Polyvinyl chloride resinous molded sheet product

Disclosed are polyvinyl chloride resinous compositions containing cellular fillers such as Silus Balloon and pearlite and molded products prepared by subjecting the compositions to heating at an increased pressure. The molded products may be combined with a core layer such as a non-woven fabric and a victria lawn, a foamed layer such as PVC paste resinous foam, a surface layer such as a non-foamed synthetic resin and molded into laminated sheet products. Those are made lighter and superior in soundproof and adiabatic effects, bending strength, dry touchness, water resistance, dimensional stability, cold resistance and the like so that structural materials such as floor coverings and the like are supplied more advantageously as compared with conventional ones.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a light composition of polyvinyl chloride 
resin and molded products thereof. More particularly, it relates to a 
polyvinyl chloride resinous composition comprising, as main ingredients, a 
polyvinyl chloride resin and a cellular filler and to molded products 
obtained by heating said composition at an increased pressure. 
2. Description of the Prior Art 
Polyvinyl chloride resins like vinyl chloride paste resins (hereinafter 
referred to as PVC resin) are normally in widespread use as a plastisol 
obtained by being mixed with a plasticizer, a stabilizer, pigments, 
fillers, diluents and the like, or as an organosol by being mixed with a 
plasticizer, a stabilizer, a solvent and the like. 
Conventionally, these PVC plastisol and organosol exhibit a specific 
gravity of 1.0 or more and an average specific gravity of about 1.2, when 
such a PVC resin with a specific gravity of about 1.4 and a plasticizer 
with a specific gravity ranging from about 0.9 to about 1.0 are used. 
In recent years such a plastisol and an organosol are widely used in a 
variety of fields including walls, floor and table coverings, book covers, 
decorative containers, upholsteries, automobile interiors, toys, leathers, 
sealants, sails, crown caps and the like. 
In the field of floor coverings, however, as backings for floor coverings, 
asbestos papers, or glass fibre non-woven fabrics impregnated or coated 
with a PVC paste sol, or non-woven fabrics of glass fibres or synthetic 
fibres such as polyester and nylon impregnated or coated with such as SBR 
and polyvinyl alcohol have been used. Among those, backings of asbestos 
papers exhibit an exceedingly high percentage but there are included 
numerous problems and deficiencies including public hazards and a danger 
to heath recently presented, peeling off at the time of re-covering, waste 
disposal of used floor coverings, and a fatal defect that when applied to 
the floor bending toward the inside at an angle greater than 90 degrees, 
backings are broken though the upper portions of floor coverings 
themselves can stand, to thereby decrease the commercial value dreadfully. 
Moreover the floor coverings themselves are water-proof, but the backings 
of asbestos papers are inferior in water-proof property with a result that 
a range of fields usable is unavoidably limited. In view of the foregoing 
numerous drawbacks, there is a strong need for floor coverings eliminating 
such drawbacks. 
Although, on the other hand, glass fibre or synthetic fibre non-woven 
fabrics, those coated or impregnated with a PVC plastisol, or those to 
which sheets of plasticized plastics having a thick tissue construction 
containing a filler in large quantities are joined as disclosed in the 
Japanese Patent Examined Publication No. 41848/1972 are, in fact, improved 
in many respects as compared with asbestos papers, the glass fibre 
non-woven fabrics expose glass fibre per se to thus adhere to workers and 
stab them in the skin while applied or transported. Further those are also 
weak in bending strength, to thus result in a decrease in commercial 
value. The backings such as those disclosed in the Japanese Patent 
Examined Publication No. 41848/1972 or non-woven fabrics coated or 
impregnated with a PVC plastisol, though improved in respects of stab in 
the skin, bending strength, peeling off and the like, still possess 
adhesiveness peculiar to the PVC plastisol and are heavy in weight, and 
accordingly difficult to handle especially at the time of transportation 
and application. Furthermore those coated or impregnated with the PVC 
plastisol have a difficulty in bonding when applied to the floor, and can 
only be applied by the selection of limited kinds of adhesives, which is a 
defect peculiar to a plasticized PVC resin. Eventually in some instances, 
those are applied to the floor by bonding thereto victria lawns and 
synthetic fibre non-woven fabrics and the like in order to improve such 
deficiencies. 
In an attempt to save the weight of the PVC sol, foaming processes, either 
by mechanical or by chemical, have been proposed. According to those 
processes, notwithstanding that lightening of molded products is assuredly 
achieved in the long run, compressive elasticity, tensile strength, tear 
strength and dimensional stability are drastically reduced, hence being 
not satisfactory in practical usefulness. 
SUMMARY OF THE INVENTION 
It is therefore an object of the present invention to provide a PVC 
resinous composition made light having superior properties, when molded 
into structural materials like backings for floor coverings. 
