JPH06108369A - Production of facing material consisting of composite resin sheet - Google Patents

Abstract

PURPOSE:To obtain a facing material capable of quickly forming diversified patterns by copying desired pattern(s) on a vinyl chloride-based copolymer fused fiber-contg. paper using a color copier followed by laminating both the surfaces of the paper with vinyl chloride-based sheets and then monolithically hot pressing. CONSTITUTION:Desired gravure-printed pattern(s) is first copied using a color copier basing on toner method on a paper comprising (A) 20-90wt.% of fused fibers consisting mainly of a vinyl chloride copolymer resin and (B) 80-10wt.% of machining binder such as pulp or PVA. Then, both the surfaces of the resulting paper are laminated with vinyl chloride-based films followed by, optionally, other synthetic resin sheets into a composite sheet, which is then monolithically put to hot pressing, thus obtaining the objective facing material having desired pattern(s).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is a composite resin that is widely applicable as a composite resin sheet in which a vinyl chloride film is laminated, as a sheet for adhesive surface mounting of floors, walls, etc., or as a sheet for thermoforming surface mounting of household furniture members. The present invention relates to a method for manufacturing a surface layer material made of a sheet.

[0002]

2. Description of the Related Art Heretofore, various designs have been created by subjecting film-laminated surface covering materials or thermoforming sheet materials to gravure printing, surface embossing, etc., alone or in combination.

However, in gravure printing and embossing, a great deal of labor, time, and time are required for platemaking and marking of patterns.
Costly. As a result, if the delivery date is long and the amount of one lot is not increased, the cost will increase.

In recent years, the market demand has been diversified and sophisticated in terms of both design and function, and it has become necessary to have a product lineup in accordance with the "multi-product, small-lot" trend. In addition, it is also required to respond to quick market requirements, that is, shorten the delivery time.
It has become difficult to respond to the market sufficiently by the conventional method.

In order to supply various designs in a short time and to impart a new function in response to the demands of the market, the inventors of the present invention described in Japanese Patent Laid-Open No. 30521/1990 disclose chloride. Appearance by heat-pressing a paper sheet made of 30% by weight or more of heat-fusible fiber containing a vinyl copolymer resin as a main component, and a fibrous sheet-like material such as a non-woven fabric, and a vinyl chloride resin sheet. We have proposed a composite resin sheet with dramatically improved processability, which can be easily processed according to the purpose of improving texture, cushioning effect, design effect, etc., and can also be welded and cut by high frequency. .

[0006]

However, the above method is
It takes a considerable amount of time and effort, and it is not enough to quickly respond to the diversified individual customer preferences of today. The present invention has been made in order to promptly meet such demands of the market.

[0007]

Means for Solving the Problems That is, the present inventors
A composite resin with high designability is created by making paper with PVC fusion fiber as the main component, copying the desired pattern on this with a copying machine, sandwiching both sides with PVC film, heating and pressing to integrate them. The present invention has been accomplished by finding that a surface material made of a sheet can be quickly provided with various designs.

That is, according to the present invention, 20 to 90% by weight of fused fiber containing a vinyl chloride copolymer resin as a main component,
Pulp or papermaking binder such as PVA 80-1
Copy the desired design on the paper consisting of 0% by weight (copy)
After that, a vinyl chloride resin sheet on both sides thereof, or a composite sheet in which another synthetic resin sheet is laminated on the vinyl chloride resin sheet is arranged, and they are heated and pressurized to be fused and integrated. The gist is a method of manufacturing a facing material made of a composite resin sheet.

In the present invention, first, paper is made into paper containing 20 to 90% by weight of heat-sealing fibers containing a vinyl chloride copolymer resin as a main component. At this time, by mixing fibers dyed with an appropriate color tone with fibers having different thicknesses and lengths, more various pattern effects can be combined and doubled.

Next, a desired pattern is copied on this paper by using a copying machine. The copying machine may be either mono-color or color. A vinyl chloride resin sheet or a composite sheet in which a vinyl chloride resin sheet is laminated is superposed on both sides of the paper on which the pattern is copied, and is heated and pressed to be fused and integrated. The design to be used may be any existing design, print binding, or a diagram or a design that is represented on a plane such as paintings, fabrics, and photographs.

