JP5332976B2 - Tile connection sheet and tile unit - Google Patents

Description

  The present invention relates to a tile connecting sheet for connecting back surfaces of a plurality of tiles, a tile unit formed by connecting a plurality of tiles with a tile connecting sheet connected to the back surfaces of the tiles, and manufacture of the tile unit. With respect to methods.

  I. A tile unit formed by connecting a plurality of tiles by bonding paper (mounting paper) with an adhesive so as to cross over adjacent tiles on the back side of the tile can be obtained by a single tile application operation. Since tiles can be constructed and effective in reducing construction work and shortening the construction period, they have been widely used in the construction of interior and exterior tiles.

  Such a tile unit is manufactured by placing tiles to be connected in a mold or the like with the back side up and aligning them, and pressing the paper coated with an adhesive onto the back side of the tile.

  In addition, the material of the paper used for a connection is prescribed | regulated to JIS5209, and has no elasticity.

  In addition, it is known to use a hot-melt adhesive as a material for the adhesive used for connection. For example, Japanese Patent Laid-Open No. 54-60723 discloses a tile unit by sticking one side of a tape having a hot melt adhesive applied on one side to an aligned and heated tile assembly. Is disclosed.

  II. By the way, tiles are generally manufactured by dry molding in which molding clay is filled in a molding die and pressure-molded.

  During this dry molding, the molding pressure is reduced at the inner peripheral edge of the molding die due to leakage of clay from the gaps of the die or deformation of the die. Therefore, the outer peripheral edge portion of the obtained molded body has a low density.

  Therefore, the upper and lower molds are preliminarily provided with an inclination called “crimping gradient” so that a sufficient molding pressure is also applied to the outer peripheral edge of the molded body. For this reason, the both sides of the tile are formed with slopes of slanted surfaces which are inclined from the front surface or the back surface toward the side peripheral edge.

  Conventionally, the crimping gradient of the back surface of the tile is about 3.8 to 9.1 °, and the width of the crimping gradient portion is about 2 to 4 mm.

  In a tile unit manufactured using tiles with a bevel gradient formed on the back side, the paper used for joining the tiles is not stretchable, so the paper on the back side of the tile is at the level of the bevel gradient. May be lifted up, and there is a risk of insufficient adhesion between the back of the tile and the paper.

  Japanese Patent Application Laid-Open No. 8-109730 describes that the adhesiveness between the paper and the tile back surface is improved by setting the crimping gradient to 1 to 4 degrees.

Japanese Patent Laid-Open No. 54-60723 JP-A-8-109730

  In a tile unit formed by connecting a plurality of tiles with paper (mounting paper) as in Patent Documents 1 and 2, when the joint material is attached to the joint gap, the joint material is the paper (mounting paper). There is a risk of peeling off due to insufficient adhesion to the portion facing the joint gap.

  The first object of the present invention is to provide a tile connecting sheet capable of satisfactorily attaching a joint material to the joint gap and a tile unit using the tile connecting sheet.

  Moreover, when the meshing gradient is made as small as 1 to 4 ° as in Patent Document 2, the density of the outer peripheral edge of the tile may be low.

  It is a second object of the present invention to provide a tile connecting sheet having good adhesion to the tile slope surface and a tile unit using the tile connecting sheet without reducing the gradient at the periphery of the tile back surface. And

The tile connection sheet of the present invention (invention 1) is a tile connection sheet for connecting the back surfaces of a plurality of tiles, and has a base material and an adhesive layer provided on the surface of the base material. In the tile connection sheet, at least a part of the surface of the adhesive layer has a concave portion and a convex portion, and the height difference between the concave portion and the convex portion is an uneven surface of 15 to 130 μm . the number of convex portions per unit area is characterized in 3-123 pieces / mm ² der Rukoto.

Tile connecting sheet according to claim 2, characterized in that Oite to claim 1, the adhesive base material is impregnated.

The tile unit of the present invention (Claim 3 ) is a tile unit in which a plurality of tiles are connected by a tile connection sheet connected to the back surface of the tile, and the tile connection sheet is described in claim 1 or 2 . The tile connecting sheet has a joint gap between the tiles, and at least a part of the uneven surface faces the joint gap.