It is another object of the present invention to provide a PVC resinous 
molded product obtained by heating at an increased pressure said PVC 
resinous composition made light with superior properties. 
It is still another object of the present invention to provide a PVC 
resinous molded product free from public hazards caused by the use of 
asbestos, and improved in respects of peeling off upon re-covering as well 
as waste disposal. 
It is a further object of the present invention to provide a PVC resinous 
molded product which is convenient in handling and application and selects 
no specific adhesives. 
It is a still further object of the present invention to provide a PVC 
resinous molded product superior in flexibility, dimensional stability and 
water-proof property, free from a disagreeable adhesiveness. 
These and other objects of the present invention together with the 
advantages thereof will become apparent to those skilled in the art from 
the detailed disclosure of the present invention as set forth hereinbelow. 
The foregoing objects are accomplished by a polyvinyl chloride resinous 
composition comprising as main ingredients a PVC resin, and a cellular 
filler and molded products obtained by heating the same at an increased 
pressure.

DETAILED DESCRIPTION OF THE INVENTION 
The present invention is to primarily provide a polyvinyl chloride resinous 
composition comprising as main ingredients PVC resin and a cellular filler 
which has a specific gravity of about 0.01 to about 0.8, preferably about 
0.1 to about 0.5 and an average size of about 1.0 to about 2000.mu., 
preferably about 1.0 to about 600.mu.. To this blending, plasticizers, 
stabilizers, and further pigments, dyes and active surface agents, if 
necessary, are added and mixed uniformly by dry-blending, to thereby 
provide a light compound. 
Where a cellular filler has been heretofore added to a paste sol compound, 
it is difficult to provide a plastisol since absorption of the plasticizer 
is vigorous because of the cellular filler being broken into the mixture, 
and when it is intended to daringly produce a sol a great amount of 
solvents has to be used. Still worse, the cellular filler added to make 
the compound light is broken out so that the desired purpose cannot be 
attained with a result that the specific gravity of the compound becomes 
approximately 1.2 times of that of a normal plastisol. 
A series of studies have been made from extensive and various points, apart 
from a conventional PVC paste sol, by the present inventors, and have 
found that a polyvinyl chloride resinous composition made light, having a 
freeflow property in a state of powder and suitable for the molding by 
heating at an increase pressure can be obtained by dry-blending a PVC 
resin, a plasticizer, a stabilizer and a cellular filler to provide 
uniform blending of the foregoings, without causing destruction of the 
cellular filler. 
The PVC resin used in the present invention comprises polymers of vinyl 
chloride and copolymers of vinyl chloride and at least one of other 
monomers copolymerizable therewith which are selected from the group 
consisting of vinyl esters such as vinyl acetate and vinyl propionate, 
acrylic or methacrylic esters, and olefinic monomers such as ethylene and 
propylene, having an average particle size ranging from about 0.2 to about 
200.mu.. Among those, PVC paste resin with particle size ranging from 0.2 
to 50.mu. is favourably employed as a main ingredient attributed from the 
excellent forming properties of the dry-blended composition when subjected 
to heat and pressure. Of course, PVC resins with particle size more than 
50.mu. can be mixed therewith to the extent that forming under heat and 
pressure is feasible. Within the scope of the present invention to give 
preferable dry-blended composition subjected to molding, the present 
invention may further include the cases where, in addition to PVC resin, 
an olefinic polymer such as polyethylene and polypropylene, an acrylic 
polymer such as polymethyl methacrylate and polybutyl acrylate, a 
rubber-like substance such as NBR and SBR, a polymer comprising 
acrylonitrile as a major ingredient, a vinyl polymer such as vinyl 
fluoride and vinyl bromide, a thermoplastic elastomer such as a copolymer 
of ethylene and vinyl acetate and the like are mixed to provide a PVC 
resinous composition. 
The cellular filler used in the present invention may include, as inorganic 
materials, "Alumina Babble" (trademark, produced by Showa Denko K.K.), 
"Kernamite" (English name is not known, produced by J. D. Mclaughlin), 
"Senospheres" (English name is not known, produced by A. A. Johnson), 
"Silus Balloon" (trademark, Kyushu Kogyo Shikenjo), "Silica Balloon" 
(trademark, produced by Shikoku Kaken K.K.), "Dia Balloon" (trademark, 
produced by Japan Metals & Chemicals Co., Ltd.), "Microballoon" 
(trademark, produced by Emerson and Cuming), pearlite and the like, which 
are made of alumina, shale, fly ash, silus, silica sand, volcanic rock, 
sodium silicate, borax, pearlite, obsidian and the like. 
