JPS6012932B2 - Method for manufacturing floor coverings - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing a multi-bed body.

In recent years, concrete buildings have become much taller, and already 1
There are many skyscrapers that exceed 00 rivers. As these buildings become taller, there is a growing demand for all building materials to be lighter in weight, and similar demands are being placed on plastic floor coverings constructed on concrete floors. The present invention relates to a method for manufacturing a floor covering that meets such requirements, that is, a lightweight floor covering that is highly anti-slip and highly decorative. In a state heated to a temperature higher than that temperature, the rough material is supplied to the first nip of an inverted L-shaped three-roll calender provided with a second roll having a temperature difference of 1.0 mm or more from the first roll and third roll. A pseudo-marble pattern sheet formed by rolling and then finishing rolling through a second nib is used as a surface layer, and a porous layer of breathable synthetic resin obtained by a mechanical foaming method is laminated on the back side as an intermediate layer, Further, an example of the method of manufacturing a bed-sleeved body characterized by providing a hair layer on the back side will be described with reference to the drawings.

The different colored synthetic resin pellets 7 are mainly made of vinyl chloride resin, and include thermoplastics such as copolymers of vinyl chloride and other monomers, vinyl acetate-ethylene copolymers, chlorinated polyethylene, ABS, and MBS. Synthetic resins can also be used. A mixture of these thermoplastic synthetic resins, either singly or mixed as a main component, with plasticizers, fillers, and colored pigments is processed into a thick sheet of about 4 to 8 skins thick. Use a beretizer to make pellets about 4 x 4 to 8 x 8 skin. Using the same method, make several types of pellets colored in different colors, weigh the amount of each pellet according to the required color scheme, and feed these weighed pellets into a mixing machine. Mix and disperse so that it is evenly distributed. The mixed pellet thus uniformly dispersed is heated to a temperature equal to or higher than the softening point of the resin constituting the pellet. The degree of heating in this case should be controlled according to the desired pseudomarble pattern; if heated to such an extent that the pellets fuse together and the original shape of the pellet is lost, the resulting pattern will have excessive pellet flow. As a result, a sheet with a homogeneous teardrop color and a flat surface with a subdued pattern is obtained.

On the other hand, if the pellet is heated in a state where it exhibits slight elasticity but retains its original shape and is fluid, the resulting agglomerated marble pattern is rough and has a rough surface with excellent anti-slip properties. It becomes something. To process the heated pellet into a surface layer sheet with a pseudo-marble pattern, use an inverted L shape 3.
Use this roll calendar. In the inverted L-shaped three-roll calender, the calender rolls are generally driven in an interlocking manner by one motor, but in the present invention, an independent drive system in which each roll can be driven independently is suitable. There is.

This is because the quality of the pseudo-marble pattern varies greatly depending on the rotation ratio between the rolls.
The rotation ratio (surface speed ratio) between roll 1 and second roll 2 is 1
It is desirable to be able to freely change the ratio within the range of :1 to 1:2.
The rotation ratio between the second roll 2 and the third roll 3 is 1:1~
It is preferable to change the ratio within the range of 1:1.4, and an interlocking drive method is also possible. Furthermore, in the present invention, providing a temperature difference between these rolls 1, 2, and 3 is an important factor.
That is, by always maintaining the temperature of the second roll 2 at least 10°C lower than the temperature of the first roll 1 and the third roll 3, a very beautiful and excellent pseudo-marble pattern can be obtained. The surface in contact with the roll 2 (which becomes the surface of the floor covering) is matte and has bulges here and there due to non-uniform melting of the pellet, resulting in an embossed effect and a highly anti-slip surface. Become. Also, this first
In the first nip 4 composed of the roll 1 and the second roll 2, the pellet is crushed and rolled into a sheet shape, and in the second nip 5 composed of the second roll 2 and the third roll 3, The sheet that has passed through the first nip is finish rolled to the correct thickness. When passing through this second nip 5, as mentioned above, the second roll always has a temperature lower than the third roll by 1000 or more, and by maintaining the temperature, the pseudo-marble pattern is not excessively disturbed, and the thickness is reduced. The action of finishing the work is imposed. The sheet 8 thus rolled is pressed between a metal roll 9 and a backup roll 10, introduced into the next cooling device, and wound up. In the next step, the agglomerated marble-patterned sheet 8 wound up in this manner is laminated with an air-permeable synthetic resin porous layer 6 obtained by a mechanical foaming method as an intermediate layer on the back surface thereof.

