DE2605880A1 - SURFACE MATERIALS - Google Patents

Description

The invention relates to the manufacture of surface covering materials including, for example, floor coverings, wall coverings and covering materials for shelves, work surfaces and the same.

Polyvinyl chloride surface covering materials are well known where the term "polyvinyl chloride" as used here, both vinyl chloride homopolymers and - Including copolymers. These surface covering materials can be produced in a variety of ways. For example one can produce sheets or sheets of polyvinyl chloride using leveling devices, and finally process into a laminate to form surface covering materials

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ORIGINAL INSPECTED

According to another method, polyvinyl chloride plastisols are applied to a substrate, after which the plastisol is in the gel state is transferred and whereupon, if desired, further polyvinyl chloride layers can be applied to surface materials with reasonable thickness. However, such surface covering materials often suffer from raised corners and dimensional instability · TJm to avoid damage from standing corners, layers of polyvinyl chloride material can be applied to both sides of the substrate, creating a balance between the material on each side of the substrate as described, for example, in British patent specification 1,029,085. That in such surface covering materials The substrate used can, for example, be a non-woven fabric, for example a glass non-woven fabric.

For certain purposes, especially in the case of floor covering materials, it is desirable to incorporate a foamed polyvinyl chloride material into the surface of the covering to make a product to obtain with increased thickness, which is elastic and shows a good step behavior. It is so well known to use flooring materials, which contain a foamed layer to be produced by being in the by calendering or by gel formation the polyvinyl chloride layers formed by the polyvinyl chloride plastisols by heat-activatable [effervescent agents incorporated and then through Decomposition of the propellant causes foaming. However, it has been shown that the incorporation of a foamed polyvinyl chloride layer in surface covering materials of the type described in the aforesaid British patent can lead to surface covering materials which, due to the above, to achieve a balance between the material. on each side of the substrate, to "avoid the Standing up from corners, described necessary measures, are excessively thick.

An object of the present invention is to provide

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of a non-woven fibrous substrate that in use in the manufacture of surface covering materials of the type described above, which reduces difficulties, which can occur due to standing up or curling of the corners, dimensional instability and the like.

In accordance with one feature of the present invention, there is provided a material that can be used as a substrate in manufacture of surface covering materials is suitable that a non-woven fiber material, or a fleece, with a zone or zones which extends from a surface of the web into the body of the web and consists of fibers. exist with a gel state resin composition are covered and another zone or zones wherein the fiber structure is fully impregnated with a gelatinized resin composition.

The resin composition is preferably a polyvinyl chloride composition, which can be applied as a plastisol and then converted into the gel state.

The non-woven fiber material or Ylies is preferably a glass fleece; such materials are generally available in both the wet produced or "wet laid" as well as the dry produced or "dry laid" Porm available. The non-woven material or Ylies should have an even and firm or cohesive lextur with sufficient have opened matrix to allow sufficient impregnation with the resin composition. One becomes advantageous non-woven substrate with as flat and even a finish or pinish as possible and accordingly Wet-laid non-woven glass materials or glass fleeces are advantageously used. Will the Ylies with a thermosetting Binding agent, as it can be in the case of glass fleeces, the thermosetting binding agent should be used in the subsequent

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Bend temperatures to be used, e.g. during heat treatment be stable to cause expansion of any foamable resin composition that is subsequently applied and any plasticizers or plasticizers that may be present not be attacked.

The substrate should be thick enough to form an adequate Strength, for ease of handling, and v / e is generally a thickness of 0.1 to 1.0 mm, advantageously about 0.4 mm. In the case of glass fleece, it is preferred to use a material that weighs at least 30 g / m, materials with 30 to 100 g / m,

ρ ρ

are advantageously 40 to 80 g / m and in particular 50 to 60 g / m particularly preferred. Of course, these material weights refer to the material before impregnation.

The invention also provides a method of making a Material suitable for use in the manufacture of surface covering material that allows impregnation of a non-woven Fiber material or a fiber fleece with an effective Amount of a liquid resin composition and heating to cause formation of the resin compositions, whereby a material is obtained having a zone or zones extending from a surface of the material into the body of the material and consists of fibers coated with a resin composition and having another zone or zones wherein the fiber structure is fully impregnated with a gelled resin composition is.