As the organic cellular filler, on the other hand, there may be included 
"Phenolic Microballoon" (trademark, produced by U.C.C.), "Salan 
Microspheres" (trademark, produced by Dow Chemical), "Eccospheres EP" and 
"Eccospheres VF-0" (trademarks, produced by Emerson & Cuming) and the 
like, which are made of phenolic resin, polyvinyliden chloride, epoxy 
resin and urea resin. There may be further included cellular fillers made 
of sinters of "Phenolic Microballoon", pitches and the like such as "Carbo 
Spheres" (trademark, produced by General Technology), "Kureca Spheres" 
(English name and a manufacturer are not known). 
Among the foregoing cellular fillers, inorganic cellular fillers are 
preferred to use in the present invention, especially "Silus Balloon", 
"Dia Balloon", "Microballoon" and pearlite are more preferred. These are 
employed singly or in combination of two or more. To the PVC resinous 
composition containing the cellular fillers, other normal fillers may 
further be added, for instance, enhancing the strength of the molded 
products by adding, for example, glass fibre, asbestos or the like. 
The plasticizer used in the present invention may include plasticizers 
generally used in polyvinyl chloride such as esters of phthalic acid, 
esters of fatty acid, esters of phosphoric acid, polyester plasticizers, 
epoxy plasticizers, chlorinated paraffins and the like. An amount used of 
the plasticizer is in a range of from about 20 to about 100 parts by 
weight, more preferably about 40 to about 80 parts by weight per 100 parts 
by weight of the PVC resin. 
Dry-blending of the ingredients is carried out at a temperature from room 
temperature to about 100.degree. C., more preferably about 50.degree. to 
80.degree. C. by the use of a suitable blending machine such as a Henshel 
mixer, a "Super Mixer" (trademark, produced by Kawata Seisakusho), a 
ribbon blender and the like. The PVC resinous compositions obtained by 
dry-blending according to the present invention possess superior powder 
properties suitable for powder molding, especially a moderate free-flow 
property. 
As stated earlier, the present invention is characterized by dry-blending a 
PVC resin and a cellular filler so that even a PVC paste resin containing 
a small particle size of about 1.mu. is possible to be dry-blended, thus 
permitting the use of a wide range of an average particle size of from 
about 0.2 to about 50.mu.. 
As apparent from the foregoing, PVC resinous compositions of the present 
invention which are made light and have a free-flow property exhibit 
unique properties that have never been obtained by a conventional 
plastisol or organosol, by far superior in particular in powder molding, 
and accordingly those are in a wide use in various fields including, for 
example, floor coverings, walls, automobile parts, toys, sealants and 
sails, as set forth above. 
Those compositions thus obtained exhibiting a superior free-flow property 
in a state of powder may be heated at an increased pressure to be formed 
into a sheet, by the use of which as a basis of structural materials a 
variety of molded products are supplied. 
The so obtained PVC sheet is used solely with its surface processed as, for 
instance, a floor covering, but is also used as a laminated product by 
combining the sheet with a core layer such as victoria lawns, glass fibre 
or synthetic fibre non-woven fabrics, a foamed layer and a surface layer 
(skin layer). When the foregoing molded products are used as, for 
instance, a floor covering backing, not only is the backing made light 
drastically, but peeling off upon re-covering and bending strength can be 
markedly improved to such a degree to enable folding covering. In 
addition, the covering of the present invention does not select the kind 
of adhesives when applied to a floor and is superior in a water-proof 
property so that it is possible to apply it to watery places. Moreover it 
is free from a disagreeable adhesiveness peculiar to a plasticized vinyl 
product containing a great amount of plasticizers and superior in dry 
touchness, besides possessing characteristics conventional backings have. 
Incidentally, the properties of the floor covering of the present invention 
are compared with those of the floor covering (plasticized plastic layer 
of a thick tissue) disclosed in the Japanese Examined Publication No. 
41848/1972 and the obtained results are given in Table 1. 
TABLE 1 
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Floor Covering 
Japanese Patent 
of the Examined Publication 
Performances 
Present Invention 
No. 41848/1972 
______________________________________ 
Specific gravity 
1 &gt; (0.5.about.0.8) 
1 &lt; (1.25.about.1.8) 
Weight Light Heavy 
Touchness Dry touch Wet and adhesive 
Bonding when 
No selection of 
Only adhesives 
applied adhesives for plasticized 
vinyls 
Handling Easy Difficult in 
transportation 
Soundproof effect 
Good Not good 
Adiabatic effect 
Good Not good 
______________________________________ 
It is understood from Table 1 that the floor covering of the present 
invention is superior in all performances to that of the Japanese Patent 
Examined Publication No. 41848/1972. 
