JPH0860829A - Embossed tile and production thereof - Google Patents

Abstract

PURPOSE: To obtain an embossed tile excellent in the design, by filling a granular decorative material in the recesses of a metal mold and charging a backing material thereon and molding it in a male die with heat and pressure to form a rugged surface. CONSTITUTION: A decorative material 5 composed of synthetic resin chips, pellets, granules like rubber, PVC, etc., is filled up to the top of recesses 3 provided at the bottom 2 of a metal mold. granular backing material 9 which is made by recycling use of waste materials like vinyl floor materials or tile carpets are charged thereon. Next, a male die 10 is fitted in a shell metal mold and a press plate 12 is put thereon and heated with pressure to melt the decorative material 5 and the backing material 9 together as a unified material and form a floor tile. The backing layer is formed to constitute decorative joints and completely correspond to the shape and color of the rugged surface of tile. In this way, an embossed tile excellent in the design can be easily obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface coating, and more particularly to a tile having a decorative layer conforming to surface irregularities and excellent in design and a method for producing the tile.

[0002]

Brick, natural stone, wood, pottery, etc. have been used as a wall or floor covering material. However, since these covering materials are expensive and require a great deal of labor to be applied, a brick-like, natural stone-like, or pottery-like patterned film sheet or paper is printed because it is cheaper and easier to apply. Was awarded. However, since the surface of these printed materials is smooth, there is a sense of incongruity with the real thing in terms of three-dimensionality, and this has been a problem in improving the design.

[0003]

Therefore, the surface of the above-mentioned printed pattern is embossed so as not to match the pattern. However, although some of these are closer to the real thing and are excellent in design, the design is rather impaired. It was Therefore, an attempt was made to match the pattern and embossing in order to bring it closer to a real covering material.

Japanese Examined Patent Publication No. 43-28636, Japanese Examined Patent Publication No. 4
The method disclosed in Japanese Patent Publication No. 6-4913 and Japanese Patent Publication No. 46-42637 discloses a method of printing several colors on the surface of a sheet formed by molding a foaming resin composition containing a foaming agent to give a pattern, By using the ink containing the foaming inhibitor and the ink not containing the inhibitor, the chemical embossing that matches the pattern appears. That is, the expansion ratio under the portion printed with the ink containing no foaming inhibitor becomes high, and the foaming inhibitor penetrates into the foamable resin composition under the area printed with the ink containing the foaming inhibitor to suppress foaming. By the technical idea of doing, the design and the embossing are matched and the design is improved. With this method, the pattern and embossing were relatively well matched, but had the following drawbacks.

This technique can be used only for foam production and not for non-foam. Usually, foam floor materials can be used in places with a relatively small amount of walking, but in places with a large amount of walking, they were severely damaged and were unsuitable for use.

Also in the foamed product, the embossed recesses are rounded and no sharp embossing can be obtained, so that the designability is not satisfactory.

Next, a method for obtaining a mechanically embossed flooring material is disclosed in US Pat. No. 3,655,312. This is a method of forming a decorative sheet having a printing and wear layer on the foam layer, heating and softening and foaming this, and then embossing with a embossing roll or the like in accordance with the pattern to impart embossing in synchronization with the pattern.

However, this method is difficult to synchronize the print pattern position and the emboss position. The reason why the pattern and the emboss do not match is that the pattern sheet is softened by heating before embossing, so that the sheet stretches and deforms due to heat expansion, pulling, etc. and does not match the embossed size. As a result, the surface coating material in which the pattern and the embossing position were not in tune with each other was not satisfactory in design.

[0009]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a floor tile whose color matches the pattern of the embossed recess and a method for manufacturing the same.

According to a first aspect of the present invention, a step of filling a concave portion of a die having at least a concave portion with a cosmetic material, and a step of placing a body die so that an inner wall lower end is in contact with a peripheral side of an outer edge of the bottom concave portion. An embossing characterized in that a step of filling a cosmetic material and a backing material of a color different from that of the cosmetic material into the body die from above the cosmetic material, and thermocompression molding of the cosmetic material and the backing material with a male die inside the body die It is a method of manufacturing tiles.

A second aspect of the present invention is the method for manufacturing an embossing style according to the first aspect, wherein the bottom of the die has a concave portion and a convex portion.

