JP2002283375A - Method for manufacturing decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative material excellent in design effect. SOLUTION: A block aggregate is constituted of a block body, which is obtained by unidirectionally winding or bending a flexible thermoplastic tape-like material molded from pellets of different colors, and a block body, which is obtained by winding or bending the flexible thermoplastic tape-like material in the opposite direction, and subjected to calender rolling molding to manufacture the decorative material such as a floor material or the like full of variety and having high design effect.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material suitable for interior materials such as floor materials and wall materials.

[0002]

2. Description of the Related Art In Japanese Patent Publication No. 43-8638, a sheet is wound or folded, cut into thin layers, and the cut pieces are inserted between rolls. The pattern penetrated not only on the surface but also in the thickness direction, and the pattern did not disappear due to wear.

[0003]

According to the above-mentioned publication, it is difficult to wind or fold the sheet itself to form a complicated grain pattern or marble pattern like a natural pattern due to the weight and width of the sheet itself. Due to the weight and width, only simple grain and straight grain patterns could be formed, and complex wood grain and marble patterns could not be formed.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a method for obtaining a decorative material having a high designability. The present invention relates to a block obtained by winding or bending a flexible thermoplastic tape formed by pellets of different colors. The gist of the present invention is a method for manufacturing a decorative material, characterized by being obtained by calender rolling a block assembly composed of a body and another block obtained by winding or bending.

[0005]

FIG. 1 is a process drawing of the present invention. The material used in the present invention is polyvinyl chloride (PV).
C), ethylene-vinyl acetate copolymer (EV
A), polyethylene (PE), polypropylene (P
P), an acrylic resin, soft urethane, rubber, or the like, is preferably a synthetic resin having flexibility enough to be calendered. These resins are softened by heating at 80 to 200 ° C., and are rolled with a calender roll or an endless belt to form a pattern.

The above resins include DHP (diisoheptyl phthalate) and DOP (di-2-ethylhexyl phthalate) as plasticizers, calcium carbonate and the like as fillers, and barium zinc as a stabilizer.
A resin mass (pad) is mixed by a Banbury mixer 1 set at 60 ° C. and kneaded with mixing rolls 2 and 2 ′ set at 100 to 150 ° C.
3 is manufactured. The pad 3 is rolled with calender rolls 4 and 4 ′ set at 100 to 120 ° C., and has a thickness of 1.0 to
The sheet 5 is 3.0 mm. The sheet 5 is crushed by a crusher 6 and sieved to obtain chips 7 of a predetermined size. The diameter of the tip is preferably 5 to 20 mm. Chips are manufactured using pigments different in color from the above pigments, and several types of chips having different colors are prepared.

[0007] Several kinds of chips 7 of different colors are mixed in a mixer 8 at an appropriate ratio, and are dispersed on a conveyor 9. This was heated to 90 to 150 ° C. by a heater 10 and then rolled by a sheeter mill roll 11 to a thickness of 1.0 to 2.0 m.
m flow pattern sheet 12.

The pattern sheet 12 is formed on its surface with elongated block units in the direction of the production line, and adjacent units of different colors are in close contact with each other. Tape-shaped 14
And cut the sheet into a block 15
Get.

In the present invention, the block bodies may be arranged in the same direction or may be bent. However, it is desirable that the block bodies be arranged in the opposite directions to each other or to be bent because the design is more complicatedly changed.

A block is made by applying pressure from the side and up and down so that no space or unevenness occurs after the calendar.
If there is a difference in thickness, the projections will flow, so it is important to make the thickness of the block uniform. This block is 1
Calendar rolls 16 and 17 set at 00 to 150 ° C
The sheet 18 is obtained by rolling
Is further heated to 100 to 150 ° C. and rolled by calender rolls 20 and 20 ′ set to 90 to 130 ° C. to obtain a final surface pattern sheet 21 having a thickness of 1.0 mm to 4.0 mm and a smooth surface. .

The sheet 21 is cooled by a cooling device 22,
The decorative material 24 of the present invention is obtained by punching out a predetermined size (preferably 450 mm square) by the punching machine 23. As another form of the decorative material of the present invention, a substrate may be further attached to one surface of the pattern material 24 and punched to a predetermined size, or a reinforcing material such as a nonwoven fabric may be laminated between the sheet and the substrate. Is also good.

The decorative material manufactured as described above is obtained by winding and / or folding a sheet cut into a tape shape and inserting it into a roll. It can express a wood grain pattern or a marble pattern that has become layered.

FIG. 2 is a plan view of the block assembly, and forms a block row A15 in which the tape-like body 14 of 1 to 5 cm width obtained in FIG. On the other hand, the block assembly row B25 wound in the opposite direction is arranged to obtain a block assembly 26. In the block aggregate, the blocks A and B may be arranged regularly or irregularly. In forming the block body, the elongated sheet may be wound in two layers. The obtained block is rolled with a calender roll or an endless belt, and the obtained sheet is cut into tiles. The block aggregate may be molded in a mold.

FIG. 3 is a plan view of another assembly, in which the wound block 15 and the folded block 27 are combined. The block assembly 28 is obtained by combining the wound block body and the folded block body in this manner.
In FIG. 2 and FIG. 3, pressure is applied from the side and the top and bottom so that no space or unevenness occurs after calendering, and a block aggregate is formed so that the tape-shaped sheet does not shift. This block assembly is rolled with a calender.

FIG. 4 is a plan view of another block assembly in which an insertion material block 31 is inserted into a gap between a folded block body portion 29 and a bent block body portion 30. By filling this intercalated material in the block gap, the production rate of non-defective products after rolling is improved. The block aggregate 32 obtained in the present invention has a filling rate of 80% or more. Even if this aggregate is rolled, the sheet is not perforated and the sheet can be produced with high efficiency, which is desirable.

FIG. 5 is a plan view of the pattern material of the present invention. The obtained block assembly is rolled at 80 to 200 ° C. by a rolling device exemplified by a calender roll, and the decorative material of the present invention such as a floor tile is obtained. Get 36. The obtained sheet may be used as it is, or a backing material obtained by mixing 50 to 500 parts of a filler with the resin may be laminated. Further, the obtained sheet may be cut into a suitable length, rolled after rolling, and rolled.

[0017]

(Example 1) Banbury set at 150 ° C. with 100 parts by weight of PVC resin, 45 parts by weight of DOP as a plasticizer, 700 parts by weight of calcium carbonate as filler, 2 parts by weight of stabilizer, and 10 parts by weight of pigment. A pad obtained by kneading with a mixer and further kneading with a mixing roll set at 100 to 150 ° C. was rolled with a calender roll set at 100 to 120 ° C. to obtain a sheet having a thickness of 2 mm. The sheet was pulverized with a crusher and passed through a 3-mesh sieve to obtain chips having a diameter of 10 mm or less.

A plurality of chips of different colors are mixed in a mixer at an appropriate ratio, and are scattered on a conveyor, heated to 90 to 150 ° C. by a heater, and then rolled by a sheeter mill roll to form a 2.0 mm sheet. And cut into a suitable length to obtain a patterned sheet. A part of the obtained pattern materials was set in a state of being wound in one direction, and another pattern material was set in a state of being wound in the other direction.

The pattern sheet was rolled with a calender roll set at 100 to 150 ° C. to form a sheet having a thickness of 3 mm, and the sheet material was heated to 100 to 150 ° C. and further set at 90 to 130 ° C. The thickness was reduced to 2 mm and the surface was smoothed by rolling with a calender roll. The obtained sheet was cooled and punched into a square of 450 mm to obtain a floor tile of the present application. The obtained floor tile had excellent design properties having a marble layered pattern.

(Example 2) In the gap between the blocks of Example 1, a stick-shaped replenishing material of the same material as that of the block was inserted, and floor tiles were obtained in the same manner as in Example 1. The floor tiles obtained were multicolored, the design was improved, and the yield was improved by 50% or more.

[0021]

According to the present invention, high design properties are obtained. By setting the filling rate of the block body to not less than%, the production efficiency without holes was improved. Complex patterns close to nature can be expressed, such as wood grain patterns in which board grain and straight grain are mixed, wood grain patterns in which annual rings form a parquet, and marble patterns that become stratified.

[Brief description of the drawings]

FIG. 1 is a process chart of the present invention.

FIG. 2 is a plan view of a block assembly.

FIG. 3 is a plan view of another block aggregate.

FIG. 4 is a plan view of another block aggregate.

FIG. 5 is a plan view of the pattern material of the present invention.

[Explanation of symbols]

 15, 27, 29 ... Block body 26, 28, 34 ... Block aggregate 24, 36 ... Decoration material

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[Procedure amendment]

[Submission date] May 2, 2001 (2001.5.2)

[Procedure amendment 1]

[Document name to be amended] Drawing

[Correction target item name] Figure 2

[Correction method] Change

[Correction contents]

FIG. 2

Continued on the front page F term (reference) 4F204 AA15 AB06 AB07 AB11 AB16 AC03 AF08 AF09 AG01 AH48 FA06 FB02 FF01 FG01

Claims (3)

[Claims] 1. A block obtained by winding or bending a flexible thermoplastic tape formed by pellets of different colors, and a block obtained by winding or bending another. A method for producing a decorative material, characterized in that the obtained block aggregate is obtained by calender rolling. 2. The method of manufacturing a decorative material according to claim 1, wherein the block assembly in which another pattern material is inserted between the block body and another block body is rolled. 3. The method for producing a decorative material according to claim 1, wherein there is substantially no gap in the block assembly.