According to the present invention, as apparent from the foregoing, various 
floor coverings are provided which were made light, superior in 
flexibility, bending strength, dimensional stability, water resistance 
property and further improved in adhesiveness peculiar to plasticized 
plastics by blending PVC paste resin, a cellular filler, a plasticizer and 
a thermal stabilizer, furthermore, if necessary, pigments, dyes, diluents, 
surface active agents and the like, then optionally combining the 
resulting blend with a core layer such as victria lawns and non-woven 
fabrics, a non-foamed layer such as a transparent PVC paste sol or a 
plasticized plastic film, a foamed layer and the like, to thereby form 
those into a sheet product. 
An example is a molded sheet product which comprises a sheet product 2 
obtained by subjecting a resinous composition of the present invention to 
heating at an increased pressure and a core layer 1 embedded in said sheet 
product, comprising such as a glass fibre non-woven fabric, a synthetic 
fibre non-woven fabric or a victoria lawn. 
Another example is a molded sheet product which comprises the core layer 1 
comprising such as a glass fibre non-woven fabric, a synthetic fibre 
non-woven fabric or a victoria lawn is provided on the one or both sides 
of said sheet product 2. 
A third example is a molded sheet product in which on the one side of said 
sheet product 2 the core layer 1 comprising such as a glass fibre 
non-woven fabric, a synthetic fibre non-woven fabric and a victoria lawn 
is provided, and on the other side a surface layer 3 comprising such as a 
non-foamed synthetic resinous layer is provided. 
A fourth example is a molded sheet product in which on said sheet product 2 
the core layer 1 comprising such as a glass fibre non-woven fabric, a 
synthetic fibre non-woven fabric and a victria lawn is provided, and on 
the core layer is further provided the surface layer 3 comprising such as 
a non-foamed synthetic resinous layer. 
A fifth example is a molded sheet product in which on said sheet product 2 
the core layer 1 comprising such as a glass fibre non-woven fabric, a 
synthetic fibre non-woven fabric and a victoria lawn is provided, on the 
core layer a foamed layer 4 comprising polyvinyl chloride paste resinous 
foam is provided, and on the foamed layer 4 the surface layer 3 comprising 
such as a non-foamed synthetic resinous layer is further provided. 
A sixth example is a molded sheet product in which on the core layer 1 
comprising such as a glass fibre non-woven fabric, a synthetic fibre 
non-woven fabric and a victoria lawn, said sheet product 2 is provided, on 
the sheet product 2 the foamed layer 4 comprising such as polyvinyl 
chloride paste resinous foam is provided, and on the foamed layer 4 is 
further provided the surface layer 3 comprising such as a non-foamed 
synthetic resin. 
A seventh example is a molded sheet product in which on the core layer 1 
comprising such as a glass fibre non-woven fabric, a synthetic fibre 
non-woven fabric and a victoria lawn, said sheet product 2 is provided, on 
the both sides of the obtained composite, foamed layers 4 are provided 
respectively, furthermore, on the foamed layer 4 in contact with said 
sheet product 2 is provided the surface layer 3 comprising such as a 
non-foamed synthetic resin. 
A eighth example is a molded sheet product in which under the core layer 1 
comprising such as a glass fibre non-woven fabric, a synthetic fibre 
non-woven fabric and a victoria lawn, said sheet product 2 is provided, on 
the both sides of the resulting composite, foamed layers 4 are provided 
respectively, on the foamed layer 4 in contact with the core layer 1 is 
further provided the surface layer 3 comprising such as a non-foamed 
synthetic resin. 
In the molded sheet products of the present invention, said sheet product 
has desirably the thickness of about 0.1 to about 5 mm, more desirably 
about 0.3 to about 3 mm, though not prevented to have the thickness 
exceeding the above range. 
As the core layer used in the present invention, non-woven fabrics such as 
a glass fibre or a synthetic fibre, and a victoria lawn are used which 
have superior dimensional stability, among which the victoria lawn is 
preferred to use. The core layer should desirably have a density ranging 
from about 30 to about 200 g/m.sup.2. 
As the surface layer (skin layer) used in the present invention, a 
non-foamed synthetic resinous layer is preferred to use, which is produced 
by providing a non-foamed PVC sol layer, then molding it by heating, or by 
heat fusing or bonding a soft plastic film such as a PVC sheet, a 
polyethylene film and the like. The thickness of the surface layer is 
preferable in a range of from about 0.1 to about 2.0 mm, more preferable 
about 0.2 to about 0.5 mm. 
The foamed layer is produced by, for example, coating of a PVC plastisol 
containing a blowing agent such as azodicarbonamide and oxybissulfonyl 
hydrazide, then allowing it to foam and gel by heating. The degree of 
foaming is preferable in a range of from about 2.5 to about 4 times of the 
original volume (the density of the foamed layer is approximately in a 
range of from about 0.3 to about 0.5). The thickness of the foamed layer 
is optionally selected from a range of from about 0.3 to about 2 mm, more 
preferably, about 0.7 to about 1.5 mm. Moreover the foamed layer may also 
be prepared by the coating of a mechanically foamable sol, not limited to 
a process using chemical blowing agents. 
