JP2008087325A - Marble tone resin sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a marble tone pattern resin sheet having an accent in the pattern and a touch of class, which is manufactured by a rolling process with a low cost. <P>SOLUTION: In the marble tone pattern resin sheet for achieving the purpose, a resin composition to be a texture is kneaded and mixed by the rolling process, and a resin base material to be a marble pattern having uneven thickness is thrown to a bank between rolls to generate the marble pattern. The resin base material to be the marble pattern is made to be a plurality of colors. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an interior material, a floor material, or the like to which a marble pattern is given by roll processing.

  Conventionally, interior materials and flooring materials have been used with designs such as single color, printing, inlaid tone, unevenness, and marble tone. The monochromatic sheet is uniformly colored with a dye or a pigment, and the inlaid sheet is obtained by interposing a pellet or chip as a pattern on a ground color sheet and closely contacting the ground sheet. The unevenness is obtained by embossing a monochromatic sheet, an inlaid tone sheet or the like.

  As for the marble-like resin sheet, a method has been proposed in which paste sol of another color is sprayed into the surface layer paste or air is blown by dropping the paste sol (see Patent Documents 1 and 2). These methods have problems such as poor dimensional shrinkability and high cost.

  In addition, a method of rolling by rolling chips and pellets having different colors on a ground sheet has been proposed (see Patent Document 3). In this method, in addition to the process of creating a sheet as a ground, a process of spraying chips and pellets and a process of rolling it are required, and there is a problem of high cost.

  Furthermore, a method of forming a marble-like resin sheet by calendering a resin composition as a ground and introducing a resin composition to be a pattern into the calendar bank is known (see Patent Document 4). According to this method, a marble pattern can be uniformly imparted to the entire surface of the sheet as a ground, but a marble pattern having a high-class feeling due to the strength and weakness of the pattern cannot be imparted.

JP-A-60-007965 JP 03-087259 A JP 09-193334 A JP-A-11-277560

The object of the present invention is to produce a marble resin sheet at low cost by roll processing,
The purpose is to provide a marble-like resin sheet with a strong and dynamic pattern.

  The marble-like resin sheet of the present invention that achieves such an object is obtained by kneading a resin composition that becomes a ground by roll processing, and introducing a resin base material having a marble pattern with a non-uniform thickness into a bank between rolls. It is a marble-like resin sheet that produces a pattern, and moreover, the resin base material that becomes the marble pattern has a plurality of colors.

  According to the present invention, by setting the resin base material to be a marble pattern to a non-uniform thickness, it becomes a strong marble pattern, and an unprecedented high-grade marble-like resin sheet can be obtained. By making the resin base material that becomes a marble pattern into a plurality of colors, the design can be further improved.

Hereinafter, preferred embodiments of the present invention will be described in detail.
The resin composition to be used in the present invention includes olefin resin, polyvinyl chloride resin, acrylic resin, polyamide resin, polyurethane resin, polyester resin, fluorine resin, ABS resin, and AAS resin. Etc. The resin includes homopolymers obtained by polymerizing the respective monomers or copolymers obtained by copolymerizing other monomers that can be copolymerized, and these can be used alone or in combination of two or more. These resins can be processed by calendering and other roll processing methods, and additives such as plasticizers, lubricants, stabilizers, antioxidants, processing aids, fillers, etc. to improve performance and processability Can also be added as appropriate. Moreover, although depending on the combination with the color of the resin base material used as a marble pattern, it can also be arbitrarily colored with colorants, such as a pigment and dye. In view of processability and cost, olefin resins and polyvinyl chloride resins are preferable.

  The resin base material used as the marble pattern used for this invention can use resin similar to the resin composition used as said ground. These resins can be processed by a known method such as an extrusion T-die method, an inflation method, or a coating method such as a paste resin, without being limited to the calendar method.

