• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
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    • 专利摘要:
    The present invention relates to a method for producing a coated PVC panel for use in both indoor and outdoor conditions, said method comprising the steps of: a) PCV panel extrusion; b) direct coating of said PCV panel with a water emulsion paint without an intermediate primer layer; c) in-line drying of said water emulsion paint in a cured coating.
    公开号:BE1023687B1
    申请号:E2015/0244
    申请日:2015-10-20
    公开日:2017-06-15
    发明作者:Bernard Lootens
    申请人:Rolvaplast；
    IPC主号:
    专利说明:

    PVC PANEL EXTRUSION AND IN-LINE COATING TECHNICAL AREA
    The present invention relates to a method for producing a coated PVC panel for use in both indoor and outdoor conditions, said method comprising the steps of: a) PCV panel extrusion; b) direct coating of said PCV panel with a water-based emulsion paint without intermediate primer layer; c) in-line drying of said water-based emulsion paint in a cured coating.
    BACKGROUND OF THE INVENTION
    Polyvinyl chloride (PVC) and unplasticized polyvinyl chloride (uPVC) are plastic polymers that are commonly used in the construction industry. PVC cladding or plating is a popular indoor and outdoor wall finish that is praised for its relative durability and low price compared to traditional building materials such as wood, clay or concrete. PCV panels are light in weight, usually have a hollow core and are often provided with tongue and groove edges for easy assembly.
    Despite all these advantages, many consumers still hesitate to apply PVC panels because of their plastic appearance and unnatural feel. Moreover, it is known that PVC is very difficult to paint. This is believed to be caused by its very low surface energy (41 mN / m at 20 ° C) - lower than the surface energy of water (72 mN / m), which results in very poor adhesion of water-based coatings to PVC surfaces and all related problems, such as odd spread of the paint over said surfaces. It is generally known that emulsion paints based on water (latex) cannot simply be used for painting PVC without labor-intensive surface preparation such as, for example, fine-grained sandblasting and / or the application of a preparatory substrate or primer.
    The above is a serious obstacle to the development of continuous PVC production and coating processes, where there is often no time to include steps that require lengthy waiting periods that would delay or hamper production progress in continuous lines of operation. For example, due to the time required for the primer layer to dry before paint can be applied to a flat PVC panel surface, and then also the time required for drying said paint layer, it is quite expensive and very challenging to quickly design curing continuous production line that includes both the extrusion of PVC panels and their immediate in-line coating; especially with regard to ecologically preferred watercolors. A watercolor layer should not only spread evenly over the PVC surface and adhere to it, but it is also important that it dries sufficiently or hardens sufficiently to allow transport and / or stacking of the coated PVC panels leaving the production line in order to save space and minimize personnel required to operate such a line. In addition to delaying the automation of PVC coating processes, the need for applying an additional primer underlay further increases the final cost price for the coated end product. Therefore, the optimum solution would be to find a paint that can cover large flat PVC surfaces without using a primer; however, it is known in the PVC manufacturing industry that a freshly extruded PVC poses an even greater challenge to coat than a PVC that has rested, probably due to the presence of various lubricants and waxes used during the extrusion process.
    Due to the above, only non-cost effective approaches, with the less favorable organic solvent-based paint formulations or production lines with additional non-standard processing units, are currently used in the in-line coating of flat PVC surfaces immediately after their extrusion. For example, WO2006036409 describes some paint compositions and various procedures for coating extruded PVC or polyolefin substrates, wherein the substrates are either initially covered by an epoxy primer or directly coated with PVDF-based paint solutions prepared in organic solvents, including methyl ethyl ketone or acetone with n methyl pyrrolidone. Another method for immediate coating of an extruded PVC is disclosed in WO9105660, wherein the coating is first applied to a separate film which is then pressed against the extruded flat PVC surface under elevated temperatures. Further known systems in the field for in-line coating of PVC include, for example, US2010119831 or US2014199538, which comprise complex installations in which PVC extruders are followed by arrangements of devices for applying and UV treatment of UV-curable coatings. The disadvantage of such installations is that, first of all, they require high intensity UV light sources that are required to initiate the UV curing reactions, which are generally expensive and must be replaced relatively often by the rapid loss of intensity; and second, the UV-curable coating compositions must include compounds such as photoinitiators, which, when exposed to UV energy, catalyze the chemical compound reactions that stimulate the curing of the coating. Of course, the use of these and other specialized chemicals in the paint compositions increases the cost price of UV-curing PVC coating installations even more.
