CA1320808C - Method for producing coloured surface-structures from thermoplastic synthetic materials - Google Patents
Method for producing coloured surface-structures from thermoplastic synthetic materialsInfo
- Publication number
- CA1320808C CA1320808C CA526296A CA526296A CA1320808C CA 1320808 C CA1320808 C CA 1320808C CA 526296 A CA526296 A CA 526296A CA 526296 A CA526296 A CA 526296A CA 1320808 C CA1320808 C CA 1320808C
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- CA
- Canada
- Prior art keywords
- weight
- strip
- granular
- layer
- particles
- 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 - Fee Related
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
- B44C3/08—Stamping or bending
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
- B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
-
- 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
- B29C43/006—Pressing and sintering powders, granules or fibres
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/30—Making multilayered or multicoloured articles
-
- 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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/02—Moulding by agglomerating
- B29C67/04—Sintering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
- B44C1/04—Producing precipitations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
-
- 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
- B29C2791/00—Shaping characteristics in general
- B29C2791/002—Making articles of definite length, i.e. discrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/06—PVC, i.e. polyvinylchloride
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/251—Particles, powder or granules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
- B29K2995/0021—Multi-coloured
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Laminated Bodies (AREA)
- Treatments Of Macromolecular Shaped Articles (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE:
A method for producing coloured, patterned, homogeneous surface-structures based upon thermoplastic synthetic materials, more particularly upon PVC, wherein freely flowing powders or particles are shaken continuously onto a carrier-belt in such a manner as to form a uniform layer, are sintered under the action of heat, until the thermoplastic synthetic material is plasticized, in order to form a coherent, porous surface-structure which is then cooled. At least one liquid or freely flowing, fusible, coloured medium is applied in predetermined patterns and penetrates into the sintered layer to the desired depth, more particularly through the entire thickness of the layer, and the coloured, sintered layer is thereafter compacted, under the action of pressure and heat, to form a compact surface-structure.
A method for producing coloured, patterned, homogeneous surface-structures based upon thermoplastic synthetic materials, more particularly upon PVC, wherein freely flowing powders or particles are shaken continuously onto a carrier-belt in such a manner as to form a uniform layer, are sintered under the action of heat, until the thermoplastic synthetic material is plasticized, in order to form a coherent, porous surface-structure which is then cooled. At least one liquid or freely flowing, fusible, coloured medium is applied in predetermined patterns and penetrates into the sintered layer to the desired depth, more particularly through the entire thickness of the layer, and the coloured, sintered layer is thereafter compacted, under the action of pressure and heat, to form a compact surface-structure.
Description
~, C~ 2 ~
The invention r~lates to a method for producin~ co~nur~!' s-lrri~ce-structures based upon thermo~lastlc s~nthetic materi;ll;.
Single-co~lcured, homogerleous surrace-structures ~ade o~ thermoplastic synthetic materials, mor~ p~rticularly of PVCJ in the form of ~trip or sheet~ with thicknesses in exces~ of 1 mm, may be produced, accorA-in~ to the state of the art~ by e~trusion-, coating- or rolling pro-ceSsss~ whereby single-colourJ homogeneous products are obtained which, from the point of view of design, have a cold plastic look and the typicala~pearance Or a synthetic material. Even mixturss of dif~e-rent granular materials, processed by extrusion or rolling, have pro-duced colour differentiation correspohding to the pigment3 used, but have b~ no means removed tha cold feel typical of the 3Dnthetic mate-rial. However, especially when ~hest or strip is used to cover floors or walls, special va~ue i9 place~ upon aesthetic appearance. In this connection, it is the purpose Or the invention to provlde surface-structures made of thermopla~tic synthetic materials giving an aes-,. - . .. ,. .. ~ ,..
theticall~ satisfying optical impre3sion and which may, if necessary have a non-directional pattern.
US Patent 3 3~1 067 disclose~ a method for ~roducing terrazzo-like floor-coverings in which soft PVC9 with fillers, dyestuffs and stabi~
lizer3, is used to produce a ~ranular material having athickne~ Or 6 to 12 mm and a dia~tq~r of ~ to '~0/~. This Is coated with a soft!Pvc paste, is shaken out into a uniform layer~ i~ heated7 sintered and, under the action of heat and pressure, is com~ressed into a continuous strip. The use of different compositions of granular material and coat~
~2~8 ing n~terial produces a covering in which the ~ranular ~aterials are embe~d~d in a soft~r sheath which thus displays different wear proper-tie~.
US Patent 3 192 29L, describes 6 method ror pro~ucing floor-coverings having a multicolour effect, for example pepper-and-salt patterns, in which th~ preferred PVC co~positions~ contalning the plasticizer and the expandin~ ag~nt.and in the form of powder, are shaken out into a layer, are heated until they are ~intered, and are then foamed by de-com~osition Or the expanding agent, whereupon the sur~ace of th~ ~aid strip, upon pas~in~ throu~h a roll-gap, is embossed in relief to half or more than half of its thickness. In this connection, the PVC compo-sition is prepared as a "dryblend~', i.e. it i~ mixed cold (to avoid premature decomposition of the expanding a~ent) and ths particles ex-hibit an average 9iZ~ of 15/um to about 3 mm, but a uniform particl~-size is used, for example 15/um~ It is al~o possible to add amounts o~ very small particles - 2 ~ - Or a copolymer. ~lowever, this may be hi~hly detrimental if the fines separate, i.e~ fall to th~ bottom and the coarse particles form an uneven surfdce.
Floor-coverings produced in accordance with US Patent 3 192 291"
with thicknesses of appro~imately 2.5 mm, are subject to crscking becau~e o~ their h~a~y surface embossing. They therefore require additional surface-protection in the form of an additional rll~. The heavy embossine also displaces the particle-structure~ thus producing elongated zones lackin~ uniformit~.
A method for rroducing a decorative multilayer covering i~ known from US Patent 3 35~ 3~2 and German Patent 12 9~ 023, in which ~mall particles, having a grain-size Or about 2.5 to 0.013 mm~ produced by _ 3 ~32~3~3~
mixing a P~C powder, a plas-tici~er, and additives at temperatures of about 93C, i.e. well below the sintering temperature of the synthetic material, are shaken out onto a substrate strip serving as a carrier, in a layer, and are sintered into a porous strip. These small particles, also called "dryblends", obtained by mixing a-t low temperatures far below the plasticizing temperature of the synthetic material, are soft and have lit-tle strength and rigidity since they are not plasticized. Upon subsequent compression, they therefore fly apart and produce, if different-coloured particles are used, mixed colours or colour contours which bleed and run in the direction of rolling. With this known method it is necessary to use a carrier-material in the form of a substrate layer. It i9 thus impossible to produce homogeneous surface-structrures, i.e. continuously designed layers without a substrate layer.
~lso with the soft particles of the dryblend, only coverings less than l mm in thickness can be produced free of cavities. Thus the coverings according to US Patent 3 359 352 are built up heterogeneously with an underlying additional carrier-layer.
It is therefore the purpose of -the invention, starting from the method of the same type according to US
Patent 3 359 352, to provide homogeneous surface-structures having clear designs and finely structured non-directional patterns.
According to the present invention there is provided a method for producing coloured, patterned surface-structures based upon thermoplastic synthetic materials, wherein freely flowing particles are shaken out continuously to form a uniform layer and are sintered under the action of heat until the thermoplastic material plasticizes, into a porous, coherent layer which is cooled, after which at least one liquid or freely flowing, fusible, coloured medium is applied in predetermined patterns and penetrates into the porous layer to -the desired depth, whereupon, under the ac-tion of pressure and heat, the coloured, porous lay er is compacted into a compact surface-struc-turet characterized in that for the purpose of producing the freely flowing particles, an initial mixture, based upon thermoplastic s~nthetic material, is processed, by thermal pretreatment above -the softening temperature, into an agglomerate or granular material and is mechanically comminuted into a granular mixture having any desired grain-size distribution; and in that, without using a substrate layre, the granular mixture is shaken out onto a conveyor-belt to form a uniform layer, - and is sintered.
Now surprisingly enough it was found possible with the technology according to the invention to produce an infinite variety of homogeneous surface-structures in which the colours and patterns extend right through the material, namely strip or sheet. These surface-structures far surpass existing marbling or patterning structures, upon which strict limits are imposed, from the point oE view of free choice and de~ign appearance, thus providing new possibilities.
The thermally pretreated particles used according to the invention exhibit a strong granular structure in contrast to dxyblend-powders. During sintering, this granular structure is retained and ensures the desired porosity for the following colour application and satisfactory penetration thereof. This granularity also prevents the printed design from running at the surface~
According to one preferred embodiment of the invention, the particles are used in the form of a granular mixt~re having a grain-size o~ up to 2 mm in any B
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desired distribution and -they are shaken onto the layer to be sintered. In order ~o achieve ~atisfactory porosity, the proportion of fines, in relation to the average size of the major part of the particles, should not be too high, in S order to prevent separation of the granular mixture. If the proportion of fines is too high, they fall through the coarser particles and collect only on the underside. This leads to a non-uniform structure and pattern.
The method according to the invention therefore 1~ provides, by applying finely divided, thermoplastic dusts and using grain-sizes preferably between 0.1 and 2 mm in diameter, on an endless support, e.g. a steel belt or a heat-resistant teflonized belt, in thicknesses of up to several mm, followed by sintering under the action of heat, a porous layer which, by a printing or spraying process, can be provided, through the entire thickness of the layer, with any desired pattern and, if necessary and after appropriate drying, if the colour-system used contains a solvent, can be made, under heat and pressure, into a homogeneous strip-product in which the pattern extends right through thematerial.
It was found, surprisingly enough, that thermally pretreated particles, in granular mixtures of a specific order of magnitude, when sintered and subsequently compressed, produce surface-structures having a finely structured, polychromal pattern which passes right through the material and has nothing in common with hitherto usual synthetic-material uniformity. Even if use is made of ; particles in a granular mixture which are of one colour only, a polychromal differentiated colouration is obtained.
By using only a few different multicolour patterned particles and mixtures containing different grain-sizes and grain-size distributions, it is possible to obtain an infinite number of colour and structural nuances.
~32~a8 It is preferable, according to the invention, to use granular mixtures of particles made from grinding dust and/or finely ground agglomerates, granular materials, chips, regsnerated materials, extruded materials, or the like. Sintered, porous layers, made from these particles, may then have colour applied to a part or to all of their surfaces.
According to a preferred embodiment of the - invention, particles produced by grinding, which form a mixture of different grain-sizes in random districution, are used to produce strip or sheet. For instance, it is possible to grind different sheets or strips made of a PVC
composition with plasticizers, fillers, stabilizers and pigments, with an abrasive belt of a specific grain-size, and thus to produce a grinding dust which initially appears to the naked eye to be of a single , : ~ , . ...
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colour, with a grain-si~e Or 0.1 to 2 ~m~ ror example. If this grind-in~ dust i9 red from a hopper, the front of whlch carries an ad~ustable rake5 onto a c~ntlnuously moving carrier-belt located thereundar, e~g~
a belt made of release-paper or steel, if the layered grinding dust i9 then allo~red to sinter under an I~-rield or in a heating duct, this produces a porous layer to which a through-pattern can be applied by printin~ or spraying. This can then be formed under pressure into a homogeneous~ cavity-fr~e ~trip or shaet with the pattern e~tending through the ~ntire thickness of the material, and the structure ~ the pattern i3 neither blurred hori~ibto~ted~
~ using only a fe.~r dirrerent~ multicolour, ~a~e~ed, ~2~ f~ es;
and by using mixtures containing different proportions, the grinding dusts produced can be varied in such a manner as to make it possible to obtain an infinite variety Or colour and structural nuances. It i~
preferable for the grains or particles obtained by grinding to be used in a mixture in which ~0 to 90% by weight i8 of a grain-size ~rom 250 . . .
to ~OO~m.
