JPS6043477B2 - Flooring manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to flooring materials, and relates to a method for manufacturing a new flooring material that has improved dimensional stability, water resistance strength, and interlaminar strength, which are particularly required properties for flooring materials. Therefore, it is intended to ensure dimensional stability, and to ensure water resistance strength and interlaminar strength by integrating the vinyl chloride film and vinyl chloride plastisol.

1. Conventionally, sheets of asbestos paper coated with vinyl chloride plastisol have been used for flooring, especially PVC flooring.

However, although this material has excellent properties in terms of dimensional stability, it was not able to obtain satisfactory performance in terms of adhesion between vinyl chloride and asbestos paper, and the delamination strength and water resistance of the asbestos paper itself. . In order to solve this problem, a method was adopted in which vinyl chloride plastisol was applied to the glass non-woven fabric, but this method had the disadvantage of causing a phenomenon called "bleed-through" in which the vinyl chloride plastisol seeped into the back side of the glass non-woven fabric. .

For this reason, a regular knife coater or reverse coater cannot provide a stable coating thickness and a smooth coating surface, and is also economically disadvantageous in terms of machine speed. Therefore, a special device is used that double coats the nonwoven fabric base material on a coater head, but even with this method, the drawbacks of the conventional method could not be completely eliminated. The present invention has been made in view of the above points.

In the present invention, as a result of repeated studies to solve the problem of "bleed through", we have found that by applying vinyl chloride plastisol onto a sheet made by laminating vinyl chloride film and glass nonwoven fabric, there is no "bleed through" and the dimensional stability is improved. They succeeded in obtaining a flooring material with excellent water resistance and interlaminar strength. That is, dimensional stability, especially dimensional stability during heating, was ensured by the glass nonwoven fabric, and water resistance and interlaminar strength were ensured by the penetration of vinyl chloride plastisol into the glass nonwoven fabric. In addition, when vinyl chloride platisol is applied to the vinyl chloride film surface of a two-layer sheet of glass nonwoven fabric and vinyl chloride film, and when vinyl chloride platisol is applied to a three-layer sheet, vinyl chloride platisol and vinyl chloride film, but since both are made of vinyl chloride, sufficient adhesive strength can be obtained.Also, regarding "bleed-through", vinyl chloride film I was able to solve the problem. Next, a method for laminating a glass nonwoven fabric and a vinyl chloride film, a method for applying vinyl chloride plastisol, and their materials will be described.

Glass nonwoven fabric is composed of glass fibers and a binder.
There are products on the market with a basis weight of 10y/d to 200y/r, but in the present invention, 20y/r! l to 8
A range of 0y/d is optimal.

As binders, thermoplastic resins such as acrylic resins, nylon resins, and vinyl chloride resins, and thermosetting resins such as PVA resins, phenol resins, epoxy resins, and melamine resins can be used. Since heat resistance is required, thermosetting resins such as PVA resin, phenol resin, epoxy resin, and melamine resin are optimal. Next, the vinyl chloride film to be laminated to the glass nonwoven fabric is generally called a soft vinyl chloride film or a semi-hard vinyl chloride film, and the amount of plasticizer added is 2 parts to 5 parts, and the thickness is about 50 μm to 200 μm. Although optimal,
It is not limited to this range. The glass nonwoven fabric and the PVC film can be laminated by a heat fusion method or by using an adhesive.

The former is a method of thermally softening either the vinyl chloride resin constituting the vinyl chloride film or the binder in the glass nonwoven fabric, or both, to fuse the vinyl chloride film and the glass nonwoven fabric under heat and pressure. The latter includes emulsion adhesives such as vinyl acetate emulsion, acrylic emulsion, ethylene acetate emulsion,
Solvents such as urethane, salt vinyl acetate, and ethylene vinyl acetate. There is a method of adhesion using a type of adhesive, and the latter is superior in terms of adhesive strength. Next, talking about how to apply vinyl chloride plastisol, vinyl chloride plastisol comes in foamed and non-foamed types, and has cushioning properties. In the case of the required flooring material, foamed vinyl chloride sol is applied on the laminated sheet to a thickness of about 0.1 to 0.5 TWL, and heated at 130 to 150°C for about 30 to 1 AC. Bring the foamed vinyl chloride sol to a semi-gelled state.

Next, gravure printing, screen printing, (rotary printing)
Patterns are applied by multicolor printing (including screen printing) or transfer printing. The pattern can be selected from abstract patterns, geometric patterns, wood grain patterns, or any other pattern, and the ink can be vinyl chloride ink or other. Furthermore, when manufacturing embossed products, anti-foaming ink is used in desired embossed areas. This ink uses foaming suppressants such as trimellitic anhydride and phthalic anhydride disclosed in Japanese Patent Publication No. 43-28636. If cushioning properties are not particularly required, non-foamed vinyl chloride plastisol is semi-gelled and patterned in the same manner as the foamed vinyl chloride sol.

