SE461776B - DECORATED, IRRIGATED CROCHET-RESISTANT COATING - Google Patents

Description

15 20 25 30 35 461 776 2 objects by forming a colored backing blank of incompletely cured, filled, resinous material, printed decorations thereon with suitable paints and subjecting the blank to high frequency heat treatment to cause the paints to cure.

A transparent incomplete hardened, filled, plastic sheet of similar resinous material can then be applied to the previously formed blank with the printed surface of the colored substrate in contact with the transparent sheet. The product is formed by casting and melting the material using heat and pressure.

U.S. Pat. No. 3,024,154 relates to a process for embossing a thermoplastic film, which comprises heating a relatively thick sheet of thermoplastic to a temperature above the softening temperature and the temperature of the film, bringing a surface of the film in a relatively cold state into contact. with the surface of the thicker sheet, joins the film and sheet between a cooled, toothed embossing means and a back pressure means for pressing the film and the sheet into the teeth of the embossing means, and then the composite structure cools.

U.S. Pat. No. 3,325,332 relates to a method of laminating a relatively thick plastic film with a compatible plastic foam by causing the foam to soften in heat, whereupon the film and the foam are compressed.

The above-mentioned properties have not been possible to eliminate satisfactorily by working according to the state of the art.

The present invention relates to a decorated, embossed curvature-resistant surface coating, which comprises a main body layer with its upper side and its underside, the layer comprising sunken parts of the layer, and raised parts of the layer, which are raised in relation to the recessed parts, a reinforcing material layer between the upper side and the lower side, a resin-containing wear layer bonded to the upper side of the main body layer and a decoration between the wear layer and the upper side. The surface coating is characterized in that the main body layer comprises a molten matrix of resinous dry mixture containing homogeneously distributed originally hollow non-thermoplastic particles; that the submerged parts consist of first submerged parts and second submerged parts, the latter comprising molten resin in a substantially coherent phase and substantially completely crushed non-thermoplastic particles, the other submerged parts having a greater depth than the first down - lowered parts; and that the raised portions of the layer are raised relative to the first and second immersed portions, the first immersed portions and the raised portions comprising molten resin in a relatively non-continuous phase with non-crushed and substantially only partially crushed non-thermoplastic particles therein.

The porous backing material may be a weakly sintered resinous dry blend with hollow non-thermoplastic particles and may be reinforced with a material such as glass filament. When the term "capable of being permeated" is used in the present description and claims, it is intended to express either that the film is permeable at the beginning or that it can be made permeable at a later stage of the process. before embossing the film and melting the resins therein, the film can be cut to the desired dimensions of the plate together with the pattern portions, while it is on the removable carrier, without the carrier being covered by the cutting and brought in contact with the top of a piece of the backing material of a similar type, whereupon the removable carrier is removed, or the film may be applied to the top of a sheet of the backing material and the film and backing material be edge cut together with the pattern on the film at the same time. Adhesive may be applied to the surface of the film which is intended to be brought into contact with the backing material or In addition, the adhesive can be included in the ink used to decorate the film.

When laminating the film with the backing material, heat was used at a temperature sufficient to activate the adhesive only together with light pressure to ensure that the film bonded to the backing material. In both cases, the backing material with the decorated film is then subjected to high frequency electrical energy and pressure in a flat bed press with a cooled embossing surface and a cooled back pressure plate to emboss the structure, melt the resins and make the film impermeable. The film can be made of vinyl and can be perforated to allow air, which is enclosed in the deeper recesses of the embossing plate, to escape. The perforations are sealed during embossing and the melting of the resins in the composite structure.

