JPS5923998B2 - Manufacturing method of synthetic resin flooring - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing synthetic resin flooring used for floors, walls, interior linings, etc. More specifically, the present invention relates to a method for manufacturing synthetic resin flooring materials used for floors, walls, interior linings, etc. The present invention relates to a method for manufacturing flooring materials.

In recent years, synthetic resin flooring materials have been widely used as flooring materials, wall materials, etc., and the reasons for this include good walking feel, ease of construction, and richness of color patterns. However, on the other hand, although these synthetic resin flooring materials are embossed on the surface, they have the disadvantage that they lack texture and three-dimensionality compared to conventional stone materials. In view of the above points, the present invention provides a method for manufacturing a synthetic resin flooring material that has the texture and three-dimensional effect of conventional stone materials and the advantages of synthetic resin flooring materials, has light reflectivity, and has excellent abrasion resistance. It provides:

Then, light-reflecting fine pieces or metal powder are mixed with a transparent or semi-transparent thermoplastic resin and made into a sheet by a calendering method or an extrusion method, and the sheet is cut into an appropriate size. Alternatively, the coarse particles containing fine particles and the metal powder coarse particles are obtained by pulverization, and the coarse particles are mixed with colored coarse particles and transparent coarse particles prepared separately from a thermoplastic resin composition, and To adopt a manufacturing method for synthetic resin flooring material, which is characterized by supplying the material in a layer of a certain thickness onto the material and then applying heat and pressure to fuse the surface of the coarse particles to form an integrated sheet-like product. The direction of the light-reflecting fine particles produced when molding a transparent or translucent thermoplastic resin sheet or extrudate containing light-reflecting fine particles by calendering or extrusion processing. This can be achieved industrially advantageously while also eliminating the problem of That is, light-reflecting fine pieces are mixed into a thermoplastic resin composition, and a transparent or translucent thermoplastic resin sheet or extrudate containing the light-reflecting fine pieces is formed by calendering or extrusion. Coarse particles obtained by cutting or crushing into appropriate sizes (hereinafter referred to as coarse particles with fine pieces) and other coarse particles separately prepared from thermoplastic resin compositions, such as filled Colored coarse particles produced from a thermoplastic resin composition containing pigment (hereinafter referred to as colored coarse particles); Colored coarse particles produced from a thermoplastic resin composition containing metal powder; Coarse particles (
Hereinafter, it will be referred to as metal powder coarse particles. ), transparent coarse particles produced from an unfilled thermoplastic resin composition (hereinafter referred to as transparent coarse particles), etc. can be arbitrarily selected and mixed to achieve various light reflection properties. It is possible to industrially advantageously achieve a synthetic resin flooring material with excellent abrasion resistance. Hereinafter, the present invention will be explained in detail based on the accompanying drawings. 1st
The figure is a schematic diagram of the manufacturing process of the present invention, and FIG. 2 is a partially enlarged plan view of the finally obtained product.

Moreover, FIG. 3 is a partially enlarged sectional view of the Paso product. In carrying out the present invention, the thermoplastic resin forming the coarse particles in the present invention includes polyvinyl chloride or a copolymer thereof, polyvinylidene chloride or a copolymer thereof, vinyl chloride monovinyl acetate, vinyl chloride monovinylidene chloride, It can be arbitrarily selected from synthetic resins such as the above polymers or copolymers such as vinylidene chloride monoacetate and vinyl chloride monoacetate-vinyl alcohol, depending on the physicochemical properties required for the coarse particles. . Furthermore, various plasticizers, stabilizers, fillers, lubricants, pigments, etc. can be contained as necessary. Further, the light-reflecting fine pieces in the present invention include metal foils such as gold leaf, Western gold foil, and aluminum foil, and metal-deposited pieces of plastic film, metal-plated glass pieces, etc., as long as they have light reflectivity. They can be freely selected, and mixtures of multiple types with different shapes, sizes, colors, or textures can also be used. Further, the metal powder in the present invention can be arbitrarily selected from gold powder, western gold powder, aluminum powder, steel powder, etc. as required. In the present invention, the thermoplastic resin forming the coarse particles is a thermoplastic resin containing pinyl chloride resin, a plasticizer, a stabilizer, a filler, a lubricant, or a pigment, although this is not intended to limit the gist of the present invention. It is preferable to use a plastic resin composition, and the fine pieces having anti-light reflective properties have a thickness of 10 to 20 mm.
Is the size 0.3 to 0.5 in μ? It is preferable to use a metal powder of approximately square size, and it is desirable to use metal powder with a mesh size of 200 mesh or less.

More specifically, coarse particles containing fine particles are produced by mixing the above-mentioned light-reflecting fine particles into a thermoplastic resin composition consisting of vinyl chloride resin, a plasticizer, and a stabilizer, and then processing the coarse particles using a device such as a Niroll mill. After being kneaded and calendered or extruded to form a transparent thermoplastic resin sheet or extrudate containing light-reflecting microscopic particles, it is fed to a dicing machine and cut into regular shapes or sheared. The material is crushed by a crusher and cut into irregular shapes to produce transparent coarse particles containing light-reflecting fine pieces.

