JP2008149507A - Decorative material and its production method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative material having a grain pattern and a variation of a spot pattern which is not a mere grain pattern and a method for producing the decorative material. <P>SOLUTION: The decorative material is formed from mutually differently colored thermoplastic resin chips and has an uppermost layer decorative layer sheet having the grain pattern and the spot pattern formed at the tip of a streak formed in the grain pattern. In the method for producing the decorative material, a decorative layer sheet having a streaky flow pattern is obtained by calendering a chip formulation containing thermoplastic resin chips not containing fibers and containing an inorganic filler and at least two kinds of mutually differently colored thermoplastic resin chips not containing fibers, and an embossed laminate which is obtained by embossing a laminate prepared by laminating the decorative layer sheet on a substrate sheet as the uppermost layer to form a notch penetrating the decorative layer sheet is rolled to be spread 3-15 times in area while being conveyed in the same direction as the rolling direction when the chip formulation is rolled. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a decorative material and a manufacturing method thereof, and more particularly to a decorative material having a wood grain pattern and a spotted pattern and a manufacturing method thereof.

  Patent Document 1 is a classic document describing an invention relating to a so-called “floor material” referred to as “thermoplastic flooring tile material”. To summarize, the “method for producing a thermoplastic floor tile material” described in Patent Document 1 is “to form a strip obtained by cutting a sheet-like body made of a thermoplastic mixture into a strip layer on a conveyor, It includes forming a sheet-like body by heating the strip layer and calendering the sheet-like body ”(refer to the claims of Patent Document 1). From the above description of Patent Document 1, it is understood that the thermoplastic floor tile material according to Patent Document 1 is a so-called “composition tile”. In the technical fields such as flooring tiles, linoleum and flooring, composition tiles usually have a total of thermoplastic resin and plasticizer of at most 30% by mass with respect to the entire tile, with the balance being an inorganic filler. It is recognized that

  In Patent Document 1, the object of the invention described in Patent Document 1 is to “provide a thermoplastic coating material having a new pattern on the surface and inside” (see page 40, right column, page 40, right column). Line to line 42). In this Patent Document 1, it is disclosed that a tile material having a “ball pattern” and a “marble pattern” can be obtained by this manufacturing method (see page 38, left column, line 38 of Patent Document 1).

  The invention described in Patent Document 2 states that “a decoration having a pattern obtained by heating a softened sheet having a base material and a coloring material into a surface and rolling the sheet in a direction of 90 degrees with respect to the slit. Material. In this decorative material, the sheet with slits is turned 90 degrees on a turntable and the sheet is rolled in a direction perpendicular to the slits, so that a cloud pattern is formed on the surface of the resulting decorative material. This Patent Document 2 does not mention a pattern other than a cloud pattern.

  In addition, the decorative material described in Patent Document 2 is “spreading 5 to 50% by weight of colored pellets 2 different from the base material 1 as a pattern material on the thermoplastic resin base material 1 with respect to the base material. 3 and 3 ′ form a sheet 4 having a relatively thick thickness of 10 to 60 mm ”. Since the invention described in this Patent Document 2 is rolled after 90 degrees of direction change with respect to the slit, a cloud pattern or a stone pattern is formed on the surface of the decorative material by expanding the slit by rolling. Yes.

  The invention described in Patent Document 3 states that “the two or more layers of fiber-containing thermoplastic resin laminates having different colors are embossed from the planned surface side, or a part thereof is cut, thereby the planned surface side. In the method of revealing a pattern of a thermoplastic resin sheet, comprising a first step of forming irregularities in a second step and a second step of rolling a laminate having irregularities on the planned surface obtained in the first step ” is there. In the method described in Patent Document 3, the roll temperature in calendering is 100 to 120 ° C., and the temperature of the concavo-convex laminate is 100 to 110 ° C. (see [0022] of Patent Document 3). Also in this example, the temperature of the upper roll and the lower roll in calendering was 110 ° C., and the temperature of the uneven laminate was 105 ° C. According to the invention described in Patent Document 3, it is said that “a unique pattern that cannot be realized by printing and cannot be expressed by words appears, unlike a conventional marble pattern or cloud pattern” ( (See Patent Literature 3 [0017]). In the method described in Patent Document 3, the temperature of the calender roll and the temperature of the concavo-convex laminate are made different, and the rotation speed of the pair of calender rolls is made different so that the surface of the concavo-convex laminate is peeled off. It tried to form a unique pattern, but it could not form a regular wood grain pattern.

