GB2028167A - Foam plastics sheet material - Google Patents
Foam plastics sheet material Download PDFInfo
- Publication number
- GB2028167A GB2028167A GB7925011A GB7925011A GB2028167A GB 2028167 A GB2028167 A GB 2028167A GB 7925011 A GB7925011 A GB 7925011A GB 7925011 A GB7925011 A GB 7925011A GB 2028167 A GB2028167 A GB 2028167A
- Authority
- GB
- United Kingdom
- Prior art keywords
- pigment
- composition
- foam
- process according
- coat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000463 material Substances 0.000 title claims abstract description 41
- 239000006260 foam Substances 0.000 title claims abstract description 33
- 229920003023 plastic Polymers 0.000 title claims abstract description 5
- 239000004033 plastic Substances 0.000 title claims abstract description 5
- 239000000203 mixture Substances 0.000 claims abstract description 68
- 239000000049 pigment Substances 0.000 claims abstract description 61
- 239000000758 substrate Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims abstract description 11
- 239000012860 organic pigment Substances 0.000 claims abstract description 10
- 239000004604 Blowing Agent Substances 0.000 claims description 14
- 239000011230 binding agent Substances 0.000 claims description 14
- 230000000694 effects Effects 0.000 claims description 9
- 238000012505 colouration Methods 0.000 claims description 7
- 229920000642 polymer Polymers 0.000 claims description 7
- 229920001169 thermoplastic Polymers 0.000 claims description 7
- 239000004416 thermosoftening plastic Substances 0.000 claims description 7
- 238000005187 foaming Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000004014 plasticizer Substances 0.000 claims description 5
- 230000003595 spectral effect Effects 0.000 claims description 2
- 238000000576 coating method Methods 0.000 abstract description 20
- 239000011248 coating agent Substances 0.000 abstract description 19
- 238000013508 migration Methods 0.000 abstract description 6
- 230000005012 migration Effects 0.000 abstract description 6
- 238000004049 embossing Methods 0.000 abstract description 5
- 235000019646 color tone Nutrition 0.000 abstract 1
- 230000001419 dependent effect Effects 0.000 abstract 1
- 239000004088 foaming agent Substances 0.000 abstract 1
- 230000001617 migratory effect Effects 0.000 description 24
- 229920001944 Plastisol Polymers 0.000 description 18
- 239000004999 plastisol Substances 0.000 description 18
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 8
- 238000009472 formulation Methods 0.000 description 7
- 239000010410 layer Substances 0.000 description 7
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- 229920001577 copolymer Polymers 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- IHZXTIBMKNSJCJ-UHFFFAOYSA-N 3-{[(4-{[4-(dimethylamino)phenyl](4-{ethyl[(3-sulfophenyl)methyl]amino}phenyl)methylidene}cyclohexa-2,5-dien-1-ylidene)(ethyl)azaniumyl]methyl}benzene-1-sulfonate Chemical compound C=1C=C(C(=C2C=CC(C=C2)=[N+](C)C)C=2C=CC(=CC=2)N(CC)CC=2C=C(C=CC=2)S([O-])(=O)=O)C=CC=1N(CC)CC1=CC=CC(S(O)(=O)=O)=C1 IHZXTIBMKNSJCJ-UHFFFAOYSA-N 0.000 description 3
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical compound CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- -1 board Substances 0.000 description 3
- 239000008199 coating composition Substances 0.000 description 3
- 238000000354 decomposition reaction Methods 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- 229920001519 homopolymer Polymers 0.000 description 3
- 125000005395 methacrylic acid group Chemical class 0.000 description 3
- 229920000058 polyacrylate Polymers 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- MQIUGAXCHLFZKX-UHFFFAOYSA-N Di-n-octyl phthalate Natural products CCCCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCCC MQIUGAXCHLFZKX-UHFFFAOYSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- 239000000020 Nitrocellulose Substances 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- QYKIQEUNHZKYBP-UHFFFAOYSA-N Vinyl ether Chemical class C=COC=C QYKIQEUNHZKYBP-UHFFFAOYSA-N 0.000 description 2
