• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method is provided for manufacturing a plate-shaped product, the steps of which are to manufacture a first intermediate product provided with at least, successively, a carrier, a plastic printing layer, a decorative printing layer and a plastic protective layer, using a multiple coating process, manufacturing a second intermediate that is provided with at least one plastic layer, using at least one calender process, and combining the first and second intermediate by laminating such that the second intermediate is attached to the first intermediate. Furthermore, a plate-shaped product is provided that is manufactured using this method.
    公开号:BE1019012A5
    申请号:E2011/0061
    申请日:2011-02-02
    公开日:2011-12-06
    发明作者:Stefaan Gerard Lucien Duyck；Vlassenrode Kristof Van；Filip Gilbert Lucien Bossuyt；Stijn Michel Vermeulen
    申请人:Ivc N V；
    IPC主号:
    专利说明:

    Method for manufacturing a plate-shaped product and plate-shaped product manufactured thereby
    The invention relates in the first place to a method for manufacturing a plate-shaped product, in particular a plate-shaped product which mainly comprises plastic materials, according to the preamble of the main claim. Such a method is known from US-B-6 511 926.
    The term "plate-shaped product" can refer to various products such as floor products, wall products, ceiling products and the like.
    Today, various methods exist for manufacturing such plate-shaped products, such as, for example, a floor product. A first typical method for manufacturing a (mainly plastic) floor product in roll form is described in the patent application US-A-2004/0102120. According to this known method, a continuous multiple coating process is carried out to apply various layers to each other. Typically, such layers may comprise a plastic backing layer, a carrier, a plastic printing layer, a decorative printing layer, and a plastic protective layer. The resulting roll-shaped floor product can be converted into modular floor products. This known coating method generally produces highly flexible and soft floor products. Such flexibility is inherent in the coating process that uses plastisols of low viscosity that are controlled by a number of liquids in the plastisol, such as plasticizers, solvents, and additives. During a subsequent gelling process, the plastisols gel and the individual layers are joined. The plasticisers work as plasticizers to keep the final floor product flexible.
    The patent application US-A-2007/0166516 describes another typical method for producing (mainly plastic) modular floor products by calender and laminating techniques. According to this known method, various continuous sheet or film-shaped layers are produced by calendering, after which these layers are laminated together using a continuous laminating process.
    As an alternative to this known continuous lamination, a so-called hot-pressing method can be used which defines a discontinuous lamination process that uses short plates cut off from the sheet or film-shaped layers produced.
    Both the continuous and the discontinuous processes have various disadvantages. The processes embrace high total costs. To produce the various sheet or film-shaped layers (e.g. backing layer, printing layer and wear layer), several calender lines are required, each of which should be provided with a melting unit (e.g. an extruder) and a drying mixer, which increases costs. Furthermore, a separate printing line will be required. Finally, an intermediate storage must be provided for the sheet or film-shaped layers on a roll.
    Using this known method, floor products are obtained that are generally harder and stiffer than the floor products obtained by the coating method. However, most calendered and laminated floor products thus obtained have poor dimensional stability and often exhibit shrinkage phenomena and residual stability that often require additional heat treatment steps (without, however, completely preventing residual shrinkage).
    The method according to the prior art according to US-B-6 511 926 combines the advantages of the coating process on the one hand and the calender process on the other hand. Thus, the product obtained by this method will not show, or only to a limited extent, the disadvantages of the products obtained by the above-mentioned known methods. The first intermediate provides the final plate-shaped product with good dimensional stability due to the presence of the support, while the second intermediate makes the final product sufficiently rigid to offer it in a modular form if required.
    In view of the foregoing, it is an object of the present invention to provide an improved method for the manufacture of a plate-shaped product.
    In accordance with the present invention, such a method is characterized in that the step of manufacturing a second intermediate comprises providing a support and two calendered backing layers laminated on either side of said support. As a result, a final plate-shaped product will be obtained that has two carriers: a first in the first intermediate and a second in the second intermediate which together provide excellent dimensional stability to the final product (e.g., the flatness of the product and shrinkage can be improved). be reduced).