  The decorative material described in Patent Document 4 is “for the purpose of providing a woodgrain decorative material without printing”. As a means for achieving this object, “the pattern material applied to the base material is heated and softened. It is a decorative material characterized by having a pattern obtained by rolling out and rolling from a plurality of slits that are oblique with respect to the flow direction of the sheet in the state. According to this patent document 4, “a mill pad of base material resin 1 kneaded by a Banbury mixer is wound around the mill roll 3, and the pattern material 2 is dropped and applied thereto. Next, the mill pad to which the pattern material is applied is provided. At the same time as the sheet material is separated from the mill roll, concentric circles or concentric polygonal figures, and other slits that are oblique with respect to the flow direction of the sheet 4 are inserted by the slitter 5 and the heat-fluid pattern material appears on the surface of the base material. It is rolled by rolls 6 and 6 'to obtain an annual ring-like wood grain pattern 7 "(see [0008] of Patent Document 4).

Japanese Patent Publication No.43-2598 Japanese Patent Publication No. 5-79232 JP-A-9-174484 JP2001-341272

  By the way, in recent years, there are various needs for patterns of decorative materials used in buildings such as houses and commercial buildings. A decorative material having a woodgrain pattern, a decorative material having a marble pattern, and the like are desired. However, since the decoration material with a pattern that imitates the grain of true wood is not formed of true wood, the wood pattern applied to the decoration material is not necessarily a true grain pattern, but imitation Tend to be evaluated only as

  An object of the present invention is to provide a decorative material having a wood grain pattern and not a simple wood grain pattern but a spotted pattern having a change, and a method for manufacturing the decorative material.

As means for solving the problems,
Claim 1 has a top layer decorative layer sheet which is formed of colored thermoplastic resin chips having different colors and has a wood grain pattern and a speckled pattern formed at the tip of a streak formed in the wood grain pattern. Is a decorative material characterized by
A second aspect of the present invention is the decorative material according to the first aspect, wherein the wood grain pattern is a plate pattern and / or a square pattern.
Claim 3 is the decorative material according to claim 1, wherein the wood grain pattern is a bamboo grain pattern.
Claim 4 is the decorative material according to any one of claims 1 to 3, wherein the decorative material is a floor material.
Claim 5 is the decorative material according to any one of claims 1 to 4, wherein the decorative material is a composition tile.
[Claim 6] A chip compound containing a thermoplastic resin chip containing no fiber and containing an inorganic filler and at least two kinds of fiber-free colored thermoplastic resin chips having different colors is calendered. Thus, a decorative layer sheet having a streak-like flow pattern is obtained, and a laminate formed by stacking the decorative layer sheet on the base sheet as the uppermost layer is formed with a cut through the uppermost decorative layer sheet. In addition, the embossed laminate obtained by embossing is conveyed in the same direction as the rolling direction when the chip compound is rolled, and the embossed laminate is rolled 3 to 15 times. A method of manufacturing a decorative material, characterized in that
7. The method for producing a decorative material according to claim 6, wherein the fiber-free thermoplastic resin chip is a vinyl chloride resin chip and / or a vinyl chloride-vinyl acetate copolymer chip.

  According to the present invention, a decorative material capable of giving a decorative change to a floor, a wall, or the like of a building by forming a pattern rich in change due to the presence of a speckled pattern, not just a simple grain pattern. Can be provided.

  The wood grain pattern may be a wood grain pattern or a wood grain pattern in wood, or may be a bamboo grain pattern that appears when a bamboo meat portion is shaved along the bamboo axis. The bamboo grain pattern includes a pattern including bamboo knots. The decorative material according to the present invention can be used as a flooring material, a wall material, and a ceiling material. The decorative material according to the present invention can be used as a composition tile that is one of flooring materials.

  According to the present invention, a combination of calendering and embossing forms not only a simple wood grain pattern but also a wood grain tone, and a speckled pattern is formed on the floor, wall surface, etc. of the building. It is possible to provide a method capable of easily producing a decorative material capable of giving a decorative change.

  The decorative material according to the present invention is suitable as an architectural decorative material, particularly as a flooring material.

  The decorative material according to the present invention will be described together with its manufacturing method. The decorative material according to the present invention can be manufactured, for example, as follows.

  The thermoplastic resin chip in this invention does not contain fibers but contains an inorganic filler, a thermoplastic resin, and a pigment.

  Examples of the inorganic filler include calcium carbonate, calcium sulfate, dolomite, talc, diatomaceous earth, kaolin, halloysite, muscovite, calcined clay, zeolite and the like. Among these various inorganic fillers, calcium carbonate, calcium sulfate, and dolomite can impart opacity to the decorative material, and talc can impart transparency or translucency to the decorative material. Suitable inorganic fillers in this invention include calcium carbonate and talc.

