JP2006103251A - Manufacturing method for floor material, its manufacturing device, and floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a floor material having a pattern which is irregular in shape and changes like a stream in each color and which is sharply outlined without collapsing even when the pattern is made thin. <P>SOLUTION: An intermediate material 6 of a prescribed shape having a flowing pattern is formed by heating a mixture of two or more colored thermoplastic resin pellets and extruding the mixture under an incomplete kneading state. The intermediate material 6 is then pulverized into pieces of a desired size and the fragments 61 of the intermediate material are laid in a uniform thickness and heated to the extent that the outline of the fragments 61 does not vanish, and molded into a sheet. In this manufacturing method for the floor material, the thermoplastic resin pellets are introduced into a die hole 21 having a smaller bore than a mixing/extruding zone 5A before being heated and discharged. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a floor material manufacturing method, a manufacturing apparatus, and a floor material, and particularly relates to a floor material manufacturing method, a manufacturing apparatus, and a floor material having a pattern on the surface.

With the diversification and upgrading of the interior of building structures such as houses in recent years, not only monochromatic flooring materials but also flooring materials having patterns on the surface have been used.
As an example of a method for producing a flooring having a pattern on such a surface, a thermoplastic resin material of two or more colors, such as powder or fluid, is used, and these are formed in a predetermined pattern so as to be substantially uniform. There is a method for producing a floor material that is spread over a uniform thickness, heated and melted as a whole, and then formed into a sheet shape.
This flooring changes so that each color that makes up the irregular pattern flows, so it is soft and can give a high-quality impression to the viewer, but the outline of the pattern tends to collapse, On the contrary, there is a problem that a blurred impression is given to the viewer, and this tendency is particularly noticeable when the pattern is made fine.

  Therefore, according to Patent Document 1, the present applicant heated a mixture of thermoplastic resin pellets of two or more colors and extruded it in an incompletely kneaded state to obtain a predetermined shape intermediate material having a flow pattern. Forming and pulverizing the intermediate material to a required size, spreading the pulverized product of the intermediate material to a substantially uniform thickness, and heating and melting the sheet so that the contour of the pattern of the pulverized product does not disappear, Proposes a method of manufacturing flooring material that is shaped into a shape.

However, this flooring manufacturing method introduces thermoplastic resin pellets into a single large-diameter die hole, heats it, and discharges it, resulting in a temperature difference between the outer peripheral portion and the central portion of the die hole. There was a problem that the pattern of the thermoplastic resin pellets was too melted to blur.
JP 2001-198967 A

  In the present invention, in view of the problems of the conventional flooring manufacturing method described above, even if the pattern is made fine in the flooring having an irregular shape and changing so that each color flows, the outline of the pattern is broken. An object of the present invention is to provide a method for manufacturing a flooring having a clear outline and a manufacturing apparatus for the same and a flooring.

  In order to achieve the above object, the method for producing a flooring material of the present invention heats a mixture of two or more colors of thermoplastic resin pellets and extrudes it in an incompletely kneaded state, thereby providing a predetermined flow pattern. An intermediate material having a shape is formed, the intermediate material is pulverized to a required size, and the pulverized product of the intermediate material is spread to a substantially uniform thickness and heated to such an extent that the contour of the pattern of the pulverized product is not lost. In the method for producing a flooring material which is melted and formed into a sheet shape, the thermoplastic resin pellets are introduced into a small-diameter die hole from a mixing / extrusion zone, heated and discharged.

  On the other hand, the floor material manufacturing apparatus of the present invention is provided with a mixing / extruding zone in which a screw to be mixed is disposed while conveying thermoplastic resin pellets of two or more colors, and an extrusion of a screw that is not directly mixed by the screw. A thermoplastic resin pellet melting zone formed in a region on the side, wherein the thermoplastic resin pellets of two or more colors are extruded into a predetermined shape in an incompletely kneaded state. The present invention is characterized in that a die for introducing a thermoplastic resin pellet into a plurality of die holes and heating and discharging the die is provided.