- FJWGYAHXMCUOOM-QHOUIDNNSA-N [(2s,3r,4s,5r,6r)-2-[(2r,3r,4s,5r,6s)-4,5-dinitrooxy-2-(nitrooxymethyl)-6-[(2r,3r,4s,5r,6s)-4,5,6-trinitrooxy-2-(nitrooxymethyl)oxan-3-yl]oxyoxan-3-yl]oxy-3,5-dinitrooxy-6-(nitrooxymethyl)oxan-4-yl] nitrate Chemical compound O([C@@H]1O[C@@H]([C@H]([C@H](O[N+]([O-])=O)[C@H]1O[N+]([O-])=O)O[C@H]1[C@@H]([C@@H](O[N+]([O-])=O)[C@H](O[N+]([O-])=O)[C@@H](CO[N+]([O-])=O)O1)O[N+]([O-])=O)CO[N+](=O)[O-])[C@@H]1[C@@H](CO[N+]([O-])=O)O[C@@H](O[N+]([O-])=O)[C@H](O[N+]([O-])=O)[C@H]1O[N+]([O-])=O FJWGYAHXMCUOOM-QHOUIDNNSA-N 0.000 description 2
- 150000001336 alkenes Chemical class 0.000 description 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- RLRMXWDXPLINPJ-UHFFFAOYSA-N dioctan-2-yl benzene-1,2-dicarboxylate Chemical compound CCCCCCC(C)OC(=O)C1=CC=CC=C1C(=O)OC(C)CCCCCC RLRMXWDXPLINPJ-UHFFFAOYSA-N 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 229920001220 nitrocellulos Polymers 0.000 description 2
- 239000001053 orange pigment Substances 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 239000000080 wetting agent Substances 0.000 description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000001464 adherent effect Effects 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 238000007754 air knife coating Methods 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 229940105329 carboxymethylcellulose Drugs 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 229920002301 cellulose acetate Polymers 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000013530 defoamer Substances 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- YOBAEOGBNPPUQV-UHFFFAOYSA-N iron;trihydrate Chemical compound O.O.O.[Fe].[Fe] YOBAEOGBNPPUQV-UHFFFAOYSA-N 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229940104573 pigment red 5 Drugs 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- CHJMFFKHPHCQIJ-UHFFFAOYSA-L zinc;octanoate Chemical compound [Zn+2].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O CHJMFFKHPHCQIJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0065—Organic pigments, e.g. dyes, brighteners
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
- D06N3/0077—Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/0028—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by colour effects, e.g. craquelé, reducing gloss
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Laminated Bodies (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
A foam plastics sheet material, such as a wallcovering, comprises a substrate web (10, 20) a printed pattern, or overall coating, (11, 21) and a foamable coating (12a, 12b, 22). The print composition includes an organic pigment and the foamable coating is selected to provide a migration path for the pigment. The degree of migration is dependent upon the foam thickness and hence graduated colour tones (30, 31, 32) can be derived from a single printing by control of foam thickness. In a preferred process, the foam thickness control is obtained by pre- embossing the substrate web. The print pattern or overall coating can include a foaming agent. <IMAGE>
Description
SPECIFICATION
Foam plastic sheet material having a decorative relief
This invention relates to foam plastics sheet materials having a decorative finish such as wallcovering materials.
The invention is concerned, for example, with the production of foamed wallcoverings having decorative effects based mainly on comparative colour intensity. Such effects can be achieved by the necessary number of printing operations, possibly with simuitaneous mechanical embossing, but this tends to increase cost and the practical range of variation becomes limited.
The invention aims to provide a new way of producing, in foam wallcovering and the like, decorative effects based on colour intensity without the need for supplementary printing operations and mechanical embossing. At the same time as providing an easy way of controlling colour intensity, the control can be corelated and registered with relief decorative effects.
Quite remarkable decorative effects may be achieved on a production scale plant in a very simple manner.
