JP5245490B2 - Manufacturing method of surface material - Google Patents

Description

  The present invention relates to a method and apparatus for manufacturing a surface material that covers a surface such as a floor or a wall, and a surface material.

  As a surface material for covering the surface of the floor, a surface material as shown in FIG. 5 is known (for example, see Patent Document 1). As shown in the figure, the surface material 100 includes a backer layer 101 and a decorative sheet 102 attached to the surface of the backer layer 101. Then, the surface material 100 is attached to the surface of the wooden substrate 105 such as a floor via the adhesive layer 104.

  The backer layer 101 constituting the surface material 100 is a thick thermoplastic resin layer provided for imparting hardness, strength, impact resistance and the like to the decorative sheet 102. On the other hand, the decorative sheet 102 is printed with a pattern such as wood grain or stone grain to impart design properties, and a surface protective layer 103 is coated on the surface thereof. Furthermore, an emboss pattern is formed on the surface of the decorative sheet 102.

Conventionally, when manufacturing the surface material 100 as described above, generally, the backer layer 101 and the decorative sheet 102 are manufactured separately, and an emboss pattern is formed on the surface of the decorative sheet 102 in advance. And the adhesive was apply | coated to the surface of the backer layer 101, and the backer layer 101 and the decorative sheet 102 were stuck by laminating | stacking the decorative sheet 102 there. In addition, when applying an adhesive to the backer layer 101, a primer treatment was applied to the surface of the backer layer 101.
JP 2006-218784 A

  However, in such a manufacturing method, the two sheets to be laminated are separately manufactured, and then an emboss pattern is formed and bonded with an adhesive, so that many steps are required for manufacturing the surface material 100. There was a problem that it took time and effort.

  The present invention has been made to solve the above problems, and an object of the present invention is to provide a method for producing a surface material that can efficiently produce a high-quality surface material. Moreover, it aims at provision of the surface material manufactured by the manufacturing apparatus for this manufacturing method, and a manufacturing method combined with this.

A method for producing a surface material according to the present invention is made to solve the above-described problem. In a gap between an embossing roll having an embossing pattern and a cooling roll adjacent to the embossing roll, a sheet for a backer layer and A feeding step for feeding the top sheet, and the surface of the top sheet is opposed to the embossing roll, and the top sheet and the backer layer sheet are placed in a state where the back surface is superimposed on the backer layer sheet. And a pressing step for pressing the two sheets with the embossing roll and the cooling roll when the two sheets pass through the gap, and the backer layer sheet is a thermoplastic in a molten state. The top sheet is made of a resin and includes a thermoplastic resin on the front side and the back side, and the backer layer casing is provided. DOO thermoplastic resin, and a thermoplastic resin in the back surface side of the topsheet are both made of a polyolefin resin, a thermoplastic resin on the surface side of the topsheet, the thermoplastic resin in the back surface side of the topsheet A thermoplastic resin on the back side of the top sheet is melted in the pressing step.

  According to this configuration, in the pressing step, the backer layer sheet made of a thermoplastic resin in a molten state and the back side of the top sheet made of the thermoplastic resin are pressed in an overlapping state, so the heat of the backer layer sheet The thermoplastic resin on the back side of the top sheet can be melted (softened) by the heat of the plastic resin. And since it presses in the state which the thermoplastic resin of the sheet | seat for backer layers, and the back surface side of a surface sheet mutually melt | dissolves (softens), the sheet | seat for backer layers and a surface sheet can be adhere | attached reliably. Moreover, since the heat of the thermoplastic resin of the sheet | seat for backer layers is transmitted to the surface side of a surface sheet, the thermoplastic resin of the surface side can be softened. And since the surface side of a surface sheet is pressed with the embossing roll in the softened state, an embossing pattern can be formed easily.

  As described above, since the embossed pattern can be formed on the surface side of the surface sheet while the backer layer sheet and the surface sheet are securely bonded, a high-quality surface material can be efficiently produced.

  According to this structure, melting | fusing point of the thermoplastic resin in the sheet | seat for backer layers, and the thermoplastic resin in the back surface side of a surface sheet can be closely approached. Thereby, since the thermoplastic resin of the surface sheet can be easily melted (softened), the backer layer sheet and the surface sheet can be more reliably bonded.

