JP6685273B2 - 熱可塑性の耐摩耗性箔を製造する方法 - Google Patents
熱可塑性の耐摩耗性箔を製造する方法 Download PDFInfo
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- JP6685273B2 JP6685273B2 JP2017500809A JP2017500809A JP6685273B2 JP 6685273 B2 JP6685273 B2 JP 6685273B2 JP 2017500809 A JP2017500809 A JP 2017500809A JP 2017500809 A JP2017500809 A JP 2017500809A JP 6685273 B2 JP6685273 B2 JP 6685273B2
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- thermoplastic material
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Description
厚さ0.3mmのPVC摩耗箔を、厚さ0.1mmの装飾層に配置した。160℃の温度と20バールの圧力と40秒のプレス時間を以て、2つの箔をPVCコア材料に積層した。得られた製品はLVT製品であった。テーバー摩擦(摩耗)試験機で試験したところ、LVT製品は、3200回転の耐摩耗性を有していると認められた。
厚さ0.3mmのPVC摩耗層を、厚さ0.1mmの装飾箔に配置した。摩耗層箔に、90wt−%のPVCと10wt−%のAl2O3とを含む150g/m2の粉体配合物を分散配置した。PVC粉体配合物と2つの箔を、PVCコア材料に対して160℃の温度と20バールの圧力と40秒のプレス時間を以て積層した。得られた製品はLVT製品であった。テーバー摩擦(摩耗)試験機で試験したところ、LVT製品は、8000回転より大きい耐摩耗性を有していると認められた。
厚さ0.3mmのPVC摩耗層を、厚さ0.1mmの装飾箔に配置した。摩耗層箔に、90wt−%のPUと10wt−%のAl2O3とを含む150g/m2の粉体配合物を分散配置した。PU粉体配合物と2つの箔を、PVCコア材料に対して160℃の温度と20バールの圧力と40秒のプレス時間を以て積層した。得られた製品はLVT製品であった。テーバー摩擦(摩耗)試験機で試験したところ、LVT製品は、8000回転より大きい耐摩耗性を有していると認められた。
0.08mmの厚さを有する印刷装飾PVC箔を、3つの層を備えるとともに4mmの厚さを有するコアに配置した。0.25mmの厚さを有するPVC摩耗層を、装飾PVC箔に配置した。アルミナ形態の耐摩耗性粒子を、40g/m2の量においてPVC摩耗層に設けた。0.05mmの厚さを有するPU箔を、耐摩耗性粒子及びPVC摩耗層に配置した。これら種々の 層を冷間−熱間−冷間加工において一体にプレスした。適用された圧力は10バールであった。冷間−熱間−冷間加工において適用された温度は、50℃、140℃、50℃であった。製品を140℃で4分間プレスした。合計プレス時間は、およそ55分であった。得られた製品はLVT製品であった。テーバー摩擦(摩耗)試験機で試験したところ、LVT製品は、8000回転より大きい耐摩耗性を有していると認められた。
Claims (45)
- 第1熱可塑性材料を含む第1箔(1)を準備する工程と、
耐摩耗性粒子(4)と第2熱可塑性材料(5)とを前記第1箔(1)に設ける工程と、
前記第1箔(1)を、前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とに接合して耐摩耗性箔(10)を形成する工程と、
を備え、
前記第2熱可塑性材料(5)は、溶融状態において設けられる、耐摩耗性箔(10)を製造する方法。 - 前記耐摩耗性粒子(4)は、互いに接合された後の前記第1箔(1)と前記第2熱可塑性材料(5)とにより囲まれる、
請求項1に記載の方法。 - 前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)は、混合体として設けられる
請求項1又は2に記載の方法。 - 前記第1熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項1乃至3のいずれか一項に記載の方法。 - 前記第2熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項1乃至4のいずれか一項に記載の方法。 - 前記第2熱可塑性材料(5)は、ポリ塩化ビニル(PVC)又はポリウレタン(PU)を含んでいる、
請求項1乃至5のいずれか一項に記載の方法。 - 前記第1箔(1)と前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とは、プレス加工によって互いに接合される、
請求項1乃至6のいずれか一項に記載の方法。 - 前記耐摩耗性粒子(4)は、アルミナを含んでいる、
請求項1乃至7のいずれか一項に記載の方法。 - 前記耐摩耗性粒子(4)は、45μm未満の平均粒径を有している、
請求項1乃至8のいずれか一項に記載の方法。 - 互いに接合された後の前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とにより形成される層の厚さは、75μm未満である、
請求項1乃至9のいずれか一項に記載の方法。 - 前記耐摩耗性箔(10)は、透明である、
請求項1乃至10のいずれか一項に記載の方法。 - コア(21)を準備する工程と、
装飾層(22)を前記コア(21)に配置する工程と、
第1熱可塑性材料を含む第1箔(1)を前記コア(21)上の前記装飾層(22)に設ける工程と、
耐摩耗性粒子(4)と第2熱可塑性材料(5)とを前記第1箔に設ける工程と、
前記コア(21)を、前記第1箔(1)と前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とに接合して建築パネル(20)を形成する工程と、
を備えた建築パネル(20)を製造する方法。 - 前記耐摩耗性粒子(4)は、互いに接合された後の前記第1箔(1)と前記第2熱可塑性材料(5)とにより囲まれる、
請求項12に記載の方法。 - 前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)とは、混合体として設けられる、
請求項12又は13に記載の方法。 - 前記第2熱可塑性材料(5)は、粉体形状において設けられる、