  Resin of the resin base material used as the marble pattern used for this invention may be compatible or incompatible with the resin composition used as the ground. When the resin composition used as the ground and the resin of the resin base material that becomes the marble pattern are compatible, the marble pattern of the marble-like resin sheet tends to flow in the roll rotation direction during roll processing, and surface roughness is reduced. If the base resin composition and the resin of the resin base material that becomes the marble pattern are incompatible, the marble pattern of the marble-like resin sheet is difficult to flow in the roll rotation direction during roll processing, and the surface tends to be rough. In some cases, the design may be highly patterned. In the case of incompatibility, it is preferable to add a compatibilizing agent to the resin composition as a base and / or resin of the resin base material to be a marble pattern in order to improve surface roughness and adhesion. As described above, different marbles can be obtained in the case of compatibility and incompatibility, but considering the mechanical properties, surface properties, and processability of the marble resin sheet, the marble resin composition and marble can be obtained. It is preferable that the resin of the resin base material used as a pattern is compatible, and it is more preferable that the resin composition used as a base and the resin base resin used as a marble pattern are the same resin. Moreover, by embossing the marble tone resin sheet, the design can be further improved, and the above-described surface roughness can be corrected.

  The resin base material used as the marble pattern of this invention can use continuous base materials, such as a sheet form, a net form, and a tape form.

That the resin base material used as a marble pattern is non-uniform thickness means providing an unevenness | corrugation in a resin base material, or notching a resin base material partially. As a method for providing unevenness, a method of drawing or embossing a resin base material, a method of laminating a resin sheet of an arbitrary shape on a film, a method of applying and solidifying a paste resin into an arbitrary shape with a rotary screen or the like Etc. Further, the resin base material can be partially cut out and used, for example, in a net shape.
Further, by forming the convex portion in a color different from that of the concave portion, a marble pattern having a good appearance can be obtained.

  In order to provide multiple colors for the marble resin base material, the base resin base material is laminated with sheets of arbitrary shapes such as triangles, squares, rhombuses, circles, ellipses, etc., or a paste resin is applied. Solidify or cut out the base resin base material into an arbitrary shape and embed the part with a different color sheet. Join different color tape-shaped resin sheets vertically, horizontally, and diagonally to the roll rotation direction. The method of doing is mentioned.

  Also, when creating a marble-like resin base material by roll processing, it is easy to emphasize the convex parts and non-notched parts, so that any convex parts and non-notched parts overlap in the roll rotation direction. For example, a staggered pattern is preferable.

Next, the roll process which produces a marble tone resin sheet is demonstrated. The base resin composition may be kneaded with a roll, or may be kneaded with an extruder, a kneader or the like and put into the roll. In the roll processing, a resin bank to be kneaded is formed between the rolls, and a marble base resin base material is directly put into the bank between the rolls or is brought into contact with the roll before the bank and then put into the bank. The resin base material is kneaded in the bank, and a marble pattern is generated.
For roll processing, a horizontal or upright processing device with 2 to 3 rolls, an upright type with 3 to 6 rolls, an L type, an inverted L type, a Z type calendar device, etc. are used alone or in combination. In the present invention, roll processing is sufficient, and the number and type of rolls are not particularly limited. The following describes the two horizontal rolls.

  First, the resin composition used as the ground is kneaded with two rolls while forming a bank between the rolls, and adjusted to a thickness between 0.1 mm and 1.0 mm. In consideration of workability and release properties, 0.2 mm to 0.5 mm is preferable.

  Next, after adjusting the thickness between the rolls, the resin base material to be a marble pattern is put directly into the bank or into the roll in front of the bank, and the sheet is taken out. The marble pattern changes depending on the molten state of the resin base material, and the greater the degree of melting, the easier the marble pattern flows in the roll rotation direction. The degree of flow of the marble pattern can be adjusted by designing the degree of polymerization of the resin, the MI of the resin, the addition amount of the plasticizer, the addition amount of the filler, and the like of the resin base material to be a marble pattern.

  The resin base material used as the marble pattern used in the present invention has a thick marble pattern when the input amount is large, and the marble pattern becomes light when the amount is small. In consideration of the harmony and processability of the color of the resin composition that becomes the ground and the color of the resin base material that becomes the marble pattern, the input amount of the resin base material that becomes the marble pattern is 2 to 50 with respect to the finished marble-like resin sheet. % By weight is preferred, and 5 to 20% by weight is more preferred.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in more detail, this invention is not limited to these Examples.