Hereinafter the present invention will be described in more detail by way 
of examples that follow, to which examples the present invention is not 
limited. 
EXAMPLE 1 
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PVC paste resin (-p = 800, Average 
100 parts by weight 
particle size: 1.mu.) 
D.O.P. 40 
Silus Balloon (Apparent specific gravity: 
50 
0.14.about.0.32) (SANKILITE-Y) (produced 
by Sanki Kogyo K.K.) 
Stabilizer (Ca--Zn) 8 
______________________________________ 
The foregoing composition was dry-blended by the use of a domestic juicer 
mixer to obtain a compound. The obtained compound had an apparent specific 
gravity of 0.53 and was superior in powder properties, especially in a 
free-flow property. 
EXAMPLE 2 
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PVC paste resin (VAc-Vcl copolymer, 
100 parts by weight 
-p = 1200, Average Particle size: 1.mu.) 
D.O.P. 50 
Silus Balloon (SANKILITE-Y) 
100 
Stabilizer (Ca--Zn) 3 
______________________________________ 
The foregoing composition was subjected to dry-blending in a similar 
fashion to that of Example 1, preparing a compound. An apparent specific 
gravity of the compound was 0.40 and exhibited a good free-flow property. 
COMATIVE EXAMPLE 1 
______________________________________ 
PVC paste resin (Vcl homopolymer, -p = 
100 parts by weight 
1700, Average particle size: 1.mu.) 
D.O.P. 60 
Silus Balloon (SANKILITE-Y) 
50 
Stabilizer (Ca--Zn) 3 
Diluent (Mineral turpentine) 
10 
______________________________________ 
The composition as aforesaid was blended by the use of an Ishikawa style 
grinder. As a result, Silus Balloon was broken out and thus liquid 
ingredients were absorbed, thereby a/paste-like compound with a very high 
viscosity being prepared. The resulting compound had a specific gravity of 
1.1, exhibited no fluidity and thus could not be used practically. 
EXAMPLE 3 
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PVC paste resin (Vcl homopolymer, -p = 
100 parts by weight 
1700, Average particle size: 3.mu.) 
T.C.P. (Tricresyl phosphate) 
55 
NB-20 (DOP containing 20% of NBR) 
10 
Silus Balloon (SANKILITE-Y) 
100 
Stabilizer (Ba--Zn) 3 
______________________________________ 
By using a Henshel style mixer the foregoing composition was dry-blended to 
prepare a compound. The resultant compound showed an apparent specific 
gravity of 0.45 and satisfactory powder properties including a free-flow 
property. 
EXAMPLE 4 
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PVC (Vcl homopolymer, Average 
100 parts by weight 
particle size: 30.mu.) 
DOP 50 
Pearlite (Apparent specific gravity: 
50 
0.04.about.0.2, Average particle size: 150.mu., 
produced by Mitui Mining & Smelting 
Co., Ltd.) 
Stabilizer (Ba--Zn) 3 
______________________________________ 
The above composition was subjected to dry-blending using a Henshel mixer 
to obtain a compound, which showed an apparent specific gravity of 0.52 
and good powder properties. 
EXAMPLE 5 
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PBM-11 (Vcl-VAc copolymer, -p = 1000, 
100 parts by weight 
Average particle size: 50.mu.) (produced by 
Kanegafuchi Chem. Ind. Co., Ltd.) 
D.O.P. 40 
Silus Balloon (SANKILITE-Y) 
50 
Stabilizer 3 
______________________________________ 
By dry-blending of the foregoing composition by the use of a Henshel style 
mixer, a compound was produced which had an apparent specific gravity of 
0.50 and was superior in powder properties. 
EXAMPLE 6 
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PVC (Vcl homopolymer, Average particle 
50 parts by weight 
size: 30.mu.) 
PVC (Vcl-VAc copolymer, -p = 800, 
50 
Average particle size: 120.mu.) 
D.O.P. 50 
Silus Balloon (SANKILITE-Y) 
50 
Stabilizer 3 
______________________________________ 
The foregoing composition was dry-blended by a Henshel mixer to thus 
prepare a compound. The obtained compound exhibited an apparent specific 
gravity of 0.52 and good powder properties. 
EXAMPLE 7 
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PBM-11 (Vcl-VAc copolymer, -p = 1000, 
50 parts by weight 
Average particle size: 50.mu.) 
PVC (Vcl-VAc copolymer, -p = 800, 
50 
Average particle size: 120.mu.) 