Before laminating this porous layer 6, a backing sheet 13 having a color similar to the dominant color of the pattern is laminated on the back side of the pseudo-marble pattern sheet 8, and this laminated sheet is used as a surface layer. A porous layer may be provided on the backing sheet 13 side.

The backing material is made by laminating a thin layer of soft synthetic resin 11 on the top surface of a fibrous sheet 11' such as woven fabric or non-woven fabric, and when installing several completed floors on the floor, it is necessary to check the compatibility with the adhesive. ,
In other words, excellent suitability such as ease of adhesion, less air entrainment when laminated with an adhesive, and less blistering due to the solvent in the adhesive is achieved by the presence of the fiber layer. Moreover, the presence of this hair batting material 11 plays an important role in that it acts as a so-called balancing sheet in that the surface layer is prevented from warping or springing up.

In addition, the air-permeable synthetic resin porous layer produced by the mechanical foaming method has a perforated pore structure and is therefore rich in cushioning properties, but the presence of the above-mentioned backing material is also essential for the cushioning properties. In addition to the above-mentioned type of hair batting material in which a fibrous sheet is covered with a thin synthetic resin layer, it is also possible to use a single synthetic resin sheet without using these fibrous sheets.
The latter type is suitable for temporarily laying the main floor covering with double-sided adhesive tape on the wooden floor of a gymnasium. An air-permeable synthetic resin paste 6 obtained by a mechanical foaming method is applied onto the upper surface of the backing material 11, that is, onto the synthetic resin layer, using a doctor-type coating machine 12. The breathable synthetic resin paste 6 is made of vinyl chloride resin plastisol with fine air bubbles dispersed therein, and the expansion ratio changes depending on the ratio of the amount of air mixed in.

The air bubbles can be mixed in with a foaming machine (foaming synthetic fiber), such as an Oaks mixer or a Texacoat foaming machine, based on the principle of dispersing and mixing a predetermined amount of air into one volume of plastisol at high speed. A synthetic resin porous body obtained by a mechanical foaming method has extremely good air permeability because all of its pores are well-suited.

Therefore, for floor coverings that are subjected to repeated stress, the cushioning properties are more durable than in the case of closed cell foam.

This is a structure in which a closed-cell porous material is made up of a large number of balloons gathered together, and as long as the balloons do not burst, they maintain excellent cushioning properties, but if the balloons burst due to repeated stress, However, in the case of mechanically foamed porous materials, the strength of the wall surface that makes up the pores absorbs the stress, and even if repeated stress is applied, the material absorbs the air. Because it has the property of restoring to its original shape once it is injected, it retains its cushioning properties as long as its cell walls are not destroyed by fatigue.In this respect, it is extremely suitable for use as floor coverings. Demonstrate. The breathable synthetic resin paste obtained by the foaming machine is a white shaving cream-like one with a viscosity of approximately 8000 to 1000 ps, which is easy to apply, and a foaming ratio of 2.0 to 2.5 times. is obtained, and is suitable for the floor covering of the present invention.

A doctor blade type applicator is suitable for applying this breathable synthetic resin paste to the backing material. This is due to the fact that it can be applied thickly and it can be applied smoothly without applying stress such as shearing force to the air bubbles that are mixed in. The application thickness of the paste should be calculated backwards from the required overall thickness of the bedding; if the overall thickness is 2.5 mm, then the surface layer is 0.
．． If the hair thickness is 0.4 skin, it is necessary to apply it to a thickness of 1.6 skin. In the case of a pinyl chloride resin paste, it can be gelled by heating to about 150° C. in the first heating furnace 14, resulting in a predetermined lightweight, breathable synthetic resin porous layer with rich cushioning properties.

After cooling through a cooling roll 15, an adhesive 25 is applied to the surface of the porous layer using a second doctor type applicator 17. Suitable adhesives include acrylic-ethylene copolymer, polyurethane, and urethane-modified acrylic adhesives.

