JPH0794150B2 - Method for producing decorative surface coating material - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a decorative surface coating material laid on a floor or the like, and more specifically, three layers of a skin layer intermediate layer and a base material layer. The present invention relates to a method for producing a decorative surface covering material having a structure.

The present invention is mainly used for manufacturing building materials such as flooring materials and interior materials.

[Conventional technology]

Conventionally, vulcanizable rubber powder composed of two or more colors
A method of forming a laminated rubber plate by spreading and filling the entire surface of a vulcanization mold cavity, placing an unvulcanized rubber plate of the same shape as the mold cavity surface on it, and pressurizing and heating with a press vulcanizer. Is disclosed.

For example, in JP-A-59-187850, a vulcanizable rubber powder composed of two or more colors is spread and filled into the entire surface of a vulcanization mold cavity, and the same shape as the mold cavity surface is formed on the vulcanization mold cavity. A method for forming a laminated rubber plate, which comprises stacking vulcanizable unvulcanized rubber plates on top of each other, pressurizing and heating them with a press vulcanizer, and laminating and vulcanizing them. 1) is disclosed, and in Claim 3 thereof, 300 to 1500 parts by weight of vulcanized rubber particles, 100 parts by weight of natural or synthetic rubber, a desired amount of vulcanizing agent, and vulcanization accelerator are disclosed. Agent, reinforcing agent, softening agent, colorant and other chemicals for rubber are mixed and kneaded with a kneader to give a mono-colored or multi-colored vulcanizable rubber powder. Disclosed is a method for forming a laminated rubber plate according to claim 1, which is a laminated rubber plate.

However, this invention has the following problems. That is, (1) a so-called two-layer structure in which vulcanizable rubber powder is used for the skin layer side and an unvulcanized rubber plate is used for the base material layer,
Due to the difference in the compounding design of the surface layer material and the rubber plate of the base material and the difference in the shape of the finish, there are problems in warpage and dimensional accuracy due to the difference in dimensional shrinkage after vulcanization, and there is a problem in terms of quality stability.

(2) 300 to 15 per 100 parts by weight of natural or synthetic rubber
This is a composition in which 00 parts by weight of vulcanized rubber powder is mixed.

In this configuration, since the ratio of natural or synthetic rubber is high, the vulcanizable rubber powder after kneading has high tackiness and agglomerates, so that the spreading work in the mold cavity is difficult and the work efficiency is extremely poor.

(3) Due to the above (2), that is, since the compounding ratio of the natural rubber or the synthetic rubber is high, the vulcanized rubber powder is submerged in the rubber, and a clear color does not appear on the surface. or,
Due to the high rubber content, the four corners of the product are likely to have a flow pattern, and it is difficult to form a uniform pattern.

(4) Fine powder of vulcanized rubber powder colored due to a high ratio of natural rubber or synthetic rubber is mixed in natural rubber or synthetic rubber, and it becomes difficult to obtain a constant color.

[Problems to be Solved by the Invention]

The present invention is to solve the problems of the prior art as described above, by using vulcanizable rubber particles for both the skin and the base material layer, dimensional stability is obtained without anisotropy, Moreover, it is to establish a technique for producing a decorative surface coating material that is free from warpage and that allows a clear multicolor pattern to appear on the surface.

[Means for solving the problem]

As a result of intensive studies on the above problems, the present inventors have made a three-layer structure of a skin layer, an intermediate layer, and a base material layer, and drastically reduce the compounding ratio of natural rubber or synthetic rubber to vulcanized rubber particles. The present invention has been made to find that vulcanizable rubber particles can be obtained even if the above is performed, and the present invention has been completed. The present invention comprises 1. (i) vulcanizing a rubber composition containing various fillers and pigments. Preparing a vulcanized rubber plate of a single color or a plurality of colors, (ii) crushing the vulcanized rubber plate to produce vulcanized rubber particles, (iii) activating the surface of the vulcanized rubber particles Then, kneading the compounded mixture with a desired amount of a vulcanizing agent, a vulcanization aid, and other rubber chemicals to produce vulcanizable rubber particles, (iv) defining a predetermined shape space The vulcanizable rubber particles forming a skin layer are spread and filled on the entire surface of the concave mold cavity, and the mold cavity A non-vulcanized rubber plate that covers the surface of the mold and forms an intermediate layer with a size reaching the mold contact surface, and (v) then contacts the unvulcanized rubber plate to form the base layer. A method for producing a decorative surface coating material, which comprises spreading and filling vulcanizable rubber particles to be formed, and then tightening a convex mold and heating under pressure. 2. The method for producing a decorative surface coating material according to claim 1, wherein the skin layer is 5 parts by weight or less per 100 parts by weight of the vulcanized rubber particles, a natural or synthetic rubber, a desired amount of a vulcanizing agent, and a vulcanization aid. The present invention relates to a method for producing a decorative surface coating material, which comprises using vulcanizable rubber particles obtained by kneading a mixture containing a chemical agent for rubber such as an agent.

