JPS5848326B2 - Method for manufacturing synthetic resin sheet with non-directional pattern - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a synthetic resin sheet having a non-directional pattern such as a woodgrain or marble pattern. It is extremely useful for interior materials such as wood.

Conventionally, various attempts have been made to preserve synthetic resin sheets having this type of non-directional pattern.

For example, in Japanese Patent Publication No. 49-35815, 1. 2. Producing a synthetic resin sheet with a color or pattern; Crush the sheet to create pieces of synthetic resin material colored in two or more colors; 3. Arranging the synthetic resin material piece in a sheet form between two templates and heating and pressurizing it to form an integral sheet-like object,
4. A method for manufacturing a synthetic resin tile in which the sheet-like material is cut along a plane substantially parallel to the wide surface of the sheet is disclosed, and Japanese Patent Laid-Open No. 5
1-28156, 1. 2. Feeding two or more types of pellets with different colors onto a net-like conveyor; 3. Vibrating the net-like conveyor to fill it with pellets and heating it to form a pellet assembly using the self-adhesive force of the pellets; 3. A method of manufacturing a sheet by rolling the pellet combination is disclosed, and is disclosed in Japanese Patent Application Laid-Open No. 51-2
Publication No. 8157 includes l. 2. Feeding multicolored colored pellets onto a conveyor conveyor from a multi-rotary nozzle that repeatedly moves in a direction perpendicular to the direction of travel of the conveyor; 2. A method for producing a patterned tile is disclosed, in which the colored pellets are melt-molded using a heating roll.

In the method disclosed in Japanese Patent Publication No. 49-35815, the mixed synthetic resin material pieces are heated and pressed between two templates, and due to the heating, the parts of the material in contact with the templates flow, are mixed, etc. occurs, but no regular orientation of the material pieces or patterns occurs.

As described above, heating and pressing using a template does not cause regular orientation of the non-directionally mixed material pieces, but continuous mass production is not possible.

JP 51-28156 and JP 51-2815
Method No. 7 heat-rolls mixed colored pellets and is suitable for continuous mass production, but the colored pellets mixed non-directionally by this rolling are oriented in the rolling direction and have a highly non-directional pattern. cannot be obtained.

The purpose of the present invention is to improve the above-mentioned conventional drawbacks, use a rolling method suitable for continuous mass production, and obtain a highly non-directional pattern, and the gist of the present invention is to carry out the rolling process in a multilayered state.

The manufacturing method of the present invention includes step 1 of mixing monochrome synthetic resin pieces of a predetermined type in a predetermined ratio.

Step 2 of spreading the mixed strips in a layer over the releasable substrate.

Step 3 of heating the spread layer of mixed strips and, if desired, applying pressure to semi-fuse the strips together.

Step 4 of manufacturing a sintered sheet by rolling the semi-fused strips while maintaining the semi-fused state.

Step 5 of manufacturing a sheet by folding the sintered sheet and rolling the folded product so that the inner layer portion is not oriented.

Step 6: slicing the sheet into two or more pieces at the inner layer portion and making the sliced surface the product surface.

It consists of the above steps 1, 2, 3, 4, 5, and 6.

The present invention will be explained in detail with reference to an embodiment shown in the drawings.

The monochromatic synthetic resin strips used in step 1 are monochromatic synthetic resin strips made of thermoplastic synthetic resins such as polyvinyl chloride, polystyrene, polymethacrylate, polyethylene, and polypropylene. It is cut into pellets, granules, and flakes by pelletizers 11A, 11B, I1C, etc.

The strips 2A, 2B, 2C preferably have a diameter of 5 to 50 rI.
It is desirable to have a scale-like shape with a thickness of about Lm and as small as possible compared to the diameter.

The strips 2A, 2B, 2C are fed onto a conveyor 12 and conveyed to a mixer 13, where they are mixed.

In step 2, as shown in FIG. 2, mixed strips 2 mixed by a mixer 13 are spread in a layer on a conveyor 14 made of a release base material.

When spreading, make sure that the mixed strips 2 do not overlap each other, layer by layer.
It is also desirable to apply two or more layers.

Here, the releasable base material includes release paper, Teflon, silicone rubber, iron plate, stainless steel plate whose surface is treated with Teflon or silicone, and the like.

In step 3, as shown in FIG. 2, the spread layer 2D of the mixed strips 2 is heated with a heater 15 (for example, a far infrared heater) to semi-fuse the mixed strips 2 together.

In step 4, as shown in FIG.
A sintered sheet 2E is manufactured by rolling the semi-fused fragment spreading layer 2D using the following steps.

Naturally, the rolling at this time is carried out at a temperature and pressure that can maintain the sheet in a sintered state, that is, the strips are in a semi-fused state, and therefore, depending on the rolling, the strips are completely fused and mixed with each other. There is no possibility that the material will become oriented in the rolling direction.

