JPS603991B2 - 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
There are several skyscrapers that are taller than 0.0 US meters.

As these buildings become taller, there are demands 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 these requirements, that is, a lightweight floor covering that is highly anti-slip and has a great decorative effect. While the synthetic resin pellet is heated to a temperature higher than its softening temperature, the first roll and third roll
It is supplied to the first nip of an inverted L-shaped three-roll calender with a temperature difference of 10 °C or more between the roll temperature of the roll and the roll temperature of the second roll, and is then roughly rolled, and then to the second nip. The surface layer is a pseudo-marble-patterned sheet finished rolled through the process, and a lightweight synthetic resin layer mixed with an inorganic fine hollow filler such as Shirasu balloon is laminated on the back side as the intermediate layer, and a backing layer is provided on the back side. An example of its implementation 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 retizer 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 amount of each pellet according to the required color scheme, and mix these weighed pellets in various ways. Mix and disperse so that it is evenly distributed. The mixed pellets uniformly dispersed in this manner 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; heating to such an extent that the pellets fuse together and the original shape of the pellets is lost;
The pattern obtained is a sheet with an excessive flow of pellets, a homogeneous warm color, and a flat surface, but with a subdued pattern.

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. Therefore, what is important in the present invention is that when producing colored pellets, an embossing effect can be obtained due to heterogeneous melting by using synthetic resins with different degrees of polymerization. That is, if the spring-colored pellet A has a polymerization degree of 650, the colored pellet B is manufactured using a resin with a polymerization degree of 1000, and these A and B are mixed and heated at the same temperature. When heated, fed into a calender, and rolled, a sheet with an excellent embossed effect in which the B portion is much more raised than the A sheet is obtained. In the case of the Emboss effect, which uses the difference in polymerization,
Excellent effects can be obtained when the difference in the relative polymerization degrees is 1.5 times or more. In this way, an inverted L-shaped three-roll calender is used to process several types of differently colored pellets with different degrees of polymerization into a surface layer sheet having a pseudo-marble pattern while being heated to a temperature higher than their softening temperature. 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, and the rotation ratio (surface speed ratio) between the first roll and the second roll 2 is 1: It is preferable that the rotation ratio between the second roll 2 and the third roll 3 can be freely changed within the range of 1 to 1:2, and it is preferable that the rotation ratio between the second roll 2 and the third roll 3 can be changed within the range of 1:1 to 1:1.4.

However, this does not negate the interlocking drive system. Also, the first
The material is placed in a calender having a temperature difference of 100 or more between the temperature of both the roll and the third roll and the temperature of the second roll.

That is, by always keeping the temperature of the second roll lower than the temperature of the 10th roll, a very beautiful and excellent pseudomarble pattern can be obtained, and the surface in contact with the second roll (
The surface of the floor covering (which will become the surface of the floor covering) is matte and has bulges here and there due to inhomogeneous melting of the pellets, resulting in an embossed effect and a highly anti-slip surface at the same time. In the first nip 4 composed of the first roll 1 and the second roll 2, the pellet is crushed and rolled flat,
In the second nip 5, which is composed of the second roll and the third roll 3, the sheet that has passed through the first nip is finished rolled to the correct thickness.

Even when passing through the second nip, the second roll is kept at a lower temperature than the third roll, so that only the thickness can be finished without disturbing the pseudo-marble pattern too much. 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 pseudo-marble pattern sheet 8 wound up in this manner is laminated with an intermediate layer of a lightweight synthetic resin layer 24. Before laminating with this intermediate layer, it is also possible to horizontally layer a backing sheet 6 having a color similar to the dominant color of the pattern on the back side of the sheet 8, and use this as a surface layer. In the process shown in Figure 2, first the backing material 11
Prepare. 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, and is suitable for use with adhesives when installing the completed floor covering on the floor surface. In other words, it has excellent suitability such as easy adhesion, low air entrainment when laminated with adhesive, and little blistering caused by the solvent in the adhesive, and the presence of this backing village. It is said that warping and springing of the surface layer is suppressed. It has an important role that requires it to act as a so-called balancing sheet. In addition to the above-mentioned hair batting material made of woven or non-woven fabric coated with a thin layer of synthetic resin, it is also possible to use a single synthetic resin sheet without using these fibrous sheets. A lightweight synthetic resin layer 24 is coated on the upper surface of this backing layer 11 using a doctor type coater 12. Lightweight synthetic resin layer 2
4 is composed of a paint made by mixing a large amount of inorganic fine hollow particles such as shirasu balloons with plastisol of vinyl chloride resin, and the specific gravity of the resulting lightweight synthetic resin layer is 0.
．． 7-0. It has a mirror-like structure, almost the same as that of a foam structure.

