Note: Descriptions are shown in the official language in which they were submitted.
:L31~32 ?
The present invention relates -to a process for
the production of dyed, homogeneous flat articles based on
thermoplastic synthetic resins wherein particles of
thermoplastic synthe-tic resins are sintered in-to a coherent
flat article, such as a sheet and the article is then press-
molded under the action heat and pressure and wherein the
starting material for forming the particles is obtained from
resin preheated above the softness temperature of the resin.
Unicolored, homogeneous flat articles made of a
thermoplastic synthetic resin, especially made of poly-
vinylchloride (PVC), in the form of sheets or panels, with
thicknesses of above 1 mm, can be manufactured according to
the state of the art by means of extrusion, spread-coating,
or rolling methods, resulting in a unicolored, homogeneous
molded article conveying, as an inherent design feature, a
cold plastic look and a typical plastic image. Even
mixtures of various granulated compositions and their
processing by means of the extrusion or rolling technique,
though providing a color differentiation corresponding to
the colors utilized, have not contributed toward lifting the
cold feeling inherent in plastic. However, especially when
using sheets or panels as floor coverings and wall
coverings, special emphasis is placed on esthetic
impression. In this connection, it is an object of the
invention to create flat articles of thermoplastic synthetic
resins conveying an esthetically pleasing optical impression
and lending themselves optionally to random patterning.
A process has been known from U.S. Pat. No.
3,381,067 for the manufacture of terrazzo-type floor
coverings wherein granules having a diameter of 6-12 mm and
a thickness of 44-800 ~um are produced from a plasticized PVC
with fillers and colorants and s-tabilizers, and coated with
a plasticized PVC paste, then piled up into a uni~orm layer,
heated, sintered, and press-molded into a continuous sheet
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with the use of pressure and heat. By u-tilizing dif-ferent
compositions for the granules and the coating s-tep, a
covering is produced wherein the granules are embed~ed in a
softer shell; i.e. a covering exhibiting differing wear
characteristics.
U.S. Pat. No. 3,192,294 discloses a process of the
type for the production oE floor coverings having a
multicolor effect, for example pepper-and-salt patterns,
wherein preferably compositionscontaining PVC, plasticizer
and blowing agent in powder form are piled up into a layer
and heated to such a degree that the layer is sintered into
a coherent sheet which is then expanded by decomposition f
the blowing agent, whereafter the sheet, while passing
through a roll nip, is embossed on the topside with a relief
occupying, e.g., one-half or more of the sheet thickness.
The PVC composition is prepared as a dry blend, i.e. mixed
in the cold state (also in order to avoid premature
decomposition of the blowing agent), and the particles
exhibit an average size of 15 ,um to about 3 mm, using in
each case a uniform particle size, for example, of 15 ,um.
It is also possible to furthermore add proportions of very
small particles of 2 ,um made of a copolymer, but this can be
very disadvantageous if the fine proportions are separated,
i.e. fall through toward the bottom, and the coarse
particles form an uneven surface.
The floor coverings produced in accordance with
U.S. Pat. No. 3,192,29~ with thicknesses of about 2.5 mm are
prone to cracking on account of their strong surface
embossing, and thus require additional surface protection in
the form of an additional film coating. Furthermore, the
particle structure i8 shifted due to the vigorous embossing,
so that elongated, nonuniform zones are formed.
U.S. Pat. No. 3,359,352 and German Pat. No.
1,298,023 describe a process for the production of a
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decora-tive, multiple layer coveri.ng wherein particles having
a grain size of abou-t 2.5 ~Im to 0.013 mm, produced by mixing
PvC powder and plasticizer as well as additives a-t
~emperatures of about 93C, i.e. well below -the sintering
S temperature of the synthetic resin, are piled up on a
substrate sheet serving as the support to form a la~er and
are sintered into a porous sheet. These particles, produced
at low temperature far below the plasticizing tempera-ture of
the synthetic resin, also called dry blends, are soft and do
not show high firmness and dimensional rigidity since they
have not been plasticized. During the subse~uent press-
molding step, the particles thus deliguesce and, when using
differently colored particles, result in mixed colors or in
deliquescing color contours with an orientation in the
lS rolling direction. It is necessary in this conventional
method to utilize a support material as the substrate layer
homogeneous flat articles, i.e. layers showing a design
throughout without a substrate layer, conse~uently cannot be
manufactured.
