JPH062416A - Manufacture of tile - Google Patents

Abstract

PURPOSE:To provide tiles which can be simply laid, which can surly and clearly exhibit a joint pattern, and which can prevent abrasion of the joint pattern. CONSTITUTION:A first colored layer 3 on a tile base member is exposed at the upper surface of the latter, and a second colored layer 4 is laminated over the rear surface of the first colored layer 3. The color of the colored layer 3 is different from the color of the colored layer 4. The peripheral edge part of at least the first colored layer 3 is removed so that the peripheral edge part 4a of the second colored layer 4 is exposed. The joint pattern is formed in such a way that the peripheral edge part 4a surround the colored layer 3 in the removed part.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing tiles for laying on the floor of various offices, lobbies, halls, indoor gyms, clubhouses, indoor playgrounds and the like.

[0002]

2. Description of the Related Art Recently, tiles made of a thermoplastic resin flat-plate molded article have been used as flooring materials for various facilities.
Such tiles generally consist of a base layer and a colored surface facing layer. Then, for example, flat square tiles are carried into the construction site, and the tiles are laid with no gaps in contact with each other.

However, when considering the finishing state of the floor surface after construction, joints are often required between adjacent tiles. Therefore, there is a method of fitting a rod-shaped joint material between the tiles. However, in order to fit the joint material on all four sides of the tile, at least two tiles are required.
Double the number of joint materials is required, and the number of parts required for floor formation increases dramatically. For this reason, it takes a lot of time and labor for the construction, and it becomes difficult to match the dimensions of the respective parts, so that the construction takes a long time.

There is also a method in which tiles are fixed with a little space left between them, a long and narrow substrate-like groove is provided between the tiles, and a liquid material is injected into the groove to be cured. However, locating a large number of tiles on the construction site without touching each other is a difficult task. Injecting a predetermined amount of liquid material, leveling the surface, and curing it are also labor-intensive operations,
Also, it takes a long time to cure. There is also a method of printing a joint pattern on the peripheral portion of the tile. However, when the user actually walks, the printed portion is easily worn and becomes unsightly in a short time after the construction.

[0005]

The present applicant has also studied a method of providing a joint pattern in advance on a tile by devising a molding method. That is, a mold having a flat plate-shaped molding space was prepared, a colored belt-shaped resin was arranged in the peripheral portion of the molding space, and a resin sheet of a different color from this was put inside the belt-shaped resin and heat-molded. However, there is a problem that the boundary between the belt-shaped resin and the resin sheet is broken and becomes unclear because the resin component flows during the heat molding.

[0006] An object of the present invention is to manufacture a tile which is easy to apply, can reveal a joint pattern clearly and surely, and does not wear out the joint pattern.

[0007]

SUMMARY OF THE INVENTION The present invention provides a tile substrate having a first colored layer exposed on the upper surface and a second colored layer laminated on the back surface of the first colored layer. At this time, the colors of the first colored layer and the second colored layer are made different, then at least the peripheral portion of the first colored layer is removed, and the peripheral portion of the second colored layer is added to the removed portion. The present invention relates to a method for manufacturing a tile, which is configured such that a portion is exposed and a joint pattern can be formed in the removed portion.

[0008]

EXAMPLES Hereinafter, a method of manufacturing tiles according to examples of the present invention will be described step by step. First, the tile base material 2 as shown in FIGS. 1 and 2 is manufactured. In this tile base material 2, the first colored layer 3 is exposed on the upper surface of the tile base material 2, and the second colored layer 4 is laminated on the back surface of the first colored layer 3. In this embodiment, the base layer 1 is further laminated on the back surface of the second colored layer 4. The base layer 1 can be omitted. Further, in the present embodiment, the planar shape of the tile base material 2 is a square, but other squares, pentagons, hexagons and triangles may be used. The thickness of the tile base material 2 is selected according to its application. The first colored layer 3 and the second colored layer 4 need to have different colors.

Tile materials that can be used in the present invention include:
There are polyvinyl chloride resin, styrene-butadiene block polymer resin, styrene-isobutylene resin, natural rubber, synthetic rubber and the like. These thermoplastic resins or rubbers are used as a compound according to a conventional method.

When manufacturing a tile base material, first, the above compound is put into a calender roll, a roll, an extruder,
It is formed into a sheet using a compressor or the like. Molding conditions such as temperature and pressure are determined according to the type of resin or rubber. Sheets corresponding to the respective layers 1, 3 and 4 are prepared in this manner, and these sheets are sequentially charged in a mold, heated and vulcanized by a conventional method, and press-formed. Then, it is cut into a predetermined size to obtain the rubber tile base material 2.

