JPH0532801A - Sheet material and manufacturing method thereof - Google Patents

Abstract

(57) [Abstract] [Purpose] Firstly, while being excellent in wear resistance, secondly
Thirdly, it is excellent in cost and color reproducibility. Thirdly, it has high heat resistance, and fourthly, it is hard to burn and can be easily thickened. Therefore, it can be used on the surface of decorative panels such as building materials and floors. The present invention proposes a sheet material and a manufacturing method thereof, which can be used for surface strengthening such as covering the surface in a film form, etc. without any hindrance. [Structure] The sheet material 15 is extrusion-molded, and particles of the ceramics 1 are mixed in nylon 4 at a weight ratio of 50% or more (for example, 70 to 90%). Further, the manufacturing method is such that the surface of the particles of the ceramics 1 is subjected to a predetermined surface treatment, and such a large amount of particles of the ceramics 1 and nylon 4 are mixed, and the extruder 12 is used.
The sheet material 15 is obtained by extrusion molding with.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet material and its manufacturing method. That is, the present invention relates to a sheet material extruded, in which ceramic particles are mixed in nylon, and a manufacturing method thereof.

[0002]

2. Description of the Related Art As a sheet material, for example, a sheet material used for the surface of a decorative interior panel such as a building material, a vinyl chloride containing a decora which is more excellent in abrasion resistance than before and a ceramic of about 10 to 40% is mixed. Etc. are used. Also, as a sheet material for covering the surface of the floor or the like in a sheet-like or film-like manner by coating, epoxy mixed with about 10 to 40% of ceramics is used. By the way, nylon has been conventionally used for various sheet materials and the like, and nylon in which ceramic particles are mixed in a weight ratio of about 30% or less is also used. It has been considered difficult to increase the ratio because the viscosity of the melted nylon during molding is extremely lowered.

[0003]

By the way, the following problems have been pointed out in such a conventional example. First of all, the one using decora has problems in cost and color reproducibility. That is, the sheet material using decora is costly because it is individually sintered and molded at high temperature,
In addition, the temperature distribution during sintering is not uniform as a whole, and there is a problem that color reproducibility is poor due to the occurrence of color shading due to the difference in temperature. Secondly, the sheet material using vinyl chloride has a problem in heat resistance. That is, a sheet material using vinyl chloride mixed with a small amount of ceramics has only a heat resistance of about 50 to 100 degrees Celsius, and has a drawback that it is softened when exposed to direct sunlight, for example.
Thirdly, the one using epoxy or the like has a problem that it is easy to burn and the wall thickness is thin. That is, the coated sheet material made of epoxy or the like is easy to burn, and since it emits harmful gas when burned, it is generally used in a state where the wall thickness is thinner than before, and there is a drawback that it cannot withstand long-term use. On the other hand, on the other hand, if you want to increase the wall thickness,
There is also a problem that work efficiency is poor because it requires repeated painting.

In view of such circumstances, the present invention has been made to solve the problems of the above-mentioned conventional examples, in which nylon is mixed with ceramic particles at a weight ratio of 50% or more and extrusion molded. As a result, firstly, it is excellent in wear resistance, secondly, it is excellent in cost and color reproducibility, thirdly, it has high heat resistance, and fourthly, it is hard to burn and easily has a thick wall. It is an object of the present invention to propose a sheet material that can be made thick and a manufacturing method thereof.

[0005]

The technical means of the present invention for achieving this object are as follows. First, claim 1
About: That is, this sheet material is extruded into a sheet shape, and ceramic particles are mixed in nylon at a weight ratio of 50% or more.
Claim 2 is as follows. That is, in this sheet material manufacturing method, first, a surface treatment is performed to reduce the friction coefficient of the surface of the ceramic particles, and then nylon and a large amount of the ceramic particles are mixed and extruded into a sheet. Thus, a sheet material in which the ceramic particles are mixed in the nylon in a weight ratio of 50% or more can be obtained.

[0006]