  Moreover, the thermoplastic resin in the surface side of the said surface sheet can be made into polyolefin resin. According to this configuration, since the thermoplastic resin on the surface side of the top sheet has a melting point close to that of the thermoplastic resin, it can be easily softened. Thereby, an emboss pattern can be formed more easily.

  Moreover, the surface material which concerns on this invention was made | formed in order to solve the said problem, and is manufactured by the manufacturing method of the surface material mentioned above.

  Moreover, in the said manufacturing method, the polyolefin-type resin of the said sheet | seat for backer layers can make a bending elastic modulus larger than the polyolefin-type resin in the said surface sheet. According to such a configuration, a surface material having practical strength can be manufactured.

  Moreover, the polyolefin resin of the said sheet | seat for backer layers can make melting | fusing point higher than the polyolefin resin in the said surface sheet. According to such a configuration, since the polyolefin-based resin in the top sheet can be reliably melted (softened), the backer layer sheet and the top sheet can be securely bonded.

  In addition, the polyolefin-based resin of the backer layer sheet can have a melt flow rate of 1 to 20 g / 10 min. According to such a configuration, the workability of the backer layer sheet can be improved. In addition, the surface of the surface sheet can be covered with a surface protective layer containing an ionizing radiation curable resin or a thermosetting resin. Moreover, a design pattern can be attached to the surface sheet. Furthermore, a primer layer can be formed on the back surface of the surface material, that is, the back surface of the backer layer formed by solidifying the backer layer sheet.

  According to the surface material manufacturing method of the present invention, a high-quality surface material can be efficiently manufactured.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is an explanatory diagram of a method for manufacturing a surface material according to an embodiment of the present invention.

  First, an example of the manufacturing apparatus used for the manufacturing method of the surface material of this invention is demonstrated. As shown in FIG. 1, the manufacturing apparatus 50 includes an embossing roll 51 and a cooling roll 52 arranged so as to be close to the embossing roll 51. A T die 53 is provided above the gap 55 between the rolls 51 and 52. And from this T dice | dies 53, the sheet-like thermoplastic resin of a heat-melting state is continuously discharged toward the gap | interval between both rolls, and this becomes the sheet | seat for backer layers of a surface material.

  The embossing roll 51 is a metallic cylindrical member, and an uneven embossing pattern is formed on the outer periphery. Examples of the embossed pattern include patterns such as a conduit groove, a satin finish, a grain, and a hairline. The cooling roll 52 is a metal cylindrical member, and has a smooth outer periphery. The embossing roll 51 and the cooling roll 52 are arranged so as to face each other so that they can be rotated with their rotation axes parallel to each other. Further, a gap 55 is formed between the embossing roll 51 and the cooling roll 52 so that a later-described surface sheet and backer layer sheet can pass therethrough. The embossing roll 51 and the cooling roll 52 are pressed. The surface sheet and the backer layer sheet that have passed through the gap are pressure-bonded to form a surface material. The width of the gap 55 is set according to the thickness of the surface material to be manufactured.

  A guide roll 54 that guides a surface material formed by being pressed by both rolls 51 and 52 is disposed obliquely below the cooling roll 52. The cooling roll 52 guides along the outer periphery while winding the surface material, and the guide roll 54 guides the surface material downstream while supporting the surface material.

  Next, the manufacturing method of the surface material which concerns on one Embodiment of this invention is demonstrated. The manufacturing method of the surface material according to the present embodiment includes a feeding step and a pressing step.

( Feeding step )
In the feeding step, the backer layer sheet 2 and the top sheet 3 are fed into the gap 55 between the embossing roll 51 and the cooling roll 52. The backer layer sheet 2 is made of the above-described molten thermoplastic resin, and is continuously extruded from the T die 53 into a sheet shape. The top sheet 3 is continuously supplied to the gap 55 after being transported by a transport device (not shown). As a conveying apparatus, it is comprised from the guide roll arrange | positioned upstream of the embossing roll 51, a belt conveyor, etc., for example, and it is comprised so that the surface sheet 3 can be conveyed to the clearance gap 55. FIG.