  The flooring material of the present invention is a flooring material produced by the method for producing a flooring material of the present invention, wherein the contour of the pattern of the pulverized product of the intermediate material appears on the surface so as not to disappear. And

  According to the method for producing a flooring material of the present invention, a mixture of thermoplastic resin pellets of two or more colors is heated and extruded in an incomplete kneaded state, whereby an intermediate material having a predetermined shape having a flow pattern is obtained. Forming and pulverizing the intermediate material to a required size, spreading the pulverized product of the intermediate material to a substantially uniform thickness, and heating and melting the sheet so that the contour of the pattern of the pulverized product does not disappear, In the manufacturing method of the floor material formed into a shape, the thermoplastic resin pellets are introduced into the small-diameter hole from the mixing / extrusion zone, heated and discharged, so that the thermoplastic resin pellets are uniformly distributed in the small-diameter hole. It can be heated and melted, thereby preventing blurring of the pattern on the outer peripheral portion of the intermediate material and producing a floor material with a clear pattern outline.

  In addition, according to the floor material manufacturing apparatus of the present invention, a mixing / extrusion zone in which a screw to be mixed is conveyed while conveying thermoplastic resin pellets of two or more colors, and a screw that is not directly affected by the mixing action by the screw A melting zone of thermoplastic resin pellets formed in a region on the extrusion side of the above, and in the floor material manufacturing apparatus for extruding the thermoplastic resin pellets of two or more colors into a predetermined shape in an incompletely kneaded state, The zone is provided with a die that introduces thermoplastic resin pellets into a plurality of die holes, heats them, and discharges them, so that the thermoplastic resin pellets can be uniformly heated and melted in the small-diameter die holes. It is possible to produce a flooring with a clear pattern outline by preventing blurring of the pattern on the outer periphery of the sheet.

  And the flooring of the present invention is a flooring manufactured by the method for manufacturing a flooring of the present invention, and appears on the surface to the extent that the contour of the pulverized product of the intermediate material does not disappear. The outline is not broken and blurred, and a soft, high-quality impression can be given to the viewer.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a floor material manufacturing method and manufacturing apparatus according to the present invention and a floor material embodiment will be described with reference to the drawings.

  In FIG. 1, one Example of the manufacturing apparatus of the flooring of this invention is shown.

  For example, thermoplastic resin pellets such as black and white, dark brown and ivory, etc., which are a combination of dark and light colors, such as a combination of dark and light colors, such as vinyl chloride resin and olefin resin, are fed to the hopper 3 of the extruder 2. throw into.

This extrusion molding machine 2 is composed of a mixing / extrusion zone 5A in which screws 4 to be mixed are disposed while conveying thermoplastic resin pellets by applying an extrusion force to thermoplastic resin pellets of two or more colors, and a screw 4. And a thermoplastic resin pellet melting zone 5B provided with heating means 52 formed of a heater or the like formed in a region on the extrusion side of the screw 4 where the mixing action does not directly affect.
The melt zone 5B is provided with a die 1 for introducing and heating thermoplastic resin pellets into a plurality of die holes 11, and dividing the thermoplastic resin pellet in the mixing / extrusion zone 5A into each die hole 11. I am trying to supply it.
The die holes 11 are formed at equal intervals on the circumference centered on the axis of the screw 4, and in this embodiment, seven circular die holes 11 having a smaller diameter than the mixing / extrusion zone 5A are provided. .
By the way, the number and size of the die holes 11 are not particularly limited as long as the diameter Db of the die holes 11 is smaller than the diameter Da of the mixing / extrusion zone. Da is set to 1/2 to 1/7, more preferably 1/3 to 1/4, and the diameter Db of the die hole 11 is set to about 50 to 15 mm, more preferably about 40 to 25 mm. It is desirable.
Moreover, the heating means 52 such as a heater is disposed at the center and the outer periphery of the die 1 so that each die hole 11 can be heated evenly.

The extrusion molding machine 2 extrudes two or more color thermoplastic resin pellets into a plurality of cylindrical shapes in an incompletely kneaded state without contacting the screw 4 and directly kneading. The cylindrical intermediate member 6 is obtained by molding.
Thereby, the intermediate material 6 having a flow pattern as shown in FIG. 3 is easily and easily blurred by the extrusion molding machine 2 for producing the intermediate material 6 by the extrusion molding. It is possible to simplify the manufacturing equipment and manufacturing process of the intermediate member 6.

In this case, the mixing / extrusion zone 5A in which the screw 4 is disposed can be further provided with a cooling means 51 comprising an air-cooled or water-cooled jacket or the like in the hopper 3 as necessary.
Thereby, in the mixing / extrusion zone 5A in which the screw 4 is disposed, and further in the hopper 3, the thermoplastic resin pellets can be prevented from being melted and kneaded under the influence of the heat of the melting zone 5B, The intermediate material 6 can be surely extruded into a predetermined shape in an incompletely kneaded state, and the predetermined shape intermediate material 6 having a flow pattern can be manufactured without blurring the outline of the pattern.

Thus, the cylindrical intermediate member 6 formed by the extrusion molding machine 2 has an extrusion speed in the melting zone 5B in relation to the resistance with the peripheral surface of the die hole 11 in the melting zone 5B, and the outer peripheral portion. Since the center portion is faster than the center portion, in the cross section including the center axis, as shown in FIG. 3 (a), a streamline-shaped striped pattern (wood grain shape ( (Pattern)) appears.
In addition, in the melting zone 5B, the melted thermoplastic resin pellets of two or more colors are not directly kneaded in contact with the screw 4, but rotate under the influence of the rotation of the screw 4. In the cross section orthogonal to the central axis, a spiral pattern (wood grain (annular ring) pattern) appears as shown in FIG.
In this case, the outer peripheral surface of the cylindrical intermediate member 6 may be kneaded by contact with the peripheral surface of the melting zone 5B of the extruder 2, and a single color may appear.
In the present embodiment, the intermediate member 6 is formed in a columnar shape, but is not limited to this, and can be extruded into a sheet having a required thickness.

Next, as shown in FIG. 2A, the intermediate material 6 is pulverized into chip-shaped pieces or pellet-shaped pieces having a required size.
Specifically, the pulverized chip-like or pellet-like pulverized product 61 is not particularly limited so that it has a rough pattern of two or more colors, but more specifically, a diameter of several mm to several tens. Grind to a size of about mm.

  Then, as shown in FIG. 2 (b), the pulverized pulverized product 61 is substantially uniformly formed on the conveyor belt 10 via a vibration conveyor 9 which is reciprocated in the front-rear direction by a vibrator 8 from a hopper 7. In order to level the surface of the pulverized material layer, a leveling plate or leveling roll (not shown) disposed at an appropriate position of the conveyor belt 10 may be used. To do.

  In this state, the pulverized material layer on the conveyor belt 10 is introduced into a heating furnace 11 provided with heating means such as a heater at the top and bottom, heated and melted, finished with a roll 12, and further, as necessary. After that, the sheet-like flooring 62 is formed.

  In this case, the heating temperature and the heating time can be appropriately set according to the raw material thermoplastic resin material, the thickness of the pulverized material layer, etc., but in general, a vinyl chloride resin, a low density polyethylene resin, The heating temperature is set higher and the heating time is set longer in the order of density polyethylene resin and polypropylene resin.

FIG. 4 shows the flooring 62 finished in this way. The surface of the flooring 62 is indefinite, and the pattern of the pulverized material 61 obtained by pulverizing the intermediate material 6 while changing so that each color flows. The outline of the pattern does not disappear, and the flow pattern with a clear outline appears.
In addition, in the melting zone 5B, the melted thermoplastic resin pellets of two or more colors are not directly kneaded in contact with the screw 4, but rotate under the influence of the rotation of the screw 4. In the cross section orthogonal to the central axis, a spiral pattern (wood grain (annular ring) pattern) appears as shown in FIG.
In the present embodiment, the intermediate member 6 is formed in a columnar shape, but is not limited to this, and can be extruded into a sheet having a required thickness.

  Thus, the method for producing a flooring material of the present embodiment is a method of heating a mixture of two or more colors of thermoplastic resin pellets, and extruding it in an incomplete kneaded state, thereby forming a predetermined shape intermediate material having a flow pattern. 6, the intermediate material 6 is pulverized to a required size, the pulverized product 61 of the intermediate material 6 is spread to a substantially uniform thickness, and the contour of the pattern of the pulverized product 61 is not lost. In the method of manufacturing a floor material which is heated and melted and formed into a sheet shape, the thermoplastic resin pellets are introduced into the small-diameter die hole 11 from the mixing / extruding zone 5A, heated and discharged, so that the small-diameter die hole 11, the thermoplastic resin pellets can be uniformly heated and melted, whereby the blurring of the pattern on the outer peripheral portion of the intermediate material 6 can be prevented and the floor material 62 with a clear pattern outline can be produced.

