JP2638729B2 - Plastic tile composition - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates, in one aspect, to an inlay tile in which a filled colored polymer chip is uniformly dispersed in a filled thermoplastic material that can be of different colors. The chips remain discrete during high temperature processing in high intensity mixers such as Banbury mixers or mixing mills. In accordance with the present invention, inlay tiles are manufactured by using decorative plastic chips that are dispersed in a thermoplastic substrate, remain discrete during processing, and do not plasticize or stretch.

[0002]

2. Description of the Related Art Conventional compositions containing chips contained in a substrate are disclosed, for example, in US Pat. Nos. 3,787,280, 3,966,857, 4,054,699 and 4,501,783. It is described in the specification. It is an object of the present invention to provide an improved tile composition and a method of making a tile.

[0003]

SUMMARY OF THE INVENTION According to the present invention, there is provided an improved colored chip formulated with a polymer, a stabilizer, a filler, a crosslinker, and a pigment different from that of the thermoplastic substrate. An inlay floor tile is provided. Tile substrates are manufactured using fillers coated with polymers, stabilizers, fillers, processing aids, pigments and internal lubricants or lubricants.
The lubricant is used to reduce the processing temperature and shear stress in the high intensity mixer, and to keep the decorative chips as discrete particles during the processing and to prevent them from flowing. According to another aspect of the present invention, the chips added to the tile substrate formulation are colored and coated mineral chips, such as quartz, glass or feldspar, wherein the coating is a pigmented polyester or epoxy. Or by ceramic technology. Alternatively, a mixture of coated mineral chips and partially crosslinked resinous chips can be used. By adding such chips, a tile product having a granite-like appearance or effect can be manufactured.

In the embodiment of the invention shown in FIG. 1, a tile product is provided that includes a tile substrate 12 that contains particles or chips 14 that are uniformly dispersed in the tile substrate 12. According to the present invention, techniques that can be used to produce the polymer phase of the chip formulation include: 1. crosslinking; Combination of partially crosslinked and high melt thermoplastic resin, wherein each chip is formulated by partial crosslink and the remainder of the chip polymer phase is a high melt thermoplastic resin.

[0005] As an example of chip production, a high intensity mixer such as a Banbury mixer with a steam jacket is used.
Chips can be made by mixing the components operating at 40-46 rpm with steam at 4 ° C. (310 ° F.). Due to the combination of the heat provided by the steam and the shearing action of the mixer, the mixed material is heated to about 177 ° C.
Mixing is continued until a temperature of (350 ° F.) is reached, under which conditions the components become a melt. The melt is then calendered and formed into about 2.54 mm (100 mil) thick sheets. The sheet may be heated by radiant heat or other means.
C. (400 ° F.) to partially crosslink the polymer component,
Thereafter, the sheet is cooled and crushed into small chips from which those having passed through 200 mesh have been removed. In another aspect,
The calendered sheet is first ground into chips and then fed into a fluidized bed to effect crosslinking of the polymer components.

The dimensions of the chips used in the present invention are mostly, ie, about 94-100% by weight, 10-200 (US).
The mesh includes particles having a mesh size of 0 to 1 part by weight, and particles having a mesh size of 0 to 5% by weight. In a preferred embodiment, the chip of the present invention has a Shore height D in the range of 75-88.
In the embodiment shown in FIG. 1, the chips made according to the present invention are not round, angular, non-uniform in shape, have sharp corners, and have the dimensions of most evenly distributed chips. It is 10 to 200, preferably 14 to 40 mesh.

[0007] In one embodiment of the chip formulation, the specification of the mesh size is as follows.

[Table 1] U.S. mesh weight% +140 to -14 to +16 2% max. -14 to +18 22 to 32% -14 to +25 70 to 90% -40 max. 2%

[0008] Examples of chip formulations are as follows.

