• 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 sheet forming product having at least one top protective PVC layer applied to an adjacent layer using a coating step and a subsequent gelling step. The method comprises the additional step of adding, in the PVC layer, an initiator and a monomer which cause a cross-link process in the PVC layer during the gelling step, and wherein the initiator is a peroxide.
    公开号:BE1019308A3
    申请号:E2011/0248
    申请日:2011-04-29
    公开日:2012-05-08
    发明作者:Stijn Michel Vermeulen
    申请人:Ivc N V；
    IPC主号:
    专利说明:

    Description
    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 with at least one upper protective PVC layer which is applied to an adjacent layer by means of a coating step and a subsequent gelling step.
    The term "plate-shaped product" can refer to various products, such as floor products, wall products, ceiling products or the like.
    The method for manufacturing such a plate-shaped product using, at least, a coating step and a subsequent gelling step of the protective PVC layer, generally uses a PVC plastisol (which may be provided with a PVC emulsion, optionally provided with extender resin, plasticizer, stabilizer, breather and viscosity reducer). In a known situation, the use of such a plastisol will lead to a rather soft upper protective layer, compared to a situation in which such an upper protective PVC layer is manufactured by calender and extrusion techniques (in which case a PVC suspension with a lower is used) liquid and plasticizer content).
    It is an object of the present invention to provide an improved method of the above-mentioned type.
    In accordance with the present invention, this method is characterized by the additional step of adding, in the PVC layer, an initiator and a monomer that cause a cross-link process in the PVC layer during the gelation step, and wherein the initiator is a peroxide .
    The use of a peroxide as an initiator and a monomer results in the formation of an additional cross-linking pattern in the upper protective PVC layer, which improves the properties of the said layer (to a level comparable to that of a calender and extrusion techniques) low). In particular, a very hard top protective PVC layer can be obtained that is extremely wear-resistant.
    In a preferred embodiment of the method according to the present invention, a peroxide is added with a decomposition temperature such that the cross-linking process and the gelling step occur substantially simultaneously.
    During such a decomposition, the peroxide decomposes into alkoxy radicals and the cross-linking process begins. The simultaneous occurrence of the cross-link process and the gelling step will lead to a final upper protective PVC layer with optimum properties. If cross-linking (at least in part) would already take place prior to the gelling step, the extent to which the gelling step occurs will be reduced. If, on the other hand, cross-linking (at least in part) will take place after the gelling step, the resulting cross-connections will be less compact. Therefore, in both cases, the cross-link process and the gelling step will negatively influence each other. However, if both the cross-link process and the gelling step occur substantially simultaneously, both will take place optimally as desired.
    As such, in an embodiment of the method according to the invention, a peroxide is added with a decomposition temperature in the range of 50 ° C to 120 ° C. During a coating process (and gelling step) that is used during the manufacture of a plate-shaped product, high temperatures are already achieved which cause the required decomposition.
    Preferably, the peroxide has a decomposition temperature in the range of 80 ° C to 90 ° C, which corresponds to processing temperatures between 160 ° C and 190 ° C corresponding to the gelling temperature of the PVC plastisol used.
    In a preferred embodiment of the process of the present invention, the peroxide is TBPIN (tert-butyl peroxy-3,5,5-trimethyl hexanoate). Such a peroxide provides acceptable properties. However, it is conceivable to use other peroxides. An example is TBPB (tert-butyl-peroxybenzoate) which will also lead to a desired cross-linking. However, during decomposition, TBPB will result in two alkoxy radicals, one of which is a carboxybenzyl radical which, in addition to initiating the monomer, will disappear via two mechanisms: H abstraction with formation of carboxybenzene and Co2 elimination resulting in benzyl radical followed by H abstraction with formation of benzene. However, global standards prohibit or limit the emissions of carboxybenzene and benzene, making the use of TBPB as peroxide less favorable.
    In an embodiment of the method according to the invention, the peroxide is added in an amount of 0.1 to 1.5 phr, preferably in an amount of 0.4 to 1 phr and most preferably in an amount of 0, 6 to 0.8 phr. The abbreviation "phr" stands for parts per hundred parts of resin. The amount of peroxide is important with regard, among other things, to the compatibility in relation to the amount added, the influence on the rheology of the plastisol (which influence must be minimized) and its influence on the thermal stability of the PVC plastisol. Tests can be performed to determine the optimum amount of peroxide, such as a "pull to break" test that measures the force required to pull the upper protective PVC layer apart, a "tear resistance" test that measures the required force for doing cracks of the upper protective PVC layer or a stain test where the resistance to permanent staining of the upper protective PVC layer is determined. Other tests can be performed to determine the influence on other properties, such as, for example, the ability of the upper protective PVC layer to be embossed at a subsequent embossing station.
    In another embodiment of the method according to the invention, the monomer is a methacrylate ester. Such a methacrylate ester provides the best results, inter alia in the field of UV stability. However, it is conceivable to use other monomers, such as acrylate esters.
    Preferably, the methacrylate ester is then a polyfunctional methacrylate ester, and preferably a trifunctional methacrylate ester. The more methacrylate functions are present, the more compact the final cross-linking will occur and the stronger the final upper protective PVC layer will be.
    In one embodiment of such a process, the trifunctional methacrylate ester is TMPT-MA (trimethylolpropane trimethacrylate).
    In addition to the amount of peroxide, the amount of monomer will also have an influence on the final upper protective PVC layer. Preferably, the monomer is added in an amount of 5 to 50 phr, more particularly in an amount of 10 to 35 phr, and most preferably in an amount of 15 to 25 phr. During a first phase of the cross-linking process, the monomer (e.g. methacrylate) will function as a plasticizer or viscosity reducer. It is important that the amount of monomer added has no negative influence on the rheology of the PVC plastisol. Therefore, the optimum amount of monomer can be based, among other things, on rheology studies.