One object of the invention homogeneous flat
articles havinga fine-textured, random design.
According to the present invention, there is
provided a process for the production of flat articles,
having a fine-textured, random design, comprising:
- processing a starting material for forming
particles of a thermoplastic synthetic resin by a thermal
pretreatment above the softening temperature of the resin
into an agglomerate or granular mixture,
- mechanically comminuting the mixture into a fine
mixture of particles having a random grain size
distribution, and
- conveying said fine mixture of particles in a
uniform layer and sintering it under the action of heat up
until plastici2ation of the thermoplastic plastics to form a
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coherent fla-t article and then compressiny the coheren-t flat
article under -the action of pressure and hea-t.
According to the present invention, there is also
provided a process for -the production of multicolored,
homogeneous flooring sheets made of -thermoplastic synthetic
resin wherein pourable particles are continuously forrned
into a uniform layer and are sintered under the action of
heat up to the plasticization of the thermoplastic synthetic
resin to form a coherent, porous layer and the porous layer
is press-molded under the ac-tion of pressure and heat to
form a flooring sheet that is void-free and smooth, and
wherein several colored batches of thermoplastic resin are
formed, with each batch having a color different from -the
other: each batch is then heat-treated above the softening
point of the thermoplastic resin and is formed into colored
agglomerates or colored granules; a blend of differently
colored agglomerates or granules is prepared in a
predetermined mixing ratio; the blend is mechanically
comminuted to form the pourable particles which comprise a
multi-colored mixture of particles having a random grain
size distribution and, thereafter, the pourable particles
are continuously applied directly to a conveyor surface to
form the uniform layer which is subsequently sintered to
form the porous layer.
According to the present invention, there is also
provided a process for the production of multicolored,
homogenous flooring sheets made of thermoplastic synthetic
resin wherein pourable particles are continuously formed
in-to a uniform layer and are sintered under the action of
heat up to the plasticization of the t~ermoplastic synthetic
resin to form a coherent, porous layer; then at least one
colored medium is appliéd ~l~n~ a predetermined pattern
penetrating into the coherent porous layer and the porous
layer is press-molded under the action of press~re and heat
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-to form a flooring sheet -that is void-free and smooth, and
wherein several colored batches of thermoplastic resin are
formed, with each batch having a color different from the
other; each batch is then heat treated above the softening
point of the thermoplastic resin and is formed into colored
agglomerates or colored granules; a blend of differently
colored agglomerates or granules is prepared in a
predetermined mixing ra-tio; the resulting blend is
mechanically comminuted to form the pourable particles which
comprise a multi-colored mixture of particles having a
random grain size dis-tribution and, thereafter, the pourable
particles are continuously applied directly -to a conveyor
surface to form the uniform layer which is subsequently
sintered to form the porous layer.
According tc a preferred embodiment there is
provided a process wherein a batch of thermoplastic
synthetic resin is prepared from a PVC composition
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containing:
- 40-60~ by weight of PVC having a K-value of 50-
80:
- 18-Z~% by weight of plasticizer based on
phthalic acid esters,
- 20-40% by weighk of a filler including calcium
carbonate, and
- 0.5-2~ by weight of stabilizer based on at least
one of a barium-cadmium, a calcium-zinc and a tin compound;
thereafter, separating the batch into smaller batches, with
each smaller batch being admixed with 0-3% by weight oE a
colorant to provide a plurality of differently colored
smaller batches, thereafter, plasticizing the smaller
batches at temperatures above the softening point of ~he PVC
and forming each smaller batch into granules or
agglomerates.
Even with the use of particles dyed in one color,
i.e. unicolored, of a grain mixture of arbitrary or random
grain distribution, a polychrome, differentia-ted coloring is
obtained. An infinite variety of color and texture nuances
is made possible with the use of only a few different
particles oE a multicolored design and by means of a
differing mixture proportion in the mixture with respect to
grain size and grain distribution.