In step 5, the sintered sheet 2E is rolled on a roll 17,
The folded product 2F is folded on a mixing roll 19 via a mixing jig 18, and the folded product 2F is formed into a sheet by a mixing jig 19 as shown in FIG.

At this time, the lower part of the folded article 2F is multi-layered and is rolled by the mixing roll 17 to such an extent that the inner layer is not oriented, but the stress due to this rolling is strongly applied to the surface layer of the multi-layered article, so that this portion In this case, the pattern is oriented in the rolling direction, but as it goes to the inner layer, the influence of stress decreases due to the stress absorption effect due to the sliding between the layers, and in the inner layer part, the pattern is hardly oriented in the rolling direction, due to the multilayering. Maintain a high degree of non-direction.

In step 6, the original sheet 2G obtained in step 5 is passed through a roll 20 to a presser roll 21A as shown in FIG.
and a knife 21B, and slice it to obtain product sheets 2H and 2I.

At this time, the original sheet 2G may be sliced and removed from the surface layer having a pattern oriented in the rolling direction to expose the inner layer, or it may be divided into two from the center, or it may be divided into three or more. .

In any case, the surface of the product is the above-mentioned sliced surface corresponding to the inner layer portion that maintains the non-directional pattern.

Figures 3 and 4 show the original sheet 2G before and after slicing.
Figure 3 shows the sheet surface of the original sheet 2G before slicing, and a surface layer with some directionality due to rolling appears, while Figure 4 shows the sheet surface after slicing. The sheet surface of the original sheet 2G is shown, and it can be seen that by slicing, an inner layer portion having a completely non-directional pattern appears on the sheet surface.

The sheet obtained in step 5 may further be folded and rolled if desired in the process.

That is, step 5 may be repeated two or more times.

The greater the number of repetitions of step 5, the more highly non-directional the product will be.

In the present invention, as mentioned above, when producing multiple colors, predetermined types of monochrome synthetic resin strips are mixed, so the product is already highly irregular in the initial stage, and if the mixing ratio is changed, products with various patterns can be produced. A sintered sheet produced by heating a spread layer of highly irregular mixed strips and, if desired, applying pressure to semi-fuse the strips with each other and rolling the strips while maintaining non-directionality. Since the sintered sheet is folded and then the folded material is rolled, the non-directionality becomes multi-layered, and as a result, the irregularity becomes even greater.Moreover, the rolling direction of the rolled surface (surface) of the original sheet that occurs when the sintered sheet is rolled. The flow is eliminated by interlayer sliding, and the slight directionality caused by the flow remains only on the surface. Therefore, such an original sheet can be sliced to remove the surface, or split into two or more to form the sliced surface. By applying the pattern to the surface of the product, the synthetic resin sheet produced by the method of the present invention has a highly non-directional pattern not only on the surface but also inside, so even if the surface is abraded, the pattern will not be exposed at all. The non-direction of does not change.

[Brief explanation of the drawing]

The figures show a system diagram of an embodiment of an apparatus for carrying out the method of the present invention, FIG. 1 is a system diagram of the manufacturing process of monochrome synthetic resin strips and the mixing process of the strips, and FIG. FIG. 2 is a systematic diagram of the steps of heating and semi-melting, rolling, folding, rolling and slicing a folded piece of mixed strips. In addition, Figures 3 and 4 are photographs substituted for drawings showing the sheet surface of the original sheet. Figure 3 is a photograph showing the sheet surface before slicing the original sheet, and Figure 4 is a photograph showing the sheet surface after slicing the original sheet. This is a photo showing. In the figure, 2A, 2B. 2C...Single color synthetic resin strip, 2...Mixed strip, 2D...Spraying layer,
2F...Folded items, 2G...Original sheets,
2H, 2I...Product sheet, 11A, 'flB
, 11C... Pelletizer - 13... Mixer, 14... Conveyor - 15...
Heater, 16... Pressure roll, 19...
・Mixing roll, 21... Slicer.

Claims (1)

[Claims] 1. Step 1 of mixing monochrome synthetic resin pieces of a predetermined type in a predetermined ratio. Step 2 of spreading the mixed strips on the releasable substrate in a layered manner. Step 3 of heating the spread layer of mixed strips and, if desired, applying pressure to semi-fuse the strips together. Step 4 of manufacturing a sintered sheet by rolling the semi-fused strips while maintaining the semi-fused state. Process 5 of manufacturing a sheet by folding the sintered sheet and rolling the folded product so that the inner layer is not oriented. Step 6: slicing the sheet into two or more pieces at the inner layer portion and making the sliced surface the product surface. A method for manufacturing a synthetic resin sheet having a non-directional pattern, comprising steps 1, 2, 3, 4, 5, and 6 above.