US20010028127A1 - Method for manufacturing a floor covering - Google Patents

Method for manufacturing a floor covering Download PDF

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Publication number
US20010028127A1
US20010028127A1 US09/782,036 US78203601A US2001028127A1 US 20010028127 A1 US20010028127 A1 US 20010028127A1 US 78203601 A US78203601 A US 78203601A US 2001028127 A1 US2001028127 A1 US 2001028127A1
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US
United States
Prior art keywords
substrate
layer
belts
coating
saturation
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.)
Abandoned
Application number
US09/782,036
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English (en)
Inventor
Terence Hinds
John Geraghty
Rolf Basler
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to US09/782,036 priority Critical patent/US20010028127A1/en
Publication of US20010028127A1 publication Critical patent/US20010028127A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/30—Making multilayered or multicoloured articles
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B29C2043/483—Endless belts cooperating with a second endless belt, i.e. double band presses

Definitions

  • the invention relates to a method for manufacturing a floor covering and in particular to a method for manufacturing a polymeric, for example, a vinyl floor covering.
  • a glassmat tissue or mineral felt is used as the base carrier material.
  • the glassmat tissue is saturated with a PVC plastisol material which is applied to the mat using a knife and/or application roller.
  • the plastisol is then gelled on a hot chrome plated drum to provide a smooth solid surface.
  • a basecoat in the form of a foamable plastisol is applied using a knife or roller to a coating thickness of typically 300 g/m 2 .
  • This basecoat is also gelled on a hot gel drum to produce a smooth surface which is suitable for printing.
  • a design is then printed on the gelled basecoat, typically using a rotogravure method in which a design/coloration is printed using a sequence of printing cylinders.
  • a rotogravure method in which a design/coloration is printed using a sequence of printing cylinders.
  • an inhibitor in a desired pattern. The inhibitor inhibits foam expansion.
  • a topcoating in the form of a clear PVC plastisol is then coated on top of the print layer and the topcoating is gelled on a hot gel drum.
  • the layered product thus formed is then heated in an oven at typically 190° C. which causes the basecoat foam layer to expand in all areas except where the inhibitor has been applied.
  • the PVC plastisol also fuses at this temperature to give a clear hard resilient surface finish.
  • a backing layer in the form of a PVC plastisol is coated onto the product.
  • the backing may be of a foamable material.
  • the surface of the floor covering thus formed may be toughened by applying a crosslinkable polyurethane or acrylic lacquer.
  • a method for manufacturing a floor covering comprising the steps of:
  • the substrate is a fibre matt material, especially a glass fibre matt material.
  • the fibre matt has less than 100 g, ideally less than 65 g and most preferably from 30 to 50 g of glass fibre per m 2 of material. This material is easily handled in roll form and provides the required reinforcing strength.
  • the gelled coating is smoothed by leading the gelled coating between a nipping means.
  • the nipping means comprises a pair of nip rollers defining a gap therebetween.
  • the method includes the step of adjusting the gap between the nip rollers. In this way the process is readily tailored to a desired final product.
  • the method comprises the steps of:
  • the first substrate is defined by a lower of the belts.
  • the second substrate is a fibre matt substrate as defined above.
  • the first and second coatings may be the same.
  • the coatings may be of a saturation material to provide a highly efficient saturation layer in which the substrate matt is impregnated from both sides.
  • the coatings may be of a different material.
  • the first coating may be of a saturation material and the second coating may be of a basecoat material.
  • the advantage of such an arrangement is that two layers may be formed in one pass through the heating section.
  • the or each coating may be pre-heated by means of an infra red heater or the like.
  • the material may be scattered to form, on heating, a basecoat layer.
  • the basecoat is preferably a foamable layer, typically formed using a blowing agent mix of azodicarbonamide and zinc oxide.
  • the basecoat is formed by a method including the steps of:
  • a substrate is defined by one of especially the lower of the belts.
  • the method includes the steps of:
  • thermoplastics material to form a backing layer on one face of the substrate and a saturation or basecoat layer on the other face of the substrate.
  • the second layer is a saturation layer and the method includes the steps of:
  • the substrate is led over a smoothing roller prior to cooling.
  • one of the belts as it is led over the smoothing roller.
  • the method includes the step of heating and/or cooling the substrate as it is led over the smoothing roller.
  • the substrate is heated or cooled by heating or cooling the smoothing roller.
  • the substrate is led over an infeed roller to the smoothing roller.
  • the substrate is led over an outfeed roller from the smoothing roller.
  • the substrate is heated or cooled as it is led over the infeed and/or outfeed rollers.
  • the substrate is cooled after gelling by leading the pair of belts through a cooling station.
  • the substrate is a mineral felt.
  • a saturation layer is typically not required and a basecoat material is applied directly to the substrate.
  • basecoat layer refers to the layer which is subsequently printed.
  • the basecoat is preferably of a foamable material.
  • the invention also provides a floor covering whenever manufactured by the method of the invention.
  • FIG. 1 is a diagrammatic side elevational view of apparatus used in the method of the invention.
  • FIG. 2 is a diagrammatic side elevational view of an apparatus of FIG. 1 used in a method for manufacturing a floor covering according to the invention in one arrangement of use;
  • FIGS. 3 to 5 are cross sectional views of a layered floor covering product at various stages in the method of FIG. 2;
  • FIG. 6 is a diagrammatic side elevational view of the apparatus of FIG. 1 in another arrangement of use;
  • FIGS. 7 to 9 are cross sectional views of a layered floor covering product at various stages in the method of FIG. 6;
  • FIG. 10 is a perspective view of part of the apparatus of FIG. 1;
  • FIG. 11 is a side elevational view of the apparatus of FIG. 10;
  • FIG. 12 is a perspective view of another part of the apparatus of FIG. 1;
  • FIG. 13 is a side elevational view of the apparatus of FIG. 12;
  • FIG. 14 is a perspective view of a smoothing roller part of an alternative apparatus.
  • FIG. 15 is a plan view of the apparatus of FIG. 14.
