JPS6038274B2 - Core material for decorative sheets - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a core material for decorative sheets mainly made of glass fiber nonwoven fabric, which has dimensional stability against temperature changes and flame retardancy suitable for core materials such as architectural flooring materials and wall materials. , relates to a core material for decorative sheets with excellent sound insulation properties.

In recent years, glass fiber nonwoven fabrics have been used as core materials for long soft floor materials because they have superior dimensional stability in all directions and fire resistance compared to other core materials. It's starting to look like this.

However, because glass fiber nonwoven fabrics are bulky and porous due to the shape and surface properties of the fibers themselves, when a direct acid range is applied to glass fiber nonwoven fabrics, depending on the material being applied, this may remain between the fibers. However, it has the disadvantage of leakage. In order to suppress the penetration of the bait range as an impregnated village, it has been proposed to use a non-woven fabric made of glass fiber mixed with asbestos fibers and impregnate it with the bait range, but this requires a complicated processing process. Not only that, but the finished product is thick and heavy, making it unsuitable for use as a core material for wall decoration sheets.

When manufacturing a long core material, when a thermoplastic resin film is superimposed on a glass fiber nonwoven fabric and the glass fiber nonwoven fabric is bonded while being heated, the air inside the voids of the glass fiber nonwoven fabric expands, causing the glass fiber film to adhere to the thermoplastic resin film. Bulges that are not bonded to the fibrous nonwoven fabric occur partially.

Flooring materials using such a core material will crack due to walking pressure, and if water or oil is sucked into the interior, debris will peel between the thermoplastic resin film and the glass fiber nonwoven fabric, making it impractical for practical use. cannot be provided. In addition, if the heating temperature is too high during roll pressure, some of the glass fibers that make up the nonwoven fabric will break through the thermoplastic resin film and protrude, creating fuzz on the surface, which will only irritate the human body. During processing, broken pieces of glass fiber (powder) are scattered to the outside from both sides of the thermoplastic resin film along with a portion of the heated and expanded air, seriously harming the working environment. In view of these problems, it is an object of the present invention to provide a core material for decorative sheets that takes advantage of the characteristics of glass fiber nonwoven fabrics, allows easy surface secondary processing, and is suitable for thin materials.

For this reason, the structure of the present invention is such that a thermoplastic resin film with a large number of grade holes is superimposed on both sides of the glass fiber nonwoven fabric and bonded by thermocompression, so that a part of the thermoplastic resin film on both sides fills the voids of the glass fiber nonwoven fabric. The top and bottom are connected and fused together.

According to the present invention, by providing a large number of string holes in advance in the thermoplastic resin film to be bonded, the air inside the glass fiber nonwoven fabric is expelled outside through the string holes during the heating and pressing process using rolls, and the thermoplastic resin film completely adheres to the glass fiber nonwoven fabric, resulting in a product with a smooth surface. The glass fiber-free fabric used in the present invention is made by cutting glass fiber monofilaments into predetermined lengths, intertwining them randomly, and bonding them together with a known resin adhesive. A thickness of about 100 ta is suitable.

Such a glass fiber nonwoven fabric is commercially available as GP8025 from Nippon Vilene Co., Ltd., for example. As the thermoplastic resin film, vinyl chloride film is suitable from the point of view of price, etc., but if necessary, resin films such as vinylon, nylon, polyester, acrylic, ethylene-vinyl acetate copolymer, polyethylene, polystyrene, etc. can be used. can. The appropriate thickness of the thermoplastic resin film is about 0.05 to 0.5 mm.

The pongee holes drilled in the thermoplastic resin film have a diameter of 0.5 to 3.
It is sufficient if the distribution density is about 3 enemies horizontally and vertically. The thermoplastic resin film is first made with pongee holes, then heated, superimposed on both sides of the glass fiber non-woven fabric, and pressed between a pressure roll and a heating drum at a pressure of about 3k9/cm, and heated to about 250°C. Temporary welding is performed by heating to ~260 qo. Further, the heating drum is heated from the outside with an infrared heater to fuse the drum under pressure and then cooled. The thermoplastic resin film softens by preheating and adapts well to the uneven (fluffy) surface of the glass fiber nonwoven fabric. When pressed with a pressure roll, the air in the voids of the glass fibers expands and becomes thermoplastic. Since it is expelled from the pongee holes of the resin film, the inner surface of the thermoplastic resin film locally melts into the voids of the glass fiber nonwoven fabric, and is bonded to the melted portion of the thermoplastic resin film on the opposite side.