The thermally pretreated particles utilized
accoxding to this invention exhibit a firm grainy structure,
as contrasted with dry blends, and this grainy structure
remains preserved during sintering and does not deliquesce.
According to a preferred embodiment of the
invention, particles produced by abrading, forming a mixture
of various grain sizes in random distribution, are used for
the manufacture of sheets or panels. It is possible, for
example, to grindoff, with a grinding belt of a specific
coarseness, differently colored panels or sheets of a PVC
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composition containing plastici~er, fillers, stabilizers,
pigments, etc. used, for example, as ~loor coverings, thus
obtaining a grinding dust havinga granular size of, for
example, 0.1-2 mm, initially appearing -to be unicolored to
the naked eye. ~y applying this grinding dust, for example
by way of a hopper with a doctor blade adjustable at -the
front side, onto a conveyor belt, e.g. separating paper or a
steel band, continuously moving thereunder, and by allowing
the piled-up grinding dust then to sinter superficially
under an infrared (IR) field or in a heating tunnel, and by
thereafter bringing this material to a temperature range
required for plasticizing, this superficially sintered rough
sheet can then be molded under pressure into a homogeneous,
void-free sheet or panel showing a design extending
throughout its total thickness. Suitable conveying belt
materials are -those from which the sheet can be pulled off
again without difficulties, such as release paper, "Teflon"*
coated fabrics, or also metal belts, such as a steel band,
for example. The heat energy required for sintering can be
provided by way of IR radiators, hot air, or also in a high-
frequency field, and the final compression step can take
place continuously via rolling mills, single-belt presses,
or preferably twin-belt presses. Depending on the surface
structure of the rolls or belts, corresponding surfaces can
be embossed. Panels can be punched out from the sheets if
desired. It was surprinsingly found, in this connection,
that there evolves from a originally unicolored grinding
dust a polychrome, finely textured, brilliant design no
longer exhibiting the plastic look of coldness and
uniformity which heretofore had been the rule.
This process of the invention can be varied, by
the use of only a few different, multicolor-design rough
sheets and by a differing the mixing proportions of the
grinding dusts derived therefrom, in such a way that an
*Teflon is a Trade mark
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infinite number oE color and -tex-ture nuances become
possible. Preferably, grains or particles produced by
abrading of a preformed resinous article such as a sheet or
panel are utilized in a grain mixture wherein -the propor-tion
of grain size of 250-800 ~m constitutes 60-90% by weight of
the mixture comprising the starting material for forming the
particles to be compressed into a sheet.
It has furthermore been found, surprisingly, that
an analogous polychrome uni-design is obtained by using, in
place of grinding dust, agglomerates likewise dyed in
different colors, for example having been brought to a
specific temperature by fric-tion in a mixer and being
applied in varicolored blends. It is furthermore possible
to change the character of the agglomerates in regard to
structure by means of a grinding step following the mixing
step. Moreover, blends of abrasion dust and agglomerate are
also possible, along with combinations of filled and
unfilled systems, i.e. PVC compositions with and without a
filler; by use of transparent synthetic resin particles, a
three-dimensional effect is conveved above and beyond the
polychrome character. Such polychrome, homogeneous-panels
or also sheets, however, can be produced not only from
grinding dust, agglomerate, but also from reclaim material
consisting of varicolored edge strips which were chopped and
ground. In the same way, a similar effect can be obtained by
way of the sinter-pressing method from correspondingly dyed
granules which have been ground up. Likewise, mixed PVC
powder with additives can be plasticized by way of a
plasticizer or extruder and processed into granules or chips
or pellets, and these can be ground by means of mills to the
desired fine grain, i.e. a fine grain mixture. The PVC
compositions can be made to be transparent, unicolored, or
also varicolored mixtures of differently colored dusts and
grain sizes can be utilized. This results, after press-
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molding, in a brilliant, finely resolved, multicolored basic
tone without direc-tional orientat:ion. Also the yrain size
and grain distribution of the par-ticles employed cause a
muted to distinct appearance of the pattern as a fine or
also coarse texture, or create small to large resolution
capacity.
