KR880002643B1 - Method of and apparatus for producing decorative floor and wall covering - Google Patents

Abstract

A method comprises (i) applying plastisol activizing by heat to sheet-supports to continuously make plastisol coated-sheet, (ii) pressing plastisol-coated-sheet onto transfer paper contg. transferable patterns, (iii) activating a plastisol continuously and gradually for the transfer of patterns from paper to plastisol during gelfication by contact between plastisol and patterns, and (iv) producing wall coverings having gelficated synthetic-resin surface and patterns from sheets.

Description

Method for manufacturing decorative floor coverings and wall coatings and apparatus

1 is a side view showing a device for manufacturing plastic sheeting and wall coating material.

FIELD OF THE INVENTION The present invention relates to a continuous process for the manufacture of decorative floor coverings and wall coverings made of foils and wall coverings, in particular of synthetic resins and of polyvinyl chloride (PVC). The present invention also relates to an apparatus for carrying out the present process, i.e., an apparatus for producing a decorative patterned floorboard and wall coating material. Polyvinyl chloride foil (foil) is reinforced in the form of glass fiber bundles, screen or grid-like material, a variety of reinforcing fibers, etc., and is engraved with a pattern to form an image while painting by the coating method.

The foil or sheet is generally in the form of a sheet of a vinyl-based liquid composition having a polyvinylchloride group composed of a plasticizer and various additives according to a conventional method to form a gel or gel effect of the material. It is made to solidify at an elevated temperature of 180 ℃.

The present gelling is effective in an oven and may also be carried out by contacting a liquid sheet with a dense abrasive heated cylinder or drum at a desired temperature. This gelation is carried out simultaneously with the formation of the surface to be patterned by embossment or printing.

The gelling cylinders or drums are useful for industrially producing polyvinyl chloride sheet and wall coating materials or for producing sheets composed of vinyl materials of different compositions. Plastic products in the form of sheets, most of which are made of vinyl chloride, such as sheets, tents, curtains, canopies, floor coatings, wall coatings, and the like, are printed with thin layers in various colors to form decorative patterns.

These prints can use a variety of techniques, such as heliography offsets, silk screens with flat or rotating screens, flexography, etc., all of which are generally decorated after gelling plastic support materials. It is used to Direct printing of the plastic support to be gelled without gelation has disadvantages such as steric instability of the support that causes deformation or twist of the pattern produced by the print when the gelation becomes effective.

Naturally, it is theoretically possible to produce a decorative coating material in a continuous manner by combining a device for printing a plastic support in a gelling device. However, it has been found that this method is not practical due to various factors such as high investment cost for combining frit machine and gelling machine. This cost includes the cost of manufacturing the molds, printing drums or rollers required to apply the color to the support to be decorated.

For example, if five colors are applied to a polyvinylchloride support, then five printing drums or molds would be needed for each ink or color application process.

Therefore, the competition between the printing apparatus and the gelling apparatus is not suitable for economic reasons, and also has the problem of preventing the production of plastic foil. In addition, if the print system is lined up according to the plastic sheet material, the cost of processing and producing the decorative sheet material increases with such a system. In addition, when the patterning system is not associated with the production, it is necessary to wind the foil before printing and unfold the foil in the printing process, both of which are time-consuming processes.

Until now, a method of applying a pattern to foil by a transfer process using decalcomania, that is, a pattern performed by a paper sheet in which the pattern is transferred to plastic foil, has been proposed.

The paper used in this case is treated with a special composition before printing, which usually allows the ink to be printed on polyvinylchloride or the use of inks or dyes which are generally polyvinylchloride and polyvinylacetate copolymers. The ink or dye is only weakly adhered to the paper and is also thermally transferred to the decorative plastic support.

In other words, the decacomania carrier or material is treated with an agent that can promote the printing of the pattern printed on the paper support to the synthetic resin foil.

