JPS6315395B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel elastic floor covering with decorative properties and a method for manufacturing the same, and more specifically, the present invention relates to a decorative layer made of various colored synthetic resin strips pressed into a sheet shape. The present invention relates to a decorative elastic floor covering having a foam sheet layer laminated thereon and having a concavo-convex drawing pattern on the surface of the decorative layer that matches the shape of colored synthetic resin strips, and a method for manufacturing the same.

Conventionally, as a floor covering with a foam layer,
A well-known floor covering is made by the so-called chemical embossing method, as typified by Publication No. 28636.As shown in Figure 4, the floor covering made by this method has foam formed directly under the transparent protective film 21. There are a printed pattern 22 made of printing ink containing an inhibitor and a printed pattern 23 made of normal printing ink.The printed pattern part made of the printing ink containing a foaming suppressant forms a concave part 25 as the foaming 24 is suppressed, and the printing pattern 23 is made of a printing ink containing a foaming suppressant. The printed pattern part formed by the printing ink undergoes normal foaming to form convex parts 26, resulting in a beautiful floor covering in which the printed pattern and the concave-convex pattern are completely in sync with each other. The foam layer 24 is formed into an uneven shape as described above, and the convex portions are normally foamed, so it exhibits a corresponding cushioning property, and an asbestos sheet with high cushioning properties is used as the backing layer 27. Therefore, the floor covering as a whole exhibits appropriate elasticity.

However, the problem with this method is that the transparent protective layer must be thin (if it is too thick, the appearance of the uneven pattern will slow down), and as a result, the wear resistance, which is most important for a floor covering, is extremely poor. accompanies.

In this type of bedding, the longevity of the transparent protective layer determines the lifespan of the bedding. In addition, since the surface has an uneven pattern corresponding to the unevenness of the foam layer, the convex parts that come into contact with the shoe wear out much faster than the concave parts, and as a result, the lifespan is extremely shortened.

In view of these circumstances, the present invention aims to provide a floor covering that has excellent abrasion resistance and durability, is highly decorative, and has excellent cushioning properties. layer 1
A thermoplastic transparent synthetic resin such as a polyvinyl chloride resin paste is used as the material and applied onto the release paper 31.

The release paper 31 is normally smooth and glossy, but if a floor covering with a dull finish that does not shine on the surface is desired, a release paper with fine irregularities (for example, a satin finish) is used. Also good. The polyvinyl chloride resin paste 1 is coated with a fixed roll type applicator 32, 33 using comma-shaped rolls at 0.15~
It is applied to a thickness of about 0.20m/m, and an electric heater 34
Heating by. After gelling, several types of colored synthetic resin strips 2', 2'', 2... having a two-layer structure, which will become the decorative layer 2, are dropped onto the top surface from the hopper 35, and then spread by spreading devices 36, 37. It is spread to a predetermined thickness.The roll 36 in the spreading device is a reverse roll, and a gap is set at a constant interval between it and the roll 37. It has a mechanism that scrapes off the pieces ', 2'', etc. and spreads the strips to a predetermined thickness.

The colored synthetic resin strip has two main colored layers a and another layer b.
It has a layered structure, and the main colored layer a is colored in the basic color of the floor covering, and is heated. Does not deform too much when compressed. The other layer b is composed of a compounded composition having a higher softening temperature than that of the main colored layer a so as not to flow, and the other layer b is composed of a compounded composition having a lower softening temperature than the main colored layer a. It is a colorless transparent or colored transparent layer that is colored differently than the original color and heated. When compressed, it softens more significantly than the main colored layer a, and deforms due to the pressing force during compression. Since the flow is large, the fusion of the pieces is easy and good, and the filling effect is high, filling the gaps between the pieces.
A dense floor covering can be obtained.

The particle size of the colored synthetic resin strips 2', 2'', 2... differs slightly depending on how the decorative layer 2 is designed, but approximately 0.5 to 5.0 mm is suitable. If there are too many particles, the decorative layer will have a subdued appearance similar to a plain object, but the decorativeness will be poor.If there are many coarse particles, the shape of each strip will form a pattern, resulting in a decorative layer with high decorativeness. 2 is obtained, but the densification is somewhat poor.Therefore, if fine particles with a particle size in the range of 0.5 to 5.0 mm or 2.5 to 5.0 mm are used in a mixed state, a dense decorative layer 2 with few voids can be obtained. .

