WO2013059188A2 - Materials handling system, striated patterned product, and process of forming a striated patterned product - Google Patents
Materials handling system, striated patterned product, and process of forming a striated patterned product Download PDFInfo
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- WO2013059188A2 WO2013059188A2 PCT/US2012/060411 US2012060411W WO2013059188A2 WO 2013059188 A2 WO2013059188 A2 WO 2013059188A2 US 2012060411 W US2012060411 W US 2012060411W WO 2013059188 A2 WO2013059188 A2 WO 2013059188A2
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- calendering roll
- calendering
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- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 45
- 230000008569 process Effects 0.000 title claims abstract description 42
- 238000005007 materials handling Methods 0.000 title claims abstract description 14
- 239000000203 mixture Substances 0.000 claims abstract description 56
- 238000003490 calendering Methods 0.000 claims abstract description 45
- 239000002245 particle Substances 0.000 claims abstract description 36
- 238000012545 processing Methods 0.000 claims abstract description 15
- 238000002156 mixing Methods 0.000 claims abstract description 13
- 238000009408 flooring Methods 0.000 claims abstract description 11
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 5
- 239000003086 colorant Substances 0.000 claims description 7
- 239000000945 filler Substances 0.000 claims description 6
- 239000000049 pigment Substances 0.000 claims description 6
- 239000003381 stabilizer Substances 0.000 claims description 4
- 229920001519 homopolymer Polymers 0.000 claims description 3
- 229920001577 copolymer Polymers 0.000 claims description 2
- 239000000047 product Substances 0.000 description 66
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 20
- 229920002554 vinyl polymer Polymers 0.000 description 20
- 239000000463 material Substances 0.000 description 17
- 230000000007 visual effect Effects 0.000 description 15
- 229920001410 Microfiber Polymers 0.000 description 8
- 239000003658 microfiber Substances 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 7
- 238000009472 formulation Methods 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 239000004014 plasticizer Substances 0.000 description 5
- 238000009827 uniform distribution Methods 0.000 description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- 235000019738 Limestone Nutrition 0.000 description 2
- 229920006266 Vinyl film Polymers 0.000 description 2
- 239000010425 asbestos Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000006028 limestone Substances 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229910052895 riebeckite Inorganic materials 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 239000004408 titanium dioxide Substances 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- OKTJSMMVPCPJKN-NJFSPNSNSA-N Carbon-14 Chemical compound [14C] OKTJSMMVPCPJKN-NJFSPNSNSA-N 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- -1 bio-based Substances 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001493 electron microscopy Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000010128 melt processing Methods 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000008029 phthalate plasticizer Substances 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/24—Calendering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
- B29B7/52—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders
- B29B7/56—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders with co-operating rollers, e.g. with repeated action, i.e. the material leaving a set of rollers being reconducted to the same set or being conducted to a next set
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/58—Component parts, details or accessories; Auxiliary operations
- B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
- B29B7/606—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material specially adapted for feeding calenders or the like
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
-
- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
-
- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/17—Articles comprising two or more components, e.g. co-extruded layers the components having different colours
- B29C48/175—Articles comprising two or more components, e.g. co-extruded layers the components having different colours comprising a multi-coloured single component, e.g. striated, marbled or wood-like patterned
-
- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/505—Screws
- B29C48/67—Screws having incorporated mixing devices not provided for in groups B29C48/52 - B29C48/66
-
- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
Definitions
- the present invention relates to materials handling systems, products fabricated from materials handling systems, and processes for fabricating products. More specifically, the present invention relates to the process of producing striated pattern products, the materials handling systems for forming the striated pattern products, and the striated pattern products.
- Vinyl and non-vinyl products can include a heterogeneous layer of colored particles or chips.
- Such flooring products are used in various facilities and applications where performance improvement comes from having the particles or chips extend throughout the thickness of the product.
- Such through-color flooring products can be formed to have relatively short-grained striated patterns. The processes and systems used to manufacture these types of products have been designed to maximize the output of the short-grained striated patterns.