  As a material for the backer layer sheet 2, a polyolefin resin can be used. Examples of the polyolefin resin include polypropylene resin and polyethylene resin.

  The polyolefin resin used for the backer layer sheet 2 preferably has a flexural modulus of 1000 MPa to 2500 MPa from a practical viewpoint. The polyolefin resin used for the backer layer sheet 2 preferably has a melting point of 140 ° C. to 170 ° C. from the viewpoint of processability. The polyolefin resin used for the backer layer sheet 2 preferably has a melt flow rate defined in JIS K7210 of 1 to 20 g / 10 min, preferably 1.5 to 10 g / 10 min, from the viewpoint of processability. Is more preferable. Moreover, 150 micrometers or more are preferable and, as for the thickness of the sheet | seat 2 for backer layers, about 250 micrometers-about 400 micrometers are more preferable.

  FIG. 2 is a cross-sectional view of the top sheet 3. As shown in FIG. 2, the topsheet 3 includes a base material layer 30 and a transparent resin layer 31 laminated on the base material layer 30. The base material layer 30 and the transparent resin layer 31 are both made of a thermoplastic resin, the base material layer 30 is disposed on the back surface side of the top sheet 3, and the transparent resin layer 31 is on the top surface side of the top sheet 3. Has been placed.

  As a material of the base material layer 30, the same material as the above-described backer layer sheet 2 can be used. The base material layer 30 preferably contains a thermoplastic elastomer component from the viewpoint of enhancing the adhesiveness with the backer layer sheet 2. Moreover, the base material layer 30 may be colored with a coloring material. As the colorant, for example, inorganic pigments such as titanium dioxide, carbon black and iron oxide, organic pigments such as phthalocyanine blue, and various dyes can be used. Moreover, although the thickness of the base material layer 30 can be suitably set by the use of the final product, the usage method, etc., generally 50-150 micrometers is preferable.

  From a practical viewpoint, the flexural modulus of the polyolefin resin used for the base material layer 30 is preferably smaller than the flexural modulus of the polyolefin resin used for the backer layer sheet 2, specifically, 500 MPa to 1200 MPa. Preferably there is. Moreover, it is preferable that melting | fusing point of polyolefin resin used for the base material layer 30 is lower than melting | fusing point of polyolefin resin used for the sheet | seat 2 for backer layers from a workability viewpoint, specifically, 135 to 160 degreeC. Preferably there is.

  A pattern 32 is printed on the surface of the base material layer 30. Examples of the pattern 32 include a grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern 32 can be formed by a printing method using an ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) in a solvent (or dispersion medium) together with a binder resin. The printing thickness of the pattern 32 is not particularly limited and can be set as appropriate according to product characteristics. The layer thickness during coating is about 1 to 15 μm, and the layer thickness after drying is about 0.1 to 10 μm.

  The transparent resin layer 31 is bonded to the base material layer 30 with an adhesive 33 applied to the surface of the base material layer 30. As the adhesive 33, for example, various adhesives including polyurethane resin, polyacrylic resin, polycarbonate resin, epoxy resin and the like can be used. The adhesive 33 may be transparent or translucent as long as the pattern 32 can be recognized. The thickness of the adhesive 33 varies depending on the type and the material of the transparent resin layer 31, but generally may be about 0.1 to 30 μm.

  From the viewpoint of the visibility of the pattern 32, the transparent resin layer 31 is preferably made of a transparent or translucent resin. As the material of the transparent resin layer 31, the same material as the above-described backer layer sheet 2 can be used. The transparent resin layer 31 includes a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, a light stabilizer, a radical scavenger, a soft component (for example, rubber). Various additives such as these may be contained. The thickness of the transparent resin layer 31 is not particularly limited, but is generally about 10 to 150 μm.