When Shirasu balloons are used, unlike those of ordinary foam layers with a lotus structure, their water absorption is very low, so there is very little change over time, and they have excellent dent characteristics such as residual dents. have For example, in the case of Sanki Light manufactured by Sanki Kogyobaran, the amount of Shirasu balloon to be added should be selected based on the following guidelines. Addition amount hair Yansu Johi garage amount sound B> Sankilight A03150 0.32 0.02 25
-45Y04 44 0.22±0.02 30-5
0 Sunkilight A03 has a large particle size and the resulting lightweight synthetic resin has a low specific gravity, but in the form of a paint it becomes a dilatant and is very difficult to apply, so the amount added is small.

Compared to this, Sankirite Y04 has a smaller particle size, so
Since the degree of dilatancy is small, the amount added can be increased compared to A03, but the specific gravity of the resulting resin layer tends to be larger than that of A03. For these paints, it is best to avoid using applicators that have a large shedding force; a doctor-type applicator is best. Therefore, in terms of viscosity, the limit is 300 to 400 poise, and the viscosity should be lower than this. When plastisol of vinyl chloride resin is used as a synthetic resin component, the first heating furnace 14 produces approximately 15,030
It becomes a predetermined lightweight synthetic resin layer by heating and gelling at a temperature of .

After the surface is cooled through cooling rolls 16, an adhesion agent 25 is applied to the surface by a second doctor type coating machine 17.

Suitable adhesives include acrylic-ethylene copolymers, polyurethane adhesives, and urethane-modified acrylic copolymers. These are resin components of the adhesive that contain unsaturated groups, albeit in small amounts, but they are not limited to these, and if the pseudo-marble pattern sheets 8 can be reliably laminated, It is also possible to pressure laminate the base of the heated intermediate layer with other types or without using it at all. After applying the adhesive 25, the solvent in the adhesive is volatilized in the second heating furnace 19, and the pseudo-marble pattern sheet 8 obtained in the first step is bonded to the roll 20 while the adhesive is activated. , 21. By cooling through the cooling roll 22, the floor covering shown in FIG. 6 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 A green colored sheet was produced according to the above recipe,
Put it through a beretizer to get a 4x4 skin-sized green beret.

{21 Preparation of colored berets Vinyl chloride resin is Nipolit SL (Chisso P=103
In Example 0), ivory-colored pellets are produced using the same amounts of other ingredients as in {1} above and using the same method.

{3} Manufacture of pseudo-marble pattern sheet {1} Above, weigh two different colored pellets (green color 50k9 ivory color 25kg each) and mix with a high-speed Nada sanding machine at a temperature of 12,000°C for 5 minutes. Heated.

Next, the moated pellet was introduced into the first nip portion of an inverted L-shaped independently driven three-roll calender.

In this way, a beautiful pseudo-marble pattern sheet with a thickness of 0.5 willow width and 135 molar length was obtained. The operating conditions for the calendar in this case were as follows.

Thin request 0 Surface Sardine Hi 1.25 1.0 Poison L Living Spirit Cod Inexorable 1.35 Roll speed 3rd roll 6.67 minutes (4)
Production of backing material Vinyl chloride-like Nivolit SK (manufactured by Chisso) f: 1030) The above compound was rolled in an inverted L-shaped four-roll calender, and a 48-inch wide 84-row vinylon cloth was pre-sized. It was laminated on top to a thickness of 0.2.

(5) Sumilit PX-N (manufactured by Sumitomo Iyaku P=1) for the preparation paste of lightweight synthetic resin intermediate layer coatings
300) 50 Weight part Right bag free adjustment Zeon 10
3ZX (manufactured by Nippon Zeon).

P=1000) 50 Inaba Ri hOP
75 Stabilizer Mark KOB 2
．． 5 ``Shirasu''〈Rune.Sankirite Y02 In the above formulation, the ingredients other than mineral spirit are planetary-
The mixture was mixed in a type mixer for about 3 boat hours, and the viscosity of the homogeneous base was 320 poise, which was higher than ever.

Next, 2.5 parts by weight of mineral spirit was added to adjust the viscosity to 250 poise.