[Table 2] Chip mix weight% 1. Polyvinyl chloride (homopolymer) 35.0 2. Phenol resin 7.0 3. Pentaerythritol 1.0 4. Magnesium oxide 1.0 5. -40 mesh limestone (420μ) 55.9 6. Red pigment (oxide) 0.1 Total 100

With respect to the chip formulation, component 1 is the main thermoplastic synthetic polymer component of the chip, and may comprise from about 25 to about 25% of the chip formulation based on the filler content level of the chip.
It is present in an amount of 80% by weight. In addition to the examples described above, the thermoplastic polymer component can be varied to one or more of the following. (A) a copolymer of vinyl chloride and vinyl acetate; (b) a polyester resin; (c) chlorinated polyethylene; these thermoplastic polymer components are not necessarily crosslinked during the manufacture of the chip, and thus are not necessarily tile substrates. It is not necessary to have a higher softening point than the polymer used for.

The above component 2 functions as a plasticizer and is initially liquefied in a Banbury mixer at an early stage, but irreversibly crosslinks with components 3 and 4 at 204 ° C. (400 ° F.). And do not liquefy again. Also, the plasticizer can be a polyester or epoxy resin, or a combination thereof. The plasticizer can be present from about 0 to 10% by weight of the chip composition.
In a preferred embodiment, the amount of plasticizer is about 5-9% by weight of the chip composition.

During chip manufacture, polyvinyl chloride or other thermoplastic polymer components are crosslinked or partially crosslinked by magnesium oxide and pentaerythritol. Phenolic resins are also crosslinked by magnesium oxide and pentaerythritol. Various color pigments can be used in the chip composition. A high melting thermoplastic resin in the form of an acrylic resin, such as a polymethyl methacrylate polymer, can be used in combination with the phenolic resin to enhance flowability. Such high melting thermoplastics soften or flow during chip manufacture, but do not soften or flow during the second stage of tile manufacture where the chips are mixed with the tile base material. In other embodiments, epoxy resins can be used in place of phenol,
Melamine is added for crosslinking the epoxy resin.

When chips are made from a combination of a partially crosslinked thermoplastic resin and a high melting thermoplastic resin, approximately 9-40% by weight of the total chip formulation is crosslinked. Thus, at least 18% by weight of the chip polymer phase is crosslinked. The amount of cross-linking is adjusted by the temperature and time in chip production and the amount of cross-linking agent used. High melting thermoplastics include materials that do not soften or flow during mixing of the chip and tile base material in a high intensity mixer. The high melting point thermoplastic resin includes, for example, a combination of an acrylic resin and PVC. The high melting thermoplastic can be present in an amount of about 5% to 50% by weight of the total chip composition. When using a crosslinked chip without a high melting point thermoplastic, there is no need to use a lubricant in the base material, provided that the chip material is irreversibly crosslinked. By using partial cross-linking together with the high melting point thermoplastic resin for chip production, the processing time required for cross-linking can be reduced from 30 minutes or more to about 15 seconds. Such a feature is very advantageous in reducing the production line time, so that the method can be implemented efficiently and economically.

[0013] The -40 mesh limestone functions as a filler in the chip formulation. Other suitable fillers such as trihydrated alumina can also be used. The chip composition contains about 10-75% by weight filler. The amount of chips used in the tile substrate is generally about 2-20% by weight of the total chip and substrate formulation.

Examples of the production of the tile composition of the present invention include:
The various components are added to an intense mixer, for example a Banbury mixer with a steam jacket at 154 ° C. (310 ° F.) until the components become a molten thermoplastic mixture (at this time pre-crosslinked chips can be added) ),
A substrate is first prepared by mixing at 40-46 rpm for about 2 minutes. After additional mixing for about 20 seconds to 1 minute,
The molten mixture is dropped at a temperature of about 149 ° C. (300 ° F.) into a two roll heated mill to form a sheet. The sheet is calendered, then cooled, and cut into tiles of desired dimensions, for example, 30 x 30 cm (12 x 12 inches). The thickness of the final tile product is generally between 0.159 and 0.58
7 cm (0.0625-0.231 inch).

Examples of the composition of the tile base material are as follows.