It was also found to be 3urpisine thatinstead of grinding dust, diPferentl~ coloured agglomeratec, heated, Por example, in a mixer,b~
frictionj to a specific temperature and applied to mdxtures of diff0-rent colours, result in a similar multi-eoloured uni-design. It is also possible to al~ti~r the nature of the agglomerate6, a~ regards structuring, b~ a grinding operation following the ~ixing. In addi-tion to this, mixtures of grinding dust and agglomerates are alsu possible, as ar~ cQmbinations of filled and unfilled systems, i.e. ;~
, PVC compositions with or. without fillers. Furthermore, the use of particles o~ transparent synthetic ~ateriàls imparts a spatial im-. ;- ' , , "
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132~
pression in addition to the polychromal character. However~ such pDly-chromal~ ho~ogeneous sheeta, o~ e~en strips~ n~y be produced not only from grinding dust and aggl~merates, but al~o from regenerated mate-rial from differently coloured edge-3trips which ha~e been chopFed up and ground. A similar effect may also be obtained from suitably coloured granular material which has been ground, by the ~inber~press;;~pro~s~. .
Simllarly, a mixed PVC powd~r with additives may be plasticized in a plasticizer or extruder~ ma~ be processed into granules, chips or plate-lets, and may b3 ~round to the desired fine granule~ or mixture of ~ine granules. The PVC compositions ma~ be trane~arent, of one co~our or multicoloured~ Mixturss of differently coloured dusts and granules may be used. After compression, this pruduce3 a brilliant~ Pinely re-solve~ multi-coloured and non-directional baQic tone. A moderate to differentiated appearance, a fi~e or coarse structure, and a slight to high ca~acit~ for resoluti~n may also be achieved by variations in grain-size and distribution of the particles used.
It is pr&ferable to use mixtures Or agglomerates produced by mixing a PVC composition at temperatures of up to 170C, brought about by frictional heat~ followed by cooling, grinding and, if necesYary, sçreening out. Such a mixture of;a~.lomerates,iwhich leads~*oparticularly attractive designs, has about 20 to 75% by weight of the grain-size from 500 to 2000 ~ in the mixture. ;~
hccording to the invention, it is possible to alter the structure o~ the strip, and therefore the de~ign9 i.e. the polychromal e~fect, b~ varying the configuration of the particles, whether the~ are in the Porm of granules, or are of different si~e~obtained by grinding or milling.
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According to a further preferred embodiment of the invention, the particles are obtained by crushing extruded material, granular material, regenerated material, chips agglomerates or mouldings, 1, 1.5 or 2 mm screens being used for screening out. All of these mixtures obtained by grinding contain thermally pretreated particles which have already been plasticized once and therefore provide a strong granular structure. The thermal pretreatment was carried out, for example, during manufacture of the agglomerate or during extrusion of mouldings which were processed into granular material, chips, edge-strips or scraps, in order to provide the starting material for the granular mixtures to be produced and used according to the invention.
A mixture of particles of different origin, for example from grinding processes, preferably contains from about 30 to 95~ by weight of the 500 to 2000/,um grain-size.
;~ It is also possible to use mixtures of particles - of different origin, colours, structures and/or grain-size distribution.
20For good porosity, leading to uniform penetration through the material, relatively uniform grain-sizes are preferred~
Strips or sheets with pa~ticularly fine, uniform and random patterns may be obtained when granular mixtures 25containing 90 to 100% by weight of ~he 300 to 800 ~m grain-size are used.
Surface-structures to be used as floor- and wall-coverings may be obtained by using a preferred embodiment of the invention. This produces transpaxent and translucent to opa~ue strip. According to such preferred embodiment one obtains, from a PVC composition containing:
60 to 80% by weight, of E, S, M-PVC having a K-value of 50 to 80, 19 to 39% by weight, of a plasticizer, 1 3 ~ 8 0.5 to 2~ by ~eight of as stabilizer, 0 to 3~ b~ weight of a colouring agent, by plasticizing at tempera-tures above the softening temperature, more particularly at about 140 to 170C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture may be obtained by comminuting, for example by milling or grinding.
; According to the present invention filled strip or sheet may preferably be produced from a PVC composition containing:
40 to 60% by weight of E, S, M-PVC having a K-value of 50 to 80, 1~ to 24% by weight of a plasticizer, 20 to 40% by weight of fillers, 0.5 to 2% by weight of a stabilizer, 0 to 3% by weight of a colouring agent by plasticizing at temperatures above the softening temperature an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture may be obtained by comminuting.
In addition to PVC, other thermoplastic synthetic materials, for example a copolymer based upon ethylene-vinylacetate, may be used.
Within the meaning of the invention, the term PVC
is also intended to include copolymers with vinyl-acetate, ethylene-~inylacetate and possibly acrylate-polymers, which may be used alone or in mixtures.
For the purpose of applying colour to the sintered, porous layer, it is preferable to use liquid, possibly coloured, media in the form of pastes such as PVC
pastes, aqueous polymer dispersions, polymers dissolved in organic solvents, or fusible, coloured, polymer powders.
The liquid media may be applied in any desired manner, 13208~g preferably by printing or spraying. The simplest way of printing is to use a rotary screen-printing installation in which the number of stations determines the additional colours and structures to be applied. Patterning may, of course, also be carried out by a spraying process, namely alternating spray-guns or nozzles operating in synchronism, as in the Chromotronic or Millitron processes. The amount of colour, applied in the form of a solution or a paste must be only enough to ensure penetration to the desired depth, i.e. the total thickness of the strip. As regards printing colours, solutions, aqueous dispersions or pastes may be used. For example, coloured PVC-pastes may be used in the case of soft PVC granules~
It is preferable to apply several differently coloured liquid media consecutively to various parts of the surfaces of the sintered strip, in the form of a pattern, but the whole surface of the strip must not be patterned since the basic sintered strip also exhibits, after being ~ .............. ... . . . . . . .. .. .. ... .
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compre~sed, sin~le- or multicolour efrects and, together with the colour applied, thus provides the desired design.
In the case of homogeneouq coverin~s, therePore~ which have patterns ; extendin~ throuEh the entire thickness Or the strip according to the method of the invention, there are now, for the first time, no longer any limits to the type and choice of patterning.
~oriented Whereas it has hitherto been possible to achieve only longitudinally~
or chip-like structures, it is now largely possible to produce patterns rangin8 from geometrical structures of lines and circles to imaginative printed ima~es correspondin~ to modern printin~ technolo~y. In addi- ~
tion to this3 all homogeneous coverings,patterned an~ structured ~ ;
accor~ing to the m~.hod of the invention, ha~-e an appearance with a t~tally different feel. It is no longer a cold structure printed on a plastic surface; instead it is a ~look~ radiating warmth hitherto kn~wn ~nly in natural pro~ucts or textilcs The method according to the invention is particularly suitable for trend indicatin~ development of textile ~tterning and structuring for synthetic material~q. The grain-size and distribution of the thermo-plastic material used makes it possible to obtain a moderate to diffe-rentiated aspect, a fine or coarse structure, or also a small or large capacity for resolution. ~;~
The method according to the invention provides a living~ three~
dimensional appearanc~ in that the printed substrake, depending upon the colour of the mono- to poly-chro~atic effect~in combination with a possible multi-coloured printing process, provides a hitherto unknown colour and space dimension.
In the case of screen-printin~, the size of the raster, the type ~ ~ !
3 C~ ~ 8 ~ ~
of printing ink, the dispersion-solutions and pastes, and the viscosity thereof, are of grea-t importance for the printed image.
According to a further preferred embodiment of the invention, prior to the application of the liquid media, the sintered layer is cooled to a temperature below 50C, preferably below 35C. This ensures proper penetration of the colour applied and premature vapourization of the solvent, or blocking of the pores, is eliminated. According to a further preferred embodiment of the invention, it is proposed to heat the sintered layer, and the applied colour, for compacting, to a temperature of at least 150C, preferably 165C.
According to the invention, one preferred method for producing surface-structures made of thermoplastic synthetic materials, in which the patterns extends right through the material, provides for the particles to be shaken out to form a layer preferably 5 to 12 mm in thickness, to be heated to a temperature of about 210 C and thus to be sintered. The sintered layer is then cooled, possibly to a temperature below 50C, after which the liquid coloured media are applied consecutively, using a weight per unit area of about 100 to 900, preferably 100 to 500 g/m , by spraying or printing. The solvent content is preferably evaporated and the sintered layer, with the applied colour, is heated to a temperature of at least 150, preferably in excess of 165C and is compressed homogeneously, at a surface-pressure of about 0.2 to 20 N/mm2 or a corresponding linear pressure in the roll-gap, to form a strip having a final thickness of about 1.5 to 4 mm.
The amount of colour applied is gouverned, more particularly, by the way it is applied, i.e. as a dispersion, a solution or a paste. The amount i9 also governed by the thickness of the porous layer and the pattern.
The material of which the con~ey~r-belt i~ made should be ~uch that the fini~hed strip can easily be removed from it, for ~xample release-paper~ a teflonized fabric, or metal, for example a steel belt~ Th~ heat energy re~uired for sintering may be obtained from an -radiator, hot air, or a high-frequency field, the subsequent com-pression being carried out continuously by a rolling mill or a single-or double-belt pres~. The surface of the strip may be embo~ed, de-pe~ding upon the surface-structure of the rolls or belts. The depth of the embossing is preferably up to about 100/um~ but may also exceed this~
Although surface-structures based upon PVC are preferred because o~
their low cost, especially for masR-procluced product~ like floor- and wall-coverings, the use of the invention i5 not restricted thereto.
The suitabilik~ Or plasticizers, stabilizers and fillers is al~o governed by the combination of materials and the purpose for which ~;
the product is to be used.
The in~ention i~ ~xplained hereinafter in greater detail, in con-~unction with examples and the drawin~ attached hareto9 wherein:
Fig. 1 is a diagram of an insta].ltion having a ;~
sintering section, colour application and com~acting;
Fig. 2 is a diagram of~o~m~a~t~ngib~`mean~lQ~,p~e~sure-rolls;
~ig 3 is a diagram of compa~ti~-wi~hl!b~lt~presses~
Fig, h is a diagram of compactin~ with a double belt-press; ;
Fig. 5 is a cross-section of the colour-application stations;
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ri~. 6 shows the phases in multirle printi.ng by means of.flat-screen-~rintinr stencils : a~.cording to Fig. 5-FigS. 7-11 .show different designs corresponding to dirferent granular mixtures and colour applications.
The method according to the invention i3 explained in conjunction with the dia~ram of Fig. 1. The carrier used is preferably an endless conveyor-belt 1 running over two defl.ecting rollers 18,19, at least one of which is dri~en. The said carrier is preferably made of release-paper, steel or also Teflon* (polytetrafluorethylene) strip.
lQ Granular mi~ture ~ is deposited onto the conveyor-belt from hopper 2, comprisi.ng an ad~lustable rake 3, preferably in the fvrm er a layer between 5 and 12 m~ in thickness.(ror ~loor-coverings),~ depending upon : the desired final thickness of the surrace-structure. It is also po~sible to use other applicator systema, for ffxample metering channels or roll-knives. Layer ~0 is then heated continuously9 for example ùnder an infra-red field 5 and/or in a heating duct 6, to the plasti-cizing temperature amd is sintered into a continuou.s surface-structure hl. Durin~ this sinter m g procesa. layer ~O decreases in volume and ~ ~
the thickness drops to approKi~ately ~ to. 10 mm. ~ :
In the continuous production p~ocess, sintered strip ~1 is allowed to cool~ after sintaring, for exam~le ~y PaaSing through a cooling station 60 which uses air-~ets shown ~acing the strip in colour appli- . -cation stations ~0,31. The number of these stations is go~arned by the desired design and the type o~ station. These determine the structures~ the number of colours in the design, the size of the raster of the rotatin~ stencils~ and tha ~olume of co~.our medium to be applied.
The col~lr-media used may be sol~ent-free systems, for example PVC
* Teflon is a Trade Mark .
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pastes or also aqueous rolymer dispersions, or also polymers dissolved in or~anic solvents~ However~ it is also possible to operate with a heated polymer fusion and with coloured polymer powder~. The use Or a usion calls for an inter-station cooling ~ection, while powders re-quire heatin~ and coolin~ zones between individual stations. n the other hand it is possible to operate ~et-on-wet.with SJStems which are liqu;.d at normal temperatures. Coloured sintered strip ~2 is then passed through a heati.ng area 70 Por dryinF the applied colour if ne-cessary and for heating i.t .~or the ~compactinF o~eration........................... :~
1;0 After the colour-application stations, strip ~2, into which the colour-media have penetrated, passes through a pressing station, for ;: exa~pIe a pair oP embossing rolls 7,~ where it is compressed and the .. . ~, surfaceis made smooth or is lightly embossed. Final product ~3 then leave~ the installation and i3 pa~sed to fàbrication.
