CN110545981A - 形成无应力多层pvc片材的方法 - Google Patents

形成无应力多层pvc片材的方法 Download PDF

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Publication number
CN110545981A
CN110545981A CN201880027197.4A CN201880027197A CN110545981A CN 110545981 A CN110545981 A CN 110545981A CN 201880027197 A CN201880027197 A CN 201880027197A CN 110545981 A CN110545981 A CN 110545981A
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CN
China
Prior art keywords
sheet
layer
plastic strand
plastic
pvc
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.)
Pending
Application number
CN201880027197.4A
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English (en)
Inventor
Y.米歇尔
W.德洪特
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Likoprast Co Ltd
KREAFIN GROUP SA
Original Assignee
Likoprast Co Ltd
KREAFIN GROUP SA
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Filing date
Publication date
Application filed by Likoprast Co Ltd, KREAFIN GROUP SA filed Critical Likoprast Co Ltd
Publication of CN110545981A publication Critical patent/CN110545981A/zh
Pending legal-status Critical Current

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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
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    • B29C48/90—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
    • B29C48/906—Thermal treatment of the stream of extruded material, e.g. cooling with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article using roller calibration
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种形成用于地板和/或墙面板的多层塑料片材(1)的方法，其中，将包括刚性PVC的第一聚合物块在压力下熔融，并且以具有一层或多层的片状塑料股线的形式以规定的排出速率通过挤出机头，从而形成多层塑料股线，该多层塑料股线被传送到精轧机架的两个或更多个辊，该精轧机架将多层塑料股线处理成限定厚度的片，其然后通过运送装置将其引导到锯切装置以被切割成所需的长度，其中，在片状塑料股线离开挤出机头后，首先使其在粗轧机架的上辊和下辊之间通过，其中，精轧机架的辊和粗轧机架的辊的速度与来自挤出机头的片状塑料股线的排出速率同步，从而使所述塑料股线在没有应力的情况下被处理。

Description

形成无应力多层PVC片材的方法
技术领域