    The present invention is made in view of the above facts and stems from an unexpected observation that a simple watercolor with a density higher than 1.25 g / cm 3 may be suitable for in-line PVC coating of fresh extruded flat panels and can be dried by air or IR sufficiently quickly to facilitate collection and stacking of the coated panels without thereby affecting the integrity and quality of the coating thus applied.
    SUMMARY OF THE INVENTION
    The present invention is defined in the appended independent claims. Preferred embodiments are defined in the dependent claims. More specifically, the present invention provides a method for producing a coated polyvinyl chloride (PVC) panel, said method comprising the steps of: a) extruding a PVC panel on a PVC panel production line; b) then in-line coating of at least one main surface of said PVC panel without an intermediate primer layer with a water emulsion paint; c) drying said in-line coated PVC panel in-line to obtain a PVC panel coated on at least one main surface with a cured paint coating.
    Furthermore, the present invention is also directed to the use of a PVC panel production line comprising the following elements: PVC extruder; - coating unit; - drying unit; for the production of a water-emulsion-coated PVC panel, said coated PVC panel comprising a PVC panel and a cured paint coating covering at least one main surface of said PVC panel without an intermediate primer layer.
    In yet another aspect, the present invention further provides a coated PVC panel for use in both indoor and outdoor conditions, wherein said coated PVC panel comprises a PVC panel and a cured paint coating, said PVC panel is characterized in that cured paint coating was applied directly as a water emulsion paint on the PVC panel with no intermediate primer layer.
    BRIEF DESCRIPTION OF THE FIGURES
    For a better understanding of the nature of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying Figure 1, which schematically shows an embodiment of a PVC panel production line suitable for carrying out the method of the present invention. The reference numbers refer to: 1 - a PVC panel, where la refers to a non-coated PVC panel, 1b-PVC panel coated with an emulsion paint (before drying), 1c - PVC panel coated with a cured paint ( after drying), ld - PVC panel cut and coated with a cured paint (after drying), ready for stacking; 2 - a PVC panel extruder; 3 - a cooling unit (e.g., cooling gauge); 4 - a degreasing unit; - a coating unit comprising a paint spraying chamber; 6 - drying units characterized as IR heaters; 7 - a cutting unit (e.g. a circular saw); and 8 - a stacking unit.
    DEFINITIONS
    As used herein, the term "panel" refers to a rigid building element for covering or plating architectural surfaces such as walls, ceilings, floors, and the like. As used herein, the term "panel" refers largely to a panel made of polyvinyl chloride (PVC) or non-plasticized polyvinyl chloride (uPVC), and is further described as "PVC panel". PVC panels are usually rectangular, flat, with a hollow core and relatively light in weight. A panel includes two large flat "main surfaces" or "main profiles" and four narrow "side profiles", at least two of which are often produced with tongue-in-groove structures allowing easy installation by mounting in a recess by stapling or nailing to more specifically, as sometimes used herein, the term "PVC panel substrate" refers to a non-coat PVC panel.
    As described herein, the term "PVC panel production line" or "PVC (panel) extrusion line" is to be interpreted as a series of consecutively positioned units starting from a PVC extruder unit, said units being configured to together form a sequence of perform operations leading to production of a finished PVC panel, which in the present context is a coated PVC panel.The specific units that can be arranged in the PVC panel production line of the invention are well known in the art. the line usually comprises at least one PCV extrusion unit, which may be a standard plastic extruder, comprising a hopper, heated vessel, breaker plate, and the die ending with a cooling device such as a calibrator or a water bath, followed by a coating unit that deposits paint on at least one surface of the extruded and cooled PVC panel processing along the production line, and at least in one drying unit which provides conditions for accelerating the drying (or curing) of said paint. As used herein, the term "in-line" is used to be interpreted as referring to a step or process performed at a certain point along the PVC extrusion line during the production of the coated PVC panel according to the method of the invention. In-line steps or operations, such as in-line coating, in-line drying, etc., usually follow the extrusion of the PVC panel substrate on the same production line, which contrasts with similar steps or operations that can be performed outside of a PVC extrusion line, ie formed at a preformed or earlier time, often at a different physical location, previously extruded PVC panel, but without all the advantages of a continuous production process.