[Table 3] Tile base material blending weight% 1. Mixed resin of 40% PVC homopolymer and 60% PVC-PVA copolymer 13.0 -40 mesh crushed limestone 59.8 3. Plasticizer DINP 4.0 4. Zinc stearate (lubricant) 0.02 5. Stabilizer Synpron1751 calcium zinc type 0.88 6. 6. Hi-Plex 100Pfizer surface treated CaCO ₃ + calcium stearate 10.0 Processing aid α-methylstyrene 1.5 8. Talc (7μ) 10.0 9. Pigment (TiO ₂ ) 0.8 Total 100.00

For the tile substrate formulation, component 1 is the main thermoplastic synthetic resin component of the tile substrate and is present in an amount of about 10-25% by weight of the tile substrate. The thermoplastic base component is a suitable filled polymer, such as a vinyl polymer (homopolymer or copolymer, or a combination thereof).
Can be manufactured from Thus, the thermoplastic polymer component is a combination of about 40-100%, preferably about 40-80%, by weight of a PVC homopolymer and about 0-60%, preferably 20-60%, by weight of a PVC-PVA copolymer. There can be. The thermoplastic polymer component may consist of polypropylene or polybutylene.

Component 2 functions as a filler for the tile substrate. Other suitable fillers can also be used. The amount of filler in the tile substrate is about 50-85% by weight. Component 3 functions as a plasticizer and can be present in an amount of about 3-6% by weight of the tile substrate. As for the lubricant component, it is possible to obtain desired lubricity by using any one of components 4, 5, and 6. Component 6 can be used in an amount up to 20%, and the surface-treated limestone contains a small amount of a lubricant that acts to control the drop temperature and shear force. By using a lubricant component for the tile base material, the falling temperature can be reduced to 149 ° C.
(300 ° F) or less, so that when added, the chips do not soften or melt, and wear of the colored mineral coated chips is reduced. In this regard, the amount of lubricant used is generally about 0.10 to 1.0% by weight of the tile substrate. Satisfactory lubricants include calcium stearate, zinc stearate, stearic acid, and various palmitates and oleates known in the art.

With respect to the method of dropping the molten mixture on a two-roll mill, it is desirable that the mixture be dropped after a short interval of about 20 seconds after the addition of chips. In order to obtain a suitable chip dispersion in the substrate material,
At least 20 seconds are required in a high intensity mixer. Thus, a time interval of about 20 seconds to 3 minutes, preferably 20 seconds to 1 minute (mixing time in a Banbury mixer) is usually used. If it is desired to mix the chips for an extended period of time, the chips can be bleed or fractured. In addition, the shear force is increased by the addition of chips, and the temperature is increased to 204 ° C. (40 ° C.).
0 ° F) or more, resulting in a softened chip. About 1
The use of a reaction temperature in the range of 49-204 ° C (300-400 ° F) is particularly desirable because the stability of the PVC component is maintained when PVC is used. 204 ° C (400 ゜
Temperatures above F) degrade the PVC and do not have enough time to use the PVC. On the other hand, about 138 ° C (280 ° C)
F) At the following temperatures, PVC cannot be properly treated or melted.

In one embodiment of the present invention, the chip and the tile substrate have the following compound hardness in a 77 ° F. indentation test according to US Federal Test Standard No. 501. Chip: 4-6 mil at 90-100 mil gauge Tile substrate: 9-11 mil at 125 mil gauge

In another embodiment of the present invention, about 2-20% by weight of the above-described partially crosslinked chips, based on the total weight of the initial composition, is added to the above-mentioned tile base composition on a two-roll blending roll machine, and the marble pattern is added. Build a roll pad. Then, the roll pad is calendered to 1.52 to 3.0.
4 mm (60-120 mils) thick and crushed into 14-40 mesh chips. The ground chips are re-formed into sheets by the following method. 1. At a temperature of about 88-116 ° C (190-240 ° F),
A method of compressing reheated chips between rolls of a sheet roll machine. 2． A method of pressing chips into a thermoplastic substrate sheet between calendar rolls. The chips are usually at a temperature of between 99-149 ° C (210-300 ° F). The thermoplastic base sheet is, for example, 149 ° C. (30
0 ° F). A thermoplastic substrate sheet having a composition as used in the tile substrate formulation described above can also contain from about 5 to 10% by weight of the partially crosslinked chip per total weight of the composition. A smooth surface finish and final thickness of the tile can be achieved by a series of calendering the sheet. The sheet is then cooled and cut into tiles with a punch press.

