JPS603987B2 - Method for manufacturing floor coverings - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method of manufacturing a floor covering.

In recent years, concrete buildings have become much taller, and already 1
Many skyscrapers exceeding 0.000 are being built.

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 of manufacturing a floor covering that meets such requirements, that is, a lightweight floor covering that is highly anti-slip and highly decorative. The temperature of the first and third rolls and the temperature of the second roll are 1.0 or more when the pellets of different colors are heated to a temperature equal to or higher than their softening temperature with a difference in temperature or length of heating time. The surface layer is a pseudo-marble pattern sheet that is supplied to the first nip of an inverted L-shaped three-roll calender with a difference for rough rolling, and then passed through the second nip for finish rolling. A porous layer of breathable synthetic resin obtained by a foaming method is laminated as an intermediate layer,
Furthermore, an example of the method of manufacturing a floor covering characterized by providing a backing layer on the back surface thereof will be described with reference to the drawings. The different colored synthetic resin pellets 7 are mainly made of vinyl chloride resin, and include copolymers of vinyl chloride and other monomers,
Vinyl acetate-ethylene copolymer, chlorinated polyethylene,
Thermoplastic synthetic resins such as ABSMBS 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 willows. Use a beretizer to make pellets about the size of 4x4 to 8x8 willows. Using the same method, make several types of pellets colored in different colors, weigh the different colored pellets 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 thus uniformly dispersed mud pellets are heated to a temperature equal to or higher than the softening point of the resin constituting the pellets. 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 warped, the resulting pattern will have an excessive flow of the pellets. As a result, a sheet with a homogeneous color mixture and a flat surface but with a subdued pattern can be obtained.

On the other hand, if the pellet is heated so that it exhibits slight elasticity but retains its original shape and is fluid, the resulting pseudo-marble pattern is rough and has a rough surface with excellent slip resistance. It becomes something. An inverted L-shaped three-roll calender is used to convert the heated pellet into a surface layer sheet having a pseudo-marble pattern. 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. At this time, by always keeping the temperature of the second roll 2 lower than the temperature of the first roll by at least 1000, a very beautiful and excellent pseudo-marble pattern can be obtained. The surface (which becomes the surface of the floor covering) is in a non-light-selected state, and there are bulges here and there due to non-uniform melting of the pellet, resulting in an embossed effect and at the same time a very anti-slip surface. This is further emphasized by supplying the colored pellets to the calender rolls with a temperature difference or heating time difference between them, and a temperature difference of 10 qo or more is also provided between the second roll 2 and the third roll 3. For example, if colored pellets A are heated at 120 qo and colored pellets B are heated at 100 qo, then if they are combined, mixed, and immediately fed to a calendar and rolled, A sheet is obtained in which B is highly bulged due to heterogeneous melting. Also, even when using a sanding machine heated to the same temperature, if you first put A in it and sand it for 5 minutes, then put B into the same sanding machine and heat it for 3 minutes while mixing with A. , while A receives sufficient heat, B does not receive much heat even if it is above its softening temperature, so when it is fed to the calender, B becomes very swollen compared to A due to heterogeneous melting. This is an effect of providing a time lag in the heating time. Therefore, in the first nip 4 composed of the first roll 1 and the second roll 2, the pellet is crushed and In the second nip 5, which is composed of the second roll 2 and the third roll 3, the first nip 4 is rolled flat.
The sheet that has passed through is finished rolled to the correct thickness. When passing through the second nip 5, the temperature of the second roll is always maintained at a temperature lower than the third roll by 1000 degrees or less, as in the case of the first nip 4, so that the pseudo-marble pattern is not excessively disturbed and the thickness is reduced. The action of finishing the work is imposed.
The sheet 8 rolled in this manner is pressed between a gold layer roll 9 and a backup roll 10, introduced into the next cooling device, and wound up. In the next step, the thus wound pseudo-marble pattern sheet 8 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 laminated on the backing sheet 13 side.

The backing material is 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. In other words, the presence of the fibrous layer provides excellent suitability such as ease of adhesion, less air entrainment when laminated with an adhesive, and less blistering caused by the solvent in the adhesive. Also, the presence of this backing material 11 plays an important role in that it acts as a so-called balancing sheet, which suppresses warping and springing up of the surface layer.

