JPS6040977B2 - Decorative sheet manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative sheet having a unique cotton-like suminagashi pattern mixed with multiple colors.

This type of decorative sheet includes what is called a marble-like patterned sheet, and these can be manufactured by surface printing, or by heating a mixture of colored thermoplastic resin particles in several colors on a calendar roll. There was a method of supplying it and rolling it into a sheet.

However, with surface printing, the pattern lacks depth;
In addition, because the printed layer is thin, it cannot be used in applications that require abrasion resistance, such as flooring, and those processed by calendar processing are Only a simple flow pattern can be created, and it is necessary to prepare coarse particles made by crushing sheets of multiple colors or pellets of multiple colors and mix and heat them together, which requires a large amount of man-hours and costs. Therefore, it had drawbacks such as being expensive. The object of the present invention is to eliminate the above-mentioned drawbacks and to provide a method for easily and inexpensively producing a sheet having a unique striped suminagashi pattern penetrating the surface layer in which multiple colors are mixed. .

That is, in the present invention, a plastisol colored according to the color pattern to be revealed is supplied onto a non-peelable base material or a peelable base to form a plastisol layer with a substantially constant thickness,
Further, one or more plastisols colored in a different color from the plastisol are supplied to the plastisol layer in a dot-like manner at a substantially constant density using a dot-like supply device such as an air spray gun, and/or , the base material or base is supplied in a linear manner using a linear supply device having a plurality of nozzle holes arranged in a direction perpendicular to the traveling direction of the base material or base. A rod-shaped object that performs circular motion, on which a polychromatic dispersion plastisol layer is formed, and a plurality of the polychromatic dispersion plastisol layers are subsequently arranged in a direction perpendicular to the direction in which the substrate travels;
Alternatively, by mechanically stirring using a stirring tool such as a comb-like blade that reciprocates in a direction perpendicular to the direction in which the base material or base moves, the polychromatic dispersion plastisol layer can have complex multicolors. The plastisol layer is heated to gel using a heating device such as a far-infrared heater, and a non-peelable base material is used. If a peelable base is used, a beautiful decorative sheet can be produced by peeling the decorative layer from the base after heating and gelling it. The content is a method for manufacturing. The non-peelable substrate used in carrying out the production method of the present invention may be of any type as long as it is in the form of a flat plate, such as PVC extrusion molded sheet, PVC
VC calender molded sheet, asbestos sheet and PVC
Covered glass non-woven fabric etc. can be used.

The removable base may be any material as long as it has a heat resistance of 18,000 or higher, is flat, and has surface removability, such as Teflon-impregnated glass cloth, silicone-treated heat-resistant machine paper, Stainless steel belts etc. can be used. Next, the plastisol used in the practice of the present invention is made by dispersing and mixing PVC paste resin in a plasticizer such as DOP, adding stabilizers, fillers, etc., and adding pigments of various amounts and colors and mixing. It is preferable to appropriately select and use plastisol from among these depending on the desired color pattern, but non-colored plastisol can also be used.
In addition to the usual pigments, various decorative components such as metal powders, colored beads, scales or mineral powders can also be used. Next, as a method for supplying plastisol onto a substrate or a base to form a plastisol layer with a substantially constant thickness, any method that can form a layer with a substantially constant thickness may be used. Alternatively, a liquid coating machine such as a knife coater, spray coater or curtain coater can be used.