A tile unit according to a fourth aspect is the tile unit according to the third aspect , wherein a gradient surface is provided on the edge of the back surface of the tile, and at least a part of the convex portion is joined to at least a part of the gradient surface. It is characterized by that.
In the present invention, the adhesive layer is preferably made of a thermoplastic adhesive, but may be made of a thermosetting adhesive.

  In the tile connection sheet of the present invention, at least a part of the surface of the adhesive layer has a concave portion and a convex portion, and the height difference between the concave portion and the convex portion is an uneven surface of 15 to 130 μm. . By manufacturing the tile unit by joining the back surface of the tile and the tile connecting sheet so that at least a part of the uneven surface faces the joint gap, the joint material is applied when the joint material is applied to the joint gap. It bites into the uneven surface and adheres firmly. Further, when one side of the back surface of the tile is a slope surface, the tile connection sheet and the back surface of the tile are joined so that at least a part of the uneven surface faces the slope surface. On the other hand, the convex part of the irregular surface adheres. Thereby, the connection between the tile and the tile connection sheet becomes strong.

When the number of the convex portions per unit area on the irregular surface is 3 to 123 / mm ² , the joint material adheres more firmly to the tile connecting sheet.

  When the adhesive of the tile connection sheet is impregnated with the adhesive, the adhesion between the base and the adhesive layer becomes strong.

  In the tile unit of the present invention, the tile connection sheet is the tile connection sheet described above, and has a joint gap between the tiles, and at least a part of the uneven surface faces the joint gap. . For this reason, when a joint material is applied to the joint gap, the joint material adheres firmly to the uneven surface.

  When a gradient surface is provided on the edge of the back surface of the tile, it is preferable that at least a part of the convex portion is bonded to at least a part of the gradient surface. Thus, the convex part of an uneven surface adheres to this slope surface, and the connection of a tile and a tile connection sheet becomes strong.

It is a top view of the back surface of the tile unit which concerns on embodiment. It is a schematic diagram explaining the manufacturing method of a tile connection sheet. It is an enlarged view of the back surface of a tile connection sheet. It is an expanded sectional view of a tile connection sheet. It is a partial expanded sectional view of a tile unit.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a plan view of the back surface of a tile unit according to the embodiment, FIG. 2 is a schematic diagram for explaining a method for manufacturing a tile connecting sheet, and FIGS. 3 and 4 are enlarged views of the back surface of the tile connecting sheet. FIG. 5 is an enlarged sectional view of a tile unit.

  As shown in FIG. 1, the tile unit 1 is formed by connecting a plurality of tiles 2 with a connecting sheet 3 connected to the back surface of the tile 2. In the tile unit 1, a row formed by arranging three tiles 2 in the horizontal direction with a joint gap is arranged in six rows in the vertical direction with a joint gap. As a result, five joint portions 4 extending in the horizontal direction in FIG. 1 of the tile unit 1 are formed, and two joint portions 5 extending in the vertical direction are formed.

  In FIG. 1, the ten connecting sheets 3 in the center of the tile unit 1 connect the back surfaces of the four tiles 2, and the outer 14 connecting sheets 3 connect the back surfaces of the two tiles 2. They are linked together.

  Next, the tile 2 will be described in detail. As shown in FIG. 1, the tile 2 is a horizontally long rectangle, and the inclined surface 2a shown in FIG. In FIG. 1, the inclined surface 2a is omitted.

  The size of the tile 2 is not particularly limited. For example, there are 45 squares (about 45 × 45 mm), 45 two (about 45 × 90 mm), and 45 three (about 45 × 135 mm) as a general shape. The length is about 5 to 13 mm. In addition, the width | variety of the joint parts 4 and 5 is 2-5 mm, for example.

  Further, the width of the gradient surface 2a, that is, the distance from the intersection of the gradient surface 2a with the bottom surface of the tile 2 to the intersection with the tree end surface is not particularly limited, but is, for example, 2 to 4 mm. The angle formed between the bottom surface of the tile 2 and the inclined surface 2a is, for example, 5 to 15 °.

  Next, the tile connection sheet 3 will be described in detail. As shown in FIG. 3, the tile connection sheet 3 is formed by providing an adhesive layer 3b on the surface of a square or rectangular base material 3a. The surface of the adhesive layer 3b is an uneven surface having a recess 3d and a protrusion 3c.