The above disadvantages of the prior art are solved by the present invention. Since the substrate material first consists of a porous material with low density and with hollow, non-thermoplastic particles, it can be subjected to vertical pressing in a flat bed press with a minimum of lateral flow. This enables a deeper, more clearly defined embossing and less distortion of the product. The process further substantially eliminates the distortion of the decoration on the film and the backing material which occurs when using a flat bed embossing press, in particular with low density compositions which are difficult to heat and cold. The invention further regulates the distortion by using high frequency heating and compositions susceptible to such heating in combination with cooling the press embossing and backing plates, so that the materials can be heated rapidly to a temperature sufficient for embossing while avoiding distortion of the film decoration during print. Because the decoration of the film is not distorted in the method according to the invention, it becomes of course possible to carry out the embossing in a simple manner in the middle of the decoration on the film. It is generally known that thermoplastic films are not dimensionally stable as they are heated sufficiently to achieve embossing. The same shows a tendency to expand or contract differently in different parts of the sheet.

By avoiding heating the materials to high temperatures for the final embossing and melting step, the formation of stresses in the materials is substantially eliminated.

This in combination with the flat, cooled bottom surface of the embossing press, containment of reinforcing glass fabric and the use of high-frequency heating gives a product that is dimensionally stable, remains flat and does not bend when exposed to heat and moisture.

Brief description of the invention Fig. 1 is a flow chart showing the various steps in the manufacture of a product according to the invention.

Fig. 2 is an enlarged cross-sectional view of a portion of a surface coating according to the invention.

Fig. 3 is an enlarged cross-sectional view of a portion of a coating produced in a modified process.

Description of the Preferred Embodiments As shown in the flow chart of Fig. 1, there are two embodiments for making a product of the invention.

In the first embodiment, the manufacturing process begins with the formation of a low density porous substrate material. As indicated in the flow chart, a first layer of a dry mixture is formed on a removable carrier. To form the support material, a particulate resinous dry mixture is prepared. The dry mixture is in the form of a free-flowing homogeneous mixture of undigested thermoplastic resin particles containing liquid vinyl plasticizer, filler, pigment and vinyl stabilizer.

Polyvinyl chloride is the preferred resin used in the formation of the coating of the invention, although copolymers of vinyl chloride with minor proportions of other substances such as vinyl acetate, vinylidene chloride, other vinyl esters such as vinyl propionate, vinyl butyrate and alkyl substituted vinyl esters may be used.

Other thermoplastic resins that can be heated at high frequency and that can be mixed with substances that are susceptible to high frequency heating can also be used. Such are e.g. polyethylene, polyurethanes, polyesters, polyamides, polyacrylates (eg polymethyl methacrylate) and polymers derived from acetates and cellulose esters.

The free-flowing mixture of resin, plasticizer, stabilizer, pigment and filler can be easily prepared by adding the resin, e.g. a homopolymer of vinyl chloride, in the form of discrete particles, together with the vinyl resin plasticizer such as di-2-ethylhexyl phthalate, butyl benzyl phthalate, epoxidized soybean oil or tricresyl phosphate, filler, pigment and the suitable stabilizer for vinyl resin, e.g. a Henschel-type mixer, in which they are mixed while heating properly, e.g. at a temperature of about 71-1040 ° C (leo-220 ° F) for a sufficient time to ensure that the liquid plasticizer and stabilizer are absorbed and thus spread over all the resin particles and those absorbed thereon. the other ingredients. Care is taken that the resin particles do not melt during the mixing and the temperature must be kept below that at which such melting would occur. In general, the addition of fillers and pigments to the mixture can be done either at the beginning, at the end of the mixing cycle, when the resin particles remain relatively hot, or after the particles of the dry mixture have been mixed and cooled.

The dry mixture which can be used according to the present invention may contain the following constituents in the stated content ranges, calculated on 100 parts of resin: Components Weight parts Polyvinyl chloride in the form of dispersion and with the average molecular weight 70,000 - 80,000 50 - 100 Polyvinyl chloride in the form of a mixture quality and with the average molecular weight 33,000 - 46,000 50 - 0 Dioctyl phthalate, plasticizer 25 - 75 organic tin compound, stabilizer 1 - 3 Titanium dioxide, paste (50% in dioctyl phthalate) 0 - 5 Limestone (50 mesh), filler 0 - 200 The mixture used of the dry mixture and perlite is obtained by simple mixing or tumbling of the two dry products, until a homogeneous mixture is obtained. About 90 parts by weight of the dry mixture and about 10.5 parts by weight of perlite were used.

