JP3713070B2 - Decorative sheet manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a decorative sheet, and more particularly to a method for manufacturing a sheet having a turbulent flow pattern without a repeating pattern.
[0002]
[Prior art]
Conventionally, as a method for imparting a pattern to a synthetic resin sheet, various patterns are formed by general printing, or a method of forming a stone-tone pattern by pressing and hardening a synthetic resin chip or the like.
Also known is a method of forming a marble pattern or a flow pattern while putting different colored beads or narrow sheets on a base sheet and rolling the sheet.
[0003]
[Problems to be solved by the invention]
Since the method for forming a pattern on a sheet by the above printing is performed using a printing roll or the like, only a pattern having a repeated pattern is obtained on the obtained sheet, and the pattern becomes monotonous, and the pattern is flat. Therefore, when the printed sheet is used as a flooring material, there is a problem that the printed pattern is worn away by wear due to walking and disappears.
[0004]
Also, in the method of forming a stone-like pattern by pressing and hardening synthetic resin chips etc., since the pattern of the sheet is formed in three dimensions, it is not worn out by abrasion and the pattern is not patterned, Only a stone-like pattern was obtained by the method.
In the method of rolling different colored beads or narrow sheets on the base sheet and rolling the sheet, only streak-like marble pattern or flow pattern is obtained only in the vertical direction where the beads or sheet are loaded on the base sheet. I couldn't.
[0005]
Furthermore, in order to form a marble pattern, there is a method of mixing a vinyl chloride resin paste colored in a plurality of colors and randomly flowing it on a base material to form a sheet by gelation, but it is extremely difficult to manufacture, Productivity is poor.
Accordingly, an object of the present invention is to provide a decorative sheet having a novel turbulent flow pattern.
[0006]
[Means for solving the problems]
The above object is achieved in Tsu by the following of the present invention. That is, the present invention superimposes two or more kinds of thermoplastic resin sheets having different hues, and in a state where the sheets are softened or melted, the sheets are passed between hot rolls having different rotation ratios, and the sheets are crushed to form a bank. A method for producing a decorative sheet, which is rolled while generating heat, and a thermoplastic resin sheet in which one or both of the front and back surfaces are colored in different colors in a single layer and a multilayer are softened or melted. In this state, the decorative sheet is rolled while passing between hot rolls having different rotation ratios and crushing the sheet to generate a bank.
According to the present invention, a decorative sheet having an unprecedented turbulent flow pattern can be provided.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
As the thermoplastic resin sheet used in the present invention, a thermoplastic resin or thermoplastic elastomer sheet that is softened by heating can be used. As such a thermoplastic resin or thermoplastic elastomer, known materials can be used. For example, polyvinyl chloride resin, vinyl acetate-vinyl chloride copolymer resin, ethylene-vinyl chloride copolymer resin, polyethylene resin, polypropylene Resin, ethylene-vinyl acetate copolymer resin, ethylene-propylene copolymer resin, ethylene-ethyl acrylate copolymer resin, ethylene-methyl acrylate copolymer resin, ethylene-methyl methacrylate copolymer resin, or other thermoplastic resins, or A vinyl chloride thermoplastic elastomer having a hard segment and a soft segment, an olefin thermoplastic elastomer, a polyester thermoplastic elastomer, a urethane thermoplastic elastomer, a styrene thermoplastic elastomer, and the like can be used.
[0008]
These thermoplastic resins or thermoplastic elastomers include plasticizers, stabilizers, organic or inorganic fillers, ultraviolet absorbers, flame retardants, antioxidants, lubricants, antistatic agents, conductive agents, gelation accelerators, A sheet can be formed by appropriately blending known additives such as a foaming agent, a processing aid, and a colorant. Furthermore, it is also possible to form a sheet by mixing these with other thermoplastic resins, thermoplastic elastomers or synthetic rubbers.
The sheet can be formed by a known processing means, for example, extrusion molding, calendar molding, paste molding, or the like.
[0009]
In the first production method of the present invention, two or more kinds of sheets having different hues are bonded together in advance by heat fusion or an adhesive, or are simply stacked and pressed and passed between hot rolls. In any lamination, it is important that the sheet is softened or melted before passing between the hot rolls. This is because if the sheet is not softened or melted when passing between the hot rolls, the sheet does not bite into the hot rolls, the surface of the sheet is not smooth, and the sheet is formed only by pressing between the hot rolls. However, it is necessary to carry out stay kneading with a hot roll until sheet molding becomes possible.
In this case, the different color sheets are sufficiently mixed and become the same color, and a turbulent flow pattern of different colors cannot be formed. Furthermore, since the sheet is not easily crushed by the hot roll, the intended turbulent flow pattern cannot be obtained. Therefore, before pressing and rolling between hot rolls, it is necessary to heat and soften or melt both of the different color sheets and put them between the hot rolls to immediately form a sheet while forming a bank. .
The thickness of each of the different colored sheets is not particularly limited, but if it is too thin, it is difficult to form. Therefore, the thickness is preferably 50 μm or more, and practically 0.1 mm to 1 mm.