The material according to the invention comprises a substrate web having thereon a base coat and a foam coat characterised in that the base coat comprises an organic pigment and some of the pigment has migrated through the foam coat to the surface of the foam coat so that the overall surface of the material exposes two different colourations.
The coats may be partial or overall so long as a part of the foam coat overlaps the. base coat to give a migration path.
The two colourations may differ in intensity or differ in spectral position.
The foam coat may have varying thickness so that the amount of pigment migrating to the surface varies according to the thickness.
The invention also provides a process for the production of a decorative sheet material comprising applying to at least parts of the surface of a substrate web a composition containing an organic pigment, applying, over at least some of the parts of the substrate to which said organic pigment had been applied, a foamable composition containing a thermoplastic polymeric material and a heat decomposable blowing agent, and heating said coated substrate to effect foaming of the foamable composition, wherein said organic pigment is soluble in, and migrates into, said foamable composition to the extent that some appear on the surface of the material.
The pigment composition may be printed on to selected areas of the substrate and then the foamable composition may be applied as an overall coating. Alternatively, if the foamable composition is applied only to some of the areas to which the pigment composition has been applied (whether or not the pigment composition had been applied overall), the foam areas above the migratory pigment bearing areas of the substrate will be depicted in a colour or tone contrasting to that of those areas where the pigment composition, but not the foam composition, had been applied. Both the migratory pigment composition and the foam composition may be applied as overall coatings with the foam composition varying in thickness, such as by applying a foamable composition of varying thickness or by using a chemical embossing technique or coating on to a pre-embossed substrate.The valleys regions of the foamed material will then exhibit a deeper colouration than the peaks.
The amount of migratory pigment, in the areas to which the migratory pigment composition is applied, is preferably in the range 0.1 to 5 g/m2. By using in the migratory pigment composition one or more non-migratory pigments, further decorative effects can be achieved if the foam composition is not applied as a coating overall. A colour change can be derived also by having mixed pigments only one of which migrates.
The substrate web may be any sheet or film material or may be a textile web. Particularly suitable substrates include paper, board, wood, plastics film or sheet, and woven or non-woven textiles made of natural or synthetic fibrous materials. The substrate web may be given a coating, over some or all of its surface, of a material containing a polymeric binder prior to application of the migratory pigment composition.
In the case of a paper substrate, an overall ground coat may be applied. In some cases, particularly where an overall migratory pigment coating is desired, the ground coat may form the migratory pigment coating by incorporation of the migratory pigment into a conventional ground coat.
The migratory pigment composition preferably contains a polymeric binder. The binder may be thermoplastic or thermosetting and may be a synthetic or a natural polymeric material. Examples of binders include the thermoplastic polymeric materials listed hereinafter in relation to the foamable composition, thermosetting polymers such as polyurethanes, phenol formaldehyde, urea formaldehyde, or melamine formaldehyde resins, synthetic rubbers, natural polymeric materials such as rubber, starch, gums and rosins.
The migratory pigment composition may be applied in liquid form and dried or fused or by application of a powdered or particulate migratory pigment to an adhesive layer on the substrate. The migratory pigment composition may be an ink or lacquer containing the migratory pigments.
Alternatively it may comprise a plastisol.
Examples of suitable thermoplastic polymeric materials that may be used as binder in the migratory pigment composition and in the foamable composition include polymers or copolymers of at least one ethylenically unsaturated monomeric material selected from olefins, for example, ethylene, propylene, butene, isobutene; vinyl chloride; vinyl esters, for example vinyl acetate; vinylidene chloride; vinyl ethers; acrylonitrile; esters of acrylic or methacrylic acids, for example methyl acrylate, ethyl acrylate, butyl acrylate, and methyl methacrylate; acrylic or methacrylic acids; styrene; butadiene; and isobutylene.
Other polymers that may be used include thermoplastic cellulosic polymers such as cellulose acetate and cellulose nitrate. Mixtures of polymers may be employed.