Silus Balloon (SANKILITE-Y) 
50 
Stabilizer 3 
______________________________________ 
By dry-blending the composition as aforesaid a compound was provided, an 
apparent specific gravity of which was 0.52, exhibiting superior powder 
properties. 
EXAMPLE 8 
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PCH-12 (Vcl-VAc copolymer, -p = 1400, 
100 parts by weight 
Average particle size: 1.mu.) (produced by 
Kanegafuchi Chem. Ind. Co., Ltd.) 
DOP 50 
Silus Balloon (SANKILITE-Y) 
100 
Stabilizer (Ca--Zn) 3 
______________________________________ 
The foregoing compound was dry-blended by the use of a Henshel style mixer 
to obtain a compound having a superior free-flow property. The compound 
thus obtained was applied by powder coating to a release paper in a 
thickness of about 0.7 mm and subjected to the treatment for 2 minutes at 
190.degree. C. under a pressure of 15 Kg/cm.sup.2. As such, a very light 
sheet product with a specific gravity of 0.7, superior in dry touchness 
and flexibility was provided. The sheet product had tensile strength of 15 
Kg/cm.sup.2 and elongation of 90%. 
EXAMPLE 9 
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PSH-10 (Vcl homopolymer, -p = 1700, 
100 parts by weight 
Average particle size: 1.mu.) (produced by 
Kanegafuchi Chem. Ind. Co., Ltd.) 
TCP (Tricresyl phosphate) 
55 
Pearlite (Apparent specific gravity: 
100 
0.4.about.0.2, Average particle size: 150.mu.) 
(produced by Mitsui Mining and Smelting 
Co., Ltd.) 
Stabilizer (Ba--Zn) 3 
______________________________________ 
The compound as aforesaid was dry-blended in a similar fashion to that of 
Example 8, thus preparing a compound with a good free-flow property. The 
powder coating of the obtained compound was uniformly made on a ferro type 
plate in a thickness of 0.6 mm, on the surface of which a glass fibre 
non-woven fabric was heaped up, then being subjected to the treatment for 
5 minutes at 180.degree. C. under a pressure of 10 Kg/cm.sup.2. The so 
obtained sheet product had a specific gravity of 0.65, being superior in 
dry touchness, flexibility and lightness. The glass fibre non-woven fabric 
was perfectly united to the compound, having an adequate bonding strength, 
and accordingly being useful as a floor covering backing. The sheet 
product exhibited tensile strength of 150 Kg/cm.sup.2 and elongation of 
5%. 
EXAMPLE 10 
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PSL-6 (Vcl homopolymer, -p = 1000, 
70 parts by weight 
Average particle size: 1.mu.) (produced by 
Kanegafuchi Chemical Ind. Co., Ltd.) 
PBM-11 (Vcl-VAc copolymer, -p = 1100, 
30 
Average particle size: 50.mu.) (produced by 
the foregoing company) 
Chlorinated paraffin (containing 45% of 
60 
chlorine) 
Dia Balloon (Apparent specific gravity: 
50 
0.12.about.0.15, Average particle size: 180.mu.) 
(produced by Japan Metals & Chemicals 
Co., Ltd.) 
Microballoon (Apparent specific gravity: 
50 
0.16.about.0.2, Average particle size: 10.mu.) 
(produced by Emerson & Cuming) 
Stabilizer (Barium stearate) 
5 
______________________________________ 
The above composition was subjected to dry-blending in a similar manner to 
that of Example 8 to thus obtain a compound superior in a free-flow 
property. On a victoria lawn located on a ferro type plate the compound 
was applied, then heated at 190.degree. C. at a pressure of 10 Kg/cm.sup.2 
for 4 minutes to provide a sheet product. The so obtained sheet product 
had a specific gravity of 0.68 and was superior in lightness, dry 
touchness and flexibility. Bonding force of the compound and the victoria 
lawn was sufficient and the sheet product showed tensile strength of 100 
Kg/cm.sup.2 and elongation of 4%. Besides those, tear strength was also 
satisfactory for use as a floor covering backing. 
COMATIVE EXAMPLE 2 
______________________________________ 
PSH-10 (Vcl homopolymer, -p = 1700, 
100 parts by weight 
Average particle size: 1.mu.) 
DOP 100 
Calcium carbonate (Average particle size: 
150 
2.1.mu.) 