These adhesives are heat-reactive adhesives in which a small amount of unsaturated groups remain in the resin component, and are most suitable for producing the floor covering of the present invention. Of course, this adhesive is not limited to these kinds and types, and other adhesives may be used as long as they can reliably layer the pseudo-marble pattern sheets horizontally, or they may be applied to the surface layer. , it is also possible to simply laminate the surface layer without using an adhesive. After applying the adhesive 25, the surface layer 8 obtained in the first step is introduced into the second heating furnace 19 to scatter the solvent in the adhesive and activate the adhesive at the same time. are laminated by lamination rolls 20 and 21.

Then, by cooling through the cooling roll 22, the sixth
The bedding shown in the figure is obtained. Next, specific embodiments of the present invention will be explained in detail with reference to Examples. 0 Example 1 '11 Preparation of colored pellets Two types of colored sheets, green and ivory, were produced according to the above recipe, and then put through a pelletizer.
Obtain two types of 4×4 elevation angles.

■ Manufacture of pseudo-marble pattern sheet (weigh the two different colored pellets obtained in step 1), a green pellet of 50k9 and an ivory colored pellet of 25k9, and weigh them using a high-speed light-polishing machine (manufactured by Mitsui Miike Manufacturing Co., Ltd.). A shell mixer) was used to heat the mixture at a temperature of 120 qo.

As for the order of loss, first, green berets were heated with 50k9 in a high-speed heat exchanger for 5 minutes at a temperature of 120°C, then ivory berets 25k9 were added thereto and heated in a heat exchanger for an additional 4 minutes. Under these conditions, some of the pellets were partially fused, but the pellets as a whole maintained a loose granular shape. Next, the Shikaai pellet was introduced into the first nip portion of an inverted L-shaped independently driven three-roll calender. In this way, thickness 0.5 skin width 13
A beautiful pseudo-marble pattern sheet (surface layer) with 50 ribs was obtained.

The operating conditions of the calender in this case were as follows: Gap at the first nip: 0.55 Gap between the second nip: 0.48 Willow o-le surface speed: 6.67 minutes at the third o-le
1. Manufacture of hair batting material The above compound was rolled using an inverted L-shaped four-roll calender, and a 48-inch width 8.
4 Laminated on electrophobic vinylon cloth to a thickness of 0.2.

'4} Preparation of breathable synthetic resin paste Vinyl chloride resin for paste: Slit PX-N (manufactured by Sumitomo Chemical: P=13
00) Weight part of 5 Vinyl chloride resin for viscosity adjustment Zeon 102× (manufactured by Nippon Zeon: P=1000)
50 Plasticizer DOP
70 〃〃 ○-150 (manufactured by Adeka Argus) 1 〃 Texanol isobutyrate 10 〃Filler Aluminum hydroxide powder 50 〃Stabilizer MarkK
CB (Manufactured by Adeka Argus) 3 Foam stabilizer F-310 (Shin-Etsu Silicon) 4 Viscosity modifier Mineral spirit (appropriate amount) Total 238 In the above formulation, mineral spirits and foam stabilizers other than F-310 The formulation is mixed in a planetary mixer for about 30 minutes to form a uniform base.

Next, foam stabilizer F-310 is added and mixing is continued.

In this case, when a foam stabilizer is added, it becomes easy to entrain air, so mix slowly for about 10 minutes so as not to entrain air. Measure the viscosity in this state, 1000-150 ps
Adjust the viscosity by adding mineral spirits to a certain degree. This is processed using a TEXTILE RUBBER & CHEMIC foaming machine (USA, TEXTILE RUBBER & CHEMIC).
(manufactured by AL), 2.0 to 2. Foam to the same foaming ratio as the envelope.

The foam had a viscosity of 8,000 to 1,000 ps and was like a pure white shaving cream. [51 Manufacture of floor coverings First, apply the above '4.
The breathable synthetic resin paste obtained in ) was applied to the 1.6-thickness side, introduced into the first heating furnace, and heated.

