WO2006087426A1 - Procede de fabrication d’un substrat support pour revetement de sol cv, substrat support pour revetement de sol cv et revetement de sol cv - Google Patents

Procede de fabrication d’un substrat support pour revetement de sol cv, substrat support pour revetement de sol cv et revetement de sol cv Download PDF

Info

Publication number
WO2006087426A1
WO2006087426A1 PCT/FI2006/050065 FI2006050065W WO2006087426A1 WO 2006087426 A1 WO2006087426 A1 WO 2006087426A1 FI 2006050065 W FI2006050065 W FI 2006050065W WO 2006087426 A1 WO2006087426 A1 WO 2006087426A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
recited
pigment
carrier substrate
flooring
Prior art date
Application number
PCT/FI2006/050065
Other languages
English (en)
Inventor
Juha Sorvari
Original Assignee
Ahlstrom Glassfibre Oy
Ahlstrom Corporation
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 Ahlstrom Glassfibre Oy, Ahlstrom Corporation filed Critical Ahlstrom Glassfibre Oy
Publication of WO2006087426A1 publication Critical patent/WO2006087426A1/fr

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • 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
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • 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
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0044—Sealing or barrier layers, e.g. against solvents, asphalt, plasticisers
    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0052—Compounding ingredients, e.g. rigid elements
    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/006—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the textile substrate as base web
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B32B2255/102—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer synthetic resin or rubber layer being a foamed layer
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4023—Coloured on the layer surface, e.g. ink
    • 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
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/18—Reinforcing agents
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/22—Addition to the formed paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/32—Multi-ply with materials applied between the sheets