Further, in the case of producing a translucent coarse granule containing light-reflecting fine particles, a small amount of pigment may be added to the thermoplastic resin composition. Other coarse particles mentioned above, such as colored coarse particles, are produced by mixing fillers and pigments such as calcium carbonate into a thermoplastic resin composition consisting of vinyl chloride resin, a plasticizer, a stabilizer, and titanium oxide. A coarse granule is produced according to a similar process. Furthermore, coarse metal powder particles are prepared by mixing the above metal powder into a thermoplastic resin composition comprising a vinyl chloride resin, a plasticizer, and a stabilizer, and following the same steps as described above. On the other hand, transparent coarse granules are produced by simply following the same steps as described above from a thermoplastic resin composition comprising a vinyl chloride resin, a plasticizer, and a stabilizer. (These are not shown.) In this way, fine individual coarse grains, colored coarse grains, metal powder coarse grains, and transparent coarse grains are produced. Alternatively, the selection and combination of textures is free. However, in order to facilitate the fusion of the coarse grains by heating and pressurizing, which will be described later, and to obtain an integral sheet-like product, it is desirable that the size of the coarse grains be seven meshes. The case where equal amounts of the above-mentioned coarse particles are mixed will be described below, but in the present invention, multiple types of coarse particles with different shapes, sizes, colors, textures, etc., are freely selected and arbitrarily mixed. They can be used in combination, and the mixing ratio of the coarse particles can also be changed freely. Moreover, the above-mentioned coarse particles can be dispersed onto a substrate in a geometric pattern or a color pattern by a known method, and the gist of the present invention is not limited thereto. The above-mentioned aggregated granules are blended according to the desired mixing ratio using a known device such as a tumbler, and then
After the coarse particles are put into the substrate, they are stacked uniformly to a constant thickness and formed into a layer on the base material 1 which is continuously supplied by a known coarse particle supply device 4 consisting of a hopper 2 and a measuring roll 3.
A laying layer 5 as shown in the figure is formed.

The base material 1 can be freely selected from asbestos, glass fiber paver, fiber cloth, paper, resin film, etc. In the present invention, it is not always necessary to apply an adhesive to the surface of the base material in advance. However, in order to facilitate adhesion of coarse particles in the subsequent process, for example, EV
It is also possible to apply a thermally active adhesive such as A resin adhesive, acetic acid-vinyl acrylic copolymer resin, acrylic acid ester resin, etc. to the surface of the base material and dry it.

Next, the laid layer 5 is sent to a known first heating device 6 such as an infrared heater, where it is heated to 130°C to 180°C, and is then pressed by a pressure roll 7 and a back-up roll 8. The base material and the coarse grains or the coarse grains are temporarily bonded to each other.

In this case, the thickness of the laying layer, the heating temperature, and the pressing force cannot be uniformly specified because they vary depending on the type and composition of the thermoplastic resin forming the coarse particles, or the thickness of the coarse particles, but the width is 1900. ? 400-3000Kf per l
It is preferable to apply temporary bonding pressure. Further, temporary adhesion can be carried out in several parts if necessary. The laying layer 5 that has been temporarily bonded is further heated again to 130°C to 180°C by the second heating device 9, and then heated to 160°C to 180°C.
Heating drum 10 and pressure roll 11 heated to 190°C
Depending on the width 1900? A pressure of 400 to 3000 Kf is applied to fuse the surfaces of the coarse particles to form an integrated wear layer. Then, it is peeled off from the heating drum 10 by the peeling roll 12, and is removed from the cooling roll 13 and the Feston type accumulator (
After being cooled by supplying it to a known cooling device such as (not shown), it is rolled up as a product 14 in the form of an integral sheet. Incidentally, if necessary, the surface of the product can be embossed using a device such as an embossing roll to increase the light reflection effect.

Furthermore, specificity can be imparted by lightly coloring the coarse grains containing fine pieces or transparent coarse grains, making the colored coarse grains marble-like, or applying valley print. As described above, light-reflecting fine pieces are mixed into the thermoplastic resin composition, and a transparent or translucent thermoplastic resin sheet containing light-reflecting fine pieces is produced by calendering or extrusion processing. After molding the product, cut or crush it into an appropriate size to obtain a coarse granule, mix the coarse granule with another coarse granule separately prepared from a thermoplastic resin composition, and spread it uniformly on a substrate. After being supplied in a thick layer, the coarse particles are heated and pressed to fuse their surfaces to form an integrated sheet. In addition to eliminating the directionality in the flow direction of light-reflecting fine particles as shown in FIG. 4, which occurs when a translucent thermoplastic resin sheet or extrudate is molded, the flow of coarse particles,
In other words, it forms a clear pattern without losing its shape,
Figure 2 and :[nd:′. ；＝＝＝↓＝A wear-resistant product with an unprecedented texture and three-dimensional effect that emits a wide variety of reflected light by complexly deforming light emitting microscopic pieces and reflecting light three-dimensionally and randomly. Excellent synthetic resin flooring can be obtained.

Examples will be described below to further specifically explain the present invention. [Example 1] Thermoplastic resin compositions A, B, C, D, shown in the above formulation examples,
Each of E was kneaded in a double roll mill, calendered to form a sheet with a width of 200 mm and a thickness of 1.6 to 1.7 wB, and then crushed in a shear type crusher to form coarse particles of 7 meshes. Each body was created.

Next, coarse grains A containing fine pieces produced in this way,
Colored coarse particles B, metal powder coarse particles C and D, transparent coarse particles E
are mixed in equal amounts using a tumbler and put into a hopper 2, and then a known coarse particle supply device 4 consisting of a hopper 2 and a measuring roll 3 is used to apply 50% of EVA resin adhesive to the surface.
Width 1900Wr coated and dried to a thickness of ~10μ! 11 Approximately 3r1 on the base material 1 of asbestos sheet with a thickness of 0.9WB
Layer 5 evenly stacked and layered to a thickness of r111
form. Next, the laid layer 5 is sent to a first heating device 6, such as a known infrared heater, where it reaches an optimum temperature of 170°C.
After heating, the pressure roll 7 and the back-up roll 8 apply a pressure of 2000 Ky per width of 1900 Tm to compress the coarse grain layer with a thickness of about 3 rm into a coarse grain layer with a thickness of about 2 WJ. and temporarily adhere. In this case, it is desirable to maintain the surface temperature of the pressure roll 7 at about 5'C to 80C. The laid layer 5 that has been temporarily bonded is again sent to the second heating device 9, where it is heated until the surface temperature of the laid layer 5 reaches 170°C, and then heated to 180°C, the heating drum 10 and the pressure roll. 11, an optimal pressure of 1000 Kf per width of 1900 wt is applied to fuse the surfaces of the coarse grains to form an integral wear layer, resulting in an integral sheet-like article. Thereafter, the integral sheet-like material is peeled off from the heating drum 10 by a peeling roll 12, cooled by a cooling roll 13 and a Feston type accumulator, and then wound up as a product 14. In this way, the directionality of the light-reflecting fine particles with respect to the flow direction is eliminated, a clear pattern is formed without causing the flow of coarse particles, and moreover, golden reflected light is emitted three-dimensionally or randomly. A synthetic resin flooring material with excellent abrasion resistance and a unique texture and three-dimensional effect was obtained.

[Example 2] Thermoplastic resin compositions X, Y, and Z shown in the above formulation examples were each prepared according to the same process as described in Example 1 above.
Coarse grains X with fine pieces that emit reflected light in the edge color, coarse grains Y with fine pieces that emit reflected light in silver color, and metal powder coarse grains Z are prepared, and coarse grains X, Y, and Z are prepared. Equal amounts of each are mixed and processed into an integral sheet-like product according to the same steps as those described in Example 1 above.

In this way, the directionality of the light-reflecting fine particles with respect to the flow direction is eliminated, and a clear pattern is formed without causing the flow of coarse particles. A synthetic resin flooring material with excellent abrasion resistance, which emitted reflected light and had a three-dimensional effect different in color or texture from Example 1, was obtained.

[Brief explanation of drawings]

FIG. 1 is a schematic diagram of the manufacturing process of the present invention, FIG. 2 is a partially enlarged plan view of a finally obtained product, and FIG. 3 is a partially enlarged sectional view of the product. FIG. 4 is a partially enlarged cross-sectional view of a transparent thermoplastic resin sheet containing light-reflecting fine particles. FIG. 5 is a partially enlarged sectional view of the laying layer 5. 1: Base material, 2: hopper, 3: Measuring roll, 4: Coarse particle supply device, 5: Laying layer,
6: First heating device, 7: Pressure roll, 8: Backup roll, 9: Second heating device, 10: Heating drum, 1
1: Pressing roll, 12: Peeling roll, 13: Cooling roll, 14: Product, 20: Fine pieces, A: Coarse particles containing fine pieces,
B: Colored coarse particles, C: Metal powder coarse particles (blue steel powder), D: Metal powder coarse particles (silver powder), E: Transparent coarse particles.

Claims (1)

[Claims] 1. Mix light-reflecting fine pieces or metal powder with a transparent or translucent thermoplastic resin to create a sheet by calendering or extrusion, and then cut or crush the sheet into appropriate sizes. A coarse granule containing fine pieces and a metal powder coarse granule are prepared by mixing the coarse granule with a colored coarse granule and a transparent coarse granule prepared separately from a thermoplastic resin composition, and the above coarse granule is placed on a substrate. A method for producing a synthetic resin flooring material, which comprises supplying the coarse particles in a layered form with a constant thickness and then heating and pressurizing them to fuse the surfaces of the coarse particles to form an integral sheet-like material.