    As used herein, the terms "preparatory undercoat" or, simply, "primet" refer to an initial or intermediate coating applied to the surface of a PVC substrate to form a bonding layer that is better prepared for receiving paint and ensures better adhesion of said paint to the surface of the substrate and extends its durability.
    As used herein, the term "emulsion paint" refers to a paint containing pigment suspension in a polymer emulsion (known as "latex" in the US). As used herein, the term "water-based" refers to a largely water-based medium that may optionally include other solvents, such as, for example, isopropanol. More specifically, the term "water emulsion paint" refers to a water dispersion of sub-micrometer polymer binder particles that dry or cure by a process called coalescence, in which first the water and then the "trace" or the coalescing agent "evaporate, contract, soften and thus fuse of the binder particles in an irreversibly bonded network film so that the paint cannot redissolve in the solvent / water in which it was originally carried.
    As used herein, the term "acrylic paint" refers to a paint containing pigment suspension in an acrylic polymer emulsion ("acrylic latex" in the US), ie an emulsion of polymeric substances derived from acrylic or methacrylic acid, or copolymers of acrylic or methacrylic acid, e.g. with styrene. Similarly, the term "water acrylic paint" refers to aqueous dispersion of sub-micrometer acrylic polymer. As used herein, the term "acrylic polymers" or "acrylate polymers" refers to homopolymers or copolymers with other monomers (e.g., acrylamides, acrylonitrile, vinyl, styrene, and butadiene) comprising acrylate monomers as building blocks. As used herein, the terms "acrylate monomers" or "acrylates" refer to esters and salts of acrylic or methacrylic acid.
    As used herein, the term "cured paint" or "cured paint coating" is to be interpreted as referring to a cured paint binder or resin, ie the film-forming substance which, after the solvent has evaporated, dry pigments and other paint components together and on the surface of the substrate "binds." For example, in oil paints, linseed oil is the binder, for acrylic paints acrylic polymer or copolymer thereof serves as binder, and the term "cured acrylic binder" is to be interpreted as being the coalesced paint film formed by acrylic polymers or copolymers, together with all components present or included in said coalesced film, more specifically pigments, extender pigments, etc., or even mineral particles such as sand particles (ie particles with a size between 0.063 and 2 mm according to the ISO 14688-1 classification scale) in certain texture paints .
    General examples of acrylates are alkyl esters of acrylic acid such as methyl, butyl, ethyl, and 2-ethylhexyl acrylate, the term "alkyl" referring to a group consisting of a monovalent radical, such as ethyl or propyl, with the general formula C n H 2n + 1. More specifically, as used herein, the term "lower alkyl" is to be interpreted as being an alkyl comprising fewer than seven carbon atoms.
    As used herein, the term "pigment" means any dye or other substance, usually in a powder form, that adds color to the paint formulation. Pigments can be both organic and inorganic and can also serve as fillers or binders for color pigments. Suitable pigments include alkaline earth carbonates such as chalk, calcium carbonate, magnesium carbonate, dolomite, precipitated and barium carbonate, talc, aluminum hydrates, zinc oxide, magnesium oxide, fluorite, alkaline lead carbonate, white and colored pigments based on titanium dioxide, iron oxide red, iron oxide black, manganese black, carbon, barium yellow , strontium chromate, calcium chromate, zinc yellow, zinc green, cadmium red, cadmium vermillion, cadmopone, vermilion, ultramarine, lead chromate, chromium yellow, molybdate red, molybdate orange, chromoxide green, chromoxide hydrate green, mangrove kaltobalt, mangrove violet alte azo series. A specific form of pigment is a so-called "paint binder" or "paint equalizer" or "extender pigment", and as used herein refers to a substance, usually a pigment, that is added to the paint formulation to increase the volume or bulk or properties such as viscosity increase. Most extenders are white and have a refractive index that corresponds to commonly used binders (1.4 - 1.7). In comparison with TiO2, which has a refractive index of approximately 2.7, they have little covering effect. Most are natural (they may require purification), and others are produced synthetically. The major extender pigments include, but are not limited to, calcium carbonate (synthetic and natural), silicon, aluminum silicate (quinite clay), magnesium silicate (talc), barium sulfate (natural - barite; synthetic - blanc fixe).