Definitions

  • the present invention relates to a method of manufacturing a carrier substrate for CV flooring, to a carrier substrate for CV flooring and to CV flooring.
  • (cushion vinyl) flooring is in most cases also known as PVC flooring. More particularly, the present invention relates to the production of a carrier substrate made of mainly glass fiber and incorporating a novel barrier layer.
  • the PVC flooring material comprises a substrate or a carrier substrate, which consists of woven or non-woven fabrics or rubber-impregnated paper.
  • Woven fabrics are made of natural or synthetic fibres e.g. viscose, cotton, or hessian.
  • Non-woven fabrics are made of synthetic or natural fibres e.g. viscose fibres bonded with polyvinyl alcohol, polyvinyl acetate or synthetic rubbers.
  • the carrier material gives both strength and dimensional stability to the PVC flooring. Manufacturers produce most PVC floors by a process known as 'plastisol spread coating'.
  • the PVC paste or so-called plastisol is applied in several layers of vinyl resin paste so that the floor is literally 'built up'.
  • these include an impregnation layer, a foam core, a decorative layer, a clear protective wear layer and a foamed or compact back layer.
  • the impregnation layer has a great importance to the final product quality as it forms a base for the other coating layers.
  • the back layer which is face downwards on the laying of the flooring material, is normally of greater thickness than the top layer giving cushioning properties to the flooring. Manufacturers can build up complex patterns and three-dimensional effects through these layers and offer choice of styles and effects. The end results are sparkling, smooth and shiny surfaces.
  • the preferred vinyl resin is polyvinyl chloride (PVC).
  • the PVC plastisol paste may contain plasticisers e.g. diisononyl phthalate (DINP), di-(2- ethylhexyl)phthalate (DEHP), benzylbutyl phthalate (BBP) and diisoheptyl phthalate (DIHP), trixylenyl and tricresyl phosphates, stabilizers e.g. barium-cadmium soap, dibutyl tin dilaurate, dibasic lead carbonate, lead stearate, pigments, fillers e.g. CaCO 3 , viscosity depressants e.g. hexylene glycol, and solvents e.g.
  • plasticisers e.g. diisononyl phthalate (DINP), di-(2- ethylhexyl)phthalate (DEHP), benzylbutyl phthalate (BBP) and diisoheptyl phthal
  • the coatings may be applied using conventional techniques e.g. spreading knife, roller coaters, screen coaters, hot melt coaters and extrusion coaters. Plastisols are rapidly fused so that the layers can be applied at a high production rate. Finally a pattern may be printed on the foam core layer after fusing.
  • a polymerised vinyl resin wear layer is provided on the printed layer, for example by coating with a vinyl resin paste.
  • the wear layer may be transparent, coloured, mottled or have patterns embossed thereon.
  • An additional polyurethane lacquer layer can be applied thereafter. Also other techniques like embossing and flake scattering are sometimes used to get special properties or effects to the final product.
  • a floor covering is disclosed where the base sheet if formed of an impregnated asbestos felt, a resin impregnated cellulose or other organic felt, or an asphalt saturated organic felt.
  • a prime coat made of latex possibly including pigments or fillers is applied on the felt to, for instance, improve the adherence of vinyl type compositions to the felt.
  • the document further teaches that the prime coat is laid on the felt separate from the felt manufacture, and on such a surface of the felt that is further provided with the various coating layers including a wear layer, i.e. on the upper side of the felt, not on the surface facing the floor.
  • the manufacture of the PVC floorings has remained substantially the same for decades.
  • the only remarkable change, which has taken place, is, that very often felt or veil or tissue made predominantly of glass fiber has replaced the various carrier materials discussed above.
  • the glass fiber tissue may be produced by any known mat-forming technique, including, for instance, so-called dry-laid, or wet-laid methods.
  • the glass fiber products which may be used in the manufacture of PVC floorings, will be discussed in more detail.
  • the products are, for the most part made of glass fibers, whereby the remaining fibrous part of the products may be made of both natural and artificial fibers.
  • the following discussion covers all fibrous substrates consisting at least 50% glass fibers.
  • Glass fibers are commonly produced by melting the glass raw materials and then fiberizing the molten liquid and applying a sizing chemical onto the filaments.
  • the filaments so produced are cut to usable length.
  • the fibers are typically deposited onto a moving, or sometimes stationary, support or collection surface to form a web of uniformly distributed fibers.
  • the deposition of fibers may be performed by using any known method, such as, for instance, so-called air-laid, foam-laid or liquid-laid technologies.
  • Liquid binder is applied on the fibers as they move along with the support or simultaneously with their spreading on the support.
  • the glass fiber web is subsequently transported into an oven in which the binder is dried and set or cured. Normally this is the product, so-called carrier substrate, which the PVC flooring, or CV flooring manufacturers buy from the glass fiber felt producers.
  • the properties of the fibrous products produced in this manner are mainly based upon the properties of the glass fibers, and the compositions of the sizing and binder chemistry. It would at times be beneficial to modify the products in order to enhance certain properties and/or reduce costs.
  • a major problem encountered in the manufacture of the PVC floorings is the costs involved in the use of PVC paste. This is especially true with regard to the carrier substrate, where compact paste is used whereas in the thick layers foam paste is most often used.
  • the carrier substrate is porous i.e. the interstices between the fibers are open all over the substrate
  • the PVC paste when applied on one surface of the substrate, both saturates the entire substrate and tends to partially penetrate or permeate the substrate.
  • This has been taken into account in prior art carrier substrates by adjusting the substrate thickness (means normally increasing the thickness of the substrate to exceed other requirements set for the thickness of the carrier layer) so that the substrate is able to absorb substantially all the PVC paste introduced thereon.
  • the thicker is the carrier substrate, the slower the paste flows therethrough.
  • the impregnation layer is the most expensive one, its thickness should be as low as possible.
  • Another problem relates to the permeation of PVC paste through the carrier substrate, i.e. the flow of the paste through the substrate.
  • the PVC paste collects onto the backing roller, from where it may be removed by doctor means, and returned back to use.
  • part of the paste remains on the opposing surface of the substrate, and gets into contact with rolls following the paste application, whereby the roll surfaces get dirty.
  • This can be avoided, for instance, by pre-gelling the paste with infrared lamps to dry the excess paste on the surface before the rolls.
  • This kind of treatment may lead to uneven coating having variations in the thickness and surface quality of the coating.
  • the penetration or permeation of the PVC paste is not a required feature, but proper and complete saturation of the substrate is normally the goal. Yet, the present technique does not know a way the complete saturation could be ensured without allowing some of the paste to penetrate or permeate the substrate.
  • an object of the present invention is to provide an improved carrier substrate for the manufacture of PVC or CV flooring.