(6) Manufacture of several beds First, apply viscosity 25 obtained in step {5) above to the top surface of the backing material prepared in step {4) above using a doctor blade type applicator.
A paste containing 0 poise Shirasparoon was applied to a thickness of 1.5 feet and introduced into the first heating furnace.

The first heating furnace consists of three heating zones, the first zone is 100 qoC, the second zone is 130 qoC, and the third zone is 1
A type that is heated to a temperature of 60 qC and gradually promotes gelation was used. In the third zone, the completely gelled lightweight synthetic resin intermediate layer is passed through cooling rolls.
With the surface temperature lowered to 50 to 60 qo, the adhesive is applied to the surface using a doctor blade type second applicator. The types and amounts of adhesives to be applied are as follows: Adhesive base material: Crysbon *4010 (urethane type, Dainippon Ink) 100 parts by weight Hard A-straddle Crissbon NX (isocyanate).

Dainippon Ink) 10'' Accelerant Accelerate - Yuhi M (Large 8 ink) 4-5 Dissolved sulfuric acid (after mixing ethyl acetate; toluene 1:1) 20-50'' Solvent Phosphorus finished 100% sulfuric acid The voice of Nadazaki acid is sardine, so it's Kamome.

After applying the 1502% elbow adhesive, the second
It was passed through a heating furnace to evacuate the solvent and activate the adhesive at the same time, and immediately after exiting the heating furnace, a thin layer of the pseudo-marbled sheet prepared in Jōjō 3' was applied.

The floor covering obtained in this way has a rough pseudo-marble pattern due to the difference in flow rate due to the difference in the degree of polymerization of the pellets, and the surface in contact with the first roll and the third roll is the back surface of the second roll.
The surface in contact with the roll becomes an embossed surface that is highly anti-slip and has a very three-dimensional effect. In addition, the cushioning properties are large on the 2.3 thickness side, and the cross-sectional structure shows a foamed structure. It is extremely superior to this type of cushioned flooring, and has a porous structure made of inorganic materials, making it excellent in terms of flame resistance. It was suitable for the floor of a facility.Example 2 After producing a pseudo-marble pattern sheet by the same method as ○}, '2] and '3} of Example 1 above, a light green backing sheet was added to the back side of the sheet. (thickness: 0.5 ribs), this was used as the surface layer, and
6}, a floor covering was obtained.

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

[Brief explanation of drawings]

The drawings show an embodiment of the manufacturing method of the present invention. Figure 2 is a cross-sectional view of manufacturing a pseudo-marble pattern sheet, Figure 2 is a lamination process diagram, Figures 3 to 6 are lines 3-3, 4-4 line, 5-
5 is a sectional view taken along lines 5 and 6-6, and FIG. 7 is a sectional view taken along line 6-6 in the second embodiment.
2 is the second roll, 3 is the third roll, 4 is the first nip, 5 is the
is the second nip, 6 is the backing sheet, 7 is the moat bullet, 8
24 is a lightweight synthetic resin layer, and 11 is a backing layer. Figure i Figure 2 Figure 5 Figure 4 Figure 5 Figure 6 Figure 7

Claims (1)

[Scope of Claims] 1 Several types of differently colored synthetic resin pellets with different polymerization degrees of synthetic resins are heated to a temperature equal to or higher than their softening temperature, and the temperature of both the first roll and the third roll and the temperature of the second roll are determined. Inverted L type 3 with a difference of 10℃ or more between roll temperature
It is fed to the first nip of this roll calender for rough rolling, then passed through the second nip for finish rolling to form a pseudo-marble pattern sheet, which is used as a surface layer and an inorganic fine hollow filler such as a shirasu balloon is coated on the back surface. A method for manufacturing a floor covering, characterized in that a mixed lightweight synthetic resin layer is used as an intermediate layer, and a backing layer is further provided on the back side of the intermediate layer. 2. The method for manufacturing a floor covering according to claim 1, wherein the synthetic resin of the lightweight synthetic resin layer that is the intermediate layer is plastisol of vinyl chloride resin. 3. After applying a lightweight synthetic resin layer to a predetermined thickness on the backing layer that has been rolled or processed into a sheet shape in advance and heating it to gel,
2. The method of manufacturing a floor covering according to claim 1, wherein the pseudo-marble pattern sheets are laminated with or without applying an adhesive to the surface thereof. 4. Manufacture 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.