一方面，本发明涉及一种形成用于地板和/或墙面板的多层塑料片材的方法，其中，将包括刚性PVC的第一聚合物块在压力下熔融，并且以具有一层或多层的片状塑料股线(strand)的形式以规定的排出速率通过挤出机头，从而形成多层塑料股线，该多层塑料股线被推向精轧机架的两个或更多个辊，该精轧机架将多层塑料股线处理成限定厚度的片，其然后通过运送装置将其引导到锯切装置以被切割成所需的长度，其中，在片状塑料股线离开挤出机头后，首先使其在粗轧机架的上辊和下辊之间通过，其中，精轧机架的辊和粗轧机架的辊的速度与来自挤出机头的片状塑料股线的排出速率同步，从而使所述塑料股线在没有应力的情况下被处理。另一方面，本发明涉及一种具有高于1000N/mm2最好在2000N/mm2至3000N/mm2之间的弹性模量(E)和规定长度和宽度的多层片材。
本发明尤其涉及一种允许以最小可能的内部应力形成多层PVC片材的方法。
背景技术
通过所述方法制造的片材尤其是由PVC制造的塑料面板，其既可以是地板面板，也可以是墙面板。这种面板的厚度优选在2至10mm之间，特别是在3至8mm之间。标准制造的面板优选具有5至300cm的宽度和10至500cm的长度。
已知的面板通过挤出过程制造。该技术的缺点是在成品材料中会产生应力。因此，存在随后在材料中产生细裂纹的风险。
日本专利公开JP2002234116A和JPH07100898A描述了一种已知的挤出过程。
发明内容
本发明的目的是提供一种能够无应力地制造片材的方法。
本发明的目的通过一种形成用于地板和/或墙面板的多层塑料片材的方法来实现，其中，将包括刚性PVC的第一聚合物块在压力下熔融，并且以具有一层或多层的片状塑料股线的形式以规定的排出速率通过挤出机头，从而形成多层塑料股线，该多层塑料股线被传送到精轧机架的两个或更多个辊，该精轧机架将多层塑料股线处理成限定厚度的片，其然后通过运送装置将其引导到锯切装置以被切割成所需的长度，其中，在片状塑料股线离开挤出机头后，首先使其在粗轧机架的上辊和下辊之间通过，其中，精轧机架的辊和粗轧机架的辊的速度与来自挤出机头的片状塑料股线的排出速率同步，从而使所述塑料股线在没有应力的情况下被处理，并且其中，将包括柔性PVC的第二聚合物块在压力下熔融并共挤出在第一聚合物块上，然后将两者以片状多层塑料股线的形式通过挤出机头，多层塑料股线的顶层由第二聚合物块形成。
在根据本发明的方法的特定实施例中，将包括柔性PVC的第二聚合物块在压力下熔融并在第一聚合物块的底面上共挤出，然后将两者以片状多层塑料股线的形式通过挤出机头，该另外的第二聚合物块形成多层片材的稳定层。稳定层优选地具有与顶层相同的厚度。稳定层将防止片材翘曲。
该方法的优选实施例在从属权利要求中描述。
本发明还涉及一种具有高于1000N/mm2最好在2000N/mm2至3000N/mm2之间的弹性模量(E)和规定长度和宽度的多层片材，其中，所述片材包括具有一层或多层的由刚性PVC形成的载体材料，其中，在加热至80°并冷却回至室温后，片材具有关于初始长度和/或宽度的最大为0.2％的膨胀或收缩，并且其中，由刚性PVC形成的载体材料具有柔性PVC顶层。优选地，在加热至80°并且冷却回至室温后，片材具有关于初始长度和/或宽度的最大为0.1％的膨胀或收缩。
在从属权利要求中描述了根据本发明的片材的优选实施例。
为了解释本发明的性质并指出其额外的优点和特殊特征，下面将对根据本发明的方法和片材进行更详细的描述。应当指出，以下描述中的任何内容均不应解释为对权利要求中要求保护的限制。
附图说明
借助于附图解释该描述，其中：
-图1是根据本发明的多层片材的示意图；
-图2示意性地示出了其中应用了根据本发明的方法的装置的一部分；
-图3说明了结构在耐磨层中的应用；
-图4示出了运送装置，沿着该运送装置将形成的多层片材引向锯切装置；
-图5示意性地示出了将底层施加到片材的底面上。
具体实施方式
根据本发明的片材(1)是由多层构成的PVC片，其优选用作防水和低噪音的地板或墙覆盖物。
从图1可以看出，片(1)由如下构成：
1)约25g/m2的UV清漆涂层(6)；
2)耐磨层(5)；
3)由PVC(可选地也可以是PP或PE)制成的装饰层(4)(膜)；
4)柔性PVC层(3)；
5)用作载体或基片的刚性PVC层(2)；
6)粘合剂层(7)，优选地是EVA粘合剂(也可以考虑其他类型的粘合剂)；
7)底层(8)，优选地由泡沫材料制成。
显然，具有某些其他结构的片材同样也落入本发明的保护范围内，例如不存在装饰层(4)并通过为耐磨层(5)(最好在底面)提供印刷来提供装饰效果的片材或者在墙壁应用中省去耐磨层并且通过装饰层(4)或在应用UV清漆涂层(6)之前通过在柔性PVC层(3)或刚性PVC层(2)上直接印刷来施加装饰效果的片材。