  Further, the bending elastic modulus of the polyolefin resin used for the transparent resin layer 31 is preferably smaller than the bending elastic modulus of the polyolefin resin used for the backer layer sheet 2 from a practical viewpoint. It is preferably ~ 1200 MPa. Moreover, it is preferable that melting | fusing point of polyolefin resin used for the transparent resin layer 31 is lower than melting | fusing point of polyolefin resin used for the sheet | seat 2 for backer layers from a workability viewpoint, specifically, 135 to 160 degreeC. It is preferable that

  The surface of the transparent resin layer 31 is covered with a surface protective layer 34. The surface protective layer 34 can contain an ionizing radiation curable resin or a thermosetting resin, and particularly preferably contains an ionizing radiation curable resin.

( Pressing step )
FIG. 3 is an enlarged view of a main part A of FIG. As shown in FIG. 3, in the pressing step, the top sheet 3 and the backer layer sheet 2 are spaced apart from each other with the surface of the top sheet 3 facing the embossing roll 51 and the back surface superimposed on the backer layer sheet 2. 55. When the top sheet 3 and the backer layer sheet 2 pass through the gap 55, the two sheets 2 and 3 are pressed by the embossing roll 51 and the cooling roll 52. The width of the gap 55 is preferably set so that the pressing force by both rolls 51 and 52 acts on the top sheet 3 and the backer layer sheet 2. Specifically, this width is preferably set between the same value as the thickness of the topsheet 3 and a value obtained by subtracting the depth of the embossed pattern from the thickness of the surface material 1 to be manufactured.

  When the top sheet 3 and the backer layer sheet 2 are pressed, the heat of the backer layer sheet 2 is transmitted to the base layer 30 of the top sheet 3, and the back side of the base layer 30 is partially melted (softened). And since the sheet | seat 2 for backing layers and the base material layer 30 are pressed in the state mutually melt | dissolved (softened), both carry out thermocompression bonding.

  Further, the heat of the backer layer sheet 2 is transmitted into the top sheet 3 and transmitted to the transparent resin layer 31. Thereby, the transparent resin layer 31 is softened. And since the surface of the surface sheet 3 is pressed by the embossing roll 51 in this state, an emboss pattern is formed on the surface of the surface sheet 3.

  Thereafter, the backer layer sheet 2 and the top sheet 3 are wound around the cooling roll 52 in a bonded state, and both sheets are cooled in this process. When the backer layer sheet 2 is cooled, it solidifies to become the backer layer 20. Thus, the surface material 1 having the backer layer 20 lined on the back surface of the top sheet 3 is formed.

  FIG. 4 is a cross-sectional view of the surface material 1. As shown in FIG. 4, an emboss pattern is formed on the surface of the surface material 1. Further, the backer layer 20 is in close contact with the back surface of the top sheet 3. Thereafter, the surface material 1 is wound around the cooling roll 52 and then conveyed downstream via the guide roll 54.

  As described above, according to the method for manufacturing a surface material according to the present embodiment, in the pressing step, the backer layer sheet 2 made of a molten thermoplastic resin and the back side of the surface sheet made of a thermoplastic resin. Since it presses in the piled-up state, the thermoplastic resin of the base material layer 30 can be melted (softened) by the heat of the backer layer sheet 2. And since it presses in the state in which the thermoplastic resin of the backer layer sheet 2 and the base material layer 30 is melted (softened), the backer layer sheet 2 and the base material layer 30 can be reliably bonded. . Moreover, since the heat of the backer layer sheet 2 is transmitted to the surface side of the top sheet 3, the thermoplastic resin of the transparent resin layer 31 can be softened. And since the transparent resin layer 31 of a softened state is pressed with an embossing roll, an embossing pattern can be formed easily. Thus, since the embossing pattern can be formed in the transparent resin layer 31 at the same time as the backer layer sheet 2 and the base material layer 30 are securely bonded, the high-quality surface material 1 can be efficiently manufactured. Can do. Moreover, since the surface sheet 3 is not heated after an embossing pattern is formed, the embossing pattern once formed can be maintained in a favorable shape.

  Moreover, since the thermoplastic resin of the backer layer sheet 2 and the base material layer 30 are both made of a polyolefin resin, the melting points of the backer layer sheet 2 and the base material layer 30 can be made closer to each other. Thereby, since the thermoplastic resin of the base material layer 30 can be easily melted (softened), the backer layer sheet 2 and the base material layer 30 can be bonded more reliably.