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. As the backing material, in addition to the above-mentioned type in which a fibrous sheet is coated with a thin synthetic resin layer, a single synthetic resin sheet without using these fibrous sheets can also be used.
The latter type is suitable for cases where several main floors are temporarily laid on the wooden floor of a gymnasium using double-sided adhesive tape. An air-permeable synthetic resin paste 6 obtained by a mechanical foaming method is applied using a doctor type applicator 12 onto the upper surface of the rhombus material 11, that is, onto the synthetic resin layer. 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. This mixing of air bubbles is achieved by a foaming machine (foaming machine) based on the principle of dispersing and mixing a predetermined amount of air into one volume of plastisol using a high-speed loss group, such as an Oaks mixer or a Texacoat foaming machine. A synthetic resin porous body obtained by a mechanical foaming method has extremely good air permeability because all of its pores are pore-like.

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, and as long as the balloons do not burst, they retain excellent cushioning properties, but if the balloons are torn due to repeated stress. In contrast, 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 air will not absorb the air. Because it has the property of restoring to its original shape when inhaled, it retains its cushioning properties as long as the cell walls are not destroyed by fatigue. Demonstrate aptitude. The breathable synthetic resin paste obtained by the foaming machine is a white shaving cream type with a viscosity of about 8000 to 1000 ps, which is easy to apply, and a foaming ratio of 2.0 to 2.3 ps. 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 because it can be applied thickly and it can be applied smoothly without applying stress such as several shear forces to remove air bubbles. The application thickness of the paste should be calculated backwards from the required overall thickness of the floor covering, and if the overall thickness is on the 2.5 side, the surface layer is 0.
．． 5. If the thickness of the backing material is 0.4, it is necessary to apply it to a thickness of 1.6. In the case of a vinyl 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 26 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 bush adhesives are heat-reactive adhesives in which a small amount of unsaturated groups remain in their resin components, 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 any other adhesive may be used as long as it can reliably laminate the pseudo-marble pattern sheets, or it may be applied to the surface layer,
It is also possible to bond the porous layer of breathable synthetic resin that has come out of the first heating furnace, or 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 disperse the solvent in the adhesive and activate the adhesive at the same time. Lamination is performed using 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. Example 1 (1) Preparation of colored pellets Vinyl chloride camphor Nipolit SL (manufactured by Chisso P=10
30) Manufacture two types of colored sheets, green and ivory, according to the above recipe, and apply them to a beletizer to obtain two types of pellets with 4×4 elevation angles.

■ Production of pseudo-marble pattern sheets The two different colored pellets obtained in '1' were weighed, 50 kg of green pellets and 25 kg of ivory colored pellets, and weighed using a high-speed milling machine (manufactured by Mitsui Miike Manufacturing Co., Ltd.). The mixture was heated using a shell mixer at a temperature of 120 pm.

As for the order of feeding, first, 50 kg of green berets were placed in a high-speed frame machine and heated for 5 minutes at a temperature of 120°C, and then ivory berets 25k9 were added thereto and heated 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 mixed pellet was placed in the first nip portion of an inverted L-shaped independently driven three-roll calender. In this way, the thickness is 0.5 willow width 13
A beautiful pseudo-marble pattern sheet (surface layer) with 50 ribs was obtained.

The operating conditions for the calendar in this case were as follows. Details of the first nip No. 0.55 Gap of the z-th nip 0.48 Willow roll surface speed 6.67 for the third roll (3) Production of backing material Pynyl chloride resin Nivolit SL (
P21030 (manufactured by Chisso Co., Ltd.) The above blend was rolled using an inverted L-shaped four-roll calender, and was laterally layered to a thickness of 0.2 on a 48-inch wide 84 Koden Pinylon cloth that had been subjected to a sizing treatment in advance.