The transfer process is generally carried out at a temperature of 100-180 ° C. under low pressure. The print side of the paper and the surface of the decorative plastic support maintain contact for a time to allow the pattern to be transferred from the paper to the plastic support.

In this process, there is a need for equipment that can bring the patterned transfer paper into close contact with the preformed decorative plastic support at the desired temperature, and the machines designed for this purpose are so-called doubling or lining machines. It was developed as an Auma, Rotoodorn, and Rotocure-type machine.

The feed rate is generally relatively fast and is about 20-50 meters per minute. In other words, the linear speed at which the two sheets convey the pattern during the contact process is about 20-50 meters per minute.

After slightly cooling to, for example, 50-80 ° C., the paper is separated from the plastic support having the pattern transferred by contact.

This system has the advantage that the patterns of various colors are transferred to the plastic support at once, but in the past, the system has a disadvantage in that it is not effectively linked to the production of the plastic support.

Accordingly, the subject of the present invention is to provide a substantially continuous process for producing decorative plastic floorboards and wall coatings or other plastic sheets which eliminates the disadvantages of past systems.

Another object of the present invention is to provide an integrated process in which plastic sheet material is produced and patterned, thereby making the required equipment relatively inexpensive and thus minimizing the investment required to perform the process.

Another object of the present invention is to provide an improved apparatus for producing and patterning synthetic sheet materials, in particular polyvinylchloride sheet materials.

This object and the like will be apparent later, but may be obtained in the form of a paper having a pattern of plastic material coated with a plastisol layer in a manner of making a floor plate or wall coating material according to the present invention, before gelling the coated product. In contact with the pattern transfer surface of the paper sheet providing a transferable pattern, the paper and the plastisol-coated reinforcement were applied simultaneously to heat and pressure to gel the plastisol and to the plastisol surface gelled in the paper sheet. The movement of the pattern is effectively performed, thereby producing the plastic layer at the same time as the pattern transfer to the latter. The paper for transferring the pattern according to the present invention is provided to the film-forming layer of the product prior to applying the pattern to facilitate the transfer of the pattern to the plastisol where the pattern is gelled when the plastic sheet is formed.

Products of this type include 17 zein-amino acids for use in the present paper coating process- carboxymethylcellulose, silicone and polyethylene, synthetic resins such as polypropylene or polyamide.

In general, any thermally active release agent used to deliver decalcomania, which is transferable by heat, may be used in accordance with the present invention.

In a preferred embodiment of the present invention, the support for reinforcing the plastic sheet consists of a layer of fibers such as glass fibers, preferably a layer comprising a plastisol layer, which gels.

Thus, the support has a surface that can be coated with a second plastisol layer to which an entirely flat, patterned paper sheet is applied.

The latter plastisol layer is, of course, gelled and patterned at the same time as the transfer pressure is applied from the paper sheet.

This strengthening process is free from disproportionation when working with the second plastisol layer, and the plastisol layer gels.

If only one plastisol layer is applied to the strengthening process, the layer comes into contact with the patterned surface of the paper sheet.

The apparatus used to carry out the production process of the present invention comprises a plastisol coating means for applying the first plastisol layer to glass fiber paper and a means for gelling the first plastisol coating and a second plastisol layer therefrom. The means for letting out the lower part of the gelling means applied to the reinforcement and the patterned paper are brought into contact with the second plastisol layer. Means and patterns to ensure that the patterned paper providing the conveying paper sheet is maintained for the time required for the transfer and gelling of the second plastisol coating under the necessary pressure against the reinforcement coated with the plystisol, and the gelling plastic from the plastic sheet. Means for separating the paper body that is peeled off by being transferred to the stisol; It consists of a step consisting of a take-up means for the plastic sheet with the appropriate pattern to the wrapper plate and walls.

Means for carrying out any final steps before winding the patterned plastic sheet may be constructed. In the figure, the support 1 is covered with plastisol 2, which causes the pattern transfer species to come into contact with 3 so that gelation and pattern transfer in the drum 11 are simultaneously performed.