However, the amount of perlite used for the composition can be varied considerably, the upper limit being determined by the ability of the composition to hold together in a useful manner after heating and light compression. The upper limit is affected by the particle size of the perlite used and, since weight parts are added or mixed, the density of the perlite particles. The particle size of the perlite that can be used according to the invention varies from about 35 to 850 u (microns). The average particle size of particles of the type used is about 60 U. The effective useful range for the proportion of perlite would be between 2 and 20% by weight after mixing with an amount of dry mixture in the range from about 98-80% by weight.

The preferred useful range for the proportion of perlite would be about 5-15% by weight and the most preferred range would be about 8-12% by weight. In the case of other types of perlite, e.g. such with a density of 0.06 and 0.17 g / cm 3, the proportions may vary depending on the larger particle size and / or density. Although it is preferred that the substrate material be formed using expanded perlite in the form of cavity particles, it is understood that cavity particles of e.g. glass, ceramics or organic substances could be used within the scope of the invention.

A 2.54 mm thick layer of mixture of perlite and dry mixture is then formed on a carrier coated with release agent and heated to a temperature sufficient for the surface portions of the resin particles to melt slightly and stick together at the contact points. A reinforcing layer of nonwoven glassware is then applied to the thus formed perlite-containing dry blend layer and lightly compressing pressure is applied to the whole. The raw material can have a basis weight of about lg-50g / m2.

Alternatively, the reinforcing layer may comprise woven or non-woven fibers of glass, polyester, polyamide and the like. Another layer of similar thickness of the mixture of dry mixture and perlite is applied to the top of the sheepskin fabric, whereupon this second layer is heated to a temperature similar to that used to form the first layer. Slightly compressing pressure is applied again. The obtained substrate * x 10 15 20 25 30 35 461 776 material is now in a brittle, but suitable handling condition for further process processing. It is also porous, which enables subsequent compression in the vertical direction with a minimum of lateral flow. It is also receptive to high frequency energy.

The preferred reinforced, sintered mixture of dry mixture and perlite has a unique, porous structure, in which each individual pore is reinforced by the rigid cell structure of the individual particles of expanded perlite. The combined effect of many reinforced pores contributes greatly to the necessary dimensional stability and low weight of the product, while still being crushable during the embossing step with limited lateral flow. Although it is preferred that the substrate material be as described, other porous structures, e.g. open-cell thermoplastic resin foams (for example, vinyl foams), thermoplastic enamels and the like are used; in general, however, the results are not as good, as paint distortion, material spraying and structural compression can occur after the treatment operations.

A dimensionally stable releasable carrier is then coated with a thermoplastic resin film, preferably 0.16 mm thick with decorated pattern parts on the surface facing away from the carrier. However, the film may vary from about 0.00254 to 0.38 mm in thickness and may at this time be permeable or impermeable, but must be permeable when the composite structure is embossed afterwards. The film can be cast, extruded or laminated on the removable carrier. The pattern or decoration can be applied either before or after application of the film to the removable carrier. The decoration can also be applied to the top of the backing material and a non-decorated film or coating applied on top. The film preferably comprises a polyvinyl chloride resin and / or copolymers thereof (eg vinyl chloride and acrylic monomers and copolymers such as ethylene-acrylic acid). However, other thermoplastics such as polyesters, polyurethanes, polyamides, polyolefins (eg polyethylenes), polyacrylates and the like can also be used according to the invention. Glue can be applied to the decorated surface of the film or the glue can be ink or combined with the ink.

