JP6484999B2 - Manufacturing method of decorative sheet for floor - Google Patents

Description

  The present invention relates to a method for producing a decorative sheet for floors.

  In recent years, sheet flooring materials in which a decorative sheet is bonded to the surface side of a wooden substrate such as plywood, medium density fiberboard (MDF), and particle board have become widespread. The background of the spread of such sheet flooring materials is that if the surface is a veneer as in the past, problems such as the color of the surface layer not matching at the construction site may occur, or if a veneer with a higher design is required There are circumstances such as using materials and becoming very expensive.

  On the other hand, when sheet flooring materials become widespread, it has been regarded as a problem that the wooden base material has variations (distribution) in impact resistance and caster resistance, and the quality is not stable. Therefore, a specification in which a backer material such as a PET film of about 0.1 mm to 0.5 mm and a wood powder-containing resin sheet is bonded to the back side of the decorative sheet has been put on the market (see Patent Document 1). Among them, the specification using a wood powder-containing resin sheet as a backer material is widely spread.

Japanese Patent No. 5045180

Conventionally, the floor decorative sheet having a backer layer is manufactured by pasting a backer layer on the back surface of a base sheet by dry lamination or the like. In such a manufacturing method, a process of applying an adhesive is performed. There is a problem that the manufacturing cost is increased.
The objective of this invention is providing the manufacturing method of the decorative sheet for floors which can reduce the coating process of an adhesive agent and can reduce manufacturing cost.

  In order to solve the above problems, in the method for manufacturing a decorative sheet for floor according to one aspect of the present invention, the resin for forming the backer layer and the hot melt adhesive are coextruded, and the decorative sheet is brought into contact with the hot melt adhesive side. The floor decorative sheet is obtained by forming a backer layer on the decorative sheet.

  According to one aspect of the present invention, a hot-melt adhesive for a sheet material comprising a resin and a hot-melt adhesive co-extruded with a resin for forming a backer layer and a hot-melt adhesive. Since the decorative sheet is brought into contact with the side to be cooled and solidified, the adhesive coating process can be reduced, the loss between the processes can be reduced, and the manufacturing cost can be reduced.

It is explanatory drawing about the outline | summary of the manufacturing method of the decorative sheet for floors concerning one Embodiment of this invention. It is explanatory drawing of arrangement | positioning of the backer layer between a cooling roll, a hot-melt-adhesive agent layer, and a decorative sheet (a pattern printing layer, a transparent upper base resin layer).

<Embodiment>
Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.
(Overview)
As shown in FIG. 1, in the method for manufacturing a decorative sheet for floors according to an embodiment of the present invention, a resin (synthetic resin) that forms a backer layer 1 and a hot melt adhesive that forms a hot melt adhesive layer 2. Are melt-extruded (co-extruded) together by a twin-screw extruder 10, and the decorative sheet 3 is brought into contact with the hot-melt adhesive side of the sheet material composed of the co-extruded synthetic resin and the hot-melt adhesive to be cooled and solidified. By doing so, the floor decorative sheet 4 in which the backer layer 1 is formed on the decorative sheet 3 is obtained.

  In the present embodiment, the coextruded synthetic resin and the hot melt adhesive are rectangular in cross section using three cooling rolls (cooling rolls) A, B, and C that serve as cooling units (coolers). Molded into a sheet. That is, a sheet material made of the coextruded synthetic resin and the hot melt adhesive is formed. The cooling rolls A, B, and C are generally used in a converting device such as a coater, a calendar, a laminator, and a slitter.

First, the coextruded synthetic resin and the hot melt adhesive are sandwiched between two cooling rolls A and B. The cooling roll A is a hot-melt adhesive side cooling roll, and the cooling roll B is a synthetic resin side cooling roll.
At this time, the decorative sheet 3 is unwound by the cooling roll A from the roll-shaped decorative sheet raw fabric X. Next, the unrolled decorative sheet 3 is inserted between two cooling rolls A and B, and a sheet material comprising a synthetic resin and a hot melt adhesive coextruded between the two cooling rolls A and B. In contact with the hot melt adhesive side. Next, the hot-melt adhesive is cooled and solidified between the two cooling rolls B and C, and the hot-melt adhesive layer 2 and the backer layer 1 are laminated in this order on the surface of the decorative sheet 3. 4 is obtained. Finally, the floor decorative sheet 4 is wound around the roll-shaped floor decorative sheet raw fabric Y.

That is, the hot melt adhesive is conveyed by using the cooling roll A on the hot melt adhesive side of the two cooling rolls A and B sandwiching the synthetic resin and the hot melt adhesive from the lamination direction. The decorative sheet 3 is brought into contact with the side to be cooled and solidified.
The line speed for co-extrusion of the above synthetic resin and hot melt adhesive is preferably in the range of 5 m / min to 20 m / min, and the temperatures of the cooling rolls A and B are 80 ° C. to 150 ° C. Within the following ranges, the cooling roll C is preferably in the range of 50 ° C. or higher and 100 ° C. or lower.