Preferred thermoplastic polymeric materials include homopolymers of vinyl chloride and copolymers of vinyl chloride with comonomers such as vinyl acetate, vinyl ethers, vinylidene chloride and olefins; copolymers of esters of acrylic or methacrylic acids; and cellulose nitrate.
Vinyl chloride homo and copolymers are particularly preferred.
Where the main coating composition is a vinyl chloride polymer plastisol, suitable organic pigments for the preliminary coating are those that are soluble in the plasticiser employed.
Examples of such pigments include C.l. Pigment Red 5, 7 and 112; C.l. Pigment Yellow 1 and 3: C.l. Pigment Orange 5; C.l. Pigment Violet 2; and C.l. Pigment Green 7. The C.l. Pigment numbers refer to the classified group of pigments as set out in the "Society of Dyers and
Colorists, Colour Index" second edition and supplement 1 963.
The migratory pigment composition may contain the same or different polymeric material to that contained in the foamable composition.
Additives that modify the decomposition temperature of the blowing agent may be incorporated into the composition.
The migratory pigment composition may itself contain a heat decomposable blowing agent.
The foamable composition is preferably applied at a rate of 40 to 1 200 g of binder material in the foamable composition per square metre of substrate.
The foamable composition preferably contains 0.5 to 15%, particularly 1 to 10%, by weight of blowing agent, based on the weight of the binder material in the composition. By the term binder material we mean the non-volatile components of the coating composition, that, on heating, coalesce to form an integrated film. In computing the quantity of binder material, inorganic non-film forming ingredients such as fillers and pigments are excluded.
A printed pattern may be applied, if desired, by known printing techniques, to the substrate bearing the layer of the foamable composition. Additionally, or alternatively, a wear layer of transparent polymeric composition, e.g. an unpigmented vinyl plastisol, may be applied. Where, after application of the foamable composition, the substrate is printed, whether with an ink containing a compound that modifies the decomposition temperature of the blowing agent or simply with a decorative ink, the wear layer, if used, should be applied after application of the ink. The coating compositions may contain other conventional ingredients, e.g. pigments, dyes, fillers, extenders, plasticisers, stabilisers, and viscosity modifiers.
After application of the foamable composition, and after application of any printing and or wear layers thereto, the coated substrate is heated to cause foaming. Where the migratory pigment composition contains a heat decomposable blowing agent, it should not be foamed prior to application of the foamable composition unless the migratory pigment composition is of such a nature that, on decomposition of the blowing agent, a residual foamed coating is obtained. This is largely a matter of the proportion of the binder material relative to the proportion of other ingredients, such as pigments, in the migratory pigment composition.Thus if the proportion of binder is such that the coating of the migratory pigment composition is merely a layer of blowing agent, migratory pigment, and any other solid ingredients adherent to the substrate, rather than a continuous matrix of the binder encapsulating the solid ingredients, upon heating to decompose the blowing agent, the gas evolved will be lost to the atmosphere and little or no foaming will occur. In such cases it is necessary that the blowing agent in the migratory pigment composition is not decomposed until after application of the foamable composition.
The invention will now be described further with reference to the accompanying drawings and examples.
Figure 1 is a sectional view of material according to the present invention;
Figure 2 is a plan diagrammatic view of the material shown in Fig. 1;
Figure 3 is a sectional view of another material according to the present invention in the course of manufacture;
Figure 4 is the material of Fig. 3 at the end of manufacture; and
Figure 5 is a plan diagrammatic view of the material of Fig. 4.
In Fig. 1 a base paper 10 has applied to it a pattern in the form of spaced parallel lines 11 of pigmented ink (exaggerated in the depth dimension). This was dried and then partially coated with a plastisol at two thicknesses 12 a, 1 b and the plastisol was foamed.
The lines 11 which were not covered with foam (indicated in Fig. 2 by close cross-hatching) presented their strong original colour. The lines 11 below foam thickness 1 2a migrated through the foam to reach the surface (indicated by open cross-hatching) to present the pigment colour 11 a reduced in intensity. At the foam thickness 12b, pigment migration had taken place but the surface of the material had not been reached, level 1 3 only be reached.