According to one embodiment of the method according to the invention the impregnation is produced by pressing the Ywoven into the liquid resin composition, the composition being a Has a thickness less than the non-pressed thickness,. jjedoch is not less than the pressed thickness of the Ylieses, after which you release the pressure.

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Thus, according to a method of the invention, the resin composition, to be applied is applied to a surface from which it can then be easily removed, i.e. a pilgrim cast carrier (a carrier suitable for bringing the resin composition into contact with this composition wear and adhere to to enable subsequent operations, the adhesion being such that the resin composition can be easily removed from the carrier after transferring to the gel state). Suitable pilgrim cast supports include for example release paper, such as kraft paper (e.g. the pilm cast paper M 4/17 of the Wiggins Teape Group). Alternatively, a metal support can be used for this purpose stainless steel is particularly suitable. The resinous composition on the release surface should have a thickness which is less than the uncompressed thickness but not less than the compressed thickness of the web.

A layer of the non-woven fabric is then pressed into the layer of the resin composition so that the non-woven fabric is entirely immersed in the resin composition. The squeezing can be done for example by means of a loaded roller. The thickness of the fleece should be greater than the thickness of the resin composition, such that when the pressure is applied to the nonwoven fabric, the topmost fibers thereof smooth out by themselves of the resin composition, whereby a coating of the resin composition remains on the fibers adjacent to the outermost surface of the fleece, but the zone of the fleece, which is adjacent to the support surface remains fully impregnated with the resin composition.

The assembly is then used to transfer the resin composition heated to the gel state, and the impregnated fleece can then be peeled from the carrier, wherein one a substrate according to the invention is obtained which is suitable for use in the manufacture of surface covering materials.

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Alternatively, the substrate can be fabricated if desired by having a non-woven material or fleece on which a resin composition in the form of a plastisol as a coating or topping was applied to a heated molding drum shows around

An ¥ alze, which forms a kink with the heated drum, is used to move the coated fleece when it is reached the heated drum into the plastisol, the gelling of the plastisol being caused by the heated drum. After passing through the kink, the pressed web recovers to form a substrate, the zone in 4, the closest passed over the heated salt is fully impregnated with the resin composition, while the zone that looks the furthest from the heated roller, made of glass fibers coated with the resin composition and a plurality of small air pockets consists.

In this embodiment, the amount applied to the fleece depends Resin composition

on the characteristics of the fleece. Preferred for glass fleece one generally applies enough resin composition to at least $ 20 and not more than 755 saturation to achieve, with about $ 50 saturation especially is preferred. For example, when using a glass fleece of 55 g / m 2, 100 to 300 g / m 2 of resin composition are advantageous applied to the fleece.

According to a further embodiment of the method according to the invention the impregnation takes place in two stages, the first stage lasing the fleece through the entire structure be coated with a first resin composition, whereupon at least to achieve partial gelation of the first Resin composition is heated and in the second stage a second bath composition is applied to one surface of the nonwoven fabric applied, which is followed by heating to form the second resin composition

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into the gel state and, if necessary, the first resin composition to completely gel.

When carrying out the last-mentioned embodiment of the invention Method, it may be appropriate to use identical formulations for the aforementioned first and second To use resin compositions

The first stage of this latter embodiment involves coating the fibers of the web throughout the structure a first resin composition. This stage is expediently carried out in such a way that first one that can be spread or applied Resin composition is applied to a surface of the web, after which the coated web is passed between nip rolls. It is possible to desirably apply the resin composition without spreading and look at the nip rollers to disperse the resin composition in the web, but generally conveniently to leave the resin composition to spread on the fleece as a coating. The application or distribution with a knife over a roller is an appropriate one Distribution technique for applying the resin composition. Passing through nip rollers serves to distribute the resin composition through the entire structure of the fleece and also, if necessary, * to squeeze out excess resin composition, which could have been applied.

The amount of the resin composition applied to the fleece in the first stage naturally depends on the characteristics of the fleece in the process according to the invention. In the case of nonwovens, it is generally preferred to apply sufficient resin composition only to coat the surface of the glass fibers. In general, this first stage provides less than 50 fo the possible weight gain, which can be obtained at full impregnation, and, for example, using a glass fleece 60 g / m and a thickness of 0.4 mm, so it has to overall

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shows that it is expedient to use 150 to 330 g / m 2 of polyvinyl chloride plastisol composition applies

After passing through, the nip roll is heated to at least to effect a partial gelation of the resin composition. This heating becomes appropriate by passing the treated substrate through an oven at a suitable temperature.