: 15 Fig. 2 is a dia~rammatical repre3entation o~ a pressing and embossing unit comprising a rubber roll 7 and a metal roll ~. For the purpose ~ .
comprassin~ the sintered strip ~2, with the applied colour, it is al~o possible to use a belt-press, as shown in Fig. 3, the belt, which runs o~er deflectin~ rollers 10~ 12, being guided in such a manner as to pre~ the sintered strip, over a predetermi~ed path, a~ainst belt-roll 9 and~ after it has cooled , to remove it from belt 20 as a fin.ished strip ~3. As æhown in Fig. ~.) it is prePerable to carry out the compression by means o~ a double belt-press which uses two endless belts running o~er dePlectiag rollers 10,11 and 1~,13. The sintered ~;
strip is pressed altennately against rolls 9 and 15 and, a~ter is has been compressed and cooled, it is remot~ed from belt 20. The surface of strip L3 may be refined either in the belt~press, or in a subse-:, .
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quent embos~in~ station, for e~ample, or also by a grinding and/or polishin~ procass~
Fig. S is sn enlarged representation of the colour-application station. In the example shown, four stations 3O to 33 are provided and are filled with difrerent colour~ 5O to 53. The said colours, or colour-media, are adaptad to penetrate into porous, open-pored sin-tered strip 1,1 right to the other side, 90 that the printad lma~e is reproduced throughout the entire thickness. After the colour-media have been applied and have penetrated, and if aqueous or solvent-containing colour-media are used, drying i5 carried out in a heating duct 70 The high~r temperatures, acting upon strip ~2 at the end of the heating duct, raise it to the temperature required for embassing in the embossing Ytation sho~n in FigS, 2 to ~, where the said strip is compacted and the surfsce i~ embossed. ~;~
Fig. 6 is a plan view of the colour-application stations according to Fig. 5, showin~ the individual ~a~terning steps in the individual phases, by way of example. Fig. 6a shows the patterned strip in cross-~ection with the different fully-penetrated coloùrs 51 to 5~. The number of printin~ operations may be carried out as desir~d. For ax-ample six colours and designs may be printed. As regards the pos~i-bilities of individual prin~ed images, there is a ~ree choice. Fig~ ~b shows the print of first colour 51 on porous, sintered strip 41, Fig.
6c shows the print of the second colour 52, FiP. 6d shows the print of third colour 53, and ~ig, 6e shows the print o~ fourth colour 54~ Areas may also be left Iree of colour since, if the base material of sintered strip ~1 is coloured, transparent or trsn~lucent, an additional pattern-in~ effect also arises here. In any cas~, the pattern applied exist~
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right through the thickness of the strip. Thus the surface design does not disappear as a result of wear and abrasion wheh the strip is used as a floor-covering, for ~xample. A strip of this kind may be almost 100~ worn out, with no 109s of the design.
The foLlowin~ examples deal with possible embodiments o~ the method ~ .
according to the invention, and with the production and use of granular mixtures and colour-media.
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A basic batch of filled soft PVC contai.ning the following ingredients: ~
31 parts by weight of P~C-Vinnol ~ 68 (Wacker-Chemie) ~-13 " " " " d7octylphthalate 2~ " " " " chalk 0.15 a stabilizer based upon Sn - . .
is first of all mixed. 70 par-ts by weight o~ thi.s batch are mixed separatel~ with the following colour-pi~ments.and, after mixing, are granulated in an extruder:
Colour No. Colour Parts by weight 1 meaium-brown 0.7 2 light-brown 9~7 ?
~ greenish-beige . 1.337 L dark-brown 0.252 : 20 E~trusion tem~erature 170C, granu~.ar material ~-~ mm in.~
The granular materials are then mixed again in the followin~ weight-. - , .
ratios: Colour No. 1:2:3~ 0~76 and ar0 processed,. by means of an extruder and a rolling mill, to form a marbled strip-product.
: Calibratlng by grinding with 50 and 100 abrasive-grain belts produces ~-a gri.nding dust having the following grain-size distribution (wet-screening):
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mm 0,~4 o,7 o,o4- 0,063 0,~
0,063 ~ 0,1 0,2 0,1 - 0,125 o,g 0,1~5 - 0,2 2,0 0,2 - 0,25 7,8 0,2s - 0,315 16,4 o,315 - o,5 35,5 0,5 - o,8 32,5 o,s - 1,o 3,1 1,o - 1,6 o,4 1,6 - 2,0 o,1 The grinding dust thus obtained is deposited, from a hopper having a vertically adjustable rake set at a 5 mm gap, onto a strip of release-paper. It is sintered under an infra-red radiator 0.6 m in length ~7,5 KW) and in a hot-air duct 6 m in length, at temperatures of between 160 and ~05C, at a speed of 1 m/min. The sintered, cooled material is then printed with coloured PVC pastes in a rotary screen-printing unit.
The composition of the pastes was as ~ollows:
270 parts by weight of PVC Vinnol~P 70 E
135 " " " " PVC Vinnol~C 65 V
164 " " " " Linplast~ 68 P
g " " " " Irgastab* T 150 9 " " " " Reoplast* 39 56 " " " " Calcicoll* SW 35 4 " " " " Minex~ 7 48 " " " " Edenol* 190 1 " " " " colour.
* Vinnol, Linplast, Irgastab, Reoplast, Calcicoll, Minex, Edenol are trade marks.
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Corresponding to the 4-colour printing design, and matching the grinding dust used, the ~ pastes requires were coloured medium-brown, light-brown, greenish-beige and dark-brown respectively. Textile structures in a 40-mesh raster-size were printed as the pattern. The printed PVC pastethen penetrates, according to ' .
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the rredetermined ~attern, ri~ht through the sintered layer. With this method it i5 possible to o~era-te wet-on-we-t with no smearin~ of indi-vidual eolours. The~amount of paste ~pF1i.ed was S~0 g/m2 After the pattern had been printed and had penetrated to th~ back of the sinter-ed layer, the materia]. wasf~assed through.a heating duct at a tempera-ture of lgO to 200C, at a speed of 2 m/min. Additional heat was applied to the surface b~ a subseqllent 7.5 KW IR~field. The sintered strip was then comp~cted in an embo~sing station,~ the surfac~ being embossed at t~le same time~ Thls produced a printed textile design extending right through the 2 mm thickness Or the strip, the e.rfect bein~ also reinforced by the polychromal basic structure of the sin-tered material. The sintered and patterned strip-material produced , in accordance with this example could also be compacted and smoothed, .
at about 170C~ in a belt-press.
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a~ple 2 .
The grinding dust obtained in ~xample 1 is ~ixed? in a 1 : 1 ratio, with a grinding dust B obtàined from another colour combination and produced in the fo].lowing composition:
COlour No. COlour Parts by weight (per 70 parts o~
th~ basic batch) S dark-greyish-brown 0;2/~
6 dark-reddish-brown 0.~5 7 medium-brown 0.
~ reddish~beige 1.0 Granu~ar ratio in mixture:
Colour No. 5 : 6 : 7-: g = 1 : 1 : 1 : 0..76.
The grain-size Or the grinding du~t was as follows: ~.
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l9 mm % '' 0,04 o,s 0,0~_ 0,0~3 ol2 0,063 - 0,1 o,2 0,1 - 0,125 1,0 0,125 - 0,2 3,9 0,2 - o,2~ 10,3 0,25 - 0,315 16,3 0,315 - 0,5 42,7 0,50,8 23,5 0"3- 1,0 o,8 1,0- 1,6 0,1 1,6- 2,0 0,1 The A and B grinding dust mixture from two differently coloured strips with a total of 8 basic colours is placed in a frame-mould with an edge 7 mm in thickness.
The material is then cooled, which reduces it to a thickness of 5 mm and the pattern is then applied by flat-screen-printing with a coloured PVC dispersion. The raster was 0.42 mm in diameter. The composition of the PVC dispersion used was as follows:
250 parts by weight of water 5 " " " " ammonium-hydroxide 250 " " " " Vestolit Dispersion M
15 " " " " Byk NP~ 3100 15 " " " " Etingal TP
30 " " " " Unimoll BB*
200 " " " " Latecoll* W 55 6 " " " " Disperbyk*
170 " " " " Colanyl Oxide Yellow G
130 " " " " Colanyl Oxide Black G.
Vestolit, Byk NP, Etingal, Unimoll BB, Latecoll, Disperbyk, Colanyl are trade marks. ~`
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~32~)8 l9a The amount applied was 176 g/m2 wet. The colour dispersion penetrated right through the layer in accordance with the printed image.
Further processing was according to Example 1.
The product ob~ained has a polychromal basic structure and a homogeneous printed pattern extending right through the material.
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h~;am~]~ -I'ro~ the ~trips produced accordin~z to ~xample 1, it ix possible to cut edge-strips, to reduce them to 5 to 10 m~ chips~ and to grind the said chips in an ~-lpine mill having a ~ mm screen.
The grain-size wa9 mm %
0,04 0,9 ~ 0,04 - 0,0~3 1 0 : 0,063 - 0,1 1,2 0,1 - 0,125 1,4 0,125 - 0,2 1,6 0,2 - 0,25 1,2 0,25 - 0,315 1,4 0,315 - 0,5 4,8 0,5 - 0,8 10,7 0,8 - 1,0 ~11,8 1,0 - 1,6 22,4 1,6 - 2,0 41,6 ;~ The ground regenerated material wa~ sintered and, after cooling, was patterned by flat-~crean-printirg and a ~ingle-colour PVC disper~
s on as in Example 2~ then dried and compressed. The colour applica-tion amounted to ~gO g~m2. ;, The 2 mm thick s~eet ~as patterned right through and also exhibited a polychromal basic ~tructure.
~ample l.
The basic batch~ containing a 1,5~ light-green colour-pigment accord-ing the ~xam~le 1, was ~ixed and granulated in an extruder at a tempe-rature of 170C, the re~ulting gra~ules being between 1, and 5 mm in dia~eter. These were ground in a type PP6 Pallmann*milI having a 0vs mm ga~.
; * Pallmann is a trade mark.
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' 2 l ~. 3 ~ 8 The ~rain-size ~:
mm ~
0,04 0,6 0,04 - o,a63 0,3 0,063 - 0,1 0,3 0,1 - 0,125 1,3 0,125 - 0,2 3,3 0,2 - 0,25 5~5 0,25 - 0,315 9,2 0,315 - 0,5 29,8 0,5 - 0,8 29,5 0,8 - 1,0 12,3 1,0 - 1,6 5,7 1,6 - 2,0 2,2 10The ground msterial was shaken according to ~x3mple 3 to form a layer 10 mm in thickness, was processed according to Example 1 by flàt-screen-printing using a coloured PYC pasta, and was then compressed a~cording to ~xample 1.
The paste a~plied amounted to 700 ~/1n2, the final thickness of the 15sheet being 2.3 mm. The result ~as a ~heat having a total thickness of 2,3 mm having a single-col~ur basic sha~le and a pattern of a darker ~hade extending right through.
~a~ple 5~ :
~: The method accordin~ to th~ in~ention may be implemented not only ~ : :
with plasticized material, i.e. granular material, regenerated material or grin~ing du~t, but also with an ag~lomarate produced specifically ; during the mixin~ process.
PVC Vinnol P 70, a plasticizer, chalk.and~:a-stabilizer are mixed according to Exa~ple 1, with separate addition of the colour-pigments, in~ Henschel*~xer,~ are heated, by the heat of friction, to a tempe- ~
rature of 1~0C~ are cooledt wit~ stirrin~, in a separate container, ~:.
* Henschel is a trade mark . ' , .
and are then passed to a ~allmann mill having a 2 mm screan.
The grain-size ~s:
mm %
0,04 0,6 0,04 - 0,063 0,4 ~ 5 0,063 - 0,1 0,9 :: 0,1 - 0,125 2,9 0,125 - 0,2 11,3 0,2 - 0,25 9,5 0,25 - 0,315 10,0 i:
0,315 - 0,5 27,1 : 0,5 - 0,8 27,9 0,8 - 1,0 7,3 ~ 1,0 - 1,6 1,8 ~ :
1,6 - 2,0 0,3 The-grou~nd material ~às placedJ according to Example 2, in a frame-mould filled to height of 5.5 mm and was further proce~sed. Pattern ;~ ing was carried out with a colour di~parsion~ the amount applied being 52~ g/m , raster-printing being applied to the ~hole area by ~lat-~; 15 screen-printing.