    The backing layers laminated on either side of the said support may have a different composition and / or thickness, but it is also possible that the backing layers laminated on either side of the said support may have a corresponding composition and / or thickness. Each backing layer may further comprise a single layer or a composite layer.
    In an embodiment of the method according to the present invention, the first intermediate product is manufactured with a plastic backing layer on the side of the carrier opposite the plastic pressure layer and the second intermediate product is attached to said backing layer.
    In a preferred embodiment of the method according to the present invention, at least the protective layer and / or, if used, the backing layer of the first intermediate product are provided with a surface structure produced by mechanical embossing. Such mechanical embossing is an alternative to chemical embossing (such as, for example, a standard foaming process for the printing layer) and is often used for structures that are not in registration with the printing. Chemical embossing is used in register with the printing, but will generally produce a shallower and less accurate structure. In most cases, only the protective layer will be subjected to mechanical embossing.
    In one embodiment, both the protective layer and the backing layer of the first intermediate product are then provided with a surface structure produced by mechanical embossing.
    However, alternatively, it is possible that both the protective layer and the backing layer of the first intermediate product are provided with a surface structure that is completely produced by gelling.
    According to yet another embodiment of the method according to the invention, a thermal cross-link process is used during the gelation process to produce the protective layer of the first intermediate product. As a result, a very hard protective layer (for example with PVC) can be obtained. This can be an important requirement for, for example, a floor product (for example a floor tile). According to such a thermal cross-linking, a part of the plasticizers normally present in the wear layer can for example be replaced by reactive methacrylates (or other reactive components) and an initiator. The latter will be activated at high temperatures and initiates a cross-linking. In addition to the gelling process during which the plasticizers diffuse into the plastic (PVC) granules and ensure that the wear layer hardens, an additional cross-linking takes place between the methacrylates themselves and between the methacrylates and the PVC chains. This results in a wear layer (protective layer) that is very hard.
    Alternatively, however, it is possible for a film to be laminated on top of the decorative printing layer to produce the protective layer of the first intermediate product.
    According to another embodiment of the present method, the carrier of the first intermediate product is impregnated with a plastic material, for example PVC, before being attached to an adjacent layer by said coating process. Such an impregnation step can improve the efficiency of the process. The impregnation layer will define the basis for the subsequent (plastic or plastisol) layers.
    In such a case, as an additional improvement to the said method, the carrier, after being impregnated, can be heated to pre-gel the plastic material.
    In accordance with yet another embodiment, when the method of the present invention comprises the additional step of providing a protective lacquer layer on top of the protective layer, the service life of the protective layer (and therefore of the plate-shaped product) can be extended.
    In another embodiment of the method, the step of manufacturing a second intermediate product also comprises the step of laminating the layers together. This includes both the possibility of forming a layer by laminating sublayers or the possibility of forming an assembly of layers to obtain the second intermediate product.
    In another embodiment of the method, the step of manufacturing a second intermediate comprises providing at least one, and preferably two or more films, optionally without carrier. Such an embodiment can be particularly useful when a very thick final plate-shaped product, such as a floor product, is required.
    The final plate-shaped product thus obtained can take various forms. The method may, for example, further comprise the step of cutting the plate-shaped product to size after the step of combining the first and second intermediate product, for example for obtaining products such as tile or plank-shaped floor products.
    The method according to the present invention can further comprise the step of providing edge plates and / or connecting provisions to the plate-shaped product. Connection provisions may, for example, be necessary for interconnecting floor products and may, as is known per se, comprise snap provisions.
