Laminated sheet of vinyl chloride resin and method for joining the same

Abstract

To provide a laminated sheet which is free from a step and a joint mark, prevents a gap from being formed between joined sheets due to aged deterioration, prevents a waterproof effect from being impaired, and prevents a joint part from being clogged with dirt.SOLUTION: A lower layer sheet 2 made of a vinyl chloride resin and an upper layer sheet 3 made of the vinyl chloride resin having the same width as that of the lower layer sheet 2 are laminated and integrated with each other while being shifted from each other in the width direction, and an upper side edge part 5 having the upper layer sheet 3 without the lower layer sheet 2 is provided on one end side in the width direction of a body part 6 where the lower layer sheet 2 and the upper layer sheet 3 are overlapped, and a lower side edge part 4 having the lower layer sheet 2 without the upper layer sheet 3 is provided on the other end side in the width direction of the body part 6.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a vinyl chloride resin laminate sheet that can be used for rooftops, roof balconies, verandas, and flooring materials inside buildings, and a method for joining the same. [Background technology]

[0002] Waterproofing sheets applied to rooftops, roof balconies, and veranda floors include the mainstream urethane rubber coating and FRP coating, but due to their weather resistance, flexibility, and price, there is an increasing trend toward waterproofing with vinyl chloride resin laminate sheets (generally vinyl chloride sheets, vinyl chloride resin waterproofing sheets).In addition, vinyl chloride resin laminate sheets (generally general-purpose vinyl flooring products, long vinyl sheets) used as flooring sheets for floors inside buildings are now widely used as general-purpose flooring materials in facilities such as schools and hospitals.

[0003] PVC laminated sheets are delivered to the construction site in rolls and laid out on the floor. For example, a single 1.2- or 1.8-meter-wide vinyl chloride sheet can be used to waterproof narrow apartment balconies without the need for splicing. However, when the area is wider than the width of the sheet, two laminated sheets are joined together. For example, when laying and joining vinyl chloride laminated sheets in areas exceeding the width of the laminated sheets, conventional methods for waterproofing vinyl chloride laminated sheets for roof balconies and verandas include applying vinyl chloride sealant to the edges of the overlapping sheets, or by overlapping two sheets 40 mm apart and welding or adhering the edge of the upper sheet to the top of the lower sheet using heat or a solvent, either with a vinyl chloride sealant or adhesive. Another method involves joining overlapping laminated sheets by applying adhesive to the overlapping area using an adhesive supply device and rolling it with a roller (see, for example, Patent Documents 1 and 2).

[0004] Furthermore, in the case of laminated vinyl chloride resin sheets for flooring sheets used in flooring construction in buildings, vehicles, ships, etc., one method involves butting the sheets together, scraping off a V-shape from the top of the butted area downward, heat welding the sheets with a vinyl chloride resin welding rod, and then cutting off the top of the welding rod to smooth the surface (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2023-151676 A (Fig. 5) [Patent Document 2] Japanese Patent Application Laid-Open No. 2-45127 (Figs. 3 and 4) Summary of the Invention [Problem to be solved by the invention]

[0006] PVC laminated sheets for waterproofing installed on rooftops and other non-pedestrian areas are approximately 1.2 mm or 1.5 mm thick, and overlapping them is unlikely to cause problems. However, in places where people are expected to walk on them, such as the rooftops of schools, kindergartens, and hospitals, the PVC laminated sheets for waterproofing installed on floors are 2 mm thick. The overlapping methods described in Patent Documents 1 and 2 pose problems: The thickness of the overlapping joints creates a step, posing a risk of tripping and hindering walking. Furthermore, dirt such as sand and dust easily accumulates in the step, leaving marks that detract from the aesthetic appearance. Furthermore, the step remains even when artificial turf or protective panels are placed on top.

[0007] The butt-jointing method shown in Patent Document 2 had the problem of a small welding area between laminated sheets of vinyl chloride resin for flooring sheets, making them prone to breakage. Furthermore, because the butt-jointed joints contain plasticizer, they deteriorate over time due to ultraviolet rays, creating gaps between the butt-jointed sheets. This means that when the sheets are washed with water, moisture can reach underneath the sheets, reducing their waterproofing and resulting in poor water resistance. Another problem was that the streaks left by the joint processing were noticeable, marring the aesthetics.