Table 1 shows the configurations and evaluation results of Examples and Comparative Examples. Table 2 shows the composition of the resin composition to be used in Examples and Comparative Examples and the composition to be used for the resin base material to be a marble pattern. Moreover, the preparation method of the resin base material (B-1 to B-10, B'-1, B'-2) used as the marble pattern used for Examples 1-10 and Comparative Examples 1 and 2 is shown below.
<Preparation method of resin base material to be marble pattern>
(B-1): A circular hole having a diameter of 70 mm was formed in a staggered pattern in a monochromatic sheet having a thickness of 0.04 mm by blending b-1 (red) and designated as B-1.
(B-2): A circular monochromatic sheet having a thickness of 0.08 mm and a diameter of 70 mm is affixed in a staggered manner on a monochromatic sheet having a thickness of 0.04 mm with a blending b-2 (white). It was set as B-2.
(B-3): Two types of monochromatic strip tapes having a thickness of 0.04 mm in the blend b-1 (red) and 0.06 mm in the thickness of the blend b-2 (white) are alternately arranged, and the length of the monochromatic strip tape The ends were joined in parallel with the direction of rotation and the direction of roll rotation (injection direction into the bank) to obtain B-3.
(B-4): Two types of monochromatic strip-shaped tapes having a thickness of 0.04 mm for formulation b-1 (red) and 0.06 mm for formulation b-2 (white) were alternately arranged, and the length of the monochromatic strip-shaped tape The ends were joined at right angles to the direction of rotation and the direction of roll rotation (injection direction into the bank) to obtain B-4.
(B-5): A circular hole having a diameter of 70 mm is formed in a staggered pattern in a monochromatic sheet having a thickness of 0.08 mm by blending b-3 (acrylic, white), and the thickness is blended by b-1 (red) in the hole. A monochromatic sheet of 0.04 mm was embedded to make B-5.
(B-6): Compound B-1 (red) with a 0.04 mm thick monochromatic sheet with 70 mm diameter circular holes in a staggered pattern, and in the holes, with formulation b-3 (acrylic, white) A monochromatic sheet having a thickness of 0.1 mm was embedded to obtain B-6.
(B-7): A monochromatic sheet having a thickness of 0.08 mm and a diameter of 70 mm in a blend b-3 (acrylic, white) is staggered on a monochromatic sheet having a thickness of 0.08 mm in the blend b-2 (white). Affixed to B-7.
(B-8): A circular monochromatic sheet having a thickness of 0.04 mm and a diameter of 70 mm is blended in a zigzag pattern on the monochromatic sheet having the blend b-1 (red) and a thickness of 0.1 mm. B-8.
(B-9): A circular hole having a diameter of 70 mm was formed in a staggered pattern in B-3 to obtain B-9.
(B-10): A circular hole having a diameter of 70 mm was formed in a staggered pattern in B-10 (EVA, red) in a monochromatic sheet having a thickness of 0.04 mm to obtain B-10.
(B′-1): A monochromatic sheet having a thickness of 0.04 mm and blend B-1 (red) was designated as B′-1.
(B′-2): A monochromatic sheet having a thickness of 0.04 mm in the blend b-2 (white) was designated as B′-2.

The resin base material which becomes a marble pattern was adjusted to a size of 720 mm in length and 300 mm in width and used as a sheet. Moreover, what was made into the staggered shape installed in the resin base material used as a marble pattern so that the circular hole or sheet | seat of diameter 70mm might become 15 in a zigzag form.

<Example 1>
The resin composition (A-1) serving as the ground of the composition shown in Table 2 was kneaded while forming a bank between the rolls with two rolls, wound on one roll surface, and adjusted to a thickness of 0.4 mm. And the resin base material (B-1) used as a marble pattern was injected | thrown-in to the bank, and the roll was rotated 2 times after injection | throwing out, and the sheet | seat was taken out and the marbled resin sheet was obtained.

<Example 2>
A marble-like resin sheet was obtained in the same manner as in Example 1 except that B-2 was used as the resin base material to be a marble pattern.