Furthermore, as a method for supplying plastisol in dots with a substantially constant density, it is preferable to spray the plastisol with one or more air spray guns attached to the base material or base, but supplying the plastisol with a roll sprinkle coater etc. It is also possible to use another method. When supplying using an air spray gun, the amount of plastisol supplied can be adjusted by adjusting the pressure for pumping the paste sol or by adjusting the opening degree of the flow rate adjustment valve provided in the plastisol supply path. Furthermore, the size of the dotted pattern can be adjusted by adjusting the pressure of the spraying air using a pressure regulating valve or the like. Furthermore, in order to supply the spray at a substantially constant density throughout the base or base, the air spray gun may be reciprocated in a direction perpendicular to the direction of movement of the base or the base. Preferably, as a method for supplying plastisol in a linear manner with a substantially constant density, small openings are provided at regular intervals at the bottom of a plastisol tank having a rectangular plane, which is arranged perpendicularly to the direction in which the base material or base moves. The plastisol may be allowed to fall naturally through the nozzle hole, or the plastisol tank may be sealed and a back pressure may be applied to the plastisol using pressurized air. It is also possible to adopt a method in which plastisol is supplied under pressure with a pump to a pipe having a plurality of nozzle holes at its lower part, which is arranged perpendicularly to the pipe. The plastisol supply methods described above may be used alone or in combination.

Next, in carrying out the manufacturing method of the present invention, it is preferable that a plurality of stirring tools used for mechanically stirring the polychromatic dispersed plastisol layer are arranged in a direction perpendicular to the direction of movement of the base material or base. A rod-shaped object that makes circular motion by lightly touching the base material or base surface, or a rod-shaped object that is installed in a direction perpendicular to the direction of movement of the base material or base material and is attached to the base material or base surface. A comb-like blade that reciprocates with light contact is used, but a stirring tool such as a wire brush may also be used. In addition to circular motion or reciprocating motion, the stirring motion can be made into continuous motion by using a complex-shaped cam or by using an electrical control system. These stirring tools can be used alone or in combination. Further, a far-infrared heater is preferably used as the heating device used in carrying out the present invention, but other heating devices such as a hot air stove, a microwave heating furnace, etc. may also be used.

Furthermore, in order to further enhance the appearance of the decorative sheet manufactured by carrying out the manufacturing method of the present invention, the surface of the sheet may be embossed with various shapes and depths by passing it through an embossing roll, or may be printed with valley prints. Various valley print patterns may be applied using a machine.

According to the manufacturing method of the present invention, as described above, it is possible to combine plastisol colors, select or combine plastisol supply methods, adjust plastisol supply amount, adjust plastisol supply form, and reduce stirring odor. It is possible to change the color pattern infinitely by selecting or combining them appropriately, and in addition, by selecting and using the base material or base as appropriate, a wide variety of colors can be created.
A decorative sheet having a suminagashi pattern penetrating the surface layer can be provided easily and inexpensively, and is of great industrial value.

Next, a part of the present invention will be explained with reference to examples and drawings.

The following examples are illustrative of the invention and are not intended to limit it. Example 1 In the diagram, 1 is an extruded P containing a carbonaceous filler.
It is a long flat base material made of VC with a medium diameter of 1,90 m/m and a thickness of 1.5 h'm.
It is being rewound at a speed of in.

3 is a knife coater, and the base material 1 is a doctor knife 31.
During this passage, a layer of brown plastisol A manufactured with the formulation shown in Formulation Example A is applied to a constant thickness of 0.3 skin.

Formulation example A PVC paste resin 65 parts by weight Extended resin 35 parts by weight Plasticizer DOP 5 parts by weight Epoxidized soybean oil 2 parts by weight Stabilizer 3 parts by weight Filler (charcoal) 1 part by weight Brown pigment Appropriate amount then plastisol Motomura 1 coated with a layer of a constant thickness passes under a group of air spray guns 4 which are arranged sequentially in the direction of movement of the substrate, but the light brown plastisol b is applied with the first air spray gun 41. Droplet diameter is 1-3m/
m, and the feed density is 130 g/min.