    In addition to extender pigments, emulsion paint formulations may further comprise other types of "thickeners" or "thickeners" that can further modify rheological properties of liquid paint, and, for example, can further improve suspension of pigments, increase paint viscosity or substrate adhesion properties, as well as, for example, cracking of the coating during the curing process can prevent. A specifically suitable type of emulsion paint thickeners that have been shown to perform very well in the method of the present invention include cellulose derivatives. As used herein, the term "cellulose derivative" refers to derivatives of cellulose obtained by substantial degradation of the cellulose chain into fragments and partial or complete reaction of the cellulose hydroxyl groups (-OH) with various reagents such as alkyl, hydroxyalkyl, or carboxyalkyl groups, preferably Preferred cellulose derivatives for the present invention include, but are not limited to, methylcellulose, ethylcellulose, ethylmethylcellulose, hydroxyethylcellulose (HEK), hydroxypropylcellulose (HPC), hydroxyethylmethylcellulose, hydroxypropylmethylcellulose (HPMC), ethylhydroxyethylcellulose, carboxymethylcellulose; cellulose acetate, cellulose acetate propionate, cellulose acetate butyrate, or benzyl cellulose.
    As used herein, the abbreviations "wt%" or "% w / w" refer to the "percent by weight" (or "percent by weight") unit with respect to a mass fraction of a particular component in a total mass of a composition.
    Furthermore, as used herein, the terms "IR heating" or "IR drying" should be interpreted as used interchangeably and constructed as removal of solvent (mainly water) by heat treatment by thermal infrared (IR) radiation. , ie radiation extending from the nominal red edge of the visible spectrum at 700 nm to 1 mm.
    As used herein, the term "spray drying" refers to a coating in which liquid substances such as paints are sprayed through the air onto a surface of a substrate. The most common types of spray coating use compressed gas (usually air) to atomize and direct the paint particles through a spray gun or, much smaller, airbrushes. Air gun spraying requires larger equipment and is typically used to cover large surfaces with an even coating of liquid. Spray guns can be automated or manually executed and have interchangeable heads to enable different spray patterns.
    DETAILED DESCRIPTION OF THE INVENTION
    The present invention relates to a method for producing a coated polyvinyl chloride (PVC) panel, said method comprising the steps of: a) extruding a PVC panel on a PVC panel production line; b) then in-line coating of at least one main surface of said PVC panel without an intermediate primer layer with a water emulsion form; c) drying said in-line coated PVC panel in-line to obtain a PVC panel coated on at least one main surface with a cured paint coating.
    The PVC panel is preferably substantially rectangular with two elongated flat main surfaces of which two longitudinal side edges have a complementary shape, whereby several of such PVC panels can be mounted together.
    In a preferred embodiment of the invention, said water emulsion paint has a density that is at least 1.25 g / cm 3, preferably at least 1.35 g / cm 3, most preferably at least 1.45 g / cm 3 . In further preferred embodiments, said water emulsion paint has a viscosity, as determined by the Stormer viscometer in Krebs units (KU), between 60-110 KU, preferably between 70-100 KU, most preferably between 80 and 90 KU.
    In particularly preferred embodiments, the water emulsion is an acrylic water emulsion comprising acrylic binder. In a preferred embodiment of the latter embodiment, said acrylic binder comprises an alkyl ester polymer of acrylic or methacrylic acid, or a styrene (or its derivative such as methyl styrene, vinyl toluene, butyl styrene, etc.), copolymer of alkyl ester of acrylic or methacrylic acid. Panels coated with styrene-acrylic copolymer are particularly suitable for wet locations because styrene increases the moisture resistance properties as well as the bonding strength and elastic characteristics of the coating. However, styrene-acrylic copolymer-based paint compositions tend to fade after exposure, so that a pure acrylic polymer-based coating is preferred in outdoor conditions when exposed to the sun due to its better color retention (less yellowing), brittle resistance and cracking resistance after prolonged exposure. Preferred styrene / acrylic emulsions contain up to 20-25% by weight or even up to 50% by weight of styrene when calculated on total monomer composition, but may, depending on the styrene used, even be present in the resin up to 70% by weight.
