JP2007032121A - Method of manufacturing composition floor tile having cloud-shaped pattern or marble pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a composition floor tile having a cloud-shaped pattern or a marble pattern of the clear contour. <P>SOLUTION: (1) This manufacturing method of the composition floor tile having the cloud-shaped pattern or the marble pattern of the clear contour is characterized by continuously cutting a surface of a plate-like material or a sheet-like material provided by calender molding by a cutting machine having a rotary blade. (2) The method recorded in (1) comprises one stage or two stages of a cutting process by the cutting machine. (3) The method recorded in (1) or (2) cuts the surface of the plate-like material or the sheet-like material in the thickness of 100 μm or more. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a composition floor tile having a sharply contoured cloud pattern or marble pattern.

Homogeneous vinyl floor tiles (vinyl floor tiles (see Non-Patent Document 1)) that use less filler and use more resin (binder amount is 30% by weight or more) than composition vinyl floor tiles described later In homogeneous floor tiles, when obtaining a pattern (stop pattern) that retains the outline of a chip as a pattern material, the pattern is sliced. That is, in the prior art, a press-formed block-like product is sliced to a predetermined thickness, and this is continuously pressed one by one with a continuous press machine (rotor cure machine, etc.), or a design with a pattern that is sliced into a roll shape. It is produced by re-pressing the sheet together with the base material. However, although these methods have the advantage of being able to produce a product with a very special design, it is necessary to use an inefficient press machine, and it is necessary to charge the continuous press machine one by one. There is a drawback that the production cost becomes high.
On the other hand, composition vinyl floor tiles (used in this industry from May 1, 1990 on vinyl chloride resin floor tiles as defined in Non-Patent Document 1 with a binder content of less than 30% by weight and a high filler content. Regarding the surface finishing method of the technical term (see Non-Patent Documents 1 and 2), the technique of Patent Document 1 according to the prior application of the present applicant is known. As described in the specification of the prior application, composition vinyl floor tiles are generally surface-finished after being molded into a plate or sheet by calendar molding using a resin composition as a raw material. As a process of this surface finishing, a grinding process with abrasive paper is included, but the purpose is smoothing the surface, and deep cutting for the purpose of improving blurred patterns as in the present invention. Completely different. Further, in the case of the manufacturing method of the prior application, the pattern near the surface of the plate or sheet is blurred due to the flow of the resin composition, but there is no effective means for improving the blurred pattern, so the product as it is This is the current situation.

Japanese Patent Laid-Open No. 2005-2692 JIS A5705 1998 “Floor Finishing Construction Textbook Plastic Flooring” issued by the Japan Interior Decoration Cooperative Association, 3rd revised edition, January 10, 1994, pp. 34-36

  An object of the present invention is to provide a method for producing a composition floor tile having a cloud-shaped pattern or a marble pattern with a sharp outline.

The above problems are solved by the following inventions 1) to 3).
1) A composition floor having a sharply contoured cloud shape or marble pattern, characterized in that the surface of a plate or sheet obtained by calendering is continuously cut by a cutting machine having a rotary blade. Tile manufacturing method.
2) The manufacturing method according to 1), wherein the cutting process by the cutting machine is one stage or two stages.
3) The production method according to 1) or 2), wherein the surface of the plate-like material or sheet-like material is cut to a thickness of 100 μm or more.