Since the present invention comprises such means, it operates as follows. First, the sheet material according to claim 1 is extrusion-molded, and ceramic particles are mixed in nylon in a weight ratio of 50% or more. Further, in the manufacturing method of the second aspect, such a sheet material is obtained by subjecting ceramics to a predetermined surface treatment, mixing such a large amount of ceramics particles and nylon, and extruding.
Therefore, firstly, this sheet material is excellent in wear resistance because the content of the ceramics is extremely large. Secondly, this sheet material is excellent in cost because it is continuously extruded, and since the material of the resin material does not change due to sintering as in the case of forming the decora sheet, the color density is different. Is less likely to occur and has excellent color reproducibility. Third,
Since this sheet material has an extremely high content of ceramics, it has a high heat resistance of about 200 degrees Celsius. Fourth
In addition, since this sheet material contains a large amount of non-combustible ceramics in nylon that is difficult to burn, it is difficult to burn and the thickness can be easily increased.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below based on the embodiments shown in the drawings. 1 to 6 are provided for explaining an embodiment of the present invention, and a manufacturing method will be described first with reference to these drawings. In this manufacturing method, the ceramic 1 is first subjected to the surface treatment 2 for reducing the friction coefficient of the particle surface. FIG. 1 (1) is a front explanatory view showing particles of ceramics 1,
FIG. 1B is an enlarged view of the main part. Examples of the ceramics 1 include aluminum-based materials such as alumina, silicon carbide, zirconia, and quartz glass, carbide-based materials, nitride-based materials,
Glass-based materials and others are selected and used according to the application, but these ceramics 1 are in the form of particles.
In other words, it is used in the form of powder, fine particles, fibrous, and other various particle forms. Then, such a ceramic 1 is subjected to a surface treatment 2 using a silicon-based, titanium-based or aluminum-based coupling agent to reduce the friction coefficient of the particle surface. In the figure, 3 is a plate.

Next, in this manufacturing method, as shown in FIG. 2 or 3, while nylon 4 is melted and a large amount of particles of ceramics 1 are mixed, pellets 5 (see also FIG. 4, which will be described later). ). The particles of the ceramics 1 are used in such a large amount that they will be mixed in the post-nylon 4 at a weight ratio of 50% or more (preferably about 70 to 90%). Nylon 4 is used in an amount corresponding to the weight ratio of such ceramics 1, and a pellet or powder is melted by heating and pressing. When the particles of the ceramics 1 are mixed in the melted nylon 4 at such a high weight ratio, generally, the friction of the surface of the particles causes the viscosity to extremely decrease and causes defective molding. As described above, since the ceramic 1 is subjected to the surface treatment 2 for reducing the friction coefficient of the particle surface, the decrease in the viscosity is prevented and the defective molding does not occur. Now, FIG. 2 is a front explanatory view showing an example of such a pellet 5 molding step, and FIG. 3 is a front explanatory view showing another example of the pellet 5 molding step. First, in the example of FIG.
A kneader 6 is used, a predetermined amount of particles of the ceramics 1 are mixed into the molten nylon 4, and both are kneaded and kneaded by a stirring blade 7, then poured into a mold 8 and cooled and molded. It is cut into pellets 5.
Further, in another example of FIG. 3, an extruder 9 is used, and the nylon 4 in powder form and the particles of ceramics 1 in powder form are
The nylon 4 is supplied to the hopper 10, the nylon 4 is melted in the heating cylinder, the particles of the ceramics 1 are mixed, and both are kneaded by a screw and extruded. Then, it is cut by the blade of the pelletizing device 11 into pellets 5.

Thereafter, in this manufacturing method, extrusion molding is carried out using a material obtained by mixing a predetermined amount of the particles of the ceramics 1 in the nylon 4 and forming the pellets 5 as a material. FIG. 4 is a front explanatory view of such an extrusion molding process. As shown in FIG. 4, pellets 5 made of nylon 4 and ceramics 1 are supplied to a hopper 13 of an extrusion molding machine 12 and a heating cylinder thereof. Rolled by being melted and fluidized by a screw and extruded from a die
4 and the like to form a sheet. Thus, nylon 4 is extruded into a sheet having a predetermined width and thickness, and particles of ceramics 1 are mixed in nylon 4 at a weight ratio of 50% or more (for example, about 70 to 90%). A sheet material 15 of ceramics 1 is obtained. FIG. 6 is a schematic perspective view of an example of such a sheet material 15. In this sheet material 15, a large amount of particles of the ceramics 1 are close to each other, and the melt-hardened nylon 4 is evenly filled between the ceramics 1 and completely filled, and thereby the ceramics 1 The lions are strongly bonded.

FIG. 5 is a front explanatory view showing another example of the extrusion molding process. That is, in the manufacturing method shown in FIG. 5, the pellet 5 forming step shown in FIG. 2 or 3 is omitted, and a predetermined amount of powdered nylon 4 and the powder subjected to the surface treatment 2 in FIG. 5 and the particles of the ceramics 1 are directly supplied to the hopper 13 of the extruder 12 shown in FIG. 5 without being pelletized. Then, according to the above, the sheet material 15 is formed. Even in the case of the manufacturing method shown in FIG. 5, since the surface of the particle of the ceramic 1 is subjected to the surface treatment 2, the decrease in viscosity is prevented and the defective molding does not occur as described above.

