US2533228A - Method of calendering sheet material - Google Patents
Method of calendering sheet material Download PDFInfo
- Publication number
- US2533228A US2533228A US702966A US70296646A US2533228A US 2533228 A US2533228 A US 2533228A US 702966 A US702966 A US 702966A US 70296646 A US70296646 A US 70296646A US 2533228 A US2533228 A US 2533228A
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- US
- United States
- Prior art keywords
- roll
- mass
- film
- face
- sheet
- 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.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims description 19
- 238000003490 calendering Methods 0.000 title claims description 11
- 239000000463 material Substances 0.000 title description 20
- 239000000839 emulsion Substances 0.000 claims description 28
- 229920001169 thermoplastic Polymers 0.000 claims description 8
- 239000004416 thermosoftening plastic Substances 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 238000007596 consolidation process Methods 0.000 claims description 5
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 2
- 239000001993 wax Substances 0.000 description 30
- 239000010426 asphalt Substances 0.000 description 10
- 239000007787 solid Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000011230 binding agent Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 4
- 238000009408 flooring Methods 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 229910021538 borax Inorganic materials 0.000 description 2
- 235000013869 carnauba wax Nutrition 0.000 description 2
- 239000004203 carnauba wax Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000010687 lubricating oil Substances 0.000 description 2
- 239000004328 sodium tetraborate Substances 0.000 description 2
- 235000010339 sodium tetraborate Nutrition 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000004018 waxing Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/235—Calendar
Definitions
- This invention relates to a. method of applying a film of lubricant to calender rolls to prevent. sheet material passing therebetween from adhering to the rolls, and toapply a film of wax to the. surface of the sheet material.
- An object of this invention is to provide a means for preventing asphalt tile sheets or other thermoplastic sheets from adhering to the hot calender roll during the sheet finishing operation.
- a further object is toproduce a fiooring tile having a surface free from chill marks or small breaks.
- a still further object is to apply a coating of wax to the surface of the tile at the time it passes through the finishing calender, thereby eliminating the subsequent waxing operation in the manufacture of flooring tile of this kind.
- the ingredients are thoroughly mixed in an internal mixer, at the completion of which the loose thermoplastic mix is dumped into a sheeting calender, one roll of which operates at about 325 F., and the other of which operates at about 180 F.
- This sheeting calender performs the step of initial heat consolidation of the loose mass into sheet form.
- a suitable scraper or doctor blade is, provided to free the sheets from the. hot roll on this initial heat consolidating calender. From this initial sheeting calender, the sheets travel by meanaof a suitable conveyor to asecond calender known as a finishing, or facing calender, the top roll of which s maintained at between 180 and 250 F. and the bottom roll of which is maintained at about F.
- This finishing or facing calender effects final heat consolidation of the thermoplastic mass.
- the temperature at which the hot roll on this finishing calender operates is sufficiently high to cause the surface of the sheets to adhere to the roll.
- the bottom roll or cold roll is operated at a temperature sufficiently low to prevent the sheet from adhering thereto.
- a series of sprayer nozzles suitable for spraying a film of aqueous wax emulsion to the surface of the roll.
- a wiper is provided to evenly distribute the aqueous wax emulsion in-v a film of uniform thickness throughout: the width of the roll.
- This lubricated roll serves as. the finishing roll or facing roll in the final calendering operation and the lubricated surface thereof prevents the face of the sheets from adhering to the calender roll. Also, the lubricated roll transfers a film of lubricant to the surface of the sheet being calendered.
- the thermoplastic sheet is provided to evenly distribute the aqueous wax emulsion in-v a film of uniform thickness throughout: the width of the roll.
- the.v finishing calenderis at a temperature of approximately 250 F. Inasmuch as this temperature is substantially above the boiling, point of the water in the wax emulsion, the water is boiled ofi, leaving a film of wax on the surface of the sheet material.
- the sheets pass through a. cooling zone and then a dieing operation which forms'the asphalt tile to the desired size and shape.
- The-accompanying drawing shows a diagrammatic view of an asphalt tile calender suitable for carrying out the process of my invention.
- 2 is aconventional facing roll or hot roll which is maintained at a temperature of between 180 F. to 25.0 F.