- a materials handling system, a striated patterned product, and a process of fabricating such a striated patterned product that do not suffer from one or more of the above drawbacks would be desirable in the art.
- a process for forming a product includes, mixing colored particles into a mixed composition, receiving the mixed composition between calendering rolls wherein a front calendering roll which is hotter than a back calendering roll, and forming a product with an elongated pattern.
- a process for forming a product includes, mixing colored paxticles into a mixed composition, receiving the mixed composition between calendering roils wherein the back calendering roll turns at a faster speed than the front calendermg roll, and forming a product with an elongated pattern.
- a materials handling system includes a mixing portion disposed to mix colored particles into a mixed composition.
- the system also include a processing portion disposed to receive the mixed composition, the processing portion having a front calendering roll which is hotter than a back calendering roll.
- a non-pvc thermoplastic, through-color, flooring product includes a narrow, long-grained, striated color pattern.
- FIG. 1 is a diagrammatic view of a known process and equipment for manufacturing vinyl composition tile having a short-grained striated pattern.
- FIG. 2 is a diagrammatic view of an exemplary process and equipment for manufacturing vinyl composition tile having an elongated visual striated pattern according to the present invention.
- FIG. 3 is a schematic diagram of an exemplar ⁇ ' materials handling system having an agitation portion and a processing portion which can be used in the exemplary process of manufacturing an elongated visual striated pattern.
- FIGS. 4A-B illustrate top views of example long-grained striated patterned products according to embodiments of the present invention.
- FIG. 5 is a flow chart of an exemplary process of forming a striated patterned product according to an embodiment of the disclosure.
- a materials handling system a striated patterned product, and a process of fabricating a striated patterned product, and in particular, a non-pvc thermoplastic, through-color, striated flooring product.
- Embodiments of the present disclosure permit fabrication of striated patterned products not previously available, provide elongated visual striated patterns with products having through-grain and through-color, and permit increased visual quality.
- a materials handling system 100 is configured to process a non-pvc thermoplastic composition of the type of material described in U.S. Patent Publication Number 2008/0081882, which is hereby incorporated by reference in its entirety.
- the materials handling system 100 includes an mixer or mixing portions 102 and a processing portion 104 arranged and disposed downstream from the mixer 102.
- the mixer 102 may be a hopper or other suitable container configured for handling a mixed composition 108.
- V CT vinyl composition tile manufacturing processes have utilized low intensity "dough" type heated mixers to compound/melt mix the tile formulation which is subsequently calendered into a layer. Higher intensity mixers such as extruders or Farrell type mixers may also be employed, and these high intensity mixers may also be heated to higher temperatures to compound the tile formulation.
- tile formulations comprising amorphous, polyester resins were mixed using a low intensity Baker Perkins heated mixer. The ingredients were added to the mixer which was heated to 325 degrees Fahrenheit. The formulations were mixed and heated for approximately 7-11 minutes on average in a Baker Perkins mixer to a drop temperature of approximately 280 degrees Fahrenheit. Depending upon the formulation, mixing time varied between 7-28 minutes and drop temperature varied between approximately 270 degrees Fahrenheit and 290 degrees Fahrenheit, as more fully described in Example 3 of U.S. Patent Publication Number 2008/0081882.
- the mixer 102 may include one or more agitator 106.
- the agitator 106 is arranged and disposed within the mixer 102 to mix the composition 108.
- the mixed composition 108 includes colored particles or chips 110 of multiple colors and sizes and one or more of other materials, such as a binder.
- the colored particl es 110 such as colored chips, are fed into an intake 1 12 of the mixer 102 upstream of the agitator 106, where the colored particles 1 10 tend to adhere to each other or settle in clumps or clusters when entering the mixer 102.
- the agitator 106 mixes, delumps and breaks up the clusters of colored particles 110 into a substantially uniform distribution within composition 108 for release at a discharge region 1 14 downstream from the agitator 106.
- the mixed composition 108 consists of only colored particles 1 10.
- the mixed composition 108 includes colored particles 110 and other materials (for example, clear particles, liquids, or other fluids).
- the mixed composition 108 includes multiple types of materials of different compositions, such as bio-based, fossil fuel based, or geological based materials.