  • the improvements include, for instance, • lowered material costs
  • the present invention provides a method of manufacturing a carrier substrate for PVC flooring, a carrier substrate and PVC flooring utilizing said carrier substrate.
  • the carrier substrate is basically manufactured in the manner described already above.
  • the thus formed substrate is coated on one side thereof with a pigment paste, which acts as a kind of a barrier layer, too.
  • the pigment coating makes the surface smooth, gives the surface a higher brightness, and prevents, at least for the most part the penetration or permeation of the PVC paste in the later manufacturing stages of the PVC flooring.
  • the carrier substrate used in the present invention may be manufactured, for instance, by a so-called wet-laid process where the glass fiber web is manufactured in a comparable manner as paper is manufactured with a paper machine.
  • Other applicable processes are the so-called foam laid or dry-laid processes.
  • the fibrous suspension is introduced from a headbox onto a wire where the liquid from the suspension is removed through the wire by means of mere gravity draining or of specific suction boxes.
  • the desired dryness binder in the form of a liquid is introduced into the web.
  • the web saturated with the binder is taken to an oven to be dried and cured. This far the process is the same as a prior art method of manufacture, whereby the above should be taken as an exemplary option for the manufacture of the carrier substrate.
  • the novel part of the process includes the coating of one of the faces of the dried and cured substrate with a pigment paste.
  • the pigment paste is applied onto the web by means of conventional techniques such as; for example spraying, film transfer coating, roller coating, curtain coating, or the like. After coating with the pigment the web is again dried in drying means and rolled. The rolls, slit to desired dimensions, are then delivered directly to the customers who produce the PVC floorings.
  • the coating pigment paste comprises at least one binder, either thermoplastic or thermoset, which is preferably a latex, like for instance, a polymeric latex binder, which is preferably composed of different acrylic esters or a co- or terpolymer of vinyl acetate, ethylene and/or acrylics, e.g. ethylvinyl acetate (EVA-latex) and styrene acrylic latex.
  • the binder may also consist of a thermoset polymer, which is preferably a polycarboxy polymer.
  • the polycarboxy polymer used in the binder may comprise an organic polymer or oligomer containing more than one pendant carboxy group.
  • the polycarboxy polymer may be a homopolymer or copolymer prepared from a variety of well-known low molecular weight unsaturated polycarboxy I ates including e.g. acrylic- maleic and acrylic-methacrylic acids or unsaturated anhydrides or their combinations.
  • the polycarboxy polymer may additionally comprise a copolymer of one or more of the aforementioned unsaturated carboxylic acids or anhydrides and one or more vinyl compounds. Methods for preparing these copolymers are well-known in the art.
  • the curable aqueous binder composition may also contain a polyol containing at least two hydroxyl groups.
  • the polyol can be industrially processed synthetic polyol such as triethanolamine, or from natural sources such as hydrolyzed fats and oils, reduced sugars and carbohydrates e.g. glycerine and mannitol.
  • binders or derivates of such as polyvinyl alcohol (PVA), starch, styrene-butadiene rubber or combinations of different binders may be used.
  • PVA polyvinyl alcohol
  • starch starch
  • styrene-butadiene rubber styrene-butadiene rubber
  • combinations of different binders may be used.
  • the binders may, in general, be either synthetic or of natural origin or a combination of both.
  • the paste further contains mineral pigments, of which at least clay (normally bentonite or kaolin), calcium carbonate, titanium dioxide, gypsum, vermiculite, perlite, volcanic ash and talcum may be mentioned. Naturally, synthetic and coloured pigments are also applicable.
  • the particle size of the filler material is usually about 5 ⁇ m or less.
  • the pigment paste contains at least 30 weight percent, preferably 60 - 90 percent on dry basis, filler material.
  • the paste may further contain cross-linkers, which are agents that are reactive with certain functional groups located primarily on the polymeric latex.
  • Cross-linkers preferably are used in a concentration of 3 to 12 percent on a dry basis to improve important characteristics such as film formation, surface energy, wet strength etc.
  • These reactive agents can be either organic or inorganic types, e.g. based on zirconium, urea/formaldehyde, melamine/formaldehyde or glyoxal derivatives.
  • the use of the above-discussed coating paste makes it possible to use a thinner carrier substrate.
  • the prior art glass fiber substrate having the basis weight of about 60 g/m 2 could be replaced with a glass fiber substrate having the basis weight of 35 g/m 2 provided with the pigment coating of the invention.
  • the pigment coating of the present invention may be from 2 to 150 g/m 2 , preferably 2 - 50 g/m 2 .
  • the basis weight of the coating may be raised even up to 150 - 200 g/m 2 .
  • the back layer of a flooring product is formed of substantially thick PVC foam.
  • the back layer may be left out and replaced with a pigment coating of the present invention coated on the back face of the substrate.
  • the present invention makes it possible to use glass fiber substrates having a basis weight below 50 g/m 2 together with a coating having a basis weight from 2 to 50 g/m 2 .
  • An advantageous feature concerning the coating of the invention is found after the impregnation of the coated glass fiber substrate.
  • the pigment layer is smooth i.e. it hides the ends of the fibers, thereby giving a finished look to the product.
  • the pigment coating does not form a totally closed surface, but such a barrier layer that prevents the free flow of PVC paste therethrough.
  • the opening size in the pigment layer is smaller than the open cavities in the basic glass fibre substrate.
  • the glass fiber material is substantially fine i.e. 8 to 15 microns, and the pigment coating is substantially thin
  • both the glass fiber substrate, and the coating include small pores, which draw due to capillary action the impregnation paste.
  • the impregnation paste not only impregnates the glass fiber layer, but also the coating layer whereby the structure of the substrate after impregnation is much more uniform than using the prior art techniques. Since the final impregnation of the paste takes place by capillary action, the impregnation paste does not enter to the open surface of the pigment layer but remains within the pores.
  • the thinner coating layer is much more flexible that the thicker prior art layers, and its resistance to liquid penetration is superior to the prior art layers.
  • the appended figure shows the carrier substrate of the invention used in a CV flooring.
  • the CV flooring utilizing the carrier substrate of the present invention comprises in the mid part thereof the glass fiber carrier substrate 20a provided with the pigment coating 22 of the present invention.
  • the actual production of the PVC flooring of this embodiment comprises several steps including a) Impregnating the glass fiber carrier substrate 20a with the impregnation paste 20b, preferably a PVC plastisol paste, b) Coating the substrate 20a with a second paste 24, on which the desired printing 26 is made. This is the so-called foam core. c) Laying the bottom layer 30 on the pigment coating 22 of the present invention. The bottom layer is most often so-called back foam, which gives the product the cushioning properties it requires, and d) Laying the top layer 28, which is a specially designed wear layer.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Floor Finish (AREA)