The first heating furnace consists of three heating zones, the first zone is 100 qC, the second zone is 130 qC, and the third zone is 1
A gelatinizer was used that was heated to a temperature of 60 degrees and gradually progressed to gelation. The completely gelled breathable synthetic resin porous layer in the third zone is passed through a cooling roll,
With the surface temperature cooled to 50 to 60 qo, adhesive is applied to the surface using a second doctor blade type applicator. The type of adhesive and the amount applied are as follows. Adhesive main agent: Crisbon #4010 (urethane type: Dainippon Ink) 10 parts by weight Curing agent: Crisbon NX (isocyanate: Dainippon Ink)
10 Accelerator (Dainippon Ink) 3 Solvent* (appropriate amount) *Do not fix the solvent as it is used to adjust the viscosity of the mixture to about 100 poise.

After applying 150 ta' of adhesive, the second one heated to 100 qo
The solvent is passed through a heating furnace to disperse it and activate it at the same time.
Immediately after coming out of the heating furnace, the pseudo-marble pattern sheet produced in '2} above is laminated.

In FIG. 1, the surface of the sheet to be laminated with the adhesive is the surface that contacts the first roll and the third roll, and the surface that was in support of the second roll appears as the surface of the floor covering. The floor covering obtained in this way has a thickness of 2.5 mm and has a large cushioning property, and has excellent shock absorption and sound absorption properties. It was an extremely excellent lightweight floor covering with excellent embossing effect and anti-slip properties, and little residual denting.

This bedding was suitable as a floor for indoor facilities where the main purpose was exercise, such as the floor of a gymnasium or the floor of a play room in a nursery school.
Example 2 After producing a pseudo-marble pattern sheet by the same method as in Example 1 [1} and '21, a light green haircut sheet (thickness: 0.5 ribs) was layered on the back side of the sheet. After that, using this as a surface layer, '3}, '41, '5' of Example 1
A floor covering was obtained according to the procedure described in the following.

When this floor covering is used in a place where there is a lot of foot traffic, even if the pseudo-marble pattern layer on the surface wears down partially, the wear is not noticeable because there is a hair sheet of the same color underneath. It had advantages.

[Brief explanation of the drawing]

The drawings show an embodiment of the manufacturing method of the present invention, and FIG. 1 is a cross-sectional view of manufacturing a pseudo-marble pattern sheet, FIG. 2 is a lamination process diagram, and FIGS. 3 to 6 are lines 3-3, A sectional view taken along lines 4-4, 5-5, and 6-6, and FIG. 7 is a sectional view taken along line 6-6 in the second embodiment, where 1 is a first roll, 2 is a second roll, 3 is the third roll, 4 is the first nip, 5 is the second
The nip, 6 is a porous layer of breathable synthetic resin, 7 is a mixture of several different colored pellets, 8 is a pseudo-marble pattern sheet, 11 is a backing layer, and 13 is a hair sheet. Fig. 1 *2 Fig. Eaves 3 Fig. Nose 4 Fig. 5 Fig. 6 Fig. 7

Claims (1)

[Claims] 1. When several types of differently colored synthetic resin pellets are heated to a temperature equal to or higher than their softening temperature, the difference between the roll temperatures of the first and third rolls and the roll temperature of the second roll is 10.
The material is fed into the first nip of an inverted L-shaped three-roll calender having a temperature difference of at least ℃ and is roughly rolled, then passed through the second nip and finished rolled to form a pseudo-marble pattern sheet, which is used as the surface layer. . A method for producing a floor covering, characterized in that a porous layer of breathable synthetic resin obtained by a mechanical foaming method is used as an intermediate layer on the back surface thereof, and a backing layer is further provided on the back surface. 2. After applying a porous layer of breathable synthetic resin on the backing layer that has been rolled or processed into a sheet in advance and gelling it by heating, a pseudo-marble pattern sheet is laminated with or without applying an adhesive to the surface. A method for manufacturing a floor covering according to claim 1, characterized in that: 3. Manufacture of a floor covering according to claim 1, characterized in that a backing sheet having a color similar to the dominant color of the pseudo-marble pattern is laminated on the back side of the pseudo-marble pattern sheet to form a surface layer. Method.