Mixtures of the agglomerates are preferably
utilized which are produced by mixing a PVC composition at
mixing temperatures of up to about 170C, generated by
frictional heat, with subsequent cooling and grinding and
optional screening. Such a mixture of agglomerate, leading
to a design of an especially pleasing appearance, has, for
example, a proportion of about 20 to 75% by weight of the
grain size of 500-2,000 ~m in the mixture.
According to this invention, the texture of the
sheet and thus the pattern, i.e. the polychrome impression,
can be varied by changing the shape of the particles,
whether produced in grain form, by abrading or by grinding
to differing size.
According to another aspect of this invention, the
particle may be obtained by grinding up agglomerate
granules, in this connection, 1, 1.5, or 2 mm screens can be
utilized, for example, for the screening step. All of these
mixtures produced by grinding contain thermally pretreated
particles which had already been plasticized once and thus
result in a firm grain structure. Thermal pretreatment took
place, for example, during the manufacture of the
agglomerate or during extrusion of molded elements subse-
~uently processed into granules, chips, edge strips, waste,
and forming the starting material for the grain mixtures to
be produced and utilized in accordance with this invention.
A mixture of particles of different origin, for
example from grinding processes, preferably contains a
proportion of the grain size of 500-2,000 um of about 30-95%
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by weigh-t.
It is moreover possible to utilize blends or
particles from various origins, colorings, structures,
and/or grain distribution.
The polychrome color image may be obtained
according to this invention especially by using mixtures of
particles with a grain dis-tribution wherein each screening
fraction is present at least with a minimum proportion of
0.1% by weight, and no screening fraction is present at a
proportion larger than 50% by weight.
Sheets or panels having an especially fine and
uniformly random design are obtained by using, according to
a further suggestion of the invention, grain mixtures
containing 80-98% by weight of grain sizes from 300 to 800
ym.
According to a further preferred embodiment of the
invention, flat articles to be utilized especially as floor
and wall coverings are obtained with the use of a process
wherein a PVC composition containing PVC, plasticizer, an
inorganic stabilizer, and a colorant is plasticized above
the soEtening temperature of the resin to form a molded
component and the molded component is comminuted into the
particle mixture.
In this process, transparent, translucent up to
completely colored-through sheets are obtained.
The process for producing the flat articles is~
preferably performed by piling the mixture of the particles~
up into a layer having a thickness of preferaby about 5-12
mm, and heating to temperatures up to about 210C and
sintering, and then press-molding, with a surface pressure
in the range from 0.2 to 20 N/mm or, respectively, a
corresponding linear pressure in the roll nip, homogeneously
into a sheet or panel having a final thickness of about 1.5-
4 mm.
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For the production of filled sheets or panels, -the
process can be carried out, according to another embodiment
of the invention, wherein the polyvinyl chloride composition
is provided with fillers such as calcium carbonate and then
processed into the particle mixture.
Such homogeneous sheet or panel material of
polychrome design can preferably be utilized as floor or
wall covering and is predestined for use especially where
abrasion or wear represent a dominating problem. Such a
covering, homogeneous with respect to its struc-ture, can
wear down over the entire thickness without a change in
pattern and texture.
The process of this invention provides a live and
also three-dimensional appearance attaining mono- to
lS polychrome effects in dependence on the given coloration, A
particular spatial, three-dimensional effect is achieved by
a transparent basic material for a portion of the particles
in which particles of another color can be embedded.
This process technique according to the invention
exhibits the additional advantage, besides a novel design
possibility, of not only reprocessing dyed, thermoplastic
products obtained as waste in a recycling step by simple
means, but also of refining these products into novel, high
quality goods, thus expanding the previous state of the art
and enriching the array of homogeneous floor coverings with
respect to texture and feel.
The thermoplastic synthetic resin useful for
purposes of this invention includes not only PVC but also
copolymers of vinyl-chloride with vinyl acetate,
ethylenevinyl acetate, and optionally acrylate polymers
which can be used individually or in mixtures.
In addition to PVC, other thermoplastic synthetic
resins, for example based on ethylene-vinyl acetate, can
also be processed into flat articles according to this
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invention.