In yet another embodiment of the present invention, about 5 to 10% by weight of the above partially crosslinked chips, based on the total weight of the initial composition, is mixed in a high intensity mixer such as a Banbury mixer.
Add to the thermoplastic tile base formulation described above. This was mixed and mixed at a temperature of 300-350 ° F (149-177 ° C).
Drop on this roll mill to make a roll pad. The pad is subjected to a series of calenders, where 1-10% by weight of additional partially crosslinked chips per total weight of the composition is applied to the sheet surface between the calenders. Chips of 14 to 40 mesh size are pressed into the surface. Since the chips are partially crosslinked, a smooth surface can be obtained without elongation of the chip pattern.

Important concepts used in the present invention include the following. 1． The use of a cross-linked material that is irreversibly cross-linked so that the desired chips are produced that do not plasticize or stretch while remaining dispersed during processing. The crosslinked product is insoluble in tetrahydrofuran (THF), indicating irreversible crosslinking. The formulation may also be partially cross-linked, as indicated by partial or very slow solubility in THF, so that the chips do not flow at the temperature in the high intensity mixer where they are added to the thermoplastic substrate. You can also. 2． Use of one or a combination of (a) partially cross-linked and (b) high melting temperature thermoplastics to produce chips that do not flow at the required temperature in a high intensity mixer. Partially crosslinked materials are those that do not flow at temperatures up to 177 ° C. (350 ° F.) when PVC is used. 3． Crosslinking the plasticizer in the chip formulation after using the plasticizer to aid in the initial processing of the PVC thermoplastic polymer. Four. Use partially cross-linked chips as necessary to keep chip elongation at a minimum where the chips are added for processing. When the chips are added to high intensity mixers with high shear forces and temperatures of about 149 ° C (300 ° F), a high degree of crosslinking is necessary to prevent plasticization or elongation. On the other hand, when chips are added to a calendar roll, the shearing force and temperature are low, which can reduce the degree of crosslinking. The reduced cross-linking reduces the amount of flow without stretching and improves the smoothness of the tile surface. Five. By using lubricants on thermoplastic substrates to reduce processing temperatures and shear forces in high intensity mixers such as Banbury, partially cross-linked and high melting temperature polymer decorative chips can be used during processing. The particles remain dispersed and do not flow. In this method, the mixing temperature is adjusted below the softening temperature of the chip. The falling temperature is typically 149 ° C. (300 ° F.) when PVC is used when dropping the melt onto a rolling machine. 6． The use of filler-rich thermoplastic substrate materials and chips to provide tile products that are dimensionally stable and can be easily cut with the punch press used to cut tiles. Generally, chips are about 10
It contains 75% by weight of filler and the substrate material is about 50-85
Contains wt% filler.

In another embodiment of the present invention, a tile base formulation similar to that described above is used, but rather than adding partially crosslinked resinous chips, the chips are colored and coated mineral chips. Yes, for example quartz with a coating made in ceramic technology or coated with pigmented polyester or epoxy resin. As an alternative, a mixture of coated chips and the above-mentioned partially crosslinked resinous chips having the same particle size range is used. The addition of such chips to the above tile substrate formulation produces a tile product having a granite-like appearance and effect as shown in FIGS.

If chips coated with polyester or epoxy are used, the coating resin used may be a commercial bead containing a mineral bead, such as glass, feldspar or quartz, which is a solid bead having a pigmented coating. Polyester or epoxy resin available from The liquid polyester coating is melted and becomes solid by the addition of a peroxide curing agent. The color can be seen through the entire surface of the chip,
Therefore, a transparent tip is selected so that wear cannot be detected. The polyester coating is a thermosetting synthetic resin produced by esterification of a polybasic acid or its anhydride with a polyhydric alcohol. For example, the degree of unsaturation is achieved by using dibasic anhydride or fumaric acid.
Unsaturated acids or anhydrides react with alcohols such as ethylene or propylene glycol to form polyesters. In addition to the unsaturated dibasic acid, a saturated acid such as phthalic anhydride or adipic acid can be mixed and used. A higher proportion of unsaturated acid results in a more reactive resin system, which improves the high temperature stiffness of the coating, which is important when hot mixing the tile substrate and the coated chips in a Banbury mixer. High saturated acids reduce reactivity, reduce the heat of exothermic curing, and reduce the stiffness of the polyester coating at elevated temperatures. Styrene monomer is used to dilute the resin to allow it to be poured and to coat the mineral chips. The polyester resin component is mixed in the resin reaction sesame and polymerized by a stepwise reaction. The reaction gives a viscous liquid with a molecular weight range of 1000-2000. After cooling, the mixture is diluted with styrene to a pourable viscosity. Polymerization inhibitors such as hydroquinone are used to prevent premature polymerization.

[0025]

Table 4 Typical Formulation (* 1) Component PHR Molar Phthalic Anhydride 28.86 0.2 Maleic Anhydride 19.11 0.2 Propylene Glycol 14.83 0.2 Ethylene Glycol 12.10 0.2 Styrene 30.00 0.3 Hydroquinone 0.02 Trace 104.92 (* 2) (* 1) Source Chem. Eng. News 37, # 51, 56 (1959
(February 21) (* 2) Approximately 2.3 kg (5 lbs) of water was removed during the elutriation.

1 to 10% by weight of pigment paste is added to give the desired color to the resin coating. Curing is initiated by adding an initiator, an organic peroxide such as benzoyl peroxide. Accelerators such as cobalt naphthenate can also be added to accelerate cure. Mineral chips are mixed in a mixer at 12.7-127 microns (0.
5-5 mils) of a colored liquid polyester polymer. After curing the coating, the colored mineral chips are prepared for use on a tile substrate to create a granite-like appearance. The commercially available polyester coated quartz material used in the present invention is manufactured by Clifford W. Estes Co.

[0027] Epoxy resin-containing pigments can also be used to coat transparent mineral chips. Typical epoxy resins are made by the condensation of epichlorohydrin with bisphenol A. An excess of epichlorohydrin is used to leave epoxy groups at each end of the polymer.
A more viscous liquid polymer of the reaction is obtained. The reaction is NaO
Performed in H solution. The epoxy resin is then cured with a polyamine. Pigments and curing agents are added to the epoxy-coated resin before encapsulation of the mineral chips.

Important factors to consider when manufacturing inlay composite plastic floor tiles using epoxy or polyester coated mineral chips are as follows. 1． Adhesion of pigmented polymer coatings to mineral chips at the high shear forces and temperatures encountered during mixing of chips and tile substrates in a Banbury mixer. 2． Use of internal lubricants in tile base formulations to minimize coating wear during heavy banbury mixing. 3． Use clear mineral chips so that the coating is visible through the backside of the chip and that wear of the coating does not affect chip hue during use.

If ceramic coated chips are used, the ceramic coating is generally in the form of clay, pigment and water, as well as other materials that melt in a ceramic glaze around the individual mineral particles by known methods. Various types of glaze can be used to change abrasion and hue. Ceramic coating thickness is about 12.7
１127 microns (0.5-1.5 mils). The shape of the ceramic-coated particles can be round or angular. Round tips reduce equipment wear problems. Other materials used for chips include, besides quartz and apatite, feldspar, anorthite and glass.

In the practice of the present invention, the Mohs 'hardness of 5 to 8 (the former Mohs' hardness standard classified into 1 to 10 steps)
U. same as below. ) And coated mineral chips having a particle size of 44-2000 microns represent about 2-2 of the total formulation.
It is added to the tile formulation in an amount of 0% by weight. The mixture is combined in a mixer or blending roll machine. 149 ~
The mixture obtained in a mixer such as a Banbury mixer at 177 ° C. (300-350 ° F.) is dropped on a roll mill where a pad about 2.54 cm (1 inch) thick is formed. Alternatively, the coated chips can be added to the blending roll machine rather than the Banbury mixer to minimize wear in the Banbury type mixer. The rolled pad is 3.81 to 6.35 mm (150 to 25 mm).
0 mil) calendered to gauge thickness. After the calendering step, additional chips in an amount of about 1 to 10% by weight of the total formulation are sprinkled on the upper surface of the sheet with a vibrating spreader and pressed with a roll. The additional chip may be a colored coated mineral chip, such as the initially added chip, a partially crosslinked resinous chip of the same particle size as described above for the coated chip, or a combination thereof. The sheet is then calendered to a final thickness of 0.38 cm (1/8 inch) by calendering. The sheet is then cut into 12 x 12 x 1/8 inch (30 x 30 x 0.32 cm) or other size tiles.