The next stage of this embodiment involves applying the second resin composition to a surface of the previously treated one Fleece. Again forms the order with the knife

an appropriate application technique. The amount of the resin composition applied is advantageously selected so that the surface of the Ylies is completely impregnated, while zones of incomplete impregnation remain and also creating a thin layer of the resin composition over the fibers on the surface of the nonwoven fabric. It is It can be seen that at this stage of the process, there is a tendency at some points for the second resin composition to penetrate deep into the fleece penetrates. However, it is important that following this process stage partially non-impregnated zones with a substantial number of voids are still present in the fleece are.

Again, the amount of resin composition applied to the web at this stage of the process depends on the characteristics of the fleece as well as the degree of impregnation achieved in the preceding process steps. For example the application with the knife over the salt used to apply the resin composition, it has proven to be advantageous to limit the amount of the resin composition applied to the minimum or at least close to the minimum that is appropriate can be applied with this technique. For example, if you use a glass fleece with 60 g / m with a thickness of

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about 0.4 mm and fiber-coated with about 230 g / m polyvinyl chloride resin composition, it has been shown that the coating applied in this process stage is advantageously 100 to

200 g / m of polyvinyl chloride plastisol composition.

The next stage of this embodiment of the method comprises heating to effect the gelation of the second applied resin composition and, if necessary, complete the gelation of the first resin composition applied during the partial impregnation step. This heating is conveniently effected by passing the little river through an oven again and be used polyvinyl chloride resin, there is an appropriate furnace temperature at 175-180 ⁰ C.

The substrate made in accordance with the present invention advantageously has a coating of the second resin composition over the fibers on the surface to which the second resin composition has been applied. The surface of this surface skin ("scrim" coating). creates, where available, the surface to which further layers are applied when using the substrate for the production of surface covering materials. The surface pile, if any, suitably has an average thickness over the fleece of not more than 0.2 mm, preferably from 0.05 to 0.1 mm. If desired, the surface can the ⁿ scrim "~ pavement are shaped as desired and it may be appropriate to combine the Gelbildungsund embossing-end steps. For example, a smooth surface characteristics, for example using a polished chrome roll for embossing a very smooth surface, expediently to be carried out by heating in the oven before cooling at the end of the step of conversion into the gel state.

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The substrates produced according to the invention comprise a fiber fleece, which is partially fully impregnated with resin composition and partially impregnated with resin composition to the rope is · Zones of total impregnation can be deeply penetrated at certain points and actually possibly completely through the nonwoven Fleece be extended, whereas at other points the fully impregnated zones are only shallow or superficially in extend the nonwoven web. The zones with partial impregnation extend from the surface of the fleece, which from the fully impregnated surface is removed into the fiber structure of the fleece. It can be seen that in these partially impregnated zones there are a number of voids which not present in the fully impregnated zones'.

As mentioned above, the resin composition is preferably a polyvinyl chloride plastisol composition. Such polyvinyl chloride plastic is oils can, for example, in addition to the polyvinyl chloride resin, Plasticizers, stabilizers, fillers, modifiers for viscosity, volatile additives and pigments included.

The polyvinyl chloride contained in the plastisol can be a homopolymer or copolymers, the copolymers used preferably having a larger proportion of units which derived from vinyl chloride. Other copolymerized monomers that can be incorporated into the copolymers as desired, include, for example, vinyl acetate and vinylidene chloride. A polyvinyl chloride polymer that is beneficial in formulation Suitable plastisols that can be used is that known under the trade name "Breon P 130/1", with "Breon" being a trademark is.

Suitable plasticizers include, for example Phthalate plasticizers, e.g. nonyl, octyl, butyl, butylbenzyl and diälphany! phthalates, phosphates (e.g. irixylenyl or *

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Trixylyl and Tricresylph.osph.ate), Adipate and Sebacate.

In general, it is necessary to incorporate an amount of stabilizer into the plastisols, i.e. a substance suitable for that purpose is to retard the decomposition of the resin during compounding and subsequent exposure to light. Suitable stabilizers include, for example, certain compounds containing lead, certain organotin compounds and certain metallic soaps, in particular stearates of metals such as zinc, cadmium, barium and aluminum.