[0010]
In the second manufacturing method of the present invention, both or one of the surfaces of the sheet is colored in a color different from the color of the sheet with printing ink or the like in a single layer or multiple layers, and this sheet is the same as in the first manufacturing method. Next, it is pressed and passed between hot rolls in a softened state or a molten state.
The sheet can be colored by a known means, and can be colored by a printing method such as gravure printing or screen printing, or by a method of coating paint, vinyl chloride resin paste or the like by casting, dipping, spraying, or the like. I can do it. The thickness of the colored layer on both surfaces or any one surface of these sheets is not particularly limited, but is preferably in the range of about 1 μm to 100 μm in terms of the thickness after drying, the thickness after gelation or curing. The film forming component of the paint to be colored is preferably a thermoplastic resin or a thermoplastic elastomer that is softened by heating, and it is desirable that the colored sheet is similarly softened or melted at a temperature at which the colored sheet is softened or melted. Even in this method, the thickness of the sheet is 50 μm or more, and it is preferable that the thickness is practically in the range of 0.1 mm to 1 mm.
[0011]
In addition, the decorative sheet of the present invention can be manufactured by combining the first manufacturing method and the second manufacturing method. For example, on the surface of the same sheet used in the first manufacturing method, a thermoplastic resin sheet colored in a different hue from the sheet is overlaid and passed between hot rolls, or a colored sheet of another hue is overlaid. It is also possible to form a decorative sheet by passing between the hot rolls. In the present invention, the sheets may be laminated in any combination.
[0012]
In order to pass between the hot rolls and crush the sheet, it is basically preferable to set the clearance between the rolls to be equal to or less than the total thickness of the sheet, but the sheet feeding speed is made faster than the rotating speed of the hot roll. Accordingly, it is possible to set the clearance between the hot rolls to be greater than the total thickness of the sheet. The clearance between the heat rolls is appropriately set by adjusting the thickness of each sheet or colored layer to be superimposed, the rotation speed of the heat roll, or the feeding speed of the sheet to the heat roll.
When forming both sides of the sheet or only one sheet that is thinly coated or colored, a turbulent flow pattern can be formed without crushing the sheet too much, and two or more thick sheets can be formed. When the two layers are formed, the desired turbulent flow pattern can be easily formed by crushing a little more strongly so that it is 50% or less of the total thickness of the original sheet. By changing the pressure between the heat rolls and the rotation ratio according to the state, the turbulent flow pattern can be patterned from small to large.
[0013]
Further, it is preferable that the two or three heat rolls to which the sheets are fed have different rotation ratios rather than the same rotation ratio. If the rotation ratio of the rolls is different, when the sheet is inserted between the hot rolls and crushed, a shearing force is applied to the sheet surface or the sheet, and the layers are easily disturbed and each layer is likely to be mixed. The colors are mixed properly and the intended turbulent pattern is likely to occur.
[0014]
In the present invention, it is also possible to use a transparent thermoplastic resin sheet. By using a transparent sheet and an opaque colored sheet on top of each other, or using a transparent sheet colored on one or both sides, the transparent layer is interposed between colored flow patterns, or the transparent layer enters the transparent layer. A three-dimensional turbulent flow pattern can be formed. In addition, after passing the sheet between hot rolls and crushing the sheet, a transparent sheet is laminated, a transparent vinyl chloride resin paste is coated on the sheet, or other urethane type, acrylic type, etc. It is also possible to coat a known transparent treatment agent. When a transparent layer is provided on the surface of the sheet after passing between the hot rolls, it can be colored to such an extent that the underlying pattern can be seen through. The thickness of the transparent layer is not particularly limited, and may be any range as long as the underlying pattern can be seen through. Furthermore, by providing a transparent layer on the surface of the decorative sheet and embossing the grain pattern, the three-dimensional effect of the grain pattern becomes more prominent, and a natural wood-like texture can be obtained.
[0015]
It is also possible to laminate a backing material such as another sheet or a fiber base material on the back surface of the decorative sheet formed by passing between hot rolls. When another sheet is laminated on the back surface of the decorative sheet of the present invention, the sheet made of the thermoplastic resin or the thermoplastic elastomer can be laminated through heat fusion or an adhesive. The thickness of the sheet to be laminated is not particularly limited and is appropriately selected according to the use of the sheet. For example, when using a sheet | seat as a flooring material, it is good to set the thickness of all the layers of a lamination sheet within the range of 1-10 mm. There is no particular limitation when laminating fiber base materials, for example, chemical fibers such as polyester fibers, nylon fibers, rayon fibers, glass fibers, woven fabrics such as natural fibers such as hemp, cotton, wool, and non-woven fabrics are used. I can do it.
[0016]
The roll referred to in the present invention is a metal roll such as a mixing roll, a calender roll, an embossing roll, a laminating roll, a polishing roll, a ceramic roll, etc., and a raw material sheet is basically passed between these two rolls. Depending on the case, a third roll installed in the L shape may be passed. In the present invention, it is necessary to heat the roll by putting steam, hot water, oil, heating wire, etc. in the roll, and this is to make it easier to keep the sheet softened even at the stage of passing the roll. Then, the molding is performed so that some bank accumulation occurs.