Further, the second air spray gun 42 supplies dark brown plastisol c at a density of 60 g/m in dots, and the third air spray gun 43 supplies white plastisol d at a density of 40 g/m in dots. Forming a polychromatically dispersed plastisol layer. FIG. 2 is a partially enlarged plan view of the planar appearance of the polychromatic dispersed blastisol layer after the plastisol application by the air spray gun group has been completed;
is a brown plastisol according to formulation example A, and b, c, and d are colored plastisols of light brown, dark brown, and white, respectively, and are otherwise plastisols of the same formulation as a. In this example, the formulations of plastisols a, b, c, and d were the same except for the pigment, but even in this case, the boundaries between the plastisols would hardly become unclear due to dispersion mixing. In order to further disperse and thicken, the viscosity and/or specific gravity of each plastisol is made different by varying the amount of plasticizer and filler, or by adding a thickener, etc. It is also possible. A decorative sheet having a unique dotted pattern can also be obtained by heating the polychromatic dispersed plastisol layer as it is to gel it, but in the present invention, the base material 1 on which the polychromatic dispersed plastisol layer is further mounted is , passes between a plurality of stirring tools 5 and a slide table 6, which are arranged in a direction perpendicular to the direction in which the substrate travels. The stirring tool 5 has a structure as partially shown in FIG. 3, and 51 is a horizontal rotating shaft supported by a bearing (not shown). 52 and 52' are bevel gears, and 53 is a vertical rotating shaft supported by a bearing (not shown).

54 is a bar, 55 is a compression coil spring, and 56 is a stirring rod-shaped body, and the bevel gear 5 is rotated at a constant speed by a motor and a reducer (not shown) to rotate the horizontal rotating shaft 51 at a constant speed.
2 and 52', a vertical rotating shaft 63 is rotated to cause a stirring rod-shaped body 56 attached to a bar 54 to move in a circular motion.

The compression coil spring 55 is attached to the base material 1 of the stirring rod-shaped body 56.
This is to adjust the contact pressure to the surface. Motomura 1
is moving at a constant speed of 3 m/min as described above, the stirring rod 56 draws a trajectory 57 as partially shown in FIG. Stir. Locus 57 drawn by the stirring rod 56
In this embodiment, the middle 58 and the phase 59 are 8 broadsides and 5 winds, respectively, but these can be changed by changing the radius of circular motion of the stirring rod 56 and/or by changing the speed of circular motion. can be varied over a wide range.
Since the plastisol used in this example has viscosity, it adheres to the surface of the tip of the stirring rod 56, moves within a certain range, and moves along the trajectory 57 drawn by the stirring rod. The multicolored plastisols a, b, c, and d intermingle in a complex manner to create a unique cotton-like suminagashi pattern. Immediately after the stirring is completed, the trajectory 57 portion is as follows.
It will be in a concave state, but after a few seconds, the surface tension of the plastisol will cause what is called a shingling phenomenon, and it will become a smooth flat surface. In the multicolor paste sol layer after stirring, the multicolors mix not only in the planar direction but also in the longitudinal cross-sectional direction, so that a suminagashi pattern that penetrates to the surface of the Motomura sheet is obtained. Figure 5 shows a partially enlarged longitudinal section of the multicolored plastisol layer after stirring, where a, b, c, and d are brown, light brown, dark brown, and white, respectively. It is colored plastisol. Next, the substrate 1 with the multicolored plastisol layer that has been stirred is led to a heating device consisting of a far-infrared heater, where it is rotated at approximately 200 pm for 3 minutes.
The multicolored plastisol layer gels and adheres to Motomura 1 to form a strong integrated decorative sheet.

Next, the integrated decorative sheet is cooled to approximately room temperature by a cooling roll 8 and then by a surface winder 9. It is rolled up into a roll. The finished decorative sheet has a PVC decorative layer thickness of 0.
PVC base layer thickness 1.5 on side 5, total thickness 2.5 on side. It is a monolithic sheet made from a mountain surface, and has a highly decorative and unique appearance, and its pattern does not change even when worn, so it has great utility in applications that require abrasion resistance, such as flooring. Embodiment 2 In Fig. 6, 1' is a removable flat base made of a steel belt of 190 min., which is installed like a belt conveyor and moves at a constant speed of 2 m/min. ing.

3' is a roll coater device, and the base 1' passes between an applicator roll 31' and a backup roll 32'. During this passage, blue plastisol a' formulated as shown in Formulation Example B is applied in a layer of a constant thickness on the 0.4 side.

