Patent GB-650784-A (GB)
Title: Improvements in or relating to plastic films and process for producing same
IPC: B44C1/20
Filed: 1947-07-30
Abstract: <PICT:0650784/IV (a)/1> A layer of an organosol comprising a vinyl resin and a dispersant is formed upon a supporting surface and a swelling agent is applied to at least part of the surface of the layer at such a stage in the setting thereof as to produce undulations in the film which is formed.  The film layer is dried and is then stripped from the support or is allowed to remain thereon as a coating or as a component of a compound sheet material.  The vinyl resin may be a copolymer of vinyl acetate and vinyl chloride.  The dispersant is a liquid or mixture of liquids which has an affinity for the resin and has a plasticizing effect during the film-forming process.  Diluents may also be present in the organosol.  The film may be made from an organosol comprising vinyl acetate-vinyl chloride copolymer, dioctyl phthalate, an aliphatic hydrocarbon mixture, and xylol or other aromatic hydrocarbon.  The proportion of plasticizer to resin is preferably greater than 0.15 to 1 and preferably less than 1.1 to 1.0.  As temporary support or carrier there may be used a paper sheet, belt, or web, with a coating of polyvinyl alcohol or other resin, or casein, or instead of paper there may be used a sheet of a cellulose derivative, asbestos paper, metal foil, or glass fibre.  A coating comprising a mixture of an alkyd resin and a melamine-formaldehyde resin may be used for forming a smooth supporting surface.  As shown, a coated paper web 10 is taken from roll 11 and is led past a coating roller 13 which applies a layer of a vinyl resin organosol to the web.  The margins of the web 10 may be left uncoated.  The web passes across table 18 which is heated by steam.  Alternatively it could be passed through an oven or could be subjected to infra-red radiation or a high-frequency electromagnetic field.  Swelling agent is applied to the surface of the vinyl resin layer by passing the carrier with the layer through trough 22.  The swelling agent may be acetone, methyl ethyl ketone, or cyclohexanone. The surface of the film becomes undulated as a result of this treatment.  The web 10 carries the film past a jet of air from pipe 23 to remove excess of swelling agent and then through oven 26 which has a drying section 26a and a section 26b where the film is brought to fusion point so as to unite the resin particles into a continuous film.  The film is then stripped and wound-up on reel 27, the web 10 being wound-up on reel 29.  If swelling agent is applied also to the carrier web before application of the vinyl resin organosol, the film may be undulated on both surfaces.  The undulating effect is increased if the swelling agent contains dissolved vinyl resin. Colouring matter may be added to the swelling agent or to the vinyl resin organosol, or to both.  The vinyl resin organosol can be brought into the necessary condition for undulations to be formed on application of the swelling agent, by adjusting the temperature of the layer and time of exposure to that temperature prior to application of the swelling agent, or by adjusting the proportions of the components of the organosol.  A practical test for determining whether the conditions are such that undulations will be formed is given.  A smooth pine-wood block of stated dimensions is laid on the organosol layer and pushed in a direction parallel to the supporting web.  If the block just slightly tears or ruptures the film surface, the layer is in the proper condition for undulations to be formed on application of the swelling agent. If the resinous organosol layer is formed so that it has regions of different thicknesses, application of the swelling agent may result in undulations in the thicker regions while the surface in the thinner regions remains smooth and flat.  A layer of varying thickness may be formed by using a coating roller which is engraved, e.g. in the form of a pattern. Alternatively, vinyl resin composition may be applied to the carrier, the conditions being such that a smooth film is formed, and after this film has been dried, vinyl resin organosol is applied in the form of a pattern, and swelling agent is applied so that the pattern layer becomes undulated.  The film with the pattern layer is then stripped.  In making the undulated film, the swelling agent may be applied irregularly, e.g. by spraying droplets or by allowing it to flow in a number of small streams over the vinyl resin organosol. Fluorescent or phosphorescent materials such as Rhodamine B, calcium sulphide, strontium sulphide, or zinc sulphide, may be added to the organosol or to the swelling agent. Metallic flakes such as aluminium flakes may be added and these flakes may have been tinted with dyes. If desired, the action of the swelling agent may be allowed to proceed to such an extent that the film besides having very pronounced undulations is actually perforated at many points and is thus rendered porous.