JPH0571711B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a floor covering having a penetrating pattern, and more specifically relates to a thermoplastic composition having various particle sizes from small to large. The present invention relates to a method for producing a floor covering having a pattern of crushed resin grains.

[Prior art]

Conventionally, methods for producing floor coverings with a pattern made by crushing thermoplastic synthetic resin grains include using a doctor blade without notches or a method in which thermoplastic synthetic resin grains are continuously opened over almost the entire width of the base material. A method is known in which the material is supplied to the entire surface of the base material using a supply device having two supply ports, and the material is heated and pressurized to fuse and integrate the material and crush it.

In this conventional method, the thickness of the product bedding was controlled by adjusting the distance between the lower edge of the doctor blade or feeder and the base material.

[Problem that the invention seeks to solve]

However, when using these conventional methods, thermoplastic synthetic resin particles containing particles with a particle size larger than the thickness of the synthetic resin layer of the floor covering to be obtained cannot be used, and large-sized thermoplastic synthetic resin particles cannot be used. Therefore, particle size had to be selected. In other words, when the thickness of the synthetic resin layer of the floor covering to be obtained is set to 3 mm, the bottom edge of the doctor blade and feeder and the base material are Normally, the spacing between the two is set to 4 mm. When the doctor blade and feeder are set in this way, thermoplastic synthetic resin particles with a particle size of 4 mm or more will be caught on the lower edge of the doctor blade or feeder and will not be fed to the substrate surface. The pattern on the floor covering is formed only by thermoplastic synthetic resin particles with a particle size of less than 4 mm, resulting in a fine pattern, and includes a large pattern obtained by crushing large-sized thermoplastic synthetic resin particles. Not only is there the problem that thermoplastic synthetic resin particles larger than 4 mm are caught on the doctor blade or the lower edge of the feeder, but the thermoplastic synthetic resin particles may not be fed onto the substrate in a streak-like manner. This has the disadvantage that unsupplied areas are formed, which may cause product defects.

[Means for solving problems]

The method for producing a floor covering of the present invention involves using a doctor blade having a notch on the surface of the base material or a synthetic resin particle supply port to feed thermoplastic synthetic resin particles ranging from small to large particle sizes. The thermoplastic synthetic resin particles are fed by an intermittent feeder so as to form a striped area with many thermoplastic synthetic resin particles, and then the base material is vibrated through a diaphragm. The thermoplastic synthetic resin particles are uniformly dispersed on the surface of the base material and fused to the base material by heating and pressurizing, and at the same time, the respective thermoplastic synthetic resin particles are fused and integrated with each other and crushed.

As the thermoplastic synthetic resin particles, any commonly used thermoplastic synthetic resin particles such as homopolymers and copolymers of polyvinyl chloride, polyethylene, and polyacrylic resins can be used. In particular, synthetic resin granules granulated by agitation granulation using a Henschel mixer, a super mixer, a Newgramachine, a Marumerizer, etc. are particularly preferred since the shape of the granules is close to a sphere.

As the base material, in addition to a release carrier such as release paper, any material that is generally used as a base material for floor coverings such as woven fabric, nonwoven fabric, asbestos sheet, synthetic resin sheet, etc. can be used. If a releasable carrier is used, the releasable carrier must be peeled off in the final step, but a floor covering without backing can be obtained. Furthermore, an adhesive may be applied to the surface of the substrate before supplying the thermoplastic synthetic resin particles to fix the thermoplastic synthetic resin particles to the substrate surface.

The width and height of the notch of the doctor blade or the width of the supply port of the supply device can be freely changed depending on the thickness of the synthetic resin layer of the floor covering to be manufactured and the size of the resin particles used. can. Although the number of notches and supply ports in the doctor blade can be determined arbitrarily, it is preferable to have a large number. This is because if the number of notches and supply ports is small, it will take time to uniformly disperse the thermoplastic synthetic resin particles by subsequent vibration. For example, thermoplastic synthetic resin particles (particle size less than t)
When supplying to the substrate surface with a thickness t and a width l, the width of the entire notch of the doctor blade is l/
2, the height of the notch should be 2t, and then it should be distributed evenly over the diaphragm, so if the width of one notch is 1/6, three notches are set. If it is possible, and it is 1/12, six notches can be set. Furthermore, the height of the notch can be made 3t by setting the entire width of the notch to 1/3.

