JPH0448101B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention provides a method for manufacturing a decorative material suitable for interior materials such as flooring and wall materials.

(Prior art and problems) Methods for manufacturing decorative materials such as chip-patterned tiles have been known for a long time, and a method for manufacturing tiles is disclosed in Japanese Patent Publication No. 49-35815, but this method lacks a three-dimensional effect. In addition, the method previously filed by the inventors (Japanese Patent Application No. 82259/1982) uses a large amount of transparent resin, which is disadvantageous in terms of cost, and there is a need for an inexpensive method that provides excellent three-dimensional effect. Ta.

Therefore, the present applicant filed Japanese Patent Application No. 59-73764 for a method for producing a decorative material with clear chip patterns and a three-dimensional effect.

(Structure of the Invention) In the above application, the external appearance was only a pattern made of chips, but the present invention provides a decorative material that has a three-dimensional effect and a printed pattern that enhances the design and further increases the commercial value. A layer of thermoplastic resin chips having a uniform thickness and gaps between the chips is formed, and a surface that melts and flows at a temperature lower than the softening temperature of the chips and comes into contact with the chip layer is formed on the layer. A transparent resin thin layer with a polyvinyl chloride colored pattern layer on the side is superimposed, heated to such an extent that the transparent resin layer flows and penetrates into the chip gap together with the pattern, and then the chip layer and the transparent resin thin layer are heated and pressed together. A method for producing a decorative material characterized by
The gist is:

The drawings will be explained below.

FIG. 1 is a process diagram for manufacturing the decorative material of the present invention. 1 is a backing material. The backing material is suitably a soft sheet such as polyvinyl chloride (PVC), a nonwoven fabric such as glass fiber, a scrim fiber material such as Kansai, or a composite thereof, and has a thickness of 0.2 mm to 1 mm. Synthetic resin chips (hereinafter referred to as chips) 4 are scattered from a hopper 3 onto a backing material 1 pulled out from a roll 2 and placed on a conveyor 16, and formed into a uniform thickness of 2 to 5 mm by a doctor blade 5.

The chips are made of PVC, acrylic resin, or polyurethane resin, and plasticizers, fillers, stabilizers, and colorants may be added as necessary. The size of the chips is preferably 5 meshes or more, more preferably 20 meshes or more.

For example, the softening temperature of chips is 170 ~ in the case of PVC.
Although 220°C is preferred, it can also be carried out at other temperatures. Note that the chips may be colored in a plurality of colors, and the chips may be granulated after imparting a motsuru pattern or a marble pattern to the sheet.

The obtained chip layer is preheated, and a transparent resin thin layer (hereinafter referred to as thin layer) 6 which starts flowing at a temperature preferably lower than the softening temperature of the chips by 15° C. or more is overlaid from a roll 7 on this chip layer. The heating rolls 8 and 9 heat the chips in a temperature range that does not soften them but allows the film to flow, allowing the fluidized resin to penetrate into the gaps between the chips, and partially covering the surface of the chip layer with the thin layer-forming resin, thereby forming the chips. Smooth the surface of the layer.

The thin layer is 10 to 500 μm, more preferably 50 to 500 μm.
A thickness of 300 μm is desirable. Further, the present invention can be practiced even with a thickness greater than this. As the above thin layer,
PVC, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, polyolefin,
Normal printing or transferable resins such as acrylic resins and hot melt resins such as thermoplastic polyurethane are used, and differences in the composition of these resins (more or less plasticizer amount), degree of polymerization, or copolymerization components are used. The flow of the resin may be started at a temperature lower than the softening temperature of the chips, preferably at least 15° C., by appropriately utilizing the differences in the types of resins.

A PVC colored pattern layer 17 in the form of a paste or the like is formed on the side of the thin layer that comes into contact with the chip layer. The colored pattern layer 17 is formed by a conventional method such as durabiya printing, screen printing, transfer printing, etc. using heat-fusible ink. Note that it is preferable to use a transparent ink as the colored pattern layer because the three-dimensional effect of the product becomes more pronounced.

A sheet 1 in which the thin layer with the pattern formed on the contact surface with the chip layer and the chip layer are in close contact with each other in this way.
If desired, an abrasion-resistant transparent film 11 is superimposed on the film 1, and the film is heated and pressed together with press rolls 12, 12' to form a finished product 13 of 1 to 4 mm and wound onto a roll. The abrasion resistant film is not limited to lamination of previously prepared transparent films, but may also be made by coating paste, latex, emulsion, ultraviolet curing resin, etc. and drying and curing it.