[0008] The present invention has been made in view of the above problems, and aims to provide a laminated sheet of vinyl chloride resin that has no steps or joint marks, does not develop gaps between joined sheets due to deterioration over time, does not impair waterproofing, and does not allow dirt to get stuck in the joints. [Means for solving the problem]

[0009] The first aspect of the present invention provides a laminated sheet, characterized in that a lower layer sheet of vinyl chloride resin and an upper layer sheet of vinyl chloride resin of the same width as the lower layer sheet are stacked together with a widthwise offset from each other, and at one widthwise end of the main body where the lower layer sheet and the upper layer sheet overlap, there is an upper edge portion without the lower layer sheet and having the upper layer sheet, and at the other widthwise end of the main body, there is a lower edge portion without the upper layer sheet and having the lower layer sheet.

[0010] According to the first aspect of the present invention, the welding area is increased, and when joined, there are no steps or joint marks, and no gaps are formed between the joined sheets due to deterioration over time, the waterproof effect is not impaired, and dirt does not get stuck in the joint area.

[0011] Furthermore, in a vinyl chloride resin laminate sheet for waterproofing, a reinforcing material made of glass cloth or resin mesh is sandwiched between the lower layer sheet and the upper layer sheet, and it is preferable that the upper edge portion does not have the reinforcing material, and the lower edge portion has the reinforcing material on top of the lower layer sheet. This is strong and more suitable for outdoor use.

[0012] A second aspect of the present invention provides a method for joining laminated sheets of vinyl chloride resin according to the first aspect of the present invention, comprising a laying step of overlapping the upper edge of one vinyl chloride resin laminate sheet on the lower edge of the other vinyl chloride resin laminate sheet, and a joining step of supplying a vinyl chloride resin solvent to the contact surface of the vinyl chloride resin laminate sheets and pressing them together. In the joining step, pressure bonding may be performed without heating or by heating and dissolving the solvent.

[0013] According to the first aspect of the present invention, there are no steps or joint marks, and no gaps develop between the joined sheets due to deterioration over time, so the waterproofing effect is not impaired and dirt does not get stuck in the joints. It also has high watertightness. Furthermore, it is preferable that the contact surfaces include a lower-layer sheet end contact surface formed by the end of the lower edge of one laminate sheet and the end of the lower sheet of the other laminate sheet, and an upper-layer sheet-lower-layer sheet contact surface formed by the upper surface of the lower edge of one laminate sheet and the lower surface of the upper edge of the other laminate sheet. [Effects of the Invention]

[0014] According to the present invention, there are no steps or joint marks, no gaps are formed between joined sheets due to deterioration over time, the waterproof effect is not impaired, and dirt does not get stuck in the joints. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic view of a laminate sheet according to a first embodiment of the present invention. [Figure 2] FIG. 2 is an explanatory view showing a method for joining laminated sheets according to the first embodiment of the present invention. [Figure 3] FIG. 1 is a side view of the vinyl chloride resin laminated sheet of Example 1 of the present invention after joining. [Figure 4] FIG. 1 is a perspective view of a vinyl chloride resin laminate sheet according to Example 1 of the present invention after joining. [Figure 5] FIG. 10 is an explanatory view showing a method for joining laminated sheets according to a second embodiment of the present invention. [Figure 6] FIG. 4 is an explanatory view showing the structure of a laminate sheet according to Example 2 of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] The vinyl chloride resin laminate sheet and the joining method thereof according to the present invention will be specifically described below using examples with reference to the accompanying drawings to illustrate preferred embodiments of the present invention, but the present invention is not limited to these examples. [Example]

[0017] (composition) FIG. 1 is a schematic diagram of a laminate sheet according to Example 1 of the present invention. The vinyl chloride resin laminate sheet 1 of Example 1 of the present invention is a vinyl chloride resin laminate sheet for flooring. The dotted lines in FIGS. 1 and 3 indicate two layers of vinyl chloride resin stacked together. The left-to-right direction of the paper in FIG. 1 corresponds to the width direction of the laminate sheet 1, and the depth direction of the paper corresponds to the length direction of the laminate sheet. The laminate sheet 1 of Example 1 of the present invention is formed by stacking a vinyl chloride resin lower layer sheet 2 and a vinyl chloride resin upper layer sheet 3 of the same width as the lower layer sheet 2 one on top of the other, offset by 40 mm in the width direction. One end of the width direction has an upper edge 5 with no lower layer sheet 2 and the upper layer sheet 3, and the other end has a lower edge 4 with no upper layer sheet 3 and the lower layer sheet 2. The portion excluding the lower edge 4 and upper edge 5 constitutes a main body 6. The main body 6 is formed by stacking the lower layer sheet 2 and the upper layer sheet 3. That is, the main body 6, where the lower layer sheet 2 and the upper layer sheet 3 are overlapped, has an upper edge 5 at one end in the width direction, and a lower edge 4 at the other end in the width direction.