The 235 mm 9trip had ~ a single-colour basic shade and also a single ~olour pattern extending ri~ht through.
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Aa in hxample 55 two batches of agglomerate were produced in light~
brown and dark~brown colours. The~e were ground in a PP6Pal~nn mill ;~-. .
and were mixed in a 1 : 1 ratio.
` The grain-giZe distribution wa~
'' mm % ~, - 0,04 1,1 0,04 - 0,063 3, 0,063 - 0,1 5,7 ~
:` 0,1 - 0,125 6,9 :
0,125 - 0,2 17,2 .o,2 - 0,25 11,7 .
0,25 - 0,31!5 11,2 O .
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- 23 - 132~8~
mm 0,315 - 0,5 22,8 0,5 - 0,8 16,2 0,8 - 1,0 2,6 1,0 - 1,6 0,8 1,6 - 2,0 0,4 - The mixture was placed in a frame-mould filled to a height of 5.5 mm. This was followed by heating in a hot cabinet for a period of 9 minutes at a temperature of 250 CO
Th~ cooled, sintered material was patterned with a colour-solution by flat-screen-printing. The composition of the said colour-solution was as follows:
49.5 parts by weight of Maragloss* GOL
2404 " " " " Maragloss* GO 045 brown 13.0 " " " " Maragloss* GO 021 yellow 9.5 " " " " Maragloss* GO 070 white `~ 1.6~ " " " " Maragloss* GQ 036 red.
The amount applied was 214 g/m2 wet.
Tha dried material was compressed at 150C. This produced a homogeneous sheet having a polychromal, structured basic shade and a pattern in a brown shade extending right through.
EXAMPLE 7 ~
: As in Example 5, an agglomerate was produced without chalk and colour. The said agglomerate was ground in an Alpine* mill having a 1.5 mm screen.
The grain-size was:
:
* Maragloss and Alpine are trade marks. ~
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mm %
~ 0~04 0,2 0,04 - 0,063 0,9 0,063 - 0,1 1,9 0,1 - 0,125 2,6 0,125 - 0,2 5,0 0,2 - 0,25 4,2 0,25 - 0,315 4,8 ~' 0,315 - 0,5 15,3 0,5 - 0,8 33,1 0,8 - 1,0 23,4 1,0 - 1,6 8,3 1,6 - 2,0 0,3 The ground mixture was deposited in the form of a layer 6 mm in height and was sintered. After cooling, the strip was patterned, by flat-screen-printing, with a plurality of yellow-reddish colour solutions.
The wet application amounted to 185 g/m2O
The composition was:
100 parts by weight of Maragloss* GOL
20 " " " " Maragloss* QNV
5 " " " " Geres* yellow 3 G.
The patterned material was dried and was then compressed at 150C to form a strip 2 mm in thickness. This produced a transparent, homogeneous sheet which, since the pattern extended right through, gave a three-dimensional effect.
~XAMPLE 8 69 parts by weight of Escorene* UL 00728 (Esso) 1) 30 " " " " Juraperle* MHM (Ulmer Fullstoff) 2) 1 " " " " colour-pigment-dyestuff mixture * Neocryl XK is a trade mark.
.' - 25 - ~ 03 08 l) ethylene-vinylaceta-te copolymer with about 28% of vinyl-acetate 2) chalk.
The Escorene*UL 00728 was preplasticized at 120 C
in a rolling mill. The filler and colour-mixture were then added batchwlse over a period of 5 minutes and rolling was continued for a further 10 minutes. The fleec~ was then removed and was reduced, in the hot condition, to sections measuring about 6 x 6 cm. The cooled sections were ground in a cutting mill having a 1.2 mm screen.
Th~ grain-size was:
mm ~ 0,25 5,5 0,25 - 0,315 1,0 0,315 - 0,5 5 5 0,5 - 0,8 1~,7 0,8 - 1,0 25,1 1,0 - 1,25 34,2 1,25 - 1,6 11,7 1,6 - 2,0 0,3 The granular material thus obtained was mixed with otherwise pigmented and similarly produced material in a 1 ratio. It was then raked onto a steel belt to form a layer 6 mm in height and was sintered at 200C.
A section of the sintered and cooled material, having a reduced thickness of 4 mm, was patterned by flat-screen-printing using a coloured acrylate-styrene dispersion~ The composition of the dispersion was as follows:
* Escorene is a trade rnark.
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- 25a - 13 2 0 8 ~ 8 50 parts by weight of water 3 " " " " 25~ ammonium-hydroxide 400 " " " " Neocryl XK* 70 22 " " " " ethoxy-ethanol 8 " " " " Etingal TP
8 " " ~ " Byk NP 3100 defoaming agent 25 " " " " 7.5% Additol XW 33~
95 " " " " Colanyl-oxide yellow G
~ ~ 35 1l n 1l ~1 Colanyl-oxide red B
30 " " " " Colanyl-oxide black B.
The amount applied was 180 g/m2 wet. The colour dispersion penetrated right through the layer corresponding ~ -to the printed image. This was followed by drying~
15The patterned and dried strip was then compacted at a temperature of 110C in a press. Th~ product obtained had a polychromal basic structure and a homogeneous pattern extending right through.,,,,,,_~,,",, .
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ample 9. - -The strip produced according to Example ~, and sintered and printed accordin~ to Example 3,may al~o be converted, in a ~in~l~ operation, by means Or an in~ra-red radiator and a smoothing rolling mill, con-tinuously, into a polychromal, rough, slip-proof co~ering 3 ~ in thickness, with a small amount of compactingqby appropriate calibration in the roll-gap. ThiS produce a covering having a depth~effect and a special textile look.
The 9intered strip ~roduced according to Example ~ may also be cali-brated in a roll-ga~, thus becoming a polychromal, slip-proof covering.
Fig 7 is a view Or the sintered, porous strip, not yet co~pacted9 ~ according to ExamlFae 1J enlarged x 1.3.
Fi~. ~ is a view of a finished product according to ~xample 1 with a free pattern~
Fig. ~ i~ a view of a finished pro~uct according to Example 3, .
Fig~ 10 is a view of a finished product according to i~ample 7, while ~ig, 11 is a view of a .~inished product according to ~xample 5.
The designs illustrated in Figs. 7 to ll show the possible. fine stPucturin~ madepoi~ible;b~the~u~e of specific granu:ar mixture~, at least in principle, since the colour-effect, and many of the colour nuances are of course eliminated by the black-and-w~ite reproduction.
:'
The invention r~lates to a method for producin~ co~nur~!' s-lrri~ce-structures based upon thermo~lastlc s~nthetic materi;ll;.
Single-co~lcured, homogerleous surrace-structures ~ade o~ thermoplastic synthetic materials, mor~ p~rticularly of PVCJ in the form of ~trip or sheet~ with thicknesses in exces~ of 1 mm, may be produced, accorA-in~ to the state of the art~ by e~trusion-, coating- or rolling pro-ceSsss~ whereby single-colourJ homogeneous products are obtained which, from the point of view of design, have a cold plastic look and the typicala~pearance Or a synthetic material. Even mixturss of dif~e-rent granular materials, processed by extrusion or rolling, have pro-duced colour differentiation correspohding to the pigment3 used, but have b~ no means removed tha cold feel typical of the 3Dnthetic mate-rial. However, especially when ~hest or strip is used to cover floors or walls, special va~ue i9 place~ upon aesthetic appearance. In this connection, it is the purpose Or the invention to provlde surface-structures made of thermopla~tic synthetic materials giving an aes-,. - . .. ,. .. ~ ,..
theticall~ satisfying optical impre3sion and which may, if necessary have a non-directional pattern.
US Patent 3 3~1 067 disclose~ a method for ~roducing terrazzo-like floor-coverings in which soft PVC9 with fillers, dyestuffs and stabi~
lizer3, is used to produce a ~ranular material having athickne~ Or 6 to 12 mm and a dia~tq~r of ~ to '~0/~. This Is coated with a soft!Pvc paste, is shaken out into a uniform layer~ i~ heated7 sintered and, under the action of heat and pressure, is com~ressed into a continuous strip. The use of different compositions of granular material and coat~
~2~8 ing n~terial produces a covering in which the ~ranular ~aterials are embe~d~d in a soft~r sheath which thus displays different wear proper-tie~.
US Patent 3 192 29L, describes 6 method ror pro~ucing floor-coverings having a multicolour effect, for example pepper-and-salt patterns, in which th~ preferred PVC co~positions~ contalning the plasticizer and the expandin~ ag~nt.and in the form of powder, are shaken out into a layer, are heated until they are ~intered, and are then foamed by de-com~osition Or the expanding agent, whereupon the sur~ace of th~ ~aid strip, upon pas~in~ throu~h a roll-gap, is embossed in relief to half or more than half of its thickness. In this connection, the PVC compo-sition is prepared as a "dryblend~', i.e. it i~ mixed cold (to avoid premature decomposition of the expanding a~ent) and ths particles ex-hibit an average 9iZ~ of 15/um to about 3 mm, but a uniform particl~-size is used, for example 15/um~ It is al~o possible to add amounts o~ very small particles - 2 ~ - Or a copolymer. ~lowever, this may be hi~hly detrimental if the fines separate, i.e~ fall to th~ bottom and the coarse particles form an uneven surfdce.
Floor-coverings produced in accordance with US Patent 3 192 291"
with thicknesses of appro~imately 2.5 mm, are subject to crscking becau~e o~ their h~a~y surface embossing. They therefore require additional surface-protection in the form of an additional rll~. The heavy embossine also displaces the particle-structure~ thus producing elongated zones lackin~ uniformit~.
A method for rroducing a decorative multilayer covering i~ known from US Patent 3 35~ 3~2 and German Patent 12 9~ 023, in which ~mall particles, having a grain-size Or about 2.5 to 0.013 mm~ produced by _ 3 ~32~3~3~
mixing a P~C powder, a plas-tici~er, and additives at temperatures of about 93C, i.e. well below the sintering temperature of the synthetic material, are shaken out onto a substrate strip serving as a carrier, in a layer, and are sintered into a porous strip. These small particles, also called "dryblends", obtained by mixing a-t low temperatures far below the plasticizing temperature of the synthetic material, are soft and have lit-tle strength and rigidity since they are not plasticized. Upon subsequent compression, they therefore fly apart and produce, if different-coloured particles are used, mixed colours or colour contours which bleed and run in the direction of rolling. With this known method it is necessary to use a carrier-material in the form of a substrate layer. It i9 thus impossible to produce homogeneous surface-structrures, i.e. continuously designed layers without a substrate layer.
~lso with the soft particles of the dryblend, only coverings less than l mm in thickness can be produced free of cavities. Thus the coverings according to US Patent 3 359 352 are built up heterogeneously with an underlying additional carrier-layer.
It is therefore the purpose of -the invention, starting from the method of the same type according to US
Patent 3 359 352, to provide homogeneous surface-structures having clear designs and finely structured non-directional patterns.
According to the present invention there is provided a method for producing coloured, patterned surface-structures based upon thermoplastic synthetic materials, wherein freely flowing particles are shaken out continuously to form a uniform layer and are sintered under the action of heat until the thermoplastic material plasticizes, into a porous, coherent layer which is cooled, after which at least one liquid or freely flowing, fusible, coloured medium is applied in predetermined patterns and penetrates into the porous layer to -the desired depth, whereupon, under the ac-tion of pressure and heat, the coloured, porous lay er is compacted into a compact surface-struc-turet characterized in that for the purpose of producing the freely flowing particles, an initial mixture, based upon thermoplastic s~nthetic material, is processed, by thermal pretreatment above -the softening temperature, into an agglomerate or granular material and is mechanically comminuted into a granular mixture having any desired grain-size distribution; and in that, without using a substrate layre, the granular mixture is shaken out onto a conveyor-belt to form a uniform layer, - and is sintered.
Now surprisingly enough it was found possible with the technology according to the invention to produce an infinite variety of homogeneous surface-structures in which the colours and patterns extend right through the material, namely strip or sheet. These surface-structures far surpass existing marbling or patterning structures, upon which strict limits are imposed, from the point oE view of free choice and de~ign appearance, thus providing new possibilities.