    In a specific embodiment of the previous embodiment, the alkyl group of said alkyl ester comprises between 1 and 15 carbon atoms, preferably between 2 and 7 carbon atoms. Said alkyl ester is preferably selected from the group consisting of: methyl acrylate or methacrylate, ethyl acrylate or methacrylate, n-propyl acrylate or methacrylate, isopropyl acrylate or methacrylate, n-butyl acrylate or methacrylate, isobutyl acrylate or methacrylate, sec-butyl acrylate or methacrylate tert or butyl acrylate methacrylate, acrylate or methacrylate of n-pentyl or isomer thereof, acrylate or methacrylate of n-hexyl or isomer thereof, and / or mixtures thereof.
    In particularly preferred embodiments of the present invention, said alkyl ester is preferably selected from a group consisting of: n-butyl acrylate or methacrylate, isobutyl acrylate or methacrylate, sec-butyl acrylate or methacrylate, tert-butyl acrylate or methacrylate, and / or mixtures thereof, and is preferably selected from a group consisting of n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, tert-butyl acrylate, and / or mixtures thereof.
    In alternative embodiments of the present invention, the acrylic binder is selected from the group consisting of n-butyl acrylate polymer, isobutyl acrylate polymer, sec-butyl acrylate polymer, tert-butyl acrylate polymer, styrene-n-butyl acrylate copolymer, styrene-isobutylacrylate copolymer, styrene -sec-butyl acrylate copolymer, styrene-tert-butyl acrylate copolymer, and / or mixtures thereof.
    The polymers can be prepared by conventional emulsion polymerization techniques. For example, conventional initiators, solvents, emulsifiers, chain transfer agents, etc., together with the desired monomers, are introduced into a temperature controlled reactor and agitator. The reaction can be carried out in an oxygen-free environment for a time sufficient to convert the monomers into polymer. The molecular weight of the polymer can vary. The use of alkyl acrylic esters in the preparation of polymers and copolymers by aqueous suspension polymerization is disclosed in, e.g., US 3691140. Similarly, styrene-acrylate copolymer resins suitable for use in the present invention can be produced by a variety of polymerization processes known in the art. For example, the resins can also be produced by conventional solution polymerization or emulsion polymerization. The resins of the present invention can also be advantageously produced by a rigid-fed emulsion polymerization process, such as that disclosed in US08264205.
    In a particularly advantageous embodiment according to any of the previous embodiments, the water emulsion paint further comprises at least one cellulose derivative, the addition of which helps to adjust the density and / or viscosity of the emulsion paint to the desired value. Many cellulose derivatives, especially the short-alkyl (C 1 -C 5) non-ionic, are water-soluble polymers that can thicken, suspend, bind, emulsify or even simultaneously form films together with the binder to provide protective colloidal action to the paint composition.
    In a preferred embodiment, the cellulose derivative is selected from the group consisting of hydroxyalkyl cellulose; alkyl cellulose; carboxymethyl cellulose; cellulose acetate, cellulose acetate propionate, cellulose acetate butyrate, benzyl cellulose, or mixtures thereof. The cellulose derivative is preferably selected from the group consisting of hydroxyalkyl cellulose; alkyl cellulose; carboxymethyl cellulose; cellulose acetate, cellulose acetate propionate, cellulose acetate butyrate, benzyl cellulose, or any mixture thereof.
    In a particularly preferred embodiment, the cellulose derivative is selected from the group consisting of hydroxyethyl cellulose (HEK), methyl cellulose, ethyl cellulose, or any mixture thereof. The cellulose derivative is preferably selected from the group consisting of hydroxyethyl cellulose (HEK), methyl cellulose, ethyl cellulose, or any mixture thereof.
    In another preferred embodiment, the water emulsion paint comprises at least one cellulose derivative or a mixture of cellulose derivatives in an amount between 3 and 8% by weight, preferably between 4 and 6% by weight.