(4) Preparation of breathable synthetic resin paste Pynyl chloride side effect for paste: Sumilit PX-N (manufactured by Sumitomo Iban: P=1
300) 50 parts by weight Viscosity Lid bag Vinyl chloride for bonito Meimeiji Zeon LO3 In the above formulation, mix the mineral spirit and the ingredients other than the foam stabilizer F-310 with a planetary mixer for about 30 minutes to make a homogeneous mixture. Make a pan 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 1 minute without entraining air. Measure the viscosity in this state, 1000-150 ps
Adjust the viscosity by adding mineral spirits to a certain degree. This was applied to a Texacoat foaming machine (manufactured by TEXTILE RUBBER & CHEMICAL, Inc., USA) to give a foaming rate of 2.0 to 2. Foam to the foaming ratio of the sound seal.

The foam had a viscosity of 8,000 to 1,000 ps and was like a pure white shaving cream. '5} Manufacture of bedding material First, apply the above {4
) The air-permeable synthetic resin paste obtained in step 1 was applied to a thickness of 1.6 cm, introduced into a first heating furnace, and heated.

The first heating furnace consists of three heating zones, the first zone is 100oo, the second zone is 130oo, and the third zone is 1
A type that is heated to a temperature of 60 qo and gradually promotes gelation was used. 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 qC, 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 Crysbon*4010 (urethane type: Dainippon Ink) 100 parts by weight Hard crab liquid Crysbon NX (isocyanate: Dainippon Ink) 10″ Healthy Crab!” Accelerator - (Dainippon Ink) 3″ each 1" Rice (appropriate amount) The rice solvent is used to adjust the rice quality of the mixture to 100 voice latitude*, so do not use it.

Application amount 1502 After applying the final adhesive, 10000
The solvent is passed through the second heating furnace which is heated to 200°C to diffuse and activate the solvent at the same time, and immediately after leaving the heating furnace, the above {2
} A pseudo-marble pattern sheet is manufactured. In FIG. 1, the surface of the sheet to be laminated with the adhesive layer is the surface that contacts the first roll and the third roll, and the surface that was in contact with the second roll appears as the surface of the bed. The floor covering obtained in this way has a thickness of 2.5 feet, has large cushioning properties, excellent shock absorption and sound absorption, and has little residual denting.Furthermore, the temperature between the rolls is Compared to the one without the difference, the pseudo-marble pattern was not disturbed by the temperature and had raised ridges due to inhomogeneous melting, and it was a lightweight floor covering with an embossing effect and even better anti-slip properties.

This bedding is suitable as a bedding for indoor facilities where the main purpose is exercise, such as the floor of a gymnasium or the floor of a nursery school play room. However,
Ta. Example 2 After producing a pseudo-marble pattern sheet by the same method as in {1} and '2} of Example 1, a light green backing sheet (thickness 0.5 side) was laminated on the back side of the sheet. After that, this was used as a surface layer to form [3', {41, [51
A floor covering was obtained according to the procedure described in the following.

This floor covering has the effect of Example 1, and even if the pseudo-marble pattern layer on the surface is partially worn away when used in a place where there is a lot of foot traffic, there is a backing sheet of the same color underneath. Therefore, it has the advantage that its wear is not noticeable.

[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, 4-4 line, 6-
5 is a sectional view taken along lines 5 and 6-6, and FIG. 7 is a sectional view taken along lines 6-6 in the second embodiment, where 1 is the first roll, 2 is the second roll, 3 is the third roll, 4 is a first nip, 5 is a second nip, 6 is an air-permeable synthetic resin porous layer, 7 is a mixture of differently colored pellets, 8 is an agglomerated marble pattern sheet, 11 is a backing layer, and 13 is a backing sheet. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7

Claims (1)

[Scope of Claims] 1. A method for heating several types of differently colored synthetic resin pellets to a temperature equal to or higher than their softening temperature by giving a temperature difference or a difference in length of heating time between the different colored pellets. It is supplied to the first nip of an inverted L-shaped three-roll calender having a temperature difference of 10°C or more between the roll temperatures of the first roll and the third roll and the roll temperature of the second roll, and is then roughly rolled. A pseudo-marble pattern sheet is formed by final rolling through two nips, which is used as the surface layer, and on the back side, a porous layer of breathable synthetic resin obtained by mechanical foaming is used as an intermediate layer, and further on the back side. A method for manufacturing a floor covering, characterized by providing a backing layer. 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.