GB682078A - An improved manufacture of surface covering sheets - Google Patents

Abstract

A binder or cement for use in making a covering sheet for floors, walls, &c., is made by reacting a mixture of rosin acids and high molecular weight unsaturated fatty acids in which the ratio of fatty acids to rosin acids is between 1 to 3 and 3 to 1 with a heat-reactive, oil-soluble phenol-formaldehyde condensate to an amount between 1 and 6 parts by weight to 28 parts of the mixed acids at a temperature of 300 DEG to 450 DEG F. until condensation is substantially complete, adding a polyhydric alcohol to the resulting resin mixture in amount sufficient to reduce the acid number to below 10, and heating the mixture at 400 DEG to 575 DEG F., incorporating in the resulting ester a siccative oil in amount of 1 part of the oil to between 2/3 and 9 parts of ester by weight, and bodying the resulting mixture to a cementitious gel, e.g. by heat polymerization or air blowing. While the preferred mixture of rosin acids and fatty acids used is crude or refined tall oil or tall oil pitch, the fatty acid component of the mixture may be derived from cottonseed pitch, soya bean pitch, linseed pitch, linseed oil, chinawood oil, fish oil, soyabean oil or tall oil. Heat reactive phenolformaldehyde condensates specified are p-phenyl-phenolic-, tertiary butyl-phenolic- and cresylic - resins. Polyhydric alcohols specified are glycerine and diethylene-, polyethylene-, propylene- and ethylene-glycols. Siccative oils specified are chinawood-, soya bean-, dehydrated castor-, perilla-, hempseed-, oiticica- and linseed oils, soya bean oil which has been reacted with maleic anhydride, linseed oil- and fish oil-dicyclopentadiene copolymers and chinawood oil-soya bean oil copolymer. Fillers which may be added to the gel are ground limestone, precipitated calcium carbonate, gypsum, barytes, asbestos, glass wool, mineral wool, diatomaceous earth, carborundum, alundum, ground slate flour, and minor quantities of ground or shredded wood, ground cork, sawdust, leather-dust, shredded rag and paper fibres. Pigments specified are oxides of titanium, antimony and zinc, lithopone, zinc sulphide, titanium extended pigments, natural and synthetic oxides, umbers, ochres, chrome oxide and hydrate, copper phthalocyanine blues and greens, indanthrene blues, toluidine reds, benzidene yellow, hansa yellow, cadmium red and yellows, ultramarine blue, black pigments, chrome orange, molybdate orange, zinc yellow, iron blue, chrome green, lithol reds, lithol rubine and tungstated and molybdated pigments. Non-drying oils, such as castor oil and curing agents, such as lead, manganese and cobalt naphthenate driers, zinc oxide and lime, may be added to the compositions. Synthetic or natural resins such as coumarone-indene resins, East India resins, run copals or other fossil resins, such as kauri, poutianak and boea, copal-type synthetic resins, rosin-modified maleic resins, ester gum and other rosin esters may be used together with alkyd resins including the drying oil modified type, the urea modified type, the natural resin-modified type, the phenol modified type and the phenol and oil extended type. Resins obtained by polymerizing oils which have been cracked at high temperatures may be used with the phenolic resin, e.g. heat-reactive aromatic type of olefinic hydrocarbon polymers obtained from petroleum, petroleum resins consisting of polymerized diolefins, and drying oils that have copolymerized with styrene, substituted styrene or cyclopentadiene, and "Petrex" resins (Registered Trade Mark). In one example, tall oil or tall oil pitch is heated with a heat reactive phenol-formaldehyde condensate and the resulting product is heated with pentaerythritol. The ester thus produced is then blended with a chinawood oil-soya bean oil copolymer in the presence of litharge and bodied by air blowing at 150 DEG to 220 DEG F. until a cementitious gel is produced. Other formulations for producing the fatty-acid-resin ester and cementitious gels are given. In producing a covering sheet, for surfacing floors, walls, stairs, furniture tops, counters and floors in buses, slips and railroad cars, a backing sheet, e.g. of burlap, cotton cloth or felt, is provided with a surface layer of the binder upon and bonded to one surface of the backing layer (see Group VIII).