Stabilizer (Ba--Zn) 3 
______________________________________ 
The aforesaid composition was blended by Ishikawa style grinder to provide 
a plastisol. The obtained plastisol was applied by coating onto a glass 
fibre non-woven fabric in a thickness of 0.5 mm and subjected to gellation 
for 5 minutes at 200.degree. C. The same product as described in the 
Japanese Patent Examined Publication No. 41848/1972 was produced. The 
product possessed a specific gravity of 1.6 and was satisfactory in 
flexibility, tensile strength and tear strength in use for a floor 
covering backing. Notwithstanding, the product exhibited strong 
adhesiveness because of high content of a plasticizer and was very heavy 
owing to thick tissue of the coated plastisol, which was basically 
different in performances from backings of the present invention. 
EXAMPLE 11 
As illustrated in FIG. 1, the same composition as used in Example 8 was 
applied by powder coating onto a release paper or a steel belt, into which 
coating layer a core layer is inserted, thereby those being heated at an 
increased pressure to be formed into a laminated sheet product comprising 
a sheet 2 of the composition and the core layer 1. 
EXAMPLE 12 
FIG. 2 depicts a laminated sheet product produced by providing the core 
layer 1 on one side of said sheet 2 and forming those into a sheet, as 
described in detail in Example 9. 
EXAMPLE 13 
As shown in FIG. 3, on the core layer 1 said sheet 2 was formed, and on 
which sheet a surface layer 3 comprising a non-foamed synthetic resin was 
further formed. 
This sheet product is prepared by, for example, conducting powder coating 
of said composition onto the release paper or the steel belt, providing 
the core layer 1 on said composition, then forming those into a laminated 
sheet by heating at an increased pressure. The obtained laminated sheet is 
removed from the release paper or the steel belt and on said sheet 2 the 
non-foamed PVC sol layer is further provided and molded thermally, or a 
soft plastic film such as a PVC sheet, a polyethylene film and the like is 
fused by heating or bonded by adhesives, as the surface layer 3. 
EXAMPLE 14 
FIG. 4 shows a laminated sheet product in which on said sheet 2 the core 
layer 1 was provided, and on the core layer the surface layer 3 comprising 
a non-foamed synthetic resin was further formed. 
This laminated sheet product is obtained, for example, in the same manner 
as in Example 13, by powder coating of said composition onto the release 
paper or the steel belt, providing the core layer 1 on the powder coating, 
heating those at an increased pressure to form into a laminated sheet. 
Thereafter the laminated sheet is removed from the release paper or the 
steel belt, on the core layer 1 the non-foamed PVC sol layer is formed 
thermally, otherwise soft plastic film such as a PVC sheet, a polyethylene 
film and the like are fused by heating or bonded by adhesives. 
The sheet products thus obtained are not only superior in heat resistance 
and dimensional stability as compared with conventional ones using 
chemically foamed products as an intermediate layer, but very useful in 
use as a floor covering since the greatest defect of the conventional 
floor coverings that those are heavy is solved. Furthermore, because of 
resinous compositions made light being used as an intermediate layer, the 
intermediate layer per se has also rigidity, especially superior in 
abrasion resistance and heat resistance so that it is not only applicable 
to use for coverings requiring abrasion resistance, but manufacturing 
process is simplified to thus decrease the cost of products and to supply 
cheaper floor coverings. The floor coverings of the present invention, as 
mentioned earlier, employ no asbestos papers, in consequence, free of 
harmful damages to health and environments. 
Hereinbelow, the performances of the present coverings are tabulated in 
Table 2 in comparison with those commercially available. 
TABLE 2 
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Floor coverings 
Chemical 
Present embossed Compact* 
Performances invention foam type type 
______________________________________ 
Weight Light Light Heavy 
Abrasion resistance 
Good Bad Better 
Cigarette resistance** 
Good Worse Better 
Bending strength 
Better Not good Not good 
Soundproof effect 
Normal Normal Normal 
Cost Normal Economical 
Expensive 
______________________________________ 
*Coverings which especially require superior abrasion resistance. 
**Resistance against burning when a cigarette was dropped on the floor 
covering. 
As can be understood from the results of Table 2, the present floor 
coverings are not only made lighter, superior in cigarette resistance and 
abrasion resistance, but are provided with functions satisfying bending 
strength and water resistance, as compared with conventional coverings. 
EXAMPLE 15 
______________________________________ 
PCH-12 (Vcl-VAc copolymer, -p = 1400, 
70 parts by weight 
Average particle size: 1.mu.) 
PBM-10 (Vcl homopolymer, -p = 1000, 
30 
Average particle size: 25.mu.) 
TCP (Tricresyl phosphate) 
70 
Silus Balloon (SANKILITE-Y02) 
100 
Stabilizer (Barium stearate) 
3 
______________________________________ 
The foregoing composition was dry-blended by a Henshel style mixer to thus 
obtain a compound with good fluidity as powder. The compound was then 
applied by powder coating onto a steel plate treated with 
polytetrafluoroethylene in a thickness of 0.5 mm and on the powder coating 
a glass fibre non-woven fabric was provided in a density of 50 g/m.sup.2, 
then those being subjected to the treatment for 2 minutes at 190.degree. 