According to one embodiment of the invention,
particles produced by abrading, consti-tuting a rnix-ture of
different grain sizas in random distribution, are used for
the manufacture of sheets or panels. It is possible, for
example, to abrade panels or sheets dyed in different colors
made up of a PVC composition with plasticizer, fillers,
stabilizers, pigments, and used, for example, as floor
coverings, by means of an abrasive belt of specific
coarseness. The result is an abraded dust which initially
appears unicolored to the naked eye and has a grain size o~,
for example, 0.1 to 2 mm. If this abraded dust is applied
for example, by way of a hopper with a doctor blade
adjustable at the front side, onto a supporting belt, e.g.
lS release paper or a steel band, moving continuously
therebeneath, and then the thus-piled up abraded dust is
superficially allowed to sinter under an infrared ~IR) field
or in a heating tunnel, then a porous layer is obtained
which can be provided with a design throughout and can
subsequently be shaped under pressure into a homogeneous,
void-free sheet or panel carrying a continuous design over
the entire thickness, the structure of the pattern not being
blurred or distorted.
This process according to the invention can be
varied by using rough sheets with a multicolor design that
is only a,little different, and by a different mixture
proportion and the thus produced abraded dusts, in such a
way that infinitely many color and texture nuances are
possible. preferably, grains or particles produced by
abrading are utilized in a grain mixture wherein the
proportion of grain sizes of 250-800 jum constitutes 60-90
by weight of the mixture.
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Suitable conveyor belt ma-terials are those
permitting the finished sheet to be pulled off again withou-t
any di-fficulties, such as release paper, "TEFLON" coated
fabric, or also metallic belts, such as steel band. The
thermal energy required for sintering can be provided by
means of IR radiators, hot air, or also in a high frequency
field; the subsequent compressing step can take place
* Teflon is a trade mark
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continuously by means of rolling mills, single-belt or twin-
belt presses. Depending on the surface texture of the rolls
or belts, corresponding surfaces can be embossed; the
embossing depth can amount preferably up to about 100 ym or
also more.
The invention will be described in greater detail
below wi-th reference to the accompanying drawings and
examples.
Fig. 1 shows a schematic view of a sintering
apparatus with a pair of pressure rollers;
Fig. 2 is a schematic view of a belt press;
Fig. 3 is a schematic view of a twin-belt press;
Figs. 4-12 show various surface designs
corresponding to different grain mixtures.
A conveyor belt 1 rotating endlessly over two
guide rollers 18,19, of which at least one is driven, is
utilized for the continuous processes according to Figs. 1,
2 and 3 as the support means. Preferred materials for the
conveyor belt l are release paper, steel, or also "TEFLON"*
(polytetrafluoroethylene) belts. By way of the hopper 2
having an adjustable doctor blade 3, the grain mixture 4 to
be applied is piled up on the conveyer belt 1 in dependence
on the desired final -thickness of the flat article,
preferably in a thickness of 5-12 mm. Other application
systems can also be utilized, for example metering chutes.
This layer 40 is then continuously heated under, for
example, an infrared heater 5 and/or a heating tunnel 6, up
to the plasticizing temperature, and sintered to form a
continuous flat sheet 41. During this sintering step, the
layer 40 loses some volume, and the thickness is reduced
correspondingly to about 4-10 mm. Subsequently, the
sintered sheet 41 passes through a pressing station, for
example an embossing unit, consisting of a metal roll 8 and
a rubber roll 7, compressing the sheet 41 and superficially
* Teflon is a trade mark
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smoothing same, or also providing same with a texture.
Thereafter, the final product 42 leaves the installation and
is passed on to finishing.
Advantageously, a belt press can be used for
compressing the sintered sheet ~1, as illustrated in Fig. 2;
the belt endlessly rotating over the guide rolls 10, 11, 12
is guided so that it urges the sintered sheet against the
roll 9 over a predetermined route. The sheet, after cooling
is removed from belt 20 as the finished sheet 42.
Especially advantageously, a -twin-belt press is utilized for
the compressing step, as schernatically illustrated in Fig.
3, this press operating with two belts endlessly rotating
over guide rollers 10, ll and 1~, 13, respectively, the
sintered sheet 41 being thereby pressed alterna-tingly
against the roll 9 and, respectively, roll 15 and, after
cooling and compressing, is taken off the belt 20. The
surface of the sheet ~2 can be finished either within the
belt press or also, for example, by means of an embossing
station arranged downstream thereof, or also by means of an
abrading and/or polishing step.
