JP2756654B2 - Floor sheet material and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor sheet material and a method for producing the same.

[0002]

2. Description of the Related Art As a floor sheet material, as shown in FIG. 6, a transparent resin sheet 90 (thickness 0.1 mm), a front resin sheet 91 (0.5 mm), a base resin sheet 92 (2 m
m) is heated and press-bonded (sheet contact is fused together). In this case, the fiber base material 93 is provided at the bottom in order to prevent separation from the floor surface due to a change in ambient temperature. To suppress expansion and contraction of the entire sheet material. Note that the above-described integration of the transparent resin sheet 90, the front resin sheet 91, the base resin sheet 92, and the fiber base material 93 is usually performed simultaneously.

[0003] The floor sheet material is applied by sticking the fiber base material 93 so that the side surface faces the floor surface, and the floor surface after the application is excellent in design.

However, since this kind of sheet material is usually formed to have a fixed width, the sheet must be cut in accordance with the floor shape at the time of construction. turn into. Further, even when the sheet material is manufactured, a piece of industrial waste is formed.

[0005] In this type of industry, experiments have been conducted to consider the recycling of industrial waste consisting of a fiber base material such as the above-mentioned cut ends and a synthetic resin material, but good results cannot be obtained. The method and results are as follows. A method for manufacturing a base resin sheet 92 by pulverizing and melting industrial waste, and manufacturing a floor-floor resin sheet using the base resin sheet 92. This method is based on the fact that the fiber base material 93 is mixed. As a result, a pinhole PH is formed in the base resin sheet 92. When the sheets 90, 91 and 92 are heated and pressed using this, a part of the front resin sheet 91 is placed in the pinhole PH as shown in FIG. Melt infiltration causes scratches such as dents 94 on the surface of the floor sheet material. Such a thing has no commercial value at all. The industrial waste is transferred to the sheets 90, 91, 92 and the fiber base material 9
3, a base resin sheet 92 is manufactured using only the sheets 90, 91, and 92, and a floor resin sheet is manufactured using the base resin sheet 92. In this method, the base resin sheet 92 is Since the pinhole PH as described above cannot be formed, a floor covering sheet material having a beautiful surface can be manufactured.
Since the work of separating the first and second fibers 92 from the fiber base 93 is required, the cost increases.

Although it is extremely difficult to reuse industrial waste as described above, in this kind of industry, even if industrial waste is reused, it can be manufactured at low cost.
There is a need for the development of a floor sheet material and a method for manufacturing the same, which have almost no scratch on the surface and have excellent force for preventing expansion and contraction of the entire sheet material.

[0007]

Therefore, according to the present invention, even if industrial waste is reused, it can be manufactured at low cost, there are almost no scratches on the surface, and the expansion / contraction force of the entire sheet material can be reduced. It is an object to provide an excellent floor sheet material and a method for producing the same.

[0008]

SUMMARY OF THE INVENTION The present invention relates to a floor sheet material which is obtained by heating and crimping at least a front resin sheet 1, a plurality of thin base resin sheets 2 and a fiber base material 3 in a laminated state. Each base resin sheet 2 is formed by heating and rolling a large number of small lumps T of industrial waste composed of a synthetic resin material and a fiber base material.

Further, the method of manufacturing a floor sheet material according to the present invention is characterized in that the industrial waste comprising a synthetic resin material and a fiber base material is converted into a small lump T
And a step of heating and rolling a large number of small lumps T to form a thin base resin sheet 2, and a state in which at least the front resin sheet 1, the plurality of base resin sheets 2 and the fiber base material 3 are sequentially laminated And a step of heating and pressing.

[0010]

The present invention operates as follows.

The base resin sheet 2 is formed by heating and rolling a small lump T of an industrial waste made of a synthetic resin material and a fiber base material to form a thin layer. Therefore, a single pinhole PH can be formed. However, since this floor sheet material is formed by laminating a plurality of thin base resin sheets 2, the pinholes PH appearing on the surface of the base resin sheet 2 in contact with the front resin sheet 1 do not penetrate. It becomes shallow (one thin base resin sheet 2). Therefore, at least the front resin sheet 1, the base resin sheet 2, and the fiber base material 3
When heat and pressure are applied in a state in which the resin sheets 1 are sequentially laminated, the depression formed on the surface of the floor sheet material due to the melt penetration of the front resin sheet 1 into the pinhole PH becomes inconspicuous. In other words, in this floor sheet material, the pinhole PH
The depth of the surface resin sheet 1 is small due to the shallow depth of the surface resin sheet 1, so that the recess formed on the surface of the floor sheet material is shallow and almost inconspicuous.

Further, since the small lump T as a raw material of the base resin sheet 2 is formed by cutting industrial waste consisting of a synthetic resin material and a fiber base material, it is formed by cutting a conventional synthetic resin material and a fiber base material. Separation work from the material is not required, so that the floor sheet material does not increase the cost.

Further, the base resin sheet 2 is in a state where the fiber base materials 3 are entangled with each other inside the base resin sheet 2, and the base resin sheet 2 also has an excellent force for preventing expansion and contraction. Therefore, the floor sheet material as a whole has an excellent expansion / contraction prevention force.

In other words, the floor covering sheet material manufactured by the method of the present invention, even if industrial waste is reused,
It can be manufactured at low cost, has almost no scratch on the surface,
It is also excellent in preventing the expansion and contraction of the entire sheet material.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The configuration of the present invention will be described with reference to the drawings shown as embodiments.