<Example 3>
A marble-like resin sheet is obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition is adjusted to 0.3 mm and B-3 is used as a resin base material to be a marble pattern. It was.

<Example 4>
A marble-like resin sheet was obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition was adjusted to 0.5 mm and B-4 was used as the resin base material to be a marble pattern. It was.

<Example 5>
A marble-like resin sheet is obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition is adjusted to 0.5 mm and B-5 is used as the resin base material to be a marble pattern. It was.

<Example 6>
A marble-like resin sheet was obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition was adjusted to 0.5 mm and B-6 was used as the resin base material to be a marble pattern. It was.

<Example 7>
A marble-like resin sheet is obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition is adjusted to 0.5 mm and B-7 is used as a resin base material to be a marble pattern. It was.

<Example 8>
A marble-like resin sheet was obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition was adjusted to 0.5 mm, and B-8 was used as the resin base material to be a marble pattern. It was.

<Example 9>
A marble-like resin sheet is obtained by operating in the same manner as in Example 1 except that the thickness of the ground resin composition is adjusted to 0.5 mm and B-9 is used as the resin base material to be a marble pattern. It was.

<Example 10>
The marble is operated in the same manner as in Example 1 except that the resin composition (A-2) serving as the ground is adjusted to a thickness of 0.5 mm and B-10 is used as the resin base material to be a marble pattern. A resin sheet was obtained.

<Comparative Example 1>
A marble-like resin sheet was obtained in the same manner as in Example 1 except that B′-1 was used as the resin base material to be a marble pattern.

<Comparative example 2>
A marble-like resin sheet was obtained in the same manner as in Example 1 except that B′-2 was used as the resin base material to be a marble pattern.

[Evaluation methods]
The marble-like resin sheets obtained in Examples and Comparative Examples were visually observed and evaluated according to the following evaluation criteria.
A: Multicolored, strong and weak marble pattern with a high-class feeling and excellent design.
○: A marble pattern with strength and weakness and high design.
X: The marble pattern does not show strength or weakness and has poor design.

  In Examples 1, 2, 7, and 10, the strength and strength of the marble pattern appeared and the design was high. By making the resin base material into a plurality of colors, Examples 3 to 6, 8, and 9 had a multi-colored marble pattern, a strong and weak pattern, and a high-class feeling and excellent design.

  In Comparative Example 1 and Comparative Example 2, no strong or weak marble pattern was observed, and the marble pattern was poor in design and unchanged from the conventional one.

ＥＶＡ１：東ソー社製、エチレン−酢酸ビニル共重合体 ＵＥ６３４
ＥＶＡ２：東ソー社製、エチレン−酢酸ビニル共重合体 ウルトラセン６２８
ＴＰＯ ：Ｂａｓｅｌｌ社製、オレフィン系熱可塑性エラストマー ＫＳ３５３Ｐ
アクリル系グラフト共重合体１：クラレ社製、アクリル樹脂２０％とアクリル系ゴム状粒子８０％
アクリル系グラフト共重合体２：クラレ社製、アクリル樹脂５０％とアクリル系ゴム状粒子５０％

EVA1: manufactured by Tosoh Corporation, ethylene-vinyl acetate copolymer UE634
EVA2: manufactured by Tosoh Corporation, ethylene-vinyl acetate copolymer Ultracene 628
TPO: manufactured by Basell, olefin-based thermoplastic elastomer KS353P
Acrylic graft copolymer 1: Kuraray Co., Ltd., 20% acrylic resin and 80% acrylic rubber particles
Acrylic graft copolymer 2: manufactured by Kuraray Co., Ltd., 50% acrylic resin and 50% acrylic rubber particles

  Since the marble-like resin sheet of the present invention exhibits high design properties, it can be used for applications such as building materials, interior materials such as vehicles, flooring materials, daily necessities, and miscellaneous goods.

Claims (2)

  A marble-like resin sheet characterized by kneading a ground resin composition by roll processing and introducing a resin base material having a non-uniform thickness into a bank between rolls to generate a marble pattern.   The marble base resin sheet according to claim 1, wherein the resin base material having a marble pattern has a plurality of colors.