NO754281L - - Google Patents

Abstract

Skumst of f-s. ammens to coating.

Description

The invention relates to a fibre-reinforced coating of wear layer and foam layer with an underlying additional barrier layer which, especially as a floor covering, has improved utility properties.

It is known to produce a floor covering from, for example, softened PVC, a fiber reinforcement and an underlying foam layer.

Should such a floor covering be sufficiently foot-resistant,

a sufficiently strong fiber reinforcement is required. In the case of glass fibres, a compact glass weave of 80 - 160 g/m 2. This must be firmly anchored in the foam layer or usually between the foam layer and the wear layer, for which a surface treatment using e.g. silanization or volanization as also usually an at least one-sided application of a connecting adhesive to the reinforcement.

The object of the invention is a fibre-reinforced foam composite coating consisting of a utility layer, an open-pore foam layer, a barrier layer closed on the back and a fiber reinforcement in the foam layer in the utility layer or preferably at the border of foam and utility layer.

The composition is particularly suitable as a floor covering, possibly also in smaller thicknesses as a wall covering. Over-■ rapidly, such a three-layer composition of wear layer } open-pore foam layer and barrier layer has a superior rebound elasticity and high point pressure load capacity, although a comparatively light fiber reinforcement can be used and this is anchored without adhesives only with the help of roller pressure, if necessary, although using an adhesive paste in the composition.

The barrier layer, in connection with the open-pored foam layer, is clearly the reason why a high degree of improvement in foot sound attenuation is achieved when excellent indentation conditions are achieved.

It turned out that in case of point pressure loading, the air displaced to the side after unloading the outer layer returns within a short time and causes the rapid decline of the wear layer.

A loss of air volume when pressure is applied to the subfloor is prevented by the barrier layer.

When using a closed-pore foam material, however, with an otherwise similar construction, the coating also displaces point pressure load and the air through the fine cell walls. However, during relief, the air volume returns only very slowly and also only partially, which results in a reduced ability to return.

A further advantage of the barrier layer is the insulation of the foam against the influence of moisture from the subfloor. Walking-one of in laying used glue in.' in the foam and plasticizer from the foam into the adhesive and vice versa, is reliably prevented. At the same time, this ensures unchanged conditions of use while maintaining the physical properties.

The outer layer or the cover layer preferably consists of PVC. However, other materials such as polyurethane, polyethylene or natural or synthetic rubber are also possible.

If used, the thickness can be 0.8 - 4 mm, usually 1 to 3 mm thick, in special cases up to approx. 6 mm, whereby a homogeneous, i.e. single-layered structure of e.g. a colored possibly continuous pattern or in itself marbled track or a heterogeneous i.e. multi-layer structure of e.g. a

■patterned or embossed upper layer and a lower non-patterned layer or a thicker overlay' and an e.g. the printed underlying foil.

In the case of using PVC, it is usual to have a soft PVC track that is possibly filled and designed.

The foam material layer, usually in thickness from 0.5 - 8 mm preferably 0.5 - 5 mm should be an open-pored or as open-pored foam layer as possible consisting of one layer or possibly two or more equal or different layers, as the anchoring of several layers preferably takes place by wet-on-wet application with corresponding foam pastes and common gel formation.

The density of the foam layer should be 0.35~0.60 g/cm<2> preferably 0.40 - 0.55 g/cm 2.-. —Suitable materials for this are possibly softened PVC polyurethanes, polyethylene and others. The single-layer barrier foil or the barrier layer consists of one or more connected layers which are completely or as much as possible impermeable to e.g. solvent, plasticizer and gases - thicknesses from 0.05 - 0.5 mm, preferably 0.1 - 0.3 mm.

Suitable materials for this are foils of PVC, polyethylene, polyurethane, etc., possibly parchment paper in pre-prepared form, preferably of pastes in particular. PVC pastes coated foils..

Barrier film and foam layer are usually produced directly from pastes as explained in more detail below. In special cases, the barrier layer can lie between two foam layers or under the foam layer, a further foamed springy and insulating layer is placed, whereby the application of a cement floor is unavoidable.

The fiber reinforcement can consist of suitable glass fibers or threads in the form of weaves, piles, possibly fiber bundles or crossing plies. Preferred and surprisingly sufficient are lightweight fiber reinforcements from 20 to 70, particularly preferred 20 to 50 g/m 2 , although compact reinforcements from 70 to approx. l60 g/m 2 is possible for very strong point loads, e.g. on sports grounds, workshop halls, stables etc.