The support 4 can be a glass fiber layer or a gelled plastisol layer with a glass layer. In this case, the support is formed from glass layer 6, which contains plastisol 5, the first plastisol layer gelling in drum 8.

Example 1 Preparation of Sheet-Folded Supporter 1 Having Various Patterned Layers

Using the coating control device 14, a glass fiber layer having a surface weight of 500 g per square meter, formed of glass fiber plates producing units not shown in the drawings, was used as plastisol 5 supplied from reservoir 7, whether woven or non-woven fiber boards. It is coated at 400 g per meter and has the following composition.

Polyvinylchloride microsuspension, K-80,

PB 1702 Form-ORGAVYL company (France)

60 g of diisooctyl phthalate

Barium Zinc Stabilizer 2g

Calcium Carbonate (average diameter 14 microns) 45 g

Titanium dioxide 5g

2g wetting agent

The viscosity of the plastisol was controlled by adding 1-2% dodecylbenzene to about 2500 centipoise (CP). It should be noted that any thermally active polyvinylchloride plastisol commonly used for stencils can be used in the present invention.

The coated glass layer gels to a temperature of 150-155 ° C. in cylinder 8 and the support sheet obtained is cooled. The support sheet 1 is coated with developable plastisol 2, supplied from reservoir 9, on the order of 300 g per square meter and has the following composition.

K-68 polyvinylchloride microsuspension

PB 1152 C form-ORGAVYL company (France) product 40g

Polyvinylchloride Emulsion P68E Form

-40g of WACKER (Germany)

Polyvinylchloride blended resin suspension

PB 8015 Form-20g of ORGAVYL company (France)

20 g of butylbenziphthalate

Dioctylphthalate 35g

10 g of calcium carbonate (average particle diameter 14 microns)

2.40 g of blowing agent (azodicarbonamide)

Catalyst stabilizer (zinc oxide) 1.20 g

Titanium Dioxide 3.60g

The viscosity of this plastisol is controlled to 4000 poise with dodecylbenzene.

Coating is effectively carried out by adjusting or reversing roll coaters as shown in the figure.

The coated support is brought into contact with the gelling cylinder 11 at the same time as a roller is pressed against the outer surface of the pre-patterned transfer paper coated with the roller. The feed paper is released from roll 10.

The transfer paper is coated with a resin such as polypropylene with a release agent of about 20 g per square meter and a surface weight of about 50 g per square meter, and the paper is printed by heliography using an ink of the following composition.

VYNS Polyvinylchloride Polyvinylacetate Copolymer-

UNION CARBIDE company 17g

Methyl ethyl ketone 80g

20 g of methyl isobutyl ketone

Microliter K-Intercept-Shiba GIGA Co., Ltd.

The viscosity is adjusted with methyl ethyl ketone to produce an ink with a viscosity of 15 seconds.

I also used inks containing diffusion inhibitors that contained about 2.5-10% of trimellitic anhydride or benzotriazole, depending on the degree of stabilization required for the pattern.

Gelling cylinder 11 is maintained at a temperature of 130-190 DEG C. The peripheral speed of the drum and the speed of the paper layer in contact with the gelling layer is 20 meters per minute.

At this rate, the temperature is preferably maintained at 170 ° C. Contact is in most aspects of the drum circumference. When the paper layer where the pattern is subdued is released from the drum, the paper layer is wound on the roll and the plastic sheet is cooled. The roll 12 paper is reprinted for continuous processing.

The polyvinylchloride sheet product has a pattern transferred to the stretchable plastisol surface.

In particular, when the ink contains a diffusion barrier that provides a stable pattern on the resin sheet, I can use a reversing roll unit that is not shown in the drawing, between the cooling stand under drum 11 and the roll 13 where the end product is wound. To be laid. This can be applied at 320 g per square meter to a transparent surface layer having the following composition.