In this embodiment, the line speed when co-extruding the synthetic resin and the hot melt adhesive is 10 m / min, and the temperatures of the cooling rolls are 100 ° C. for the cooling rolls A and B, and the cooling roll C is It shall be 60 degreeC.
In practice, the cooling rolls A, B, and C may be heat rolls (heating rolls). In this case, the heat roll is also handled as one of the cooling rolls. Further, the cooling rolls A, B, and C may be other metal rolls such as a gravure roll, a coating roll, a backup roll, and a guide roll. That is, the cooling rolls A, B, and C may be rolls.

(Backer layer 1)
The backer layer 1 is formed on the decorative sheet 3 by melt extrusion (coextrusion) together with the hot melt adhesive layer 2. When the backer layer 1 is formed by extrusion molding of a synthetic resin, for example, extrusion molding using a T die can be suitably used. Moreover, when the backer layer 1 is a multilayer, for example, a multi-manifold type or a feed block type T-die may be used to perform multilayer simultaneous extrusion.

  The synthetic resin for forming the backer layer 1 is not limited, but is preferably a thermoplastic resin. For example, polypropylene, ethylene-vinyl alcohol copolymer, polymethylene, polymethylpentene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, poly Examples include arylate, polyethylene naphthalate-isophthalate copolymer, polyimide, polystyrene, polyamide, and ABS resin (acrylonitrile, butadiene, styrene copolymer synthetic resin).

The backer layer 1 preferably has an initial flexural modulus of 1000 MPa or more, and preferably 1500 MPa or more. The upper limit of the initial elastic modulus is not particularly limited, but may be about 2500 MPa.
In the present embodiment, the backer layer 1 is made by kneading 62% by mass of commercially available homopolypropylene, 30% by mass of paper powder, 5% by mass of a pigment for coloring, and 3% by mass of calcium stearate. The paper powder is obtained by pulverizing virgin paper (virgin pulp) to a particle size of 50 μm using a ball mill. The backer layer 1 has a thickness of 0.5 mm and a width of 450 mm. Moreover, the bending initial elastic modulus is 1500 MPa.

(Hot melt adhesive layer 2)
The hot melt adhesive layer 2 is formed on the decorative sheet 3 by melt extrusion (coextrusion) together with the backer layer 1. The hot melt adhesive layer 2 can be formed by curing the hot melt adhesive. A hot melt adhesive is a thermoplastic adhesive that is solid at room temperature but is applied to an adherend in a liquefied state by heating and melting at about 80 ° C. to 100 ° C. and forms a bond by cooling and solidification. is there. Curing is fast and no gas is generated because no solvent is used.

Examples of the hot melt adhesive include EVA (Ethylene Vinyl Acetate) type hot melt adhesive and PUR (Poly Urethane Reactive) type hot melt adhesive.
EVA hot melt adhesives are made of ethylene vinyl acetate copolymer (combined ethylene and vinyl acetate) as a raw material, and are excellent in adhesiveness and workability. The EVA hot melt adhesive can be repeated many times in the cycle of melting by heating and curing by cooling the heat. On the other hand, EVA hot melt adhesives have low heat resistance.

A PUR-based hot melt adhesive is mainly composed of a polyurethane-based uncured resin (prepolymer), and is heated and dissolved, and then reacts with moisture (humidity) in the air to be cured. Once the reaction is complete, a tough film is formed and exhibits strong adhesion. Since the PUR hot melt adhesive after the reaction is not dissolved again by heat, it is excellent in heat resistance and cold resistance. Moreover, since it has a tough film and strong adhesion performance, it is possible to significantly reduce the coating amount compared to EVA hot melt adhesives.
In this embodiment, a PUR hot melt adhesive (“Tyforce FH315” manufactured by DIC Corporation) is used for the hot melt adhesive layer 2. The hot melt adhesive layer 2 has a thickness of 0.05 mm and a width of 450 mm.

(Decorative sheet 3)
As shown in FIG. 2, the decorative sheet 3 has a structure in which a pattern printing layer 3a and a transparent upper resin layer 3b are laminated in this order. This decorative sheet 3 is used as a base sheet of the floor decorative sheet 4 according to this embodiment. In practice, the decorative sheet 3 may be separately formed on a general base sheet (not shown). In this case, the base sheet is a part of the decorative sheet 3. The decorative sheet 3 is bonded to the backer layer 1 in contact with the hot melt adhesive layer 2 side in the three cooling rolls A, B, and C serving as a cooling unit for the backer layer 1 described above. Here, when the decorative sheet 3 contacts the hot melt adhesive layer 2 side, the back side of the pattern printing layer 3a is arranged on the hot melt adhesive layer 2 side, and the transparent upper resin layer 3b is on the surface side of the cooling roll. Be placed.

