and webs of this type, which are suited both as wall coverings and floorings and which in view of the insignificant waste are cheaper than the products hitherto made.
The object of the invention is realized by granulating a cellulose material, particularly cork, mixing the granulate with a fusible plastics and making a mat therefrom, cutting from a cellulosic material of the same kind as or another kind than the first mentioned cellulosic material thin slices which in the state obtained with the through holes and recesses therein are placed on the mat thus made, applying a film of fusible plastics on the thin slices of cellulosic material and compressing the laminate thus obtained under supply of heat for melting the plastics and urging the material of the mat into the holes and recesses of the slice, and then cooling the compressed tile.
The most characteristic feature of the method according to the invention is the use of an entirely new type of base layer which consists of granulated cellulosic material in a matrix of fusible plastics. If the cellulosic material is cork and the base layer has a thickness of about 2 mm, the particle size must not exceed 2 mm and is preferably below 1.5 mm. When at the manufacture of the tile, panel or web the thin decorative layer is placed on said base and the layers are subjected to a compressing operation at such a temperature that the plastics cures/melts, the plastic mass with its cork filling will "rise" into and fill out the holes and recesses of the decorative layer, whereby a decorative layer with a smooth surface and perfect appearance is obtained.The filling material can be given any desired nuance, for instance a nuance which more or less conforms with the predominant nuance of the decorative layer or constrasts with said nuance.
The wear resisting layer which normally consists of a precoated 0.5 mm film of softened PVC, is placed on the decorative layer before said layer is united with the base layer, i.e. all three layers are united with each other in the same operation. In the compressing operation the wear resisting layer is thus also molten so that it well adheres to the decorative layer. The wear resisting layer may also consist of a coating material other than a film, such as plastisol, different kinds of lacquers, polyurethane etc.
After the product has been compressed for a predetermined time it is transferred to a cold press in which it is cooled and simultaneously subjected to a higher pressure, suitably approximately twice as high as that in the hot press. The tile, panel or web which is removed from the cold press, has the above-mentioned advantageous appearance and an entirely smooth wear resisting surface and is usable for wall covering and flooring purposes.
To provide a tile, panel or web with relief surface there is required a natural material having, what may be called, a "memory of its resilience". Cork is such a material. The cork with its percu liar cellular system is compressed when subjected to pressure but once the load has been relieved it partially springs back after some time lag. As the load in the above case is not relieved until the plastics has cooled off, the state of tension of the cork is blocked so that the tile, panel or web obtains the smooth wear resisting layer face.
If, however, the tile, panel or web is subjected after cooling to heating in a free state (i.e. without being acted upon by the press plate or like means) to a temperature exceeding the softening temperature of the plastics, the state of tension of the cork relaxes and the cork returns to the shape it had before the pressing operation. If use is made of softened PVC, a reheating temperature of 70-1 50"C is suitable. After reheating the tile, panel or web is allowed to cool, likewise in a free state. By this change of state one obtains a relief wear resisting layer face of very advantageous appearance, since the relief of the wear resisting layer is controlled by the material of the decorative layer, whereby a perfect synchronization of pattern and relief is obtained.
As hinted at in the foregoing, the cork has proved extremely advantageous for the manufacture of a tile of natural material having a relief face, in which the decorative appearance depends upon the structure and composition of the thin layer or veneer employed. The layer is produced by splitting a block of cork conglomerate into thin sheets which display a range of different growth zones of varying relative orientation and compressibility. The different zones possess varying resilience and restorative capacity, whereby the relief formation can vary from simple knottiness to a perfect work of art of nature.
Although cork is the most suitable material forthe time being, other cellulosic materials are also conceivable, that have or may be given the "memory of resilience" required for the relief formation.
Applying the method according to the present invention, one gains the special advantage that no cellulosic material is wasted, as all waste is converted into granulate. This of course entails savings of cost beyond those obtained because the decorative layer need not be stopped up and there is only an insignificant discard of finished products.
A tile, panel or web manufactured in the abovedescribed manner and having a base layer of granulated cellulosic material in a matrix of fusible plastics, a thin decorative layer on the base layer and a wear resisting layer of a plastic film of fusible plastics, which latter layer by a cold pressing operation after the hot pressing has a smooth upper face or by renewed heating in a free state after the cold pressing operation has a relief surface, is highly decorative and extremely advantageous in use because it is both wear resistant and comfortable to walk on owing to its resilience and insulating capacity.
The invention will now be more fully described with reference to an example.
A 1 mm thick cork veneer was placed on a calendered 2 mm base layer of softened PVC and cork granulate having a particle size of up to 1.5 mm, and a 0.5 mm thick wear resisting layer film of softened PVC was then placed on said cork veneer.
The material was put into a press mould having distance means and provided on both sides with paper coated with a mould release agent. The pressing operation was performed in a hot press (180"C) under successively increasing pressure up to 2 kg/cm2 for five minutes. The mould with the material contained therein was then transferred in hot condition to a cold press for five minutes, whereupon the cold product was removed from the mould. The product now was entirely planar, but at the subsequent heating to 1 300C for two minutes a relief pattern was formed on the surface, the appearance of which was determined by the structure used for the cork veneer.