C. under a pressure of 15 Kg/cm.sup.2. In the following way a floor 
coverng was made while using the obtained laminated sheet as a backing. 
(Foamed sol composition) 
______________________________________ 
PSL-10 (Vcl homopolymer, -p = 1000, 
100 parts by weight 
Average particle size; 1.mu.) 
PBM-10 (Vcl homopolymer, -P = 1000, 
50 
Average particle size: 25.mu.) 
DOP 50 
Secondary plasticizer (alkylbenzene) 
5 
Blowing agent (azodicarbonamide) 
3 
TiO.sub.2 2 
Blowing assistant (ZnO) 
1 
______________________________________ 
(Non-foamed sol composition) 
______________________________________ 
PSH-10 (Vcl homopolymer, -p = 1700, 
70 parts by weight 
Average particle size: 1.mu.) 
PBM-B3 (Vcl homopolymer, -p = 1000, 
30 
Average particle size: 30.mu.) 
DOP 45 
TXIB (Texanol isobutylate) 
5 
Stabilizer (AC-118, produced by Adeka 
3 
Argus Chem. Co., Ltd.) 
______________________________________ 
The foregoing compositions were blended and deaerated by an Ishikawa style 
grinder to thus obtain a foamed sol and a non-foamed sol, respectively. 
On the side of the non-woven fabric of the backing the foregoing foamed sol 
is applied in a thickness of 0.3 mm and subjected to preliminary gellation 
at 170.degree. C. for 2 minutes to provide a foamed layer. On the foamed 
layer the foregoing non-foamed sol was applied in a thickness of 0.2 mm 
and then subjected to preliminary gellatin at 170.degree. C. for 2 minutes 
to thus form a surface layer (skin layer). 
After measurement of the thickness of the preliminarily gelled layer, 
foaming was continued at 210.degree. C. for 2 minutes. The foaming degree 
of the foamed layers was about 3.5 times and a light floor covering was 
produced. The obtained floor covering had a specific gravity of 0.75 and 
was superior in flexibility and dry touchness. 
COMATIVE EXAMPLE 3 
In accordance with a process disclosed in the Japanese Patent Examined 
Publication No. 41848/1972, a backing was prepared with a composition 
stated below. 
______________________________________ 
PSH-10 (PVC homopolymer, -p = 1700, 
100 parts by weight 
Average particle size: 1.mu.) 
DOP 100 
CaCO.sub.3 (average particle size: 2.1.mu. ) 
150 
Stabilizer (Ca--Zn) 3 
______________________________________ 
A plastisol was obtained by blending the foregoing composition by an 
Ishikawa style grinder. The plastisol so obtained was applied onto a glass 
fibre non-woven fabric in a density of 50 g/m.sup.2 in a thickness of 0.5 
mm, then subjected to the treatment at 200.degree. C. for 5 minutes. The 
laminated sheet so obtained was the same as that described in said 
publication and possible to serve as a backing. 
On the surface of the non-woven fabric the foamed sol and the non-foamed 
sol described in Example 15 were applied, then subjected to gellation and 
foaming in the same way as in Example 15, thus a floor covering being 
provided. The foaming degree was 3.5 times and superior in uniformity of 
cells. The floor covering had a specific gravity of 1.55, very heavy and 
adhesive in the surface of the backing, though superior in flexibility, at 
which points it differed essentially from that obtained in Example 15. 
The floor coverings obtained in Example 15 and Comparative Example 3 were 
compared and the results are shown in Table 3. 
TABLE 3 
______________________________________ 
Floor covering 
Japanese Patent 
Present Examined Publica- 
Performances invention tion No. 41848/1972 
______________________________________ 
Specific gravity 
0.75 1.55 
Weight Light Very heavy 
Strength Superior Superior 
Touchness Dry Wet, adhesive 
Adhesives Free choice 
Only adhesives 
for soft vinyls 
Soundproof effect 
Superior Normal 
Adiabatic effect 
Superior Normal 
______________________________________ 
As is apparent from the above comparison, the composition and molded 
product of the present invention, when used in a floor covering, produce 
an outstanding effect of making it lighter than the conventional 
coverings, for instance, if compared with those revealed in the Japanese 
Patent Examined Publication No. 41848/1972, can be reduced to a half or 
below in weight. (The specific gravity of the present floor coverings 
ranges from about 0.5 to about 0.8). Moreover, those are by far superior 
in respects of soundproof effect, adiabatic effect, bending strength, dry 
touchness, water resistance, dimensional stability, cold resistance and 
the like so that the present invention is capable of supplying floor 
coverings more advantageously as compared with the conventional ones.