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A Polyvinyl Chloride Resinous Composition and Product Thereof

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A Polyvinyl Chloride Resinous Composition and Product Thereof Europaisches Patentamt (191 European Patent Office (J) Publication number: 0 172 341 Office europeen des brevets A2 12 EUROPEAN PATENT APPLICATION (21) Application number: 85107299.1 © int. ci.4: C 08 L 27/06 C 08 J 9/32, B 32 B 27/30 @ Date of filing: 09.06.82 C 08 K 7/22 @ Priority: 09.06.81 JP 88966/81 @ Applicant: KANEGAFUCHI KAGAKU KOGYO KABUSHIKI 09.06.81 JP 88967/81 KAISHA 22.06.81 JP 97272/81 2-4 Nakanoshima 3-chome 24.08.81 JP 133171/81 Kita-ku Osaka-shi Osaka-fu(JP| ^z) Inventor: Takeuchi, Tooru @ Date of publication of application: 31-403, 5-Banchi, 5-ChomeTorigainishi 26.02.86 Bulletin 86/9 Settsu-shi Osaka-futJP) @ Designated Contracting States: @ Inventor: Nakamura, Masaru DE FR GB IT Higashiyama-danchi 6-201 45-Banchi, 2-Chome Higashiyama Hirakata-shi Osaka-futJP) @ Publication number of the earlier application in accordance with Art. 76 EPC: 0 067 418 @ Inventor: Aoishi, Eiji 10-12, 6-chome, Tsutsujigaoka Tarumi-ku, Kobe-shi Hyogo-ken(JP) @ Representative: Vossius VossiusTauchner Heunemann Rauh Siebertstrasse 4 P.O. Box 86 07 67 D-8000 Miinchen 86(DE) polyvinyl chloride resinous composition and product thereof, §A Disclosed is a laminated sheet comprising a polyvinyl chloride resinous layer and a core layer obtained by dry-blending a polyvinyl chloride resin and a cellular filler as main ingredients with a plasticizer. The product of the invention is lighter and superior in soundproofing and adiabatic effects, bending strength, dry (texture) touchness, water resistance, dimensional stability, cold resistance and the like so that structural materials such as floor coverings and the like are supplied more advan- tageously than conventional ones. < BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a light composi- tion 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, this 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 have been widely used in a variety of fields including walls, floor and table coverings, book covers, decorative con- tainers, 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 polymers such as SBR and polyvinyl alcohol have been used. Asbestos papers make up an extremely large proportion of these backings but these entail numerous problems and defects. These include problems of public health as hazards recent- ly discovered, peeling off at the time of re-covering and the waste disposal of used floor coverings. Further there is the fatal defect that when applied to a floor bending toward the inside at an angle greater than 90 degrees, the backings break though the upper portions of the floor coverings themselves can stand. This means that their commercial value is badly damaged. Moreover the floor coverings themselves are water-proof, but the backings of asbestos papers are inferior in water-proof properties with the result that the range of uses is unavoidably limited. In view of the foregoing numerous drawbacks, there is a great need for floor coverings eliminating such drawbacks. In the Japanese Patent Examined Publication No. 41848/1972 there are disclosed, glass fibre or snythetic fibre non- woven fabrics, which are coated or impregnated with a PVC plastisol, or to which sheets of plasticized plastics having a thick tissue construction containing a filler in large quantities are joined. These materials are, in fact, improved in many respects as compared with asbestos papers, but the glass fibres of non-woven glass fibre fabrics tend to adhere to those handling them and cut their skin when being used or transported. Further these fabrics are weak in bending strength, resulting 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 plasti- sol, though improved in respect of injury to 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 fabrics coated or impregnated with the PVC plastisol do not bond readily when applied to the floor, and can only be applied using selected adhesives, which is a de- fect peculiar to plasticized PVC resins. Eventually in some instances these coverings are applied to the floor by bonding thereto victoria lawns and synthetic fibre non-woven fabrics and the like in order to remedy such deficiencies. In an attempt to save on the weight of the PVC sol, foaming processes, either mechanical or chemical, have been proposed. Using such processes, although lightening of molded products is assuredly achieved in the long run, compressive elasticity, tensile strength, tear strength and dimensional stability are drastically reduced, and hence these coverings are not satisfactory in terms of their practical usefulness. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a PVC resinous composition which is lighter, having superior properties when mdded 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 lighter PCV resinous composition with superior properties. It is still another object of the present invention to provide a PVC resinous molded product free from public health hazards caused by the use of asbestos, and improved in respect 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 to handle and use and requires no specific adhesives. It is a still further object of the present inven- tion to provide a PVC resinous molded product superior in flexibility, dimensional stability and water-proof property, free from 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 poly- vinyl chloride resinous composition comprising as main ingredients a PVC resin, >and a cellular filler and by molded products obtained by heating the same at increased pressure. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 to FIG. 8 are schematic representations illustrating embodiments of molded products of the present invention. FIG. 1 illustrates a molded sheet product in which a core layer is interposed. FIG. 2 depicts a molded sheet product, to one side of which a core layer is provided. FIG. 3 shows a molded sheet product comprising a surface layer, a molded sheet and a core layer, molded in a body. FIG. 4 is illustrative of a molded sheet product comprising a surface layer, a core layer and a molded sheet, molded in a body. FIG. 5 is a molded sheet product comprising a surface layer, a foamed layer, a core layer and a molded sheet, molded in a body. FIG. 6 shows a molded sheet product comprising a surface layer, a foamed layer, a molded sheet and a core layer, molded in a body. FIG. 7 is a molded sheet product comprising a surface layer, a foamed layer, a molded sheet, a core layer and a foamed layer, molded in a body. FIG. 8 shows a molded sheet product comprising a surface layer, a foamed layer, a core layer, a molded sheet and a foamed layer, molded in a body. 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 2000p, preferably about 1.0 to about 600µ. To this blending, plasticizers, stabilizers, and further pigments, dyes and surface active 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 was difficult to provide a plasti- sol since absorption of the pla'sticizer was 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 liquid state additives such as plasticizers had to be used. Still worse, the cellular filler added to make the compound light was broken out so that the desired purcose could nnt be attained, with the result that the specific gravity of the compound became approx.
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