The sheet material 15 and the method for manufacturing the same according to the present invention are as described above. Therefore, it becomes as follows. First, the sheet material 15 is extrusion-molded by the extruder 12 (see FIGS. 4 and 5), and the particles of the ceramics 1 are mixed in the nylon 4 at a weight ratio of 50% or more (for example, 70 to 90%). (See FIG. 6). In addition, the manufacturing method is such that the surface of the particles of the ceramics 1 is subjected to a predetermined surface treatment 2 (see FIG. 1), and a large amount of the particles of the ceramics 1 thus surface-treated 2 and nylon 4 are mixed. The sheet material 15 is obtained by extrusion molding (see FIGS. 4 and 5). Then, the following first, second, third and fourth are performed.

First, the sheet material 15 is made of nylon 4 with a weight ratio of particles of ceramics 1 of 50% or more.
Since it is mixed in and the content of ceramics 1 is extremely large, the weak points of nylon 4 are reinforced and the wear resistance is excellent. That is, the sheet material 15 has wear resistance comparable to iron-based metal materials and stone materials such as marble. Secondly, the sheet material 15 is continuously formed by the extruder 12.
Since it is extruded as shown in Fig.4 and Fig.5, it is more cost effective than the conventional example using a decorator, and the material change of the resin material due to sintering occurs when the decorator sheet is molded. Since there is no color shade, it is also excellent in color reproducibility. Thirdly, since the sheet material 15 contains a large amount of the ceramics 1 as described above,
It has a high heat resistance of about 00 degrees and is superior in heat resistance to a conventional example using vinyl chloride or the like, which has only a heat resistance of about 50 to 100 degrees Celsius. Fourthly, since a large amount of ceramics 1 which is a non-combustible material is mixed in nylon 4 which is self-extinguishing and hardly burns, it is difficult to burn. Therefore, even when it is used for covering the surface of a floor or the like in a film for surface reinforcement, there is no problem even if the wall thickness is increased, and furthermore, the wall thickness can be easily increased by extrusion molding. That is, unlike the conventional example of coating epoxy or the like, it is not necessary to use it with a thin wall thickness, and there is no need to repeat coating many times, resulting in good work efficiency.

[0013]

As described above, in the sheet material of claim 1 and the manufacturing method of claim 2 according to the present invention, ceramic particles are mixed in nylon in a weight ratio of 50% or more and extrusion molded. The following effects are exhibited. That is, firstly, it is excellent in abrasion resistance, and damage such as scratches is unlikely to occur. Secondly, since it is extrusion-molded, it is cost-effective, and the temperature distribution is entirely uniform, and color reproducibility is also improved. Excellent, thirdly, it has high heat resistance, for example, it does not soften even when exposed to direct sunlight, and fourthly, it is hard to burn and can easily be thickened, and it can withstand long-term use and has good working efficiency. To be Therefore, for example, it can be used as a surface of a decorative interior panel such as a building material, or can be used for strengthening the surface of a floor or the like so as to cover it with a film, and can be used for various other purposes without any trouble. As described above, all the problems existing in this type of conventional example can be eliminated at once, and the effect of the present invention can be remarkably large.

[Brief description of drawings]

FIG. 1 is used to explain an embodiment of a method for manufacturing a sheet material according to the present invention. FIG. 1 (1) is a front explanatory view showing ceramic particles, and FIG. 2 (2) is an enlarged view of a main part thereof. .

FIG. 2 is a front explanatory view showing an example of the pellet forming process.

FIG. 3 is a front explanatory view showing another example of the pellet forming process.

FIG. 4 is an explanatory front view showing an example of the extrusion molding process.

FIG. 5 is a front explanatory view showing another example of the extrusion molding step.

FIG. 6 is a schematic perspective view of a sheet material for explaining an example of a sheet material and a manufacturing method thereof according to the present invention.

[Explanation of symbols]

1 Ceramics 2 Surface treatment 3 plates 4 nylon 5 pellets 6 kneader 7 Stirrer 8 mold 9 Extruder 10 hopper 11 Pelletizing device 12 Extruder 13 hopper 14 rolls 15 sheet materials

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Claims (2)

[Claims] 1. A sheet material extruded into a sheet shape, wherein ceramic particles are mixed into nylon in a weight ratio of 50% or more. 2. First, a surface treatment for reducing the friction coefficient on the surface of ceramic particles is performed, and then a mixture of nylon and a large amount of the ceramic particles is extruded into a sheet to form a sheet in the nylon. A method for producing a sheet material, comprising: obtaining a sheet material in which particles of the ceramic are mixed in a weight ratio of 50% or more.