In Fig. 3, an embossed paper base 20 has been given an overall coating 21 of pigmented ink (exaggerated in the depth dimension). This overall coating 21 was then itself coated overall with a foamable plastisol composition 22, the composition being at various depths by reason of the embossing of base 20. The plastisol composition 22 was then heated to cause the plastisol to foam and take up various depths and the pigment in the ink to migrate. Pigment migrates intensely to level 30 (as indicated by the close hatched box); it migrates weakly to the level 31 (as indicated by the open hatched box); and migration stops at level 33 and hence level 32 of the foam is unpigmented.
Three examples of the invention will now be given. In these examples all parts and percentages are by weight.
Example 1 (This example can be related to Figs. 1 and 2 of the drawings)
A brown printing ink was made up to the following formulation:
Parts
Styrene/acrylic polymer emulsion 13.0
Polyvinyl alcohol soln. 26.0
Water 70.0
Wetting agent 0.25 0.92 Ammonia 0.2
Clay 100.0 C.l. Pigment Orange 5 10.0
Red Oxide 7.5
Black 0.5
A white grounded wallpaper base paper of substance 1 20 g -2 was printed flexographically with the ink in a simple design consisting of lines and dots.
The printed paper was dried and then screen printed with a PVC plastisol of the following formulation in a series of broad stripes of thickness 0.1 mm.
Parts
Vinyl chloride homopolymer 100
Dicaprylphthalate (plasticiser) 55.5 Binder
Epoxidised oil (stabiliser) 3 material
Viscosity depressant 3
Titanium dioxide 21
Cadmium/zinc octoate (activator) 4
Azodicarbonamide (blowing agent) 5.5
The plastisol print was gelled at 150"C for 20 secs. and then a second plastisol of the same formulation overprinted onto the gelled print in the form of a few narrow stripes.
The wallcovering was then heated at 200 "C for 60 secs. to expand the vinyl print.
The single layer of plastisol expanded to a thickness of 0.6 mm and showed the original flexo print design in orange where the orange pigment alone had migrated into the foam layer on heating. This contrasted with the original dark brown print design in the valleys between the plastisol print.
The double thickness of plastisol print expanded to a thickness of 1.3 mm and showed no migration of the pigment, remaining completely white.
Example 2 (This example can be related to Figs. 3, 4 and 5 of the drawings)
A 150 gm-2 wallpaper base paper was given an all over air knife coating of an orange ground coat of the following formulation:
Parts
Styrene/acrylic polymer emulsion (50% solids) 18.0
Wetting Agent 0.12
Clay 50.0 0.92 Ammonia 0.5
Cellulose thickener (1 % soln.) 3.0
Defoamer 0.06
Water 42.5 C.l. Pigment Orange 5 6.0
The coating was dried at 120"C to give a dry weight of 25 gm-2 and then the coated paper mechanically embossed with an overall design having many different depths of emboss.
The embossed paper was then given an all over coating of foamable plastisol of formulation as in example 1 by means of a knife over roller coater.
Total plastisol coat weight was 150 gm-2 but the coat thickness varied depending on the depth of emboss in the paper.
The coating was then foamed by heating at 200 C for 75 secs.
The resulting product showed the emboss in the paper in reverse relief and had the appearance of being valley inked.
Where only a thin layer of PVC had been coated the orange pigment had migrated through to the surface but in the high relief areas where the thickness of foam was greater than 1.0 mm the foamed PVC remained white. In between the extremes the orange colouration varied in strength as the foam thickness varied.
Example 3 (This example also uses the invention disclosed in our co-pending application No. 79/25010 which claims priority from GB 30409/78 and 30408/78)
A printing ink was made up to the following formulation:
Parts
Styrene/acrylic polymer emulsion (50% solids) 8
Aqueous polyvinyl alcohol solution (1 2+%) 8
C.l. Pigment Violet 2 5
Water 97 p,p-oxybis (benzenesulphonylhydrazide) 1 2 Carboxy methyl cellulose 1
The pigment (C.l. Pigment Violet 2) is soluble in dicaprylphthalate.