According to a third aspect of the present invention, an embossing style in which a backing layer and a decorative layer different in color from the backing layer are formed on the backing layer in a state having at least convex portions on the surface, and the makeup layer is in tune with the surface irregularities in both color and shape Is.

A fourth aspect of the embossing style according to the third aspect is that the decorative layer is formed separately on the backing layer, and the surface is provided with recesses and protrusions, and the recesses are joints where the backing layer is exposed.

The present invention will be described below with reference to the drawings.
"FIG. 1", "FIG. 2" and "FIG. 3" are cross-sectional views of manufacturing steps of the floor tile of the present invention. In FIG. 1, a metal mold 1 having a concave and convex top surface, preferably a square mold bottom 2 having a side of 10 to 100 cm, is placed. The metal mold bottom 2 is formed by appropriately selecting a metal such as iron, aluminum, an alloy, or a metal frame in which a resin mold such as epoxy resin or silicon resin is fitted. The mold bottom has a concave portion 3 and convex portions 4a and 4b, and the concave portion 3 is separated by the convex portions 4a and 4b.
The metal plate 1 may be omitted.

The decorative material 5 is filled in the recess 3. As the decorative material, chips, pellets or granules of synthetic resin such as rubber or PVC are suitable, and the average particle size is 10 μm to 5 mm. The cosmetic material becomes a surface decorative layer of the present embossing style after heat compression molding. It is desirable that the decorative material be scraped and filled to the depth d of the recess 3. As a result, the cosmetic material is filled almost exactly to the depth d and to a lesser extent. The depth d is preferably 0.3 to 10 mm. The size and shape of the concave portion 3 are not limited, and may be circular, polygonal, or any other irregular shape as long as it is finally formed into a tile shape.

As shown in FIG. 2, the lower end 7'of the inner wall 7 of the body mold 6 is in contact with the outer side of the outer periphery of the recess 3 of the outermost protrusion 4b of the bottom of the mold filled with the decorative material. To place. The convex portion 4b is preferably horizontal. The body die is a metal tubular body, and by combining the die bottom and the body die, a female die 8 for ordinary press working can be obtained.

The lining material 9 is filled on the inside of the body die from above the decorative material. The backing material is distinct from the cosmetic material and is identifiable. The backing material has a synthetic resin, rubber or the like as a main binder, and may be added with a filler, a fiber, a heat stabilizer, a weather resistance agent, a pigment, and other processing aids. The backing material is preferably chips, pellets or granules having a particle size of 0.1 to 10 mm. The backing material can be used by recycling waste such as vinyl flooring, tile carpet and vinyl leather.

In FIG. 3, the decorative material 5 is slid into the concave portion 3 and filled, and the backing material 9 is filled therein more than half the depth of the body mold. Next, the male die 10 is fitted inside the body die, the press plate 12 is placed on the male die and heated and pressed, and the stepped ear portion 11 of the male die is the body die. Apply pressure until it comes into close contact with the tip. After this, the decorative material and the backing material are melt-integrated to obtain a floor tile.

The obtained embossing style is taken out by reversing from the mold, and the convex portion, which is the decorative layer, and the backing layer, which is the concave portion, completely match the irregularities of the tile surface with the design and color.

FIG. 4 is a sectional view of another embodiment of the tile manufacturing process of the present invention. In the present invention, a concave portion 15 having a smooth bottom surface 14 is formed on the mold bottom portion 13, a horizontal portion 16 is formed on the peripheral edge of the concave portion, and a decorative material 17 is formed in this concave portion.
Slice and fill. Next, the body metal mold 18 is placed on the outer horizontal portion of the periphery of the metal mold recess, and the backing material 19 is placed on the body metal mold 18.
To fill. Thereafter, by heating and pressurizing with the male die 20 as described above, an embossed style having no recess in the central portion can be obtained.

FIG. 5 is a sectional view of the floor tile obtained by the present invention, FIG. 6 is a perspective view, 21 is a decorative layer, and 22 is a backing layer. The decorative layer is formed of the above-mentioned decorative material, and preferably the square backing layer having a side of 10 to 100 cm is formed by thermocompression molding of the backing material. The decorative layer and the backing layer are different in color, and the decorative material preferably has a depth of 0.3.
Only the mold recesses of 10 mm are scraped and filled, and the depth is almost the same as that of the mold recesses. Therefore, the obtained backing layer is not mixed with the decorative layer, and the embossed recesses 22 and the backing layer are not formed. The embossing style 23 of the present application is obtained in which the makeup joints are formed in conformity with each other, and the convex portion, which is the decorative layer, and the backing layer, which is the concave portion, completely match the irregularities and shapes and colors of the tile surface. In addition, a subtle uneven pattern may be provided on the surface of the embossed decorative layer.