  Furthermore, since the thermoplastic resin of the transparent resin layer 31 is made of a polyolefin resin, the transparent resin layer 31 has a melting point close to that of the backer layer sheet 2 and can be easily softened. Thereby, an emboss pattern can be more easily formed in the transparent resin layer 31.

  As mentioned above, although one Embodiment of this invention was described, the specific aspect of this invention is not limited to the said embodiment.

  For example, in the above embodiment, a polyolefin resin is used as the material for the backer layer sheet 2, the base material layer 30, and the transparent resin layer 31, but the material is not particularly limited as long as it is a thermoplastic resin. Vinyl and acrylic resin may be used. Further, the top sheet 3 is not necessarily formed from a plurality of layers as described above, and can be formed from, for example, a single layer thermoplastic resin.

  Moreover, in the said embodiment, although the sheet | seat 2 for backer layers was a single layer, the laminated body of two or more layers may be sufficient. When such a backer layer sheet 2 is formed, a manifold type or field block type T dice can be used.

  Moreover, in the said embodiment, although the cooling roll 52 was a metal roll by which the surface was formed smoothly, if the backer layer sheet | seat 2 and the surface sheet 3 can be pressed with the embossing roll 51, the structure will be sufficient as it. There is no particular limitation. For example, a rubber roll having a satin pattern on the surface may be used.

  In the above embodiment, the surface sheet 3 is not particularly processed. However, the surface sheet 3 may be preheated before the surface sheet 3 is fed to the gap 55. The preheating can be performed by, for example, a heater arranged in the conveyance path of the top sheet 3. Thereby, the transparent resin layer 31 can be easily softened, and an emboss pattern can be reliably formed on the surface of the topsheet 3.

  An adhesive may be applied to the back surface of the top sheet 3 before feeding the top sheet 3 to the gap 55. Thereby, the adhesion between the topsheet 3 and the backer layer 20 can be made stronger. Further, before feeding the backer layer sheet 2 to the gap 55, the front and back surfaces of the backer layer sheet 2 may be subjected to ozone treatment. Further, after the surface material 1 is manufactured, the back surface of the surface material 1 may be subjected to primer treatment.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the present invention is not limited to this embodiment.

  As an example, the surface material 1 shown in FIG. 4 was manufactured by the method for manufacturing a surface material according to the present invention. Moreover, the surface material was manufactured as a comparative example with the manufacturing method of the surface material which concerns on a prior art. First, conditions common to the examples and comparative examples will be described.

( Surface sheet )
As shown in FIG. 2, the base material layer 30 in the top sheet 3 is made of a colored polyolefin resin, has a thickness of 60 μm, and is subjected to corona treatment on the front and back surfaces. On the surface of the base material layer 30, a solution obtained by dissolving an acrylic-urethane resin in a mixed solvent of methyl ethyl ketone and butyl acetate is applied so that the solid content is 2 g / m ^2. A layer is formed. The solution is applied by a gravure printing method.

The picture pattern 32 is a wood grain pattern, and is printed on the primer layer for printing by a gravure printing method. The printing ink was an acrylic-urethane resin solution. A thermosetting urethane resin adhesive 33 is applied on the pattern 32. The adhesive 33 is applied so that the solid content is 8 g / m ^2, and its thickness is 8 μm.

  The transparent resin layer 31 is made of a polypropylene resin and has a thickness of 80 μm. The transparent resin layer 31 can be formed by extruding a molten thermoplastic resin from a T die and solidifying it. On the surface of the transparent resin layer 31, a surface protective layer 34 made of a urethane acrylate electron beam curable resin having a thickness of 15 μm is formed. The surface protective layer 34 can be formed by applying a resin and drying it, and then irradiating and curing an electron beam under the conditions of 125 KeV and 5 Mrad in an environment where the oxygen concentration is 200 ppm. The thickness of the top sheet 3 was 160 μm.

[Example]
The above surface sheet 3 and the backer layer sheet 2 are fed into a gap between an embossing roll 51 having a surface temperature of 20 ° C. and a cooling roll 52 having a surface temperature of 20 ° C., and pressed by the two rolls. 1 was produced.