A wallpaper base paper of substance 90 g/m2 was screen printed with the above ink to a floral design. The combined weight of blowing agent and pigment applied was 4.7 g/m2 to the printed areas.
The printed paper was dried and then coated with a PVC plastisol having the formulations as given in Example 1.
The plastisol was applied as an overall coating of thickness 0.25 mm (corresponding to a polymer weight of 1 62 g/m2) and then the coated paper was heated in an overn for 60 secs. at 200"C to effect foaming.
The resultant product displayed the floral design in a fine blister texture which was pale pink in colour, while the parts of the foam that were not above the printed pattern exhibited a smooth white coloured surface.
Claims (11)
1. Foam plastics sheet material having a decorative finish such as wallcovering materials and the like comprising a substrate web having thereon a base coat and a foam coat characterised in that the base coat comprises an organic pigment and some of the pigment has migrated through the foam coat to the surface of the foam coat so that the overall surface of the material exposes at least two different colourations.
2. Material is claimed in claim 1 characterised in that the foam coat has plural thicknesses.
3. Material as claimed in claim 1 or 2 in which the colourations differ in intensity.
4. Material as claimed in claim 1 or 2 or 3 in which the colourations differ in spectral position.
5. A process for the production of a decorative sheet material comprising applying to at least parts of the surface of a substrate web a composition containing an organic pigment, applying, over at least some of the parts of the substrate to which said organic pigment had been applied, a foamable composition containing a thermoplastic polymeric material and a heat decomposable blowing agent, and heating said coated substrate to effect foaming of the foamable composition, wherein said organic pigment is soluble in, and migrates into, said foamable composition to the extent that some appears on the surface of the material.
6. A process according to claim 5 in which the foamed composition has at least two thicknesses and the pigment has migrated to the surface of the shallower thickness but not to the surface of the deeper thickness.
7. A process according to claim 5 in which the foamable composition includes a polymer dispersed in a plasticiser and the pigment is soluble in the plasticiser.
8. A process according to claim 7 in which the pigment composition contains a polymeric binder.
9. A process according to claim 5 in which the pigment composition is applied at a rate to give a pigment application of from 0.1 to 5 g/m2 and the foamable composition is applied at a rate of from 40 to 1 200 g/m2.
1 0. A process according to claim 5 in which the substrate web is embossed before application of the foamable composition.
11. A process according to claim 5 in which the pigment composition includes a heat decomposable blowing agent which causes foaming of the pigment composition.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB7830407 | 1978-07-19 | ||
| GB7834417 | 1978-08-24 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2028167A true GB2028167A (en) | 1980-03-05 |
| GB2028167B GB2028167B (en) | 1982-06-16 |
Family
ID=26268277
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB7925011A Expired GB2028167B (en) | 1978-07-19 | 1979-07-18 | Foam plastics sheet material |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2028167B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2550242A1 (en) * | 1983-08-04 | 1985-02-08 | Mohr Gmbh & Co | PROCESS FOR THE MANUFACTURE OF THREE-DIMENSIONAL PATTERN WALLPAPERS FOR THE DECORATIVE COATING OF SURFACES AND WALLPAPERS MANUFACTURED BY THE SAME |
-
1979
- 1979-07-18 GB GB7925011A patent/GB2028167B/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2550242A1 (en) * | 1983-08-04 | 1985-02-08 | Mohr Gmbh & Co | PROCESS FOR THE MANUFACTURE OF THREE-DIMENSIONAL PATTERN WALLPAPERS FOR THE DECORATIVE COATING OF SURFACES AND WALLPAPERS MANUFACTURED BY THE SAME |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2028167B (en) | 1982-06-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732 | Registration of transactions, instruments or events in the register (sect. 32/1977) | ||
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19950718 |