The amount of spreading by the spreading device also varies depending on the thickness of the decorative layer 2, but when the sheet thickness after pressing is 1.5 to 1.8 mm, the gap between the rolls 37 and 36 is
A clearance of 2.5 to 3.0 times is taken and set to about 3.75 mm to 5.4 mm, and an appropriate spreading amount is 2 to 3 Kg/m ² .

After spreading the colored synthetic resin strips 2', 2''... on the gelled surface layer 1 in this way, the first heating furnace 3
8 and heat the strips. Soften. The first heating furnace is usually divided into three chambers, and the temperature of each chamber can be controlled independently. In the case of the present invention, it is suitable that the temperature of the first chamber is 195°C, the second chamber is 200°C, and the temperature of the second chamber is gradually raised at intervals of 5°C from 205°C. The spread layer of strips heated in the first heating furnace 38 is immediately compressed between compression devices 39 and 40 to form a sheet having a predetermined thickness of 1.5 to 1.8 mm. This densified sheet is placed on a release paper 31, and after being cooled by cooling rolls 41 and 42, the adhesive 3 is applied onto the sheet by doctor blade type applicators 43 and 44. Instead of the doctor blade 43, a comma-shaped fixed roll system used for coating the surface layer 1 may be used.

Adhesive 3 can be any adhesive such as polyvinyl chloride resin paste, thermosetting acrylic adhesive, reactive polyurethane adhesive, etc., but adhesives with excellent initial adhesion properties that are slightly pressure sensitive are suitable. . After applying the adhesive 3, if necessary, heat it with an electric heater to make it semi-gel or volatilize the solvent.
Next, the synthetic resin foam sheets 4 are laminated together using laminating devices 45 and 46. This synthetic resin foam sheet 4
If necessary, a backing material 6 may be laminated with a flexible foam sheet made of vinyl chloride resin or the like. Further, a structure in which a coarse glass woven fabric 5 is integrally laminated or embedded in the surface or surface layer of the synthetic resin foam sheet 4 may be used. For example, the coarse glass woven fabric 5 laminated on the foam sheet 4 is as shown in Table 1.
A material having physical properties as shown in (a) is suitable and is laminated on the surface of the foam sheet during the manufacturing process of the foam sheet 4. To briefly describe this process, a foamable synthetic resin sheet is introduced into a foaming furnace and heated. Immediately after being foamed and sent out from the foaming furnace, that is, while the synthetic resin foam layer is still sufficiently molten, it is passed through a laminating device and placed on the foam sheet surface while holding the glass woven fabric on the pressed metal roll surface. Supply and laminate.

At this time, by adjusting the gap between the pressing metal roll and the back-up rubber roll, a structure in which the glass woven fabric is placed on the surface of the foam sheet, and a structure in which the glass fabric is sunk and embedded in the foam sheet layer can be obtained. .

After the synthetic resin foam sheets 4 are bonded together, they are passed through a second heating furnace (drying furnace) 47 and heated to harden or gel the adhesive 3 to complete the adhesion between both layers 2 and 4, and at the same time color synthesis. The compressive strain of the resin strips 2', 2''... is released.

It is important to note here that the thermoplastic synthetic resin strips 2', 2'' used in the floor covering of the present invention have a two-layer structure consisting of a main colored layer a and another layer b. Demonstrate.

As mentioned above, one of the important significances of the two-layer structure is that layer b has the effect of filling voids to achieve densification and solid welding of the pieces together, but another important significance is that of the main colored layer a. It's a behavior. The main colored layer a has a higher softening and melting temperature than other layers b, so it is 195 to 205
When a layer of strips is compressed at a temperature of ℃, it deforms to fill the voids between the strips, as in layer b. Deformation of layer b, although no flow is shown. As it flows, it is forced to undergo some deformation (because it is integrated into strips), and as a result, it is cooled through the compression devices 39 and 40 and becomes a sheet-like layer with a smooth surface. However, the compression strain caused by the pressing force applied by this compression device is large, and there is a potential force within the material to restore it to its original strip shape by reheating.

Therefore, the reheating in the drying oven cures or gels the adhesive 3 and completes the bonding.
The result is that the compression strain applied by the compression devices 39 and 40 is released, and the action of restoring the strip to its original shape is rapidly exerted.

As a result, the smooth sheet surface develops irregularities that match the shape of the strips, giving it an appearance and decorative effect that are extremely suitable for use as a floor covering.

Immediately after the sheet, which has been bonded and released from compressive strain in the drying oven, is sent out from the drying oven, it is blown with cold air at about 15° C. by cold air blowers 48 and 49 to create a structure in which the compressive strain is released. is fixed and sent to the cooling rolls 50 and 51, and even if it comes into contact with the cooling roll surface, it will no longer be deformed (in this case, it means a smooth surface), and the unevenness will match the shape of the strip. A floor covering with a tied pattern and excellent cushioning properties is obtained, and thus the floor covering 52 has a release paper 31.
They are separated from each other and wound up separately.

As mentioned above, the colored synthetic resin strips 2', 2''... have a two-layer structure of the main colored layer a and the other layer b, where the main colored layer a has a higher softening and melting temperature than the layer b, and the layer b has the main colored layer a. It is required that the layer be composed of a compounded composition having a lower softening and melting temperature than layer a.Such expressions are somewhat abstract, but if defined from the point of view of specific compounding technology,
The main colored layer a is a composition in which 100 parts by weight of polyvinyl chloride resin with a degree of polymerization of about 1000 is mixed with about 40 parts of a plasticizer such as DOP and about 100 to 150 parts of a filler such as heavy calcium carbonate. In contrast, vinyl chloride-vinyl acetate copolymer resin with a polymerization degree of about 800 and containing 5% vinyl acetate is suitable as
A blended composition in which about 50 parts of a plasticizer such as DOP and about 50 parts of a filler such as heavy calcium carbonate are added to 100 parts by weight is suitable as layer b. The expressions "softening melting temperature high" or "low" have a relative meaning under the heating temperature in the first heating furnace, so it is difficult to determine them numerically, and it is also difficult to determine them numerically. The relative relationship between the main colored layer a and the other layers b should be determined depending on the degree of flexibility and the like.

In addition to the above-mentioned polyvinyl chloride resin paste, the surface layer 1 may be made of a paste that has been given cigarette resistance by using a reactive plasticizer such as diallyl phthalate, or a reaction-curing urethane prepolymer alone or polychlorinated. Mixtures with vinyl resin pastes are also suitable.

The technical requirements for this surface layer 1 are that it must be in a form that can be coated onto the release paper, i.e. paste, solution,
Or it must be in the form of an organosol,
It should be transparent or translucent to the extent that it does not impede the decorative effect of the decorative layer 2, and it should have appropriate abrasion resistance. Examples include.

Therefore, if this requirement is met, it would be rather welcome to add other properties, such as adding cigarette resistance in the case of PVC paste containing diallyl phthalate, or adding UV-curable paint. When using , the properties of both heel mark resistance and cigarette burn resistance are added.

In addition to the above-mentioned vinyl chloride resin (suspension polymerization straight polymer) and vinyl chloride-vinyl acetate copolymer resin, the main component resins of the colored synthetic resin strips are:
Various so-called PVC copolymer resins, EVA resins, chlorinated polyethylene, acrylic resin modifiers,
Various thermoplastic synthetic resins such as ABS resin and MBS resin can be used alone or in the form of a mixture with other resins, and synthetic rubbers such as NBR and chloroprene can also be used by adding them to the various thermoplastic synthetic resins mentioned above. Can be done.

The production of two-layer structure strips is relatively simple; a sheet to be the main colored layer A and a sheet to be to be the main colored layer B are rolled according to a predetermined composition, and after the two sheets are laminated, they are crushed by a crusher. The particles are sieved into particles with a predetermined size or range. In this case, the thickness of the main colored layer a and the other layer b can be set arbitrarily, but usually the ratio of the thickness of the main colored layer a and the other layer b is in the range of 3:1 to 5:1, and the lamination The thickness of the subsequent sheet is preferably about 1.0 to 2.0 mm in relation to the thickness of the decorative layer. When two sheets are laminated and crushed using an extruder, it can be said to be rational because the steps of sheeting → lamination → crushing can be performed consistently.