  As the material of the base material 3a, for example, synthetic resin, glass fiber, nonwoven fabric, cloth, paper, or the like is used. As this paper, kraft paper, roll paper, high quality paper or the like is used.

  Although there is no limitation in particular in the dimension of this base material 3a, the length of the vertical direction and a horizontal direction is about 15-30 mm, for example, and thickness is about 0.05-0.7 mm.

  As the material of the adhesive layer 3b, an EVA-based, urethane-based, acrylic-based, vinyl chloride-based, olefin-based thermoplastic adhesive or the like is preferably used, but a thermosetting adhesive may also be used.

  The height difference between the concave portion 3d and the convex portion 3c of the adhesive layer 3b is 15 to 130 μm, and preferably 20 to 100 μm. When the thickness is 10 μm or more, the joint material firmly bites into the concavo-convex surface composed of the concave portion 3d and the convex portion 3c, and the joint material is prevented from peeling off. A height difference of 130 μm or less can be formed relatively easily.

  The average thickness of the adhesive layer 3b is, for example, 30 to 200 μm, preferably 60 to 150 μm. When the thickness is 30 μm or more, the bonding between the adhesive layer 3b and the tile 2 becomes good. When the thickness is 200 μm or less, the material cost of the adhesive can be reduced.

  The height difference and the average thickness of the adhesive layer 3a mean values measured with a microscope at a magnification of 50 times. Specifically, the heights of all the convex portions 3c and the concave portions 3d existing in the region of 10 mm × 10 mm are measured at a magnification of 50 times with a microscope, and the average height of the convex portions 3c and the height of the concave portions 3d are measured. The difference from the average value of height is defined as “height difference”. Moreover, about the average thickness of the adhesive bond layer 3b, the said 10 mm x 10 mm area | region is cut | disconnected diagonally, and let the average value of the thickness of the adhesive bond layer 3b in this cross section be an average thickness.

The density of the protrusions 3c (that is, the number of the protrusions 3c per unit area on the uneven surface) is 3 to 123 / mm ² , preferably 4 to 120 / mm ^2, particularly 4 to 50 / mm ^2. It is. When the number is 3 pieces / mm ² or more, the joint material bites into the uneven surface and the joint material is prevented from peeling off. If it exceeds 123 pieces / mm ² , the difference between the convex portion 3c and the concave portion 3d becomes small, and the biting of the tile 2 into the adhesive layer 3b becomes weak.

In addition, this density means the value measured as follows. That is, an SEM photograph of the uneven surface is taken, 100 square sections of 1 × 1 mm are drawn on the photograph, the number of convex portions 3c existing in each section is measured, and the total number is calculated as 100 sections. The value divided by the total area (100 mm ² ) is taken as the density of the convex portions 3c.

  FIG. 2 shows an example of a method for manufacturing the tile connecting sheet 3. In FIG. 2, a roll coater 10 supplies a flat belt 16, a pair of rollers 11 and 12 disposed above the flat belt 16, and an adhesive 14 made of a heated thermoplastic resin to the rollers 11 and 12. Supply means 15 to be used. The roller 12 can be rotated by power, and a slight clearance is provided between the roller 12 and the roller 11. The supply means 15 is arranged so as to be able to supply the adhesive 14 in the vicinity of the upper part of the closest part of the rollers 11 and 12. The clearance is adjusted so that the adhesive 14 adhering to the peripheral surface of the roller 12 has a desired thickness when the peripheral surface of the roller 12 passes through the closest portion.

Using the roll coater 10 configured as described above, the tile connection sheet 3 is manufactured as follows. The base material 3 a unwound from the original roll 3 </ b> A is placed on the flat belt 16 and conveyed in the unwinding direction, and is inserted between the flat belt 16 and the roller 12. In addition, the roller 12 rotates, and the adhesive 14 is supplied from the supply means 15 in a timely manner near the upper part of the closest part of the rollers 11 and 12. The adhesive 14 attached to the peripheral surface of the roller 12 is transferred to the upper surface of the substrate 3a after having a desired thickness through the clearance of the rollers 11 and 12. At this time, the average thickness and the unevenness can be adjusted by adjusting the conveyance speed of the substrate 3a, the heating temperature of the adhesive 14, and the clearances of the rollers 11 and 12. After cooling, the tile connection sheet 3 is obtained by cutting into a predetermined shape.
FIG. 3 shows a copy of a photograph of the back surface of the tile connecting sheet manufactured by this method. In FIG. 3, the convex part 3c is shown as a filament which shows the ridgeline of the top part. As shown in the figure, the convex portions 3c are dispersed in the form of dots on the base material 3a. Many of the individual protrusions 3c have a lint-like shape extending substantially in the vertical direction in FIG. This vertical direction is along the axial direction of the roll 12. The convex portion 3c is presumed to be formed by the surface tension of the adhesive when the surface of the roll 12 is separated from the applied adhesive 14.