  In addition, the floor material manufacturing apparatus of the present embodiment directly affects the mixing / extrusion zone 5A in which the screw 4 to be mixed is disposed and the mixing action by the screw 4 while conveying thermoplastic resin pellets of two or more colors. And a thermoplastic resin pellet melting zone 5B formed in a region on the extrusion side of the non-screw 4, and the floor material manufacturing apparatus for extruding the two or more color thermoplastic resin pellets into a predetermined shape in an incompletely kneaded state In the melting zone 5B, the thermoplastic resin pellets are introduced into the plurality of die holes 11 and heated and discharged, so that the thermoplastic resin pellets are uniformly heated and melted by the small-diameter die holes 11. As a result, the blurring of the pattern on the outer peripheral portion of the intermediate material 6 can be prevented, and the flooring 62 with a clear pattern outline can be manufactured.

  And the flooring material of the present embodiment is the flooring material 62 manufactured by the flooring manufacturing method of the present invention described above, and appears to the extent that the contour of the pattern of the pulverized product 61 of the intermediate material 6 does not disappear on the surface. Therefore, the outline of the pattern is not broken and blurred, and a soft and high-quality impression can be given to the viewer.

  As mentioned above, although the manufacturing method and the manufacturing apparatus of the flooring of the present invention, and the flooring were explained based on the example, the present invention is not limited to the composition described in the above-mentioned example, and in each example. The configurations can be changed as appropriate without departing from the spirit of the invention, for example, by appropriately combining the configurations described.

  As described above, the floor material manufacturing method and manufacturing apparatus according to the present invention, and the floor material, by uniformly heating and melting the thermoplastic resin pellets with a small-diameter die hole, prevent blurring of the pattern on the outer peripheral portion of the intermediate material. Since it has the characteristic that a flooring with a clear outline can be produced, it can be suitably used for a flooring having a flow pattern.

One Example of the manufacturing apparatus of the flooring of this invention is shown, (a) is the longitudinal cross-sectional view, (b) is a cross-sectional view of dice | dies. The manufacturing method of the flooring of this invention is shown, (a) is explanatory drawing which shows the crushing process of an intermediate material, (b) is explanatory drawing which shows the process of making the crushed intermediate material into a sheet form. An example of an intermediate material is shown, (a) is a sectional view including a central axis, and (b) is a sectional view orthogonal to the central axis. It is a front view which shows one Example of the flooring of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Dice 11 Die hole 2 Extruder 21 Die hole 3 Hopper 4 Screw 51 Cooling means 52 Heating means 5A Mixing / extrusion zone 5B Melting zone 6 Intermediate material 61 Ground material 62 Floor material 7 Hopper 8 Vibrator 9 Vibratory conveyor 10 Conveyor Belt 11 Heating furnace 12 Room temperature roll Da Diameter of mixing / extrusion zone Db Diameter of die hole

Claims (3)

  A mixture of thermoplastic resin pellets of two or more colors is heated and extruded in an incompletely kneaded state to form an intermediate material of a predetermined shape having a flow pattern. In the method for producing a floor material, which is pulverized, spread and ground to a substantially uniform thickness, melted and melted to such an extent that the contour of the pattern of the crushed material does not disappear, A method for producing a flooring material, characterized in that a thermoplastic resin pellet is introduced into a small-diameter die hole from a mixing / extrusion zone, heated and discharged.   Melting of the thermoplastic resin pellets formed in the mixing / extrusion zone in which the screw to be mixed is disposed while the thermoplastic resin pellets of two or more colors are transported and the extrusion side region of the screw where the mixing action by the screw does not directly affect A floor material manufacturing apparatus that extrudes thermoplastic resin pellets of two or more colors into a predetermined shape in an incompletely kneaded state, and introduces thermoplastic resin pellets into a plurality of die holes in the melting zone And a flooring manufacturing apparatus provided with a die for heating and discharging.   A flooring material produced by the method for producing a flooring material according to claim 1, wherein the contour of the pattern of the pulverized intermediate material appears on the surface so as not to disappear.