The thermally pretreated particles used according to the invention exhibit a strong granular structure in contrast to dxyblend-powders. During sintering, this granular structure is retained and ensures the desired porosity for the following colour application and satisfactory penetration thereof. This granularity also prevents the printed design from running at the surface~
According to one preferred embodiment of the invention, the particles are used in the form of a granular mixt~re having a grain-size o~ up to 2 mm in any B
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desired distribution and -they are shaken onto the layer to be sintered. In order ~o achieve ~atisfactory porosity, the proportion of fines, in relation to the average size of the major part of the particles, should not be too high, in S order to prevent separation of the granular mixture. If the proportion of fines is too high, they fall through the coarser particles and collect only on the underside. This leads to a non-uniform structure and pattern.
The method according to the invention therefore 1~ provides, by applying finely divided, thermoplastic dusts and using grain-sizes preferably between 0.1 and 2 mm in diameter, on an endless support, e.g. a steel belt or a heat-resistant teflonized belt, in thicknesses of up to several mm, followed by sintering under the action of heat, a porous layer which, by a printing or spraying process, can be provided, through the entire thickness of the layer, with any desired pattern and, if necessary and after appropriate drying, if the colour-system used contains a solvent, can be made, under heat and pressure, into a homogeneous strip-product in which the pattern extends right through thematerial.
It was found, surprisingly enough, that thermally pretreated particles, in granular mixtures of a specific order of magnitude, when sintered and subsequently compressed, produce surface-structures having a finely structured, polychromal pattern which passes right through the material and has nothing in common with hitherto usual synthetic-material uniformity. Even if use is made of ; particles in a granular mixture which are of one colour only, a polychromal differentiated colouration is obtained.
By using only a few different multicolour patterned particles and mixtures containing different grain-sizes and grain-size distributions, it is possible to obtain an infinite number of colour and structural nuances.
~32~a8 It is preferable, according to the invention, to use granular mixtures of particles made from grinding dust and/or finely ground agglomerates, granular materials, chips, regsnerated materials, extruded materials, or the like. Sintered, porous layers, made from these particles, may then have colour applied to a part or to all of their surfaces.
According to a preferred embodiment of the - invention, particles produced by grinding, which form a mixture of different grain-sizes in random districution, are used to produce strip or sheet. For instance, it is possible to grind different sheets or strips made of a PVC
composition with plasticizers, fillers, stabilizers and pigments, with an abrasive belt of a specific grain-size, and thus to produce a grinding dust which initially appears to the naked eye to be of a single , : ~ , . ...
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colour, with a grain-si~e Or 0.1 to 2 ~m~ ror example. If this grind-in~ dust i9 red from a hopper, the front of whlch carries an ad~ustable rake5 onto a c~ntlnuously moving carrier-belt located thereundar, e~g~
a belt made of release-paper or steel, if the layered grinding dust i9 then allo~red to sinter under an I~-rield or in a heating duct, this produces a porous layer to which a through-pattern can be applied by printin~ or spraying. This can then be formed under pressure into a homogeneous~ cavity-fr~e ~trip or shaet with the pattern e~tending through the ~ntire thickness of the material, and the structure ~ the pattern i3 neither blurred hori~ibto~ted~
~ using only a fe.~r dirrerent~ multicolour, ~a~e~ed, ~2~ f~ es;
and by using mixtures containing different proportions, the grinding dusts produced can be varied in such a manner as to make it possible to obtain an infinite variety Or colour and structural nuances. It i~
preferable for the grains or particles obtained by grinding to be used in a mixture in which ~0 to 90% by weight i8 of a grain-size ~rom 250 . . .
to ~OO~m.
It was also found to be 3urpisine thatinstead of grinding dust, diPferentl~ coloured agglomeratec, heated, Por example, in a mixer,b~
frictionj to a specific temperature and applied to mdxtures of diff0-rent colours, result in a similar multi-eoloured uni-design. It is also possible to al~ti~r the nature of the agglomerate6, a~ regards structuring, b~ a grinding operation following the ~ixing. In addi-tion to this, mixtures of grinding dust and agglomerates are alsu possible, as ar~ cQmbinations of filled and unfilled systems, i.e. ;~
, PVC compositions with or. without fillers. Furthermore, the use of particles o~ transparent synthetic ~ateriàls imparts a spatial im-. ;- ' , , "
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pression in addition to the polychromal character. However~ such pDly-chromal~ ho~ogeneous sheeta, o~ e~en strips~ n~y be produced not only from grinding dust and aggl~merates, but al~o from regenerated mate-rial from differently coloured edge-3trips which ha~e been chopFed up and ground. A similar effect may also be obtained from suitably coloured granular material which has been ground, by the ~inber~press;;~pro~s~. .
Simllarly, a mixed PVC powd~r with additives may be plasticized in a plasticizer or extruder~ ma~ be processed into granules, chips or plate-lets, and may b3 ~round to the desired fine granule~ or mixture of ~ine granules. The PVC compositions ma~ be trane~arent, of one co~our or multicoloured~ Mixturss of differently coloured dusts and granules may be used. After compression, this pruduce3 a brilliant~ Pinely re-solve~ multi-coloured and non-directional baQic tone. A moderate to differentiated appearance, a fi~e or coarse structure, and a slight to high ca~acit~ for resoluti~n may also be achieved by variations in grain-size and distribution of the particles used.
It is pr&ferable to use mixtures Or agglomerates produced by mixing a PVC composition at temperatures of up to 170C, brought about by frictional heat~ followed by cooling, grinding and, if necesYary, sçreening out. Such a mixture of;a~.lomerates,iwhich leads~*oparticularly attractive designs, has about 20 to 75% by weight of the grain-size from 500 to 2000 ~ in the mixture. ;~
hccording to the invention, it is possible to alter the structure o~ the strip, and therefore the de~ign9 i.e. the polychromal e~fect, b~ varying the configuration of the particles, whether the~ are in the Porm of granules, or are of different si~e~obtained by grinding or milling.
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According to a further preferred embodiment of the invention, the particles are obtained by crushing extruded material, granular material, regenerated material, chips agglomerates or mouldings, 1, 1.5 or 2 mm screens being used for screening out. All of these mixtures obtained by grinding contain thermally pretreated particles which have already been plasticized once and therefore provide a strong granular structure. The thermal pretreatment was carried out, for example, during manufacture of the agglomerate or during extrusion of mouldings which were processed into granular material, chips, edge-strips or scraps, in order to provide the starting material for the granular mixtures to be produced and used according to the invention.
A mixture of particles of different origin, for example from grinding processes, preferably contains from about 30 to 95~ by weight of the 500 to 2000/,um grain-size.
;~ It is also possible to use mixtures of particles - of different origin, colours, structures and/or grain-size distribution.
20For good porosity, leading to uniform penetration through the material, relatively uniform grain-sizes are preferred~
Strips or sheets with pa~ticularly fine, uniform and random patterns may be obtained when granular mixtures 25containing 90 to 100% by weight of ~he 300 to 800 ~m grain-size are used.
Surface-structures to be used as floor- and wall-coverings may be obtained by using a preferred embodiment of the invention. This produces transpaxent and translucent to opa~ue strip. According to such preferred embodiment one obtains, from a PVC composition containing:
60 to 80% by weight, of E, S, M-PVC having a K-value of 50 to 80, 19 to 39% by weight, of a plasticizer, 1 3 ~ 8 0.5 to 2~ by ~eight of as stabilizer, 0 to 3~ b~ weight of a colouring agent, by plasticizing at tempera-tures above the softening temperature, more particularly at about 140 to 170C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture may be obtained by comminuting, for example by milling or grinding.
; According to the present invention filled strip or sheet may preferably be produced from a PVC composition containing:
40 to 60% by weight of E, S, M-PVC having a K-value of 50 to 80, 1~ to 24% by weight of a plasticizer, 20 to 40% by weight of fillers, 0.5 to 2% by weight of a stabilizer, 0 to 3% by weight of a colouring agent by plasticizing at temperatures above the softening temperature an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture may be obtained by comminuting.
In addition to PVC, other thermoplastic synthetic materials, for example a copolymer based upon ethylene-vinylacetate, may be used.
Within the meaning of the invention, the term PVC
is also intended to include copolymers with vinyl-acetate, ethylene-~inylacetate and possibly acrylate-polymers, which may be used alone or in mixtures.
For the purpose of applying colour to the sintered, porous layer, it is preferable to use liquid, possibly coloured, media in the form of pastes such as PVC
pastes, aqueous polymer dispersions, polymers dissolved in organic solvents, or fusible, coloured, polymer powders.
The liquid media may be applied in any desired manner, 13208~g preferably by printing or spraying. The simplest way of printing is to use a rotary screen-printing installation in which the number of stations determines the additional colours and structures to be applied. Patterning may, of course, also be carried out by a spraying process, namely alternating spray-guns or nozzles operating in synchronism, as in the Chromotronic or Millitron processes. The amount of colour, applied in the form of a solution or a paste must be only enough to ensure penetration to the desired depth, i.e. the total thickness of the strip. As regards printing colours, solutions, aqueous dispersions or pastes may be used. For example, coloured PVC-pastes may be used in the case of soft PVC granules~
It is preferable to apply several differently coloured liquid media consecutively to various parts of the surfaces of the sintered strip, in the form of a pattern, but the whole surface of the strip must not be patterned since the basic sintered strip also exhibits, after being ~ .............. ... . . . . . . .. .. .. ... .
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compre~sed, sin~le- or multicolour efrects and, together with the colour applied, thus provides the desired design.
In the case of homogeneouq coverin~s, therePore~ which have patterns ; extendin~ throuEh the entire thickness Or the strip according to the method of the invention, there are now, for the first time, no longer any limits to the type and choice of patterning.
~oriented Whereas it has hitherto been possible to achieve only longitudinally~
or chip-like structures, it is now largely possible to produce patterns rangin8 from geometrical structures of lines and circles to imaginative printed ima~es correspondin~ to modern printin~ technolo~y. In addi- ~
tion to this3 all homogeneous coverings,patterned an~ structured ~ ;
accor~ing to the m~.hod of the invention, ha~-e an appearance with a t~tally different feel. It is no longer a cold structure printed on a plastic surface; instead it is a ~look~ radiating warmth hitherto kn~wn ~nly in natural pro~ucts or textilcs The method according to the invention is particularly suitable for trend indicatin~ development of textile ~tterning and structuring for synthetic material~q. The grain-size and distribution of the thermo-plastic material used makes it possible to obtain a moderate to diffe-rentiated aspect, a fine or coarse structure, or also a small or large capacity for resolution. ~;~
The method according to the invention provides a living~ three~
dimensional appearanc~ in that the printed substrake, depending upon the colour of the mono- to poly-chro~atic effect~in combination with a possible multi-coloured printing process, provides a hitherto unknown colour and space dimension.
In the case of screen-printin~, the size of the raster, the type ~ ~ !
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of printing ink, the dispersion-solutions and pastes, and the viscosity thereof, are of grea-t importance for the printed image.
According to a further preferred embodiment of the invention, prior to the application of the liquid media, the sintered layer is cooled to a temperature below 50C, preferably below 35C. This ensures proper penetration of the colour applied and premature vapourization of the solvent, or blocking of the pores, is eliminated. According to a further preferred embodiment of the invention, it is proposed to heat the sintered layer, and the applied colour, for compacting, to a temperature of at least 150C, preferably 165C.
According to the invention, one preferred method for producing surface-structures made of thermoplastic synthetic materials, in which the patterns extends right through the material, provides for the particles to be shaken out to form a layer preferably 5 to 12 mm in thickness, to be heated to a temperature of about 210 C and thus to be sintered. The sintered layer is then cooled, possibly to a temperature below 50C, after which the liquid coloured media are applied consecutively, using a weight per unit area of about 100 to 900, preferably 100 to 500 g/m , by spraying or printing. The solvent content is preferably evaporated and the sintered layer, with the applied colour, is heated to a temperature of at least 150, preferably in excess of 165C and is compressed homogeneously, at a surface-pressure of about 0.2 to 20 N/mm2 or a corresponding linear pressure in the roll-gap, to form a strip having a final thickness of about 1.5 to 4 mm.