  • FIGS. 1 and 2 of the drawings there is illustrated an apparatus used in a method for manufacturing a floor covering according to the invention.
  • a substrate 1 in this case in the form of a glass fibre matt material having 30 to 50 g/m 2 of glass fibre material is led from a supply reel 2 onto a lower conveyor belt 3 .
  • a material is scattered in a curtain 5 onto the glass fibre matt substrate 1 to form a scattered layer 6 .
  • the fibre matt substrate 1 with the scattered layer may then be passed without any further layers being applied between an upper belt 10 and a lower belt 11 of a thermofixing oven unit 12 .
  • the belt 11 forms a continuation of the belt 3 .
  • the oven unit 12 is a heated low pressure double belt press which applies heat to the scattered layer 6 and glass fibre matt 1 to bind the non woven glass matt to the scattered layer 6 .
  • the oven unit comprises a number of upper and lower sections 13 , 14 .
  • the operating temperature of each section or groups of sections 13 , 14 may be varied.
  • the substrate supported between the upper and lower belts 10 , 11 is led between a pair of nipping rollers 15 , 16 to smooth the gelled coating to provide a layer of desired thickness.
  • the gelled layered substrate is then cooled between the pair of belts at a cooling station 17 .
  • the cooling station 17 comprises a plurality of top and bottom cooling sections 18 , 19 , the operating temperature of which may be adjusted in groups or individually.
  • the layered substrate 30 may then be wound onto a take-up reel 40 .
  • Further layers may be scattered onto the gelled substrate by leading the substrate through the apparatus again as described above or through another similar apparatus arranged in series.
  • a substrate such as a fibre matt 26 may be applied over the first scattered layer either before or after heating.
  • One or more further layers may be formed by scattering a dry blend material onto the second substrate 26 at a second applying station 28 upstream of the heating oven 12 .
  • An infra red heater 27 may be used to heat the first scattered layer and/or substrate in advance of oven heating and second scattering.
  • the scattered material forms, on heating, a saturation layer to receive a basecoat material.
  • the material is scattered to form, on heating, a foamed basecoat layer.
  • the basecoat may be formed by scattering a foamable basecoat material onto the saturation layer of the substrate, and heating the dry blend to form a foamed basecoat layer.
  • the substrate may be defined by one of the heating belts 3 , 11 .
  • a first material may be scattered onto the first belt 3 , 21 at the first scattering station 4 , a substrate 26 applied over the first coating and a second coating applied over the substrate 26 from the second scattering station 28 .
  • the substrate with the first and second scattered layers is then led under the second belt 10 and the layered product is heated to gel the coatings.
  • a backing layer may be formed on one face of the substrate and a saturation or basecoat layer on the other face of the substrate.
  • the second layer is a saturation layer and the method includes the steps of scattering a further coating over the saturation layer and heating the third coating to form a basecoat layer on the saturation layer.
  • the material that is scattered on the substrate may be in any suitable form such as powder, granules or pellets.
  • a blended powder may be extruded to produce a fully fused compound which is then pelletised and in some cases pulverised.
  • Such pellets have the advantage that they are more easy to control and are less adherent to the belts generally than powders. Thus, a more controlled scattering, higher processing speed and a more uniform product may be achieved.
  • the pellets are from 0.5 to 2 mm diameter, preferably about 1 mm, and from 1 to 2 mm long, preferably about 1.5 mm.
  • the pulverised particles are generally in the 100 to 500 micron range.
  • the belts are at least coated with a release material such as a silicone-based material and/or Teflon or the like material.
  • the gelled coating may be smoothed or further smoothed by leading the substrate supported on the lower belt 11 over a large diameter smoothing roller 20 .
  • the substrate is first led over an infeed roller 21 on the infeed side and is led over an outfeed roller 22 at the outfeed side of the smoothing roller 20 .
  • the substrate may be heated or cooled by circulating a heating or cooling fluid through the smoothing roller 20 .
  • a heating or cooling fluid may be circulated through the infeed and/or outfeed rollers 21 , 22 .
  • a glass fibre matt material having 50 g/m 2 of glass fibre material is used as the substrate.
  • a saturation layer forming dry blend of the following formulation was used.
  • the dry blend may be in the form of a powder or in the form of granules or the like material. Parts by Weight Suspension Grade PVC 100 Di-2-Ethyl Hexyl Phthalate 40-60 Butyl Benzyl Phthalate 10-30 Calcium Carbonate Filler 100-160 Barium/Zinc Stabiliser 2-3
  • an amount of typically 200 g/m 2 of the saturation dry blend is applied on a substrate belt.
  • the glass fibre matt is then applied over the scattered material as described above and at a second scattering station an amount of typically 200 g/m 2 of the saturation dry blend is scattered on top of the fibre matt.
  • an amount of 350 g/m 2 of the saturation dry blend may be applied to the top of the fibre matt at only one scattering station.
  • the substrate is then passed between heated belts at a temperature typically in the range of 180° C. to 200° C. at a residence time in heating of typically one minute.
  • the heated layered substrate is passed between nip rollers and then cooled by passing between a pair of cooling belts which are maintained at typical process water conditions.
  • the residence time in cooling is typically one minute.
  • a glass fibre matt with a smooth surface top and bottom is formed in a highly cost efficient manner which may be processed further using conventional techniques or by passing through the same oven unit or another similar unit arranged in series.
  • a foamed basecoat material may be applied to a saturated substrate using the following basecoat dry blend formulation: Parts by Weight Suspension Grade PVC 95-100 Dispersion Grade PVC 0-5 Di-2-Ethyl Hexyl Phthalate 20-50 Butyl Benzyl Phthalate 20-50 Calcium Carbonate Filler 20-80 Barium/Zinc Stabiliser 1.5-3.5 Blowing Agent Mixture 2-4 (Azodicarbonamide/Zinc Oxide) Titanium dioxide 6-10
  • the foamable basecoat material is scattered onto the saturated substrate at a single scattering station at a rate of from 250-450 g/m 2 and further processed as described above in Example 1.
US09/782,036 1997-08-27 2001-02-14 Method for manufacturing a floor covering Abandoned US20010028127A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US09/782,036 US20010028127A1 (en) 1997-08-27 2001-02-14 Method for manufacturing a floor covering