[0022]

According to the present invention, the concave portion of the mold is slid and filled with the cosmetic material to a position substantially corresponding to the depth of the concave portion, and the body die is placed so that the inner wall is in contact with the outer side of the peripheral edge of the concave portion. By filling the interior with a backing material of a different color from that of the cosmetic material layer and heat-pressing the cosmetic material and the backing material, an embossed style in which the cosmetic layer matches the surface irregularities on the backing layer is obtained. To be

[0023]

The embossing style in which the backing layer constitutes the makeup joint and the makeup layer is in tune with the unevenness of the tile surface in the color and shape was obtained.

[0024]

Example A chip for a cosmetic material preheated to 120 ° C. is cut into a concave part having a depth of 4 mm at the bottom of a square mold having a side of 50 cm and having irregularities preheated at 150 ° C. on a press plate by the depth of the concave part. Filled.

Formulation A PVC (vinyl acetate 5% copolymer) 100 parts by weight DOP 40 filler (calcium carbonate) 150 ba-zn complex stabilizer 3 epoxidized soybean oil 2 pigment suitable amount

As chips for cosmetic materials, 5 color chips were used in which the composition of Formulation A was dispersed in a super mixer, extruded by an extruder, cooled and pulverized, and passed through a 20-mesh sieve.

After filling with the cosmetic material, a preheated barrel mold was placed on the horizontal portion outside the peripheral edge of the recess at the bottom of the mold.

As the backing material composed of the composition of the formulation B, chips made of two colors different from the cosmetic material, which were dispersed in a super mixer, extruded by an extruder, cooled, crushed, and passed through a sieve having a diameter of 2 mm, were used. .

Formulation B PVC (vinyl acetate 5% copolymer) 100 parts by weight DOP 55 filler (calcium carbonate) 350 ba-zn complex stabilizer 3 epoxidized soybean oil 2 pigment suitable amount

The inner space of the body metal mold is filled with the above chips for the backing material preheated to 120 ° C., pressurization is started by the preheated male mold fitted to the body metal mold, and the space between the press plates at 150 ° C. The male mold is pressed with the ear mold of the male mold until it completely adheres to the body mold, and after heating and pressurizing for 5 minutes, the male mold is removed, and the molded product is taken out to reveal the convex portion of the decorative layer pattern. An embossed style having a total thickness of 10 mm and an embossing depth of 4 mm, in which the concave portions of the makeup joint pattern were matched and which was excellent in design, was obtained.

[Brief description of drawings]

FIG. 1 is a sectional view of an embossing style manufacturing process.

FIG. 2 is a sectional view of an embossing style manufacturing process.

FIG. 3 is a sectional view of an embossing style manufacturing process.

FIG. 4 is a process chart of another embodiment of the embossing style.

FIG. 5 is a sectional view of an embossed style.

FIG. 6 is a perspective view of an embossed style.

[Explanation of symbols]

2 ... Mold bottom part, 3 ... Mold bottom concave part, 4a, 4b ... Mold bottom convex part 5 ... Decorative material, 9 ... Lining material, 21 ... Decorative layer, 2
2 ... Lining layer 23 ... Embossed style

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Claims (4)

[Claims] 1. A step of filling a mold bottom concave portion having at least a concave portion with a cosmetic material, a step of placing a body metal mold so that a lower end of an inner wall is in contact with an outer periphery of a bottom concave portion, and A method for manufacturing an embossing style, which comprises a step of filling a backing material having a color different from that of the decorative material inside the body mold, and thermocompressing the cosmetic material and the backing material with a male mold fitted inside the body mold. . 2. The method for manufacturing an embossing style according to claim 1, wherein the mold bottom has a concave portion and a convex portion. 3. An embossed style in which a backing layer and a decorative layer of a color different from that of the backing layer are formed on the backing layer so as to have at least convex portions on the surface, and the decorative layer is in tune with the surface irregularities in terms of color and shape. 4. The embossing style according to claim 3, wherein a decorative layer is separately formed on the backing layer, and a concave portion and a convex portion are provided on the surface, and the concave portion is a joint where the backing layer is exposed.