    Without striving for completeness, the following embodiments may also be mentioned: as a support in the first intermediate a non-woven glass fiber support is used, while as support in the second intermediate a woven or non-woven support is used which may be based on glass fiber material ; a step of providing a surface structure in the protective layer and / or the backing layer of the first intermediate product and / or the side of the second intermediate product remote from the first intermediate product, wherein such a step of providing a surface structure can be used performed by chemical embossing (in particular providing an embossing pattern by a local expansion of a foam layer); a step may be used to provide an anti-slip coating or an adhesive coating that is covered with a free toxic film on the side of the second intermediate product remote from the first intermediate product.
    In a second aspect the invention relates to a plate-shaped product with, on top of each other, a first intermediate product which is provided with at least, successively, a carrier, a plastic printing layer, a decorative printing layer and a plastic protective layer coated on top of each other, and a second intermediate product attached to the first intermediate product and provided with at least one calendered plastic layer, which second intermediate product is provided with a support and two backing layers laminated on either side of said support, the plate-shaped product being manufactured using the method according to the present invention.
    In an embodiment of the plate-shaped product it is further provided with a plastic backing layer on the side of the carrier opposite the plastic pressure layer. Furthermore, it is possible that the second intermediate product is provided with at least one, and preferably two or more films, optionally without carrier.
    The carrier in the first intermediate may be a non-woven glass fiber carrier, while the carrier in the second intermediate may be a woven or non-woven carrier that may be based on fiberglass material, and whose position is selected such that the dimensional stability (such as flatness ) is optimally improved.
    Furthermore, it is possible that an anti-slip coating or an adhesive coating that is covered with a release film is provided on the side of the second intermediate product remote from the first intermediate product.
    The plate-shaped product according to the present invention can be in the form of a floor tile or floor board or can be provided in the form of a roll.
    The invention will be explained below with reference to the drawing, which shows a schematic cross section of an embodiment of a plate-shaped product embodying the floor product according to the present invention.
    With reference to the drawing, an embodiment of a floor product according to the present invention is shown in cross-section (it is noted that this cross-section is not necessarily to scale and that the relative dimensions of its component parts may differ from what is shown). This floor product has a first upper intermediate product 1 and a second lower intermediate product 2 which, in the ways to be described below, are manufactured separately and then assembled.
    In the illustrated embodiment, the first upper intermediate 1 has, successively, a PVC plastisol backing layer 3, a non-woven fiberglass support 4, a PVC plastisol printing layer 5, a decorative printing layer 6 and a PVC plastisol protective layer 7. These layers are superposed under use of a multiple coating process. Each layer has its specific composition, thickness, weight and function in the final floor product.
    The most important components of the plastisols are PVC, fillers, plasticizers, viscosity regulators, stabilizers and foaming agents.
    A first step for the production of the first intermediate product 1 can consist of impregnating a glass fiber carrier 4 with a PVC paste. Subsequently, the impregnated carrier is transported over a heated roller for pre-gelling (hardening) of the liquid paste. As a next step, the printing layer 5 is coated on top of the impregnated support 4. The printing layer, which will define the basis for the decorative printing layer 6, may comprise a white foam layer.
    The decorative printing layer 6 is applied on top of the printing layer 5, for example by means of a suitable printing technique (such as, for example, rotary intaglio). The inks used may contain an inhibitor which inhibits the foaming of the printing layer 5 for locally forming a relief (such as a seam in a tile-shaped floor product). Finally, the protective layer 7 will be coated on top of the decorative printing layer 6. Usually, the protective layer 7 will be a transparent PVC layer that provides important mechanical properties to the floor product.
    Preferably, a thermal cross-link process is used to produce the protective layer 7 of the first intermediate 1 during a gelling process. As a result, a very hard protective wear layer can be obtained. This can be an important requirement for a floor product (for example a floor tile). According to such a thermal cross-linking, part of the plasticizers normally present in the wear layer is replaced by reactive methacrylates and an initiator. The latter will be activated at high temperature and initiates a cross-linking. In addition to the gelling process during which the plasticizers diffuse into the plastic (PVC) granules and ensure that the wear layer hardens, an additional cross-linking takes place between the methacrylates themselves and between the methacrylates and the PVC granules. This results in a wear layer (protective layer) that is very hard.
