JP5557207B2 - Floor sheet - Google Patents

Description

  The present invention relates to a floor sheet made of synthetic resin, and more specifically, the surface layer pellets dispersed on the sheet base material and integrated by hot pressing are difficult to peel off from the sheet base material and are crushed during hot pressing. For difficult floor sheets.

  Conventionally, various synthetic resin floor sheets have been developed and applied, and as one of them, the area ratio of the chip and the thermoplastic resin base sheet is 5:95 to 90:10. In addition, the chip and the base material sheet are integrated by spraying the chip on the base material sheet and subsequently embossing after heating and melting, so that the chip and the base material sheet are substantially smooth (floor sheet). Is known (see Patent Document 1).

  According to Patent Document 1, this design sheet has no concern that the appearance is unsightly because the base sheet and the chip are worn simultaneously, and the area ratio of the chip and the base sheet is 5:95 to 90. : It is described that since it is 10, the amount of chip used is small and the cost can be suppressed.

JP-A-2005-290607

  However, since the above design sheet spreads chips on the thermoplastic resin base sheet that has been made into a sheet from the beginning, if the chips dropped on the base sheet drop vigorously on the base sheet surface, There is a problem that it is difficult to form an intended pattern or design because the chip bounces and the chip cannot be placed at a desired position or the chips overlap each other.

  In addition, when a chip having a small volume is dispersed on a substrate sheet having an extremely large volume compared to the chip as in the above-described design sheet, when the substrate sheet and the chip are heated to melt and integrate, A small chip enters a molten state earlier than the base sheet, and the melted chip sticks to the surface of the base sheet. Such a phenomenon is further accelerated because heating is normally performed from the upper side of the base sheet. Therefore, when shaped with a roll, the chips that are quickly melted are spread out with the roll and are not sufficiently embedded in the surface layer part of the base sheet, so that a blurred pattern or pattern with a blurred chip form is formed, When used as a floor sheet, there was a problem that the chip peeled off from the base sheet. Such a problem is further promoted by heating because the surface of the base material sheet directly below the chip is hidden by the chip and is not sufficiently heated and melted.

  The present invention has been made in view of the above problems, and the problem to be solved is that the surface layer pellet can be placed at a desired position of the sheet base material, and the surface layer pellet is not easily crushed, and the sheet base material It is intended to provide a floor sheet in which surface layer pellets are embedded in the surface layer part and sufficiently melted and integrated so that the surface layer pellets are not easily dropped from the sheet base material.

In order to solve the above problems, the floor sheet according to the present invention is obtained by spraying thermoplastic resin surface layer pellets on a thermoplastic resin sheet base material, and integrating the sheet base material and surface layer pellets by hot pressing. a and floor sheet, the area ratio of the surface layer pellet occupies the floor sheet surface is 5 to 95% Ri pellet layer der heat molding previous sheet substrate is made of a thermoplastic resin base material for pellets The surface layer pellet has a true specific gravity larger than that of the substrate pellet .

  In the floor sheet of this invention, it is preferable that the average volume of the surface layer pellet is the same as or larger than the average volume of the base material pellet.

  In the floor sheet of the present invention, since the sheet base material before hot pressing is a pellet layer made of thermoplastic resin base material pellets, even if the sprayed thermoplastic resin surface pellets collide with the pellet layer Since the pellet layer absorbs the impact, the surface layer pellet is less likely to jump and the surface layer pellet can be placed at a desired position. Therefore, when the surface layer pellets are, for example, pellets having different colors for forming a pattern or a pattern, a desired pattern or pattern can be easily and accurately formed.

Also, if the sheet substrate is a pellet layer, the surface pellets and pellet substrate pellets are heated and melted to approximately the same degree by the heat during hot pressing, and the surface pellets are more than the substrate pellets. Since the true specific gravity is large, the pellet for the surface layer tends to settle in the pellet layer due to the difference in specific gravity, and the pellet for the base material of the surface layer portion of the pellet layer is not extremely crushed by the pressure during hot pressing Since the pellets are intertwined in a state where they are half buried between them and are firmly welded and integrated, the shape of the surface layer pellets may be greatly broken, or the surface layer pellets may fall off the sheet base material after hot pressing Almost disappear.