The examples set forth below represent embodiments
of the process of this invention as illustrated in Fig. l,
and of the production and use of the grain mixtures.
EXAMPLE 1
a basic batch is first of all mixed from filled
plasticized PVC, with the following proportions:
31 parts by weight of PVC "Vinnol* Y 68 M"
(company: Wacker-Chemie)
13 of dioctyl phthalate
25 of chalk
0.15 of stabilizer based on Sn,
and respectively 70 parts by weight of this batch is
* Vinnol Y 68 M ls a trade mark
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combined separa-tely with -the coloring pigments set forth
below and is granulated after mixing by means oE an
extruder:
5 Color Number Color: Parts by Weight:
1 Medium brown 0.7
2 light brown 0.987
3 beige-greenish 1.337
4 dark brown 0.252
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Extrusion temperature 170C, granule diameter 4-5 mm.
The granules are then once again mixed in the
following weight rations: color number 1:2:3:4=1:1:1:0.76,
and processed by means of extruder and rolling mill into a
marbled sheet material. During cal.ibrating by abrading with
belts of number 50 and number 100 abrasive gr~in, an
abrasion dust is obtained having the following grain
distribution (wet screening):
mm
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0.04 0.7
0.04 -0.063 0.4
0.963-0.1 0.2
0.1 -0.125 0.9
0.125-0.2 2.0
0.2 -0.25 7.8
0.2 -0.315 . 16.4
0.315-0.5 35.5
0.5 -0.8 32.5
0.8 -1.0 3.1
1.0 -1.6 0.4
1.6 -2.0 0.1
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The thus obtained grinding dust is applied via a
hopper with level-adjustable doctor blade with a gap set-ting
of 5 mm onto a release paper sheet, see Fig. 1, and
superficially sintered under an infrared radiator having a
length of 0.6 (7.5 kW) and through a hot-air tunnel having a
length of 6 m, at temperatures of 160-205C and at a rate
of lm/min.
The sintered sheet can thereafter be continuously
compacted and embossed in one operating step by way of
infrared radiators and an embossing roll unit -to form
polychrome, compact uniform covering having a thickness of 2
mm.
EXAMPLE 2
_ _
The grinding dust obtained according to Example 1
is mixed in a proportion of 1:1 with a grinding dust B
obtained from a different color combination and produced in
the following composition: :
Parts by Weight
Color Number Color: (per 70 parts of basic
batch according to
Example 1):
: -
dark greyish brown 0.24
6 dark reddish brown 0.45
7 medium brown 0.4
8 beige-reddish 1.0
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The mixture had the granule ratio of: color
number 5:6:7:8=1:1:1:0.76.
The grinding dust had the following grain
structure:
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mm %
0.04 0.9
0.04 -0.063 0.2
0.063-0.~ 0.2
0.1 -0.125 ~.0
0.125-0.2 3.9
0.2 -0.25 10.3
0025 -0.315 16.3
0.315-0.5 42.7
0.5 -0.8 23.5
0.8 -0.1 0.8
1.0 -1.6 0.1
1.6 -2.0 0.1
.
The grinding dust mixture A+B from two sheets dyed
with different marbling, with a total of 8 basic colors, is
sintered analogously to Example 1 and, after cooling, is
punched outand press-molded under the action of a press at a
temperature of 150C to a homogeneous sheet having a
thickness of 2 mm and exhibi-ting a brilliant polychrome
mixture.
EXAMPLE 3
From the sheets produced according to Example 1,
edge strips can be cut off, comminuted into chips having a
size of 5-10 mm, and ground in an "Alpine*" mill with a 2 mm
size screen. The sheets and panels sintered and compressed
from the ground reclaim analogously to Example 1 likewise
yield, in dependence on -the grain size and grain
distribution, a polychrome texture, the appearance of which,
when viewed close-up, as also in case of Examples 1 and 2,
* Alpine is a trade mark
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is not orien-ted nor strictly bounded and, from afar, have
the effect of live unitary structures with respect to their
charac-ter.
mm
0.04 0.9
0.04 -0.063 1.0
0.063-0.1 1.2
0.1 -0.125 1.4
0.125-0.2 1.6
0.2 -0.25 1.2
0.25 -0.315 1.4
0.31~-0.5 4.8
0.5 -0.8 10.7
0.8 -1.0 11.8
1.0 -1.6 22.4
1.6 -2.0 41.6
EXAMPLE 4
.
