JPS5949883B2 - Method for forming patterns on polyvinyl chloride sheets - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of forming a pattern on a polyvinyl chloride sheet, and more specifically, the present invention relates to a method of forming a pattern on a polyvinyl chloride sheet, and more specifically, the present invention relates to a method of forming a pattern on a polyvinyl chloride sheet used for flooring, etc. The present invention relates to a method for forming a pattern on a polyvinyl chloride sheet, in which the pattern of the resin paste is continuously formed along the thickness direction of the sheet material while making a pattern of equal height visible.

Embossing methods, pressing methods, casting methods, and the like are known as methods for forming irregularities or planar patterns on the surface of thermoplastic resin sheets such as polyvinyl chloride.

However, even if a pattern is formed on the surface of a resin sheet by these methods, if heat exceeding the molding degree is applied to the resin sheet afterwards, the sheet becomes plasticized and the pattern tends to disappear. In practice, it is quite difficult to leave a pattern that does not lose its shape in the final product. Also, since the pattern is substantially formed on the surface of the resin sheet or over a small thickness from the surface,
For example, when the final product is used as a flooring material, there is a drawback that the pattern gradually becomes thinner over time due to wear. A pattern forming method is also known in which a resin paste filling hole is formed in a thermoplastic resin sheet, a sol-like resin paste is filled in the hole, and then the resin paste is gelled by heating. Because the surface tension of the paste, air bubbles in the holes, etc. prevent the resin paste from entering the holes, the adhesive strength between the sheet material and the resin paste is insufficient. It is virtually impossible to produce sheet material.

The present invention solves the practical drawbacks recognized in the conventional methods of forming patterns on thermoplastic resin sheets, especially polyvinyl chloride sheets, as described above, and improves the required depth not only on the sheet surface but also along the thickness direction of the sheet. The main purpose is to form a pattern that does not lose its shape over the course of the process.

Another main object of the present invention is to have a pattern with excellent surface smoothness by a relatively small number of steps, and the pattern is formed continuously along the thickness direction of the sheet. The object of the present invention is to find new technical means for producing polyvinyl chloride sheets that can be used as flooring materials for heavy walking.

The object of the present invention is to provide a method for forming a pattern on a polyvinyl chloride sheet, which comprises a first polyvinyl chloride sheet and an inorganic filler whose weight is equal to or more than three times the weight of the resin component. A process of overlapping and fusing a second polyvinyl chloride sheet containing the agent, and a step of stacking and fusing the first polyvinyl chloride sheet from the surface of the first polyvinyl chloride sheet to the second polyvinyl chloride sheet so that the pore diameter on the suction side is small (described later). A step of drilling a pore having an intermediate step portion with a large pore diameter on the resin paste filling side through the fused sheet, and applying a polyvinyl chloride resin paste into the pore by suction pressure from the pore. a step of removing the excess resin paste from the surface of the first polyvinyl chloride sheet with a doctor knife, and a step of heating and gelling the resin paste filled into the pores. By employing the above-mentioned method, it can be advantageously achieved industrially.

Hereinafter, the method of the present invention will be explained in detail based on the illustrations of the accompanying drawings.

In the drawings, FIG. 1 is an explanatory diagram showing the connection of steps suitable for carrying out the method of the present invention, FIG. 2 is an enlarged longitudinal cross-sectional view of a fusion sheet with pores, and FIG. An enlarged vertical cross-sectional view of the adhesive sheet immediately after removing the resin paste,
FIG. 4 is an enlarged longitudinal sectional view of a patterned polyvinyl chloride sheet produced by the method of the present invention. In these drawings, the first polyvinyl chloride sheet 20 and the second polyvinyl chloride sheet 30 containing an inorganic filler whose weight is equal to or more than three times the weight of the resin component are pore-perforated. The sheets 20 and 30 are fed under heating in an overlapping state between an embossing roll 10 having projections on the surface thereof and a pinch roll 12 for pressing the sheets 20 and 30 against the embossing roll 10 to form a single sheet material. , and at the same time continuous pores 42 and 44 are drilled through the sheet material from the surface of the first sheet 20 to the second sheet 30 as seen in FIG. Ru.

In carrying out the present invention, the sheet fusing process and the pore drilling process may be separate processes, but in this case, the first and second sheets are overlapped by a calender roll (not shown) or the like. It is desirable that the two sheets be fused under heat and then fed to the pore drilling process. The pores are through holes that function as suction holes that apply suction pressure to the resin paste when suctioning the resin paste in a subsequent step,
It is desirable to adjust the hole diameter and the relationship between the hole diameter and the axial length of the hole so that the sucked resin paste is not exposed on the suction side surface of the fusion sheet, that is, on the back surface of the fusion sheet. For this purpose, the thickness of the sheet material and the magnitude of the suction pressure are related, so it cannot be specified uniformly.
The diameter of the suction side 44 of the pores is desirably maintained within a range of 30 to 75% of the diameter of the resin paste filling side 42, and is limited in order to increase the degree of freedom in pattern formation with the resin paste on the fused sheet. Although not ideal, the diameter of the pores is less than 3u, more preferably 2u.
It is recommended that the total length along the axial direction of the pores, that is, the thickness of the fusion sheet, be at least equal to the diameter of the pores. However, the pore diameter can be adjusted to 3
In this case, in order to facilitate the removal of air bubbles in the pore, the bottom surface of the step inside the pore is inclined toward the center of the pore to prevent the air bubbles from remaining. The corners of the involved pores are substantially eliminated, or two or more suction side pores 44 are formed in one resin paste filling side pore 42.
It is desirable to open the Incidentally, the inorganic filler in the present invention means an inorganic filler that can be blended into polyvinyl chloride resin, such as calcium carbonate, clay, and shirasu balloon, among which calcium carbonate is most suitable.

The perforated fused sheet moving in the direction of the arrow in FIG. 1 is cooled to 100° C. or less, more preferably about 70° C., in a cold nine furnace 11 by a conventional method to prevent shrinkage of the pores. , the pores 42 and 44 are filled with a polyvinyl chloride resin paste 40 supplied from the hopper 14 and the knife coater 13. The resin paste 40 is then suctioned by the suction pressure of a suction tank 16 connected to a negative pressure source (not shown) outside the system to increase its packing density, and is further applied to the first polymer by the doctor knife 18. The excess resin paste is removed from the surface of the vinyl chloride sheet 20, and the first sheet 20 is deposited in the pores as shown in FIG.
Form a resin paste surface that is slightly lower than the surface.
At this time, since the pore diameter on the suction side of the pores is narrowed to 30 to 75% of the pore diameter on the resin paste filling side, the resin paste 40 is drawn into the pores 42 on the resin paste filling side despite the effect of the suction pressure. Entry is essentially blocked until it reaches the bottom.
The fusing sheet from which the excess resin paste has been removed is introduced into the heater 19 with its pores filled with an appropriate amount of the resin paste 40 and heated to a gelling temperature. By this heating, the resin paste 40 is solidified to form a resin paste surface substantially at the same height as the surface of the first sheet 20, as shown in FIG. In practicing the present invention, the first and second polyvinyl chloride sheets 20 and 30 and the resin paste 40 have a resin paste surface that is substantially at the same height as the surface of the first sheet 20 in the final product as described above. In order to form a resin sheet, it is desirable to adjust the content of the inorganic filler as well as the type and content of a plasticizer, stabilizer or dispersant according to a conventional method, depending on the composition of the resin sheet and paste. The degree of gelation in the heating process is also adjusted.

Further, when the patterned sheet material produced according to the present invention is used, for example, as a flooring material, the portion filled with the resin paste 40 and the first sheet material 20 and/or the second sheet material excluding the resin paste filled portion It may be desired to make the sheet material 30 a different color, and for this purpose it is desirable to adjust the color of the pigment blended into the resin paste and the first and/or second sheet material. Hereinafter, the method of the present invention will be explained with reference to Examples, but the scope of the present invention is not limited in any way by the description of such Examples. Example average degree of polymerization 1000 (l) D based on parts by weight of PVCIOO
Parts by weight of OP4O, 3 parts by weight of epoxy plasticizer, 3 parts by weight of stabilizer
A polyvinyl chloride sheet having a thickness of 0.5 μm was prepared according to a conventional method from a resin composition containing 1 part by weight, 1 part by weight of a lubricant, 40 parts by weight of calcium carbonate, and 0.5 part by weight of a light green pigment.