The colored synthetic resin strip has two main colored layers a and another layer b.
Although a layered structure is used in principle, a multilayered structure of a, b, c or a, b, a, b may be better in terms of effective use of compressive strain, and this combination is also within the scope of the present invention. It's not something to deviate from.

This means that strip 2' and strip 2'' are colored strips with different colors, and strip 2 is a colored strip that is different from the first two. In this way, there are a wide variety of strips, from single colors to mixed colors. An excellent feature of the present invention is that decorative layers having a variety of colors can be provided relatively easily and in complete forms.

The unevenness of the surface caused by the release of compressive strain provides anti-slip properties, which is an important property of floor coverings, and even if the protrusions wear out, the protrusions are not simply embossed, but are caused by the protrusions of the strips themselves. It can always maintain the same color and decorativeness, and it also has a rough surface effect due to natural unevenness, that is, a desirable dull matte effect without excessive shine, and yet has a natural texture. mud. It has the advantage of being easy to clean without being clogged with dust.

Next, specific embodiments of the present invention will be explained in detail with reference to Examples.

Example (1) Production of colored synthetic resin strips 1 Formulation 1: Main colored layer (a) Vinyl chloride resin (degree of polymerization = 1000) 100 parts by weight DOP 40 Epoxidized soybean oil 2 Stabilizer (powder) 3 Heavy calcium carbonate 150 〃 Brown pigment (titanium white, Bengara, carbon black)
Appropriate amount 2 Blend 2: Layer (b) PVC-vinyl acetate copolymer 100 parts by weight (degree of polymerization = 800, vinyl acetate content 5%) DOP 50 〃 Epoxidized soybean oil 2 〃 Stabilizer (liquid) 3 〃 Heavy Calcium carbonate 50 〃 Light brown pigment (Titanium white. Bengara) Appropriate amount First, mix the formulation 2 with an intensive mixer, heat it thoroughly with a mixing roll and knead it to gel, then apply it to an inverted L-shaped 4-roll calender. A layer b sheet of beige color with a thickness of 0.25 mm is obtained.

Next, Formulation 1 was applied to an upright two-roll calender and rolled into a brown layer A sheet with a thickness of 1.25 mm.
At the same time, layer b sheets were hot laminated using a take-off device.

After cooling, the laminated sheet for the strips is slit into 40 cm width, crushed by a crusher, and sieved to a size of 0.5 cm.
Strips in the ~5.0 mm range were obtained.

(2) Manufacturing formulation for floor coverings 3 Vinyl chloride resin for paste 100 parts by weight DOP 50 〃 Stabilizer (liquid) 4 〃 Viscosity modifier Appropriate amount Adjust the transparent synthetic resin paste (viscosity 5000 cps) for the surface layer according to formulation 3. , on release paper (thickness 0.20 mm, width 1930 mm, weight 180 g/m ² ) with a pear finish.
After applying it to a thickness of 0.15 mm, it is heated with an electric heater to gel.

Colored synthetic resin strips 2' obtained in (1) on gelled paste coatings and strips 2'' of light green (layer a) and white (layer b) produced in exactly the same manner as 1.
A mixture of the following was dropped from the hopper in a ratio of 1:1, and then a layer of strips was spread to a bulk thickness of 4.5 mm using a spreading reverse roll device.

After spreading, the temperature of the first chamber is 195℃, and the temperature of the first chamber and the second chamber is 195℃.
The mixture was introduced into a first heating furnace at 200°C and heated for 5 minutes, and then compressed using a compression device to make it densified. In this case, the thickness including the surface layer was approximately 1.8 mm, the surface had a 60 degree gloss of 28 to 31, and was quite smooth.

After cooling to about 100° C. in a cooling device, the same paste as in Formulation 3 was applied to a thickness of 0.1 mm on the surface of this compressed sheet, and immediately a 1.5 mm thick PVC foam sheet was bonded thereto. A coarse glass woven fabric (manufactured by Kanebo Stevens Co., Ltd., KS5305) with a square opening of 5 mm was embedded in advance on the surface of this PVC foam sheet.
The back side was lined with coarse linen cloth (18 threads per inch).

Then a second heating furnace (drying furnace) heated to 160℃
The adhesive is heated for 3 minutes to gel the adhesive, complete the bonding, and simultaneously release the compressive strain.