Claims (7)

1. A method of making decorative laminated products, such as tiles, panels or webs, characterised by granulating a cellulosic material, particularly cork, mixing the granulate with a fusible plastics and making a mat therefrom, cutting from a cellulosic material of the same kind as or another kind than the first mentioned cellulosic material thin slices which in the state obtained with the through holes and recesses therein are placed on the mat thus made, applying a film of fusible plastics on the thin slices of cellulosic material, and compressing the laminate thus obtained under supply of heat for melting the plastics and urging the material of the mat into the holes and recesses of the slice, and then cooling the compressed tile.
2. A method as claimed in claim 1, characterised by effecting the cooling of the product in a cold press in which the tile is subjected to a higher pressure than in the hot pressing operation.
3. A method as claimed in claim 1 or 2, characterised by subjecting the tile after cooling to free heating and cooling for relief formation of the plastics film.
4. A method as claimed in any one of claims 1-3, characterised in that at least the thin layer of natural material is cork.
5. A method as claimed in any one of claims 1-3, characterised in that at least the granulated natural material is wood.
6. A method as claimed in any one of the preceding claims, characterised in that the plastics are softened PVC.
7. A method of making decorative laminated products, such as tiles, panels or webs, to be performed substantially as hereinbefore described and claimed.
GB08212782A 1981-05-05 1982-05-04 Method of making decorative laminated products such as tiles, panels or webs Withdrawn GB2108426A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
SE8102784A SE435199B (en) 1981-05-05 1981-05-05 KIT FOR PRODUCING DECORATIVE PLATES

Publications (1)

Publication Number Publication Date
GB2108426A true GB2108426A (en) 1983-05-18

Family

ID=20343727

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08212782A Withdrawn GB2108426A (en) 1981-05-05 1982-05-04 Method of making decorative laminated products such as tiles, panels or webs

Country Status (10)

Country Link
JP (1) JPS581557A (en)
AT (1) AT381064B (en)
CA (1) CA1183440A (en)
DE (1) DE3215684A1 (en)
FI (1) FI74906C (en)
FR (1) FR2505257A1 (en)
GB (1) GB2108426A (en)
NL (1) NL8201781A (en)
NO (1) NO156855C (en)
SE (1) SE435199B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2072192A2 (en) * 1993-05-13 1995-07-01 Quetglas Manuel Vilar System for ornamenting the surface of tiles (slabs) made from natural materials such as cork
EP0904932A2 (en) * 1997-09-29 1999-03-31 Kabushikikaisha Edagumi Floor material and flooring using the floor material
WO2011149370A1 (en) 2010-05-25 2011-12-01 Dyn Cork - Technical Industry, Lda. Cork fabric and process for the production thereof
CN105768367A (en) * 2016-04-19 2016-07-20 广州润凯实业股份有限公司 Method of making glitter soles, glitter sole and shoe

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0274337A (en) * 1988-09-09 1990-03-14 Daido Kasei Kk Sheet prepared by hot contact of cork sheet with vinyl sheet
DE9115156U1 (en) * 1991-12-06 1992-02-13 Heidtmann, Barbara, 5810 Witten Arrangement for covering the walls of containers for holding animals and/or plants

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1187576A (en) * 1968-06-12 1970-04-08 Plexowood Inc Method and apparatus for Moulding Wood-Resin Articles

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2072192A2 (en) * 1993-05-13 1995-07-01 Quetglas Manuel Vilar System for ornamenting the surface of tiles (slabs) made from natural materials such as cork
EP0904932A2 (en) * 1997-09-29 1999-03-31 Kabushikikaisha Edagumi Floor material and flooring using the floor material
EP0904932A3 (en) * 1997-09-29 2000-08-09 Kabushikikaisha Edagumi Floor material and flooring using the floor material
US6212838B1 (en) 1997-09-29 2001-04-10 Kabushikikaisha Edagumi Floor material and flooring using the floor material
WO2011149370A1 (en) 2010-05-25 2011-12-01 Dyn Cork - Technical Industry, Lda. Cork fabric and process for the production thereof
CN105768367A (en) * 2016-04-19 2016-07-20 广州润凯实业股份有限公司 Method of making glitter soles, glitter sole and shoe
CN105768367B (en) * 2016-04-19 2017-11-17 广州润凯实业股份有限公司 A kind of method for making Ge Lite soles, Ge Lite soles and shoes

Also Published As

Publication number Publication date
FI821540A0 (en) 1982-05-03
NL8201781A (en) 1982-12-01
FI74906C (en) 1988-04-11
FI74906B (en) 1987-12-31
ATA165782A (en) 1986-01-15
NO156855C (en) 1987-12-09
FR2505257A1 (en) 1982-11-12
CA1183440A (en) 1985-03-05
DE3215684C2 (en) 1990-09-20
NO156855B (en) 1987-08-31
DE3215684A1 (en) 1982-12-02
JPH0351579B2 (en) 1991-08-07
JPS581557A (en) 1983-01-06
AT381064B (en) 1986-08-25
SE8102784L (en) 1982-11-06
SE435199B (en) 1984-09-10
FI821540L (en) 1982-11-06
NO821452L (en) 1982-11-08

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