The fiber reinforcement is usually preferably placed at the boundary of the foam layer and the useful layer. However, with the same result, it is possible to introduce the fiber reinforcement by pressing into the still wet foam layer or to place between two foam layers or between two layers of use or the wear layer, where appropriate one of the two possibly touching layers is also wet. and not jellied. Directly on the fiber reinforcement, especially in some cases, the adhesive paste can form a thin layer and contribute to anchoring the fiber reinforcement in the composition.

All those known in the art are suitable as adhesive pastes. However, such is preferred on the basis of copper lymerisates of vinyl chloride with amounts of 3 to 25% by weight, preferably 5 to 20% by weight of vinyl acetate, usually together with a plasticizer.

The comparatively light fiber reinforcement works surprisingly with or without adhesive paste as a "distributor plate"■ and distributes as it acts punctually on the floor or the utility layer evenly - on a larger surface' or underlying foam layer, which in turn, with the help of the barrier layer, causes a rapid decline.

For the production and the composition according to the invention, one or more thermoplastic or utility or wear layers produced by the paste ironing method can serve to the same extent as one or more pre-produced or preferably wet-formed foam layers from pastes and one or more pre-produced or preferably on-site wet-formed barrier layers. However, it is . preferred directly on each other

the following work processes from a compact paste to form the barrier layer and then wet-on-wet to apply one or more layers of the same or different layers of foam-forming pastes and preferably together to gel the applied layers.

A further object of the invention is therefore a method for the production of a foam composition coating according to the invention, the method being characterized in that i. continuous working method applies to a suitable tape substrate in sequence one or more applications of one compact ironing paste, a barrier film on top of that by one or more applications of a foam paste, a layer of foam material and then or in a separate work process and kascheres- one or more useful,

.or wear layer or is formed from pastes as a -fiber reinforcement is incorporated into the foam in the useful layer or preferably on the border between foam and useful joint.-

Such coating can, for example, take place with a reverse roll-coater or similar equipment. Endless steel bands or Relaise-paper are usually used as tape backing. A pre-formed barrier film can also be added which, if necessary, simultaneously serves as a tape substrate. The fiber reinforcement usually as woven strips of working width can be allowed to run to the same apparatus and preferably applied or impressed on the still wet layer..

The gel formation is usually carried out together after the last coat or also after one. or several times of paste application at the same time

it applies approx. 170 - 250°C usually in a heat tunnel, e.g. by IR heating.

The product thus produced on a coating machine that has not yet been equipped with a utility or wear layer can be stored and shipped as an intermediate product.

The application of the useful layer takes place by masking, for example at temperatures of 100 - 150°C and a lower roller pressure of approx. 2-3 atmospheres, unless the useful layer is formed by an ironing paste applied directly one or more times.

When laminating, the use of an adhesive paste is appropriate, especially when fiber reinforcements such as the top layer are at the border of the useful layer. In the case of compact fiber reinforcements over approx. 70 g/m<2>, the use of adhesive paste is advisable, likewise for particularly thick composite materials. Preferably light fiber reinforcements do not in every case require an adhesive paste, especially not when reinforcements are incorporated into a foam or useful layer formed from paste that is still wet. Furthermore, there is no need for any adhesive paste in the case of only thin useful or wear layers or thin lower useful or wear layers.

With regard to the ironing pastes used, there are no restrictions among the known plastics, plasticizers, pigments etc.

If foam is used, suitably a mechanically gas-treated paste, as in a Eur.oinatic-, Oakes- or similar mixer, air is mixed in finely divided into a paste. However, it is also possible to use propellant with low decomposition temperatures of 80 - approx. 120°C as e.g. "porophore" D33.

The manufacturing method, especially the one according to

requirement 4 enables a. continuous and uncomplicated production and yet high-quality products are obtained.

The degree of improvement in walking noise reduction is measured according to

DIN 52 210, the measurement change (6 hours storage at 80°C) according to DIN 51 692 and the residual impression according to DIN. 51 955-

The principle structure of the composition according to the invention is shown in the drawing in cross-section.

Beneath the utility or wear layer 1 is the open-pored foam layer 2, for example at the border of these the fiber reinforcement 3 and as the bottom layer the barrier layer 4.

Example 1.

To form a barrier layer, a PVC paste is prepared according to the following recipe:

65 parts by weight E-paste PVC with a K value of 70

33 dioctyl phthalate

2" epoxidized soybean oil

30- " chalk

1 color

0.5 tin stabilizer.

This paste is applied with a reverse roll-coater in one

quantity of 300 g/m 2 on a steel band.

Directly on the wet paste layer, a mechanical gas-treated PVC foam paste is applied to form the foam material layer

in 3 mm thickness which produces a foam of density 0.4 g/cm 2.