  Examples of the thermoplastic resin include polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, polyvinylidene chloride resin, EVA (ethylene-vinyl acetate copolymer), polyethylene, ethylene, and α-olefins having 3 to 8 carbon atoms. Examples of the copolymer include polypropylene, a copolymer of polypropylene and an α-olefin having 4 to 8 carbon atoms, an acrylic resin, a methacrylic acid resin, polyvinyl acetate, and polyvinyl alcohol. Among these, polyvinyl chloride and / or vinyl chloride-vinyl acetate copolymer are preferable. Polyvinyl chloride and / or vinyl chloride-vinyl acetate copolymer can be suitably subjected to calendering, and as a result, a streak pattern is formed on the decorative material on a transparent or translucent ground by thermoplastic resin. It is because it can be.

  Examples of the pigment include titanium oxide, carbon black, bengara, aluminum powder, gold powder, and silver powder. The kind and ratio of the pigment contained in the thermoplastic resin chip are appropriately determined.

  The blending amount of the inorganic filler is usually 100 to 800 parts, preferably 200 to 700 parts by weight with respect to 100 parts by weight of the thermoplastic resin. When the blending amount of the inorganic filler is less than the lower limit value, a bank is formed between the rolling rolls, and as a result, a streak pattern may not be formed well, and the blending amount of the inorganic filler is When it is larger than the upper limit, the mechanical strength of the decorative material may be lowered.

  This thermoplastic resin chip can contain a plasticizer, a stabilizer, a processing aid, a binder and the like in addition to the inorganic filler and the thermoplastic resin.

  Examples of the plasticizer include DINP (diisononyl phthalate) and DOP (di-2-ethylhexyl phthalate). Examples of the stabilizer include barium zinc.

  The thermoplastic resin chip in the present invention can be suitably manufactured, for example, as follows.

  A thermoplastic resin, an inorganic filler and a pigment, and further a plasticizer and a stabilizer as necessary are mixed by a mixer set at, for example, 120 to 160 ° C., for example, by a Banbury mixer, and this is set at, for example, 100 to 150 ° C. For example, a resin lump (pad) is formed between the mixing rolls by kneading with a mixing roll. Next, this pad is rolled by, for example, a rolling mill set at 100 to 120 ° C., for example, a calender roll to form a sheet having a thickness of 0.5 to 10 mm, preferably 1 to 5 mm. The sheet is pulverized with a crusher such as a crusher and sieved with a sieve to obtain a thermoplastic resin chip containing an inorganic filler having a predetermined size.

  The chip formulation in this invention does not contain fibers. When fibers such as synthetic fibers, natural organic fibers, natural inorganic fibers, etc. are included, when the laminate having the decorative layer sheet as the uppermost layer is embossed, the fiber ends are exposed on the surface of the decorative layer sheet, etc. This is because the appearance is poor and the wood grain pattern is not well formed.

  The decorative layer sheet in this invention can be formed as follows.

  First, a decorative layer sheet is manufactured by calendering a chip formulation including thermoplastic resin chips colored differently. The reason why the thermoplastic resin chips having different colors are blended is to form a streak pattern in the colored ground color.

  In order to manufacture the decorative layer sheet, specifically, first, as shown in FIG. 1, for example, the thermoplastic resin chips are put into the heating stirrer 1 and mixed while heating these thermoplastic resin chips. To do. The heating temperature in the heating stirrer 1 is usually 30 to 80 ° C. By heating the thermoplastic resin chip to a temperature within the above temperature range by the heating stirrer 1, the calendar process as the next step can be smoothly performed. Subsequently, the chip composition obtained by the heating stirrer 1 is supplied to the fixed amount feeder 2, and a predetermined amount of the chip composition is supplied from the constant amount feeder 2 to the belt conveyor 3. Since the belt conveyor 3 is moving in an endless track at a constant speed, the chip composition discharged from the fixed quantity feeder 2 is thinly spread on the conveying surface of the belt conveyor 3. The chip compound in a state of being thinly spread on the conveying surface of the belt conveyor 3 moves along with the movement of the conveying surface of the belt conveyor 3. The belt conveyor 3 passes through the heating device 4. The inside of the heating device 4 is preheated by heating means (not shown). The chip compound conveyed by the belt conveyor 3 is transferred to the chip loading device 5. The chip composition in a thinly spread state transferred to the chip transfer device 5 is transferred to the first calendar device 6.

  The conveying means in the present invention is means for conveying and supplying the chip compound to the calender roll in the calendar device, and is formed by the belt conveyor 3 and the chip feeding device 5 in FIG.

  The chip compound that has spread on the conveying surface is supplied to the pair of calendar rolls in the first calendar device 6.