[0017]
When heating a roll, it is good to set it as the temperature which shape | molds the thermoplastic resin sheet to be used, but as long as it is below the temperature which the thermoplastic resin does not decompose | disassemble, you may set the temperature of a roll to what degreeC. For example, when a soft compounded vinyl chloride resin is used for the sheet, these resins are usually molded in the range of 150 to 200 ° C., and the roll temperature is preferably set in this range.
[0018]
Moreover, the roll to be used can be generally the same size as the roll used in sheet forming, embossing, laminating, etc., and may be in a wide range of diameters of 30 mm to 1 m, for example. The roll width can also be used according to the sheet width.
In order to make the raw material sheet softened or melted, before passing the hot roll, a method of heating the raw material sheet in a non-contact manner with an infrared heater, hot air, etc., a method of softening or melting the raw material sheet by contacting the hot roll Alternatively, the raw material sheet may be passed between hot rolls while in a softened or molten state immediately after coextrusion molding or calendar molding. For example, two or more raw material sheets are formed by coextrusion molding, and immediately after being extruded from a die, the sheet is passed between two hot rolls to crush the sheet while generating a bank, and has a turbulent flow pattern. The decorative sheet of the present invention can be formed.
[0019]
When passing between the hot rolls, the rolls are kept hard so that the raw material sheet is not twisted, so that excessive bank pools are not formed. If the bank pool is formed excessively, the residence time in the bank will become longer, the colors will be mixed into a single color in the bank, and the colors of the different sheets and colored layers will be mixed to obtain the desired turbulent flow pattern. I can't. The turbulent flow pattern sheet of the present invention is formed by adjusting the ratio of the rotational speed of the hot roll and the sheet supply speed so that the bank pool does not become excessive. The rotation speed of the hot roll and the sheet supply speed are not particularly limited.
[0020]
In the present invention, the raw material sheet is basically crushed while generating a bank by passing between two or three heat rolls, but in order to smooth the surface of the formed sheet thereafter Further, it is also possible to pass the formed sheet between hot rolls having a clearance.
The width of the raw material sheet is not limited, but it is preferable that the width of the raw material sheet is such that the raw material sheet does not protrude from the hot roll at the stage where the raw material sheet passes between the hot rolls and is crushed. When the raw material sheet is crushed with a hot roll, the raw material sheet spreads in both the width direction and the longitudinal direction, and for the spread in the longitudinal direction, the tension of the winding device or the supply device is adjusted and molded.
In addition, the flow pattern can be varied by providing several partition plates between the hot rolls so that the bank does not protrude outside.
[0021]
【Example】
Next, the present invention will be described with reference to specific examples.
Example 1
A soft vinyl chloride resin sheet colored in the respective colors according to the composition shown in Table 1 was formed into a long shape having a width of 1800 mm and a thickness of 0.3 mm with a calendar.
Of these, three sheets colored brown, yellow and black are superposed and heated with an infrared heater so that the sheet temperature is about 180 ° C., the clearance is 0.2 mm, and the rotation ratio is 1: 1. The sheet was crushed while passing between two mixing rolls heated to 190 ° C. 2 to generate a bank, and a decorative sheet of the present invention having a turbulent flow pattern with a thickness of 0.3 mm was formed.
On the surface of the obtained sheet, a wood grain turbulent flow pattern in which brown, yellow and black were incompletely mixed with each other was formed.
[0022]
Example 2
A white paint mainly composed of an acrylic resin and a vinyl chloride resin was coated on both surfaces of a brown soft vinyl chloride resin sheet formed by the formulation shown in Table 1 so that the thickness after drying was 20 μm.
This sheet is heated with an infrared heater so that the sheet temperature becomes 180 ° C., and is passed between three calender rolls having a rotation ratio of 1: 1.1 heated to 190 ° C. with a clearance of 0.1 mm, The decorative sheet of the present invention having a thickness of 0.2 mm was formed by squashing while generating a bank.
In the obtained sheet, a deep turbulent flow pattern in which a white color based on brown and a mixture of brown and white were formed was formed.
[0023]
Table 1
Vinyl chloride resin (degree of polymerization 1000) 100 parts by weight DOP 45 parts by weight Ba-Zn stabilizer 3 parts by weight Calcium carbonate 10 parts by weight Colorant Suitable amount
【The invention's effect】
According to the present invention, an unprecedented complicated turbulent flow pattern can be imparted to the sheet, and since the sheet pattern is formed in the thickness direction, it disappears like a printed pattern even if the sheet is worn away by abrasion. Never do.

Claims (2)

Two or more kinds of thermoplastic resin sheets having different hues are stacked, and while the sheets are softened or melted, they are passed between hot rolls having different rotation ratios, and rolled while generating a bank by crushing the sheets. A method for producing a decorative sheet. In a state where either one or both of the front and back surfaces are softened or melted in different colors in a single layer and multiple layers, the sheet is passed between hot rolls with different rotation ratios, and the sheet is crushed. A method for producing a decorative sheet, comprising rolling while generating a bank.