(Picture printing layer 3a)
The pattern print layer 3a gives the decorative sheet 3 design characteristics with a desired pattern, and the type of the pattern is not particularly limited. Examples thereof include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern.

The method for forming the pattern print layer 3a is not particularly limited, for example, a colored ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) in a solvent (or dispersion medium) together with a binder resin, What is necessary is just to form by the printing method etc. which used the coating agent etc.
Examples of colorants include inorganic pigments such as carbon black, titanium white, zinc white, dial, bitumen, cadmium red; azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, dioxazine pigments. Organic pigments such as aluminum powder, metal powder pigments such as bronze powder, pearlescent pigments such as titanium oxide-coated mica and bismuth oxide chloride; fluorescent pigments; These colorants can be used alone or in admixture of two or more. These colorants may further contain a filler such as silica, an extender pigment such as organic beads, a neutralizing agent, a surfactant and the like.

  Examples of the binder resin include acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum Resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, fiber derivative, rubber resin and the like. These resins can be used alone or in admixture of two or more.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene Inorganic solvents and the like, such as water; chlorinated organic solvents. These solvents (or dispersion media) can be used alone or in admixture of two or more.

Examples of the printing method used for forming the pattern printing layer 3a include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method. Further, when forming the entire surface solid pattern printing layer 3a, for example, roll coating method, knife coating method, air knife coating method, die coating method, lip coating method, comma coating method, kiss coating method, flow coating method, Various coating methods such as a dip coating method may be mentioned. In addition, the hand-drawn method, the ink-sink method, the photographic method, the transfer method, the laser beam drawing method, the electron beam drawing method, the metal partial evaporation method, the etching method, etc. may be used or combined with other forming methods. good.
In this embodiment, as a pattern print layer 3a, a colored polypropylene film (“OW” manufactured by Riken Technos Co., Ltd.) and gravure ink (“Lamistor” manufactured by Toyo Ink Manufacturing Co., Ltd.) are used to print wood grain printing by a gravure printing machine. Use the one provided. The pattern printing layer 3a has a thickness of 80 μm.

(Transparent upper resin layer 3b)
As long as the transparent upper resin layer 3b is transparent, it includes any of colorless and transparent, colored and translucent. The resin component contained in the transparent upper resin layer 3b is not limited, but is preferably a thermoplastic resin, particularly preferably polypropylene, and more preferably homopolypropylene.

  In the present embodiment, homopolypropylene is used as the transparent upper resin layer 3b. The transparent upper resin layer 3b has a thickness of 80 μm. Thus, since the pattern printing layer 3a has a thickness of 80 μm and the transparent upper base resin layer 3b has a thickness of 80 μm, the pattern printing layer 3a and the transparent upper base resin layer 3b are provided in this order. The decorative sheet 3 has a total thickness of 160 μm.

(Effect of this embodiment)
According to this embodiment, the following effects can be obtained.
(1) In the method for manufacturing a decorative sheet for floor according to the present embodiment, a resin and a hot melt adhesive are formed by coextruding a resin that forms a backer layer, and the resin and hot melt adhesive that form the coextruded backer layer. A decorative sheet for flooring in which a backer layer is formed on the decorative sheet is obtained by bringing the decorative sheet into contact with the hot melt adhesive side of the sheet material to be cooled and solidified.
In this way, the resin forming the backer layer and the hot melt adhesive are coextruded, and the decorative sheet is brought into contact with the hot melt adhesive side to be cooled and solidified. Loss can be reduced and manufacturing costs can be reduced.

(2) Of the two rolls sandwiching the resin and hot melt adhesive forming the coextruded backer layer, the hot melt adhesive side is used to convey the decorative sheet using the hot melt adhesive side roll. Make contact with the decorative sheet.
In this way, the resin that forms the backer layer and the hot melt adhesive are coextruded and bonded to the decorative sheet using a roll such as a cooling roll, thus reducing the adhesive coating process and reducing the loss between processes. It is possible to reduce the manufacturing cost as well as to reduce.

(3) The decorative sheet includes a pattern printing layer that imparts design properties with a pattern and a transparent upper resin layer having transparency in this order. When the decorative sheet is conveyed using a roll, the back side of the pattern printing layer is arranged on the hot melt adhesive side, and the transparent upper resin layer is arranged on the surface side of the roll.
Thereby, the pattern printing layer which has a pattern pattern inside the decorative sheet for floors can be formed, and the transparent upper base resin layer which has transparency can be formed in the outer side (surface side).