Further, a second polyvinyl chloride sheet having a thickness of about 2.0 mm was prepared from a resin composition having the same composition as above except that the weight ratio of calcium carbonate was changed to 190 parts by weight to PVCIOO weight parts. On the other hand, as a polyvinyl chloride resin paste, an emulsion-polymerized PVC composition with a viscosity of 3000 cps was prepared by blending parts by weight of DOP5O, 3 parts by weight of a Ba-Zn stabilizer, and 0.4 parts by weight of a dark green pigment with respect to parts by weight of PVCIOO. It was adjusted and fed into the hopper. The first polyvinyl chloride sheet and the second polyvinyl chloride sheet are stacked between an embossing roll and a pinch roll having protrusions for punching pores on the surface, and are fed under heating temperature of 183°C to form a single sheet. fused to form a sheet material of
At the same time, a resin paste filling side pore with a diameter of 2wE and a diameter of 1u
A through-hole was formed along the thickness direction of the fusion sheet, and the pore was concentrically connected to the suction-side pore.

After the fused sheet is cooled to about 70°C in a cooling furnace, the pores are filled with the polyvinyl chloride resin paste supplied from a hopper and a knife coater, and the sheet reaches a suction tank where it is heated. The applied suction pressure of 150 uHy increased the packing density of the resin paste within the pores.
The fusing sheet is then removed from the surface of the first sheet by a doctor knife which resiliently engages the surface of the first sheet to remove the excess resin paste and fill the pores with the first resin paste. A resin paste surface was formed that was slightly lower than the surface of the sheet. The fusion sheet, whose pores are filled with an appropriate amount of resin paste in this way, is then guided by a guide roll and reaches a heater, where it is heated to 175°C. The resin paste was gelled. As a result, a resin paste surface substantially at the same height as the surface of the first sheet was formed in the final product. As can be easily understood from the above description, the method of the present invention has excellent utility because it can produce a polyvinyl chloride sheet with a substantially smooth patterned surface under stable operating conditions. There is.

In addition, by changing the density and area of the pores for resin paste filling, or by changing the color of the resin component, various patterns can be formed on the surface of the sheet material. Coupled with the advantage of being formed over almost the entire thickness, it can greatly contribute to extending the service life of the final product. The present invention also overcomes the drawbacks observed in conventional methods of using sheet materials with resin paste filling holes of equal diameter extending from the front surface of the first sheet to the back surface of the second sheet, namely, that the resin paste does not fill the sheet material. It also eliminates the inconvenience of leaking to the back side of the product, and greatly contributes to improving the aesthetic appearance of the product.

[Brief explanation of the drawing]

Fig. 1 is an explanatory diagram showing the connection of steps suitable for carrying out the method of the present invention, Fig. 2 is an enlarged longitudinal cross-sectional view of a fused sheet with pores formed therein, and Fig. 3 is a diagram showing the process of removing excess resin paste. FIG. 4 is an enlarged longitudinal sectional view of the fusing sheet immediately after, and FIG. 4 is an enlarged longitudinal sectional view of the final product according to the present invention. 20: First sheet material, 40: Resin paste, 30:
Second sheet material, 42, 44: thin 1LK.

Claims (1)

[Claims] 1. A method for forming a pattern on a polyvinyl chloride sheet,
a step of overlapping and fusing the first polyvinyl chloride sheet and a second polyvinyl chloride sheet containing an inorganic filler whose weight is equal to or more than three times the weight of the resin; From the surface of the polyvinyl chloride sheet to the second polyvinyl chloride sheet, pores having an intermediate stage portion having a smaller pore diameter on the suction side described later and a larger pore diameter on the resin paste filling side described later are made to penetrate the fusion sheet. a step of filling the pores with a polyvinyl chloride resin paste by suction pressure from the pores, and removing excess polyvinyl chloride from the surface of the first polyvinyl chloride sheet with a doctor knife. The method described above, comprising a step of removing the resin paste, and a step of heating and gelling the resin paste filled in the pores.