Fillers can be incorporated into the plastisols as optional ingredients. Various inert inorganic Substances are used as fillers, the most suitable being calcium carbonate, e.g. in the form of chalk (whiting), precipitated chalk or precipitated lime, ground limestone or ground dolomite.

Viscosity modifiers can also be used as required may be incorporated to affect the viscosity characteristics of the plastisols, hexylene glycol being an example of is a viscosity modifier which can be suitably used.

Volatile additives can also be incorporated into the plastisols will. Examples of such additives are solvents such as white spirit (turpentine substitute) and low-boiling ones Ester.

Preferred plastisols for use according to the invention contain per 100 parts by weight of polymer present from 30 to 100 parts by weight of plasticizer up to 5 parts by weight of stabilizer, up to 200 parts by weight, preferably up to 20 parts by weight of fillers, up to 10 parts by weight of viscosity-modifying agents and up to 20 Parts by weight of volatile additives.

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Substrates that are manufactured according to the invention have a special application in the manufacture of flooring materials, which contain a foamed layer. Such floor ■ Covering materials can be made by applying a layer of. foamable resin composition, e.g. a foamable poly

YpIl

Tinyl chloride plastisol composition on the impregnated surface of the substrate, on which further layers of resin composition, e.g., one or more decorative layers and / or protective layers, if desired, can be applied will. According to one method, a total layer is made foamable resin composition is applied to a substrate produced by the present invention, and it becomes a desired one Pattern by any conventional method, such as in-situ gravure printing or lamination of a previously printed film, applied, a transparent protective layer is added and everything is foamed and transformed into the gel state. If it is desired to bring about a texture effect in the end product, this can be achieved by using a printing ink, which is an inhibitor or accelerator for the foamable resin composition. Alternatively, texture effects, for example using substrates according to the invention in the case of the British patent 1,409,295, in DOS 2 408 199 and DOS 2 408 683 getting produced.

For example, a surface covering material with a texture effect can be produced by (a) a foamable Applying resin composition or foamable resin compositions to selected surfaces of a substrate according to the invention, (b) at least one overall layer of essentially non-foaming composition via the substrate and the foamable resin composition or the foamable resin compositions applied thereto and (c) heated to cause foaming of the foamable resin composition (s). Alternatively can produced a surface covering material with a texture effect

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by (a) applying at least one resin composition to selected surfaces of a substrate of the invention; (b) one or more overall layers of at least one foamable resin composition over the substrate and the applying resin composition (s) thereon; and (c) to cause the foamable resin composition to expand warmed up. Another alternative includes (a) applying a layer of a first foamable resin composition to a substrate of the invention, (b) applying a second foamable resin composition to selected ones Areas of the surface of the first foamable resin composition; (c) applying at least one substantially non-foaming layer over the first and second foamable resin compositions; and (d) heating to effect the Foaming the first and second foamable resin compositions; wherein the first and second foamable resin compositions are selected are, 'so that when heated, substantially the second foamable resin composition foams before a substantial one Foaming of the first foamable resin composition occurs.

It can be seen that the three above methods are given by way of example only and the use of those according to the invention Substrates for obtaining surface covering materials is not limited to the above three methods.

Surface covering materials and in particular floor covering materials, in particular foamed flooring materials incorporating a non-woven fiber substrate, this substrate being two Comprises zones, one zone of which extends from a surface of the substrate into the body of the substrate and consists of fibers, which are coated with a gelled resin composition and the second zone is a fibrous one Having structure fully impregnated with a gelatinized resin composition constitute another Feature of the present invention.

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The durability or protective layer that is used during manufacture the surface covering materials according to the invention is used, is desirably one that is formulated and processed to minimize the amount of shrinkage is and preferably has a small thickness, e.g. 0.05 mm to 0.5 mm, preferably not more than 0.2 mm. The protective layer can be applied as a previously calendered IPiIm or applied as a plastisol

As mentioned above, the application of the invention diminishes Substrates generally address the problems of corner curling and dimensional instability. This is especially true with the Manufacture of surface covering materials from EaIl, in which a foamed layer immediately adjacent to the fully impregnated one Surface of the substrate is incorporated. Without a binding theory regarding the processing of the invention To want to dispense substrates, it is assumed that the fully impregnated zone of the substrate is dimensionally stable and acts as a pivot point in the surface covering material; that a foamed layer that is immediately adjacent to the surface of the fully impregnated zone of the substrate, some shrinkage of any layer, e.g. the protective layer applied on it allows without undulating forces on the stable, fully impregnated zone of the substrate transferred to; and that the region of the substrate consisting of lasers containing the resin composition gelated treated, shrinks sufficiently to minimize the curling forces exerted by the foamed layer on the stable fully impregnated zone of the substrate are transferred to compensate.