  As the material for the backer layer sheet 2, homopolypropylene resin was used. The thickness of the backer layer sheet 2 extruded from the T dice 53 was 500 μm. The temperature of the homopolypropylene resin for the backer layer at this time was 260 ° C. And the surface material and the sheet | seat for backer layers were thermocompression bonded by the method mentioned above with the apparatus shown in FIG.

[Comparative example]
First, a primer layer made of a urethane-cellulose resin was formed on the back surface of the top sheet 3 described above. This primer layer can be formed by applying a resin solution by a gravure printing method so that the solid content becomes 2 g / m ² . In the urethane-cellulose resin solution, urethane and nitrified cotton are added to a mixed solution of methyl ethyl ketone and methyl isobutyl ketone, and 5 parts by weight of hexamethylene diisocyanate is added to 100 parts by weight of the mixture of urethane and nitrified cotton. It is prepared by doing. Thereafter, the surface sheet 3 was wound around a heating roll at 100 ° C., and the thermoplastic resin in the surface sheet 3 was melted by heating the sheet surface to 150 ° C. with an infrared heater. Next, the embossing pattern was formed on the surface of the surface sheet 3 by feeding the surface sheet 3 into the gap between the embossing roll and the rubber roll adjacent to the embossing roll, and pressing the surface sheet 3 with two rolls. . Thus, the top sheet 3 having an embossed pattern was manufactured.

  Note that the embossing roll and the rubber roll are supplied with cooling water at 20 ° C. and are configured to be able to cool the sheet in contact with the surface. The rubber roll has a satin pattern on the surface.

  Subsequently, a homopolypropylene resin was extruded from the T-die into a sheet shape and cooled to produce a backer layer. The thickness of the backer layer was 500 μm. Moreover, the corona treatment was performed to the front and back of the backer layer. Subsequently, a thermosetting urethane resin adhesive was applied to the back surface of the top sheet 3, and a backer layer was stuck at a conveyance speed of 20 m / min. Thus, the surface material according to the comparative example was manufactured.

  When the example and the comparative example were compared, the manufacturing process could be simplified in the example. Moreover, in the Example, the adhesiveness of the backer layer 20 and the surface sheet 3 was able to be improved. The adhesive strength of the example was 50 N per 25 mm width, while the adhesive strength of the comparative example was 25 N per 25 mm width. The measurement of adhesive strength was based on "JIS K6854-3 T-type peeling test".

It is explanatory drawing of the manufacturing method of the surface material which concerns on one Embodiment of this invention. It is sectional drawing of a surface sheet. It is the figure which expanded the principal part of FIG. It is sectional drawing of a surface material. It is sectional drawing of the conventional surface material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Surface material 2 Backer layer sheet 3 Surface sheet 20 Backer layer 30 Base material layer 31 Transparent resin layer 50 Surface material manufacturing apparatus 51 Emboss roll 52 Cooling roll 53 T dice 55 Gap

Claims (3)

A feeding step of feeding the backer layer sheet and the top sheet to the gap between the embossing roll having the embossing pattern and the cooling roll adjacent to the embossing roll;
With the front surface of the top sheet facing the embossing roll and the back surface overlaid on the backer layer sheet, the top sheet and the backer layer sheet are passed through the gap, and the two sheets pass the gap. A pressing step of pressing the two sheets with the embossing roll and the cooling roll when passing through,
The backer layer sheet is made of a molten thermoplastic resin,
The top sheet comprises a thermoplastic resin on the front side and the back side,
The thermoplastic resin of the backer layer sheet and the thermoplastic resin on the back side of the top sheet are both made of a polyolefin resin,
It has a pattern between the thermoplastic resin on the front side of the top sheet and the thermoplastic resin on the back side of the top sheet ,
The manufacturing method of the surface material which fuses the thermoplastic resin in the back surface side of the said surface sheet in the said press step.   The method for producing a surface material according to claim 1, wherein the thermoplastic resin on the surface side of the surface sheet is made of a polyolefin-based resin.   The surface material manufacturing method according to claim 1 or 2, wherein a surface of the surface sheet is coated with a surface protective layer containing an ionizing radiation curable resin or a thermosetting resin.

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