Furthermore, the shape of the notch and the supply port may be any shape, but it is preferable that the doctor blade having the notch or the lower end of the feeder having the supply port intermittently be connected to the thermoplastic synthetic resin particles. or damage to the base material caused by the doctor blade or the lower end of the feeder;
In order to prevent cutting, etc., it is preferable that the lower end (the side in contact with the substrate) of the doctor blade or feeder be shaped as smoothly as possible, such as a wave, semi-ellipse, or semicircle. .
Further, in the case of a shape such as a triangle that easily damages the base material, the tip may be ground into an arc shape.

In addition, the supply amount of thermoplastic synthetic resin particles can be adjusted by
This is done by raising and lowering an adjusting plate provided above the notch to adjust the area of the notch. The shape of the lower end of this adjusting plate may be linear, or if it is desired to pass synthetic resin particles with a large particle size, it is preferably wavy or uneven. If the lower end of the adjustment plate is to have a wavy or uneven shape, it is necessary to shift the phase from the shape of the doctor blade, the notch of the feeder, or the lower end of the feed port, or change the shape or size. be.

〔Example〕

Example 1 Polyvinyl chloride resin particles (mixed with particle diameters of 1 mm to 5 mm) were stirred and granulated using a Henschel mixer.
Width 180cm made of 0.3mm thick glass fiber non-woven fabric
on a base material with a width of 18 mm and a height close to the surface of the base material.
Supplied in stripes with a 180 cm long doctor blade having 100 13 mm isosceles triangular notches,
Subsequently, the base material supplied with the polyvinyl chloride resin particles was vibrated through a vibrating plate to uniformly disperse the polyvinyl chloride resin particles on the base material. After heating this, it was hot pressed using a flat embossing roll provided with a clearance of about 2 mm to crush each polyvinyl chloride resin particle and fuse and integrate it to obtain a floor covering.

The resulting floor covering had a mixed appearance of small crushed granular patterns and large crushed granular patterns. The thickness of this floor covering was 3 mm.

In this example, particles with a diameter of 1 mm to 5 mm do not get caught on the doctor blade.
They were mixed and supplied onto the substrate without any problem.

Example 2 The same doctor blade used in Example 1 was provided with an adjusting plate with a straight lower end for adjusting the supply amount, the height of this adjusting plate was 5.5 mm from the lower end of the doctor blade, and the notch was A floor covering was manufactured in the same manner as in Example 1, except that the shape was a trapezoid with a base of 18 mm, a height of 5.5 mm, and a top of about 10.5 mm, and a 180 cm doctor blade having 100 notches was used.

In this example, by providing a supply rate adjustment plate, the supply rate of synthetic resin particles can be adjusted, and after heating, approximately
The thickness of the product after hot pressing with a flat embossing roll with a clearance of 1.5 mm was 2 mm.

Comparative Example 1 The doctor blade used had no notch at all, and the distance between the base material and the doctor blade was 5.
A floor covering was manufactured in the same manner as in Example 1 except that the diaphragm was set to mm and the diaphragm was not used.

As a result, since the gap between the base material and the doctor blade matches the particle size of the large synthetic resin particles and there is not enough room, particles with a particle size of about 5 mm get stuck in the gap between the base material and the doctor blade, and the synthetic resin particles The uncoated portions appeared in the form of streaks, and even after heating and pressing, the streaks could not be filled in, resulting in defective products with streak-like depressions. In addition, because the amount of synthetic resin particles supplied could not be adjusted, the product thickness was extremely thick at 4.5 mm.If the thickness was to be less than this, the distance between the base material and the doctor blade should be made small, and the synthetic resin particles should be The diameter also had to be made small, and the products obtained by pressing after heating had significantly poor decorative properties.

[Action/Effect]

In the present invention, a doctor blade having a notch or a feeder provided with intermittently supply ports is used to form a striped area in which many thermoplastic synthetic resin grains are present. The particles are supplied to the base material and the base material is vibrated to disperse the thermoplastic synthetic resin particles over the entire surface of the base material, so particles of small to large particle sizes can be arbitrarily supplied onto the base material. Even if the thickness of the floor covering to be obtained is thin, a large crushed granular pattern can be formed.

Claims (1)

[Claims] 1. Thermoplastic synthetic resin particles ranging from small to large particle sizes are streaked using a doctor blade with a notch on the surface of the base material or a feeder equipped with an intermittently synthetic resin particle supply port. The thermoplastic synthetic resin particles are uniformly distributed on the surface of the substrate by supplying the substrate so as to form a portion where many thermoplastic synthetic resin particles are present, and then vibrating the substrate by passing it over a diaphragm, 1. A method for manufacturing a floor covering, which comprises heating and pressurizing the particles to fuse them to a base material, simultaneously melting and integrating the thermoplastic synthetic resin particles with each other and crushing them.