    Secondly, the invention relates to a plate-shaped product with at least one upper protective PVC layer made using the method of the present invention.
    Such a plate-shaped product can take the form of a floor tile or floor board, but can also be provided in a form for use on a wall or on a ceiling. Its geometric shape can vary (although, preferably, it will be rectangular or square).
    An example of such a plate-shaped product can, successively, be provided with a backing layer, a carrier, a printing layer, a decorative printing layer and the top protective PVC layer. These components of the plate-shaped product can be manufactured using any combination of different techniques such as, for example, coating, laminating, calendering and extruding.
    In addition to the top protective PVC layer, other components of the plate-shaped product can also be made from or impregnated with a plastic material, for example PVC. Finally, it is noted that the plate-shaped product can also have the shape of a roll.
    The present invention provides a process which allows using a coating technology to manufacture a plate-shaped product (such as, for example, a modular PVC floor tile) with an extremely wear-resistant upper protective PVC layer that is comparable in its properties to a plate-shaped product of which such an upper layer has been produced by calender or extrusion techniques. Such a coated top layer can be laminated to, for example, a PVC backing layer to obtain such a final product with properties comparable to those of a fully calendered product. The use of a coated upper layer allows the manufacture of a decorative printing layer and upper layer during a single continuous process, while the decorative printing layer and the upper layer are produced during two separate processes during calendering.
    The invention will be explained below with reference to the drawing (figure 1) which shows a schematic cross-section of a plate-shaped product in the form of a floor product according to the 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 that are manufactured separately and then assembled, for example by a laminating process.
    In the embodiment shown, 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 superimposed using 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.
    The upper protective PVC layer 7 is coated and then gelled in accordance with the present invention while adding a peroxide initiator and a monomer, preferably TBPIN (tert-butyl-peroxy-3,5,5-trimethylhexanoate) and TMPTMA (trimethylolpropane). trimethacrylate) in preferred amounts of 0.6 to 0.8 phr (parts per hundred parts of resin) and 15 to 25 phr, respectively.
    In the embodiment shown, the second intermediate product 2 comprises a first compact 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 compact 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 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 (17)
    [1]
    A method for manufacturing a plate-shaped product with at least one upper protective PVC layer that is applied to an adjacent layer using a coating step and a subsequent gelling step, characterized by the additional step of adding, in the PVC layer, an initiator and a monomer that cause a cross-linking process in the PVC layer during the gelation step, and wherein the initiator is a peroxide.
    [2]
    The method of claim 1, wherein a peroxide is added with a decomposition temperature such that the cross-linking process and the gelling step occur substantially simultaneously.
    [3]
    The method of claim 2, wherein a peroxide is added with a decomposition temperature in the range of 50 ° C to 120 ° C.
    [4]
    The method of claim 3, wherein the peroxide has a decomposition temperature in the range of 80 ° C to 90 ° C.
    [5]
    The method of any preceding claim, wherein the peroxide is TBPIN (tert-butyl-peroxy-3,5,5-trimethyl hexanoate).
    [6]
    The method of any one of the preceding claims, wherein the peroxide is added in an amount of 0.1 to 1.5 phr.
    [7]
    The method of claim 6, wherein the peroxide is added in an amount of 0.4 to 1 phr.
    [8]
    The method of claim 7, wherein the peroxide is added in an amount of from 0.6 to 0.8 phr.
    [9]
    The method of any one of the preceding claims, wherein the monomer is a methacrylate ester.
    [10]
    The method of claim 9, wherein the methacrylate ester is a polyfunctional methacrylate ester.
    [11]
    The method of claim 10, wherein the polyfunctional methacrylate ester is a trifunctional methacrylate ester.
    [12]
    The method of claim 11, wherein the trifunctional methacrylate ester is TMPTMA (trimethylolpropane trimethacrylate).
    [13]
    The method of any one of the preceding claims, wherein the monomer is added in an amount of 5 to 50 phr.
    [14]
    The method of claim 13, wherein the monomer is added in an amount of 10 to 35 phr.
    [15]
    The method of claim 14, wherein the monomer is added in an amount of 15 to 25 phr.
    [16]
    A plate-shaped product with at least one upper protective PVC layer made using the method according to any of the preceding claims.
    [17]
    A plate-shaped product according to claim 16 in the form of a floor tile or floorboard.
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    同族专利:
    公开号 | 公开日
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    GB1255742A|1968-04-09|1971-12-01|Arfa Roehrenwerke Ag|Polyvinyl chloride sintering powder|
    US3804933A|1972-02-04|1974-04-16|Gaf Corp|Chemical embossing|
    DE2454235A1|1974-11-15|1976-05-20|Teroson Gmbh|Plastisols of methyl methacrylate polymers - contg organic plasticiser as coatings for metals, textiles or cables|
    US4402887A|1978-03-14|1983-09-06|Dainippon Ink And Chemicals Inc.|Sheet-like articles of polyvinyl chloride|
    GB2120266A|1982-05-14|1983-11-30|Halstead James Ltd|Floorcoverings made from plastics materials|
    EP0342562A2|1988-05-17|1989-11-23|Tarkett Pegulan Aktiengesellschaft|Use of acrylate plastisols in the preparation of covering layers for PVC floor coverings|
    DE10345045A1|2003-09-26|2005-04-14|Röhm GmbH & Co. KG|Surface coating of materials, e.g. to form a protective layer, involves laminating with a film made from a mixture of methyl methacrylate-based polymer and an acrylic copolymer with reactive comonomer units|
    法律状态:
    2022-01-19| MM| Lapsed because of non-payment of the annual fee|Effective date: 20210430 |
    优先权:
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