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
IE970633 1997-08-27
US14132698A 1998-08-27 1998-08-27
IE970633 1998-08-27
US09/782,036 US20010028127A1 (en) 1997-08-27 2001-02-14 Method for manufacturing a floor covering

Related Parent Applications (1)

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US14132698A Continuation 1997-08-27 1998-08-27

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US20010028127A1 true US20010028127A1 (en) 2001-10-11

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US (1) US20010028127A1 (fr)
EP (1) EP0899372B1 (fr)
AT (1) ATE324482T1 (fr)
DE (1) DE69834297D1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013143903A1 (fr) * 2012-03-28 2013-10-03 Tarkett Gdl Revêtement de surface multicouche
WO2016115556A1 (fr) * 2015-01-18 2016-07-21 Magma Flooring LLC Substrats polymères dotés d'un coefficient de dilatation thermique amélioré et son procédé de production
US10501945B2 (en) 2012-05-30 2019-12-10 Magma Flooring LLC Polymeric composites, resulting panels, and method for producing the same
US20190375222A1 (en) * 2016-12-15 2019-12-12 Ricoh Company, Ltd. Method of forming a surface covering, apparatus for forming a surface covering, and a surface covering
US10543626B2 (en) 2015-05-20 2020-01-28 Magma Flooring LLC Poly(vinyl chloride) substrates and method for producing the same
US10792846B2 (en) 2015-10-07 2020-10-06 Magma Flooring LLC Method for producing composite substrates
US10808109B2 (en) 2016-02-25 2020-10-20 Interfacial Consultants Llc Highly filled polymeric concentrates
US10948232B2 (en) * 2016-11-29 2021-03-16 Autefa Solutions Germany Gmbh Textile fiber drying
US20220388034A1 (en) * 2021-06-07 2022-12-08 Olbrich Gmbh Method for manufacturing a multilayer pvc semifinished product and a corresponding apparatus