  The chip composition supplied to the first calendar device 6 is processed into a thin sheet, and the colored thermoplastic resin chips form a streak pattern by the calendar roll in the first calendar device 6. The heating temperature of the calendar roll in the first calendar device 6 is usually 90 to 140 ° C. When a thinly spread compound enters between the calender rolls heated to a temperature within this temperature range, thermoplastic resin chips having different colors are welded to each other by the heat of the calender rolls, so that the sheet-like material is formed. It becomes long and is discharged from between the calendar rolls. The long sheet-like material to be discharged is formed with a streak-like flow pattern of pigment by melting of the thermoplastic resin chip and stretching by a calender roll.

  In the present invention, the decorative layer sheet is not limited to being manufactured as described above.

  The long sheet-like material discharged from the first calendar device 6 is transferred to the transfer surface of the second belt conveyor 7 and is transferred by the movement of the transfer surface. The second heating device 8 is disposed at a predetermined position, for example, an upper position, facing the transport surface of the second belt conveyor 7. In the second heating device 8, the long sheet-like material conveyed by the second belt conveyor 7 maintains flexibility, and the sheet-like material is torn on the second belt conveyor 7 during the conveyance. Do not bend or fold. The long sheet-like material that is conveyed by the second belt conveyor 7 is supplied to the second calendar device 9. When the long sheet-like material is supplied between the calender rolls in the second calender device 9, the thermoplastic resin is melted by the heat of the calender rolls in the second calender device 9, and the rotation speed of the pair of calender rolls Are different from each other, the thermoplastic resin on the surface of the sheet-like material causes the thermoplastic resin to flow along the direction of transport of the sheet-like material, and by these actions, the pigment formed on the surface of the sheet-like material The flow pattern is more prominent, and a long streaky flow pattern having various lengths and various thicknesses is formed on the surface of the long sheet-like material.

  As shown in FIG. 2, this decorative layer sheet 11 is colored on the surface portion 11A formed of a thermoplastic resin and an inorganic filler with a pigment in the thermoplastic resin chip, and in the calendering rolling direction (in other words, Then, this rolling direction is the conveying direction of the sheet-like material discharged from between the calender rolls, and is the longitudinal direction of the sheet-like material.) It has the formed checkerboard pattern 11B.

  As shown in FIG. 2, the decorative layer sheet 11 has a thickness of 0.2 to 2.5 mm when the decorative material according to the present invention is used for a flooring. In addition, the thickness of the decorative layer sheet in this invention is not limited to the said range, The thickness of a decorative layer sheet is suitably determined according to the use of the decorating material which concerns on this invention.

  The decorative material of the present invention is manufactured from, for example, a laminated product in which at least one decorative layer sheet and a base sheet obtained by using a thermoplastic resin are laminated, that is, a laminate.

  The base sheet is a sheet that cannot be seen from the outside when the decorative material is applied as a floor material, for example, and ensures the thickness of the entire decorative material according to the type of the floor material, etc. Has a function of ensuring elasticity, rigidity, mechanical strength, etc., and / or a warpage prevention function. As long as this base material sheet is formed using a thermoplastic resin, there is no restriction | limiting in the manufacturing method. The raw material for manufacturing the base sheet is appropriately selected according to the use and function of the decorative material.

  As shown in FIG. 3, in order to manufacture the decorative material according to the present invention, at least one decorative layer sheet and a base sheet are overlapped to prepare an overlapped product. The decorative layer sheet 11 is stacked on the base sheet 12.

  In FIG. 3, the base sheet 12 is drawn as one sheet, but the number of base sheets 12 to be laminated is not particularly limited. Depending on the use and purpose of the decorative material, at least one decorative layer sheet may be laminated on one base sheet, and at least one decorative layer sheet may be provided on a plurality of base sheets. May be laminated. As shown in FIG. 3, two decorative layer sheets 11 may be laminated on the base sheet 12, or two or more decorative layer sheets 11 may be laminated. The number of base sheet and the number of decorative layer sheets are appropriately determined in consideration of the streak pattern that looks like wood grain and the wear resistance required for the decorative material. The

  The color by the pigment in each of the plurality of decorative layer sheets 11 stacked on the base sheet 12 may be the same or different. The color of the streak pattern that looks like a grain formed on the surface of the decorative layer sheet 11 may be the same as or different from the color of each streak as the pattern.

  When at least two of the decorative layer sheets 11 are laminated on the base sheet 12, as shown in FIG. 3, a plurality of decorative layer sheets are formed so that the formation directions A of the streaks in the decorative layer sheet 11 coincide with each other. 11 is preferably laminated.