So it is with the production of foamed surface covering materials possible to use substrates according to the invention to make surface covering materials with good dimensional stability and To provide resistance to corner curling.

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without the need for leveling reinforcement layers to apply the substrate. Shall apply a reinforcement layer should be avoided, the choice of any layer (e.g. the protective layer) that is incorporated into the material, carefully taken to ensure a minimal contribution to shrinkage and a foamed layer should desirably to be created immediately adjacent the surface of the fully impregnated zone of the substrate to the transmission of corrugation forces on the fully impregnated zone of the To absorb and diminish the substrate.

The surface of the substrate according to the invention, which is made of coated Fiber has an appearance generally found in products made using the substrate does not need to be covered and is suitable for being in direct contact with a floor or other surface, which should be covered. The surface of the fully impregnated zone of the substrate is also generally a flat, smooth surface that is essentially free of irregularities is a good basis for applying other layers, especially foam layers, during manufacture of surface covering materials.

Since a reinforcement layer is not necessary, it enables the present invention, dimensionally stable loosely laid floors to manufacture at low cost and enables relatively thin! flooring or other surface covering materials with properties which are generally owned by thicker and more expensive materials.

For a better understanding of the invention, reference is made to the accompanying drawings:

FIGS. 1 r: id 7 show substrates according to the present invention; the "P ' gures 2 and 6 illustrate schematically

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various stages according to a procedure for producing a textured foamed flooring material using a substrate according to the invention; and Figures 8-11 schematically illustrate various stages of an alternative method of making a textured foamed flooring material using a substrate according to the invention.

As can be seen from FIG. 1, zone 1 is non-woven Fleece 2 fully impregnated with a bath composition. The fibers 3 adjacent to the surface of the fleece those remote from zone 1 are only covered with the resinous material.

With reference to Figures 2 to 6, a textured Foamed flooring material can be produced by first applying an overall layer 4 to the substrate 2 of FIG a first foamable resin composition. On selected areas of the Ge total layer 4 is then a second foamable resin composition 5 is applied. A non-foamable one pigmented resin composition 6 is then applied to selected areas of the second foamable resin composition applied. Finally, a transparent protective layer 7 is applied and the whole is used to cause foaming of the foamable compositions is heated.

The substrate shown in Figure 7 comprises a fleece 8. In certain Zones in which voids 9 are shown are the fibers of the nonwoven 8 with a first resinous composition 10 plated. In other zones 11, the fleece is full of a combination of the first resin composition and a second Resin Composition 12 impregnated.

^ (Surface skin ) j

On one surface of the nonwoven there is a "scrim layer" 1 ^/ T5 ~ of the second resin composition which, when used, creates a surface onto which one or more, as desired

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2 6 C) 5 8 8 O - U -

Layers of bath composition can be applied.

With reference to Figures 8-11, a foamed flooring material can be made by first opening the substrate 14 is an overall layer 15 of a foamable resin composition applies. A pattern of printing ink 16 is then applied to selected areas of the overall layer 15 by means of a Gravure printing process applied. A transparent overall protective layer 17 is then applied and the whole is heated to foam and gel to form.

Although the above describes the printing of a pattern prior to foaming, it will be appreciated that if any Protective layer is not required, heating to cause the foaming of the entire layer 15 before the application of the printed Pattern can be made.

As an alternative to printing a pattern on the surface of the overall layer 15, it is also possible to use a printed PiIm to laminate to the assembly.

The above description specifically refers to the application of a plastisol as a resinous composition. It goes without saying, however, that other resin compositions, for example in the form of emulsions and solutions can be used.