The amount of colour applied is gouverned, more particularly, by the way it is applied, i.e. as a dispersion, a solution or a paste. The amount i9 also governed by the thickness of the porous layer and the pattern.
The material of which the con~ey~r-belt i~ made should be ~uch that the fini~hed strip can easily be removed from it, for ~xample release-paper~ a teflonized fabric, or metal, for example a steel belt~ Th~ heat energy re~uired for sintering may be obtained from an -radiator, hot air, or a high-frequency field, the subsequent com-pression being carried out continuously by a rolling mill or a single-or double-belt pres~. The surface of the strip may be embo~ed, de-pe~ding upon the surface-structure of the rolls or belts. The depth of the embossing is preferably up to about 100/um~ but may also exceed this~
Although surface-structures based upon PVC are preferred because o~
their low cost, especially for masR-procluced product~ like floor- and wall-coverings, the use of the invention i5 not restricted thereto.
The suitabilik~ Or plasticizers, stabilizers and fillers is al~o governed by the combination of materials and the purpose for which ~;
the product is to be used.
The in~ention i~ ~xplained hereinafter in greater detail, in con-~unction with examples and the drawin~ attached hareto9 wherein:
Fig. 1 is a diagram of an insta].ltion having a ;~
sintering section, colour application and com~acting;
Fig. 2 is a diagram of~o~m~a~t~ngib~`mean~lQ~,p~e~sure-rolls;
~ig 3 is a diagram of compa~ti~-wi~hl!b~lt~presses~
Fig, h is a diagram of compactin~ with a double belt-press; ;
Fig. 5 is a cross-section of the colour-application stations;
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ri~. 6 shows the phases in multirle printi.ng by means of.flat-screen-~rintinr stencils : a~.cording to Fig. 5-FigS. 7-11 .show different designs corresponding to dirferent granular mixtures and colour applications.
The method according to the invention i3 explained in conjunction with the dia~ram of Fig. 1. The carrier used is preferably an endless conveyor-belt 1 running over two defl.ecting rollers 18,19, at least one of which is dri~en. The said carrier is preferably made of release-paper, steel or also Teflon* (polytetrafluorethylene) strip.
lQ Granular mi~ture ~ is deposited onto the conveyor-belt from hopper 2, comprisi.ng an ad~lustable rake 3, preferably in the fvrm er a layer between 5 and 12 m~ in thickness.(ror ~loor-coverings),~ depending upon : the desired final thickness of the surrace-structure. It is also po~sible to use other applicator systema, for ffxample metering channels or roll-knives. Layer ~0 is then heated continuously9 for example ùnder an infra-red field 5 and/or in a heating duct 6, to the plasti-cizing temperature amd is sintered into a continuou.s surface-structure hl. Durin~ this sinter m g procesa. layer ~O decreases in volume and ~ ~
the thickness drops to approKi~ately ~ to. 10 mm. ~ :
In the continuous production p~ocess, sintered strip ~1 is allowed to cool~ after sintaring, for exam~le ~y PaaSing through a cooling station 60 which uses air-~ets shown ~acing the strip in colour appli- . -cation stations ~0,31. The number of these stations is go~arned by the desired design and the type o~ station. These determine the structures~ the number of colours in the design, the size of the raster of the rotatin~ stencils~ and tha ~olume of co~.our medium to be applied.
The col~lr-media used may be sol~ent-free systems, for example PVC
* Teflon is a Trade Mark .
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pastes or also aqueous rolymer dispersions, or also polymers dissolved in or~anic solvents~ However~ it is also possible to operate with a heated polymer fusion and with coloured polymer powder~. The use Or a usion calls for an inter-station cooling ~ection, while powders re-quire heatin~ and coolin~ zones between individual stations. n the other hand it is possible to operate ~et-on-wet.with SJStems which are liqu;.d at normal temperatures. Coloured sintered strip ~2 is then passed through a heati.ng area 70 Por dryinF the applied colour if ne-cessary and for heating i.t .~or the ~compactinF o~eration........................... :~
1;0 After the colour-application stations, strip ~2, into which the colour-media have penetrated, passes through a pressing station, for ;: exa~pIe a pair oP embossing rolls 7,~ where it is compressed and the .. . ~, surfaceis made smooth or is lightly embossed. Final product ~3 then leave~ the installation and i3 pa~sed to fàbrication.
: 15 Fig. 2 is a dia~rammatical repre3entation o~ a pressing and embossing unit comprising a rubber roll 7 and a metal roll ~. For the purpose ~ .
comprassin~ the sintered strip ~2, with the applied colour, it is al~o possible to use a belt-press, as shown in Fig. 3, the belt, which runs o~er deflectin~ rollers 10~ 12, being guided in such a manner as to pre~ the sintered strip, over a predetermi~ed path, a~ainst belt-roll 9 and~ after it has cooled , to remove it from belt 20 as a fin.ished strip ~3. As æhown in Fig. ~.) it is prePerable to carry out the compression by means o~ a double belt-press which uses two endless belts running o~er dePlectiag rollers 10,11 and 1~,13. The sintered ~;
strip is pressed altennately against rolls 9 and 15 and, a~ter is has been compressed and cooled, it is remot~ed from belt 20. The surface of strip L3 may be refined either in the belt~press, or in a subse-:, .
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quent embos~in~ station, for e~ample, or also by a grinding and/or polishin~ procass~
Fig. S is sn enlarged representation of the colour-application station. In the example shown, four stations 3O to 33 are provided and are filled with difrerent colour~ 5O to 53. The said colours, or colour-media, are adaptad to penetrate into porous, open-pored sin-tered strip 1,1 right to the other side, 90 that the printad lma~e is reproduced throughout the entire thickness. After the colour-media have been applied and have penetrated, and if aqueous or solvent-containing colour-media are used, drying i5 carried out in a heating duct 70 The high~r temperatures, acting upon strip ~2 at the end of the heating duct, raise it to the temperature required for embassing in the embossing Ytation sho~n in FigS, 2 to ~, where the said strip is compacted and the surfsce i~ embossed. ~;~
Fig. 6 is a plan view of the colour-application stations according to Fig. 5, showin~ the individual ~a~terning steps in the individual phases, by way of example. Fig. 6a shows the patterned strip in cross-~ection with the different fully-penetrated coloùrs 51 to 5~. The number of printin~ operations may be carried out as desir~d. For ax-ample six colours and designs may be printed. As regards the pos~i-bilities of individual prin~ed images, there is a ~ree choice. Fig~ ~b shows the print of first colour 51 on porous, sintered strip 41, Fig.
6c shows the print of the second colour 52, FiP. 6d shows the print of third colour 53, and ~ig, 6e shows the print o~ fourth colour 54~ Areas may also be left Iree of colour since, if the base material of sintered strip ~1 is coloured, transparent or trsn~lucent, an additional pattern-in~ effect also arises here. In any cas~, the pattern applied exist~
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right through the thickness of the strip. Thus the surface design does not disappear as a result of wear and abrasion wheh the strip is used as a floor-covering, for ~xample. A strip of this kind may be almost 100~ worn out, with no 109s of the design.
The foLlowin~ examples deal with possible embodiments o~ the method ~ .
according to the invention, and with the production and use of granular mixtures and colour-media.
~. .
A basic batch of filled soft PVC contai.ning the following ingredients: ~
31 parts by weight of P~C-Vinnol ~ 68 (Wacker-Chemie) ~-13 " " " " d7octylphthalate 2~ " " " " chalk 0.15 a stabilizer based upon Sn - . .
is first of all mixed. 70 par-ts by weight o~ thi.s batch are mixed separatel~ with the following colour-pi~ments.and, after mixing, are granulated in an extruder:
Colour No. Colour Parts by weight 1 meaium-brown 0.7 2 light-brown 9~7 ?
~ greenish-beige . 1.337 L dark-brown 0.252 : 20 E~trusion tem~erature 170C, granu~.ar material ~-~ mm in.~
The granular materials are then mixed again in the followin~ weight-. - , .
ratios: Colour No. 1:2:3~ 0~76 and ar0 processed,. by means of an extruder and a rolling mill, to form a marbled strip-product.
: Calibratlng by grinding with 50 and 100 abrasive-grain belts produces ~-a gri.nding dust having the following grain-size distribution (wet-screening):
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mm 0,~4 o,7 o,o4- 0,063 0,~
0,063 ~ 0,1 0,2 0,1 - 0,125 o,g 0,1~5 - 0,2 2,0 0,2 - 0,25 7,8 0,2s - 0,315 16,4 o,315 - o,5 35,5 0,5 - o,8 32,5 o,s - 1,o 3,1 1,o - 1,6 o,4 1,6 - 2,0 o,1 The grinding dust thus obtained is deposited, from a hopper having a vertically adjustable rake set at a 5 mm gap, onto a strip of release-paper. It is sintered under an infra-red radiator 0.6 m in length ~7,5 KW) and in a hot-air duct 6 m in length, at temperatures of between 160 and ~05C, at a speed of 1 m/min. The sintered, cooled material is then printed with coloured PVC pastes in a rotary screen-printing unit.
The composition of the pastes was as ~ollows:
270 parts by weight of PVC Vinnol~P 70 E
135 " " " " PVC Vinnol~C 65 V
164 " " " " Linplast~ 68 P
g " " " " Irgastab* T 150 9 " " " " Reoplast* 39 56 " " " " Calcicoll* SW 35 4 " " " " Minex~ 7 48 " " " " Edenol* 190 1 " " " " colour.
* Vinnol, Linplast, Irgastab, Reoplast, Calcicoll, Minex, Edenol are trade marks.
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Corresponding to the 4-colour printing design, and matching the grinding dust used, the ~ pastes requires were coloured medium-brown, light-brown, greenish-beige and dark-brown respectively. Textile structures in a 40-mesh raster-size were printed as the pattern. The printed PVC pastethen penetrates, according to ' .
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the rredetermined ~attern, ri~ht through the sintered layer. With this method it i5 possible to o~era-te wet-on-we-t with no smearin~ of indi-vidual eolours. The~amount of paste ~pF1i.ed was S~0 g/m2 After the pattern had been printed and had penetrated to th~ back of the sinter-ed layer, the materia]. wasf~assed through.a heating duct at a tempera-ture of lgO to 200C, at a speed of 2 m/min. Additional heat was applied to the surface b~ a subseqllent 7.5 KW IR~field. The sintered strip was then comp~cted in an embo~sing station,~ the surfac~ being embossed at t~le same time~ Thls produced a printed textile design extending right through the 2 mm thickness Or the strip, the e.rfect bein~ also reinforced by the polychromal basic structure of the sin-tered material. The sintered and patterned strip-material produced , in accordance with this example could also be compacted and smoothed, .
at about 170C~ in a belt-press.
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a~ple 2 .
The grinding dust obtained in ~xample 1 is ~ixed? in a 1 : 1 ratio, with a grinding dust B obtàined from another colour combination and produced in the fo].lowing composition:
COlour No. COlour Parts by weight (per 70 parts o~
th~ basic batch) S dark-greyish-brown 0;2/~
6 dark-reddish-brown 0.~5 7 medium-brown 0.
~ reddish~beige 1.0 Granu~ar ratio in mixture:
Colour No. 5 : 6 : 7-: g = 1 : 1 : 1 : 0..76.
The grain-size Or the grinding du~t was as follows: ~.
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l9 mm % '' 0,04 o,s 0,0~_ 0,0~3 ol2 0,063 - 0,1 o,2 0,1 - 0,125 1,0 0,125 - 0,2 3,9 0,2 - o,2~ 10,3 0,25 - 0,315 16,3 0,315 - 0,5 42,7 0,50,8 23,5 0"3- 1,0 o,8 1,0- 1,6 0,1 1,6- 2,0 0,1 The A and B grinding dust mixture from two differently coloured strips with a total of 8 basic colours is placed in a frame-mould with an edge 7 mm in thickness.
The material is then cooled, which reduces it to a thickness of 5 mm and the pattern is then applied by flat-screen-printing with a coloured PVC dispersion. The raster was 0.42 mm in diameter. The composition of the PVC dispersion used was as follows:
250 parts by weight of water 5 " " " " ammonium-hydroxide 250 " " " " Vestolit Dispersion M
15 " " " " Byk NP~ 3100 15 " " " " Etingal TP
30 " " " " Unimoll BB*
200 " " " " Latecoll* W 55 6 " " " " Disperbyk*
170 " " " " Colanyl Oxide Yellow G
130 " " " " Colanyl Oxide Black G.