For the production of this foam paste, a mechanically gas-treated paste is produced in a euromatic mixer by incorporating air, using the following recipe: 250 parts by weight of E-paste PVC, K-value 70, emulsifier-containing 100 "butyl benzyl phthalate

80 " dioctyl phthalate

100 chalk,

In the foam that has not yet formed, according to the invention, a 35 g/m 2 glass fabric is reached.

The two iron layers lying on top of each other gel together at 190°C in a gelling channel and are removed from the steel band.

The foam web thus produced, equipped with a barrier layer, is coated on the woven side with an adhesive paste consisting of 55 parts by weight of copolymer, consisting of 10% vinyl acetate and 90% polyvinyl chloride with a K-value of 65

25 " butyl benzyl phthalate-

20 dioctyl phthalate

in an amount of 150 g/m 2and is masked with a 2 mm thick homogeneous thermoplastic method according to the calendering method produced utility or wear layer under IR radiation at 130°C on a roller.

The 5 mm thick composite coating constructed in this way had a degree of improvement in walking noise reduction of 20 dB, a measurement change of 0.1%. and one residual indentation after 24 hours of loading' and unloading of 0.11 mm.

Example 2.

It is produced in the same way as in example 1, a track consisting of barrier foil, foam layer and glass fiber substrate, with the exception that a coater equipped with a revolving steel band was used and the barrier foil had a thickness of 0.2 mm foam material,

2 a thickness of 2.5 mm and the glass fabric a basis weight of 30 g/m.

No adhesive paste was used.

This graduate. pre-product applies to a likewise on a steel band produced heterogeneously from two ironing layers built up useful layer of a total of 1.3 mm.

1st application 1000 g/m.<2>

65 parts by weight E-paste PVC, K-value 70

34 " .. butyl benzyl phthalate

1" epoxy soybean oil.

5" chalk

2" colour

1" stabilizer.

,2. application 1000 g/m<2>

57 parts by weight E-paste PVC, K-value 70'

42 " dioctyl phthalate

1" epoxy soybean oil

85 " Chalk

0.5" stabilizer

4" color

Gelation temperature: 250°C.

Example 2a.

In a similar way as in example 2, the composition referred to there is prepared, however the useful layer was

produced in a .separate work process on a coater with steel band.

The utility layer produced in this way is masked and embossed analogously - example 1, with the pre-product of barrier layer, foam web and glass fabric using copolymer paste.

The manufactured 4 mm thick, composite coating has a degree of improvement of 20 dB, a measurement change of 0.03$ and a residual impression after 24 hours' loading and unloading of 0.12 mm. Example 3.

One. analogously to example 1, however, a 1.5 mm thick foam sheet and a 0.2 mm thick barrier foil were prepared and gelled after laying the glass fabric. A 0.45 mm thick PVC layer is then masked and embossed, which was produced from a paste according to the recipe analogous to example 2, 2nd application and with a 0.15 mm thick soft PVC foil printed on the back.

The property of the 2.3-mm thick composite coating is 17 dB improvement degree of walking noise protection, measurement change 0.04$,

residual impression after 24 hours of loading and unloading of 0.05 mm.

Claims (8)

1. Fibre-reinforced foam f-composite coating consisting of a utility or wear layer, an open-pore foam layer, a barrier layer closed on the back and a fiber reinforcement in the foam layer, in the utility layer, or preferably on the border between foam and utility layer. 2. Foam composite coating according to claim 1, characterized by . that directly above a fiber reinforcement lying at the boundary of the foam layer and the utility layer, a layer formed from an adhesive paste is arranged. 3. Foam composite coating according to one of claims 1-2, characterized in that the foam layer has a density of 0.35 - 0.60 g/cm, preferably 0.40 - 0.55 g/cm. 4..; Method for the production of foam f-composite coating according to one of the claims .1-3"characterized by "that in a continuous working mode it is applied to a suitable track substrate in sequence by one or more applications of a compact ironing paste, a barrier foil on top of that by a or multiple application of a foam paste, a foam material layer' and then or in a separate work process and one or more utility or wear layers are masked or formed from pastes, as a fiber reinforcement is incorporated into the foam in the utility layer or preferably at the border of foam and utility layer . 5. Method according to claim 4, characterized "in that the wet-applied" layer and the barrier foil and one or more foam layer gels together when heated. 6. Method according to one of claims 4 or 5, characterized in that the fiber reinforcement is applied or impressed on the still wet foam layer before the gel formation. - 7. Method according to one of the claims 4-'63. characterized by . that an adhesive paste is applied directly to the fiber reinforcement, 8. Method, according to one of claims 4-7, characterized in that an adhesive paste is used for masking a useful layer on a pre-product consisting of a foam layer and barrier foil.