請求項12乃至14のいずれか一項に記載の方法。 - 前記第2熱可塑性材料(5)は、溶融状態において設けられる、
請求項12乃至14のいずれか一項に記載の方法。 - 前記第1熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項12乃至16のいずれか一項に記載の方法。 - 前記第2熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項12乃至17のいずれか一項に記載の方法。 - 前記第2熱可塑性材料(5)は、ポリ塩化ビニル(PVC)又はポリウレタン(PU)を含んでいる、
請求項12乃至17のいずれか一項に記載の方法。 - 前記第1箔(1)と前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とは、プレス加工によって互いに接合される、
請求項12乃至19のいずれか一項に記載の方法。 - 前記耐摩耗性粒子(4)は、アルミナを含んでいる、
請求項12乃至20のいずれか一項に記載の方法。 - 前記耐摩耗性粒子(4)は、45μm未満の平均粒径を有している、
請求項12乃至21のいずれか一項に記載の方法。 - 互いに接合された後の前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とにより形成される層の厚さは、75μm未満である、
請求項12乃至22のいずれか一項に記載の方法。 - 前記第1箔(1)と前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)とは、耐摩耗性箔(10)を形成する、
請求項12乃至23のいずれか一項に記載の方法。 - 前記コア(21)は、第3熱可塑性材料を含んでいる、
請求項12乃至24のいずれか一項に記載の方法。 - 前記第3熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項25に記載の方法。 - 前記コア(21)は、HDF、MDF,パーチクルボード、OSB、木材プラスチック複合材(WPC)、又は鉱物ボードである、
請求項12乃至24のいずれか一項に記載の方法。 - キャリア(7)を準備する工程と、
耐摩耗性粒子(4)と第2熱可塑性材料(5)とを前記キャリア(7)に設ける工程と、
前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)とを互いに接合して耐摩耗性箔(10、10’)を形成する工程と、
を備え、
前記第2熱可塑性材料(5)は、溶融状態において設けられる、耐摩耗性箔(10、10’)を製造する方法。 - 前記耐摩耗性粒子(4)は、互いに接合された後の前記第2熱可塑性材料(5)により囲まれる、
請求項28に記載の方法。 - 前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)とは、混合体として設けられる、
請求項28又は29に記載の方法。 - 前記第2熱可塑性材料(5)は、ポリ塩化ビニル(PVC)又はポリウレタン(PU)を含んでいる、
請求項28乃至30のいずれか一項に記載の方法。 - 前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とは、プレス加工によって互いに接合される、
請求項28乃至31のいずれか一項に記載の方法。 - 前記耐摩耗性粒子(4)は、45μm未満の平均粒径を有している、
請求項28乃至32のいずれか一項に記載の方法。 - 互いに接合された後の前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とにより形成される層の厚さは、75μm未満である、
請求項28乃至33のいずれか一項に記載の方法。 - 前記耐摩耗性箔(10、10’)を前記キャリア(7)から剥離する工程を更に備える、
請求項28乃至34のいずれか一項に記載の方法。 - 前記キャリア(7)は、熱可塑性コア、木材プラスチック複合材(WPC)、木材系ボード又は鉱物ボードのコア(21)であり、
前記耐摩耗性粒子(4)と前記第2熱可塑性材料(5)とを接合する工程は、前記キャリア(7)を前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とに接合する工程を含む、
請求項28乃至34のいずれか一項に記載の方法。 - コア(21)と、
前記コア(21)に配置された装飾層(22)と、
前記装飾層(22)に配置された耐摩耗性箔(10、10’)と、を備え、
前記耐摩耗性箔(10、10’)は、第2熱可塑性材料(5)と、前記第2熱可塑性材料(5)に実質的に均一に散布された耐摩耗性粒子(4)と、を含んでいる、
建築パネル(20)。 - 前記耐摩耗性粒子(4)は、前記第2熱可塑性材料(5)と前記コア(21)とにより囲まれる、
請求項37に記載の建築パネル(20)。 - 前記耐摩耗性箔(10、10’)は、第1熱可塑性を含む第1箔(1)を更に備える、 請求項37又は38に記載の建築パネル(20)。
- 前記第1箔(1)に含まれる第1熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項39に記載の建築パネル(20)。 - 前記第2熱可塑性材料は、ポリ塩化ビニル(PVC)、ポリエステル(PE)、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項37乃至40のいずれか一項に記載の建築パネル(20)。 - 前記耐摩耗性粒子(4)は、アルミナを含んでいる、
請求項37乃至41のいずれか一項に記載の建築パネル(20)。 - 前記耐摩耗性粒子(4)は、45μm未満の平均粒径を有している、
請求項37乃至42のいずれか一項に記載の建築パネル(20)。 - 互いに接合された後の前記第2熱可塑性材料(5)と前記耐摩耗性粒子(4)とにより形成される層の厚さは、75μm未満である、
請求項37乃至43のいずれか一項に記載の建築パネル(20)。 - 前記コア(21)は、ポリ塩化ビニル(PVC)、ポリエステル、ポリプロピレン(PP)、ポリエチレン(PE)、ポリスチレン(PS)、ポリウレタン(PU)、ポリエチレン・テレフタレート(PET)、ポリアクリレート、メタクリレート、ポリカーボネート、ポリビニル・ブチラール、ポリブチレン・テレフタレート、又はこれらの組合せを含んでいる、
請求項37乃至44のいずれか一項に記載の建築パネル(20)。
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