  This adhesive 14 may be impregnated in the thickness direction of the substrate 3a. For example, the base material 3a may be impregnated in an amount of 1 to 99%, particularly about 30 to 70%.

  The adhesive 14 supplied near the upper part of the closest part of the rollers 11 and 12 is preferably heated to have a viscosity of 500 to 15000 mPa · S, particularly 1000 to 10,000 mPa · S. If the viscosity is too small, unevenness cannot be formed satisfactorily. When the viscosity is too large, the application efficiency to the substrate 3a is lowered.

When a thermoplastic adhesive melted to a viscosity of about 23,000 to 27000 mPa · S is applied to kraft paper, the conditions of the roll coater 10 are preferably as follows.
The conveyance speed of the base material 3a: 10 to 30 m / min, particularly 15 to 25 m / min The heating temperature of the adhesive 14: 100 to 200 ° C., particularly 150 to 200 ° C.
Clearance between rollers 11 and 12: 50 to 200 μm, particularly 90 to 130 μm

  In the present embodiment, the feed speed of the base material 3a and the peripheral speed of the outer peripheral surface of the roller 12 are substantially the same, but the feed speed of the base material 3a is reduced even if it is faster than the roller peripheral speed. Also good. The appropriate heating temperature of the adhesive 14 varies depending on the material of the adhesive 14.

  In order to manufacture the tile unit 1, for example, a predetermined number of tiles 2 are arranged on the joint frame so that the back surfaces of the tile units 1 are up, and the connection sheets 3 are arranged so that the adhesive layer faces downward. These are arranged on the back surface of the tile 2 and are bonded by pressing the connecting sheet 3 on the heavy metal flat plate or joint frame back surface and heating in a curing furnace. Thereby, as shown in FIG. 5, the tile unit 1 in which the adhesive layer 3b is firmly bonded to the back surface of the tile 2 is manufactured.

  In the tile unit 1, the tile connection sheet 3 is bonded not only to the bottom surface of the tile 2 but also to the inclined surface 2 a through the adhesive layer 3 b. Thereby, joining of the tile 2 and the tile connection sheet 3 becomes strong.

  As shown in FIG. 5, in this tile unit 1, the portion of the tile connecting sheet 3 that faces the joint gap is an uneven surface having a convex portion 3c and a concave portion 3d.

  When manufacturing a tile construction wall surface using the tile unit 1, for example, an adhesive is applied to a wall base surface, and the back surface of the tile unit 1 is pressed against the adhesive and adhered. After the required number of tile units 1 are attached to the wall base surface, the joint material is applied to the entire surface of the attached tile wall according to the joint joint method. Thereafter, the joint material adhered to the surface of the tile 2 is wiped off with a cloth or the like, and cured until the joint material is cured, whereby the tile construction wall surface is manufactured.

  Here, the portion of the surface of the tile connection sheet 3 exposed in the joint gap is an uneven surface having the concave portion 3d and the convex portion 3c as described above, and the joint material bites into the uneven surface. As a result, the joint material adheres firmly to the tile connection sheet 3.

  The above embodiment is an example of the present invention, and the present invention is not limited to the above embodiment.

  For example, although the gradient surface 2a is provided on the four edges of the back surface of the tile 2, the gradient surface 2a may be provided on the first to third edges, or may not be provided. The back surface of the tile 2 is not provided with a back foot, but a back foot may be provided. Although the tile 2 is a horizontally long rectangle as shown in FIG. 1, the shape of the tile 2 is not limited to this, and may be a vertically long rectangle, a square, other polygons, or the like.