Next, at least the peripheral portion of the first colored layer 3 is removed, and the peripheral portion of the second colored layer 4 is exposed at the removed portion. In this embodiment, as shown by the alternate long and short dash line A in FIG. As a result, the cross section of the removed portion of the first colored layer 3 becomes a trapezoid, and the cross section of the removed portion of the second colored layer 4 becomes a right triangle. After this, the tile 12 as shown in FIG. 3 is obtained. In the tile 12, a slope 3b is formed on the peripheral edge of the first colored layer 3, and a slope 4a is formed on the peripheral edge of the second colored layer 4 so as to surround the slope 3b.

At the construction site, this tile 12 is shown in FIG.
As shown in, lay them without making a gap while making contact with each other. As a result, the surfaces 3a of the first colored layer 3 are regularly arranged at predetermined intervals, the slope 3b surrounds the periphery of the surface 3a, and the slope 4a surrounds the periphery of the slope 3b. The first colored layer 3 and the second colored layer 4 are different in color from each other, and the inclined surface 4a forms a joint pattern of a base joint shape.

According to the above-mentioned manufacturing method, since the joint pattern is formed on the tile 12 in advance, no special part for forming the joint is required. Further, unlike the method of forming joints by injecting a liquid material, since tiles are laid while making contact with each other, it is easy to position the tiles and the time required for construction is shortened. Further, unlike these conventional methods, since the size of the joint portion is determined at the stage of manufacturing the tile 12, the joint line is less likely to be displaced or distorted.

Further, since the peripheral portion of the tile base material 2 is removed to expose the second colored layer 4 to form the joint pattern, the joint pattern is worn away unlike the case where the joint pattern is formed by printing. There is nothing to do. Moreover, the boundary line between the joint pattern and the surface 3a appears clearly and surely.

Further, as shown in FIG. 4, in the state where the tiles 12 are laid, the removed portions are interposed between the adjacent tiles 12, and the surfaces 3a of the adjacent tiles 12 are not directly continuous with each other. For this reason, the thickness of the tile 12 may be slightly uneven, or the concrete body surface may be uneven.
Even if there is a deviation in the height of the, this deviation is almost invisible.

In FIG. 2, if the total thickness of the colored layers 3 and 4 is d, and the removal width on the surface 3a is l, then l
It is preferable that the size of d is not less than d / 2 because the joint pattern appears more clearly. Further, in the above example, the flat slopes 3b and 4a are formed, but the slopes 3b and 4a may be rounded and expanded in an arc shape. Further, in the present invention, it is necessary to remove at least the peripheral portion of the first colored layer 3, and the second colored layer 4 does not necessarily have to be removed. As the removing method, there are a method of polishing and removing with an abrasive and a method of cutting with a blade.

In the present invention, three or more colored layers can be provided. That is, in the example shown in FIG.
The second colored layer 4 is laminated on the rear surface of the first colored layer 3, the third colored layer 5 is laminated on the rear surface of the colored layer 4, and the base layer 1 is laminated on the rear surface of the colored layer 5. Then, the peripheral portions of the first, second and third colored layers 3, 4 and 5 are obliquely removed as shown in FIG. 5 to expose the slopes 3b, 4a and 5a to manufacture the tile 22. ing. In this case the tile
The joint pattern when 22 is laid becomes a two-color strip pattern.

Specific manufacturing examples will be described below. Example 1. A tile having a thickness of 5 mm, a length of 500 mm and a width of 500 mm was manufactured. First, each of the following formulations was prepared.

[0019]

[Table 1]

[0020]

[Table 2]

[0021]

[Table 3]

First, the compound for the first colored layer 3 and the compound for the second colored layer 4 were separately compounded, kneaded, and put into a heat-in roll to have a thickness of 1.5 mm and a lengthwise direction. 600 m
Each sheet having a size of m and a width of 600 mm was prepared. The sheet was cooled and cut into a size of 520 mm in length and 520 mm in width. Further, the base layer 1 mixture was blended, kneaded, and put into a heat-in roll to prepare a sheet having a thickness of 2 mm, a length of 600 mm and a width of 600 mm. This sheet is cooled to 520 mm length and 520 mm width.
Cut to size. Next, each of these three layers of sheets was placed in a mold having a thickness of 5 mm and dimensions of 520 mm × 520 mm and laminated in the order shown in FIG. Then, the rubber was vulcanized by heating and pressurizing according to a conventional method.