The film is then cut to the desired dimensions in the middle of the pattern, while the film is on the removable carrier, but without cutting the carrier. The backing material is cut into shapes that correspond to the shapes of the cut parts of the film.

The decorated surface of the cut parts of the film is then brought into contact with the top of the shaped parts of the backing material, the removable carrier is removed and the film is perforated. The cut film pieces can be preheated to heat only the adhesive, so that lamination can be performed at a relatively low temperature.

The pieces of backing material can also be preheated, but not completely straight through. The composite structures thus formed are then applied to a flat bed press, which contains a cooled, deep-embossed plate and a cooled flat back pressure plate. After the press is closed, high frequency energy is applied. The temperature of the material passes from room temperature to 177 ° C. The high frequency effect is then switched off and the pieces are allowed to settle under pressure for about 4-20 sec. The press is then opened, the pieces are taken out and edge cut. Glue is applied to the back of the pieces and removable paper is applied.

In the second embodiment of the manufacturing method, the same materials and methods were used except that the film and the backing material were cut with the pattern portions of the film, after the pattern-bearing surface of the film was brought together with the top of the backing material and after the removable carrier was separated from the film. .

The following examples are intended to illustrate processes for the manufacture of a product according to the invention which, however, are not limited to the same. All parts and percentages are by weight unless otherwise indicated.

Example I To form the substrate material for the surface coating according to the invention, grains were prepared from a dry mixture by mixing the following ingredients in an ordinary dry mixer while heating from room temperature to 10 ° C and cooling to room temperature, using the following ingredients in the indicated the components: Ingredients Weight components Polyvinyl chloride resin in the form of dispersion 66.6 Polyvinyl chloride resin in the form of a mixture grade 33.4 dioctyl phthalate 25 - 75 organotin compound, stabilizer 2 titanium dioxide paste (50% in dioctyl phthalate) 2 limestone (50 mesh) filler 100 were mixed with perlite particles in the following proportions: Weight parts Dry mixture Particles 90 perlite 100.5 461 776 10 15 20 25 30 35 12 The above dry materials were mixed together by simple stirring until a homogeneous mixture was obtained.

The dry mix mixture was applied to a release agent coated surface to form a uniform layer having a thickness of about 0.025 mm. Heat was then applied by infrared irradiation of the upper surface and electric heating of the lower plate for about 2 minutes to raise the temperature to about 190 ° C, so that the surface portions of the granules of the dry mixture were caused to partially melt and stick together at the contact surfaces.

A sheet of nonwoven glass filament of a glass having a basis weight of about 35 g / m 2 and having linear dimensions similar to those of the dry blend was applied on top of the whole and weakly compressing pressure was applied by passing the structure through a roller lamination machine.

Another layer of the same dry blend mixture having a thickness similar to that of the first layer was applied to the coating of glassware and similarly heated and densified in the same manner. After cooling, the composite sheet, which was about 0.025 mm thick, was cut. in parts with a plate size of about 18 x 18 cm, which had a low density, were porous, reinforced and were in a suitable condition for handling and further treatment procedures.

A coating of polyvinyl chloride having a thickness of 0.610 mm was applied to a 0.036 mm thick removable polyester support and heated to an interface temperature of about 143 ° C. The resulting film was then printed with vinyl paints in a decorative pattern. An acrylate type varnish having the following composition was then applied to the decorated surface of the film to ensure good bonding between the film and the backing material.

Parts by weight of methacrylate resin 13 ethyl acetate 43 methyl ethyl ketone 13 10 15 20 25 30 35 461 776 13 The decorated film was cut into shapes and sizes corresponding to the substrate material without the cut enclosing the support. The decorated surface of the film was then brought into contact with the top of the pieces of backing material, which were preheated to heat only the top. Heat was applied from a silicone roll heated to about 204 ° C to soften the adhesive on the decorated surface of the film, whereupon light pressure was applied by a roll laminating machine to bond the film to the backing material. After cooling, the removable carrier was removed. The decorated film was perforated using a pin roller to provide a number of openings at a distance of about 8 mm from each other.

The composite structures were then applied in a press with a flat bed and water-cooled embossing and backing plates. Electric high-frequency energy was applied to melt the resins in the structures, which were then embossed by the downward pressure exerted by the embossing plate. The products were then allowed to cool under pressure, taken out of the press and cut to remove excess material at the edges. An acrylic-type aqueous adhesive having the following composition was then applied to the back of the finished pieces to facilitate their subsequent attachment to a surface such as a wall or floor: Parts by weight Polyacrylic acid emulsion 98.62 Sodium polyacrylate solution 1,31 1,2-Benzisothiazolin-3-one 0.7 A release-coated paper was applied to the adhesive.

The paper is easy to remove at the time the product is to be applied to a substrate. The product is a stress-free, decorated, embossed surface coating without a tendency to bend. 461 776 10 15 20 25 30 35 14 Example II A stress-free, embossed, decorated surface coating was formed using the same starting material consisting of mixing perlite and dry mixture and the same procedure as in Example I. The decorated film was also prepared with the same material and procedures as in Example I. However, in the preparation of this coating, neither the decorated film nor the backing material was cut prior to the lamination of the film and backing material. In this process, the decorated surface of the film was brought into contact with the top of the backing material, whereupon heat and pressure were applied to activate the adhesive. After cooling, the removable carrier was removed and the film was perforated, and the film and backing material were cut into registers with the pattern on the film.

Embossing of the structure, melting of the resins, edge cutting to remove excess material, application of glue and releasable paper to the back of the product were done in the same manner and using the same material as in Example I.

As shown in FIG. 2 of the drawings, the coating obtained by the indicated process comprises a main body part layer 1 with an upper side 2 and a lower side 3, and comprises a melt matrix of resinous dry mixture 4 containing hollow non-thermoplastic particles 5. the upper side 2 of the layer 1 has immersed portions 6 and 7, the immersed portions 7 being considerably deeper than the immersed portions 6 and containing molten resin 8 in a substantially continuous phase with substantially completely crushed non-thermoplastic particles 9. Raised portions 10 are arranged on the upper side 2 of the main body layer 1 and is at a higher level than the two immersed portions 6 and 7. The raised portions and the shallow immersed portions 6 contain molten resin in a substantially non-coherent phase with non-crushed and substantially only partially crushed non-thermoplastic particles. . A reinforcing nonwoven sheepskin article cloth 11 of glass is arranged between the upper and lower sides 2 and 3 of the main body part layer 1. A substantially impermeable, transparent molten wear layer 12 of resin is bonded to above side 2 of the layer 1 and there is a decoration 13 between the wear layer 12 and the upper side 2 of the main body part layer 1. A removable coating 14 is attached by means of an adhesive coating 15 to the bottom surface 3 of the surface coating to facilitate removal after the coating 14 stalling of the surface coating on a substrate such as a wall or a floor. The surface coating is substantially stress-free and has no bending tendencies; it is relatively easier and more economical to manufacture and is an improved, more aesthetically pleasing product with improved stability.

Fig. 3 shows a modification of the invention described above. The element 16 in Fig. 3 is a thermoplastic layer with a lower melting temperature than the wear layer 12.

It has been found that the perforations which make it easier for the air to escape during the embossing are not completely sealed in some cases. One case where this could occur is when the embossing plate is very deep and does not have sufficiently raised surface portions for the perforations to be dense in the same way as in a soft, even and recessed plate. The presence of unsealed holes leads to dyes penetrating into the finished product, which is undesirable. By inserting a second resinous thermoplastic layer under the upper decorative layer or film, which second layer has a lower softening, melting or curing temperature or which floats at a temperature lower than the temperature of the decorative overlying film have, the perforations or holes of the film are repaired. This is due to the fact that the greatest heat is generated within the structure of the substrate that is located next to the softer, more fluid second layer.

An example of a product according to the above modification 461 776 10 15 20 25 30 16 is as follows. A 0.0762 - 0.1016 mm thick coating film or layer is applied to a 0.036l mm thick removable polyester support and heated to an interfacial temperature of 14300. The whole is provided with a decorative pattern in accordance with what described above. A second layer consisting of a 0.0254 mm thick polyvinyl chloride coating and in this case containing white pigment is applied to the decorated surface of the polyvinyl chloride film and heated to an interface temperature of 132 ° C. In this way, the structure in Fig. 2 is modified by providing a second layer on the first coating film or wear layer and by applying this structure thereto on the substrate material as in Example I, so that the second layer is located between the decorated upper film layer and the top of the backing material. If an adhesive is used in the process, the same is applied to the decorated surface of the first coating or film layer to ensure good bonding between the first and second layers.

In the above example, the thermoplastic layer was a liquid plastisol of polyvinyl chloride. The second layer may optionally be a sintered powder of vinyl thermoplastic such as VYFS from Union Carbide. Both the Union Carbide vinyl powder and the liquid plastisol coating used in the example given soften and begin to soften at a lower temperature than the top decorated film, leading to the perforations being completely sealed in the final product. At a temperature of 82.2 DEG C. of the embossing plate, the second layer softens and will float before the upper film, since the second layer is closer to the substrate material with a higher temperature. In this way, the second layer helps to seal the perforations of the first or upper film.

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Claims (9)

10 15 20 25 30 35 461 776 .17 ____, “ä 1 _ PAIENTKRAV 1. l. Decorated, embossed curvature-resistant surface coating, which comprises a main body layer (1) with an upper side (2) and a lower side (3), the layer comprising sunken parts of the layer, and raised parts of the layer, which are raised in relation to the recessed parts, a reinforcing material layer (II) between the upper side (2) and the lower side (3), a resin-containing wear layer (12) bonded to the upper side (2) of the main body layer (1) and a decoration (13) between the wear layer (12) and the upper side (2), characterized in that the main body layer (1) comprises a molten matrix of resinous dry mixture containing homogeneously distributed originally hollow non-thermoplastic particles; the immersed parts consist of first immersed parts (6) and second immersed parts (7), the latter comprising molten resin (8) in a substantially coherent phase and substantially completely crushed non-thermoplastic particles (9), wherein the second submerged parts (7) have a greater depth than the first submerged parts (6); and that the raised parts (10) on the layer are raised in relation to the first (6) and the second (7) submerged parts, the first submerged parts (6) and the raised 10 15 20 25 30 35 461 776 The 18 parts (10) comprise molten resin in a relatively non-cohesive phase with non-crushed and substantially only partially crushed non-thermoplastic particles therein. 2. A coating product according to claim 1, characterized in that the molten resinous dry blend layer is a softened vinyl resin composition. 3. A coating product according to claim 2, characterized in that the vinyl resin is polyvinyl chloride. 4. A coating product according to claim 1, characterized in that the crushed and partially crushed, originally hollow, non-thermoplastic particles are perlite. 5. A coating product according to claim 1, characterized in that the reinforcing material layer (II) is a glass filament. Coating product according to Claim 1, characterized in that the resin-containing wear layer (12) consists of softened vinyl resin. Coating product according to Claim 1, characterized in that the resinous wear layer (12) is a selected fracking group consisting of polyamides, polyacrylates, polyurethanes, polyesters and polyethylenes. Coating product according to claim 1, characterized in that it contains an adhesive coating on the underside of the main body part layer and a removable material which covers the coating and is held in place by the adhesive. Coating product according to claims 1-8, characterized in that it also comprises an impermeable, transparent resinous wear layer (12) bonded to the top of the molten resinous layer and a decoration (13) located between the wear layer ( 12) and the molten resinous layer.