片材的刚性PVC层(2)还可以在其底面上设置有柔性PVC层，该柔性PVC层用作稳定化(稳定)层。稳定层优选具有与形成顶层(3)的柔性PVC层相同的厚度。稳定层与顶层同时应用。通过稳定层的存在，片材将不易受到所谓的“双金属效应”的影响，并且片材将保持笔直并且不会翘曲。
在单个生产过程中制造(施加)构成片的各种层，并且如果在表面上也施加结构，则这例如可以是木制或石材结构。下面描述了该方法以及需要注意的精确点，以保持其无应力。
步骤1：制造载体片：
片(1)的基础或核心是刚性PVC层(2)，其设置有柔性PVC层(3)。这两层都通过所谓的多层T模具(9)制造。所述模具连接到两个单独的挤出机。主挤出机为刚性PVC层(2)提供材料，第二挤出机即所谓的共挤出机为柔性PVC层(3)提供材料。这两层以指定的厚度和密度在片宽度上分布在模具中。
在主挤出机中处理包括各种成分的刚性PVC。填料和矿物质也可通过混合机在挤出机的顶部加入，以获得片(1)的最佳热稳定性。化学发泡剂的添加在片中产生小的气泡，从而减小了片的比重。在挤出过程中，将添加剂与PVC混合并熔融，此熔体在指定的压力和温度下进入模具，并通过“帽架”原理在模具的整个宽度上并以指定的厚度扩散。
共挤出机的作用是相似的；送入共挤出机的材料是具有指定肖氏硬度的柔性PVC。柔性PVC的肖氏硬度优选在80至100之间，更特别地在85至95之间。柔性PVC层的目的一方面是为了确保与装饰膜的完美热熔合(见下文)，另一方面是为了打造柔软的手感。
重要的是模具中两层的流动以相同的速度前进，以避免在随后的热加载期间片的应力和翘曲。模具的唇部开口(其中将材料推出)必须按照指定的比例进行设置，以使共挤出的片的最终厚度在指定的厚度比内离开模具。如果这些速度在模具的宽度上差异太大，则冷却片时的收缩比率将不足以能够确保良好的稳定地板。
步骤2，片的预厚度校准+装饰(膜)层和耐磨层的预层压(参见图2)
一旦熔体从模具(9)中出来，该熔体就被形成粗轧机架一部分的两个辊(10、11)接收，即上辊(10)和下辊(11)。这些辊的特定特征是必须将它们保持在规定的温度下，以使由于辊和热熔体之间的温差过大而不立即冷却离开模具(9)的热熔体。为此选择特定组成的有机硅辊。
粗加工机架的操作如下：
a)离开T模具(9)的熔体以及所施加的装饰层(4)和耐磨层(5)的厚度的第一预校准。因此，两个辊(10、11)之间的间隙必须非常精确，以使辊(10、11)不会过度压在仍然很热的片上。
b)在热片上轻压装饰层。装饰层优选是PVC膜层。该PVC膜来自事先生产的辊。膜的展开是通过多个辊进行的，辊RPVC1是不断地测量装饰层(PVC膜)(4)上应力的辊，并确保所施加的对于展开PVC膜所需的力总是相同的，而无论PVC膜的辊的直径或膜厚度如何。辊RPVC2位于指定的角度。该辊的目的是将膜带到耐磨层(5)之下和粗加工机架的辊(10、11)之间，以使在一方面的PVC膜(4)与耐磨层(5)和挤出的PVC片之间没有空气夹杂。温度、应力、角度和距离对于获得稳定的过程非常重要。当然，整个展开单元具有连续的幅材(web)张紧和幅材引导。
c)在已经存在的3个层：装饰膜、柔性PVC层和刚性PVC层上施加耐磨层(5)。磨损层(5)也由具有幅材张紧和幅材引导的完整的展开单元展开。然而，必须考虑许多点。
1)根据耐磨层(5)的厚度，必须通过例如IR辐射加热器(12)对其进行一定程度的加热，以使整体稍微更柔韧，而且在它们层压在一起时限制热冲击；从模具(9)出来的熔体的温度约为150°，装饰膜(4)如此薄，以至于它立即达到该温度，但是耐磨层(5)的厚度为0.1至1.0mm，因此必须被一定程度地加热。这由IRWL辐射加热器(12)提供。
2)在该预加热之后，膜越过辊机架RWL2和RWL3，且角度、距离和应力再次非常重要。目的是通过顶部辊(10)几乎无应力地夹带预加热的耐磨层，并且重要的方面是耐磨层与顶部辊接触的接触表面或角度。
d)最后，顶部辊(10和11)将从模具(9)出来的熔体、PVC装饰膜和耐磨层压在一起。辊(10、11)之间的间隙很重要。它必须与从模具出来的熔体的厚度以及要压在一起的膜和耐磨层的厚度成比例。如果接触不充分，空气将滞留在不同的层之间。由于过度接触或过度挤压在一起，可能会在压缩片上形成肉眼可见的折痕，但在热状态下也会产生机械力，这会在以后造成危害，在片冷却时可能具有负的热稳定性。