Immediately after coming out of the heating furnace, heat to approximately 10℃ from above and below.
After cooling the sheet layer and release paper by blowing cold air, and cooling the sheet surface sufficiently with a cooling roll,
The floor covering and release paper are peeled off and rolled up.

The floor covering obtained in this way is extremely beautiful, with an uneven pattern on the surface that matches the pattern of the strips.
The surface had a dull luster with a 60° gloss level of 10 to 15.

The floor covering according to the present invention has the following characteristics:
That is, the first feature is that since the decorative layer is a densified sheet layer made by compressing colored synthetic resin strips, the decorative effect does not change at all even when abrasion occurs. The second feature is that the decorative layers have different softening temperatures.
Because it uses strips with a layered structure, the sheet has a dense structure with no voids, and the strips adhere perfectly to each other, resulting in a floor covering with excellent wear resistance.

The third feature is that when a laminated glass fabric is used as a foamed synthetic resin sheet, the floor covering has a structure in which the glass fabric is interposed in the middle like a sandwich, so it is difficult to process the floor covering. Also, unnecessary and harmful stretching action does not occur during construction on buildings, so shrinkage after construction is extremely small, and the presence of the glass woven fabric has an added effect of preventing shrinkage. Shrinkage is significantly smaller than that of ordinary foam floor coverings. The fourth feature is that when the strip layer is compressed, the compressive strain stored in the compressed strips is released by reheating, and the surface of the decorative layer has natural irregularities that match the shape of the strips. This makes it possible to provide suitable anti-slip properties and appropriate gloss as a floor covering, resulting in an extremely unique floor covering.

[Brief explanation of the drawing]

The drawings show an example of the implementation of the present invention; Fig. 1 is a sectional view of a floor covering, Fig. 2 is a sectional view of a colored synthetic resin strip, Fig. 3 is an explanatory diagram of the manufacturing process, and Fig. 4 is a conventional one. 1 is a cross-sectional view of a floor covering, in which 1 is a surface layer, 2 is a decorative layer 2', 2'', 2... are synthetic resin strips, 3 is an adhesive, 4 is a synthetic resin foam sheet, and 5 is glass. It is a woven fabric.

【table】

Claims (1)

[Claims] 1. The surface layer is formed of a transparent synthetic resin layer, and
A sheet-like layer made by heating, compressing and compacting colored synthetic resin strips with a two-layer structure is used as a decorative layer, and a synthetic resin foam sheet is attached to the back side of the decorative layer via an adhesive, and heated in a drying oven. A decorative elastic floor covering having a concave-convex concave pattern, characterized in that the compressive strain of the colored synthetic resin strip is released at the same time as the adhesion is completed to form a concave-convex concave pattern that matches the shape of the strip. . 2. The decoration having a concavo-convex drawing pattern as described in item 1 above, characterized in that the synthetic resin foam sheet has a glass woven fabric integrally laminated or embedded in the surface or surface layer that is bonded to the adhesive. Elastic floor covering. 3. A method for producing a decorative elastic floor covering having a concave-convex pattern, characterized by the following steps: First step: Applying a transparent synthetic resin solution or transparent synthetic resin paste to the release surface of the release paper and drying or gelling it. Second step: Applying colored synthetic resin strips with a two-layer structure to a gel coating. Third step: Next, the colored synthetic resin strips are supplied to the first heating furnace to be heated and softened, and immediately after being sent out from the heating furnace, the softened strips are passed between compression rolls. Process of compressing and compacting to form a sheet Fourth process: Process of applying adhesive to the upper surface of the strip sheet and pasting the foamed synthetic resin sheet together Fifth process: The laminate obtained in the fourth process is The process of drying or gelling the adhesive by placing it in a heating furnace and simultaneously heating the colored synthetic resin strips to release the compressive strain Sixth process: The laminate is placed in a cooling device without passing through a pressure roll. After cooling, the release paper is peeled off and each piece is rolled up.Step 4: The colored synthetic resin strips have a two-layer structure, one layer is the main colored layer, the softening melting temperature is higher than the other layer, and the other layer is The layer is a colored layer or a transparent layer that is different from the main colored layer, has a softening temperature lower than the main colored layer, and has the property of softening significantly more than the main colored layer when heated and compressed, transforming into molten metal, and flowing. 4. A method for manufacturing a decorative elastic floor covering having a concavo-convex pattern according to item 3 above.