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DE19955713C1 (de) * 1999-11-18 2001-07-05 Johns Manville Int Inc Wand- und Fußbodenbeläge
US7199065B1 (en) 1999-07-30 2007-04-03 Johns Manville Non-woven laminate composite
BE1020722A3 (nl) 2012-06-01 2014-04-01 Unilin Bvba Paneel voor het vormen van een vloerbekleding en werkwijze voor het vervaardigen van dergelijke panelen.
DE202018006061U1 (de) 2018-03-13 2019-01-31 Olbrich Gmbh Vorrichtung für die Nachbehandlung eines homogenen Bodenbelags

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US3700366A (en) * 1970-05-25 1972-10-24 Congoleum Ind Inc Apparatus for producing resinous sheetlike products
DE3031839C2 (de) * 1980-08-23 1983-10-20 Dynamit Nobel Ag, 5210 Troisdorf Verfahren zum kontinuierlichen Herstellen einer gemusterten Bahn aus thermoplastischem Kunststoff
US4778547A (en) * 1984-10-11 1988-10-18 Armstrong World Industries, Inc. Process for making a dimensionally stable, embossed, ornamented tile surface covering
DE3546184A1 (de) * 1985-12-27 1987-07-02 Dynamit Nobel Ag Verfahren zur kontinuierlichen herstellung von bahnenware fuer das bauwesen
DE4238764C2 (de) * 1992-11-10 1994-09-29 Golze & Soehne Otto Verfahren zum einseitigen Beschichten von Flächengebilden aus Fasern mit Kunststoff, Vorrichtung zur Durchführung des Verfahrens und Verwendung der Verfahrensprodukte
DE4240025C2 (de) * 1992-11-28 1994-09-08 Berstorff Gmbh Masch Hermann Verfahren und Einrichtung zum Herstellen einer Formstückbahn aus thermoplastischem Kunststoff

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104302472A (zh) * 2012-03-28 2015-01-21 塔吉特Gdl公司 多层表面覆盖物
RU2625879C2 (ru) * 2012-03-28 2017-07-19 ТАРКЕТТ ДжиДиЭл Многослойное поверхностное покрытие
WO2013143903A1 (fr) * 2012-03-28 2013-10-03 Tarkett Gdl Revêtement de surface multicouche
US10781596B2 (en) 2012-05-30 2020-09-22 Magma Flooring LLC Polymeric composites, resulting panels, and method for producing the same
US10501945B2 (en) 2012-05-30 2019-12-10 Magma Flooring LLC Polymeric composites, resulting panels, and method for producing the same
WO2016115556A1 (fr) * 2015-01-18 2016-07-21 Magma Flooring LLC Substrats polymères dotés d'un coefficient de dilatation thermique amélioré et son procédé de production
US10479057B2 (en) 2015-01-18 2019-11-19 Magma Flooring LLC Polymeric substrates with an improved thermal expansion coefficient and a method for producing the same
US10543626B2 (en) 2015-05-20 2020-01-28 Magma Flooring LLC Poly(vinyl chloride) substrates and method for producing the same
US10792846B2 (en) 2015-10-07 2020-10-06 Magma Flooring LLC Method for producing composite substrates
US10808109B2 (en) 2016-02-25 2020-10-20 Interfacial Consultants Llc Highly filled polymeric concentrates
US10948232B2 (en) * 2016-11-29 2021-03-16 Autefa Solutions Germany Gmbh Textile fiber drying
US20190375222A1 (en) * 2016-12-15 2019-12-12 Ricoh Company, Ltd. Method of forming a surface covering, apparatus for forming a surface covering, and a surface covering
US20220388034A1 (en) * 2021-06-07 2022-12-08 Olbrich Gmbh Method for manufacturing a multilayer pvc semifinished product and a corresponding apparatus
US11951511B2 (en) * 2021-06-07 2024-04-09 Olbrich Gmbh Method for manufacturing a multilayer PVC semifinished product and a corresponding apparatus

Also Published As

Publication number Publication date
EP0899372A3 (fr) 2001-10-31
EP0899372A2 (fr) 1999-03-03
DE69834297D1 (de) 2006-06-01
EP0899372B1 (fr) 2006-04-26
ATE324482T1 (de) 2006-05-15

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