[0018] The lower layer sheet 2 and the upper layer sheet 3 contain a vinyl chloride resin and a plasticizer. The vinyl chloride resin, collectively referred to as vinyl chloride resin, may be a polyvinyl chloride resin, which is a vinyl chloride homopolymer, or a copolymer of vinyl chloride with vinyl acetate, ethylene, propylene, (meth)acrylic acid ester, vinylidene chloride, or the like. Vinyl chloride resins commonly used for flooring materials can be used. The plasticizer can be a plasticizer commonly used in vinyl chloride resin sheets, such as a phthalate-based plasticizer such as DOP. Additives such as stabilizers may also be blended. In this embodiment, the lower layer sheet 2 and the upper layer sheet 3 are made of different types of vinyl chloride resins, but they may also be the same type.

[0019] (Manufacturing method) The vinyl chloride resin laminate sheet 1 is a long product formed by heating and melting two or one vinyl chloride resin compositions and forming them into sheets by a calendaring or extrusion method to obtain two sheets, a lower layer sheet 2 and an upper layer sheet 3, which are then laminated and integrated by a calendaring method and wound into a roll. In the rolled state, the length direction of the vinyl chloride resin laminate sheet 1 is the circumferential direction and the width direction is the longitudinal direction. When the vinyl chloride resin laminate sheet 1 is wound around a roll, if the upper edge 5 is on the right side of the roll, the lower edge 4 is on the left side. Therefore, no matter how long the vinyl chloride resin laminate sheet 1 is cut, the upper edge 5 is at one end and the lower edge 4 is at the other end. When stacked, the lower layer sheet 2 and the upper layer sheet 3 are overlapped with a 40 mm offset in the width direction. The lower layer sheet 2 and the upper layer sheet 3 are stacked and passed between multiple rollers in a roll arrangement such as a Z-type or H-type, and are welded and integrated at 160 to 200 degrees, at which point the vinyl chloride resin begins to melt. Note that the welding temperature is an example and is not limited to this. A vinyl chloride resin laminate sheet with an overall width of 1200 to 2000 mm is manufactured using rollers with a width of 2500 mm. The manufacturing method of this example is an example and other manufacturing methods may also be used. The thickness of the vinyl chloride resin laminate sheet 1 of this example is 2 mm. In this example, the thickness ratio of the lower layer sheet 2 to the upper layer sheet 3 is 1:4. Note that the thickness ratio of the lower layer sheet to the upper layer sheet of the laminate sheet is an example and is not limited to this. The laminate sheet 1 of this example is a flooring sheet, a two-layer sheet made by overlapping two types of vinyl chloride resin without a glass cloth sandwiched between them.

[0020] (Jointing method) FIG. 2 is an explanatory diagram showing a method for joining laminated sheets according to Example 1 of the present invention. Laminated sheet 1 is a long sheet made of soft vinyl chloride, extending in all four directions in both the length and width directions. For illustrative purposes, FIG. 2 depicts only a portion of the overlapping portion of the laminated sheets. In this example, the laminated sheets are fixed to the substrate using an adhesive, and the method for joining the laminated sheets is solvent welding using a welding agent. When laying the laminated sheets on a floor whose length exceeds the width of the laminated sheets 1, adjacent laminated sheets 1 are joined as follows. The method for joining laminated sheets according to Example 1 of the present invention includes a laying step in which the upper edge 4a of one vinyl chloride resin laminate sheet 1a is overlapped on the lower edge 5b of the other vinyl chloride resin laminate sheet 1b, and a joining step in which a vinyl chloride resin solvent is applied to the contact surfaces of the vinyl chloride resin laminated sheets and the sheets are heated and pressed together. In this example, the joining step is performed without heating, but heating and melting may also be used for pressure bonding. The sheets are overlapped in a so-called "double ladle" fashion, and the upper edges are turned up, and the overlapping surfaces of the two sheets are welded together using liquid and heat. The heating temperature is preferably 160 to 200°C. Note that this heating temperature is an example and is not limited to this. Figure 3 is a side view of the vinyl chloride resin laminate sheets of Example 1 of the present invention after joining. The contact surface 7 between the vinyl chloride resin laminate sheet 1a and the vinyl chloride resin laminate sheet 1b includes the lower surface and edge of the upper edge 5b and the upper surface and edge of the lower edge 4a. Specifically, contact surface 7 includes (1) a lower-layer sheet end contact surface 72 formed by the end of lower edge 5b of one vinyl chloride resin laminate sheet 1b and the end of main body 6a of the other vinyl chloride resin laminate sheet 1a (near the base of upper edge 4a), and (2) an upper-layer sheet-lower-layer sheet contact surface 73 formed by the upper surface of lower edge 5b of one vinyl chloride resin laminate sheet 1b and the lower surface of upper edge 4a of the other vinyl chloride resin laminate sheet 1a. Furthermore, in this embodiment, contact surface 7 also includes (3) an upper-layer sheet end contact surface 71 formed by the end of upper edge 4a of the other vinyl chloride resin laminate sheet 1a and the end of main body 6b of one vinyl chloride resin laminate sheet 1b (near the base of lower edge 5b).

[0021] FIG. 4 is a perspective view of the PVC laminate sheets of Example 1 of the present invention after joining. For illustrative purposes, FIG. 4 shows only a portion of the overlapping portion of the laminate sheets cut away. The contact surfaces 7 are three surfaces: the upper sheet end contact surface 71, the lower sheet end contact surface 72, and the upper-lower sheet contact surface 73. A PVC solvent is applied to these three surfaces, melting the PVC resin on the surfaces and pressing them together, resulting in a strong bond between the PVC laminate sheets 1a and 1b. Even if the solvent is not directly applied to the upper sheet end contact surface 71, the liquid will rise up and adhere to the upper surface during pressing. Any liquid spilling over onto the upper surface is wiped off. In this example, tetrahydrofuran is used as the PVC solvent; however, other solvents capable of dissolving PVC resin may be used. After application and overlapping, the layers are pressed together and adhere in 20 to 30 seconds, but it is preferable to press them from above with a roller or a plate-shaped pressing tool and then leave them for 24 hours.

[0022] (effect) The laminated sheet and joining method using this embodiment result in no unevenness or joint marks, no gaps between joined sheets due to aging, no loss of waterproofing, and no dirt clogging in the joints. It also has high watertightness and weather resistance. The overlapping joints are flat, eliminating any unevenness and the risk of tripping. It also offers high safety for children, the elderly, and the sick, as it poses no obstacles to walking. This expands the range of applications for joints. Furthermore, the lack of unevenness prevents the accumulation of dirt such as sand and dust, and the lack of dirt marks contributes to an aesthetically pleasing appearance. Furthermore, no unevenness is created even when artificial turf or protective panels are placed on top. The large welded area between the sheets makes them less likely to break. Furthermore, because they are integrated, there are no gaps between the sheets, preventing water penetration even when washed with water, resulting in high waterproofing and water resistance. The integrated structure without any joint processing marks results in an aesthetically pleasing appearance. Liquid welding allows for quick and easy joining without relying on tools such as hot air welding. The joints become less noticeable, giving the sheet a seamless appearance. The laminated sheet of this example is made of vinyl chloride, which is resistant to heat and cold, salt damage, and bird damage, so it can be used both indoors and outdoors, and can also be used in places where weather resistance is required, such as near the sea. [Example]

[0023] FIG. 5 is an explanatory diagram showing a method for joining a laminate sheet according to Example 2 of the present invention. FIG. 6 is an explanatory diagram showing the structure of a laminate sheet according to Example 2 of the present invention. A vinyl chloride resin laminate sheet 1' according to Example 2 of the present invention is a long sheet made of soft vinyl chloride, and is a vinyl chloride resin laminate sheet for waterproofing used on floor surfaces such as roof balconies and hospital rooftops. The laminate sheet 1' extends in all four directions in both the length and width directions, and FIG. 5 shows only a portion of the overlapping portion of the laminate sheet for illustrative purposes. The thickness of the vinyl chloride resin laminate sheet 1' according to this example is 2 mm. In this example, the thickness ratio of the lower layer sheet 2' to the upper layer sheet 3' is 1:4. Note that the thickness ratio of the lower layer sheet to the upper layer sheet of the laminate sheet is an example and is not limited to this. The laminate sheet 1' according to this example is a waterproof sheet, made by sandwiching glass cloth between two types of vinyl chloride resin sheets and overlapping them. The laminated sheet of Example 2, sandwiched between glass cloth layers, prevents stretching and strengthens the sheet even in harsh environments, providing weather resistance and strength, making it suitable as a waterproof sheet for outdoor use. The glass cloth layer is almost thin, and the upper and lower vinyl chloride resin layers contact and integrate through the glass cloth stitches. In Figure 6, the left-to-right direction of the page is the width direction, and in Figure 6, the width direction is shortened to illustrate the height direction. The vinyl chloride resin laminated sheets 1'a and 1'b of Example 2 of the present invention are laminated with glass cloth 8 sandwiched between the upper layer sheet 3' and the lower layer sheet 2' as a reinforcing material. There is no glass cloth at the upper edge 4'a, and the glass cloth 8 is located on the lower layer sheet 2' at the lower edge 5'b. A resin mesh such as polypropylene mesh may be used as a reinforcing material instead of glass cloth. The rest of the structure is the same as in Example 1, and the joining method is also the same. That is, the appearance of the laminated sheet of this example is the same as the schematic diagram of Example 1 shown in Figure 1, the outline of the joining method is the same as the explanatory diagram of Example 1 shown in Figure 2, and after joining, it becomes the same as the perspective view of Example 1 shown in Figure 4. In each figure, the glass cloth sandwiched therebetween is omitted from the illustration.Because the glass cloth 8 is mesh-like, the contact area between the upper edge 4'a and the lower edge 5'b remains large, and the integration of the vinyl chloride resin laminated sheets 1'a and 1'b is not impaired. Therefore, the same effects as in Example 1 are achieved. This product is suitable for use in places where people are likely to walk, such as roof balconies, large verandas, and hospital rooftops.

[0024] The lower layer sheet 2' and the upper layer sheet 3' contain a vinyl chloride resin and a plasticizer. The vinyl chloride resin, collectively known as vinyl chloride resin or PVC, may be a polyvinyl chloride resin, which is a vinyl chloride homopolymer, or a copolymer of vinyl chloride with vinyl acetate, ethylene, (meth)acrylic acid ester, vinylidene chloride, or the like. A vinyl chloride resin commonly used for waterproof sheets can be used. The plasticizer can be a plasticizer commonly used in vinyl chloride resin sheets, such as a phthalate-based plasticizer such as DOP. Additional additives such as stabilizers, colorants, fillers, and lubricants may also be blended. In this example, the lower layer sheet 2' and the upper layer sheet 3' are made of different types of vinyl chloride resin, but they may also be the same type.

[0025] The present invention is not limited to the above-described embodiments, and various modifications and variations are possible without departing from the spirit of the invention. Furthermore, the components of the above-described embodiments can be combined in any manner without departing from the spirit of the invention. [Explanation of symbols]

[0026] 1a, b, 1'a, b laminated sheet 2a, b, 2' Lower sheets 3a, b, 3' upper sheets 4a, b, 4'a upper edge 5a, b, 5'b lower edge 6a, b, 6'a, b Main body 7 Contact surface 71 Upper sheet edge contact surface 72 Lower sheet edge contact surface 73 Contact surface between upper and lower sheets 8 Glass cloth

Claims

1. A vinyl chloride resin laminated sheet, characterized in that a lower layer sheet of vinyl chloride resin and an upper layer sheet of vinyl chloride resin of the same width as the lower layer sheet are laminated together with a widthwise offset from each other, and that at one widthwise end of the main body where the lower layer sheet and the upper layer sheet overlap, there is an upper edge portion where the lower layer sheet is absent and where the upper layer sheet is present, and at the other widthwise end of the main body, there is a lower edge portion where the upper layer sheet is absent and where the lower layer sheet is present.

2. A vinyl chloride resin laminated sheet according to claim 1, characterized in that a reinforcing material made of glass cloth or resin mesh is sandwiched between the lower layer sheet and the upper layer sheet, and the reinforcing material is absent at the upper edge, while the reinforcing material is present on top of the lower layer sheet at the lower edge.

3. 3. A method for joining vinyl chloride resin laminate sheets according to claim 1 or 2, comprising: a laying step of overlapping the upper edge of one vinyl chloride resin laminate sheet on the lower edge of the other vinyl chloride resin laminate sheet; and a joining step of supplying a vinyl chloride resin solvent to the contact surfaces of the vinyl chloride resin laminate sheets and pressing them together.

4. 4. A method for joining vinyl chloride resin laminate sheets according to claim 3, characterized in that the contact surfaces include a lower sheet end contact surface formed by the end of the lower edge of one laminate sheet and the end of the lower sheet of the other laminate sheet, and an upper sheet-lower sheet contact surface formed by the upper surface of the lower edge of one laminate sheet and the lower surface of the upper edge of the other laminate sheet.

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