US 11,850,774 B2
Method for producing an extruded sheet
Thomas Grafenauer, Lichtenau (AT)
Assigned to FLOORING INDUSTRIES LIMITED, SARL, Bertrange (LU)
Appl. No. 16/759,041
Filed by FLOORING INDUSTRIES LIMITED, SARL, Bertrange (LU)
PCT Filed Nov. 1, 2018, PCT No. PCT/EP2018/079920
§ 371(c)(1), (2) Date Apr. 24, 2020,
PCT Pub. No. WO2019/086566, PCT Pub. Date May 9, 2019.
Claims priority of application No. 10 2017 125 743.8 (DE), filed on Nov. 3, 2017.
Prior Publication US 2020/0331166 A1, Oct. 22, 2020
Int. Cl. B29C 43/24 (2006.01); B29C 48/00 (2019.01); B29C 48/285 (2019.01); B29C 48/07 (2019.01); B29C 48/797 (2019.01); B29B 7/00 (2006.01); B29B 7/82 (2006.01); B29B 7/90 (2006.01); C08J 3/20 (2006.01); C08J 7/04 (2020.01); C08K 3/26 (2006.01); C09D 125/06 (2006.01); E04F 15/10 (2006.01); C08J 7/043 (2020.01); C08J 7/046 (2020.01); B29K 27/06 (2006.01); B29K 105/00 (2006.01); B29K 105/16 (2006.01); B29K 491/00 (2006.01); B29K 509/00 (2006.01); B29L 7/00 (2006.01); B29L 31/00 (2006.01); C08K 5/098 (2006.01)
CPC B29C 43/24 (2013.01) [B29B 7/007 (2013.01); B29B 7/823 (2013.01); B29B 7/90 (2013.01); B29C 48/0011 (2019.02); B29C 48/0022 (2019.02); B29C 48/07 (2019.02); B29C 48/287 (2019.02); B29C 48/797 (2019.02); C08J 3/203 (2013.01); C08J 7/042 (2013.01); C08J 7/043 (2020.01); C08J 7/046 (2020.01); C08K 3/26 (2013.01); C09D 125/06 (2013.01); E04F 15/105 (2013.01); B29K 2027/06 (2013.01); B29K 2105/0038 (2013.01); B29K 2105/0044 (2013.01); B29K 2105/16 (2013.01); B29K 2491/00 (2013.01); B29K 2509/00 (2013.01); B29K 2995/0096 (2013.01); B29L 2007/002 (2013.01); B29L 2031/732 (2013.01); C08J 2327/06 (2013.01); C08J 2423/00 (2013.01); C08J 2475/04 (2013.01); C08K 5/098 (2013.01); C08K 2003/265 (2013.01)] 19 Claims
 
1. A process for the production of an extruded sheet comprising at least the following steps:
a) provision of calcium carbonate (CaCO3) powder,
b) provision of polyvinylchloride (PVC) powder,
c) provision of additives in the form of stabilizers, comprising at least Ca/Zn stabilizers, impact modifiers and internal and external waxes, where
c1) the proportion of calcium carbonate (CaCO3) powder is between 70 and 80% by weight, the proportion of polyvinylchloride (PVC) powder is between 20 and 30% by weight and the proportion of additives is up to 5% by weight,
d) mixing of a first portion of the calcium carbonate (CaCO3) powder with the polyvinylchloride (PVC) powder, and the additives, and then
e) heating of the mixture to a temperature of 100 to 140° C. until the polyvinylchloride (PVC) softens to a kneadable composition and the calcium carbonate (CaCO3) binds at least to some extent to the polyvinylchloride (PVC), and then
f) cooling of the composition to a temperature of 40 to 50° C., after which a second remaining portion of calcium carbonate (CaCO3) is mixed with the composition,
g) conveying of the obtained composition to an extruder by means of screws, wherein said extruder comprises an outlet and a slot die at said outlet,
h) melting and extrusion of the composition by said extruder and molding by said slot die to give a sheet, and then
i) compressing the sheet following the step of melting and extrusion while the sheet generally maintains the temperature when emerging from the slot die by means of at least two calender rolls to a desired final thickness.