- a series of suitable spray nozzles, indicated at it, is provided for applying a. film, of wax emulsion to the surface essential that the wax be disposed uniformly on the roll, not only to prevent particles from adhering to all areas of the roll but to transfer auniform film of wax to the face of the calendered tile.
- the cold roll, indicated at 3 in the drawing is usually maintained at a temperature of approximately 130 F. At this low temperature, there is. no tendency for the'sheet material to adhere to the surface of the roll 3.
- a belt conveyor suitable for delivering the unfinished sheet material to the calender rolls and "5 indicates a belt conveyor suitable for carrying the finished waxed sheets away from the finishing calender to the subsequent dieing operation.
- the sheet material has a film of wax applied to the wear surface thereof at the time it passes through the finishing calender. This eliminates the necessity for having a separate operation to perform this step in the process of manufacturing asphalt tile or similar flooring materials.
- a method of forming a sheet from a thermoplastic mass comprising delivering to the nip between a pair of calendering rolls a mass of thermoplastic material heated to a temperature above 212 F., at which said heated mass is plastic and may be sheeted by calendering, the face-forming roll of said calender being maintained at a temperature at which said heated mass would normally adhere under consolidating pressure in sheet formation, interposing a film of an aqueous wax emulsion between the surface of the face-forming roll and said heated mass under treatment, said heated mass being nonadherent to said face-forming roll with said interposed film under consolidating pressure in sheet formation, consolidating said mass into a sheet between said rolls with said film of aqueous wax emulsion interposed between said face-forming roll and said heated mass, removing water from said wax emulsion film by the application of heat thereto from said heated mass under consolidation, and removing the formed and wax coated sheet from said calender rolls substantially free of cracks or breaks in
- thermoplastic material delivered to the nip between the calender rolls is heated to a temperature of about 250 F.
- aqueous wax emulsion comprises by weight parts carnauba wax, 14 parts triethanolamine, 6 parts borax, 14 parts white oleine, and sufiicient water to form an emulsion containing from 12 to 25% solids.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Paper (AREA)
Description
Deco 112,. El5 c. E. DELL. 23 533 228 METHOD OF CALENDERING SHEET MATERIAL Filed Oct. 12, 1946 FIGJ IN V EN TOR.
Patented Dec. 12, 1950 METHOD OF CALENDERINGSHEET MATERIAL Charles E. Dill, Dover, N.. 1., assignor to Armstrong-Cork Company, Lancaster, 2a., a corporation of Pennsylvania Application October 12, 1946, S'eriaINo. 702,966
7 Claims. 1
This invention relates to a. method of applying a film of lubricant to calender rolls to prevent. sheet material passing therebetween from adhering to the rolls, and toapply a film of wax to the. surface of the sheet material.
An object of this invention is to provide a means for preventing asphalt tile sheets or other thermoplastic sheets from adhering to the hot calender roll during the sheet finishing operation. A further object is toproduce a fiooring tile having a surface free from chill marks or small breaks. A still further object is to apply a coating of wax to the surface of the tile at the time it passes through the finishing calender, thereby eliminating the subsequent waxing operation in the manufacture of flooring tile of this kind.
The use of lubricants to prevent calendered sheets from adhering to the calender rolls is old in the art of manufacturing sheet material, but the lubricating oil usually used for this purpose is not satisfactory for the manufacturing process here under consideration due to the fact that the binder for the thermoplastic sheet material is compatible with the lubricating oil. This causes a certain amount of binder to be dissolved in the oil resulting in defective material due to the fact that only a partial amount of the required binder remains in the finished product.
Attempts have been made to produce asphalt tile by means of cold calender rolls (below 130 F.). This process prevents the sheets from adhering to the rolls but the cold roll produces chill marks on the surface of the tile sheets. These chill marks are actually small cracks or breaks in the surf'aceof the tile and are highly undesirable in the wear surface of hard surface fioor covering. Furthermore, it has been customary in the past to apply a'film of wax to the finished material before it is packaged for shipment to the dealer. This requires another step in the process of manufacturing asphalt tile.