  The thickness of the laminate 14 formed by laminating at least one decorative layer sheet 11 on one or a plurality of substrate sheets 12 is usually 10 to 50 mm when the decorative material is a flooring. Of course, depending on the application of the decorative material, the thickness of the laminate 14 may be greater than 50 mm and may be less than 10 mm.

  In the present invention, the laminate is embossed. Specifically, as shown in FIG. 4, the laminate 14 is transferred into the heating device 15 by, for example, a transport device having a belt conveyor 16 or the like. The reason why the laminate 14 is heated by the heating device 15 is to melt and bond the base sheet 12 and the decorative layer sheet 11 lightly so that they do not shift during the calendering process in the subsequent process. Therefore, the heating temperature by the heating device 15 is set so that heat to the extent that the base sheet 12 and the decorative layer sheet 11 are melt-bonded is applied to the laminate 14.

  A laminated body in which the base sheet 12 and at least one decorative layer sheet 11 are lightly bonded to each other so as not to be displaced from each other by the heating device 15 is provided to the embossing device 17.

  This embossing device 17 has a pair of opposing rolls. An uneven pattern is formed on the surface of one or both of the pair of rolls. A roll having an uneven pattern is referred to as an embossing roll.

  The uneven pattern formed on the surface of the embossing roll becomes a factor that determines the pattern formed on the surface of the decorative layer sheet 11. For example, when a “grid pattern” as shown in FIG. 2 is formed on the surface of the uppermost decorative layer sheet 11 in the laminate 14 supplied to the embossing processing device 17, it is formed on the surface of the embossing roll. The concavo-convex pattern is preferably a tooth pattern that cuts the filaments in the “grid pattern”. An example of a tooth pattern that is an uneven pattern formed on the roll surface is shown in FIG. The tooth pattern shown in FIGS. 6 (a) and 6 (b) is shown as a pattern that appears when the surface of a cylindrical roll is made flat. As shown in FIG. 6 (a), the front end surface is disposed on the surface of the embossing roll 30 in a direction parallel to the axial direction A of the embossing roll 30 and is formed so as to protrude from the surface of the embossing roll 30. An example is a tooth pattern in which projecting pieces 30A, 30B, 30C, and 30D having a thin rectangular shape are arranged in parallel to each other. As the tooth pattern for cutting the line in the grid pattern, a plurality of protrusion pieces 30D extending long in the axial direction A of the embossing roll as shown in FIG. 6 (a) are predetermined on the peripheral surface of the embossing roll. Tooth-shaped patterns arranged in parallel at intervals, as shown in FIG. 6A, a plurality of the same length or different lengths arranged in a line along the axial direction A of the embossing roll A tooth pattern formed by arranging the protruding pieces 30A in parallel on the peripheral surface of the embossing roll, extending with a predetermined length along the axial direction of the embossing roll as shown in FIG. A plurality of protruding pieces 30B and a plurality of other protruding pieces 30C extending at a predetermined length along the axial direction of the embossing roll are arranged on the peripheral surface of the embossing roll. Tooth pattern Rukoto can. Further, as another tooth pattern for cutting the line in the grid pattern, as shown in FIG. 6 (b), the protrusion 30E inclined at a predetermined angle with respect to the axial direction A of the embossing roll is provided with the embossing. An example is a tooth pattern that is arranged so as to be parallel to each other along the circumferential surface of the roll. The plurality of protruding pieces 30E arranged so as to be parallel to each other may be arranged in a line on the peripheral surface of the embossing roll, or may be arranged in a plurality of lines. Further, the plurality of protrusion pieces 30E arranged so as to be parallel to each other, and the protrusion pieces 30E are formed at different inclination angles and arranged in a line on the peripheral surface of the embossing roll so as to be parallel to each other. A plurality of protruding pieces 30E, and a tooth pattern having an inverted shape of a letter C when viewed along the axial direction of the embossing roll is also suitable for the uneven pattern formed on the surface of the embossing roll. As an example.

  The front end surface of the protruding piece constituting the concavo-convex pattern formed on the surface of the embossing roll is depicted as an elongated rectangle in FIG. 6, but is not limited to such an elongated rectangle, and may be a circle, a square, or the like. May be. Further, the tip surface of the protruding piece is not limited to a flat surface, but may be a sharp pointed surface or a blade.