    Additional decorative particles can be dispersed in the protective layer 7.
    It is possible to pre-gel the PVC plastisols in the printing layer 5 and the protective layer 7 through a heated roller. The carrier 4 can also be pre-gelled.
    The backing layer 3 can then be coated on the impregnated support 4, for example using a foaming technique (e.g. chemical or mechanical, as is known per se).
    This backing layer 3 provides the final floor product with the required comfort (resilience and damping).
    Subsequently, the intermediate product 1 is placed in a convection oven (heated to 205 ° C, for example) for a few minutes and complete gelling and foaming takes place. After cooling the floor product, a lacquer layer (not shown) can be applied on top of the protective layer 7. Alternatively, the lacquer layer is applied prior to gelling.
    Finally, the protective layer 7 and the backing layer 3 can be provided with a surface structure (e.g. by mechanical embossing).
    The obtained first intermediate product 1 can be finished (inter alia by cutting it to size, removing edges) and can be stored until later lamination with the second intermediate product 2.
    The second intermediate product 2 is not manufactured by coating techniques, but by calendering, possibly laminating techniques, which, among other things, use calender (and laminating) rollers. In an example of an embodiment of such a calender process, compositions based on PVC, mineral and organic fillers, plasticizers, additives and colorants are first produced that are fed to an extruder. A homogenization and melting of the composition takes place in the extruder. The extruded material is supplied to the calender rolls for producing PVC films.
    In the embodiment shown, the second intermediate product 2 comprises a first compactly calendered backing layer 8, a carrier 9 (which may be pre-coated, for example with a plastisol, to improve adhesion with the calendered layers) and a second compactly calendered backing layer 10. Each of the backing layers 8 and 10 may, if required, contain various separately calendered layers (films, but also foam layers) (for example, to achieve a required minimum thickness) that are laminated together. The carrier 9 may comprise a woven or non-woven carrier which may be based on glass fiber material.
    The carrier 9 is supplied to one or more laminating rollers, together with the backing layers 8 and 10 and the layers are laminated together to obtain the second intermediate product 2. It is also possible to pre-heat the backing layers and / or the carrier for improvement of lamination, for example through the use of infrared lamps or heated rollers.
    Once the first and second intermediates 1 and 2 have been manufactured, these products are joined by a subsequent laminating process to obtain the final floor product. If necessary, finishing steps can be carried out (including embossing the top and bottom of the final product, cutting the product to size and applying connection provisions).
    The invention is not limited to the embodiments described above, which can be varied widely within the scope of the invention as defined by the appended claims.
    权利要求:
    Claims (29)
    [1]
    A method for manufacturing a plate-shaped product, comprising the steps of - manufacturing a first intermediate product which is provided with at least, successively, a carrier, a plastic printing layer, a decorative printing layer and a plastic protective layer, using a multiple coating process, - manufacturing a second intermediate product provided with at least one plastic layer, using at least one calender process, - combining the first and second intermediate products by laminating such that the. second intermediate product is attached to the first intermediate product, characterized in that the step of manufacturing a second intermediate product comprises providing a support and two calendered backing layers laminated on either side of said support.
    [2]
    Method according to claim 1, wherein the backing layers laminated on either side of said support have a different composition and / or thickness.
    [3]
    Method according to claim 1, wherein the backing layers laminated on either side of said support have a corresponding composition and / or thickness.
    [4]
    A method according to any of claims 1 to 3, wherein the first intermediate product is manufactured with a plastic backing layer on the side of the carrier opposite the plastic pressure layer and wherein the second intermediate product is attached to said backing layer.
    [5]
    A method according to any one of claims 1 to 4, wherein at least the protective layer and / or, if used, the backing layer of the first intermediate product are provided with a surface structure produced by mechanical embossing.
    [6]
    The method of claim 5, wherein both the protective layer and the backing layer of the first intermediate are provided with a surface structure produced by mechanical embossing.