- the geological based material includes clay or limestone. The length of time the colored particles are mixed contributes to the variation in color in the final product 118, i.e. the longer the colored particles are mixed, the more variation in color that can be achieved,
- the colored particles 110 are a maximum of about 1/2 inch in width, height and/or length. In one embodiment, the colored particles 110 are a minimum of about 1/32 inch in width, height and/or length. In one embodiment, the colored particles 1 10 are between about 1/32 inch and about 1/2 inch in width, height and/or length, are between about 1/16 inch and about 1/4 inch in width, height and/or length, and between about 1/8 inch and about 1/4 inch in width, height and/or length, or any suitable combination or sub-combination thereof. In one embodiment, the colored particles may be approximately cubed shaped or any other shape which yields the desired visual to the product 1 18.
- the colored particles 110 will comprise about 5% of the total mixed composition, 20% of the total mixed composition, 25% of the total mixed composition, 80% of the total mixed composition, between about 5% and about 80% of the total mixed composition, between about 15% and about 40% of the total mixed composition, between about 20% and about 25% of the total mixed composition, or any suitable combination or sub-combination thereof.
- copolymer resins are present in the colored particles 1 10, for example, by weight in an amount between about 4% and about 16%, between about 4% and about 5%), between about 9% and about 15%, between about 14% and about 16%, of about 4%, of about 5%), of about 10%, of about 15%, or any suitable combination or sub-combination thereof.
- homopolymer resins are present in the colored particles 1 10, for example, by weight in an amount up to about 10%, up to about 5%, between about 1% and about 10%, between about 1% and about 5%, between about 5% and about 10%, of about 2%, of about 5%), of about 9%, of about 10%, or any suitable combination or sub-combination thereof,
- plasticizers are present in the colored particles 110, for example, by weight in an amount between about 1% and about 10%, between about 1% and about 5%>, between about 4%» and about 6%, between about 5% and about 10%, of about 2%>, of about 3%, of about 4%, of about 5%, of about 8%, or any suitable combination or sub-combination thereof.
- stabilizers are present in the colored particles 1 10, for example, by weight in an amount up to about 0.5%, up to about 1%, between about 0. 1 %) and about 1%», between about 0.1% and about 0.5%, between about 0.5% and about 1%, of about 0.3%, of about 0.5%), of about 0.9%, or any suitable combination, or sub-combination, range thereof.
- colored particles 110 includes fillers, such as, but not limited to talc, clay, pigments, or limestone at a concentration of, by weight, between about 70% and about 90%, between about 70% and about 80%, between about 80% and about 90%, at about 80%, at about 85%, at about 90%, or any suitable combination or sub-combination thereof.
- fillers such as, but not limited to talc, clay, pigments, or limestone at a concentration of, by weight, between about 70% and about 90%, between about 70% and about 80%, between about 80% and about 90%, at about 80%, at about 85%, at about 90%, or any suitable combination or sub-combination thereof.
- the processing portion 104 includes a receiving portion 116, such as a nip.
- the receiving portion 116 is arranged and disposed to receive the mixed formulation of substantially uniform distribution of the colored particles 1 10 to form a product 118 with a predetermined pattern (see also FIGS. 4A-B).
- the processing portion 104 includes any suitable mechanism, such as two or more calendering rolls 120, 122 to form the product 118.
- the calendering rolls 120, 122 include further processing features, such as rotating at different speeds and operating at different heating temperatures, to provide the predetermined pattern of the product 118.
- the back calendering roll 120 turns faster than the front calendering roll 122.
- the speed of the back roll or upstream roll 120 is between about 1.1 to about 3.0 times faster than the speed of the front roll or downstream roll 122, between about 1.2 to about 2.0 times faster than the speed of the front roll 122, between about 1 ,2 to about 1.9 times faster than the speed of the front roll 122, between about 1.5 to about 1.8 times faster than the speed of the front roil 122, or any suitable combination or sub-combination thereof. Small changes to the relative speed of the rolls 120, 122 will not greatly impact the visual of the product 1 18.