e)因此非常重要的是，以一定的张力展开装饰膜和耐磨层，这足以使所有融合在一起而又不夹杂空气，也无需拉伸膜和耐磨层。另一方面，也很重要的是，从模具出来的熔体在上辊和下辊之间没有应力。此外，极其重要的是，可以精确且分别地设置上辊和下辊的速度。精轧机架的辊C1、C2和C3充当主辊，其对于粗轧机架的上辊和下辊的速度至关重要。后者现在与辊C1、C2和C3的速度同步，并有可能在这两个速度之间设置一定的偏差，以防止产生应力。反过来，挤出速度以及来自T模具的熔体的相关排出速率也与同样考虑到这些速度的可能偏差的粗轧机架的上辊和下辊同步，再次防止可能产生应力。
步骤3：最终校准厚度并引入结构化表面(压花)(参见图3)
一旦前述各层已经相互(预)层压，它们仍需要融合在一起，对厚度进行更好地校准，并且表面必须具有限定的压花结构。所有这些都必须在规定的温度下完成，当然具有最小的应力。
在粗轧机架后，片(1)越过2个从动支撑辊(S1和S2)。执行以下两个操作需要此间隔：
1)完成所有层的热熔合。当然重要的是，所使用的各个层在化学组成方面彼此相容(可熔)。
2)软化(加热)片的顶层，以最终用辊C2压印有吸引力的表面结构(压花)。因此，借助于第二IR辐射加热器(13)再次使耐磨层(5)的顶部***。该辐射加热器(13)的灯具有特定的波长，该波长仅软化耐磨层的顶部。非常重要的是不要再次加热整个耐磨层。这就是为什么为此使用具有特定波长的IR灯的原因。连续测量IR辐射加热器之后的表面的温度，并通过PID控制***将其保持恒定。在这一点上非常重要的是，在片的整个表面上具有恒定的表面温度，以最终通过辊C2产生在片中尽可能均匀的压花结构。
因此，S1和S2只是支撑辊，没有上辊会压缩片厚度。
此外，极其重要的是，在离开模具之后并且在其随后的路径期间，片不处于张紧状态。换句话说，不得拉动该片，否则会在片中产生过大的应力。另一方面，必须确保片也不会过度下垂。在该情况下，片将在其自身重量下拉伸，并且不可能实现稳定过程。因此，一方面至关重要的是与一方面来自T模具的排出速度与所有上述辊的速度之间的必要的偏移可能性非常好的同步性以获得稳定的厚度，并且另一方面以在片中产生最小的机械应力。
在支撑辊和用IR辐射加热器(13)加热耐磨层之后，片进入精轧机架(轧光机)的辊中。所有三个辊都有特定的恒定温度。中间辊C2是结构辊，其将在片(1)的表面上施加特定结构(压花)。该结构的精度或锐度取决于在辊之间通过的组装片的厚度，而且还取决于温度。再次有必要在辊之间的温度、压力和厚度设定之间找到正确的条件。这些因素的最细微偏差都会导致光洁度降低。
结构辊中的结构的深度通常比最终片中的结构的深度略深。这种生产方法的最大困难是，在片仍几乎完全柔软(尚未硬化)时在其上压印结构。因此，可以在没有太大困难的情况下将片弄平，这本身会使该过程容易一些。然而，经验和测试告诉我们，这会给片带来很大的机械负载，如果我们以这些引入的应力来形成片并对其进行冷却，则冷却后我们获得的热性能实际上非常差。
步骤4，在长辊台上以指定角度无应力地冷却片(参见图4)
在专利持有人的较早的专利出版物中已经描述了该过程。在此，片将在以一定角度设置的长辊台上冷却。在该辊台的端部有两个从动夹送(pinch)辊(TR)，其可确保片以指定的线速度前进。片将在辊C3和辊台的第一辊(15)之间下垂。下垂的值或因数由测量传感器测量。这些测量的值将被转换并通过PID控制***控制夹送辊(TR)的圆周速度。这样，片的下垂值(因数X)将始终保持恒定，并且我们能够说片是无应力冷却的。一旦片达到夹送辊的高度，其便已冷却至其处于固体状态的程度，因此不再受到某些机械应力的影响，其可能会在该过程的后续过程(锯掉边缘条、粘合吸声底层、锯成一定长度)中受到该应力。
如果我们现在一起检查图2、3和4，我们可以指出，在此过程中，辊C1、C2和C3的速度是决定性的(主动)。因此，这些具有操作者选择的速度。在这些辊之前和之后的辊作为从动件(被动)自动操作，因此，这些通过同步、测量和补偿***适应其圆周速度，从而能够确保恒定张力下的完整生产过程。当然，为了使该过程总体上保持稳定，来自模具(9)的熔体的排出速率也必须恒定。
步骤5，粘合底层(参见图5)
底层(8)优选是预挤出的PS泡沫层，其被粘合到片(1)的底面上。该底层的目的在浮动地板覆盖物的应用中通常是已知的。