    [7]
    The method of claim 4, wherein both the protective layer and the backing layer of the first intermediate are provided with a surface structure that is completely produced by gelling.
    [8]
    A method according to any one of the preceding claims, wherein a thermal cross-link process is used during the gelation process to produce the protective layer of the first intermediate product.
    [9]
    A method according to any of claims 1-7, wherein a film is laminated on top of the decorative printing layer to produce the protective layer of the first intermediate product.
    [10]
    A method according to any one of the preceding claims, wherein the carrier of the first intermediate product is impregnated with a plastic material, for example PVC, before being attached to an adjacent layer by said coating process.
    [11]
    The method of claim 10, wherein the carrier, after being impregnated, is heated to pre-gel the plastic material.
    [12]
    Method according to one of the preceding claims, with the additional step of providing a protective lacquer layer on top of the protective layer.
    [13]
    13. A method according to any one of the preceding claims, wherein the step of manufacturing a second intermediate also comprises the step of laminating the layers together.
    [14]
    A method according to any one of the preceding claims, wherein the step of manufacturing a second intermediate comprises providing at least one, and preferably two or more films, optionally without carrier.
    [15]
    The method of any one of the preceding claims, further comprising the step of cutting the plate-shaped product to size after the step of combining the first and second intermediate product.
    [16]
    A method according to any of the preceding claims, further comprising the step of providing edge grooves and / or connecting provisions to the plate-shaped product.
    [17]
    A method according to any one of the preceding claims, wherein a non-woven glass fiber support is used as the support in the first intermediate product, while a woven or non-woven support can be used as support in the second intermediate product which can be based on glass fiber material.
    [18]
    A method according to any one of the preceding claims, further comprising the step of providing a surface structure in the protective layer and / or the backing layer of the first intermediate product and / or the side of the second intermediate product remote from the first intermediate product.
    [19]
    The method of claim 18, wherein the step of providing a surface structure is performed by chemical embossing.
    [20]
    The method of any one of the preceding claims, further comprising the step of providing an anti-slip coating or an adhesive coating that is covered with a release film on the side of the second intermediate product remote from the first intermediate product.
    [21]
    A plate-shaped product with, on top of each other, a first intermediate product which is provided with at least, successively, a carrier, a plastic printing layer, a decorative printing layer and a plastic protective layer coated on each other, and a second intermediate product which is attached to the first intermediate product and is provided with at least one calendered plastic layer, which second intermediate product is provided with a support and two back layers laminated on either side of said support, the plate-shaped product being manufactured using the method according to one of the preceding claims.
    [22]
    22. Plate-shaped product according to claim 21, further provided with a plastic backing layer on the side of the carrier opposite the plastic pressure layer.
    [23]
    A plate-shaped product according to claim 21 or 22, wherein the backing layers laminated on either side of said carrier have a different composition and / or thickness.
    [24]
    A plate-shaped product according to claim 21 or 22, wherein the backing layers laminated on either side of said carrier have a corresponding composition and / or thickness.
    [25]
    A plate-shaped product according to any of claims 21-24, wherein the second intermediate product is further provided with at least one, and preferably two or more films, optionally without carrier.
    [26]
    A plate-shaped product according to any of claims 21-25, wherein the carrier in the first intermediate is a non-woven glass fiber carrier, while the carrier in the second intermediate is a woven or non-woven carrier that may be based on glass fiber material.
    [27]
    A plate-shaped product according to any one of claims 21-26, wherein an anti-slip coating or an adhesive coating covered with a release film is applied to the side of the second intermediate product remote from the first intermediate product.
    [28]
    A plate-shaped product according to any of claims 21-27, in the form of a floor tile or floorboard.
    [29]
    A plate-shaped product according to any of claims 21-27, in the form of a roll.
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    同族专利:
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    EP11152888.1A|EP2481848B1|2011-02-01|2011-02-01|Method for manufacturing a plate shaped product and plate shaped product manufactured thereby|
    EP11152888|2011-02-01|
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