    In alternative embodiments, the water emulsion may further comprise at least one pigment or extender pigment. As defined above, the term "pigment" refers to at least one color substance such as, but not limited to, titanium dioxide (TiO 2). Accordingly, the term "extender pigment" refers to a pigment substance added to a paint formulation to increase its volume or bulk or properties such as viscosity; the most prominent examples include synthetic or natural calcium carbonate and silicon. In specific embodiments, the cured paint coating on the PVC panel substrate comprises 20 - 65% by weight, preferably 35 - 55% by weight, most preferably between 40 - 45% by weight of pigments or extender pigments. In preferred arrangements, said cured paint coating comprises between 25-55% by weight, preferably between 35-45% by weight, extender pigments comprising calcium carbonate or silicon.
    In a specific embodiment of the method of the present invention, the water emulsion paint may further comprise, e.g., sand-sized mineral particles suitable for creating a textured coat on the coated PVC panel of the invention. Examples of such texture effects include, for example, stucco, and the particles that can be used in such paint formulations include any type of siliciclastic (especially containing quartz, feldspars or other silicon-based heavy minerals) or carbonate-based particles with a size between 0.063 and 2. mm, according to the ISO 14688-1 classification scale. In preferred embodiments, the water emulsion paint comprises from 5 to 30% by weight, preferably from 10 to 25% by weight, more preferably from 15 to 20% by weight, most preferably from about 17% by weight, of mineral particles having an average particle size comprised between 0, 02 and 2 mm.
    It is advantageous for shortening the general production time that the curing of the in-line coat on at least one surface of said PVC panel in the method of the invention proceeds quickly enough. Therefore, the in-line drying in step c) of the method of the invention is advantageously accelerated by means of air ventilation or heat, preferably by a combination of both. Therefore, in the preferred embodiment of the method of the invention, the in-line drying in step c) is carried out by air drying, convection oven, or IR heating. IR heating is particularly suitable for curing and drying water emulsion coatings because IR wavelengths correspond well with the water absorption bands. Additionally, since IR heating does not penetrate the surface very deeply and generally only heats the outer surface, it is suitable for drying coated plastic without the risk of melting or distortion of the underlying plastic substrates; provided, of course, that the temperatures do not exceed certain values during exceptionally long periods.
    In an advantageous embodiment according to the above-mentioned embodiment, the in-line drying in step c) is carried out by IR heating at temperatures between 30 and 70 ° C, preferably between 38 and 68 ° C, advantageously combined with air ventilation or circulation.
    The biggest advantage of IR heating over convection heating is probably that IR emitters directly transfer the energy in exact amounts to a specific point. IR radiation is a direct-view technology, which means that it only transfers heat to the surface of an object that is in direct line of sight from an IR emitter. This property further minimizes the possibility of potential heat distortion of the PVC panel substrate during heat drying and further saves energy because almost no heat is lost to the underlying substrate. Lastly, and in line with the above, IR heating is the preferred method for drying coated flat PVC panels in that their flat coated surfaces absorb the energy evenly, that uniform drying of the panel along its length during inline production process.
    IR radiation can be generated by one of three different technologies: electric, gas catalytic, or irradiation gas (the latter being used primarily for space heating instead of process heating). Electric and gas catalytic IR technologies have specific characteristics that make them more or less suitable, depending on the material and the process type. Gas catalytic IR systems generally require a larger capital investment than the other two, but they have lower operating costs. Therefore, in advantageous embodiments, the method of the present invention uses a gas catalytic IR drying system, e.g., a quartz IR heating lamp.
    In another advantageous embodiment of the present invention, the method of the invention according to any of the preceding embodiments further comprises an additional step between steps a) and b), said step comprising degreasing the at least one main surface of said PVC panel that has been subjected to the inline coating in step b). In order not to delay the coated PVC panel production line, labor-intensive and / or time-consuming PVC surface preparations are not preferred and often cannot be included in the method of the invention. However, it is possible to include a simple step in which the PVC substrate surface to be coated continues on a conveyor belt under a material covered with degreasing agent, such as a sponge, a piece of soft cloth, or a roll covered with one of the latter. Such a short degreasing treatment is not absolutely necessary when preferred paint formulations, as described above, are used in the method of the invention; however, it can make an advantageous improvement depending on the PVC extrusion arrangements. The degreasing is preferably carried out after cooling of the freshly extruded PVC panel in the cooling unit (e.g. vacuum calibrator) and just before applying the aqueous emulsion paint. Examples of suitable degreasing agents include, e.g., the degreasing products provided by Ge-ka supplies (http://www.ge-ka-supplies.com/).