Hereinafter, the present invention will be described in detail.
As described above, a method of slicing a press-formed block-like material used in the manufacture of homogeneous floor tiles to a predetermined thickness to produce a pattern is not efficient. In addition, this method is suitable for a compound system that has a large amount of resin and is easy to flow during processing, and is not suitable for a composition floor tile that cannot be sliced or wound.
Therefore, the present inventors examined a method for producing a composition floor tile having a cloud shape or a marble pattern with a sharp outline continuously and efficiently from a plate or sheet obtained by calendering. Here, the “clear outline pattern” refers to the following pattern. That is, in the production of composition floor tiles, when a raw material resin composition is calendered to create a plate or sheet, the surface layer has the temperature and speed conditions of the calender roll different from other parts. Since the resin composition is different, the resin composition easily flows and the pattern is blurred. However, the pattern is not blurred because the resin composition hardly flows except in the traveling direction in portions other than the surface layer. Therefore, if the surface layer is cut to a portion where the pattern is not blurred, a pattern with a clearer outline than the surface layer can be made to appear. In the present invention, the “clear outline pattern” refers to an unblurred pattern other than such a surface layer (see actual samples A and B in the property submission document. A shows a clear outline pattern by cutting). The floor tile sample according to the present invention, B, is a floor tile sample with a blurred surface layer pattern by conventional calendering).

Here, a flow pattern and a cloud pattern by calendar molding (rolling using a calendar roll) and a formation mechanism thereof will be described. FIG. 3 is an image diagram of roll rolling.
First, the flow pattern refers to a pattern in a state where the pattern material is elongated in the rolling direction. Since the pattern formed at this time is similar to the marble pattern, it is also called a marble pattern. FIG. 4 is a simplified representation of this pattern (the arrow in the figure indicates the rolling direction, and the gray portion indicates the marble pattern).
Next, the cloud pattern is a pattern obtained by rolling a marble pattern formed as shown in FIG. 4 while rotating the rolling direction by 90 degrees. When such a rolling operation is performed, if the surface layer portion is rolled sequentially and continuously, the resulting pattern simply spreads vertically and vertically as shown in FIG. It becomes only and does not become a cloud pattern. However, in reality, when the pattern portion is rolled in a direction transverse to the original longitudinal flow direction, the base material existing immediately below the pattern material is locally exposed on the surface, and the pattern material and the base material Are intertwined in a complicated manner as shown in FIG. 6 in a simplified manner, and a cloud pattern is formed. In other words, the pattern material and the base material are bitten into the rolling roll in a state where the pattern material and the base material are torn in a complicated manner, and a cloud pattern is formed.

Such a cloud pattern can be realized by controlling the relationship between the temperature of the resin supplied to the rolling roll and the temperature of the rolling roll. That is, by making the roll temperature much lower than the resin temperature and preventing the resin from flowing on the roll surface as much as possible, a delicate tearing occurs on the resin surface when it bites into the roll, and the pattern material and the base material A complicated pattern (cloud-shaped pattern) appears on the surface.
In general, when a plurality of sheets are stacked and supplied to a rolling roll, each sheet does not necessarily pass through the roll while maintaining its vertical relationship while reducing its thickness. The uppermost sheet is most likely to bite into the roll, and if the supply is insufficient in quantity, the lower sheets are also bite into the roll. At this time, each sheet is complicatedly cut and mixed on the roll surface by the rotational force of the roll. Since the sheets of different colors are cut and mixed in a complicated manner, a cloud pattern different from the simple flow pattern sheet is obtained.

  A method for displaying a cloud pattern on a thermoplastic resin sheet using a rolling roll as described above is known from Japanese Patent No. 3522920 related to the prior application of the present applicant (Photo 4 of the property submission of the prior application). Etc.) As described in the specification of the prior application, the cloud pattern and its production method have been known since the linoleum era (see Japanese Patent Publication No. 33-3725), but vinyl chloride resin and the like are used in comparison with linoleum. In the flooring material, it is difficult to reveal a cloud pattern due to differences in thermal fluidity. The invention of the prior application solves this problem by a specific device. However, the present invention further realizes a cloud-shaped pattern with a sharp outline that cannot be obtained by the prior art for the composition floor tile. .