  Although the tile connection sheet 3 is illustrated in a substantially square shape, the present invention is not limited to this, and may be, for example, a rectangle, other polygons, a circle, an ellipse, or the like. Further, the horizontal length of the tile connecting sheet in FIG. 1 is increased so that three or more (6 or more tiles when combined vertically) tiles 2 arranged in the horizontal direction are joined by one tile connecting sheet. It may be. Further, the length of the connecting sheet in FIG. 1 is increased, and three or more (6 or more when combined up and down) tiles 2 arranged in the vertical direction are joined by one connecting sheet. Also good.

  In the tile connection sheet 3 described above, the entire surface of the adhesive layer 3b is an uneven surface, but a part of the surface of the adhesive layer 3b may be an uneven surface. For example, only the portion of the surface of the adhesive layer 3b that faces the joint gap of the tile unit 1 may be an uneven surface, and the portion that faces the joint gap and the gradient surface 2a is an uneven surface. Also good.

  In the tile unit 1 described above, the tiles 2 are arranged in six rows and three rows. However, the tile unit 1 is not limited to this. It may be arranged in 5 rows or 7 rows or more, 1, 2 rows or 4 rows or more horizontally.

<Production of tile connection sheet>
Experiment No. 1
Using the roll coater 10 of FIG. 2, the tile connection sheet 3 having the configuration shown in FIGS. As the base material 3a and the adhesive 14, the following were used.

Base material 3a: Kraft paper (basis weight 110 ± 4.0 g / m ³ , thickness 150 ± 15 μm)
Adhesive 14: Thermoplastic resin (specific gravity 0.98 ± 0.05 g / cm ² ,
Melting temperature 95 ± 7 ° C,
Melt viscosity 5250 ± 1200mPa · S / 180 ° C)

  The operating conditions of the roll coater 10 were as shown in Table 1.

  About the obtained tile connection sheet 3, the height difference of the adhesive layer 3b and the density of the convex portions were determined according to the above-described method. The results are shown in Table 1.

Experiment No. 2-6
A tile connection sheet 3 was prepared in the same manner as in Example 1 except that the control conditions of the roll coater 10 were as shown in Table 1, and the height difference and the convex portion density were obtained. The results are shown in Table 1.

<Tensile test>
For each of the tile connecting sheets (20 mm × 20 mm) of Examples 1 to 6, a joint material (cement-based joint material “Inageji” manufactured by INAX Co., Ltd.) was applied to the entire surface to a thickness of 2 mm and cured for 48 hours. Was used as a test piece.

  Metal pieces were bonded to both sides of each test piece via an epoxy adhesive. The first metal piece bonded to the base material 3a and the second metal piece bonded to the joint material are chucked by a tensile tester, and the first metal piece and the second metal piece are separated from each other. Added force. Table 1 also shows the results when the tensile test was performed at a tensile speed of 3 mm / min.

<Discussion>
As shown in Table 1, the density of the convex part of the adhesive layer is 3 to 123 pieces / mm ² and the difference in height between the concave part and the convex part is 15 to 130 μm. Nos. 2 to 5 have high adhesive strength between the base material 3a and the adhesive layer 3b. 2 and 3 have extremely high adhesive strength.

DESCRIPTION OF SYMBOLS 1 Tile unit 2 Tile 2a Gradient surface 3 Tile connection sheet 3a Base material 3A Original fabric roll 3A
3b Adhesive layer 3c Convex 3d Concave 4,5 Joint

Claims (4)

A tile connection sheet for connecting back surfaces of a plurality of tiles,
In a tile connection sheet having a base material and an adhesive layer provided on the surface of the base material,
At least a part of the surface of the adhesive layer has a concave portion and a convex portion, and the height difference between the concave portion and the convex portion is a concave-convex surface of 15 to 130 μm ,
Tile connecting sheet the number of the convex portions per unit area in the concave convex surface and wherein 3-123 pieces / mm ² der Rukoto. Oite to claim 1, tile connecting sheet, characterized in that the adhesive to the substrate is impregnated. In a tile unit formed by connecting a plurality of tiles with a tile connection sheet connected to the back surface of the tile,
The tile connection sheet is the tile connection sheet according to claim 1 or 2 ,
A tile unit having a joint gap between tiles, wherein at least a part of the uneven surface faces the joint gap. The tile unit according to claim 3 , wherein a slope surface is provided on the edge of the back surface of the tile, and at least a part of the convex portion is joined to at least a part of the slope surface.

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