  (4) In another aspect, in the method for producing a decorative sheet for floor according to the present embodiment, a resin that forms a backer layer and a hot-melt adhesive are coextruded, and a resin that forms a coextruded backer layer Using a cooling roll that cools the hot-melt adhesive, the decorative sheet is brought into contact with the hot-melt adhesive side of the sheet material composed of the resin and the hot-melt adhesive forming the co-extruded backer layer, and hot-melt bonding is performed. A backer layer and a decorative sheet are bonded to each other with an agent to cool and solidify the hot melt adhesive, thereby obtaining a decorative sheet for a floor in which a backer layer is formed on the decorative sheet.

In this way, the resin that forms the backer layer and the hot melt adhesive are coextruded and bonded to the decorative sheet using a cooling roll, thus reducing the adhesive coating process and reducing the loss between processes. Manufacturing costs can be reduced.
As mentioned above, although embodiment of this invention was explained in full detail, actually, it is not restricted to said embodiment, Even if there is a change of the range which does not deviate from the summary of this invention, it is included in this invention.

DESCRIPTION OF SYMBOLS 1 Backer layer 2 Hot-melt-adhesive agent layer 3 Cosmetic sheet 3a Picture printing layer 3b Transparent upper resin layer 4 Floor decorative sheet 10 Twin screw extruder A, B, C Cooling roll X Cosmetic sheet original Y Floor decorative sheet original

Claims (7)

Co-extrusion of the resin that forms the backer layer and the hot melt adhesive,
A sheet material and a decorative sheet made of the resin that forms the co-extruded backer layer and the hot melt adhesive, a first roll located on the decorative sheet side, and a second roll located on the backer layer side sandwiched between rolls, the decorative sheet contacting the cooled and solidified by the hot melt adhesive side of the sheet material,
After contacting the decorative sheet on the hot melt adhesive side, the sheet material and the decorative sheet are sandwiched between the second roll and the third roll,
The backer layer is formed on the decorative sheet by setting the first roll and the second roll to the same temperature, and setting the third roll to a temperature lower than that of the first roll and the second roll. A method for producing a decorative sheet for floors, characterized by obtaining a formed decorative sheet for floors. Of the first roll and the second roll that sandwich the co-extruded resin that forms the backer layer and the hot melt adhesive, the first roll located on the hot melt adhesive side is used. The method for producing a decorative sheet for floor according to claim 1, wherein the decorative sheet is conveyed to bring the decorative sheet into contact with the hot melt adhesive side. The decorative sheet includes a pattern printing layer that imparts design properties by a pattern and a transparent upper resin layer having transparency in this order,
When conveying the decorative sheet using the first roll, the back side of the pattern printing layer is arranged on the hot melt adhesive side, and the transparent upper resin layer is arranged on the front side of the first roll. The manufacturing method of the decorative sheet for floors of Claim 2 characterized by the above-mentioned. The line speed when coextruding the resin forming the backer layer and the hot melt adhesive is in the range of 5 m / min to 20 m / min,
The temperature of the first roll and the second roll is within the range of 80 ° C. or more and 150 ° C. or less,
The method for producing a floor decorative sheet according to any one of claims 1 to 3, wherein the temperature of the third roll is set in a range of 50 ° C to 100 ° C. The line speed when co-extruding the resin forming the backer layer and the hot melt adhesive is 10 m / min,
The temperature of the first roll and the second roll is 100 ° C.,
The method for producing a decorative sheet for a floor according to any one of claims 1 to 3, wherein the temperature of the third roll is 60 ° C. The position of the rotation center of the first roll is lower than the position of the rotation center of the second roll;
The resin forming the backer layer and the hot melt adhesive are coextruded in a direction perpendicular to a straight line connecting the position of the rotation center of the first roll and the position of the rotation center of the second roll. The method for producing a floor decorative sheet according to any one of claims 1 to 5, wherein: Co-extrusion of the resin that forms the backer layer and the hot melt adhesive,
A sheet material and a decorative sheet made of the resin that forms the co-extruded backer layer and the hot melt adhesive, a first roll located on the decorative sheet side, and a second roll located on the backer layer side Sandwiched between rolls, the decorative sheet is brought into contact with the hot melt adhesive side of the sheet material and cooled and solidified,
The position of the rotation center of the first roll is lower than the position of the rotation center of the second roll;
The resin forming the backer layer and the hot melt adhesive are coextruded in a direction perpendicular to a straight line connecting the position of the rotation center of the first roll and the position of the rotation center of the second roll. By doing so, the decorative sheet for floors in which the said backer layer was formed in the said decorative sheet is obtained, The manufacturing method of the decorative sheet for floors characterized by the above-mentioned.

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