底层来自辊，通过恒定的幅材引导和由辊U1测量的恒定的幅材张紧，层(8)将被粘合到我们的片的底部。粘合剂层(7)通过特殊的粘合头(滑移喷嘴)施加。底层(8)以指定的力在滑移喷嘴上滑移，这将在底层上施加一定量的胶粘剂；胶粘剂在储存器中被加热，并且通过齿轮泵而被压到辊***U2和U3上的滑移喷嘴中，确保滑移喷嘴(14)的出口和底层(8)之间的恒定接触面积，从而恒定量的胶粘剂将被施加在底层上。然后，底层进入夹送辊TR下方，并因此压靠在如上所述生产的片上。
齿轮泵的速度由夹送辊TR的速度控制，从而保证了每平方米胶粘剂的恒定量。必须考虑诸如胶粘剂的残留温度和打开时间等因素。
恒定的幅材引导确保始终或将始终以相同的张力将底层粘合在片上。
现在，生产过程的几乎所有步骤都已完成。在粘合后，将片修整至一定宽度，通过圆锯、切割或切断装置去除左右边缘条，从而我们最终获得恒定宽度的片。在去除边缘条之后，优选通过锯切、切割或切断装置将片减小到所需的长度。
一旦将片减小到所需的长度，就通过刷子***去除锯切操作中的所有残留物，并且在最后步骤中，为片提供UV清漆涂层(6)。该清漆涂层一方面提供了哑光效果，另一方面该清漆涂层可以额外防止地板弄脏。
使用经典的旋转式涂胶机施加清漆涂层，湿法湿涂两层，涂完清漆后，用UV灯将这些固化。

Claims (15)

1.一种形成用于地板和/或墙面板的多层塑料片材(1)的方法，其中，将包括刚性PVC的第一聚合物块在压力下熔融，并且以具有一层或多层的片状塑料股线的形式以规定的排出速率通过挤出机头，从而形成多层塑料股线，该多层塑料股线被传送到精轧机架的两个或更多个辊，该精轧机架将多层塑料股线处理成限定厚度的片，其然后通过运送装置将其引导到锯切装置以被切割成所需的长度，其中，在所述片状塑料股线离开挤出机头后，首先使其在粗轧机架的上辊和下辊之间通过，其中，所述精轧机架的辊和粗轧机架的辊的速度与来自挤出机头的片状塑料股线的排出速率同步，从而使所述塑料股线在没有应力的情况下被处理，其特征在于，将包括柔性PVC的第二聚合物块在压力下熔融并共挤出在所述第一聚合物块上，然后将两者以片状多层塑料股线的形式通过挤出机头，所述多层塑料股线的顶层由第二聚合物块形成。
2.根据权利要求1所述的方法，其特征在于，通过在片状塑料股线通过上辊和下辊之间之前在塑料股线上施加PVC装饰层(4)，从而使塑料材料具有装饰效果。
3.根据权利要求2所述的方法，其特征在于，在片状塑料股线通过上辊和下辊之间之前，在装饰层(4)上施加厚度在0.1至1mm之间的耐磨层(5)。
4.根据权利要求1所述的方法，其特征在于，通过在片状塑料股线通过上辊和下辊之间之前在塑料股线上施加厚度为0.1至1mm的具有印刷的透明耐磨层(5)，从而使塑料材料具有装饰效果。
5.根据权利要求3或4所述的方法，其特征在于，在施加所述耐磨层(5)之前对其进行加热。
6.根据前述权利要求中任一项所述的方法，其特征在于，所述片状塑料股线在所述挤出机头和粗轧机架之间经历偏转。
7.根据权利要求3-6中任一项所述的方法，其特征在于，在所述粗轧机架之后，所述片状塑料股线在所述精轧机架的方向上经过两个支撑辊，其中，片状塑料股线的耐磨层(5)在所述支撑辊之间被再次部分地加热，然后借助于精轧机架的辊在耐磨层(5)中施加结构。
8.根据前述权利要求中任一项所述的方法，其特征在于，所述片材(1)具有高于1000N/mm2的弹性模量(E)。
9.一种具有高于1000N/mm2的弹性模量(E)和规定长度和宽度的多层片材(1)，其中，所述片材包括具有一层或多层的由刚性PVC形成的载体材料(2)，其中，在加热至80°并冷却回至室温后，片材具有关于初始长度和/或宽度的最大为0.2％的膨胀或收缩，其特征在于，由刚性PVC形成的载体材料(2)具有柔性PVC顶层(3)。
10.根据权利要求9所述的多层片材，其特征在于，所述片材包括由PVC装饰层(4)形成的装饰效果。
11.根据权利要求10所述的多层片材，其特征在于，在所述装饰层(4)上施加厚度为0.1至1mm之间的耐磨层(5)。
12.根据权利要求9所述的多层片材，其特征在于，所述片材包括由具有印刷的厚度为0.1至1mm之间的透明耐磨层(5)形成的装饰效果。
13.根据权利要求9-12中任一项所述的多层片材，其特征在于，由刚性PVC形成的载体材料(2)在其底面上具有柔性PVC稳定层。
14.根据权利要求13所述的多层片材，其特征在于，所述稳定层具有与顶层(3)相同的厚度。
15.根据权利要求9-14中任一项所述的多层片材，其特征在于，所述载体材料还具有通过EVA粘合剂紧固至载体材料的底层。
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