A polychrome uniform covering can also be
produced, just as of grinding dust and ground reclaim, from
the primarily produced granulated composition. The mixture,
prepared in correspondence with Example 1 in 4 colors, was
separately plasticized in an extruder, and granules having a
size oE 4-5 were produced therefrom, and likewise the
mixtures prepared according to Example 1 in 4 colors. Both
granulated materials are mixed 1:1, comminuted in an
"Alpine*" mill with a 2 mm screen, and applied to a metal
belt in a thlckness of about 5 mm, sintered, and
subsequently press-molded in a press into a sheet at a
temperature of 150C. Here, too, with only two basic
'
* Alpllle lS a trade mark
- 1 9
,
.... .. ~ .. .. .. .. .. .
: ~:
,
~.3~32~
colors, a polychrome color differentiation is attained.
The grain distribution was:
mm
0.04 1.0
0.04 -0.063 0.5
0.063-0.1 0.8
0.1 -0.125 1.3
0.125-0.2 1.6
0.2 -0.25 1.2
0.25 -0.315 1.3
0.315-0.5 3.8
0.5 -0.8 8.8
0.8 -1.0 11.5
1.0 -1.5 24.6
1.6 -2.0 43.6
EXAMPLE 5
The processing of this invention can be performed
not only with plasticized material, such as granules,
reclaims or abraded dust, but also with agglomerate that can
be manufactured during the mixing process in a controlled
fashion.
PVC "Vinno~ P 70", plasticizer, chalk, s-tabilizer
are mixed in accordance with Example 1 with separate
addition o~ the coloring pigments in a powder mixer with
rotor, and heated by frictional heat to 140C, and cooled
under agitation in a separate vessel and thereafter passed
through an "Alpine*" mill with a 2 mm screen.
The four differently dyed agglomerate batches are
mixed in the following proportion:
s * Vinnol P 70 is a trade mark
- 20 -
.. : ~-.
. .
, ,
. ~ . :
. .
~, ~
~ ~63~
color number 1:2:3:4=1:1:1:0.76, and processed on
a continuous conveyor as shown in Fig. 1 in correspondence
with Examples 1-4 into polychrome uniform sheets.
The grain distribution was:
mm %
0.04 3.1
0.04 -0.063 lO.1
0.063-0.1 16.4
0.2 -0.125 6.2
0.125-0.2 8.6
0.2 -0.25 4.1
0.25 -0.315 3.5--
l~ 0.315-0.5 7.3
0.5 -0.8 9.6
0.8 -l.0 7.3
l.0 -1.6 13.4
1.6 -2.0 10.4
EXAMPLE 6
In correspondance with Example 5, an agglomerate
~5 is produced without adding filler and dye, in a transparent
grade. The 4-color agglomerate mixture produced according
to Example 5 is mixed with the filler-free agglomerate in a
rotio 1:1, applied to a "Teflon" belt in a thickness of 6
mm, superficially sintered, and continuously compacted in a
belt press, thus obtaining a polychrome covering with depth
effect.
The grain structure was:
. ~ :
- 21 ~
'
'
~c~
mm
0 04 0.2
0.04 -0.063 1.2
0.063-0.1 3.2
0.1 -0.125 3.2
0.125-0.2 6.9
0.2 -0.25 5.4
0.25 -0.315 5.7
0.315-0.5 14.4
0.5 -0.8 17.2
0.8 -1.0 10.8
1.0 -1.6 15.7
1.6 -2.0 16.1
EXAMPLE 7
The abraded dust described in Example 1 is mixed
with the reclaim ground in Example 3 and the grain mixture
ground Erom granules in Example 4, in a ratio of 2:4:4, and
processed analogously to Example 6, thus obtaining, in spite
of the differing grain structures and platicizing stages
within the blend, a brilliant and clear polychrome
appearance.
The graln structure was:
- 22 -
,
'
,
.
~L3~2
mm %
0.04 0.6
0.0~ -0.063 0.5
0.063-0.1 0.6
0.1 -0.125 1.2
0.125-0.2 2.0
0.2 -0.25 3.3
0.25 -0.315 5.3
0.315-0.5 13.0
0.5-0.8 24.6
0.8-1.0 18.2
1.0-1.6 14.6
1.62.0 16.1
_ __
EXAMPLE 8
69 parts by weight of "Escorene* UL 00728"
(company: ESSO)( ).
30 parts by weight of "Juraperle* MHM"(company:
Ulmer Fuellstoffe)(2)
1 part by weight of color pigment-dye mixture
_ _
1) Ethylene-vinylacetate copolymer with about 28~ of vinyl-
acetate
2) Chalk.
"Escorene UL 00728" was preplasticized at 120C in
a rolling mill, then filler and color mixture were added in
portions within 5 minutes, and rolling was continued for 10
mi~nutes. The the rolled sheet was taken off and
* Escorene UL 00728 i8 a trade mark
* Juraperle MHM lS a trade mark
- 23 _
: ' ~
:' ' ,
, ~ ~
-- --
preliminarily comminuted in the warm condi-tion into sections
of about 6X6 cm. The cooled-off sections were ground on a
cutting mill with a 1.2 mm screen.
The grain distribution was:
mm %
-
0.25 5.5
0.25 -0.315 1.0
0.315-0.5 5.5
0.5 -0.8 16.7
0.8 -1.0 25.1
1.0 -1.25 34.2
1.25 -1.6 11.7
lS 1.6 -2.0 0.3
The resultant grain was mixed with a differently
pigmented material, produced in the same way, in a ratio of
1:1:1:1. Thereafter, the premix is applied with a doctor
blade onto a steel belt with a thickness of 6 mm and
sintered. The sintered sheet, reduced in thickness to about
4 mm thereby, molded in a twin-belt press at a temperature of
110C into a polychrome sheet having a thickness of 2 mm.
EXAMPLE 9
The sintered sheet produced according to Example 1
can likewise be produced in one working step by way o~
in~rared radiators and a smoothing roll unit continuously
into a polychrome, rough, nonslip covering having a
thickness of 3 mm, with a lesser amount of compacting by a
corresponding calibration in the roll nip. A covering is
thus obtained showing a depth e~fect and having a special
. ~
- 24 _
'
':
~31~
textile appearance.
Analogously, the sintered sheet produced in
accordance with Example 8 can be calibrated by way of a roll
nip, thus producing a nonslip, polychrome covering.
Figs. 4 through 12 show designs of floor coverings
that can be obtained in accordance with the examples. 1'he
black-white reproduction fails, of course, to convey the
colored impression, but the fine texturing can be recognized
at least in its basic traits, even though -the color nuances
are lost.
The thus produced sheets or panels exhibit a
design not only on the surface but have such design
throughout the entire thickness of the sheet, so that with
wear and abrasion during use the surface design is not lost.
Fig. 4 shows a top view of a finished product made
up of four different agglomerates according to Example 4,
but with different grain distribution.
FigO 5 shows a top view of the sintered sheet
according to Example l in a 1.3-fold magnification, and Fig.
6 shows a top view of the finished product according to
ExampIe 1, i.e. the compacted sheet.
Fig. 7 is a view of the finished product according
to Example 3.
Fig. 8 is a view of a finished product according
~5 to Example 2, but with only two differently coloured
granular materials.
Fig. 9 is a view, enlarged x 1.3, of a sintered
strip made from grinding dust of one colour. The open-pore
structure of the sintered strip is easily recognizable.
Fig. 10 shows the finished product according to
Example 5.
Fig. 11 is a view of the finished product
according to Example 6, with an agglomereate containing
transparent material.
- 25 -
':
Fig. 12 is a view of the finished product
according to Example 7.
The surfaces of the compacted sheet or strip may
be further refined, for example by embossing (smooth) or by
very slight profiling -to a maximal depth of 100 ~m.
- 26 -
.
.