  In particular, when the average volume of the pellets for the surface layer is the same as or larger than the average volume of the pellets for the substrate, the pellets for the surface layer do not enter the molten state earlier than the pellets for the substrate during hot press molding. Therefore, the above-described effects are more remarkably exhibited because the base pellets are securely embedded and integrated with the base pellets while substantially maintaining the shape of the pellets for use.

(A) is the partial top view of the floor sheet which concerns on one Embodiment of this invention, (b) is the partial top view before the hot-pressure shaping | molding of the same floor sheet. (A) is the fragmentary sectional view of the same floor sheet, (b) is the fragmentary sectional view before the hot-pressure forming of the same floor sheet.

  Hereinafter, an embodiment of a floor sheet according to the present invention will be described with reference to the drawings.

  A floor sheet S shown in FIGS. 1 (a) and 2 (a) is formed by forming a pattern 2 having a different hue on the surface (surface layer portion) of a sheet substrate 1, and this sheet substrate 1 is 1 (b) and 2 (b), the pellet layer 10 is made of pellets 1a made of a thermoplastic resin substrate before hot pressing, and a pattern 2 is formed on the pellet layer 10. The surface layer pellets 2a for forming the surface layer are sprayed, and the pellet layer 10 and the surface layer pellets 2a are integrated by hot pressing.

  That is, the floor sheet S is made by melting the surface pellet 2a and the substrate pellet 1a with heat at the time of hot-pressure molding, and transforming the surface pellet 2a with the pressure at the time of hot-pressure molding. 1a is embedded, and the pellets 10 are formed into a sheet by welding the surface pellets 2a, the surface pellets 2a and the substrate pellets 1a, and the substrate pellets 1a together. While forming, the pattern 2 of the different color by the welded pellet 2a for surface layers is formed in the surface layer part of the sheet | seat base material 1. FIG.

  The substrate pellets 1a and the surface layer pellets 2a may be different in color and have substantially the same composition, that is, pellets having different types and addition amounts of colorants such as pigments. The main material resin of the pellets 1a and 2a can be used as long as it is a thermoplastic resin. Among them, a soft vinyl chloride resin containing a plasticizer that has been conventionally used as a material resin for flooring, An olefin resin is preferably used. To these resins, inorganic fillers such as calcium carbonate and talc may be added for the purpose of increasing the amount and improving the texture, and a chemical foaming agent is added to reduce the weight of the floor sheet S and provide elasticity. May be improved. In addition, anti-slip pellets can be obtained by adding silicon-based or metal-based anti-slip particles, heat-reflective pellets can be obtained by adding heat-reflective agents, and anti-bacterial / anti-wrinkle pellets can be added by adding anti-bacterial / anti-fouling agents. Or by adding wax or the like to obtain an antifouling pellet, or a phosphorescent agent may be added to obtain a phosphorescent pellet. When these pellets are appropriately used as a surface layer pellet or a substrate pellet, There is an advantage that a floor sheet having a function can be produced. Needless to say, heat stabilizers and molding aids necessary for molding are added to the resin.

  The pellets 1a and 2a for the substrate and the surface layer were pulverized by extruding the thermoplastic resin composition to which various additives were added as described above into a plate shape having a thickness of about 0.5 to 10 mm using an extruder. Or a pellet that is extruded into a cylindrical shape having a diameter of about 0.5 to 10 mm and cut into a short cylindrical shape with a cut blade, and the pellet layer 10 of the base material pellet 1a and the surface layer pellets sprayed thereon. It is preferable to use amorphous pellets so that the pellets can be intertwined and firmly melted and integrated when hot-pressing 2a. The amorphous pellets may be produced by secondary pulverization of the above pulverized product or cut product.

The size (average volume) of the pellets 1a and 2a for the substrate and the surface layer is not particularly limited, but pellets having an average volume of approximately 0.001 to 100 mm ³ can be used. In addition, it is preferable to use pellets having an average volume of 0.1 to ⁵ mm ^{3 because} the hot press moldability and handleability are good. The average volume of the surface layer pellets 2a is preferably equal to or larger than the average volume of the base material pellets 1a, and the surface layer pellets 2a are dispersed on the pellet layer 10 of the base material pellets 1a. When hot pressing is performed, the surface layer pellets 2a are not melted faster than the base material pellets 1a, so that the shape of the surface layer pellets 2a is substantially maintained and the base material pellets 1a are securely embedded between each other. There is an advantage that it can be welded and integrated firmly.

  Moreover, it is preferable to use the pellet 2a for surface layer with a larger true specific gravity than the pellet 1a for base materials. In this way, the pellet 2a for the surface layer tends to settle on the pellet layer 10 due to the difference in specific gravity, and the pellets 1a and 2a are intertwined and firmly entangled with each other between the pellets 1a for the substrate on the surface layer portion of the pellet layer 10 There is an advantage that it can be fused and integrated.

The ratio between the true specific gravity of the substrate pellet 1a and the true specific gravity of the surface pellet 2a is preferably in the following relationship.
True specific gravity of substrate pellets: True specific gravity of surface layer pellets = 1: 1.05-1.5
When the ratio of the true specific gravity of the pellets 2a for the surface layer to the true specific gravity of the pellets for the base material is smaller than the above range (1.05 to 1.5), the pellets 2a for the surface layer In the case where it is difficult to be buried between the base material pellets 1a and is larger than the above range, since most of the surface layer pellets 2a are buried and the surface layer pellets 2a become inconspicuous, either case is not preferable.
The true specific gravity of the pellets 1a and 2a can be easily adjusted by increasing or decreasing the amount of the filler added to the pellet main material resin.

  Of course, the surface layer pellets 2a may be used in combination with a plurality of types of pellets having different hues. In that case, the pattern 2 on the surface of the floor sheet S becomes colorful and the design is further improved.

  If the pellet layer 10 is formed by spraying the base pellet 1a on the endless conveyor to a substantially uniform thickness as a whole surface with a desired width and substantially no gap, using a known spraying method. Good. As shown in FIG. 2 (b), the pellet layer 10 to be formed is appropriate to have a thickness in which about two pellets 1a for base materials overlap each other, but may have a thickness in which three or more pellets overlap. The thickness may be one grain.

  On the other hand, the surface pellet 2a is sprayed by a known method such as rotating the engraving roll to drop the surface pellet 2a, dropping from a sieve hole, or dropping using a vibrating plate. May be sprayed at a desired position of the pellet layer 10. Even when the surface layer pellets 2a are sprayed in this way, the pellet layer 10 absorbs the drop impact of the surface layer pellets 2a, so that the surface layer pellets 2a are hardly splashed and placed at a desired position.

  And after spraying the surface layer pellets 2a, it is preferable to give a slight vibration to the pellet layer 10 on the conveyor. In this case, the base material pellets 1a and the surface layer pellets 2a are easily entangled, so they are fused and integrated. Sometimes, the surface layer pellet 2a is more difficult to drop off. In particular, when there is a difference in specific gravity between the pellets 1a and 2a, the surface layer pellet 2a is immediately embedded by microvibration and sufficiently entangled with the substrate pellet 1a, and is firmly melted and integrated at the time of hot pressing. Become so.

It is necessary to adjust the application amount of the surface layer pellets 2a so that the area ratio of the surface layer pellets 2a in the surface of the floor sheet S is 5 to 95%, and the surface layer pellets 2a are formed when the area ratio is less than 5%. The pattern 2 becomes smaller and is hardly noticeable. On the other hand, if it exceeds 95%, most of the surface of the floor sheet S is occupied by the pattern 2, so that the hue of the pattern 2 is illusioned with the hue of the surface of the floor sheet S, and the pattern 2 becomes difficult to understand.
In addition, to supplement, the area ratio of the surface layer pellets 2a in the surface of the floor sheet S is the sum of the area corresponding to the surface layer pellets 2a exposed on the surface of the floor sheet S after hot pressing. Shows the ratio of the floor sheet S to the surface.

The hot pressing after spraying the surface layer pellets 2a heats the base material pellets 1a and the surface layer pellets 2a of the pellet layer 10 by a known method such as hot air or heat ray irradiation, and then presses them with a roll or a press plate. You can do it. As for heating conditions, for example, in the case of hot air heating, it is appropriate that the hot air temperature is about 10 to 100 ° C. higher than the softening temperature of the pellet resin, and the heating time is about 1 to 15 minutes. The pressure condition is suitably 0.5 to ³ kN / cm ² .

  As described above, the pellets 10a for the base material are spread on the conveyor to form the pellet layer 10, and the pellets 2a for the surface layer are spread and hot pressed to form the pellets 10a. As shown in (a), a pattern 2 having a different hue is formed in the surface layer portion of the sheet base material 1 in an embedded state, and the surface layer pellet floor sheet S (sheet base material 1) constituting the pattern 2 is formed. A floor sheet S having an area ratio of 5 to 95% on the surface can be produced.

  In the floor sheet S having the above-described configuration, the sheet base material 1 is the pellet layer 10 made of the thermoplastic resin base material pellets 1a before the hot-press molding, and thus the dispersed thermoplastic resin surface layer pellets 2a. The surface impact pellets 2a are absorbed by the pellet layer 10 and the surface layer pellets 2a are less likely to splash. Therefore, the surface layer pellets 2a having different hues can be placed at desired positions on the pellet layer 10 to easily obtain the desired pattern 2 or design. It can be formed accurately. Also, the surface layer pellet 2a and the base material pellet 1a of the pellet layer 10 are heated and melted to approximately the same degree by the heat at the time of hot pressing, and only the surface layer pellet 2a is not crushed by the pressure at the time of hot pressing. Since it is embedded between the base material pellets 1a of the pellet layer 10 and welded and integrated while being intertwined with each other, the shape of the surface layer pellets 2a is greatly broken, or the surface layer pellets 2a are Therefore, the desired pattern 2 or design that has a clear outline and is less prone to degeneration (deterioration) due to dropping of the surface layer pellets 2a can be formed.

  In addition, although the floor sheet S of the said embodiment uses the pellet 1a for base materials and the pellet 2a for surface layers which are fundamentally the same compositions and only different hues, if fusion integration is possible, both of them will be used. It goes without saying that the composition may be varied by appropriately changing and adding the type and amount of resin and additives between the pellets.

  Moreover, although the floor sheet S of the said embodiment is provided with the substantially smooth surface, you may form an unevenness | corrugation on the surface by embossing, Furthermore, on the surface of the floor sheet S, antifouling property and killing resistance, You may provide the coating-film layer for providing weather resistance. Further, a backing sheet may be laminated on the lower surface of the sheet substrate 1, or a reinforcing fiber layer such as a glass nonwoven fabric may be provided between the sheet substrate 1 and the backing sheet or on the lower surface of the backing sheet. In that case, the backing sheet is also preferably formed by laminating a pellet layer made of thermoplastic resin backing pellets on the lower side of the pellet layer 10 and melting and integrating them by hot pressing.

DESCRIPTION OF SYMBOLS 1 Sheet base material 1a Base material pellet 2 Pattern 2a Surface layer pellet 10 Pellet layer S Floor sheet

Claims (2)

A floor sheet in which thermoplastic resin surface pellets are dispersed on a thermoplastic resin sheet base material, and the sheet base material and surface layer pellets are integrated by hot pressing, and the surface layer pellets occupy the floor sheet surface. the area ratio is 5% to 95%, the pellet layer der heat molding previous sheet substrate is made of a thermoplastic resin base material for the pellets is, the surface layer pellets true specific gravity is larger than the pellets for the base material A floor sheet characterized by that.   The floor sheet according to claim 1, wherein the average volume of the surface layer pellets is equal to or larger than the average volume of the base material pellets.

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