By using the composite resin sheet of the present invention, in addition to the versatility of the decorative effect of the non-woven fabric and paper different from the film, it is possible to further diversify due to the freedom of the design of the copy and the instant reproduction effect. Become. In addition, the amount of PVC fusion fiber,
If the amount is too small, the adhesiveness to the film will be poor, and if it is too large, the paper-making property will be poor, so the amount of the vinyl chloride-based fusible fiber is preferably in the range of 20 to 90%. The rest of the structure may be a normal papermaking floc, but P
VA, natural pulp and the like are preferable in terms of paper-making property.

[0012]

EXAMPLES Next, the present invention will be specifically described with reference to Examples. (Example 1) 75% by weight of vinyl chloride-based heat-sealing fiber flock (3 d x 10 m / m) obtained from a copolymer of 85% by weight vinyl chloride and 15% by weight vinyl acetate, and PVA fiber flock (1.0 d) × 3 m / m) 10% by weight, natural pulp 15
Using a floc composed of 10% by weight and a basis weight of 35 g / m
² papers were made. Next, using a color copying machine by the toner method, the gravure printing pattern of the bookbinding commercial book was copied on the papermaking paper. After that, a 50 micron composite resin sheet in which a vinylidene difluoride film / acrylic film / vinyl chloride film is laminated is placed on the copy surface, and the other surface is a 100 micron gravure-printed with an appropriate pattern. After placing the semi-rigid PVC film on the drum heated to 140 ° C., the layers were laminated, then pressed by an embossing roller to be fused and integrated. Further, an acrylic pressure-sensitive adhesive was applied at 40 g / m ² and a release paper was attached to make a covering material. By this method, it is possible to instantly reproduce the printed pattern of the book, and the mild decorative effect due to the effect of some pulp remaining on the paper adds the pattern gravure printed on the lower PVC film, which is obtained with the film laminated sheet length We were able to obtain a wide variety of surface covering materials.

(Example 2) 75% by weight of vinyl chloride-based heat-sealing fiber flock (3d × 10 m / m) obtained by copolymerization of 85% by weight of vinyl chloride and 15% by weight of vinyl acetate, and PVA
Fiber Flock (1.0d × 3m / m) 5% by weight, Acry Fiber Flock (2
5d × 2m / m) 5% by weight (2.5% for each color) and 15% natural pulp are used, and the basis weight is 30 g /
Paper of m ² was produced. Next, a checkered commercial floor tile pattern was copied on the papermaking paper using a color copying machine using the toner method. After that, a 100-micron transparent PVC film was placed on the upper surface of the copy paper, and a 100-micron white opaque PVC film was placed on the lower surface. After laminating on a drum heated to 140 ° C., it was peeled off from the drum, and immediately after that, a matte feeling was obtained. Embossing was carried out to produce a fusion-bonded material. Further, a 400-micron hard PVC sheet was laminated under this laminated sheet by a laminator similar to the above to form a laminated composite. Using this sheet, match it with the MDF board that was previously cut for kitchen doors and has been given a hot melt agent,
Integrated by vacuum molding. By this method, it was possible to obtain a kitchen door coordinated with a floor handle in an extremely short time.

[0014]

INDUSTRIAL APPLICABILITY According to the present invention, a composite resin sheet for a surface layer material, which has excellent paper formability and designability due to non-fused fibers, and has excellent workability due to fused fibers made of vinyl chloride fiber In addition, it becomes possible to quickly arrange various designs.

Claims (1)

[Claims] 1. A fusion fiber containing a vinyl chloride copolymer resin as a main component in an amount of 20 to 90% by weight, pulp or P.
After copying (copying) the desired pattern on paper composed of 80% to 10% by weight of a binder for papermaking such as VA, a vinyl chloride resin sheet on both sides thereof, or another synthetic resin on the vinyl chloride resin sheet A method for producing a surface layer material comprising a composite resin sheet, which comprises arranging composite sheets in which sheets are laminated, and heating and pressing the composite sheets to fuse and integrate them.