Composite sheet and manufacturing method for a foamed decorative sheet free of PVC and plasticizers

Inactive Publication Date: 2017-01-05
JSC VEIKA
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0021]Surprisingly, it has been found that by using a specific group of plastics, it is possible to minimize the curling effect and to produce a curling-free composite sheet for manufacturing a foamed decorative sheet of large dimensions and in a continuous manner.
[0022]The base layer should have a higher dimensional stability compared to the foamable layer. The base layer has an elastic modulus of >1 GPa, shows a shrinkage/expansion of less than 2% in a temperature range of 0° C. to 220° C., and has a thickness of 0.05 to 0.15 mm which corresponds roughly to 50 to 150 g/m2. As a

Problems solved by technology

The main drawback of choosing PVC as a material is that its production can have a negative environmental impact.
Furthermore, to achieve the required properties, such as strength and flexibility, PVC must be mixed with stabilizing agents, plasticizers and solvents which are suspected of being harmful to health, and which can migrate to the room environment.
In addition, PVC recycling or combustion is problematic due to formation of hydrochloric acid and low energy recovery.
With respect to the

Method used

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  • Composite sheet and manufacturing method for a foamed decorative sheet free of PVC and plasticizers
  • Composite sheet and manufacturing method for a foamed decorative sheet free of PVC and plasticizers
  • Composite sheet and manufacturing method for a foamed decorative sheet free of PVC and plasticizers

Examples

Experimental program
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Effect test

example 1

[0064]The foamable layer has been made of polyolefin material having an elastic modulus of <0.1 GPa. The components of the foamable layer were mixed at 140° C., 60 RPM. Then the foamable layer has been laminated on paper at 140° C.

[0065]More specifically the foamable layer consisted of:

Ethylene-octene copolymer, melt100 parts by weight flow index 5, modulus 0.011 GPaAzodicarbonamide5 parts by weightZnO1 parts by weight

[0066]The layer had a thickness of 0.15 mm and had good adhesion to the substrate. No curling occurred after cooling to room temperature.

example 2

[0075]The foamable layer consisted of:

Ethylene-octene copolymer, melt100 parts by weight flow index 5, modulus 0.011 GPaCalcium carbonate60 parts by weightActivated azodicarbonamide 5 parts by weightTitanium dioxide10 parts by weightDicumyl peroxide 1 parts by weight

[0076]The layer thickness was around 0.15 mm. In the next step, the layer was laminated to the base layer and cross-linked at 170° C. for 1 min. The layer was printed on a laboratory gravure printing machine with water based ink suitable for polyolefins surface and foamed in a convection oven at 1 min 205° C. FIGS. 3A and 3B show that the composite sheet including the foamable layer with <0.1 GPa (FIG. 3A) exhibited good foaming that is comparable to PVC based foams used for wall cover (FIG. 3B).

example 3

[0077]The foamable layer consisted of:

Ethylene-octene copolymer, melt100 parts by weight flow index 17, modulus 0.06 GPaLDPE, melt flow index 10, modulus10 parts by weight0.32 GPaCalcium carbonate60 parts by weightAzodicarbonamide 5 parts by weightZinc oxide 1 parts by weight

[0078]The layer with 0.2 mm thickness was laminated to 0.1 mm non-woven material and foamed in a convection oven at 1 min 215° C. Afterwards, it was hot-embossed at about 140° C. FIGS. 4A and 4B show that the embossing structure of the composite sheet including the foamable layer with <0.1 GPa (FIG. 4A) was comparable to PVC-composite sheets (FIG. 4B).

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Abstract

A composite sheet and a manufacturing process for producing a decorative sheet using the composite sheet are provided. The composite sheet has a base layer and a foamable layer bonded to the base layer. The foamable layer includes 100 parts by weight of a polyolefin material having an elastic modulus of <0.1 GPa, 0.1-10 parts by weight of a foaming agent, and 0-200 parts by weight of additives. The foamable layer has a thickness of 0.05 to 0.3 mm.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation application of international patent application PCT / EP2015 / 050975, filed Jan. 20, 2015, designating the United States and claiming priority from European application 14158061.3, filed Mar. 6, 2014, and the entire content of both applications is incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention relates to a composite sheet for producing decorative sheets and to a corresponding manufacturing method of the decorative sheets.BACKGROUND OF THE INVENTION[0003]Decorative sheets having a composite sheet with a foamed plasticized polyvinyl chloride (PVC) layer on one side and paper or non-woven material on the other side are widely used today.[0004]One of the applications for these decorative sheets are wall covers. They are very popular due to their wear resistance, washability, and longevity as compared to natural paper based wallcoverings, as well as due to their low cost. The ...

Claims

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Application Information

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IPC IPC(8): B32B5/24C08J9/00C08K3/26D06N7/00B32B5/20D06N3/00D06N3/04C08J9/10C08K3/22
CPCB32B5/245D06N2211/063C08J9/0066C08K3/26C08K3/22B32B5/20D06N3/005D06N3/045D06N7/0002C08J2323/08C08J2203/04C08K2003/265C08K2003/2241D06N2203/042D06N2205/04C08J9/103C08J9/10D21H27/20D21H21/56C08J2323/02B32B27/12B32B29/007B32B2266/025C08J9/0004B32B5/022B32B5/024B32B27/065
Inventor ETIN, ALEKSEY
Owner JSC VEIKA
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