- the back calendering roll 120 has a lower temperature than the front calendering roll 122.
- the temperature of the back roll 120 is between about 150 degrees Fahrenheit to about 270 degrees Fahrenheit, between about 220 degrees Fahrenheit to about 270 degrees Fahrenheit, between about 240 degrees Fahrenheit to about 260 degrees Fahrenheit, or any suitable combination or sub-combination thereof.
- the temperature of the front roll 122 is between about 250 degrees Fahrenheit to about 330 degrees Fahrenheit, between about 280 degrees Fahrenheit to about 330 degrees Fahrenheit, between about 290 degrees Fahrenheit to about 310 degrees Fahrenheit, or any suitable combination or sub-combination thereof.
- a process 200 of fabricating a product for example, the product 1 1 8 of FIGS. 1 through 4A-B.
- the process 200 includes mixing colored particles into a mixed composition with a substantially uniform distribution (step 202), for example, by rotating the agitator 106. This allows the colored particles to be properly distributed on the product 118, thereby providing a more gradual transition between colors for a more pleasant visual on the product 118.
- the process 200 includes receiving the mixed composition of the colored particles 110 (step 204), for example, in the nip or receiving portion 116, and forming a product 118 with an elongated pattern (step 206), for example, by use of calendering rolls 120, 122,
- the predetermined pattern formed is a long- grained, striated color pattern.
- the composition will stick to the back roll 120 and smear against the front roll 122. The smearing will cause the elongation and additional blending of the colored particles 110 to produce the desired visual of the product 118.
- the formed product is removed from the back roll 120 by means of an doctor blade 130 or other known device (step 208).
- the relative speed and temperatures of the rolls 120, 122 provide the visual as described herein, In addition, the relative speed and temperatures of the rolls 120, 122 also helps to minimize gas bubbles from being trapped in the composition as the product is formed. Therefore, blisters formed by gas bubbles or air entrapment is minimized, resulting in less waste and a better visual for the product.
- the process 200 includes further breaking up the colored particles 110 (step 210), for example, by passing through a grid 150 downstream from the agitator 106, as more fully described in co-pending U.S. Patent Application Serial Number 13/274,868, which is hereby incorporated by reference in its entirety.
- the process 200 includes any other suitable steps for forming the features described above.
- the process 200 permits fabrication of products having a striated pattern and the feature of through- color and/or through-pattern, thereby maintaining the visual quality of the patterned product as the surface of the product wears away over time.
- the product 118 includes a vinyl composition.
- Suitable vinyl compositions include, but are not limited to, polyvinylchloride (including copolymers and/or homopolymers), luxury vinyl tile, vinyl compositions of vinyl composition tile, and vinyl compositions of vinyl asbestos tile (or products replacing asbestos).
- the vinyl composition includes one or more plasticizers, one or more stabilizers, one or more binders, one or more fillers, and/or one or more pigments, such as a chloride processing pigment (for example, titanium dioxide).
- the vinyl composition includes one or more plasticizers, one or more stabilizers, one or more binders, one or more fillers, and/or one or more pigments, such as a chloride processing pigment (for example, titanium dioxide).
- the plasticizer includes or is a non-phthalate plasticizer.
- the binder includes or is any suitable polymeric material.
- the product 1 18 includes bio-based materials (for example, materials having a carbon- 14 signature identifying the materials as being from a non-synthetic source), recycled materials (for example, materials capable of being identified as being from a previously used product), renewable materials (for example, materials capable of being decomposed), or combinations thereof,
- the product 118 includes filler, at a concentration of, by weight, between about 20°/» and about 90%, between about 30% and about 80%, between about 40% and about 70%, between about 50% and about 60%, between about 20% and about 30%, between about 30% and about 40%), between about 40%) and about 50%, between about 50% and about 60%, between about 60%) and about 70%, between about 70% and about 80%), between about 80% and about 90%, at about 20%, at about 30%, at about 40%, at about 50%, or any suitable combination or sub-combination thereof,
- the binder includes or is any suitable polymeric materia] ,
- the predetermined pattern of die product 118 is a narrow, long-grained, striated color pattern.