Formulation example B PVC paste resin 7 parts by weight PVC extended resin 3 parts by weight Plasticizer DOP 4 parts by weight Epoxidized soybean oil 2 parts by weight Stabilizer 3 parts by weight Pigment (blue) Appropriate amount Next, add blue plastisol a' The base 1' coated in a layer with a constant thickness passes under a group of linear supply devices 4' which are sequentially arranged in parallel in the direction of travel of the base.

The linear supply device group 4' is a group of plastisol tanks having a rectangular planar shape and having a longitudinal length that is approximately the same as the inside of the base 1' and has a large number of small-diameter nozzle holes (not shown) attached to the bottom surface. It consists of During this passage, the green plastisol is first fed from the first linear feeder 41' with a diameter of 1.5 mm.
The bran-like plastisol is supplied approximately evenly over the entire base in a linear shape of m/m so that the interval between each bran-like plastisol is 5 ribs. Next, in the second linear supply device 42', the yellow plastisol c' is arranged in a linear form with a diameter of 1.5 mm, and the distance between each linear plastisol is IQ. It is combined in a position where it does not overlap with plastisol b'. Next, in the third linear donor device 43', the white plastisol d' was combined in a linear shape with a diameter of 1 and the spacing between each linear plastisol was 10 ribs. green and yellow plastisol b'
and c', and a polychromatic dispersed paste sol layer is formed. b', c' and d' are
The formulations were prepared according to Formulation Example B', except that they were colored green, yellow, and white, respectively. FIG. 7 shows a partially enlarged plan view of the multicolored dispersed plastisol layer after the linear supply of multicolored plastisol has been completed, and shows a', b', c' and d'. show blue, green, yellow and white plastisol, respectively. Further, the base 1' on which the polychromatic dispersion plastisol layer is placed passes between the stirring tool 5' and the slide stage 6'. Stirring odor 5
' has a structure as shown in Fig. 8, 51' is a rotating shaft, 52' is a crank that is locked to the rotating shaft,
53' is a connecting joint rotatably connected to the crank 53', and 54' is a slide plate, which is connected to the connecting joint with a rotatable pin, etc., and is supported for free reciprocation by a receiver (not shown). has been done. Further, 55' is a comb-shaped blade which is fastened to the slide plate 54'. The comb teeth of the comb-like blade 55' have a spacing of 1 inch, and are attached so that the tips of the comb teeth lightly touch the surface of the base 1'. When the rotating shaft 51' is rotated by a motor and a reducer (not shown), the crank 52'' rotates,
The slide plate 54' reciprocates via the connecting joint 53', and at the same time the comb-like blade 55' also reciprocates. Since the base 1' is moving at a constant speed as described above, the comb-like blade 55' draws a trajectory 56' as partially enlarged in FIG. stir. During the stirring, the locus 56' forms a multi-line sine curve due to the relationship between the moving speed of the base 1' and the reciprocating speed of the comb-like blade. can be changed by changing the length of the arm of the crank 52'', and the wavelength 58' can be freely changed by changing the relationship between the base moving speed and the rotational speed of the crank 52''. Although they can be changed, in this example, good results were obtained by using the wavelength 57' as the 4th point and the wavelength 58' as the 5th point. Since plastisol has viscosity, it adheres to the tip of the comb-like blade 55' and the colored plastisol in that part moves within a certain range along the trajectory 56' drawn by the comb-like blade 55'. The result is a cotton-like suminagashi pattern that is a complex mixture of blue, green, yellow, and white. Immediately after stirring, the locus 56' becomes concave, but after a few seconds, a so-called webbing phenomenon occurs due to the surface tension of the plastisol, and it becomes a smooth plane. Furthermore, since the multicolored plastisol after stirring intersects not only in the planar direction but also in both longitudinal directions, a suminagashi pattern that penetrates to the part in contact with the surface of the base 1' can be obtained. FIG. 10 is a partially enlarged vertical cross-sectional view of the multicolored plastisol layer after stirring, and a, b, c, and d are blue, green, yellow, and white plastisol, respectively. The base 1' on which the multicolored plastisol layer has been stirred is then guided to a heating device 7' consisting of a far-infrared heater, where it is heated at 200 qC for about 3 minutes to form a layer of multicolored plastisol. The layer gels and becomes a decorative sheet. After being further cooled to approximately room temperature by the cooling device 8',
The decorative sheet is peeled off from the base 1' and wound into a roll by a winder 9'. The completed decorative sheet is a translucent sheet with a penetrating multicolor striped Suminagashi pattern with a thickness of 0.6 mm, and the sheet can be used as a beautiful decorative sheet as is, and can also be used in other sheet shapes. By laminating it with materials such as urethane foam sheets, wooden boards, glass boards, etc., it can be widely applied to wall materials, flooring materials, decorative mats, etc., and has great industrial value.