Vestolit, Byk NP, Etingal, Unimoll BB, Latecoll, Disperbyk, Colanyl are trade marks. ~`
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~32~)8 l9a The amount applied was 176 g/m2 wet. The colour dispersion penetrated right through the layer in accordance with the printed image.
Further processing was according to Example 1.
The product ob~ained has a polychromal basic structure and a homogeneous printed pattern extending right through the material.
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h~;am~]~ -I'ro~ the ~trips produced accordin~z to ~xample 1, it ix possible to cut edge-strips, to reduce them to 5 to 10 m~ chips~ and to grind the said chips in an ~-lpine mill having a ~ mm screen.
The grain-size wa9 mm %
0,04 0,9 ~ 0,04 - 0,0~3 1 0 : 0,063 - 0,1 1,2 0,1 - 0,125 1,4 0,125 - 0,2 1,6 0,2 - 0,25 1,2 0,25 - 0,315 1,4 0,315 - 0,5 4,8 0,5 - 0,8 10,7 0,8 - 1,0 ~11,8 1,0 - 1,6 22,4 1,6 - 2,0 41,6 ;~ The ground regenerated material wa~ sintered and, after cooling, was patterned by flat-~crean-printirg and a ~ingle-colour PVC disper~
s on as in Example 2~ then dried and compressed. The colour applica-tion amounted to ~gO g~m2. ;, The 2 mm thick s~eet ~as patterned right through and also exhibited a polychromal basic ~tructure.
~ample l.
The basic batch~ containing a 1,5~ light-green colour-pigment accord-ing the ~xam~le 1, was ~ixed and granulated in an extruder at a tempe-rature of 170C, the re~ulting gra~ules being between 1, and 5 mm in dia~eter. These were ground in a type PP6 Pallmann*milI having a 0vs mm ga~.
; * Pallmann is a trade mark.
:. . . . .
',' ', , ~ ,' ' . ~' .
.
' 2 l ~. 3 ~ 8 The ~rain-size ~:
mm ~
0,04 0,6 0,04 - o,a63 0,3 0,063 - 0,1 0,3 0,1 - 0,125 1,3 0,125 - 0,2 3,3 0,2 - 0,25 5~5 0,25 - 0,315 9,2 0,315 - 0,5 29,8 0,5 - 0,8 29,5 0,8 - 1,0 12,3 1,0 - 1,6 5,7 1,6 - 2,0 2,2 10The ground msterial was shaken according to ~x3mple 3 to form a layer 10 mm in thickness, was processed according to Example 1 by flàt-screen-printing using a coloured PYC pasta, and was then compressed a~cording to ~xample 1.
The paste a~plied amounted to 700 ~/1n2, the final thickness of the 15sheet being 2.3 mm. The result ~as a ~heat having a total thickness of 2,3 mm having a single-col~ur basic sha~le and a pattern of a darker ~hade extending right through.
~a~ple 5~ :
~: The method accordin~ to th~ in~ention may be implemented not only ~ : :
with plasticized material, i.e. granular material, regenerated material or grin~ing du~t, but also with an ag~lomarate produced specifically ; during the mixin~ process.
PVC Vinnol P 70, a plasticizer, chalk.and~:a-stabilizer are mixed according to Exa~ple 1, with separate addition of the colour-pigments, in~ Henschel*~xer,~ are heated, by the heat of friction, to a tempe- ~
rature of 1~0C~ are cooledt wit~ stirrin~, in a separate container, ~:.
* Henschel is a trade mark . ' , .
and are then passed to a ~allmann mill having a 2 mm screan.
The grain-size ~s:
mm %
0,04 0,6 0,04 - 0,063 0,4 ~ 5 0,063 - 0,1 0,9 :: 0,1 - 0,125 2,9 0,125 - 0,2 11,3 0,2 - 0,25 9,5 0,25 - 0,315 10,0 i:
0,315 - 0,5 27,1 : 0,5 - 0,8 27,9 0,8 - 1,0 7,3 ~ 1,0 - 1,6 1,8 ~ :
1,6 - 2,0 0,3 The-grou~nd material ~às placedJ according to Example 2, in a frame-mould filled to height of 5.5 mm and was further proce~sed. Pattern ;~ ing was carried out with a colour di~parsion~ the amount applied being 52~ g/m , raster-printing being applied to the ~hole area by ~lat-~; 15 screen-printing.
The 235 mm 9trip had ~ a single-colour basic shade and also a single ~olour pattern extending ri~ht through.
~`, ' ~, ",.
Aa in hxample 55 two batches of agglomerate were produced in light~
brown and dark~brown colours. The~e were ground in a PP6Pal~nn mill ;~-. .
and were mixed in a 1 : 1 ratio.
` The grain-giZe distribution wa~
'' mm % ~, - 0,04 1,1 0,04 - 0,063 3, 0,063 - 0,1 5,7 ~
:` 0,1 - 0,125 6,9 :
0,125 - 0,2 17,2 .o,2 - 0,25 11,7 .
0,25 - 0,31!5 11,2 O .
.," :, , ,..... . ; . , : . . , :
- 23 - 132~8~
mm 0,315 - 0,5 22,8 0,5 - 0,8 16,2 0,8 - 1,0 2,6 1,0 - 1,6 0,8 1,6 - 2,0 0,4 - The mixture was placed in a frame-mould filled to a height of 5.5 mm. This was followed by heating in a hot cabinet for a period of 9 minutes at a temperature of 250 CO
Th~ cooled, sintered material was patterned with a colour-solution by flat-screen-printing. The composition of the said colour-solution was as follows:
49.5 parts by weight of Maragloss* GOL
2404 " " " " Maragloss* GO 045 brown 13.0 " " " " Maragloss* GO 021 yellow 9.5 " " " " Maragloss* GO 070 white `~ 1.6~ " " " " Maragloss* GQ 036 red.
The amount applied was 214 g/m2 wet.
Tha dried material was compressed at 150C. This produced a homogeneous sheet having a polychromal, structured basic shade and a pattern in a brown shade extending right through.
EXAMPLE 7 ~
: As in Example 5, an agglomerate was produced without chalk and colour. The said agglomerate was ground in an Alpine* mill having a 1.5 mm screen.
The grain-size was:
:
* Maragloss and Alpine are trade marks. ~
: .
'~
, - . . ~ .~, ', ', ' .
- 24 - ~32~8~
mm %
~ 0~04 0,2 0,04 - 0,063 0,9 0,063 - 0,1 1,9 0,1 - 0,125 2,6 0,125 - 0,2 5,0 0,2 - 0,25 4,2 0,25 - 0,315 4,8 ~' 0,315 - 0,5 15,3 0,5 - 0,8 33,1 0,8 - 1,0 23,4 1,0 - 1,6 8,3 1,6 - 2,0 0,3 The ground mixture was deposited in the form of a layer 6 mm in height and was sintered. After cooling, the strip was patterned, by flat-screen-printing, with a plurality of yellow-reddish colour solutions.
The wet application amounted to 185 g/m2O
The composition was:
100 parts by weight of Maragloss* GOL
20 " " " " Maragloss* QNV
5 " " " " Geres* yellow 3 G.
The patterned material was dried and was then compressed at 150C to form a strip 2 mm in thickness. This produced a transparent, homogeneous sheet which, since the pattern extended right through, gave a three-dimensional effect.
~XAMPLE 8 69 parts by weight of Escorene* UL 00728 (Esso) 1) 30 " " " " Juraperle* MHM (Ulmer Fullstoff) 2) 1 " " " " colour-pigment-dyestuff mixture * Neocryl XK is a trade mark.
.' - 25 - ~ 03 08 l) ethylene-vinylaceta-te copolymer with about 28% of vinyl-acetate 2) chalk.
The Escorene*UL 00728 was preplasticized at 120 C
in a rolling mill. The filler and colour-mixture were then added batchwlse over a period of 5 minutes and rolling was continued for a further 10 minutes. The fleec~ was then removed and was reduced, in the hot condition, to sections measuring about 6 x 6 cm. The cooled sections were ground in a cutting mill having a 1.2 mm screen.
Th~ grain-size was:
mm ~ 0,25 5,5 0,25 - 0,315 1,0 0,315 - 0,5 5 5 0,5 - 0,8 1~,7 0,8 - 1,0 25,1 1,0 - 1,25 34,2 1,25 - 1,6 11,7 1,6 - 2,0 0,3 The granular material thus obtained was mixed with otherwise pigmented and similarly produced material in a 1 ratio. It was then raked onto a steel belt to form a layer 6 mm in height and was sintered at 200C.
A section of the sintered and cooled material, having a reduced thickness of 4 mm, was patterned by flat-screen-printing using a coloured acrylate-styrene dispersion~ The composition of the dispersion was as follows:
* Escorene is a trade rnark.
:~
::
:
: ~ ~
- 25a - 13 2 0 8 ~ 8 50 parts by weight of water 3 " " " " 25~ ammonium-hydroxide 400 " " " " Neocryl XK* 70 22 " " " " ethoxy-ethanol 8 " " " " Etingal TP
8 " " ~ " Byk NP 3100 defoaming agent 25 " " " " 7.5% Additol XW 33~
95 " " " " Colanyl-oxide yellow G
~ ~ 35 1l n 1l ~1 Colanyl-oxide red B
30 " " " " Colanyl-oxide black B.
The amount applied was 180 g/m2 wet. The colour dispersion penetrated right through the layer corresponding ~ -to the printed image. This was followed by drying~
15The patterned and dried strip was then compacted at a temperature of 110C in a press. Th~ product obtained had a polychromal basic structure and a homogeneous pattern extending right through.,,,,,,_~,,",, .
:, :: : :
~ ~: : :: : .
:
;, :: : '. , :
, , , ': . ' '' :
. .:
~ 08~
ample 9. - -The strip produced according to Example ~, and sintered and printed accordin~ to Example 3,may al~o be converted, in a ~in~l~ operation, by means Or an in~ra-red radiator and a smoothing rolling mill, con-tinuously, into a polychromal, rough, slip-proof co~ering 3 ~ in thickness, with a small amount of compactingqby appropriate calibration in the roll-gap. ThiS produce a covering having a depth~effect and a special textile look.
The 9intered strip ~roduced according to Example ~ may also be cali-brated in a roll-ga~, thus becoming a polychromal, slip-proof covering.
Fig 7 is a view Or the sintered, porous strip, not yet co~pacted9 ~ according to ExamlFae 1J enlarged x 1.3.
Fi~. ~ is a view of a finished product according to ~xample 1 with a free pattern~
Fig. ~ i~ a view of a finished pro~uct according to Example 3, .
Fig~ 10 is a view of a finished product according to i~ample 7, while ~ig, 11 is a view of a .~inished product according to ~xample 5.
The designs illustrated in Figs. 7 to ll show the possible. fine stPucturin~ madepoi~ible;b~the~u~e of specific granu:ar mixture~, at least in principle, since the colour-effect, and many of the colour nuances are of course eliminated by the black-and-w~ite reproduction.
:'
Claims (25)
1. A method for producing coloured, patterned surface-structures based upon thermoplastic synthetic materials, wherein freely flowing particles are shaken out continuously to form a uniform layer and are sintered under the action of heat until the thermoplastic material plasticizes, into a porous, coherent layer which is cooled, after which at least one liquid or freely flowing, fusible, coloured medium is applied in predetermined patterns and penetrates into the porous layer to a desired depth, where-upon, under the action of pressure and heat, the coloured, porous layer is compacted into a compact surface-structure, characterized in that for the purpose of producing the freely flowing particles, an initial mixture, based upon thermoplastic synthetic material, is processed, by thermal pretreatment above the softening temperature, in-to an agglo-merate or granular material and is mechanically comminuted into a granular mixture having any desired grain-size distri-bution; and in that, without using a substrate layer, the granular mixture is shaken out onto a conveyor-belt to form a uniform layer, and is sintered.
2. A method according to claim 1, characterized in that the granular mixture of particles is obtained, by grinding strip or sheet based upon thermoplastic synthetic materials in the form of grinding dust or by fine-grinding agglomerates, granular material, chips, regenerated material or extruded material, with grain-sizes of up to 2 mm.