40g polyvinylchloride microsuspension

K-50, PB 1702 form-product made by ORGAVYL company

Polyvinyl chloride emulsion K-80, P-80 form 40 g

-Product made by WACKER

20 g polyvinylchloride suspension

K-65, C65V Type-WACKER

Butylbenzylphthalate 26g

Dioctylphthalate 70g

Taxonus Sobutyrate 7g

4g epoxidized soybean oil

3 g barium zinc stabilizer

0.2 g of UV absorbers

Degassing agent 0.2g

5g dodecylbenzene

The support for coating is passed through an oven heated to 200-210 ° C., at which temperature the blowing agent is decomposed to yield a chemical sponge, except for the part coated with the inhibitor or treated with ink.

This surface gels.

The produced pattern plate may be coated with a mechanical sponge or a foam having the following composition.

Polyvinylchloride Emulsion K-70, EF 701

Form-PLASTIMER (France) Products 100g

Butylbenzylphthalate 25g

Dioctylphthalate 25g

2 g of barium zinc stabilizer

Calcium Carbonate (average particle size 14 microns 20 g

3g silicone surfactant

The plastisol is mechanically foamed by mixing dry air in a mechanical beater in the form of a monodomix.

A mechanical foam having a density of 500 g / l and a weight of 300 g / m 2 is applied to the flooring. It is gelled at 175 ° C. in an oven.

The gelled and decorated sheet is wound at 13 positions.

EXAMPLE 2 Preparation of Wall Coating Material with Tensile and Stable Pattern

Glass fiber sheet 1 having a surface weight of 50 g / m 2 was directly coated with the following composition 2 at the 15 position.

Polyvinylchloride microsuspension K-68 59 g

Polyvinylchloride suspension K-68 50 g

Butylbenzylphthalate 25g

Dioctylphthalate 35g

Calcium Carbonate Powder 40g

2.40 g of blowing agent (azodicarbonamide)

Zinc Oxide Catalyst 1.20g

Titanium Dioxide and Slices 7g

Barium Zinc Stabilizer 2g

5g epoxidized soybean oil

The viscosity of the plastisol is adjusted to 5000 centipoise by alcohol. It is coated on the glass fiber sheet at a rate of 400 g / m 2.

A transfer paper of 3, i.e., 500 g / m 2 of paper coated with 20 g / m 2 of polyamide, is prepared, which transfers the pattern to the plastisol and at the same time gives a final coating on the plastisol.

The final coating applied to the paper can be illuminated with acrylics of the following composition.

20 g of acrylic resin (ELVACITE 2041)

-DUPONT de NEMOURS (USA)

Methyl ethyl ketone 100g

10% by weight of micro-amorphous silica (trade name SILOID, manufactured by GRACE) is added to the composition and used as an end-of-visibility treatment.

Paper is also printed in a pattern using the ink of the following composition.

Acrylic resin ELVACITE 2041 17g

Methyl ethyl ketone 80g

20 g of ethyl isobutyl ketone

ACRYLIC SECTION-ROWALID FORM PP.AC.

0.1-10 g of product made by ROWA (Germany)

Diffusion inhibitors may be added to the ink and added at 5% trimellitic anhydride to stabilize the pattern slightly, 10% by weight to significantly stabilize.

The pattern and the light agent are transferred simultaneously with the gelation of the plastisol by contacting the plastisol-coated glass sheet with the patterned surface of the paper when it reaches the gelling cylinder 11.

The conveying paper is then removed and the streaks and lights that convey the plastisol surface are passed through an oven at 200-200 ° C. which is not shown in the figure.

The resulting wall coating has a stable pattern, which is coated with a surface light agent and is detected at 13 positions.

Example 3 Preparation of Unstretchable Flapboard and Wall Coating Support 1

A glass fiber sheet having a weight of 50 g / m 2 was coated by controlling Plastisol 5 having a weight of 300 g / m 2 having the following composition at 14 positions.