Next, the rubber sheet base material after pressure molding was cooled and cut by a hydraulic cutting machine to obtain a rubber sheet base material 2 having a length of 500 mm and a width of 500 mm. Polishing was performed using a normal belt sander so that the shape shown by the one-dot chain line A in FIG. At this time, the angles of the slopes 3b and 4a were 45 °, and the dimension 1 was 3 mm. Wash the polished part with water, dry it, wax it, and apply it to the rubber tile 12 shown in FIG.
Got In this rubber tile 12, slopes 3b and 4a
The boundary with and the joint line were clear. In addition, due to the construction,
It could be easily laid as shown in. FIG. 1 shows a state in which four rubber tiles 12 of this example are laid.

Example 2. Each formulation as shown in Table 4 was prepared. However, Table 4 shows the formulation for the first colored layer and the formulation for the second colored layer.

[0025]

[Table 4]

The formulations for the first colored layer shown in Table 4 were mixed by a Henschel mixer, and formed into a sheet having a width of 600 mm and a thickness of 1.5 mm by an extruder with a T-die at 180 ° C. It was cut to a size of 520 mm in length and 520 mm in width. Similarly, the composition for the second colored layer was extruded into a sheet having a thickness of 3.5 mm, which was cut into a size of 520 mm in length and 520 mm in width. Next, insert each sheet into the mold space of 520 mm in length, 520 mm in width, and 5 mm in thickness, and press for 10 minutes at a temperature of 170 ° C and a pressure of 30 kg / cm ² , and then move the mold up to around 60 ° C. It was cooled and the tile consisting of two layers was taken out. Naturally cool this tile,
It was cut into a size of 500 mm in length and 500 mm in width.

Then, in the same manner as in Example 1, the peripheral edge of the tile base material 2 was polished. As a result, it was possible to obtain the tile 12 in which the surface 3a and the slope 3b were gray and the slope 4a constituted white joints. In this tile 12, the boundary between the slopes 3b and 4a and the joint line were clear. Also, it was easy to lay as shown in FIG. 4 in terms of construction.

[0028]

According to the manufacturing method of the present invention, the peripheral portion of the first colored layer is removed and the peripheral portion of the second colored layer is exposed at the removed portion, whereby a joint pattern is preliminarily formed on the tile. Form. Therefore, there is no need for special parts or processes forming joints at the construction site. Unlike the method of forming joints by injecting a liquid material, since the tiles are laid while making contact with each other, it is easy to determine the position of the tiles and the time required for construction is shortened. Further, unlike these conventional methods, since the size of the joint portion is determined at the stage of manufacturing the tile, the displacement or distortion of the joint line is unlikely to occur.

Further, since the second coloring layer is exposed by removing the peripheral portion of the tile base material to form the joint pattern, the joint pattern is worn away unlike the case where the joint pattern is formed by printing. There is no. Moreover, the boundary line between the joint pattern and the surface appears clearly and surely.

Further, in the state where the tiles are laid, the removed portion is interposed between the adjacent tiles, and the surfaces of the adjacent tiles are not directly continuous with each other. Therefore, even if the height of the surface is deviated due to the unevenness of the thickness of the tile or the unevenness of the surface of the concrete skeleton, the deviation is hardly noticeable.

[Brief description of drawings]

FIG. 1 is a perspective view showing a tile base material 2. FIG.

FIG. 2 is a cross-sectional view showing a tile base material 2.

FIG. 3 is a cross-sectional view showing a tile 12.

FIG. 4 is a perspective view showing a part of a floor surface on which tiles 12 are laid.

FIG. 5 is a cross-sectional view showing a tile 22.

[Explanation of symbols]

 1 Base Layer 2 Tile Base Material 3 First Colored Layer 3a Surface 3b Slope 4 Second Colored Layer 4a, 5a Slope 5 Third Colored Layer 12, 22 Tile

Claims (1)

[Claims] 1. A tile base material having a first colored layer exposed on the upper surface and a second colored layer laminated on the back surface of the first colored layer is prepared. Differentiate the color of the colored layer and the second colored layer, then remove at least the peripheral portion of the first colored layer to expose the peripheral portion of the second colored layer to the removed portion,
A method for manufacturing a tile, which is configured to form a joint pattern in the removed portion.