The wear and transparency of the mineral chips are the salient features of the present invention. Abrasion is affected by the choice of coating so that the abrasion and abrasiveness of the final product are controlled and the problem of abrasion due to the action of hard particles on the processing equipment during manufacture of the product is reduced. It is also preferred to select a transparent mineral so that the colored coating is visible and transparent through the front and back surfaces of the chips, so that the chips do not change color when worn. Thus, for example, the particles can be made from a transparent quartz material with a Mohs' hardness of 8, and the abrasion can be reduced by using a pigmented polyester or ceramic coating on ground quartz.
In the embodiment of the present invention shown in FIG.
A tile product 20 is provided that includes a tile substrate 12 containing angular coated mineral chips 22 uniformly dispersed therein. The embodiment of FIG. 3 shows a tile substrate having round coated mineral chips 24 uniformly distributed on the tile substrate 12 and additional round coated mineral chips 24 sprayed and pressed onto the surface of the tile substrate 12. Tile product 30 including
It shows. The embodiment of FIG. 4 shows a mixture of round coated mineral chips 24 and partially cross-linked chips 26 uniformly dispersed in the tile substrate 12, and additional chips 24 sprayed and pressed onto the surface of the tile substrate 12. 26 shows a tile product 40 including a tile substrate having 26;

In another embodiment of the invention, the coated mineral chips are added on a two-roll mill after the hot substrate from the high-speed mixer is formed into a pad covering the front roll of the roll. The pad is formed into a continuous sheet of desired thickness by a series of calendering and then cut into tiles by a punch press. Tile rejects and recycled materials generated by press webbing are 0.64 cm
Crushed into (1/4 inch) size chips. The reclaimed chips are heated to 116 ° C. (240 ° F.) and returned to a roll mill or spread on sheets between calenders at a sheet temperature of about 149 ° C. (300 ° F.). By using the method of the invention, the wear-inducing ceramic chips do not enter the high intensity mixer, thus avoiding premature mixer wear. After the initial calendering, 2-10% by weight of the coated mineral or partially crosslinked chips, or a combination thereof, per total formulation is applied to the surface of the sheet, mainly to compensate for the skinning effect caused by the rolling machine. Can be added. These chips are pressed into sheets by press rolls or calenders.

FIGS. 5 and 6 show the granite-like appearance obtained by the present invention, based on the case where the amount of chip material used is relatively small (FIG. 5) and the case where the amount of chip material is relatively large (FIG. 6). The different results obtained are shown. In the selection of additional chips sprayed on the upper surface of the tile substrate, features to consider are coated mineral chips, which have the advantage of not being destroyed during mixing and of being relatively inexpensive, and to some extent Chip features that provide improved fluidity and a smooth improved surface effect. The main reason for spraying additional chips on the top surface is mainly to overcome the "skinning effect" caused by the rolling machine and also by the calender. When the roll pad is processed, the surface chips tend to be covered by the substrate formulation, resulting in the surface chips becoming invisible. To compensate for this result, the additional chips are spread on the upper surface and pressed in by rolls or calenders. The tiles can also be polished to remove skin. As shown in FIG. 6, in embodiments where a chip-rich surface coating is desired, the chips used for the surface coating have a mesh range of -35 to -100. It is preferable that 96 to 100% by weight of the chips on the surface be in the above range, and 0 to 2% by weight is larger than the above range and 0 to 2% by weight is smaller than the above range.

The present invention may be embodied without departing from its spirit or essential characteristics. Therefore, all aspects of the present invention described above are taken into consideration, and the scope of the present invention is defined by the appended claims, and all claims that fall within the scope of the appended claims and equivalents thereof are described. Are included.

[Brief description of the drawings]

FIG. 1 contains a tile substrate in which particulate matter is dispersed,
1 shows a vertical cross section of a portion of a tile product of the present invention.

FIG. 2 shows a vertical cross-section of a tile product of the present invention containing a tile substrate with angular coated mineral chips dispersed therein.

FIG. 3 shows a vertical section similar to FIG. 2 containing a tile substrate with round coated mineral chips dispersed therein.

FIG. 4 shows a vertical section similar to FIG. 2 containing a tile substrate in which a mixture of round coated mineral chips and partially crosslinked chips is dispersed.

FIG. 5 is a top view showing the surface of a tile product of the present invention using a relatively small amount of chip material.

FIG. 6 is a top view similar to FIG. 5, using a relatively large amount of chip material.

[Explanation of symbols]

 Reference Signs List 10 tile products 12 tile base materials 14 chips 20 tile products 22 angular coated mineral chips 24 round coated mineral chips 26 partially crosslinked chips

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location C04B 14:02 16:04)

Claims (29)

(57) [Claims] 1. (i) 10 to 25% by weight of a thermoplastic polymer in the form of a polyvinyl chloride homopolymer or a vinyl chloride copolymer mainly comprising vinyl chloride moieties, (ii) 50 to 85% by weight of a filler material and (iii) A) a thermoplastic tile substrate containing a lubricant component, wherein the tile substrate is in the form of a mixture of (a) mineral chips coated with a polyester or epoxy coating and (b) partially crosslinked resinous chips. 2-20% by weight of the total composition of the particulate material is evenly dispersed, the mineral chips are each separately coated and wrapped with a colored polyester or epoxy coating, and the The coated mineral chips have an old Mohs hardness of 5 to 8 and a particle size of 44 to 2000 microns, and furthermore, The resulting chips are (i) a thermoplastic polymer 25-8 in the form of a polyvinyl chloride homopolymer or a vinyl chloride copolymer consisting mainly of vinyl chloride moieties.
0% by weight, (ii) 10-75% by weight of the filling material and (ii)
i) a plasticizer selected from the group consisting of phenolic resins, polyester resins or epoxy resins, wherein each of the partially crosslinked chips comprises 18% by weight of the polymer phase
From the above, a tile composition formed using mineral chips coated so as to produce a granite-like appearance, characterized in that the tiles are cross-linked in an amount equal to or less than an amount that prevents flow at elevated temperatures . 2. A transparent mineral and a colored coating are used on said chip, said colored coating being transparent through the front and back of the chip and not changing color when the chip is worn. The tile composition according to claim 1. 3. The tile composition according to claim 1, wherein the mineral for the chip is selected from the group consisting of quartz, apatite, feldspar, anorthite and glass. 4. The tile composition according to claim 1, wherein from 1 to 10% by weight of the total composition of the additional particulate material is pressed into the upper surface of the tile substrate. 5. The tile composition according to claim 4, wherein said additional particulate material is a coated mineral chip having an old Mohs hardness of 5-8. 6. The tile composition according to claim 4, wherein a transparent mineral and a colored coating are used for said additional particulate material. 7. The tile composition of claim 4, wherein said additional particulate material is a partially crosslinked resinous chip. 8. The tile composition according to claim 4, wherein said additional particulate material is in the form of a mixture of coated mineral chips and partially crosslinked resinous chips having an old Mohs hardness of 5-8. . 9. The tile composition of claim 1 wherein said chips are coated with a polyester or epoxy coating having a thickness of 12.7 to 127 microns (0.5 to 5 mils). 10. The tile composition of claim 1, wherein said particulate material is present in an amount of from 2 to 20% by weight of the total composition. 11. The tile composition according to claim 1, wherein the coated mineral chips are round. 12. The tile composition according to claim 1, wherein the coated mineral chips have a square shape. 13. The composition of claim 7, wherein said partially crosslinked chips are comprised of a filled thermoplastic material. 14. (i) a polyvinyl chloride homopolymer,
Or a thermoplastic tile substrate containing 10-25% by weight of a thermoplastic polymer in the form of a vinyl chloride copolymer with a predominantly vinyl chloride portion, (ii) 50-85% by weight of a filler material and (iii) a lubricant component. And the tile substrate comprises (a)
In the form of a mixture of ceramic-coated mineral chips and (b) partially cross-linked resinous chips that remain as separate particles within the substrate, 2-20% by weight of the total composition of the particulate material is uniformly distributed. Dispersed, the mineral chips are each separately coated and encased with a colored ceramic coating, wherein the ceramic coated mineral chips have an old Mohs hardness of 5-8 and a 44-2000 micron hardness. The partially crosslinked chips having a particle size and further comprising (i) 25-80% by weight of a thermoplastic polymer in the form of a polyvinyl chloride homopolymer or a vinyl chloride copolymer based on vinyl chloride moieties, (ii) 10 to 75% by weight of a filler material and (iii) a plasticizer selected from the group consisting of a phenolic resin, a polyester resin and an epoxy resin, wherein the partial crosslinking Each of the resulting chips is crosslinked in an amount greater than or equal to 18% by weight of the polymer phase and less than or equal to the amount that prevents flow at elevated temperatures, to produce a granite-like appearance. A tile composition formed using ceramic coated mineral chips. 15. A chip, wherein a transparent mineral and a colored ceramic coating are used on said chip, said colored coating is visible through to the front and back of the chip and does not change color when the chip is worn. Item 15. The tile composition according to Item 14. 16. The mineral for chips is quartz, apatite,
15. The tile composition according to claim 14, wherein the tile composition is selected from the group consisting of feldspar, anorthite and glass. 17. The tile composition according to claim 14, wherein 1 to 10% by weight of the total composition of the additional particulate material is pressed into the upper surface of the tile substrate. 18. The tile composition according to claim 17, wherein a transparent mineral and a colored ceramic coating are used for the additional particulate material. 19. The tile composition of claim 17, wherein said additional particulate material is a partially crosslinked resinous chip. 20. The tile composition of claim 14, wherein said chips are coated with a polyester or epoxy coating having a thickness of 0.5 to 5 mils. 21. The tile composition according to claim 19, wherein the partially crosslinked chips are a filled thermoplastic material. 22. A tile substrate formulation in the form of (a) a filled thermoplastic material, wherein the tile substrate comprises (i) a polyvinyl chloride homopolymer or a chloride based on a vinyl chloride moiety. 10 to 25% by weight of a thermoplastic polymer in the form of a vinyl copolymer (ii) 50 to 85% by weight of a filler material
And (iii) a lubricant component, and (b) a particulate material in the form of a mixture of (a) coated mineral chips and (b) partially crosslinked resinous chips, wherein the particulate material is 2-20 parts of the total mixture. % By weight is blended with the tile substrate formulation in a mixer to provide a mixture in which the particulate material is uniformly dispersed and which remains as discrete particles throughout the tile substrate formulation. Mineral chips are 5
Each separately coated and wrapped with a colored coating selected from the group consisting of polyester, epoxy and ceramic to provide a coated mineral chip having an old Mohs hardness of ~ 8, and further comprising The crosslinked chips comprise (i) 25-80% by weight of a thermoplastic polymer in the form of a polyvinyl chloride homopolymer or a vinyl chloride copolymer based on vinyl chloride moieties, (ii) 10-75% by weight of a filler material and ( iii) containing a plasticizer selected from the group consisting of phenolic resins, polyester resins or epoxy resins, wherein each of the partially crosslinked chips has a flow at elevated temperature of at least 18% by weight of the polymer phase. (C) forming the mixture into a sheet, and (d) calendering the sheet to a final thickness. Encompasses Rukoto, manufacturing method of inlay plastic tile that has the appearance of granite-like. 23. A transparent or translucent and colored coating is used on the chip, the colored coating being visible from the front and back of the chip and not changing color when the chip is worn. 23. The method of claim 22, wherein 24. The mineral for chips is quartz, apatite,
23. The method of claim 22, wherein the method is selected from the group consisting of feldspar, anorthite and glass. 25. The method of claim 22, wherein 1-10% by weight of the total composition of the additional particulate material is pressed into the upper surface of the tile substrate. 26. The additional particulate material is a coated mineral chip having an old Mohs hardness of 5-8.
5. The method according to 5. 27. The method according to claim 26, wherein a transparent or translucent mineral and a colored coating are used for the additional particulate material. 28. The additional particulate material is a crosslinked resinous chip, wherein the resinous chip has an amount of from 18% by weight or more of the polymer phase to an amount that prevents flow at elevated temperatures. 26. The method of claim 25, wherein the method is cross-linked. 29. The additional particulate material comprises a mixture of coated mineral chips and resinous chips having an old Mohs hardness of 5 to 8, wherein the resinous chips are 18% by weight of the polymer phase. 26. The method according to claim 25, wherein the crosslinking is carried out in an amount of not less than% and not more than an amount that prevents flow at elevated temperatures.