3. A method according to claim 2, characterized in that the granular mixture produced by grinding contains between 60 and 90% by weight of particles of the 250 to 800 µm grain-size.
4. A method according to claim 2, characterized in that the granular mixture is obtained from a agglomerates which are produced by mixing a PVC composition, at temperatures of up to 170°C, following by cooling, grinding and screening-out, and which contain about 20 to 75% by weight of the 500 to 2000 µm grain-size.
5. A method according to claim 2, characterized in that the granular mixture is obtained from ground, screened-out regenerated material, granular material or chips, the said granular mixture containing about 30 to 95%
by weight of particles having a grain-size of 500 to 2000 µm.
by weight of particles having a grain-size of 500 to 2000 µm.
6. A method according to claim 1, characterized in that the layer to be shaken out is made from mixtures of particles of different origin, colour, structure or grain-size distribution.
7. A method according to claim 1, characterized in that the granular mixture of particles contains a grain-size distribution with 90 to 100% by weight of the 300 to 800 µm grain-size.
8. A method according to claim 1, 2, 3, 4, 5, 6 or 7, characterized in that one obtains from a PVC
composition containing:
60 to 80% by weight, of E, S, M-PVC having a K-value of 50 to 80, 19 to 39% by weight of a plasticizer, 0.5 to 2% by weight of as stabilizer, 0 to 3% by weight of a colouring agent, by plasticizing at temperatures above the softening temperature an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture obtained by comminuting.
composition containing:
60 to 80% by weight, of E, S, M-PVC having a K-value of 50 to 80, 19 to 39% by weight of a plasticizer, 0.5 to 2% by weight of as stabilizer, 0 to 3% by weight of a colouring agent, by plasticizing at temperatures above the softening temperature an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture obtained by comminuting.
9. A method according to claim 1, 2, 3, 4, 5, 6 or 7, characterized in that one obtains, from a PVC
composition containing:
40 to 60% by weight, of E, S, M-PVC having a K-value of 50 -to 80, 18 to 24% by weight of a plasticizer, 20 to 40% by weight of fillers, 0.5 to 2% by weight of a stabilizer, 0 to 3% by weight of a colouring agent, by plasticizing at temperatures above the softening temperature, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by comminuting.
composition containing:
40 to 60% by weight, of E, S, M-PVC having a K-value of 50 -to 80, 18 to 24% by weight of a plasticizer, 20 to 40% by weight of fillers, 0.5 to 2% by weight of a stabilizer, 0 to 3% by weight of a colouring agent, by plasticizing at temperatures above the softening temperature, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by comminuting.
10. A method according to claim 1, characterized in that a layer of the granular mixture, between 5 and 12 mm in thickness, is shaken onto the conveyor-belt, is heated to a temperature of about 210°C, is sintered and is then cooled to a temperature of below 50°C, after which the liquid, coloured media are applied consecutively, in a weight per unit area of about 100 to 900 g/m2, by spraying or printing, the solvent contained is evaporated, and the sintered layer, carrying the applied colour, is heated to a temperature of at least 150°C, and is compressed at a surface-pressure of the order of about 0.2 to 20 N/mm2, or at a corresponding linear pressure in the roll-gap, homogeneously, into a strip or sheet having a final thickness of about 1.5 to 4 mm.
11. A method according to claim 1, characterized in that the liquid media are used in the form of pastes, aqueous polymer dispersions, or polymers dissolved in organic solvents.
12. A method according to claim 10 or 11, characterized in that the liquid media are printed or sprayed-on.
13. A method according to claim 12, characterized in that the liquid media are applied by the rotary-screen-printing process.
14. A method according to claim 1, 2, 3, 4, 5, 6, 7, 10, 11 or 13, characterized in that a copolymer based upon ethylene-vinylacetate is used as the thermoplastic synthetic material.
15. A method according to claim 1, 2, 3, 4, 5, 6, 7, 10, 11 or 13, characterized in that compression is carried out under the action of pressure and heat, in the roll-gap, with little compacting, so that a rough surface-structure is obtained.
16. Coloured patterned surface-structures produced by particles obtained by grinding thermoplastic synthetic materials by the method according to claim 1, 2, 3, 4, 5, 6, 7, 10, 11 or 13.
17. A method according to claim 1, characterized in that one obtains from a PVC composition containing:
65 to 70% by weight, of E, S, M-PVC having a K-value of 50 to 80, 24 to 34% by weight of a plasticizer based upon diisooctylphthalate, butylbenzylphthalate and, epoxidized soyabean oil, 0.5 -to 2% by weight of as stabilizer based upon barium-cadmium, calcium-zinc or tin compounds, 0 to 3% by weight of a colouring agent in the form of soluble or insoluble pigments and organic and inorganic fillers, by plasticizing at temperature at about 140 to 170°C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by milling or grinding.
65 to 70% by weight, of E, S, M-PVC having a K-value of 50 to 80, 24 to 34% by weight of a plasticizer based upon diisooctylphthalate, butylbenzylphthalate and, epoxidized soyabean oil, 0.5 -to 2% by weight of as stabilizer based upon barium-cadmium, calcium-zinc or tin compounds, 0 to 3% by weight of a colouring agent in the form of soluble or insoluble pigments and organic and inorganic fillers, by plasticizing at temperature at about 140 to 170°C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by milling or grinding.
18. A method according to claim 1, characterized in that one obtains, from a PVC composition containing:
40 to 60% by weight, of E, S, M PVC having a K-value of 50 to 80, 18 to 24% by weight of a plasticizer based upon phthalic-acid esters in the form of diisooctylphthalate, butylbenzylphthalate and epoxidized soya-bean oil, 20 to 40% by weight of fillers which are calcium-carbonate, 0.5 to 2% by weight of a stabilizer based upon barium-cadmium or calcium-zinc or tin compounds, 0 to 3% by weight of a colouring agent in the form of soluble and insoluble pigments, organic and inorganic dyestuffs, by plasticizing at temperatures at about 130 to 170°C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by milling or grinding.
40 to 60% by weight, of E, S, M PVC having a K-value of 50 to 80, 18 to 24% by weight of a plasticizer based upon phthalic-acid esters in the form of diisooctylphthalate, butylbenzylphthalate and epoxidized soya-bean oil, 20 to 40% by weight of fillers which are calcium-carbonate, 0.5 to 2% by weight of a stabilizer based upon barium-cadmium or calcium-zinc or tin compounds, 0 to 3% by weight of a colouring agent in the form of soluble and insoluble pigments, organic and inorganic dyestuffs, by plasticizing at temperatures at about 130 to 170°C, an initial material in the form of strip, sheet, mouldings, granular material, agglomerates from which the granular mixture is obtained by milling or grinding.
19. A method according to claim 1, characterized in that a layer of the granular mixture, between 5 and 12 mm in thickness, is shaken onto the conveyor-belt, is heated to a temperature of about 210°C, is sintered and is then cooled to a temperature of below 50°C, after which the liquid, coloured media are applied consecutively, in a weight per unit area of about 100 to 900 g/m2, by spraying or printing, the solvent contained is evaporated, and the sintered layer, carrying the applied colour, is heated to a temperature of at least 165°C and is compressed at a surface-pressure of the order of about 0.2 to 20 N/mm2, or at a corresponding linear pressure in the roll-gap, homogeneously, into a strip or sheet having a final thickness of about 1.5 to 4 mm.
20. A method according to claim 19, characterized in that the liquid media are used in the form of PVC pastes, aqueous polymer dispersions, or polymers dissolved in organic solvents.
21. A method according to claim 19 or 20, characterized in that the liquid media are printed or sprayed-on.
22. A method according to claim 21, characterized in that the liquid media are applied by the rotary-screen-printing process.
23. A method according to claim 21, characterized in that a copolymer based upon ethylene-vinylacetate is used as the thermoplastic synthetic material.
24. A method according to claim 23, characterized in that compression is carried out under the action of pressure and heat, in the roll-gap, with little compacting, so that a rough, still porous surface-structure is obtained.
25. The use of particles obtained by grinding thermoplastic synthetic materials for the production of coloured, patterned surface-structures by the method according to claim 1, 2, 3, 4, 5, 6, 7, 10, 13, 17, 18, 19, 20, 22, 23 or 24.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19853546151 DE3546151A1 (en) | 1985-12-27 | 1985-12-27 | METHOD FOR PRODUCING COLORED DESSINATED HOMOGENEOUS SURFACES BASED ON THERMOPLASTIC PLASTICS |
| DEP3546151.9 | 1985-12-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1320808C true CA1320808C (en) | 1993-08-03 |
Family
ID=6289587
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA526296A Expired - Fee Related CA1320808C (en) | 1985-12-27 | 1986-12-24 | Method for producing coloured surface-structures from thermoplastic synthetic materials |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0228654B1 (en) |
| JP (1) | JPS62160212A (en) |
| AT (1) | ATE64338T1 (en) |
| CA (1) | CA1320808C (en) |
| DE (2) | DE3546151A1 (en) |
| ES (1) | ES2022111B3 (en) |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB9214401D0 (en) * | 1992-07-07 | 1992-08-19 | James Halstead Ltd | Apparatus and method for compressing a continuous web |
| US5891564A (en) * | 1995-06-07 | 1999-04-06 | Mannington Mills, Inc. | Decorative surface coverings |
| ITTO980558A1 (en) | 1998-06-29 | 1999-12-26 | Mondo Spa | PROCEDURE FOR MAKING RUBBER-BASED COATINGS AND RELATED INTERMEDIATE AND FINAL PRODUCTS |
| US6588772B2 (en) | 2000-12-28 | 2003-07-08 | The Burton Corporation | Sintered sheet plastic material and gliding board base material |
| EP1679171A1 (en) * | 2005-01-10 | 2006-07-12 | Tarkett SAS | Homogenous surface covering |
| CN108602217A (en) | 2016-02-03 | 2018-09-28 | 阿德勒佩尔泽控股有限公司 | Film production method, film production component and plastic film |
| CN110726306B (en) * | 2019-10-22 | 2021-03-30 | 湖南理工学院 | High-utilization-rate belt type sintering machine |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE887265C (en) * | 1951-11-08 | 1953-08-20 | Continental Gummi Werke Ag | Process for the production of porous bodies |
| US3381067A (en) * | 1961-03-09 | 1968-04-30 | Congoleum Nairn Inc | Method of making a terrazzo plastic composition product |
| US3192294A (en) * | 1962-06-21 | 1965-06-29 | Us Rubber Co | Method of molding vinyl resin sheet material having an embossed surface |
| US3286008A (en) * | 1965-05-17 | 1966-11-15 | Formica Corp | Method of molding intractable polymers |
| US3359352A (en) * | 1965-06-18 | 1967-12-19 | Congoleum Nairn Inc | Process for producing decorative surface covering |
| CH476776A (en) * | 1967-01-25 | 1969-08-15 | Plast Labor Sa | Process for the production of porous bodies from finely divided polyethylene |
| JPS59199743A (en) * | 1983-04-27 | 1984-11-12 | Chisso Corp | Flexible vinyl chloride resin composition |
-
1985
- 1985-12-27 DE DE19853546151 patent/DE3546151A1/en active Granted
-
1986
- 1986-12-17 EP EP86117572A patent/EP0228654B1/en not_active Expired - Lifetime
- 1986-12-17 DE DE8686117572T patent/DE3679796D1/en not_active Expired - Lifetime
- 1986-12-17 ES ES86117572T patent/ES2022111B3/en not_active Expired - Lifetime
- 1986-12-17 AT AT86117572T patent/ATE64338T1/en not_active IP Right Cessation
- 1986-12-24 CA CA526296A patent/CA1320808C/en not_active Expired - Fee Related
- 1986-12-25 JP JP61308079A patent/JPS62160212A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| DE3546151C2 (en) | 1989-06-29 |
| EP0228654B1 (en) | 1991-06-12 |
| DE3546151A1 (en) | 1987-07-30 |
| ES2022111B3 (en) | 1991-12-01 |
| DE3679796D1 (en) | 1991-07-18 |
| EP0228654A2 (en) | 1987-07-15 |
| JPS62160212A (en) | 1987-07-16 |
| ATE64338T1 (en) | 1991-06-15 |
| EP0228654A3 (en) | 1988-06-08 |
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