In the case of calender molding described in Patent Document 1, generally, the molded product has undulations. Therefore, when a complete surface finish is to be performed, the surface must be cut by about 100 to 200 μm. Therefore, various studies have been made. For example, when cutting is performed using a belt sander, 5 to 7 stages in which the sandpaper count is changed as # 80 → # 100 → # 120 → # 150 → # 180 → # 240 → # 320. This process is necessary and is very inefficient. Therefore, it has been found that it is not practical unless the cutting thickness is less than 100 μm and the cutting process can be reduced.
On the other hand, it was found that when the surface of the calendar molded product was cut to obtain a cloud-shaped pattern or marble pattern with a clear outline, it was necessary to cut at least 100 μm, preferably 150 μm. However, as described above, if the belt sander is used to cut 100 μm or more, particularly 150 μm or more, the efficiency is extremely lowered. Furthermore, if the load is excessively applied to the belt sander, clogging will become remarkable, and the running cost will inevitably increase.

Therefore, in order to overcome the above problems and efficiently perform deep cutting of 100 μm or more, it is decided to use a commercially available cutting machine developed mainly for woodworking. The means of cutting itself is a well-known technique and is widely used in woodworking and the like (for example, “Mechanical Engineering Handbook” B. Application, Chapter 5, Cutting, 1998, 8th edition, New Edition, Japan) (See, for example, published by the Japan Society of Mechanical Engineers) Deep cutting of the surface is a method that is not very familiar with plastic processing, and as far as the present inventors know, there are no examples applied to the appearance of continuous patterns of composition floor tiles. .
As a result of various investigations by the present inventors, the cutting object is a plate-like object or sheet-like object made of a resin composition, and therefore it is necessary to give sufficient consideration to heat generation unlike the case of cutting wood. From the results, it was found that the rotational speed of the cutting blade of the cutting machine is preferably 3000 to 7000 rpm and the feed rate is preferably in the range of 8 to 16 m / min. Thereby, for example, a material having a thickness of 3.09 to 3.19 mm before cutting can be cut to a thickness of 2.89 to 3.09 mm. This cutting can be carried out in one step, and at most two steps. However, if you try to obtain a smooth surface, cutting speed may occur due to the rapid rotation, so the cutting blade material, shape, rotation speed, feed speed, dust collection position and angle, gap, etc. are appropriate. I also found it necessary to adjust. Even a slight level difference caused by such adjustment can be eliminated by sanding the surface using a belt sander without applying a large load. Furthermore, since even a fine count sander is a grindstone, a certain amount of reed (grinding marks) is generated. Therefore, it is preferable to perform final finishing of the surface by buffing the nonwoven fabric in order to eliminate this reed.

In addition, since composition floor tiles tend to have a small amount of resin and are likely to be soiled and scratched, in the usual case, a cross-coated paint or other coating material is applied as a protective film and surface coated to obtain a final product. For such surface coatings, UV curable acrylic resin-based paints, urethane resin-based paints, metal cross-linked acrylic resin-based emulsion waxes, etc. are used as coating compositions, and are applied by known methods such as roll coaters and spray coating methods. And can be formed by curing or drying. As the curing and drying method, an ultraviolet curing method, a drying method using hot air, and the like can be arbitrarily selected. The surface coat thickness after curing is several microns to several hundred microns, preferably 5 to 50 microns.
In addition, the method of the present invention can be applied to a homogeneous blend having a larger amount of resin than a composition blend.
In normal cases, the production is carried out continuously. The final product is cut into a certain shape as necessary. The size after cutting is, for example, 10 to 120 cm square, preferably 30 to 60 cm square, and a thickness of 2 to 100 mm, preferably 2 to 12 mm. However, it is not limited to these sizes and thicknesses.

Examples of the resin material of the resin composition used for the composition floor tile of the present invention include polyvinyl chloride, ethylene-vinyl chloride copolymer, polyolefin, polyester, and polyacrylate. A typical example of a composition floor tile is a composition vinyl floor tile. According to JIS A5705, the content of a binder composed of a vinyl resin, a plasticizer and a stabilizer is less than 30%. It is prescribed.
As fillers of the resin composition, silica, diatomaceous earth, alumina, titanium oxide, zinc oxide, barium ferrite, pumice and other oxides; aluminum hydroxide, magnesium hydroxide and other hydroxides; calcium carbonate, magnesium carbonate, Carbonate such as dolomite, (sulfur) sulfate such as calcium sulfate, barium sulfate, calcium sulfite; silicate such as talc, clay, mica, asbestos, glass fiber, glass balloon, calcium silicate, bentonite; carbon black, Carbon such as graphite; iron powder, aluminum powder, potassium titanate, wood powder, shell fiber, cotton, starch and the like.

As the plasticizer, those known as plasticizers for the respective resins can be used. For example, phthalic acid esters such as dimethyl phthalate, diethyl phthalate, dioctyl phthalate, diisodecyl phthalate, butyl benzyl phthalate, dimethyl isophthalate; -Fatty acid esters such as ethylhexyl adipate, diisobutyl adipate, dibutyl adipate, dibutyl sebacate, di-n-hexyl azelate; epoxidized esters such as epoxidized soybean oil, epoxy butyl stearate; adipic acid ester, adipic acid polyester Examples of polyesters include normal phosphate esters such as triphenyl phosphate, tricresyl phosphate, and cresyl diphenyl phosphate.
Examples of the stabilizer include metal soaps such as lithium stearate, magnesium stearate, calcium stearate, calcium laurate, barium stearate, barium laurate, cadmium ricinoleate, zinc stearate, zinc laurate, and lead stearate. Usually used in combination of two or more components. In addition, organotin stabilizers, lead stabilizers, antimony stabilizers; nonmetallic stabilizers such as epoxy compounds and phosphites can be used as stabilizing aids.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the composition floor tile which has the cloud-shaped pattern or the marble pattern of the clear outline which cannot be obtained by a prior art can be provided. Further, the conventional method is not suitable for mass production, but the method of the present invention can be continuously produced, is suitable for mass production, and is low in cost.

  EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further more concretely, this invention is not limited at all by these Examples.

Example 1
Using a resin composition comprising 100 parts by weight of polyvinyl chloride, 32 parts by weight of dioctyl phthalate as a plasticizer, 500 parts by weight of calcium carbonate as a filler, and 3 parts by weight of a mixture of calcium stearate and zinc stearate as a stabilizer, A composition sheet having a thickness of 2.2 mm was obtained by calendering.
After taking out this sheet-like material from the calender roll and water-cooling it through an aging process, the thickness of the surface is 0.2 mm (200 μm) by one cutting using the rotary cutting machine whose partial structure is shown in FIGS. ) Cutting and finally buffing to finish the surface.
As a result, the blurred surface layer of the pattern in the sheet-like material before cutting was removed, and a composition floor tile having a cloud-shaped pattern with a sharp outline was obtained.

Comparative Example 1
The composition sheet-like material obtained in the same manner as in Example 1 was cooled with water through an aging process and then cut with a belt sander. However, in order to cut the surface with the same thickness of 0.2 mm as in Example 1, the sandpaper count was changed to # 80 → # 100 → # 120 → # 150 → # 180 → # 240 → # 320. It was extremely inefficient.

A schematic side view of a rotary cutting machine. The figure which shows the shape of a rotary blade, (a) Top view, (b) Front view. An image of roll rolling. A simplified representation of the marble pattern. The figure which simplified and represented the pattern obtained when a surface layer part was rolled sequentially and continuously. A simplified representation of a cloud pattern.

Claims (3)

  A composition floor tile having a sharply contoured cloud pattern or marble pattern, characterized in that the surface of a plate or sheet obtained by calendering is continuously cut by a cutting machine having a rotary blade. Production method.   The manufacturing method according to claim 1, wherein the cutting process by the cutting machine is one stage or two stages. The manufacturing method of Claim 1 or 2 which cuts the surface of a plate-shaped thing or a sheet-like thing 100 micrometers or more in thickness.