Poly(vinyl chloride) substrates and method for producing the same

1. An article comprising a substrate derived from thermal compression bonding a particulate poly(vinyl chloride) compound or a particulate reclaimed poly(vinyl chloride) compound, the substrate having voids to provide a density less than or equal to 1.35 g/cm 3 as measured by ASTM D792, and a flexural modulus of about 1,000 MPa to about 7,600 MPa as measured by ASTM D790.

2. An article according to claim 1 , wherein the substrate comprises greater than 85% by weight of reclaimed poly(vinyl chloride).

3. An article according to claim 1 , wherein the substrate possesses non-homogeneous color.

4. An article according to claim 1 , wherein the substrate is thermoformable.

5. An article according to claim 1 , wherein the substrate comprises a building material, wall covering, door covering, furniture material, acoustic panel, ceiling tile, a panel for recreational vehicle walls, or a base for a laminate construction.

6. An article according to claim 1 , further comprising a film on at least one surface of the substrate wherein the film is added before the thermal compression bonding.

7. An article according to claim 1 , further comprising inorganic fillers, organic fillers, high aspect ratio fillers, lightweight fillers, cellulosic materials, modifiers, naturally occurring inorganic materials, coupling agents, lubricants, antimicrobials, inorganic antioxidants, light stabilizers, fibers, antiblocking agents, heat stabilizers, impact modifiers, biocides, compatibilizers, flame retardants, plasticizers, pigments, colorants, processing aids, lubricants, pigments, and other plastics, or combinations thereof.

8. A method comprising:

(a) providing a particulate poly(vinyl chloride) compound or particulate reclaimed poly(vinyl chloride) compound,

(b) scattering the particulate poly(vinyl chloride) compound or the reclaimed poly(vinyl chloride) particulate compound onto a lower belt of a double belt press,

(c) co-scattering a second particulate poly(vinyl chloride) compound or a second particulate reclaimed poly(vinyl chloride) compound;

(d) contacting and thermal compression bonding the particulate poly(vinyl chloride) compound or the particulate reclaimed poly(vinyl chloride) compound and second particulate poly(vinyl chloride) compound or second particulate reclaimed poly(vinyl chloride) compound with an upper belt on a double belt press to form a substrate having voids to provide a density of less than 1.35 g/cm 3 as determined by ASTM D792 and a rigidity demonstrated by a flexural modulus of about 1,000 MPa to about 7,600 MPa in accordance with ASTM D790; wherein the second particulate poly(vinyl chloride) compound or the second particulate reclaimed poly(vinyl chloride) compound have a different coefficient of thermal expansion than the particulate poly(vinyl chloride) compound or the particulate reclaimed poly(vinyl chloride) compound and the substrate exhibits a degree of cupping of at least 0.15% and up to 5%.

9. A method according to claim 8 , further comprising (i) applying a film to the lower belt prior to (b) or (ii) applying a film over the scattered particulate poly(vinyl chloride) compound or particulate reclaimed poly(vinyl chloride) compound prior to (d) or both (i) and (ii) to form a multilayered substrate.

10. A method according to claim 8 , further comprising cooling the substrate during thermal compression bonding, wherein the cooling includes cooling platens and the cooling platens are gapped at least 1 mm greater than the thickness of the substrate.

11. A method comprising:

(a) providing a particulate poly(vinyl chloride) compound or particulate reclaimed poly(vinyl chloride) compound having particulates comprising a range of sizes and shapes,

(b) scattering the particulate poly(vinyl chloride) compound or the particulate reclaimed poly(vinyl chloride) compound onto a lower belt of a double belt press,

(c) co-scattering a second particulate poly(vinyl chloride) compound or a second particulate reclaimed poly(vinyl chloride) compound;

(d) applying vibrating forces to at least partially segregate particulates according to size, wherein smaller particulates migrate closer to the lower belt,

(e) contacting the particulates with an upper belt on a double belt press wherein the compression forces on the upper belt of the double belt press are limited,

(f) thermal compression bonding the particulates to form a substrate wherein the particulates nearest the lower belt are fused and the particulates nearest the upper belt form a non-consolidated surface,

wherein the second particulate poly(vinyl chloride) compound or the second particulate reclaimed poly(vinyl chloride) compound have a different coefficient of thermal expansion than the particulate poly(vinyl chloride) compound or the particulate reclaimed poly(vinyl chloride) compound and the substrate exhibits a degree of cupping of at least 0.15% and up to 5%.

12. A method according to claim 11 , wherein the substrate comprises a fused surface with an average height of at least 0.2 mm and up to 5 mm and further comprises a non-consolidated surface wherein the total substrate has a thickness of 2 mm to 25 mm.

13. A method comprising,

(a) scattering a particulate poly(vinyl chloride) compound or a particulate reclaimed poly(vinyl chloride) compound onto the lower belt of a double belt press,

(b) co-scattering a second particulate poly(vinyl chloride) compound or a second particulate reclaimed poly(vinyl chloride) compound;

(c) contacting the particulates with an upper belt on a double belt press and thermal compression bonding the particles to form a substrate, and

(d) cooling the substrate during thermal compression bonding, wherein the cooling includes cooling platens and the cooling platens are gapped at least 1 mm greater than the thickness of the substrate, wherein the substrate upon cooling exhibits a controlled degree of cupping of at least 0.15% and up to 5%,

wherein the second particulate poly(vinyl chloride) compound or the second particulate reclaimed poly(vinyl chloride) compound have a different coefficient of thermal expansion than the particulate poly(vinyl chloride) compound or the particulate reclaimed poly(vinyl chloride) compound.

14. A method according to claim 13 , wherein the substrate possesses non-homogeneous color.