    After the extrusion of the PVC panel, its cooling and preferably also short degreasing on at least one of its surfaces, the in-line coating of said PVC panel can be performed by any technique known in the art the art and suitably compatible with the design and speed of the PVC panel production line according to the method of the present invention. In a preferred embodiment, the water emulsion paint is applied by in-line spraying, blasting, roll coating, brush coating, or inkjet application, and is preferably coated by spraying. Spray coating or radiation according to the method of the invention can be carried out according to any known technique in the art. It is preferably carried out at room temperature by means of spray guns.
    In a further aspect, the present invention provides a use of a PVC panel production line comprising at least the following elements: - PVC extruder for extruding a PVC panel; - coating unit for coating said PVC panel with a water emulsion paint; drying unit for drying said water emulsion paint; for the production of a water-emulsion-coated PVC panel, wherein coated PVC panel comprises a PVC panel and a cured paint coating covering at least one main surface of said PVC panel without an intermediate primer layer.
    An example of a preferred embodiment of a PVC panel production line suitable for the above application and for carrying out a method according to the invention is schematically illustrated in Figure 1. In this example, the production line starts with the PVC panel (1). ) extrusion system or, simply, the extruder (2), as schematically illustrated by the block with a conical hopper. The extrusion process begins when small granules (particles) of PVC, possibly mixed with any desired auxiliary material such as plasticizers, etc., are added to the heated vessel of the extruder, where they are gradually melted into an even and hot PVC mass. The molten PVC mass is then continuously pushed toward the exit of the extruder vessel, ie toward the breaker plate and the die including the opening that provides the shape to the hot and still uncoated PVC panel (1a) being pressed through and leaves the opening of the mold. Said panel is usually first transferred to the cooling unit (3), which can be, for example, a water bath or a calibrator, e.g. a vacuum calibrator. In preferred embodiments of the production line of the invention, the cooling unit is a calibrator; however, other systems that are known in the art can also be used. As described above, in a suitable embodiment, the non-coated panel (1a) can also be transferred through a degreasing unit (4), such as, e.g., a soft roller or a brush comprising a degreasing agent.
    In this phase, the defatted non-coated panel (1a) is transferred to a coating unit (5), such as a paint station or a spray coating chamber, as schematically illustrated in Figure 1. In a preferred embodiment, the paint is applied by a paint gun under pressure . The paint gun is possibly of the type in which the amount of paint and / or the paint spray pressure can be varied, which enables the production of a number of different visual and textural effects. Alternatively, a paint gun can be used in which the amount of paint sprayed onto the extruded PVC panel and the pressure are fixed to produce a predetermined visual effect. In a standard example of a pressure gun, the paint can be released under the pressure of +/- 2 - 4 bar and sprayed onto the defatted panel surface at ambient temperature (approximately 22 ° C). For an aqueous emulsion paint without texture, between 50 - 200 g / m2, preferably 70 - 120 g / m2 of paint is used per PVC panel surface, which results in a dried coating with a final thickness between 20 - 80 microns, preferably between 30 and 30 - 50 micrometer.
    After the in-line coating in the coating unit (5), the coated PVC panel (1b) is transferred to a drying unit (6), schematically illustrated in Figure 1 as two IR ovens. It is, of course, immediately apparent to anyone skilled in the art that the type and amount of drying units can vary depending on the desired operation time and the amount of heat that a PVC panel can withstand. For reasons as explained above, in a particularly preferred embodiment, the coating unit comprises an IR heating system, preferably a gas catalytic IR heating system, such as a quartz IR heating lamp. In preferred embodiments of the above embodiments, the amount of IR heating units can be between 1 and 10, preferably 2 to 6 units, most preferably 4 or 5 units. For example, for a watercolor-coated PVC panel (lb) with dimensions of approximately 30 cm by 2.5 m, transferred by a series of four IR ovens, each set at a temperature between 40 - 60 ° C, the drying time can be around 1 hour 30 minutes.