  The embossing depth imprinted on the surface of the laminate by the embossing roll having such a concavo-convex pattern on the peripheral surface needs to be long enough to penetrate the uppermost decorative layer sheet 11. This is because, when the laminate is inserted between a pair of embossing rolls, a cut is formed through the uppermost cosmetic layer sheet by the protruding piece in the embossing roll, and then the uppermost cosmetic layer sheet is inserted through the calendar roll. This is because the cuts in Fig. 4 are further enlarged, and a spotted pattern is favorably formed on the surface of the uppermost decorative sheet. The emboss depth by such a protrusion piece is appropriately determined depending on the thickness of the laminate and the thickness of the uppermost decorative layer sheet, and is preferably 0.1 to 30 mm in many cases.

  Embossing is performed by the embossing processing device 17 so that the base sheet 12 and at least one decorative layer sheet 11 are bonded or bonded to each other, and the base sheet 12 and at least one sheet are also subjected to rolling in the next calendar process. The decorative layer sheets 11 are not displaced from each other, and a cut is formed that penetrates the stripes in the streaks formed on the surface of the uppermost decorative layer sheet 11 in the laminate 14.

  The laminated body 14 that has passed through the embossing device 17 is conveyed by a conveying device having conveying means such as a belt conveyor 19 while being heated by the heating device 18. Heating by the heating device 18 facilitates the melt flow of the thermoplastic resin in the laminate 14. Usually, the temperature of the laminated body 14 heated by the heating device 18 is preferably 100 to 130 ° C. as the temperature immediately before the next calendering.

  For example, the laminate 14 heated to the temperature range is fed between the calender rolls in the third calender device 20.

  The temperature of the calendar roll in the third calendar device 20 is usually adjusted to 80 to 110 ° C. More preferably, the temperature of the calender roll is adjusted so that the temperature of the calender roll falls within the above temperature range and is lower than the temperature of the laminated body 14 that is fed. In calendering by the third calender device 20, when the temperature of the calender roll is lower than the temperature of the laminate 14, the degree of melt flow of the thermoplastic resin in the laminate 14 decreases, in other words, the molten thermoplastic resin flows. Since it does not become too much, the grain pattern formed on the surface of the decorative layer sheet 11, that is, the grid pattern, will not be destroyed. More preferably, among the pair of calendar rolls, the temperature of the upper calendar roll is set 5 to 10 ° C. lower than the temperature of the lower calendar roll. Thus, by adjusting the temperature of each of the pair of calendar rolls, the cut part of the grid pattern formed on the surface of the decorative layer sheet 11 cut by the uneven pattern of the emboss roll is, for example, FIG. As shown in Fig. 5, the spot pattern is formed in a scattered shape or a randomly dispersed shape.

  Although FIG. 7 is a schematic diagram, the actual situation is well expressed. When the laminated body subjected to the embossing is calendered by the calender device 20, the grain of the grid pattern is cut, and the pattern of the spot 11C in which the wood conduit is exposed at the cut part of the grain is the surface of the decorative layer sheet 11 Formed.

  The rotation speeds of the pair of calendar rolls in the calendar device 20 may be the same, but it is preferable to make the rotation speeds different from each other. In the case of calendering in which the laminate laminated so that the decorative layer sheet is on the upper side and the base sheet is on the lower side is calendered, the rotation speed of the calender roll located on the upper side is determined. It is preferable to make it smaller than the rotational speed of the calender roll located on the lower side. When the rotation speed of the upper calendar roll is lower than the rotation speed of the lower calendar roll, the upper calendar roll works to spread the cuts on the surface of the decorative layer sheet, and the spot pattern appears to expose the conduit. Can be easily formed.

  The rolling ratio of the pair of calendar rolls in the third calendar device 20 is usually 1/2 to 1/20, preferably 1/4 to 1/10. With such a rolling ratio, the effect of randomly dispersing the cuts formed on the surface of the decorative layer sheet by the embossing roll is excellent.

  The laminated body 14 that has passed the calendar roll in the third calendar device 20 is held at a predetermined temperature by the heating device 21 and is transferred by a transport device having a belt conveyor 22. As for the laminated body 14 conveyed by the belt conveyor 22, the surface of the laminated body 14 is smooth | blunted by the 4th calendar apparatus 23. FIG. The smoothed laminate 14 is cooled by a cooling device 24, dried by a drying device 25, punched into a shape of a product form by a cutting device 26, or cut, and thus a decorative material is obtained. The obtained decorative material is a wood lattice pattern on the surface, and the lattice pattern is cut in some places to form a scattered spot pattern that looks like a conduit at the cut portion.

  Next, the production of a woodgrain decorative material having a grain pattern and a spotted pattern as a wood grain pattern will be described.

  The laminated body 14 having the decorative layer sheet 11 having the checkered pattern shown in FIG. 2 on the surface is provided to the first embossing apparatus 17A shown in FIG. This laminated body 14 is the same as the laminated body 14 manufactured in the decoration material manufacturing apparatus shown by FIG.

  The first embossing device 17A has a pair of opposing rolls. An uneven pattern for forming a grain pattern is formed on the surface of one or both of the pair of rolls. A roll having a concavo-convex pattern for forming a grain pattern is referred to as a grain embossing roll.

  The concavo-convex pattern for forming the grain pattern formed on the surface of the embossing roll for grain is a factor that transforms the pattern formed on the surface of the decorative layer sheet 11 into a grain pattern. As an example of the concavo-convex pattern for forming the grain pattern, as shown in FIG. 8, a pattern formed by the tip surface of one or a plurality of rhombus projections 40A on the peripheral surface of the embossing roll for grain. Can be mentioned. One or more rhombus-like protrusions 40A may be formed on the peripheral surface of the embossing roll for grain. When the plurality of rhombus-shaped protrusions 40A are formed on the peripheral surface of the embossing roll for grain, in a line along the axial direction A of the embossing roll for grain, and along the peripheral surface of the embossing roll for grain May be arranged in a row.

  Another example of the uneven pattern for forming a grain pattern formed on the surface of the grain embossing roll is, as shown in FIG. 9, a plurality of circles are concentrically formed on the peripheral surface 50 of the grain embossing roll. An example is a concentric pattern formed by the tip surfaces of the concentric protrusions 50A formed so as to overlap substantially concentrically. It is sufficient that at least one concentric protrusion 50A is provided on the peripheral surface of the embossing roll for grain. A plurality of concentric protrusions 50A may be arranged in a line along the axial direction A of the embossing roll for the grain, and the embossing roll for the graining. May be arranged in an oblique line with respect to the axial direction A on a plane in which the peripheral surface is developed.

  8 and FIG. 9 concludes by generalizing from the uneven pattern for forming a grain pattern, and the uneven pattern for forming a grain pattern protrudes from the surface of the embossing roll for the grain pattern, and a plurality of them are arranged side by side. It is desirable that it be formed by the distal end surface of the curved protrusion.

  The laminate 14 is embossed with the embossing roll for grain of the first embossing processing device 17A, so that the surface of the decorative layer sheet 11 arranged in the uppermost layer of the laminate 14 is aligned with each other, Moreover, a curved cut is made.

  As shown in FIG. 5, the laminate 14 having the decorative layer sheet 11 having a plurality of curved cuts arranged on the surface as a top layer by passing through the first embossing device 17A is a heating device. While being heated by 18, it is conveyed by a conveying device having conveying means such as a belt conveyor 19. The effect | action by the heating apparatus 18 is the same as that of the heating apparatus 18 at the time of manufacturing the decorative material of the checkered pattern shown by FIG. Usually, the temperature of the laminated body 14 heated by the heating device 18 is preferably 100 to 130 ° C. as the temperature immediately before the next calendering.

  For example, the laminate 14 heated to the temperature range is fed between the calender rolls in the third calender device 20.

  The temperature of the calendar roll in the third calendar device 20 is usually adjusted to 80 to 110 ° C. More preferably, the temperature of the calender roll is adjusted so that the temperature of the calender roll falls within the above temperature range and is lower than the temperature of the laminated body 14 that is fed. In calendering by the third calender device 20, when the temperature of the calender roll is lower than the temperature of the laminate 14, the degree of melt flow of the thermoplastic resin in the laminate 14 decreases, in other words, the molten thermoplastic resin flows. Therefore, the wood grain pattern, that is, the grain pattern formed on the surface of the decorative layer sheet 11 does not collapse. More preferably, among the pair of calendar rolls, the temperature of the upper calendar roll is set 5 to 10 ° C. lower than the temperature of the lower calendar roll. By adjusting the temperature of each of the pair of calendar rolls in this way, the pattern of the decorative layer sheet positioned at the uppermost layer of the laminate 14 is formed into a plate-like pattern by the uneven pattern for forming the plate-like pattern of the plate-like embossing roll. It is formed.

  Next, the laminated body 14 having the decorative layer sheet having a grain pattern as the uppermost layer is provided to the second embossing processing device 17B.

  This 2nd embossing processing apparatus 17B has an embossing roll which makes the cut | interruption penetrated in the filament in the board pattern currently formed in the decorative layer sheet located in the uppermost layer of the laminated body 14. FIG. On the surface of the embossing roll, a tooth pattern that is an uneven pattern for cutting the filament is formed. An example of the tooth pattern is the tooth pattern shown in FIG.

  The laminated body 14 in a state in which the slits penetrating the filaments in the plate pattern formed on the surface of the uppermost decorative layer sheet 11 by the second embossing processing device 17B is It is kept at a predetermined temperature and is transferred by a conveying device having a belt conveyor 22. As for the laminated body 14 conveyed by the belt conveyor 22, the surface of the laminated body 14 is smooth | blunted by the 4th calendar apparatus 23. FIG. When the laminated body 14 is rolled by the fourth calendar device 23, the strips (streaks) in the plate pattern formed on the surface of the decorative layer sheet 11 cut by the embossing roll in the second embossing processing device 17B. ) Are cut so as to penetrate, and the penetration cut is expanded so as to further expand, and as a result, for example, a spot pattern having a scattered shape or a randomly dispersed shape is formed. The spot pattern in the plate pattern is not shown, but is the same as the spot pattern 11C in FIG.

  As mentioned above, although one Example of this invention was described, this invention is not limited to the said Example.

FIG. 1 is an explanatory view showing an example of a method for producing a decorative layer sheet for producing the decorative material of the present invention. FIG. 2 is an explanatory view schematically showing an example of a decorative layer sheet for producing the decorative material of the present invention. FIG. 3 is an explanatory view showing a laminate obtained by superposing a base sheet and a decorative layer sheet. FIG. 4 shows an example of a process and an apparatus for manufacturing a decorative material having a so-called wood grain pattern having a grid pattern and a duct-like spot pattern from a laminate obtained by superposing a base sheet and a decorative layer sheet. It is explanatory drawing. FIG. 5 shows an example of a process and an apparatus for producing a decorative material having a so-called woodgrain pattern having a plate pattern and a duct-like spot pattern from a laminate obtained by superimposing a base sheet and a decorative layer sheet. It is explanatory drawing shown. FIG. 6 is an explanatory diagram showing a state in which the surface of an embossing roll for making a cut in a line forming a grid pattern is developed on a surface of the decorative layer sheet positioned at the uppermost layer in the laminate. FIG. 7 is a schematic diagram showing a decorative layer sheet in which a speckled pattern is formed in a checkered pattern by calendering a laminate having a decorative layer sheet having cut lines in the checkered pattern in the uppermost layer. FIG. 8 is an explanatory diagram showing rhomboid protrusions formed on the surface of the embossing roll by developing the peripheral surface of the embossing roll into a flat surface in the first embossing processing apparatus. FIG. 9 is an explanatory view showing concentric protrusions formed on the surface of the embossing roll by developing the peripheral surface of the embossing roll into a flat surface in the first embossing processing apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Heating stirrer 2 Fixed_quantity | feed_rate feeder 3 Belt conveyor 4 Heating device 5 Chip feeding device 6 1st calender device 7 2nd belt conveyor 8 2nd heating device 9 2nd calender device 10 Cutting machine 11 Cosmetic layer sheet 11A Surface part 11B Flow pattern 11C Spotted pattern 12 Base sheet 14 Laminate 15 Heating device 16 Belt conveyor 17 Embossing processing device 17A First embossing processing device 17B Second embossing processing device 18 Heating device 19 Belt conveyor 20 Third calendar device 21 Heating device 22 Belt conveyor 23 Fourth calendar device 24 Cooling device 25 Drying device 26 Cutting device 30 Emboss roll peripheral surfaces 30A, 30B, 30C, 30D, 30E Protrusion piece 40 Emboss roll peripheral surface 40A Rippled projection 40B Concentric projection

Claims (7)

  A decoration having a top layer decorative layer sheet formed of colored thermoplastic resin chips having different colors and having a wood grain pattern and a spotted pattern formed at the tip of a streak formed in the wood grain pattern Wood.   The decorative material according to claim 1, wherein the wood grain pattern is a grain pattern and / or a lattice pattern.   The decorative material according to claim 1, wherein the wood grain pattern is a bamboo wood grain pattern.   The decoration material according to any one of claims 1 to 3, wherein the decoration material is a flooring material.   The decorative material according to any one of claims 1 to 4, wherein the decorative material is a composition tile.   It is streaked by calendering a chip compound containing a thermoplastic resin chip containing no fiber and containing an inorganic filler and at least two kinds of fiber-containing colored thermoplastic resin chips having different colors. A decorative layer sheet having a flow pattern is obtained, and a laminate formed by superimposing the decorative layer sheet on the base material sheet as an uppermost layer is embossed so as to produce a cut through the uppermost decorative layer sheet. The embossed laminate is conveyed in the same direction as the rolling direction when the chip compound is rolled, and the embossed laminate is rolled 3 to 15 times. A method for manufacturing a decorative material.   The method for producing a decorative material according to claim 6, wherein the fiber-free thermoplastic resin chip contains a vinyl chloride resin chip and / or a vinyl chloride-vinyl acetate copolymer.

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