Patent GB-1390122-A (GB)
Title: Structured synthetic wall or floor covering and method for the production thereof
IPC: D06N7/00
Filed: 1972-03-16
Abstract: 1390122 Continuous moulding of textured sheets FORBO BETRIEBS AG 16 March 1972 [22 March 1971] 12294/72 Heading B5A [Also in Division B2] A wall or floor-covering having one surface textured comprises a discontinuous first layer forming the textured surface composed of cross-linked plastics possessing a Young's bending modulus of elasticity of 10,000- 30,000 kg./cm. and a continuous second layer formed of cross-linked plastics possessing a Young's bending modulus of elasticity of 3000-10,000 kg./cm., both layers being interconnected with one another by mutual crosslinking. An intermediate layer may be included between the first layer and second layer, the intermediate layer being formed of a crosslinked plastics having a Young's bending modulus of elasticity between that of the first layer and that of the second layer, the intermediate layer being interconnected by joint polymerization with the first layer and second layer by mutual cross-linking. The web may be produced by applying to a moulding band possessing depressions a first mass containing a hardenable polyester mixture in such quantity that only the depressions of the moulding band are filled, thereafter gelling and cooling the mass, applying to the gelled, cooled mass a second mass containing a hardenable polyester resin mixture, smoothing the second mass into a layer, and then hardening the entire unit at elevated temperature and removing it from the moulding band. A member may be embedded into the layer formed of this second mass prior to polymerization so that it is at most partially penetrated by such mass thereby forming a base layer. The base layer may be a fleece, paper, plastics foil, metal foil, cardboard, fabric, foamed material formed of polyurethane or polyvinyl chloride, glass fibres. The free surface of the base layer may be provided with an adhesive, e.g. a bitumen layer or a contact adhesive and the adhesive layer may be protected by a coating of siliconized paper. The hardenable polyester mixture may be a mixture of unsaturated polyester and a vinyl comonomer, e.g. styrene. The polyester may be modified by (1) addition of adipic acid and/or sebacic acid to the acidic component of the polyester, (2) addition of phthalic anhydride, (3) addition of a second cdmonomer, e.g. methyl methacrylate, (4) addition of a third comonomer with plasticizing properties, e.g. diallyl phthalate. As shown in Fig. 1, a plastisol-moulding layer 3 is applied to the surface of jute fabric 2 and having on its surface a thin plastisol-adhering polymerized layer. The moulding layer 3 is pre-gelled by heating device 6 so that the layer is still plastic, and a pattern impressed into the layer by moulding roller 7 having recesses 8. The resulting moulding band 10 is hardened in tunnel 11 at 180 C. and a hardenable polyester resin mixture cast thereon from device 13. The mass is levelled by doctor blade 14 so that only the depressions 15 of the band 10 are filled, gelled in heating tunnel 17, cooled and another hardenable polyester resin mixture poured on to the gelled layer from device 19. This mass is levelled by doctor blade 20 and the entire unit is polymerized in heating tunnel 22. Thereafter the finished web material 23 is lifted off the moulding band 10, while the band 10 is rolled up about roll 24. The products are used as linings or coverings for building structures.