The following examples serve to illustrate the production of substrates according to the invention and their use in Manufacture of foamed flooring materials.

example 1

A non-foamable resin composition of the following formulation is produced:

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G-ew. - horny

PYC homopolymer (from to paste production 100

suitable degree)

Dincxoyl phthalate 15

Butyl benzyl phthalate 25

Hexylene glycol 5

Barium-cadmium stabilizer 2.5

epoxidized soybean oil 3

White Spirit 3

! Titanium dioxide 8

Pigment 2

The resin composition that comes in ΊΡοπη a spreadable paste is present, is applied as an overall coating by means of a doctor blade Glass fiber fleece applied with a coating weight of 250 g / m. The glass fiber fleece used as the substrate comprises glass fibers with an average diameter of 16 microns bound by means of a cross-linked urea-formaldehyde resin. The total substance weight of the glass fleece is 60 g / m 2

The coated substrate is then passed into a Eante Alze the ¥ coated between a rubber and cooled with water and a coated ΡΤΙΈ steel roll heated to 180 ⁰ C, is formed. The coated fleece is kept in contact with the heated roller for at least 50 % of its circumference.

Subsequently, a foamable resin composition becomes the following Formulation made:

Weight light

PYC homopolymer (from to paste production 100

suitable degree)

Dialkyl 79 phthalate * 63

Hexylene glycol 3

Foam base 609836/0841 "13

Pigment 1

* Dialkyl ester of phthalic acid with 7-9 carbon atoms in the alkyl part

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The Sehaum basic approach used in formulating the above Composition used was previously prepared as follows:

Parts by weight

Azodicarbonamide 1.25

dibasic lead phthalate 2.00

! Titanium dioxide 4.00

Butyl benzyl phthalate 4.00

This foamable resin composition, which is in the form of a spreadable paste, is applied by means of a doctor blade as a total coating of 0.25 mm to the coated non-woven glass fiber substrate. The foamable coating is dried to a matte finish ( "matte finish") by means of infrared heating to 14O ⁰ C, followed by cooling in contact with a gekühlen with water roller.

A second foamable bath composition of the following formulation is then produced:

PYC homopolymer (from to paste production

suitable degree)

Dialkyl 79 phthalate

Hexylene glycol

Cadmium-zinc stabilizer (Mark SIiD) * Titanium dioxide

Basic foam approach

(-Commercial stabilizer manufactured by Lankro Chemicals).

The foam base used in the formulation above was made as follows:

Parts by weight ,1 100 , 0 65 ,8th 3 2 4th 5

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Weight ropes , 5 2 , 5 3 , 0 4th

Azodicarbonamide Dialkyl 79 pnthalate titanium dioxide

The second foamable resin composition is applied to selected areas the surface of the total first foamable resin composition to a thickness of 0.1 mm using a rotary screen printer upset. It is then dried by infrared heating, careful attention being paid to that the temperature of the first foamable resin composition is below the temperature at which foaming would start. The substrate is then made in contact with water chilled roller cooled. A second non-foamable composition of the following composition is then prepared:

Parts by weight

PTC homopolymer (from to paste production 100

suitable degree)

Dialkyl 79 phthalate 65

Hexylene glycol 3

Barium-cadmium stabilizer 2.5

epoxidized soybean oil 3 »0

Titanium dioxide. 2.0

Pigment 0.5

The second non-foamable resin composition is printed on selected areas of the second foamable resin composition to a depth of 0.0125 mm using a rotary screen printer. It is then dried by heating with an infrared heater to a temperature of 135 ^° C. and cooled with a roller cooled with water.

A fifth resin composition for providing a protective layer

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is then made with the following formulation:

Weight-horny

PTC homopolymer (from to paste production 100

suitable degree)

Dinonyl phthalate 15

Butyl benzyl phthalate 25

Hexylene glycol 3

Barium-cadmium stabilizer 2.5

epoxidized soybean oil 3

White Spirit - 3

This fifth plastisol, which is in the form of a spreadable paste, is applied as a total coating up to a thickness of 0.2 mm using a doctor blade. After the application of this overall coating the whole is heated 100 seconds to 180 ^0C, in order to transfer the plastisols in the gel state and to cause the expansion of the foamable plastisol. Subsequent to the heating, it is cooled and rolled up to obtain the finished product.

