JPH042705B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a decorative board made by integrally molding stretched vinyl chloride resin fibers under pressure, and a method for manufacturing the same.

It is widely known that decorative boards such as tiles for flooring or sheets for walling are made by molding vinyl chloride as a raw material. In order to give an effect to the surface of the decorative board, patterns are printed on the surface or undulations are created by pressing.
However, even when the undulations are formed by pressing, the undulations do not match the printed pattern and lack interest, and it is extremely difficult to make the undulations match irregular and fine patterns.

The present invention was developed in view of the above-mentioned circumstances, and provides a decorative board having a surface finished with a fine and irregular fibrous pattern with undulations that perfectly match the pattern, and a method for manufacturing the same. The purpose is to

The present invention relates to a decorative board, in which drawn vinyl chloride resin fibers are integrally molded under pressure in a mold, and after molding, the surface is made into fibers by heat shrinking outside the mold at a temperature below the melting point of the fibers. The method for producing it is to fill a mold with a large number of stretched vinyl chloride resin fibers, and then to place the fibers at temperatures above the softening point and below the melting point of the fibers. The product is integrally molded under high pressure using a press mold while being maintained at a temperature of It is made up of When it is formed using a mold, it is a plate with a dense and smooth surface.
The decorative board thus manufactured has a very attractive appearance as the processing strain (described later) due to the pressure applied in the mold is released, the fibers are lifted, and irregular undulations are created along the fibers. Additionally, the undulating pattern varies slightly from board to board, giving the board the appearance of being handmade.

Embodiments of the present invention will be described below based on the drawings. FIG. 1 shows a process for manufacturing a decorative board according to the present invention. In the figure, reference numeral 1 denotes a metal mold that receives a pressing mold 2 from above. The mold 1 includes a heater 4 that heats the molding material.

First, a mold is filled with a large number of stretched vinyl chloride resin fibers 3 (hereinafter referred to as "fibers") that will serve as a molding material (FIG. 1). The fiber must be drawn during the manufacturing process. The reason for this is that, as will be described later, the present invention utilizes the property of the above-mentioned fibers after forming to return to the state before being stretched by heating. The amount of fibers to be filled into the mold is appropriately determined depending on the thickness of the decorative board, and the thickness, length, color combination, etc. of the fibers are arbitrarily selected in consideration of the appearance of the surface of the decorative board.

Next, the fibers are heated by the heater 4 through the mold 1 to a temperature above the softening point and below the melting point of the fibers, and the fibers are pressed under high pressure by the press die 2 to be integrally molded. The above temperature and pressure are determined taking into consideration the temperature characteristics of the fiber. When high pressure is applied at the above temperature, each fiber softens and flows without melting, and is tightly bonded to each other to form a dense and smooth plate (see Fig. 1, 2). , 3).
At this time, since this molding is performed under pressure, some of the heat shrinkability of the fiber is preserved as processing strain. This heat shrinkability differs from fiber to fiber depending on the degree of flow it receives during the softening flow process, and therefore varies irregularly from place to place.

Next, the plate is taken out from the mold 1 and heated to the heater 6.
The plate is then heated again at a temperature below the melting point of the fibers (FIG. 1, 4). At this time, the plate was in the atmosphere and was not pressurized at all.
The fibers on the surface of the plate then contract to relieve the stress (processing strain) caused by the stretching. As the fibers shrink, they increase in thickness and are pulled together by other fibers that are bonded to each other, creating undulations on the surface of the board due to the fibers themselves (Fig. 1, 5). Particularly, the portions where the fibers are oriented in the same direction during the softening and flow process have severe undulations. The board that has gone through the above steps is taken out of the heating furnace 5 and cooled to complete the decorative board.

If you want to change the surface of the decorative board obtained as described above, you can change the thickness and thickness of the fibers as described above.
One idea is to change the length and color, or to combine different fibers, but it is also possible to combine fibers made of materials with different melting points and softening points, so that some of the fibers are melted and some of them are left as is. There is also a method of changing the material by shrinking it by heating.

Furthermore, the strength of the decorative laminate can be improved by arranging a board of the same type in the center and arranging the above-mentioned fibers on one or both sides of the laminate, instead of composing the entire decorative laminate with the above-mentioned fibers.

In this way, by changing the thickness of the decorative board and arbitrarily determining its strength, it is possible to obtain tiles, sheets, etc. with an attractive appearance. In particular, since an irregular undulation pattern along the fibers can be formed on the surface of a rigid board without using a special mold for forming undulations, the decorative board of the present invention looks as if it were handmade. , and can be manufactured at low cost. In addition, fiber waste can be used as the material, making it possible to reuse resources and reduce material costs.

In addition, in the above-described examples, the case where the fiber used was vinyl chloride resin was explained, but it is understood that other resins can also be used as long as they have heat shrinkability when stretched. I would like to add.

[Brief explanation of drawings]

FIG. 1 is a step-by-step process diagram showing the manufacturing process of a decorative board according to the present invention. 1...Stretched vinyl chloride resin fiber, 2
...Mold, 3...Press mold.

Claims (1)

[Scope of Claims] 1. In a plate in which stretched vinyl chloride resin fibers are integrally molded under pressure in a mold, after molding, heat shrinkage outside the mold at a temperature below the melting point of the fibers causes the surface to have a shape along the fibers. A decorative board characterized by the formation of irregular undulations. 2. After filling a large number of stretched vinyl chloride resin fibers into a mold, they are integrally molded under high pressure using a press mold while maintaining the temperature above the softening point and below the melting point of the fibers, and then integrally formed. A method for producing a decorative laminate, which comprises removing the molded product from the mold and heating it at a temperature below the melting point until irregular undulations along the fibers are formed on the surface.