) Also, using a screen printing method (including a rotary screen printing method), a pattern can be directly applied to the laminated sheet using a colored vinyl chloride plastisol paste ink.

In order to obtain an embossed product using this method, the number of lines (mesh) of the plate forming the convex portions and the plate forming the concave portions must be changed, or the convex portions must be foamed. A colored vinyl chloride plastisol paste ink containing a foaming agent is used, and a colored vinyl chloride plastisol paste ink that does not contain a foaming agent is used for the recessed portions. After these printings, a pattern is printed on the surface. Apply clear vinyl chloride plastisol to protect the area.

This vinyl chloride plastisol contains approximately 30 to 100 parts by weight of a plasticizer, and may or may not contain a transparent pigment. Opaque pigments are not preferred because they hide the pattern. Next, this is heated to foam the foaming type plastisol and the paste ink containing a foaming agent, and completely gelatinize the non-foaming type plastisol and the paste ink that does not contain a foaming agent, as well as the transparent plastisol on the surface. At the same time, it is gelled to obtain flooring material.

The flooring material manufactured in the manner described above has excellent dimensional stability, water resistance strength, and interlaminar strength, and exhibits surface properties comparable to conventional products.The manufacturing process also requires changes to conventional equipment. There are some products that can be used to manufacture flooring without having to do so.

Example 1 A soft vinyl chloride film with a thickness of 0.17 rrm was laminated on a 25 fI/d glass nonwoven fabric using an acrylic emulsion adhesive printing.

Next, foamed vinyl chloride plastisol was applied to the glass nonwoven fabric surface of this laminated sheet using a knife coater for 250 y/w.
Immediately after coating and heating at 150°C for 1 minute, the glass nonwoven fabric is sandwiched between the vinyl chloride film and the foamed vinyl chloride plastisol, and the glass nonwoven fabric is sandwiched between the vinyl chloride film and the foamed vinyl chloride plastisol, and the glass nonwoven fabric is sandwiched between the vinyl chloride film and the foamed vinyl chloride plastisol, and the glass nonwoven fabric is sandwiched between the vinyl chloride film and the foamed vinyl chloride plastisol, and the glass nonwoven fabric is sandwiched between the vinyl chloride film and the foamed vinyl chloride plastisol. The whole is integrated by fusion. Multicolor printing was performed on this using ordinary PVC gravure ink.

Only one type of this ink is trimellitic anhydride 20
A suppressor ink containing % was used. Next, apply transparent vinyl chloride sol to the printing surface using a knife coater for 200y/d.
After coating and heating at 200° C. for 2 minutes, it was immediately cooled. As a result, an uneven decorative PVC flooring material was obtained in which the suppressing ink area was a concave part and the other normal ink area was a convex pattern that matched the pattern. This flooring material has an interlaminar strength of 5.5k9/25
? The dimensional accuracy of the pattern is within 0.05% of the printing plate size in both the vertical and horizontal directions, and the surface properties are comparable to conventional asbestos backing flooring materials, and it is water resistant. The strength was also good. Example 2 A semi-rigid vinyl chloride film having a thickness of 1.0 rm was laminated on a 25y/Bo glass nonwoven fabric using an ethylene vinyl acetate emulsion adhesive.

The conditions at this time were a temperature of 180℃ and a linear pressure of 500k9.
/100cm. Next, a pattern was printed on the glass nonwoven fabric surface of this sheet using a rotary screen printer using colored PVC plastisol ink and colored foamed PVC plastisol ink. The viscosity of each ink is 40
At 00CP, the drying conditions were 15 (generations) and 2 minutes. Next, transparent PVC plastisol was applied to the entire surface using a rotary screen peta plate at a coating rate of 250y/y and heated at 220°q for 2 minutes to obtain a flooring material with unevenness that matched the pattern. Ta. The performance of this flooring material was as good as that of the flooring material obtained in Example 1. Example 3 Between two 0.1 m thick soft vinyl chloride films, 2
A flooring material was obtained in the same manner as in Example 1, except that sheets laminated using an acrylic emulsion adhesive and sandwiching a glass nonwoven fabric of 5y/j1' were used.

Example 4 A flooring material was obtained in the same manner as in Example 1, except that foamed vinyl chloride plastisol was applied to the soft vinyl chloride film surface of the laminate sheet.

Claims (1)

[Claims] 1. Apply vinyl chloride platisol to the glass nonwoven fabric side or the vinyl chloride film side of a sheet made of a laminated glass nonwoven fabric and vinyl chloride film, or apply a three-layer laminated sheet with a glass nonwoven fabric sandwiched between two vinyl chloride films. A method for producing a flooring material, which comprises applying vinyl chloride plastisol on the upper surface and then integrating the vinyl chloride plastisol and the laminated sheet by heating.