Example 2

A non-foamable resin composition of the following formulation is produced:

Weight-horny

PVC homopolymer (from to paste production 100

suitable degree)

Dinonyl phthalate 15

Butyl benzyl phthalate 25

Hexylene glycol 3

Barium-cadmium stabilizer 2.5

epoxidized soybean oil 3

White Spirit 3

Titanium dioxide 8

Pigment 2

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2 6 O.B 8 8 0

The above resin composition, which is in 1Orm of a spreadable Paste is present, is applied by means of a doctor blade as an overall coating on a glass fiber fleece with a coating weight of 230 g / m applied. The non-woven glass fabric used as the substrate comprises glass fibers having a middle 16 micron diameter knife, which is cross-linked by means of a Earnea-formaldehyde resin are bound. The total substance weight of the glass fleece is 60 g / m.

The coated substrate is passed between two nip rollers, one of these rollers is made of rubber and the other is made of metal, thereby forming the resin composition is distributed through the structure of the glass fiber fleece.

The treated Ylies is then passed through an oven at 180 ⁰ C in order to effect gel formation.

Another application of the above-mentioned resin composition is then applied by means of a doctor blade as a total coating with a coating weight of 120 g / m 2. This coating creates a complete impregnation on the surface of the Ylies to which it is applied, whereas areas remote from the surface to which the application was made are only partially impregnated and it also becomes a "scrim coating" of the resin assemblies
achieved. * (Surface skin)

Coating "of the resin composition on the surface of the non-woven fabric

The coated substrate is then passed through a heated oven at 150 ° C. again to effect gel formation. At the exit of the oven, the surface of the "scrim coating" is provided with a flat surface embossing by contact with a heated, polished chrome roller.

Finally, a foamable composition of the following formulation is prepared:

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Parts by weight

PVC homopolymer (from to paste production 100

suitable degree)

Dialkyl 79 phthalate 63

Hexylene glycol 3

Foam base approach 13

Pigment 1

The one used in formulating the above composition Foam base was made as follows:

Parts by weight

Azodicarbonamide 1.25

dibasic lead phthalate 2.00

Titanium dioxide 4.00

Butyl benzyl phthalate 4.00

This foamable resin composition, which is in the form of a stretchable Paste is present, is applied as an overall coating using a doctor blade

coated
of 0.25 mm applied to dasyyGlasx fiber fleece substrate. Of the

foamable coating is, is followed by cooling in Zontakt with a water-cooled roll by infrared heating at 140 ⁰ C to a matte finish ( "matte finish") dried.

It is then applied to the surface of the foamable resin composition a pattern is printed by gravure printing.

A protective layer composition is made with the following formulation manufactured:

Parts by weight

PYC homopolymer (from to paste production 100

suitable degree)

Dinonyl phthalate 15

Butyl benzyl phthalate 25 hexylene glycol 3

Barium Oadm ^ Uii Stabilizer 2.5

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- 24 -

Parts by weight

epoxidized soybean oil 3

White Spirit 3

The spreadable protective coating composition is applied by means of a doctor blade as Gesamtuberzug to a thickness of 0.2 mm, whereupon the assembly 100 seconds, heated to 180 ⁰ C to the plastisols to be converted into the gel state and to cause the expansion of the foamable Plastisolzusammensetsung. After heating, it is cooled and rolled up to form the final product.

609838/0841

Claims (1)

2 6 0S 880 Claims · As a substrate in the manufacture of a surface covering material suitable material that is a non-woven fiber material or a fleece with a zone or zones that extend from a surface of the "fleece" into the body of the fleece extends and consists of fibers, which with one in the Cfelstatus transferred resin composition are coated and a further zone or further zones in which the fiber structure is fully is impregnated with a gelled resin composition comprises " 2 » Material according to claim 1, characterized in that the Ylies is a glass fleece or glass fiber fleece. 3. Material according to claim 2, characterized in that the fleece has a weight of at least 30 g / m. 4. Material according to claim 3, characterized in that the fleece has a weight of 30 to 100 g / m 2. 5. Material according to claim 4 »characterized in that the fleece has a weight of 40 to 80 g / m ² . 6. Material according to one of the preceding claims with a thickness of 0.1 to 1 mm. 7. Material according to claim 6 having a thickness of about 0.4 mm. 8 .. Material according to any one of the preceding claims, characterized in that the resin composition is a polyvinyl chloride composition is. 9. Material according to claim 8, characterized in that the resin composition further includes one or more plasticizers, Stabilizers, fillers, viscosity modifiers 609838/0841 26G5880 Has agents, volatile additives and / or pigments. 10. Material according to one of the preceding claims, characterized characterized in that it has a skin of gelatinized bath composition on one surface, which comes from a "scrim" coating, the surface skin is adjacent to the fully impregnated zone or zones. 11. Material according to claim 10, characterized in that the Surface skin has an average thickness not exceeding 0.2 mm. 12. Material according to claim 11, characterized in that the Surface skin has an average thickness of 0.05 to 0.1 mm. 13. Process for the manufacture of a material that is used for application in the production of a surface covering material is suitable, characterized in that a non-woven fleece with an effective amount of a liquid resin composition impregnated and heated to gel the resin composition to effect, whereby one obtains a material with a zone or zones which stand out from a surface of the fleece extends into the body of the fleece, consisting of fibers coated with a gel state Resin composition and a further zone or further zones in which the fiber structure is completely in the gel state transferred resin composition is impregnated. 14 · The method according to claim 13, characterized in that a glass fiber fleece is used. 15. The method according to claim 14, characterized in that one. a wet-made or wet-laid glass fiber fleece is used . 609838/0841 261) 5880 16. The method according to claim 14 or 15, characterized in that that you have a fleece with a weight of at least 30 g / m used· 17. The method according to claim 16, characterized in that one a fleece with a weight of 30 to 100 g / m is used. 18. The method according to claim 17, characterized in that one a fleece with a weight of 40 to 80 g / m is used. 19 · The method according to any one of claims 13 to 18, characterized in that that the thickness of the fleece is 0.1 to 1.0 mm. 20. The method according to claim 19, characterized in that the Thickness is about 0.4 mm. 21. Method according to one of claims 13 to 20, characterized in that that the resin composition comprises a polyvinyl chloride composition. 22. The method according to any one of claims 13 to 21, characterized in that that the impregnation is carried out by pressing the nonwoven fabric in .die liquid resin composition, wherein this composition is a thickness less than the uncompressed thickness but not less than the compressed thickness of the fleece has, on which one sets the pressure. 23. The method according to claim 22, characterized in that impregnation is carried out in that a fleece on which the bath composition applied as a layer to a heated molding drum, with a roller that leads to forms a kink with the heated drum is used to press the fabric into the resin composition when it reaches the heated drum and the gelation of the resin composition is caused by the heated drum. 609836/0841 2 6 U 5 8 8 O 24. The method according to claim 22 or 23, characterized in that 100 to 300 ι
to be brought. that 100 to 300 g / m resin composition on the "fleece on- 25. The method according to any one of claims 13 to 21, characterized in that that the impregnation is effected in two stages, the first stage coating the fibers of the Nonwoven fabric is comprised throughout the structure with a first resin composition, followed by heating to at least one partial transfer to the gel state of the first bath composition to effect and in the second stage a second resin composition is applied to a surface of the nonwoven fabric , followed by heating to effect gelation of the second resin composition and, if necessary, the To complete gelation of the first resin composition. 26. The method according to claim 25, characterized in that 150 to 330 g / m bath composition on the fleece in the first stage applied and 100 to 200 g / m resin composition be applied to the fleece in the second stage. 27. Material suitable for use as a substrate in manufacture of surface covering material, manufactured according to one of claims 13 to 26. 28. Material suitable for use in the manufacture of a surface material manufactured according to one of the claims 22 or 23. 29. Material suitable for use as a substrate in manufacture of surface covering material produced according to claim 24 or 25. 30. Surface covering material that uses a material as a substrate 609838/0841 261) 5880 according to any one of claims 1 to 12. 31. Surface covering material according to claim. 30 that continues comprises at least one foamed resin composition. 32. Surface covering material according to claim 31, wherein the foamed Composition or one of the foamed compositions only in selected zones of the surface covering material is present so that the surface covering material has a textured effect. 33. Surface covering material according to claim 30 or 32, the furthermore has a protective layer. 34 · Surface covering material according to claim 33 »characterized in that that the protective layer has a thickness of 0.05 to 0.5 mm. 35. Surface covering material according to one of claims 30 to in the form of a flooring material. 36. A method for producing a surface covering material, characterized in that a material according to one of Claims 1 to 12 is used as a substrate. 37. Surface covering material obtained according to claim 36. 609836/0841