The floor sheet material of this embodiment is shown in FIGS.
As shown in FIG. 1, the surface has a large number of circular protrusions T, and the transparent resin sheet 10, the front resin sheet 1, the four thin base resin sheets 2 and the fiber base material 3 are sequentially laminated and heated and It is formed by pressure bonding (sheet contact surfaces are heat-sealed to each other).

The transparent resin sheet 10 is made of a vinyl chloride resin, and its thickness is set to about 0.1 mm.

The front resin sheet 1 is made of vinyl chloride resin, and its thickness is set to about 0.5 mm.

The base resin sheet 2 is made of vinyl chloride resin, and its thickness is set to about 0.5 mm. Therefore, when four base resin sheets 2 are stacked, the total thickness is about 2.0 mm, which is equivalent to the thickness of the conventional base resin sheet. In this embodiment, the scraps (industrial waste) of the floor sheet material are reused in the production of the base resin sheet 2, and the small lump T obtained by cutting the industrial waste is shown in FIG. And a transparent / front / base resin sheet 90, 91, 92 and a fiber base material 93.

As shown in FIGS. 2 and 3, the fiber base 3 is
It is composed of nylon fiber fabric. In addition, as the fiber substrate 3, the above-mentioned nylon fiber, glass fiber, hemp fiber, cotton fiber, polyester fiber, paper, etc. can be adopted.
For fibers, knitting can also be employed.

Here, a method for producing the above floor sheet will be described. [First Step] First, a piece of floor covering sheet material, which is industrial waste, is cut into small blocks T of 2 to 3 mm. In this state,
Although the synthetic resin material and the fiber base material forming the small lump T are integrated (see FIG. 3), it is not necessary to separate them in this method. [Second Step] As shown in FIG. 4, a large number of small lumps T are heated and rolled by a heating roller R to form a thin base resin sheet 2 of about 0.5 mm. In addition, this base resin sheet 2
As shown in FIG. 5, although the short fiber base material 3 is entangled in the inside thereof, it is excellent in the elasticity preventing force, but the pinhole PH may be formed. [Third Step] The transparent resin sheet 10, the front resin sheet 1, the four base resin sheets 2 and the fiber base material 3 are sequentially laminated. In this state, even if the base resin sheet 2 has the pinholes PH, the pinholes PH of the base resin sheets 2 are unlikely to overlap each other. The thickness is about the thickness of one base resin sheet 2 (see FIG. 2). [Fourth Step] The floor sheet of this embodiment is obtained by laminating the sheets 10, 1, 2 and the fiber base material 3 between heating rollers (not shown) and heating and pressing them to integrate them. The material is completed. In addition, many dimples are formed on the surface of the heating roller on the side in contact with the transparent resin sheet 10 so as to form the circular protrusion T on the floor sheet material. In the above-mentioned completed state, a part of the front resin sheet 1 has melted and penetrated into the pinholes PH.
Is inconspicuous. That is, the floor sheet material manufactured by this method does not reduce the commercial value. Further, since the base resin sheet 2 contains a large amount of the fiber base material 3, the overall weight is reduced.

In the above-described embodiment, the small lump T is formed from a piece of the floor sheet material that becomes an industrial waste. However, the present invention is not limited to this. Any industrial waste comprising a plastic resin) and the above-mentioned fiber base material can be used.

In the above embodiment, four base resin sheets 2 are used. However, the present invention is not limited to this.
, Five or more.

[0024]

The present invention has the following effects since it has the above configuration.

As described in the column of action, even if industrial waste is reused, it can be manufactured at low cost,
The present invention has provided a floor sheet material and a method for producing the same, which have almost no scratches on the surface and are excellent in the force of preventing expansion and contraction of the entire sheet material.

[Brief description of the drawings]

FIG. 1 is an external perspective view of a floor sheet material according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of the floor sheet material.

FIG. 3 is a perspective view of a small lump of industrial waste used for manufacturing the floor sheet material.

FIG. 4 is a diagram showing a process of manufacturing a base resin sheet from the small blocks.

FIG. 5 is a cross-sectional view of the base resin sheet.

FIG. 6 is a cross-sectional view of a prior art bedding sheet material.

FIG. 7 is a cross-sectional view of a bedding sheet material manufactured by a method of the prior art.

[Explanation of symbols]

 T Small lump 1 Front resin sheet 2 Base resin sheet 3 Fiber substrate 10 Transparent resin sheet

Claims (2)

(57) [Claims] 1. A floor sheet material comprising at least a front resin sheet (1), a plurality of thin base resin sheets (2) and a fibrous base material (3) which are heated and pressure-bonded in a state of being sequentially laminated. A floor sheet material characterized in that the base resin sheet (2) is formed by heating and rolling a large number of small lumps (T) of industrial waste composed of a synthetic resin material and a fiber base material. 2. A step of cutting industrial waste comprising a synthetic resin material and a fiber base into small blocks (T), and heating and rolling a large number of small blocks (T) to form a thin base resin sheet (2). A method for producing a floor covering sheet material, comprising: a forming step; and a step of heating and pressing at least in a state where a front resin sheet (1), a plurality of base resin sheets (2), and a fiber base material (3) are sequentially laminated.