By my invention it is possible to make asphalt tile from the, usual thermoplastic mass and pass it through a calender-having a'heated facing roll. This-is: accomplished by spraying a film of wax emulsion on the heated. roll. The binder used in asphalt tile composition is not watersoluble and, therefore, any small amount of water remaining in the wax emulsion has; no effect upon the binder. Furthermore, the wax emulsion used to. prevent the sheets from adhering to the calender roll remains on the surface of the sheet material and serves as a wax coating to protect the wear surface of the. flooring material,
In the manufacture of asphalt tile, the ingredients: are thoroughly mixed in an internal mixer, at the completion of which the loose thermoplastic mix is dumped into a sheeting calender, one roll of which operates at about 325 F., and the other of which operates at about 180 F. This sheeting calender performs the step of initial heat consolidation of the loose mass into sheet form. A suitable scraper or doctor blade is, provided to free the sheets from the. hot roll on this initial heat consolidating calender. From this initial sheeting calender, the sheets travel by meanaof a suitable conveyor to asecond calender known as a finishing, or facing calender, the top roll of which s maintained at between 180 and 250 F. and the bottom roll of which is maintained at about F. This finishing or facing calender effects final heat consolidation of the thermoplastic mass. The temperature at which the hot roll on this finishing calender operates is sufficiently high to cause the surface of the sheets to adhere to the roll. The bottom roll or cold roll is operated at a temperature sufficiently low to prevent the sheet from adhering thereto.
To overcome the problem of the sheets adhering to the hot roll, I have arranged a series of sprayer nozzles; suitable for spraying a film of aqueous wax emulsion to the surface of the roll. In addition to this sprayer device, a wiper is provided to evenly distribute the aqueous wax emulsion in-v a film of uniform thickness throughout: the width of the roll. This lubricated roll serves as. the finishing roll or facing roll in the final calendering operation and the lubricated surface thereof prevents the face of the sheets from adhering to the calender roll. Also, the lubricated roll transfers a film of lubricant to the surface of the sheet being calendered. The thermoplastic sheet. material as it passes through the.v finishing calenderis at a temperature of approximately 250 F. Inasmuch as this temperature is substantially above the boiling, point of the water in the wax emulsion, the water is boiled ofi, leaving a film of wax on the surface of the sheet material.
After this final calendering operation, the sheets pass through a. cooling zone and then a dieing operation which forms'the asphalt tile to the desired size and shape.
The-accompanying drawing shows a diagrammatic view of an asphalt tile calender suitable for carrying out the process of my invention. In this drawing, 2 is aconventional facing roll or hot roll which is maintained at a temperature of between 180 F. to 25.0 F. A series of suitable spray nozzles, indicated at it, is provided for applying a. film, of wax emulsion to the surface essential that the wax be disposed uniformly on the roll, not only to prevent particles from adhering to all areas of the roll but to transfer auniform film of wax to the face of the calendered tile. The cold roll, indicated at 3 in the drawing, is usually maintained at a temperature of approximately 130 F. At this low temperature, there is. no tendency for the'sheet material to adhere to the surface of the roll 3.
At 3 there is shown a belt conveyor suitable for delivering the unfinished sheet material to the calender rolls and "5 indicates a belt conveyor suitable for carrying the finished waxed sheets away from the finishing calender to the subsequent dieing operation.
In carrying out the process of my invention, the best results have been obtained by use of the sprayer-wiper combination explained above, although the invention can be carried out in various other ways such as the use of a wick for applying wax emulsion to the rolls. Also the wax emulsion may be dropped on the roll by gravity instead of by the sprayer system.
Several of the commercially obtainable wax emulsions have been found to be satisfactory in carrying out the process of my invention, but I have found the best results to be obtained with an emulsion of the following formulation:
2 Pounds Carnauba wax 100 'Iriethanolamine 14 Borax 6 Nhite oleine 14 Sufficient water to form an emulsioncontaining 15% solids.
While the above formulation is preferred for carrying out my invention, it will be understood, of course, that other waxes in emulsion form may be employed satisfactorily,
I have found the best results to be obtained with a wax emulsion having a solids content of 15%, however, satisfactory results are obtained with solids content ranging from 12 to 25%. If more than 25% solids are present in the emulsion, there is a tendency for the wax to build up on the roll rather than be transferred from the roll to the surface or he sheet material. Also, if an emulsion containing a greater percentage of solids is used, the wiper becomes clogged and does not perform its proper function in distributing the wax emulsion uniformly across the surface of the roll. If the emulsion contains less than 12 solids, it does not prevent the surface of the sheet material from adhering to the calender roll, and, furthermore, the wax film remaining on the wear surface of the tile is not sufficiently heavy to properly protect the tile.
In the manufacture of asphalt tile in accordance with the process outlined above, the difficulty of the face of the tile sticking tov the hot roll has been eliminated and the finished tile has a substantially smooth wear surface free from chill marks and other defects which usually arise when a cold roll is used as a facing roll for this material. In addition to this advantage, the sheet material has a film of wax applied to the wear surface thereof at the time it passes through the finishing calender. This eliminates the necessity for having a separate operation to perform this step in the process of manufacturing asphalt tile or similar flooring materials.
While I have described and illustrated certain preferred embodiments of my invention, it will be understood that the invention may be otherwise embodied and practiced within the scope of the following claims.
I claim:
1. In a method of forming a sheet from a thermoplastic mass, the steps comprising delivering to the nip between a pair of calendering rolls a mass of thermoplastic material heated to a temperature above 212 F., at which said heated mass is plastic and may be sheeted by calendering, the face-forming roll of said calender being maintained at a temperature at which said heated mass would normally adhere under consolidating pressure in sheet formation, interposing a film of an aqueous wax emulsion between the surface of the face-forming roll and said heated mass under treatment, said heated mass being nonadherent to said face-forming roll with said interposed film under consolidating pressure in sheet formation, consolidating said mass into a sheet between said rolls with said film of aqueous wax emulsion interposed between said face-forming roll and said heated mass, removing water from said wax emulsion film by the application of heat thereto from said heated mass under consolidation, and removing the formed and wax coated sheet from said calender rolls substantially free of cracks or breaks in the face thereof.
2. A method in accordance with claim 1 in which the aqueous wax emulsion is sprayed on the face-forming roll to form a film thereon and in which a portion at least of the film is transferred from the face-forming roll to the face of the consolidated sheet during consolidation and sheet formation.
3. A method in accordance with claim 1 in which the aqueous wax emulsion contains from 12 76 to 25% of solids.
4. A method in accordance with claim 1 in which the face-forming roll is maintained at a temperature between 180 F. and 250 F.
5. A. method in accordance with claim 4 in which the mass of thermoplastic material delivered to the nip between the calender rolls is heated to a temperature of about 250 F.
6. A method in accordance with claim 1 in which the aqueous wax emulsion comprises by weight parts carnauba wax, 14 parts triethanolamine, 6 parts borax, 14 parts white oleine, and sufiicient water to form an emulsion containing from 12 to 25% solids.
7. A method in accordance with claim 1 in which the aqueous w x emulsion contains about 15% solids.
CHARLES E. DILL.
REFERENCES CITED The following references are of record in the file of this patent:
UNITED STATES PATENTS Number Name Date 1,312,682 Clapp Aug. 12, 1919 1,590,638 Marquette June 29, 1926 1,698,267 Kirschbraun Jan. 8, 1929 2,025,375 Cameron et al Dec. 24, 1935 2,177,240 Brumbaugh Oct. 24, 1939 2,349,326 Wilson May 23, 1944
Claims (1)
1. IN A METHOD OF FORMING A SHEET FROM A THERMOPLASTIC MASS, THE STEPS COMPRISING DELIVERING TO THE NIP BETWEEN A PAIR OF CALENDERING ROLLS A MASS OF THERMOPLASTIC MATERIAL HEATED TO A TEMPERATURE ABOVE 212*F., AT WHICH SAID HEATED MASS IS PLASTIC AND MAY BE SHEETED BY CALENDARING, THE FACE-FORMING ROLL OF SAID CALENDAR BEING MAINTAINED AT A TEMPERATURE AT WHICH SAID HEATED MASS WOULD NORMALLY ADHERE UNDER CONSOLIDATING PRESSURE IN SHEET FORMATION, INTERPOSING A FILM OF AN AQUEOUS WAX EMULSION BETWEEN THE SURFACE OF THE FACE-FORMING ROLL AND SAID HEATED MASS UNDER TREATMENT, SAID HEATED MASS BEING NONADHERENT TO SAID FACE-FORMING ROLL WITH SAID INTERPOSED FILM UNDER CONSOLIDATING PRESSURE IN SHEET FORMATION, CONSOLIDATING SAID MASS INTO A SHEET BETWEEN SAID ROLLS WITH SAID FILM OF AQUEOUS WAX EMULSION INTERPOSED BETWEEN SAID FACE-FORMING ROLL AND SAID HEATED MASS, REMOVING WATER FROM SAID WAX EMULSION FILM BY THE APPLICATION OF HEAT THERETO FROM SAID HEATED MASS UNDER CONSOLIDATION, AND REMOVING THE FORMED AND WAX COATED SHEET FROM SAID CALENDAR, ROLLS SUBSTANTIALLY FREE OF CRACKS OR BREAKS IN THE FACE THEREOF.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US702966A US2533228A (en) | 1946-10-12 | 1946-10-12 | Method of calendering sheet material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US702966A US2533228A (en) | 1946-10-12 | 1946-10-12 | Method of calendering sheet material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US2533228A true US2533228A (en) | 1950-12-12 |
Family
ID=24823369
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US702966A Expired - Lifetime US2533228A (en) | 1946-10-12 | 1946-10-12 | Method of calendering sheet material |
Country Status (1)
| Country | Link |
|---|---|
| US (1) | US2533228A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2998327A (en) * | 1957-09-20 | 1961-08-29 | Samcoe Holding Corp | Method and apparatus for moistening fabric |
| US3276424A (en) * | 1962-06-22 | 1966-10-04 | Azoplate Corp | Process and apparatus for the development of latent electrostatic images |
| US20060180546A1 (en) * | 2005-02-15 | 2006-08-17 | William L. Stuth, Sr. | Wastewater treatment system and method |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1312682A (en) * | 1919-08-12 | Albert l | ||
| US1590638A (en) * | 1924-05-08 | 1926-06-29 | Fisk Rubber Co | Controlling the temperature of rubber-working rolls |
| US1698267A (en) * | 1922-12-26 | 1929-01-08 | Anaconda Sales Co | Metallic-surfaced roofing and process of making same |
| US2095375A (en) * | 1935-05-07 | 1937-10-12 | Fleetwood Craftsmen Inc | Shape retaining fiber mattress |
| US2177240A (en) * | 1939-05-17 | 1939-10-24 | Universal Chemical Corp | Wax and like composition and method for preparing the same |
| US2349326A (en) * | 1938-12-31 | 1944-05-23 | Carbide & Carbon Chem Corp | Emulsion |
-
1946
- 1946-10-12 US US702966A patent/US2533228A/en not_active Expired - Lifetime
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1312682A (en) * | 1919-08-12 | Albert l | ||
| US1698267A (en) * | 1922-12-26 | 1929-01-08 | Anaconda Sales Co | Metallic-surfaced roofing and process of making same |
| US1590638A (en) * | 1924-05-08 | 1926-06-29 | Fisk Rubber Co | Controlling the temperature of rubber-working rolls |
| US2095375A (en) * | 1935-05-07 | 1937-10-12 | Fleetwood Craftsmen Inc | Shape retaining fiber mattress |
| US2349326A (en) * | 1938-12-31 | 1944-05-23 | Carbide & Carbon Chem Corp | Emulsion |
| US2177240A (en) * | 1939-05-17 | 1939-10-24 | Universal Chemical Corp | Wax and like composition and method for preparing the same |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2998327A (en) * | 1957-09-20 | 1961-08-29 | Samcoe Holding Corp | Method and apparatus for moistening fabric |
| US3276424A (en) * | 1962-06-22 | 1966-10-04 | Azoplate Corp | Process and apparatus for the development of latent electrostatic images |
| US20060180546A1 (en) * | 2005-02-15 | 2006-08-17 | William L. Stuth, Sr. | Wastewater treatment system and method |
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