The vulcanized rubber plate used in the present invention produces vulcanized rubber such as sulfur, vulcanization accelerator, antiaging agent, calcium carbonate oil, etc., in addition to pigments selected so as to exhibit a desired pattern, color and the like. It is basically manufactured by mixing a rubber chemical which is usually used for this purpose with rubber, but a used vulcanized rubber plate may be used.

In the present invention, the vulcanized rubber plate is crushed into particles, and it is preferable that the vulcanized rubber plate has passed through a sieve having a particle size of 10 mm or less. In the present invention, the particles produced in this step are used as "vulcanized rubber particles".

In the present invention, the vulcanized rubber particles are stirred at an appropriate temperature to activate the surface, and the temperature at that time is preferably in the range of 150 to 220 ° C. This activation step is also one of the features of the present invention. In this step, a Henschel type mixer is used to cut the sulfur bridges between rubber molecules by friction heat of vulcanized rubber particles and oxygen in the air. The oxidative polymerization on the surface of the vulcanized rubber particles progresses to a vulcanizable activated state, and the central portion becomes a vulcanized rubber state. Therefore, natural rubber or synthetic rubber is not added, or vulcanized rubber particles
The vulcanized rubber particles whose surface has been activated in this activation step can be vulcanized in addition to sulfur and vulcanization accelerator. A vulcanizable rubber composition is prepared by compounding with various kinds of rubber chemicals usually used for producing rubber. In the present invention, this vulcanizable rubber composition is used under the term "vulcanizable rubber particles".

In the present invention, the vulcanizable rubber particles are used as a constituent material for the skin layer material and the base material layer. That is, when it is desired to impart a colored scattered pattern to the skin layer of the final product of the present invention, vulcanizable rubber particles produced from vulcanized rubber particles produced by blending a pigment of a desired color are used. , One color or several colors are mixed and used as the material for the skin layer, depending on the design of the color pattern to be exposed.

The vulcanizable rubber particles used as the material of the base material layer of the present invention are advantageous because the cost can be reduced if a used vulcanized rubber plate or a waste tire is manufactured as a raw material. That is, after crushing the used vulcanized rubber into particles that have passed through a sieve of 10 mm or less and activating the surface, sulfur, vulcanization accelerator, etc. are compounded together with a rubber chemical usually used for producing a vulcanized rubber. The vulcanizable rubber particles produced in this manner are suitable as a material for the base material layer.

The vulcanizable rubber particles for the skin layer produced in this way are spread-filled in a concave mold cavity defining an appropriate shape space prepared in advance. Then, after placing an unvulcanized rubber plate having a thickness of 0.5 to 1.0 mm formed larger than the mold cavity surface on this, spread vulcanizable rubber particles for the base material layer on the rubber plate surface. A decorative surface coating material having a three-layer structure of a skin layer, an intermediate layer, and a base material layer is manufactured by extending and filling, clamping and heating under pressure.

Further, in the present invention, it is suggested that natural or synthetic rubber is added within a range of 5 parts by weight or less to 100 parts by weight of vulcanized rubber particles in the production process of vulcanizable rubber particles. By doing so, the bond between the vulcanizable rubber particles becomes strong. The addition of this natural rubber or synthetic rubber is arbitrarily selected depending on the purpose and application.

Although the basic configuration of the present invention has been described above, the most important feature of the present invention is that vulcanizable rubber particles are used as the constituent material of the skin layer and the base material layer, and an unvulcanized rubber plate is used as the intermediate layer. It is fully understood that there is something to do.

In the present invention, there is a particularly important aspect by selecting the physical properties and morphology of the vulcanized rubber particles and the vulcanizable rubber powder. For example, when vulcanized using a vulcanized rubber particle having a wide range of particle size distribution and a wide range of particles passing through a sieve having a particle size of 10 mm, the surface of the vulcanizable rubber particle is in a vulcanizable activated state. However, since the central part is in the state of vulcanized rubber, when vulcanized using a mold with a smooth surface, uneven shapes are expressed and appear on the surface, so there is a deep design effect and surface anti-slip Sex is also obtained. In addition, the skin layer of the molded article of the present invention produced by using transparent vulcanized rubber particles has a rich depth of color, and by coloring the intermediate layer, a more complex color effect and optical effect can be obtained. Be effective.

[First Embodiment] The present invention will be described in detail below with reference to the drawings. The parts are those based on weight.

(Manufacture of vulcanized rubber particles) Compounding component part NR 30 SBR 70 Sulfur 2.5 Sulfuric acid accelerator 2 Stearic acid 1 Anti-aging agent 2 Zinc white 5 Oil 10 Calcium carbonate 80 Silica 20 White pigment 1 Total 223.5 Knead the above mixture Then, it is rolled and a rubber plate with a thickness of approximately 15 mm is prepared. This was vulcanized to form a vulcanized rubber plate, and this plate was crushed by a crusher to produce white vulcanized rubber particles that passed through an 8-mesh screen.

(Production of Vulcanizable Rubber Particles) The vulcanized rubber particles produced by the above-mentioned formulation are stirred at a temperature of 150 to 220 ° C. with a Henschel type mixer to activate their surface, and then cooled to obtain the following symbols. Vulcanizable rubber particles were produced by kneading in a ratio. Compound component part Vulcanized rubber particles 100 Sulfur 2 Vulcanization accelerator 2 Zinc white 3 Stearic acid 1 Coumaron resin 3 Total 111 (Production of vulcanizable rubber particles for base material layer) Vulcanizable produced by the above method Although different rubber particles may be used as the material for the base material layer, the used vulcanized rubber was used to manufacture the material for the base material layer in order to reduce the cost. That is, after crushing the vulcanized used rubber molding, after activating by the same method as above,
Vulcanizable rubber particles for the base material layer were produced by the following formulation. Compound component part Vulcanized rubber scrap particles 100 SBR 5 Sulfur 2 Vulcanization accelerator 2 Zinc white 3 Stearic acid 1 Coumaron resin 3 Calcium carbonate 20 Total 136 (Production of unvulcanized rubber plate for intermediate layer) Compound component part NR 70 SBR 30 Sulfur 3 Vulcanization accelerator 2 Stearic acid 1 Coumaron resin 5 Zinc leather 5 Titanium oxide 3 Calcium carbonate 30 Hard clay 70 Process oil 10 Total 229 Knead the mixture of the above mixture and roll it to a thickness of 1 mm An unvulcanized rubber plate that covers the mold cavity surface and is cut into a size that reaches the mold contact surface 9 is prepared.

(Manufacture of decorative surface coating material) As shown in FIG. 2, rubber particles 6 capable of being vulcanized to a depth of 6 mm are spread and filled into a cavity of a concave mold 4 having a depth of 30 mm so as to be substantially uniform. After that, the unvulcanized rubber plate 7 is placed.
As shown in FIG. 2, the unvulcanized rubber plate 7 contacts the vulcanizable rubber particles 6 in the central portion, and its end face is placed so as to slightly contact the rising die contact surface 9. Then, vulcanizable rubber particles 8 that form a base material layer in contact with the rubber plate 7 are spread and filled up to the upper surface of the cavity, the convex mold 5 is closed, and the vapor pressure is 5 kg / cm ² by a press vulcanizer. By heating for 15 minutes, a decorative surface coating material having a three-layer structure of a skin layer 1, an intermediate layer 2 and a base material layer 3 as shown in FIG. 1 was produced.

[Example 2] In the compounding component table described in the production of the vulcanized rubber particles of Example 1, the white pigment was replaced with black and brown respectively, and Example 1
White, black and brown vulcanized rubber particles were produced by the same procedure as described above.

Then, these three colors of vulcanized rubber particles were treated with white by the same method as in the production of the vulcanizable rubber particles described in Example 1.
Black and brown vulcanizable rubber particles were produced respectively. The white, black and brown vulcanizable rubber particles are then 8: 1: 1.
To produce vulcanizable rubber particles 6 forming a skin layer. The vulcanizable rubber particles thus produced are spread-filled into the cavity of the concave mold 4 having a depth of 30 mm to a depth of 6 mm so that the surface becomes substantially uniform. Then, similarly to Example 1, the unvulcanized rubber plate 7 and the vulcanizable rubber particles 8 forming the base material layer are sequentially placed, press-vulcanized after mold clamping, and white, black and brown are applied to the skin layer. A flooring material was produced in which the particles were dispersed and exposed in a pattern.

〔The invention's effect〕

1. In the manufacturing process of vulcanizable rubber particles forming a skin layer,
Since the addition ratio of the natural or synthetic rubber component to 100 parts by weight of the vulcanized rubber particles is at most 5 parts by weight or less, the vulcanizable rubber particles have weak adhesion and do not aggregate. Therefore, the work of spreading and filling in the mold cavity is easy, and the work efficiency is greatly improved compared to the conventional method.

2. As described in 1 above, the vulcanizable rubber particles do not sink in the binder because the proportion of rubber added is small. Therefore, the color of the vulcanized rubber particles appears clearly.

3. Since the vulcanizable rubber particles are used for both the skin and the base material layer, the difference in shrinkage rate and anisotropy during vulcanization are small, and the product does not warp. Therefore, the dimensional accuracy is greatly improved and the quality is improved.

4. Since the intermediate layer is interposed, the vulcanizable rubber particles forming the base material layer are prevented from being mixed into the skin layer and disturbing the pattern pattern and color design. Further, by interposing the intermediate layer, it is possible to reduce the cost because the skin layer using the vulcanizable rubber particles colored at high cost can be thinly formed. Further, the skin layer and the base material layer are strongly bonded to the intermediate layer, which has the effect of improving the overall strength.

5. The unvulcanized rubber plate was formed to be larger than the cavity surface of the concave mold. With this configuration, the material forming the base material layer does not flow out to the skin layer side along the side surface of the mold, so that the product is prevented from being contaminated and the quality is improved.

[Brief description of drawings]

The drawings show one embodiment of the present invention. FIG. 1 is a perspective view of the product of the present invention, and FIG. 2 is an explanatory view showing a state where materials are charged into a mold. 1 ... skin layer, 2 ... intermediate layer 3 ... base material layer, 4 ... concave mold 5 ... convex mold 6,8 ... vulcanizable rubber particles 7 ... unvulcanized rubber plate 9 ...... Mold contact surface

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Claims (2)

[Claims] 1. A vulcanized rubber plate of a single color or a plurality of colors obtained by vulcanizing a rubber composition containing (i) various fillers and pigments, and (ii) crushing the vulcanized rubber plate. To produce vulcanized rubber particles, (iii) after activating the surface of the vulcanized rubber particles, a mixture containing a desired amount of a vulcanizing agent, a rubber chemical such as a vulcanization aid, and the like is added. Kneading to produce vulcanizable rubber particles, (iv) spread-filling the vulcanizable rubber particles forming a skin layer on the entire surface of a concave mold cavity defining a predetermined shape space, An unvulcanized rubber plate, which covers the mold cavity surface and forms an intermediate layer with a size reaching the mold contact surface, is placed thereon. (V) Then, the unvulcanized rubber plate is brought into contact with the unvulcanized rubber plate. , A decorative table characterized in that after the vulcanizable rubber particles forming the base material layer are spread and filled, the convex mold is closed and heated under pressure. Method for producing a dressing. 2. The method for producing a decorative surface coating material according to claim 1, wherein the skin layer is 100 parts by weight of the vulcanized rubber particles,
It is characterized in that vulcanizable rubber particles obtained by kneading a mixture of 5 parts by weight or less of a natural or synthetic rubber and a desired amount of a vulcanizing agent, a vulcanization aid and other rubber chemicals are kneaded. A method for producing a decorative surface coating material.