Abstract

La présente invention concerne le substrat support d’un revêtement de sol PVC, le procédé de fabrication dudit substrat support et le revêtement de sol PVC. Le revêtement de sol PVC est généralement connu sous le nom de revêtement CV (revêtement vinyle). La présente invention concerne en particulier la production d’un substrat support à la fibre de verre comprenant une nouvelle couche barrière, ladite couche barrière étant formée d’un revêtement de pigment appliqué sur une face dudit substrat fibreux (20a).
PCT/FI2006/050065 2005-02-15 2006-02-14 Procede de fabrication d’un substrat support pour revetement de sol cv, substrat support pour revetement de sol cv et revetement de sol cv WO2006087426A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20050167 2005-02-15
FI20050167A FI20050167A (fi) 2005-02-15 2005-02-15 Menetelmä kantajasubstraatin valmistamiseksi PVC-lattianpäällystettä varten, kantajasubstraatti ja PVC-lattianpäällyste

Publications (1)

Publication Number Publication Date
WO2006087426A1 true WO2006087426A1 (fr) 2006-08-24

Family

ID=34224205

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI2006/050065 WO2006087426A1 (fr) 2005-02-15 2006-02-14 Procede de fabrication d’un substrat support pour revetement de sol cv, substrat support pour revetement de sol cv et revetement de sol cv

Country Status (2)

Country Link
FI (1) FI20050167A (fr)
WO (1) WO2006087426A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008008510A3 (fr) * 2006-07-13 2008-03-20 Owens Corning Intellectual Cap Voile fibreux à teneur élevée en charge
WO2008039262A1 (fr) * 2006-09-27 2008-04-03 Owens Corning Intellectual Capital, Llc Voile fibreux à teneur élevée en charge
WO2012107233A1 (fr) * 2011-02-11 2012-08-16 Johns Manville Europe Gmbh Non-tissé en fibres de verre et produits contenant des non-tissés en fibres de verre
US9493954B2 (en) 2009-09-28 2016-11-15 Owens Corning Intellectual Capital, Llc Underlayment with slip-resistant surface
US9702148B2 (en) 2005-09-29 2017-07-11 Owens Corning Intellectual Capital, Llc Rubberized roof underlayment
US10378135B2 (en) 2013-08-06 2019-08-13 Johns Manville Glass fibre mat and products containing glass fibre mats

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4138521A (en) * 1974-11-14 1979-02-06 Nairn Floors Limited Flooring materials
US4175155A (en) * 1977-12-22 1979-11-20 Gaf Corporation Decorative covering material
JPH06272193A (ja) * 1993-03-17 1994-09-27 Mitsubishi Paper Mills Ltd シート材料
JPH1046485A (ja) * 1996-07-30 1998-02-17 Mitsubishi Paper Mills Ltd ガラス繊維混抄塗工紙
WO2000036214A1 (fr) * 1998-12-16 2000-06-22 Owens Corning Couche de non-tisse obtenue par voie humide et procede de fabrication
US20030175478A1 (en) * 2000-07-18 2003-09-18 Claude Leclercq Plasterboard and its manufacture
JP2005256217A (ja) * 2004-03-11 2005-09-22 Mitsubishi Paper Mills Ltd ガラス繊維混抄不織布

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4138521A (en) * 1974-11-14 1979-02-06 Nairn Floors Limited Flooring materials
US4175155A (en) * 1977-12-22 1979-11-20 Gaf Corporation Decorative covering material
JPH06272193A (ja) * 1993-03-17 1994-09-27 Mitsubishi Paper Mills Ltd シート材料
JPH1046485A (ja) * 1996-07-30 1998-02-17 Mitsubishi Paper Mills Ltd ガラス繊維混抄塗工紙
WO2000036214A1 (fr) * 1998-12-16 2000-06-22 Owens Corning Couche de non-tisse obtenue par voie humide et procede de fabrication
US20030175478A1 (en) * 2000-07-18 2003-09-18 Claude Leclercq Plasterboard and its manufacture
JP2005256217A (ja) * 2004-03-11 2005-09-22 Mitsubishi Paper Mills Ltd ガラス繊維混抄不織布

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 199443, Derwent World Patents Index; Class A25, AN 1994-347664, XP002380728 *
PATENT ABSTRACTS OF JAPAN vol. 1998, no. 06 30 April 1998 (1998-04-30) *
PATENT ABSTRACTS OF JAPAN vol. 2003, no. 12 5 December 2003 (2003-12-05) *

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9702148B2 (en) 2005-09-29 2017-07-11 Owens Corning Intellectual Capital, Llc Rubberized roof underlayment
WO2008008510A3 (fr) * 2006-07-13 2008-03-20 Owens Corning Intellectual Cap Voile fibreux à teneur élevée en charge
WO2008039262A1 (fr) * 2006-09-27 2008-04-03 Owens Corning Intellectual Capital, Llc Voile fibreux à teneur élevée en charge
US9493954B2 (en) 2009-09-28 2016-11-15 Owens Corning Intellectual Capital, Llc Underlayment with slip-resistant surface
WO2012107233A1 (fr) * 2011-02-11 2012-08-16 Johns Manville Europe Gmbh Non-tissé en fibres de verre et produits contenant des non-tissés en fibres de verre
US20130337251A1 (en) * 2011-02-11 2013-12-19 Johns Manville Glass Fibre Mat and Products Containing Glass Fibre Mats
US10378135B2 (en) 2013-08-06 2019-08-13 Johns Manville Glass fibre mat and products containing glass fibre mats

Also Published As

Publication number Publication date
FI20050167A0 (fi) 2005-02-15
FI20050167A (fi) 2006-08-16

Similar Documents

Publication Publication Date Title
CN101166873B (zh) 内墙板和其制造方法
US4138521A (en) Flooring materials
AU679565B2 (en) Decorative surface layer and process for its production
US7285183B2 (en) Making foam coated mats on-line
US4794020A (en) Process for manufacturing inlaid types of sheet materials
EP1462559B1 (fr) Mareriau non tissé avec de bonnes propriétes masquées, laminé et procédé d' obtention
WO2006087426A1 (fr) Procede de fabrication d’un substrat support pour revetement de sol cv, substrat support pour revetement de sol cv et revetement de sol cv
WO2005037549A1 (fr) Couche d'usure fibreuse pour revetement souple et autres produits
US20090130416A1 (en) Highly Filled Fibrous Veil
JPH0229391B2 (fr)
WO2001000406A1 (fr) Revetement de sol decoratif comprenant une couche de poly(ethylene terephtalate) dans la couche de surface et son procede de fabrication
JPH0116943B2 (fr)
JPH0229503B2 (fr)
US4983443A (en) Embossed and wiped decorative surface coverings
US20080014815A1 (en) Highly filled fibrous veil
US4816317A (en) Decorative surface coverings
US3259515A (en) Method for reducing gloss of printed surface coverings, and product thereof
EP0875618B1 (fr) Procédé pour la fabrication en continu de revêtements de murs contenant une étoffe non-tissée et revêtements de murs ainsi obtenus
KR20030040694A (ko) 승화 전사 공법 적용 및 섬유 파일을 사용한 비닐바닥재와 그의 제조방법
CA2456384A1 (fr) Starifie permeable a l'air
WO1995027007A1 (fr) Produits incrustes souples et leurs procedes de fabrication
JP2015158030A (ja) 人工皮革、及び人工皮革の製造方法
CN101622400A (zh) 用于树脂纸的印刷基的处理方法
CA1203724A (fr) Methode de fabrication de substrats poreux impregnes de pates thermoplastique de polymere et substrats ainsi produits
JP3447679B2 (ja) ステキヒトサイズ度が３０分以上である壁紙及びその製造方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application
NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 06708969

Country of ref document: EP

Kind code of ref document: A1

WWW Wipo information: withdrawn in national office

Ref document number: 6708969

Country of ref document: EP