As is clear from the above description, the decorative sheet obtained by carrying out the manufacturing method of the present invention has a unique striped suminagashi pattern in which multiple colors are intricately mixed, and moreover, in the longitudinal cross-sectional direction. Since it has a penetrating pattern, it not only has a superior design compared to conventional products, but also has the advantage that the pattern has depth, and the pattern hardly changes even if it wears out. Since it is simple, the decorative sheet can be produced extremely easily and at low cost.

[Brief explanation of the drawing]

The drawings show a part of the embodiment of the method for manufacturing the decorative sheet of the present invention, and FIGS. 1 and 6 are side views schematically showing the manufacturing process, and FIGS. 2 and 7 are side views of the intermediate product. 3 and 8 are perspective views schematically showing the structure of the stirring tool, and FIGS. 4 and 9 are the trajectory of the stirring rod and the trajectory of the comb-like blade. FIGS. 5 and 10 are partially enlarged vertical cross-sectional views of the intermediate product. 1... Non-peelable base material, 1'... Peelable base, 2... Rewinding machine, 3'... Roll coater device, 3...
...Knife coater, 31'...Applicator roll, 31
...Doctor knife, 32'...Backup roll,
32... Backup roll, 4'... Linear supply device group, 4... Air spray gun group, 41'...
... 1st linear feeding device, 41... 1st Easu spray gun, 42'... 2nd woven feeding device, 42...
...Second air spray gun, 43'...
・Third linear supply device, 43... Third air spray gun, 5'... Stirring tool, 5... Stirring tool, 51
'...Rotation axis, 51...Horizontal rotation axis, 52''...
...Crank, 52, 52'...Bevel gear, 53'
...Connection node, 53... Vertical rotation axis, 54'
...Slide plate, 54...Bar, 55'...Comb tooth blade, 55...Compression coil spring, 56
′...Trajectory, 56...Stirring rod, 57'...Shaking, 57...Trajectory, 58'...
・Wavelength, 58...Medium, 59...Phase, 6...Slide stand, 6'...Slide stand, 7...Heating device, 7'...Heating device, 8...Cooling roll, 8'... ...cooled pupils,
9... Surface winding machine, 9'... Winding machine, a.
...Brown plastisol, a'...Blue plastisol, b...Light brown blastisol, b'.
...Green plastisol, c...Dark brown plastisol, c'...Yellow plastisol, d
...White plastisol, d'...White plastisol. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10

Claims (1)

[Claims] 1. A colored plastisol is supplied onto a non-peelable base material or a peelable base to form a plastisol layer having a substantially constant thickness, and subsequently, a color different from the colored plastisol is applied to the plastisol layer. One or more colored plastisols are supplied in the form of dots and/or lines with a substantially constant density to form a polychromatic dispersed plastisol layer, and then the polychromatic dispersed plastisol layer is applied in the form of a rod that moves in a circular motion. By mechanically stirring the plastisol layer using an object or a stirring tool such as a reciprocating comb-shaped blade, a multicolored striped suminagashi pattern is created, and the plastisol layer is further heated. A method for producing a decorative sheet comprising causing gelation.