- the predetermined pattern is variegated or marbleized.
- the predetermined pattern includes a majority of long, thin, linear, substantially parallel, mottled color marks, strands, bands or patches.
- the streaks or color marks are randomly located in the pattern such that the average distance between similarly sized mottled color marks of the predetermined pattern varies.
- the features "elongated”, “narrow”, “thin”, “long”, and “long-grained” are relative to ratio characteristics of the color marks.
- the color mark ratio characteristic includes a first dimension, for example, length, and a second dimension, for example, width, whereby the width may range from about 1/32 inch to about 1/2 inch and die length may range from about 2 inches to about 24 inches, or any suitable combination or sub-combination thereof.
- the ratio of the first dimension to the second dimension is abou t 500 or more to 1, about 65 to 1 , about 12 to 1 , about 6 to 1, about 4 to 1 , between about 500 to 1 and about 4 to 1, or any suitable combination or sub-combination thereof.
- the wider streaks or color marks can be more blended and more subdued relative to the background color of the product 1 18, while the narrower streaks can be more concentrated and more pronounced than the wider streaks, [0039]
- the predetermined pattern is termed "Striations".
- the Striations pattern is produced in a VCT flooring product,
- the Striations pattern includes a first color group, for example, a lighter colored background, and a second color group, for example, darker colored mottled elongate marks.
- the substantially uniform distribution of the colored particles 110 provides the predetermined pattern throughout the thickness of product 1 1 8 so that the desired visual pattern remains as the top layer of product is worn away from use over time,
- the predetermined pattern is configured to simulate naturally occurring striated patterns, found in organic materials such as glacier rock, marble or wood.
- the substantially uniform distribution of the colored particles 110 provides for the predetermined pattern colors and textures to be distributed substantially uniformly throughout the thickness of product 1 1 8, such that the product 118 is configured to be through-color, through-grained, and meets or exceeds the specification standards for through-pattern Class 2 according to ASTM F 1066 guidelines, in 1995, the American Society for Testing and Measurement (ASTM) provided a definition for 1066 Class 2 through-pattern tile as "either the pattern and colors on the surface of the tile extend entirely through the thickness of the tile without significant change, or the colors appearing on the surface shall extend throughout the entire thickness of the tile, although the appearance of the pattern created by these colors will change throughout the thickness",
- the predetermined pattern of product 118 is produced by calendering rolls 120, 122.
- a portion or all of the vinyl composition of the product 118 (for example, the resin(s), the plasticizer(s), and the filler(s)) is blended and mixed, then milled and melt-processed to form the product 118.
- the melt-processing is by calendering, extruding, continuous mixing, molding, milling, other melt-processes, or a combination thereof.
- the processing portion 104 includes suitable mechanisms to provide pre -heating before calendering, additional calendering, subsequent heating, curing, or any suitable combination or subcombination thereof.
- the product 118 includes a backing layer and/or one or more surface layers, In one embodiment, after initial processing, the product 118 is further cooled, and then press die-cut into planks, tiles, or any other suitable product.
- color strands or patches refers to strands or patches composed of groupings of color micro-fibers of various widths.
- micro-fibers are any suitable micro-fibers suspended within a material or arranged by any suitable technique,
- the term "micro-fiber” refers to any fiber having a dimension that is on the order of micrometers ( ⁇ 6 meters). Individually, the micro-fibers are visually indiscernible.
- the micro-fibers have a diameter of less than about 1500 micrometers, a diameter of less than about 100 micrometers, a diameter of less than about 50 micrometers, a diameter of less than about 10 micrometers, a diameter range of about 10 micrometers to about 1500 micrometers, a diameter range of about 10 micrometers to about 1000 micrometers, a diameter range of about 20 micrometers to about 500 micrometers, a diameter range of about 50 micrometers to about 500 micrometers, a diameter range of about 100 micrometers to about 500 micrometers, a diameter range of about 20 micrometers to about 400 micrometers, or a diameter range of about 40 micrometers to about 200 micrometers, the diameter being measured over a central 20°/», 50%, 80%, or all of the micro-fiber, for example, as measured through image analysis tools coupled with electron microscopy. Additionally or alternatively, in embodiments of the present disclosure, the micro-fibers have dimensional variance of less than 20%), dimensional
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Floor Finish (AREA)
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1408706.8A GB2510303B (en) | 2011-10-17 | 2012-10-16 | Materials handling system, striated patterned product, and process of forming a striated patterned product |
CN201280056060.4A CN103930251B (en) | 2011-10-17 | 2012-10-16 | Materials handling system, striated patterned product, and process of forming a striated patterned product |
AU2012326335A AU2012326335B2 (en) | 2011-10-17 | 2012-10-16 | System and process for forming a striated patterned product |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US201161548049P | 2011-10-17 | 2011-10-17 | |
US61/548,049 | 2011-10-17 | ||
US13/308,691 US9770851B2 (en) | 2011-12-01 | 2011-12-01 | Materials handling system, striated patterned product, and process of forming a striated patterned product |
US13/308,691 | 2011-12-01 |
Publications (2)
Publication Number | Publication Date |
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WO2013059188A2 true WO2013059188A2 (en) | 2013-04-25 |
WO2013059188A3 WO2013059188A3 (en) | 2013-07-11 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2012/060411 WO2013059188A2 (en) | 2011-10-17 | 2012-10-16 | Materials handling system, striated patterned product, and process of forming a striated patterned product |
Country Status (4)
Country | Link |
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CN (1) | CN103930251B (en) |
AU (1) | AU2012326335B2 (en) |
GB (1) | GB2510303B (en) |
WO (1) | WO2013059188A2 (en) |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080081882A1 (en) | 2006-10-02 | 2008-04-03 | Dong Tian | Polyester binder for flooring products |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2319040A (en) * | 1939-12-28 | 1943-05-11 | Eastman Kodak Co | Method of forming particles of thermoplastic materials |
US2314062A (en) * | 1940-06-03 | 1943-03-16 | Uvalde Rock Asphalt Company | Method and apparatus for marbleizing plastic compositions |
US2534291A (en) * | 1948-02-26 | 1950-12-19 | Eastman Kodak Co | Process for forming thermoplastic sheeting |
US2917781A (en) * | 1952-08-23 | 1959-12-22 | Congoleum Nairn Inc | Method for making thermoplastic composition products |
US3129194A (en) * | 1957-03-27 | 1964-04-14 | Congoleum Nairn Inc | Resinous molding composition |
DE1504434B2 (en) * | 1961-07-11 | 1970-11-05 | Joh. Kleinewefers Söhne, 4150 Krefeld | Method and device for the production of homogeneous, stretchable film webs from non-crystalline macromolecular plastics |
BE625193A (en) * | 1962-01-19 | |||
FR2852551B1 (en) * | 2003-03-21 | 2007-01-26 | Usines Gabriel Wattelez | PROCESS FOR THE PRODUCTION OF AN ACCOUSTIC AND / OR ANTI-VIBRATION ISOLATION COATING |
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2012
- 2012-10-16 WO PCT/US2012/060411 patent/WO2013059188A2/en active Application Filing
- 2012-10-16 CN CN201280056060.4A patent/CN103930251B/en not_active Expired - Fee Related
- 2012-10-16 AU AU2012326335A patent/AU2012326335B2/en not_active Ceased
- 2012-10-16 GB GB1408706.8A patent/GB2510303B/en not_active Expired - Fee Related
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080081882A1 (en) | 2006-10-02 | 2008-04-03 | Dong Tian | Polyester binder for flooring products |
Also Published As
Publication number | Publication date |
---|---|
WO2013059188A3 (en) | 2013-07-11 |
GB2510303A (en) | 2014-07-30 |
AU2012326335B2 (en) | 2015-10-01 |
CN103930251A (en) | 2014-07-16 |
GB201408706D0 (en) | 2014-07-02 |
CN103930251B (en) | 2017-03-22 |
AU2012326335A1 (en) | 2014-05-29 |
GB2510303B (en) | 2017-04-19 |
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