    After the in-line drying in at least drying unit (6), the PVC panel coated with a cured (dried) paint (1c) can be cut into shorter coated panels (1d) as end products that can be stacked (ld), packaged, and shipped to their final distributor.
    In the latter aspect, the present invention provides the end product of the above-described process thus obtained, ie the coated PVC panel for use in indoor and outdoor conditions, wherein said coated PVC panel comprises a PVC panel and a cured paint coating said PVC panel is characterized in that said cured paint coating was applied directly as a water emulsion paint on the PVC panel with no intermediate primer layer.
    权利要求:
    Claims (15)
    [1]
    Conclusions [
    A method of producing a coated polyvinyl chloride (PVC) panel, said method comprising the steps of: a) extruding a PVC panel on a PVC panel production line; b) then in-line coating of at least one main surface of said PVC panel with no intermediate primer layer with a water emulsion paint; c) drying said in-line coated PVC panel in-line to obtain a PVC panel coated on at least one main surface with a cured paint coating.
    [2]
    A method according to claim 1, wherein said water emulsion paint has a density that is at least 1.25 g / cm 3, preferably at least 1.35 g / cm 3, most preferably at least 1.45 g / cm 3.
    [3]
    The method of claim 1 or 2, wherein the water emulsion comprises acrylic binder.
    [4]
    The method of claim 3, wherein said acrylic binder comprises an alkyl ester polymer of acrylic or methacrylic acid, or a styrene copolymer of alkyl ester of acrylic or methacrylic acid.
    [5]
    The method of claim 4, wherein the alkyl group of said alkyl ester is between 1 and 15 carbon atoms, preferably between 2 and 7 carbon atoms.
    [6]
    The method of any one of the preceding claims, wherein the water emulsion paint further comprises at least one cellulose derivative.
    [7]
    The method of claim 6, wherein the cellulose derivative is selected from the group comprising hydroxyalkyl cellulose, preferably hydroxyethyl cellulose (HEK); alkyl cellulose, preferably methyl cellulose or ethyl cellulose; carboxymethyl cellulose; cellulose acetate, cellulose acetate propionate, cellulose acetate butyrate, benzyl cellulose, or any mixture thereof.
    [8]
    A method according to any one of the preceding claims, wherein the in-line drying in step c) is carried out by air drying, convection oven or IR heating.
    [9]
    The method of claim 8, wherein the in-line drying in step c) is performed by IR heating at temperatures between 30 and 70 ° C, preferably between 38 and 68 ° C.
    [10]
    A method according to any one of the preceding claims, said method comprising an additional step between steps a) and b), wherein said step comprises degreasing the at least one main surface of said PVC panel that has been subjected to the inline coating in step b).
    [11]
    A method according to any one of the preceding claims, wherein the water emulsion paint is applied by in-line spraying, firing, roll coating, brush coating, or inkjet application.
    [12]
    The method of any one of the preceding claims, wherein the water emulsion paint further comprises mineral particles suitable for creating a texture coat.
    [13]
    13. Use of a PVC panel production line comprising the following elements: - PVC extruder for extruding a PVC panel; - coating unit for coating said PVC panel with a water emulsion paint; drying unit for drying said water emulsion paint; for the production of a coated PVC panel, wherein said coated PVC panel comprises a PVC panel and a cured paint coating that covers at least one main surface of said PVC panel without an intermediate primer layer.
    [14]
    Use according to claim 13, wherein the coating unit comprises an IR heating system, preferably a gas catalytic IR heating system.
    [15]
    A coated PVC panel for use in both indoor and outdoor conditions, said coated PVC panel comprising a PVC panel and a cured paint coating, said PVC panel characterized in that said cured paint coating was applied directly as a water emulsion paint on the PVC panel without an intermediate primer layer.
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    同族专利:
    公开号 | 公开日
    BE1023687A1|2017-06-15|
    WO2016083022A1|2016-06-02|
    EP3224306A1|2017-10-04|
    EP3026077A1|2016-06-01|
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    法律状态:
    2021-07-15| MM| Lapsed because of non-payment of the annual fee|Effective date: 20201031 |
    优先权:
    申请号 | 申请日 | 专利标题
    EP14194821.6A|EP3026077A1|2014-11-25|2014-11-25|PVC Panel Extrusion and In-line Coating|
    EP14194821.6|2014-11-25|
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