Polyvinylchloride emulsion-K-80, 100 g

E80CA, WACKER

Dioctylphthalate 60g

25 g chlorinated paraffin

150 g of barium-cadmium-zinc stabilizer

Titanium Dioxide and Section 3.5g

1.5 g wetting agent

Viscosity Reducer 2-4g

Viscosity is controlled at 3500 centipoise. After gelling the plastisol in drum 8 heated to 140-145 ° C., a second plastisol 2 is applied to support 1 at a rate of 350 g / m 2 using coating apparatus 15.

This second plastisol has the following composition.

Polyvinylchloride Emulsion K-70 40g

Polyvinylchloride Emulsion K-80 40g

Polyvinylchloride Emulsion K-75 20g

40g calcium carbonate

Dioctylphthalate 40g

2 g of barium zinc stabilizer

Titanium Dioxide and Slices 5g

Support 1 coated with plastisol 2 is pressed onto a transfer paper and a cylinder at 180 ° C. The stripped paper is wound at 12 outer teeth and a transparent plastisol coating is applied on the patterned surface at a rate of 100 g / m 2 to make a floor covering.

This transparent plastisol composition is as follows.

Polyvinylchloride microsuspension-K-70,

PB 1302, ORGACYL manufactured 50g

Polyvinylchloride emulsion-K-70,

P 70, WACDER 50g

Santicizer 213

-40 g of Monsanto (Belgium)

3 g of barium zinc stabilizer

Octyl Epoxytearate 4g

UV absorber 0.2g

2g dodecylbenzene

The plastisol coating is degassed under vacuum, applied by reverse roll technology and gelled in an oven at 210 ° C.

The surface is woven by mechanical stamping before the cover is wound in the 13 position.

Claims (11)

Continuously applying a thermally activatable plastisol to the sheet support to form a plastisol-coated sheet, continuously compressing the plastisol-coated sheet into a transportable pattern of at least transfer species, and continuously and gradually increasing the The plastisol is thermally activated to gel the pattern of the paper while it is in contact with it, thereby transferring the pattern from the paper to the plastisol and forming a gelled synthetic resin surface formed from the sheet during gelation. Continuous manufacturing method of the floor covering and wall coating material comprising the step. The method of claim 1, wherein the plastisol applied to the support is stretchable and further includes stretching the plastisol while it is in contact with the top pattern. The method of claim 1 including coating the paper with a film layer prior to applying the pattern to facilitate transfer of the pattern to the sheet. The manufacturing method according to claim 3, wherein the material of the film layer is selected from polyethylene, polypropylene and polyamide resin. The method of claim 3, wherein the material of the film layer is silicon. 4. A process according to claim 3, wherein the material of the film layer is selected from those consisting of zein and carboxymethylcellulose. The method according to claim 1, wherein the support is formed by impregnating a fibrous layer into a plastisol and gelling the platisol-impregnated fibrous layer. The manufacturing method according to claim 7, wherein the fiber is glass fiber. A means for storing a supply of the first plastisol, a means for connecting the plastisol to include a fiber layer in the plastisol, and a means for gelling the layer containing the plastisol to form a support between the second and the sheet support. Means for contacting the furnace plastisol-coated plastisol with the second plastisol-coated sheet support with a transportable pattern moved by a paper layer and thermally activating the second plastisol to gelate the paper layer And a means for collecting the pattern from the paper, and a means for collecting the paper to which the pattern is conveyed, and a means for winding the sheet formed by gelling the second plastisol and transferring the pattern. 10. An apparatus according to claim 9, wherein the sheet support coated with the second plastisol and the pattern on the paper layer are brought into contact with a heated drum to gel the second plastisol and to effect pattern transfer from the paper layer. The floor covering and wall coating material produced by the method of claim 1.

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