Since the product is crimped with a pressure roller, a product with a flat surface can be obtained. FIG. 1 shows an outline of a manufacturing apparatus for producing a core material for a decorative sheet according to the present invention.

The glass fiber nonwoven fabric 1 is introduced by a guide roll, is circulated along a preheating drum 4 with a tension roll 3 and a guide roll 5, and is further guided to a heating drum 10. On the other hand, the thermoplastic resin film 6 moves along a perforation roll 20 with a large number of needles implanted in its surface, and after being perforated with a large number of pongee holes, the thermoplastic resin film 6 is transferred to a child heating drum 18 by a tension roll 7 and a guide roll 8. The glass fiber nonwoven fabric 1
and is pressed onto the heating drum 10 using a pressure roll 9. Here, the inner surface is heated by the heating drum 10 and the outer surface is heated by the infrared heater 11, and the expanded air inside the voids of the glass fiber nonwoven fabric 1 is expelled from the holes in the thermoplastic resin film 6 to the outside. After passing through the heating drum 10, the polymer 16 of the glass fiber nonwoven fabric 1 and the thermoplastic resin film 6 is further heated from both sides by the infrared heaters 11 and 12, and the polymer 16 is heated between the rubber roll 13 and the pressure cooling roll 14. The product 19 is fused under pressure and cooled, and wound onto a cooling drum 17 via a cooling roll 15 to form a product 19.

The pressure applied to the polymer body 16 by the pressurized cooling drum 14 may be on the order of 5k9 mm, and the winding speed of the polymer body 16 may be up to approximately 20 mm/min.

Next, the method for manufacturing the core material for decorative sheets according to the present invention will be explained as follows.

After making a large number of pongee holes with a diameter of about 0.5 ribs at intervals of 3 sides in length and width on a soft vinyl chloride film (40 parts, manufactured by Takasago Rubber Industries Co., Ltd.) with a thickness of 0.07 mm, this was Preheated to around 120 degrees Celsius.

On the other hand, a glass fiber non-woven fabric (thickness: 25 mm, product number CP8025, manufactured by Nippon Vilene Co., Ltd.) was similarly heated to about 120°C, and the above-mentioned soft vinyl chloride film was superimposed on both sides of the fabric, and heated at a temperature of 260°C and a pressure of 5 k9/cm. After being fused under pressure, it was cooled to obtain a product in which European vinyl chloride film was fused to both sides of the glass fiber nonwoven fabric.

The core material for a decorative sheet obtained as described above has a very flat surface, and the presence of pores cannot be visually recognized.

Then, the glass fibers are in close contact with the inside of the vinyl chloride film, and a portion of the vinyl chloride film on both the front and back surfaces is inserted into the voids of the glass fiber nonwoven fabric from the inner surface in an almost spherical shape, as shown in Figure 2. The spherical parts 6a that have melted and bit into each other, or that have melted from both sides, are combined with each other to form a joint part 6.
It is recognized that b is scattered.

In the core material for decorative sheets according to the present invention, the glass fiber non-woven fabric has excellent dimensional stability, and the vinyl chloride films on both the front and back sides bite into the inside of the glass fiber non-woven fabric and are bonded together, so it has no tearing force. Even if added, the vinyl chloride films on both the front and back surfaces will not cause delamination.

Therefore, on the surface of the core material for a decorative sheet according to the present invention,
By laminating printed synthetic resin films or applying a foamed resin-containing coating, it can be used not only as floor coverings and wall materials, but also as accordion curtain materials, underlays for exhibits, heating floor materials, and more. It can also be widely used in fields such as furniture and interior decoration items.

[Brief explanation of the drawing]

FIG. 1 is a schematic configuration diagram of a manufacturing apparatus for a core material for a decorative sheet according to the present invention, and FIG. 2 is a cross-sectional view of the core material for a decorative sheet. 1...Glass fiber nonwoven fabric, 4...Preheating drum, 6...Thermoplastic resin film, 9...
... Pressure roll, 10 ... Heating drum, 1
1, 12... Infrared heater, 14...
Pressurized cooling drum, 18... Preheating drum, 20.
...Perforated roll. Figure 1 Figure 2

Claims (1)

[Claims] 1. Thermoplastic resin films with a large number of pores are superimposed on both sides of a glass fiber nonwoven fabric and bonded by thermocompression, and parts of the thermoplastic resin films on both sides communicate with each other in the voids of the glass fiber nonwoven fabric and are fused. A core material for decorative sheets characterized by: