Polyvinyl chloride resin laminate sheet and joining method thereof

Abstract

To provide a laminated sheet which has no step or joint marks, no gaps caused by aging deterioration between joined sheets, no loss of waterproofing effect, and no clogging of dirt in joints. [Solution] A lower sheet 2 of polyvinyl chloride resin and an upper sheet 3 of polyvinyl chloride resin of the same width as the lower sheet 2 are laminated and integrated with each other while being shifted from each other in the width direction, and at one end of the width direction of the main body 6 where the lower sheet 2 and upper sheet 3 overlap, there is an upper edge portion 5 without the lower sheet 2 and with the upper sheet 3, and at the other end of the width direction of the main body 6, there is a lower edge portion 4 without the upper sheet 3 and with the lower sheet 2.

Description

[Technical field]

[0001] The present invention relates to a laminated sheet of vinyl chloride resin 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 cost, there is an increasing number of cases where vinyl chloride resin laminated sheets (generally vinyl chloride sheets, vinyl chloride resin waterproofing sheets) are used for waterproofing.In addition, vinyl chloride resin laminated sheets (generally general-purpose vinyl floors, long PVC sheets) used as flooring sheets for floors inside buildings are also currently widely used as general-purpose flooring materials in facilities such as schools and hospitals.

[0003] The polyvinyl chloride resin laminated sheet is delivered to the site in a roll and spread out on the floor. In a narrow balcony of an apartment building, a single 1.2m or 1.8m wide polyvinyl chloride sheet can be used for waterproofing without being joined, but when the area is to be spread wider than the width of the sheet, two laminated sheets are joined together. For example, when laying and joining a polyvinyl chloride resin laminated sheet in a place that is wider than the width of the laminated sheet, conventionally, for polyvinyl chloride resin laminated sheets for roof balconies and verandas, there are methods of attaching a polyvinyl chloride seal to the small edge of the overlapped sheets, and methods of integrating the sheets by overlapping them with a width of 40 mm and welding or adhering the end of the upper sheet to the upper surface of the lower sheet with a polyvinyl chloride seal or adhesive using heat or a solvent, and there is also a method of joining overlapped laminated sheets by supplying adhesive to the overlapping parts using an adhesive supplying device and rolling them with a roller (see, for example, Patent Documents 1 and 2).

[0004] Furthermore, in the case of laminated polyvinyl chloride resin sheets for flooring used in flooring construction in buildings, vehicles, ships, etc., one method involves butting the sheets together, scraping off a V shape downward from the top of the butt joint, heat welding the sheets with a polyvinyl chloride resin welding rod, and then cutting off the top of the welding rod to make the surface smooth (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 laid on non-pedestrian areas such as roofs are about 1.2mm or 1.5mm thick, and overlapping them does not cause problems. However, in places where people are expected to walk on them, such as the roofs of schools, kindergartens, and hospitals, the thickness of the PVC laminated sheets for waterproofing attached to the floor is 2mm, and the overlapping method shown in Patent Documents 1 and 2 has the problem that the thickness of the overlapping joints creates a step, creating a risk of people tripping and causing obstacles to walking. In addition, there is a problem that dirt such as sand and dust easily accumulates in the step, leaving dirt marks that spoil the aesthetics. Furthermore, there is a problem that the step is not eliminated and remains even if artificial turf or protective panels are placed on top.

[0007] The butt joint method shown in Patent Document 2 had the problem that the welded area between laminated sheets of polyvinyl chloride resin for flooring sheets was small and prone to breakage. In addition, because the butt joints contained plasticizer, they deteriorated over time due to ultraviolet rays, causing gaps between the butted sheets, and when washed with water, moisture reached underneath the sheets, reducing the waterproofing effect and lowering 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 consideration of these problems, and aims to provide a laminated sheet of vinyl chloride resin that is free of steps or joint marks, that does not develop gaps between joined sheets due to deterioration over time, that does not impair waterproofing, and that does not become clogged with dirt in the joints. [Means for solving the problem]

[0009] The first aspect of the present invention provides a laminated sheet, which is formed by stacking a lower layer sheet of polyvinyl chloride resin and an upper layer sheet of polyvinyl chloride resin of the same width as the lower layer sheet, shifted from each other in the width direction and integrating them, and characterized in that at one end of the width direction of the main body where the lower layer sheet and the upper layer sheet are overlapped, there is an upper edge portion without the lower layer sheet and having the upper layer sheet, and at the other end of the width direction 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 the sheets are 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 joints.

[0011] In addition, in a laminated sheet of vinyl chloride resin 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 the lower layer sheet. It 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 an upper edge portion of one vinyl chloride resin laminate sheet on a lower edge portion 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, the sheets may be pressed together without heating or may be pressed together by heating and dissolving them.

[0013] According to the first aspect of the present invention, there are no steps or joint marks, 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 joints. It also has high watertightness. In addition, it is preferable that the contact surface includes a lower sheet end contact surface consisting of an end of the lower edge of one laminate sheet and an end of the lower sheet of the other laminate sheet, and an upper sheet-lower sheet contact surface consisting of the upper surface of the lower edge of one laminate sheet and the lower surface of the upper edge of the other laminate sheet. Effect of the Invention

[0014] According to the present invention, there are no steps or joint marks, 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 joints. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic diagram of a laminate sheet according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is an explanatory diagram showing a method for joining laminated sheets according to the first embodiment of the present invention. [Diagram 3] FIG. 2 is a side view of the vinyl chloride resin laminated sheet according to the first embodiment of the present invention after joining. [Figure 4] FIG. 2 is a perspective view of the vinyl chloride resin laminated sheet according to the first embodiment of the present invention after joining. [Diagram 5] FIG. 11 is an explanatory view showing a joining method of the laminated sheets according to the second embodiment of the present invention. [Figure 6] FIG. 4 is an explanatory diagram showing the structure of a laminate sheet according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0017] (composition) FIG. 1 is a schematic diagram of a laminated sheet of Example 1 of the present invention. The laminated sheet 1 of vinyl chloride resin of Example 1 of the present invention is a laminated sheet of vinyl chloride resin for flooring. The dotted lines shown in FIG. 1 and FIG. 3 indicate that two layers of vinyl chloride resin are overlapped. The left-right direction of the paper of FIG. 1 is the width direction of the laminated sheet 1, and the depth direction of the paper is the length direction of the laminated sheet. The laminated sheet 1 of Example 1 of the present invention is a laminated sheet of vinyl chloride resin and an upper layer sheet 3 of vinyl chloride resin having the same width as the lower layer sheet 2, which are stacked and integrated with each other by shifting each other by 40 mm in the width direction, and an upper edge portion 5 having the upper layer sheet 3 without the lower layer sheet 2 is provided at one end side in the width direction, and a lower edge portion 4 having the lower layer sheet 2 without the upper layer sheet 3 is provided at the other end side. The part excluding the lower edge portion 4 and the upper edge portion 5 is the main body portion 6. The main body portion 6 is formed by stacking the lower layer sheet 2 and the upper layer sheet 3. In other words, the main body 6, where the lower sheet 2 and the upper 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, which is generally referred to as a vinyl chloride resin, may be a polyvinyl chloride resin, which is a vinyl chloride homopolymer, or a copolymer of vinyl chloride and vinyl acetate, ethylene, propylene, (meth)acrylic acid ester, vinylidene chloride, or the like, and vinyl chloride resins generally used for flooring materials can be used. As the plasticizer, a plasticizer generally used in sheets made of vinyl chloride resin, for example, a phthalic acid plasticizer such as DOP, can be used. In addition, additives such as a stabilizer may 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 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 method or an 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 wound on a roll has an upper edge 5 on the right side of the roll, it has a lower edge 4 on the left side, and no matter how long the vinyl chloride resin laminate sheet 1 is cut, it will have an upper edge 5 at one end and a lower edge 4 at the other end. When stacking, the lower layer sheet 2 and the upper layer sheet 3 are overlapped with a shift of 40 mm 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-shape or H-shape, and are integrated by welding at 160 to 200 degrees, at which the vinyl chloride resin begins to melt. 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 a roller with a width of 2500 mm. The manufacturing method of this embodiment is an example and may be manufactured by other methods. The thickness of the vinyl chloride resin laminate sheet 1 of this embodiment is 2 mm. In this embodiment, the thickness ratio of the lower layer sheet 2 and the upper layer sheet 3 is 1:4. The thickness ratio of the lower layer sheet and the upper layer sheet of the laminate sheet is an example and is not limited to this. The laminate sheet 1 of this embodiment is a flooring sheet, and is a two-layer sheet in which two types of vinyl chloride resin are stacked together 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 the first embodiment of the present invention. The laminated sheet 1 is a long sheet made of soft vinyl chloride, and spreads in all four directions in both the length and width directions. For the purpose of explanation, FIG. 2 shows only a cut-out portion of the overlapping portion of the laminated sheet. The method for fixing the laminated sheet to the base in this embodiment is an adhesive method using an adhesive, and the method for joining the laminated sheets according to this embodiment is solvent welding using an adhesive. When the laminated sheets are laid on a floor having a length that exceeds the width of the laminated sheet 1, the adjacent laminated sheets 1 are joined and joined as follows. The method for joining laminated sheets according to the first embodiment of the present invention includes a laying step in which the upper edge 4a of one vinyl chloride resin laminated sheet 1a is laid on the lower edge 5b of the other vinyl chloride resin laminated sheet 1b, and a joining step in which a vinyl chloride resin solvent is supplied to the contact surface of the vinyl chloride resin laminated sheets and the sheets are heated and pressed together. In the joining step, the sheets are pressed together without heating in this embodiment, but they may be heated and melted before pressing. The sheets are overlapped in a so-called ladle-like manner, and the upper edge is turned up, and the overlapping surfaces of the two sheets are welded by liquid and heat. The heating temperature is preferably 160 to 200 degrees. Note that the heating temperature is an example and is not limited to this. Figure 3 is a side view of the vinyl chloride resin laminated sheet of Example 1 of the present invention after joining. The contact surface 7 of the vinyl chloride resin laminated sheet 1a and the vinyl chloride resin laminated sheet 1b includes the lower surface and end of the upper edge 5b and the upper surface and end of the lower edge 4a. In detail, the contact surface 7 includes (1) a lower sheet end contact surface 72 consisting of an end of the lower edge 5b of one vinyl chloride resin laminate sheet 1b and an end of the main body 6a of the other vinyl chloride resin laminate sheet 1a (near the base of the upper edge 4a), and (2) an upper sheet-lower sheet contact surface 73 consisting of an upper surface of the lower edge 5b of one vinyl chloride resin laminate sheet 1b and a lower surface of the upper edge 4a of the other vinyl chloride resin laminate sheet 1a. In this embodiment, the contact surface 7 also includes (3) an upper sheet end contact surface 71 consisting of an end of the upper edge 4a of the other vinyl chloride resin laminate sheet 1a and an end of the main body 6b of the one vinyl chloride resin laminate sheet 1b (near the base of the lower edge 5b).

[0021] FIG. 4 is a perspective view of the laminated sheet of vinyl chloride resin according to the first embodiment of the present invention after joining. For the purpose of explanation, FIG. 4 shows only a part of the overlapping portion of the laminated sheet cut out. The contact surface 7 is made up of three surfaces, namely, the upper sheet end contact surface 71, the lower sheet end contact surface 72, and the upper sheet-lower sheet contact surface 73. The vinyl chloride resin on the three surfaces is melted and pressed by applying a solvent for vinyl chloride resin to the three surfaces, so that the laminated sheet of vinyl chloride resin 1a and the laminated sheet of vinyl chloride resin 1b are firmly integrated. Even if the solvent is not applied directly to the contact surface of the upper sheet end 71, the liquid rises between the upper sheet end contact surface 71 and adheres to the surface during pressing. The liquid spilling over the upper surface is wiped off. In this embodiment, tetrahydrofuran is used as the solvent for vinyl chloride resin, but other solvents that can dissolve vinyl chloride resin may be used. After coating and overlapping, the layers are pressed together and adhere within 20 to 30 seconds, but it is preferable to press the layers from above with a roller or a plate-shaped pressing tool and then leave the layers to stand for 24 hours.

[0022] (effect) According to the laminated sheet and the jointing method using the laminated sheet of this embodiment, there are no steps or joint marks, and no gaps are formed between the joined sheets due to aging, the waterproofing effect is not impaired, and dirt does not get stuck in the joints. It is highly watertight and weather resistant. Since the overlapping joints are flat, there are no steps and there is no risk of people tripping. It is also highly safe because children, the elderly, and sick people cannot walk without any obstacles. Therefore, the fields suitable for joints are expanded. In addition, since there are no steps, it is possible to prevent dirt such as sand and dust from accumulating, and since there are no dirt marks, it is excellent in aesthetics. Furthermore, even if artificial turf or a protective panel is placed on top, there is no step. Since the welding area between the sheets is large, it is difficult to break. In addition, since the sheets are integrated, no gaps are formed between the sheets, and even when washed with water, water does not penetrate, and the waterproofing and water resistance effects are high. Since there are no joint processing marks and the sheets are integrated, it is excellent in aesthetics. Since liquid welding can be used, the joints can be completed easily and in a short time without relying on tools such as hot air welding machines. The joints become less noticeable, giving the sheet a seamless appearance. The laminated sheet of this embodiment is made of polyvinyl chloride, and 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. EXAMPLES

[0023] FIG. 5 is an explanatory diagram showing a method of joining the laminated sheet of Example 2 of the present invention. FIG. 6 is an explanatory diagram showing the structure of the laminated sheet of Example 2 of the present invention. The laminated sheet 1' of vinyl chloride resin of Example 2 of the present invention is a long sheet made of soft vinyl chloride, and is a laminated sheet of vinyl chloride resin for a waterproof sheet used for floor surfaces such as roof balconies and hospital roofs. The laminated sheet 1' spreads in all four directions in both the length direction and the width direction, and FIG. 5 shows only a part of the overlapping part of the laminated sheet cut out for the purpose of explanation. The thickness of the laminated sheet 1' of vinyl chloride resin of this example is 2 mm. In this example, the thickness ratio of the lower layer sheet 2' and the upper layer sheet 3' is 1:4. Note that the thickness ratio of the lower layer sheet and the upper layer sheet of the laminated sheet is one example and is not limited to this. The laminated sheet 1' of this example is a waterproof sheet, and is a sheet in which glass cloth is sandwiched between two types of vinyl chloride resin sheets and overlapped. The laminated sheet of Example 2 is suitable as a waterproof sheet for outdoor use because it has glass cloth sandwiched between it, which prevents the sheet from expanding and contracting in harsh environments and strengthens its breaking strength, and has weather resistance and strength. The glass cloth layer is almost thin, and the upper and lower vinyl chloride resin layers are in contact with each other and integrated between the meshes of the glass cloth. In FIG. 6, the left-right direction of the paper is the width direction, and in FIG. 6, the length in the width direction is shortened to explain the structure in the height direction. The laminated sheets 1'a and 1'b of vinyl chloride resin 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, with no glass cloth at the upper edge 4'a and the glass cloth 8 on the lower layer sheet 2' at the lower edge 5'b. A resin mesh such as a polypropylene mesh may be used as a reinforcing material instead of the glass cloth. The rest is the same as in Example 1, and the jointing method is also the same. That is, the appearance of the laminated sheet of this embodiment is similar to the schematic diagram of Example 1 shown in Fig. 1, the outline of the joining method is similar to the explanatory diagram of Example 1 shown in Fig. 2, and after joining, it becomes similar to the perspective view of Example 1 shown in Fig. 4. The glass cloth sandwiched between the sheets is omitted in each drawing.Since the glass cloth 8 is mesh-shaped, the contact area between the upper edge 4'a and the lower edge 5'b remains large, and the integration of the polyvinyl chloride resin laminated sheets 1'a and 1'b is not impaired. Therefore, the same effect as in Example 1 is achieved. This is suitable for use in places where people may walk, such as roof balconies, large verandas, and hospital rooftops.

[0024] The lower sheet 2' and the upper sheet 3' contain a vinyl chloride resin and a plasticizer. The vinyl chloride resin, collectively referred to 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, and may be a vinyl chloride resin generally used for waterproof sheets. As the plasticizer, a plasticizer generally used in vinyl chloride resin sheets, for example, a phthalic acid plasticizer such as DOP, may be used. In addition, additives such as a stabilizer, a colorant, a filler, and a lubricant may be blended. In this embodiment, the lower sheet 2' and the upper sheet 3' are made of different types of vinyl chloride resins, but they may be the same type.

[0025] The present invention is not limited to the above-described embodiment, 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 Sheet 3a, b, 3' Upper sheet 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 end contact surface 72 Lower sheet end contact surface 73 Contact surface between upper and lower sheets 8 Glass Cloth

Claims

1. A lower layer sheet of polyvinyl chloride resin and an upper layer sheet of polyvinyl chloride resin of the same width as the lower layer sheet are laminated and integrated with each other by shifting them in the width direction, and at one end of the width direction 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 end of the width direction of the main body, there is a lower edge portion without the upper layer sheet and having the lower layer sheet, A polyvinyl chloride resin laminated sheet, 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 upper edge portion is free of the reinforcing material, while the lower edge portion is provided with the reinforcing material on top of the lower layer sheet.

2. A method for joining laminated sheets of polyvinyl chloride resin, in which a lower sheet of polyvinyl chloride resin and an upper sheet of polyvinyl chloride resin of the same width as the lower sheet are stacked together with a shift between them in the width direction, and an upper edge portion having the upper sheet but no lower sheet is provided at one end side in the width direction of the main body where the lower sheet and upper sheet overlap, and a lower edge portion having the lower sheet but no upper sheet is provided at the other end side in the width direction of the main body, the method comprising the steps of: laying a layering process in which the upper edge portion of one polyvinyl chloride resin laminate sheet is overlapped on the lower edge portion of the other polyvinyl chloride resin laminate sheet; and a joining process in which a vinyl chloride resin solvent is supplied to the contact surface of the polyvinyl chloride resin laminate sheets and pressure-bonded them.

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

4. 4. A method for joining vinyl chloride resin laminate sheets as claimed in claim 2 or 3, characterized in that the contact surfaces include a lower sheet end contact surface formed by the end of the lower edge portion of one of the laminate sheets and the end of the lower sheet of the other of the laminate sheets, and an upper sheet-lower sheet contact surface formed by the upper surface of the lower edge portion of one of the laminate sheets and the lower surface of the upper edge portion of the other of the laminate sheets.

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