In addition, as a manufacturing method of the present invention, the above-mentioned backing material, chip, thin layer, and wear-resistant film may be stacked on a flat press machine and integrated under heat and pressure.
Especially when using chips with a size of 10 meshes or more, it is desirable to use a flat press machine to obtain a more uniform and smooth surface.

Thus, a decorative material with a three-dimensional effect can be obtained by combining the clear chip pattern and the colored pattern.

FIG. 2 is a cross-sectional view of the fabric obtained according to the present invention. 1 is a backing material and 4 is a chip. The resin 15 from the thin layer 6 formed on the chip is heated and flows into the gap in the chip 14.

At this time, the PVC colored pattern layer 1 formed on the thin layer 6
7' flows together with the resin 15, and the ink penetrates deep into the gaps between the chips.As a result, the decorative material 13 has a three-dimensional effect due to the combination of the appearance of the chips and the colored pattern created by the printed ink. .

In addition, if desired, a transparent wear-resistant resin layer 11 may be provided on the surface.
The resin that forms it is PVC, thermoplastic polyurethane,
Film, paste, sol, emulsion or latex of acrylic resin or ultraviolet curable resin are suitable.

(Effect of the invention) In the present invention, a clear and three-dimensional effect can be obtained by the chip pattern, and in particular, in the present invention, a thin layer and a colored pattern made of ink are integrated and heated to penetrate between the pellets, thereby giving a three-dimensional effect and design. This further improves the quality of the decorative material and makes it possible to provide such decorative materials at low prices.

Furthermore, when transparent ink is used, the pellets can be seen through the pattern layer, improving the commercial value.

Furthermore, if conventional printing is attempted directly on the chip layer, the printed surface will be rough if the mesh is rough, but in the case of the present invention, a good printed surface can be obtained even if chips with an average roughness of more than 20 meshes are used. Furthermore, durability can be improved by forming a transparent wear-resistant layer on the surface.

Example 1 Formulation A PVC (=740) 100 parts Plasticizer 25〃 Heavy calcium carbonate 500〃 Stabilizer 1〃 Pigment Small amount Place a 0.5 mm thick PVC backing sheet on a conveyor belt and line it Chips made of the composition of the above formulation A (softening temperature 140°C, 5°C) were placed on the sheet.
A layer of 3.5 mm thick was formed by spraying a layer of 3.5 mm thick. A 0.2 mm thick vinyl chloride-vinyl acetate copolymer film (softening temperature 85°C) of formulation B was placed on the chip layer in advance.
A layer printed with a colored pattern using PVC paste ink by gravure printing is formed on the side that contacts the above chip layer, and further has a thickness that becomes the surface wear-resistant layer of Formulation C.
Place a 0.3mm transparent calendar film and heat to 160℃
The mixture was preheated using a press roll, and then heated and pressed at the same temperature using a press roll. A decorative sheet with a thickness of 3 mm and an excellent three-dimensional effect was obtained.

Formulation B PVC (10% vinyl acetate copolymerization) 100 parts Plasticizer 35 Stabilizer 3 Processing aid 3 Formulation C PVC (=800) 100 parts Plasticizer 30 Stabilizer 3 Processing aid 3 Examples 2 Chips with an average size of about 12 meshes of Formulation A were dispersed to form a layer with a thickness of 3.5 mm on the bed of a flat press machine on which a PVC backing material with a thickness of 0.5 mm was previously placed. A decorative sheet having a total thickness of 3 mm was obtained by heating and pressing in the same manner.

In both Examples 1 and 2, the vinyl chloride-vinyl acetate copolymer film was heated and flowed together with the printing ink and penetrated into the gaps between the chips, while the shape of the chips remained sharp without changing even slightly, giving the chips a three-dimensional appearance. The printed pattern can be expressed integrally, and a decorative material with extremely excellent design and decorative properties can be obtained at a low cost.

[Brief explanation of the drawing]

FIG. 1 is a manufacturing process diagram of the decorative material of the present invention, and FIG. 2 is a sectional view of the decorative material of the present invention. 4 is a synthetic resin chip, 6 is a transparent resin thin layer, 11 is a wear-resistant resin layer,
17 and 17' are colored pattern layers.

Claims (1)

[Claims] 1. Form a layer of thermoplastic resin chips with a uniform thickness and with gaps between the chips, and on the layer, melt and flow at a temperature lower than the softening temperature of the chips, and on the side that contacts the chip layer. A transparent resin thin layer provided with a polyvinyl chloride colored pattern layer was superimposed, heated to such an extent that the transparent resin layer flowed into the chip gap together with the pattern, and then the chip layer and the transparent resin thin layer were integrated under heat and pressure. A method for producing a decorative material, characterized by: