JP6790355B2 - Floor material - Google Patents

Description

The present invention relates to a flooring material.

Flooring materials are often used on the floors of indoor or outdoor buildings in recent years. Most flooring is made by painting the veneer, but while it has a wood grain design and a natural texture, it is required to have surface performance such as scratch resistance, stain resistance, and weather resistance in practical use. For this reason, many recent flooring materials have a decorative sheet having such surface performance attached to a wood-based base material (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2003-239517

Flooring materials using decorative sheets are also used for concrete structures such as condominiums and office buildings. The surface of a concrete floor is often uneven. Therefore, the floor material using the decorative sheet is required to have non-landing followability to the floor surface in addition to surface performance such as scratch resistance, stain resistance, and weather resistance.
Therefore, the present invention has been made in view of such circumstances, and provides a flooring material having excellent surface performance such as scratch resistance, stain resistance, and weather resistance, and also having excellent non-land followability. The purpose is.

In order to solve the above problems, the flooring material according to one aspect of the present invention includes a thermoplastic resin base material, a decorative sheet provided on the front surface side of the resin base material, and a back surface side of the resin base material. It is characterized by including a first cushion layer provided in the above, and a second cushion layer provided between the resin base material and the decorative sheet.

According to one aspect of the present invention, it is possible to provide a flooring material having excellent surface performance such as scratch resistance, stain resistance, and weather resistance, and also having excellent non-land followability.

It is sectional drawing which shows typically the structural example of the floor material 10 which concerns on 1st Embodiment of this invention. It is sectional drawing which shows typically the structural example of the decorative sheet 13. It is sectional drawing which shows typically the structural example of the floor material 20 which concerns on 2nd Embodiment of this invention. It is sectional drawing which shows typically the structural example of the floor material 30 which concerns on 3rd Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, in all the drawings described below, the parts corresponding to each other are designated by the same reference numerals, and the description below will be omitted as appropriate in the overlapping parts. Further, the embodiment of the present invention exemplifies a configuration for embodying the technical idea of the present invention, and specifies the material, shape, structure, arrangement, dimensions, etc. of each part as follows. Not. Further, the drawings are schematic, and the length and thickness dimensions of each layer in each drawing are different from the actual ones, and their ratios and the like may also be different from the actual ones. The technical idea of the present invention may be modified in various ways within the technical scope specified by the claims stated in the claims.

<First Embodiment>
〔Constitution〕
FIG. 1 is a cross-sectional view schematically showing a configuration example of the floor material 10 according to the first embodiment of the present invention.
As shown in FIG. 1, the floor material 10 is provided on the resin base material (backer layer) 11, the decorative sheet 13 provided on the front surface 11a side of the resin base material 11, and the back surface 11b side of the resin base material 11. A first cushion layer 15 is provided, and a second cushion layer 17 provided between the resin base material 11 and the decorative sheet 13 is provided.

(1) Resin Base Material The resin base material 11 is a thermoplastic resin base material, and its thickness is 1.5 mm or more and 5 mm or less. The resin base material 11 contains polypropylene (PP) -based resin, wood powder, talc and the like.
The resin constituting the resin base material 11 is not limited to the PP resin, but is limited to polyethylene, ethylene-vinyl alcohol copolymer, polyethylene, polymethylbenzene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyarylate, and polyethylene naphthalate. -Isophthalate copolymer, polyimide, polystyrene, polyamide, acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene copolymer (AS) and the like may be used.

(2) Decorative sheet The decorative sheet 13 is a decorative sheet for heavy walking floors. Here, the decorative sheet for heavy walking floors is a decorative sheet for floors in a harsh usage environment, where the amount of walking is large, soil and sand are brought in by adhering to shoes, and trolleys are expected to come and go. That is. Examples of such a floor surface include the floor surface of the entrance of an apartment or an office building, the floor surface of a store, and the like.

As shown in FIG. 1, the surface 13a of the decorative sheet 13 may be provided with irregularities. Since the surface 13a of the decorative sheet 13 has irregularities, the anti-slip performance of the surface 13a can be improved. This unevenness can be formed by embossing.
2 (a) and 2 (b) are cross-sectional views schematically showing a configuration example of the decorative sheet 13. As shown in FIG. 2A, the decorative sheet 13 has an olefin-based decorative sheet 131 and a surface protective layer 133 provided on the surface 131a side of the olefin-based decorative sheet 131. Although not shown, a pattern layer such as wood grain may be provided on the surface 131a side of the olefin-based decorative sheet 131. Further, the pattern layer (not shown) may be covered with the surface protection layer 133.

The surface protective layer 133 is preferably transparent enough to allow the surface 131a (or a pattern layer (not shown) of the olefin-based decorative sheet 131 below the surface protective layer 133 to be seen through. The surface protective layer 133 is preferably colorless and transparent, but may be colored transparent or translucent, and may contain a colorant or a filler. In addition, transparency means transparency to the extent that the back side can be visually recognized from the front side.

The surface protective layer 133 is an ionomer-based clear layer. The thickness of the entire decorative sheet 13 having the olefin-based decorative sheet 131 and the ionomer-based clear layer is 150 μm or more and 500 μm or less, and particularly preferably 300 μm or more and 400 μm or less.
Alternatively, the surface protection layer 133 may be a linear low density polyethylene (hereinafter, LLDPE) -based clear layer. The thickness of the entire decorative sheet 13 having the olefin-based decorative sheet 131 and the LLDPE-based clear layer is 150 μm or more and 500 μm or less, and particularly preferably 300 μm or more and 400 μm or less.

Alternatively, the surface protection layer 133 may be a polyolefin-based clear layer. The thickness of the entire decorative sheet 13 having the olefin-based decorative sheet 131 and the polyolefin-based clear layer is 100 μm or more and 300 μm or less, and particularly preferably 120 μm or more and 200 μm or less.
An amorphous polyethylene terephthalate (hereinafter, A-PET) layer may be provided on the back surface 13b (see FIG. 1) of the decorative sheet 13. For example, as shown in FIG. 2B, the A-PET layer 135 may be attached to the back surface 131b of the olefin-based decorative sheet 131.

(3) First Cushion Layer The first cushion layer 15 shown in FIG. 1 is a resin foam having a thickness of 0.1 mm or more and 10 mm or less (more preferably 0.5 mm or more and 3 mm or less). Here, the resin foam refers to a resin in which a large number of cavities are present on the surface and inside of the resin, and the entire resin is formed into a porous material. As an example of the resin foam constituting the first cushion layer 15, a polyethylene (PE) -based foam can be mentioned.

The resin foam constituting the first cushion layer 15 is not limited to the PE-based foam, but is not limited to the PE-based foam, but is a polyurethane (PUR) -based foam, polystyrene (PS) -based foam, or polypropylene (PP) -based foam. It may be.
Further, the first cushion layer 15 may be a rubber-based sheet having a thickness of 0.1 mm or more and 10 mm or less (more preferably 0.5 mm or more and 3 mm or less) instead of a resin foam. For the rubber-based sheet, natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), butyl rubber (IIR), urethane rubber (U) and the like are used. be able to.

(4) Second Cushion Layer The second cushion layer 17 shown in FIG. 1 is a resin foam having a thickness of 0.1 mm or more and 10 mm or less (more preferably 0.5 mm or more and 3 mm or less). As an example of the resin foam constituting the second cushion layer 17, a polyethylene (PE) -based foam can be mentioned. The resin foam constituting the second cushion layer 17 is not limited to the PE-based foam, but is not limited to the PE-based foam, but is a polyurethane (PUR) -based foam, polystyrene (PS) -based foam, or polypropylene (PP) -based foam. It may be.

[Effect of the first embodiment]
The first embodiment of the present invention has the following effects (1) to (6).
(1) The floor material 10 includes a thermoplastic resin base material 11, a decorative sheet 13 provided on the front surface 11a side of the resin base material 11, and a first cushion provided on the back surface 11b side of the resin base material 11. A layer 15 and a second cushion layer 17 provided between the resin base material 11 and the decorative sheet 13 are provided. By covering the surface 11a of the resin base material 11 with the decorative sheet 13, it is possible to realize a flooring material having excellent surface performance such as scratch resistance, stain resistance, and weather resistance in addition to being able to impart a desired design property. it can.

Further, the back surface 11b of the resin base material 11 is covered with the first cushion layer 15. As a result, even when the floor material 10 is arranged on an uneven floor surface such as a concrete floor surface, the first cushion layer 15 can be deformed according to the unevenness, and the back surface of the resin base material 11 can be deformed. It is possible to prevent a gap from being formed between the 11b and the floor surface. As a result, the back surface side of the floor material 10 can be brought into close contact with the floor surface.

From the above, it is possible to provide a floor material having excellent surface performance such as scratch resistance, stain resistance, and weather resistance, and also having excellent non-land followability. Further, since the first cushion layer 15 and the second cushion layer 17 can be repeatedly deformed and restored and have shock absorbing performance, it is possible to provide a floor material having excellent shock resistance.

(2) The decorative sheet 13 may be composed of an ionomer-based clear layer / olefin-based decorative sheet, an LLDPE-based clear layer / olefin-based decorative sheet, or an olefin-based clear layer / olefin-based decorative sheet.
For the ionomer-based clear layer, one in which a metal ion is bonded between polymer structures made of materials such as ethylene-based, polypropylene-based, urethane-based, styrene-based, and fluorine-based can be used, and among them, the most distributed. It is desirable in terms of cost and material procurement to select the ethylene type. One of these features is that it has good elasticity and flexibility, so it has good performance such as impact resistance and wear resistance. In addition, since it is easy to mold by heating, it has excellent extrusion workability and embossing workability. Furthermore, in addition to having high weather resistance, it is possible to add various weather resistant agents.

Further, as the polyolefin-based clear layer, materials such as polyethylene, propylene homopolymer, ethylene-propylene random copolymer, and ethylene-propylene block copolymer can be used. The thickness may be 50 to 200 μm, particularly preferably 70 to 130 μm. The polyolefin-based clear layer is available at a relatively low cost and has good molding processability.

A second surface protective layer may be further provided on the surface side of the surface protective layer. For the second surface protective layer, any one or more materials of a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin can be used. This makes it possible to impart further surface hardness.
From the above, it is possible to provide a floor material having further improved wear resistance, scratch resistance (caster resistance), weather resistance and cold impact resistance.

(3) The decorative sheet 13 may have an A-PET layer 135 on the back surface side thereof. Thereby, it is possible to provide a floor material having further improved (dent restoration property). When a load or impact is applied from the surface side of the decorative sheet 13, the cushion layer 15 can absorb those stresses, but in some cases, it becomes difficult to restore the concave shape. Therefore, by providing the A-PET layer 135 on the back surface side, the toughness of the decorative sheet 13 is increased, and the dent can be restored.

(4) The resin base material 11 is thermoplastic. The thermoplastic resin base material 11 can be repeatedly deformed and restored. Therefore, it is possible to provide a floor material having further improved impact resistance, heel mark property and simple workability. Since it can be easily bent, cut and folded, the flooring material can be stored even in a space with a complicated shape.
(5) The first cushion layer 15 may be a resin foam or a rubber-based sheet. The resin foam or rubber-based sheet can be repeatedly deformed and restored, and has high shock absorption performance and high sound absorption performance. Therefore, since the first cushion layer 15 is a resin foam or a rubber-based sheet, it is possible to provide a floor material having further improved impact resistance, soundability, and non-landing followability.

(6) The second cushion layer 17 may be a resin foam. The resin foam can be repeatedly deformed and restored, and has high shock absorption performance and high sound absorption performance. Therefore, since the second cushion layer 17 is a resin foam, it is possible to provide a floor material having further improved impact resistance and soundability.

<Second Embodiment>
FIG. 3 is a cross-sectional view schematically showing a configuration example of the floor material 20 according to the second embodiment of the present invention.
As shown in FIG. 3, the floor material 20 includes a foamed polypropylene (PP) base material 21, a decorative sheet 13 provided on the front surface 21a side of the foamed PP base material 21, and a back surface 21b side of the foamed PP base material 21. A first cushion layer 15 provided in the above, and a second cushion layer 17 provided between the foamed PP base material 21 and the decorative sheet 13 are provided. The foamed PP base material 21 contains polypropylene (PP) as a main component. In the present specification, the principal component is a component having a high proportion in the whole substance, and refers to, for example, a case of 70 parts by mass or more when the whole is 100 parts by mass. The foamed PP base material 21 is a backer layer, and its thickness is 0.1 mm or more and 10 mm or less (more preferably 0.5 mm or more and 3 mm or less). Even with such a configuration, the same effects as those of the above-described first embodiments (1) to (6) can be obtained.

Also in this second embodiment, as in the first embodiment, the decorative sheet 13 is composed of an ionomer-based clear layer / olefin-based decorative sheet or an LLDPE-based clear layer / olefin-based decorative sheet, and is a decorative sheet. A decorative sheet for a heavy walking floor having a total thickness of 150 μm or more and 500 μm or less may be used. Further, the decorative sheet 13 may be composed of a polyolefin-based clear layer / an olefin-based decorative sheet, and the total thickness of the decorative sheet 13 may be 100 μm or more and 300 μm or less.

Further, in the second embodiment, the foamed PP base material 21 is exemplified as the foamed resin base material, but the resin (material) constituting the foamed resin base material is not limited to polypropylene (PP). In the present invention, as the foamed resin base material, a base material obtained by foaming various resins such as polyurethane (PUR) and polystyrene (PS) may be used.

<Third Embodiment>
FIG. 4 is a cross-sectional view schematically showing a configuration example of the floor material 30 according to the third embodiment of the present invention.
As shown in FIG. 4, the floor material 30 includes an SF base material 31, a decorative sheet 13 provided on the front surface 31a side of the SF base material 31, and a first surface material 30 provided on the back surface 31b side of the SF base material 31. A second cushion layer 17 provided between the SF base material 31 and the decorative sheet 13 is provided. Here, the SF base material 31 is a resin base material containing wood powder, and contains wood powder 35% or more and 45% or less, talc 10% or more and 20% or less, and polyethylene 35% 45% or less in terms of mass ratio. Further, the SF base material 31 may contain additive components other than wood powder, talc and polyethylene. The SF base material 31 contains each component such as wood powder, talc, and polyethylene in the above range, and the value obtained by adding the mass% of each component and the additive component is 100%. The mass% is adjusted respectively. The SF base material 31 is a backer layer, and its thickness is 0.1 mm or more and 10 mm or less (more preferably 0.5 to 3 mm). Even with such a configuration, the same effects as those of the above-described first embodiments (1) to (6) can be obtained.

Also in this third embodiment, similarly to the first embodiment, the decorative sheet 13 is composed of an ionomer-based clear layer / olefin-based decorative sheet or an LLDPE-based clear layer / olefin-based decorative sheet, and is a decorative sheet. A decorative sheet for a heavy walking floor having a total thickness of 150 μm or more and 500 μm or less may be used. Further, the decorative sheet 13 may be composed of a polyolefin-based clear layer / an olefin-based decorative sheet, and the total thickness of the decorative sheet 13 may be 100 μm or more and 300 μm or less.

<Others>
The technical idea of the present invention is not specified in each of the above-described embodiments. Based on the knowledge of those skilled in the art, design changes and the like may be added to each embodiment of the present invention, and each embodiment of the present invention may be arbitrarily combined, and such modified embodiments may be made. Is also included in the technical idea of the present invention.

10, 20, 30 Floor material 11 Resin base material 11a, 13a, 21a, 31a, 131a Front surface 11b, 13b, 21b, 31b, 131b Back surface 13 Decorative sheet 15 First cushion layer 17 Second cushion layer 21 Foamed PP group Material 31 SF base material 131 Olefin-based decorative sheet 133 Surface protection layer 135 A-PET layer

Claims (10)

With a thermoplastic resin base material
A decorative sheet provided on the surface side of the resin base material and
A first cushion layer provided in contact with the back surface of the resin base material and
A second cushion layer provided between the resin base material and the decorative sheet is provided.
The first cushion layer is a rubber-based sheet that is not a resin foam and does not contain an inorganic filler.
The rubber-based sheet is made of natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), or butyl rubber (IIR) .
The thickness of the first cushion layer is in the range of 0.1 mm or more and 3 mm or less.
The second cushion layer is made of a polyurethane-based foam.
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. Foamed resin base material and
A decorative sheet provided on the surface side of the foamed resin base material and
A first cushion layer provided in contact with the back surface of the foamed resin base material,
A second cushion layer provided between the foamed resin base material and the decorative sheet is provided.
The first cushion layer is a rubber-based sheet that is not a resin foam and does not contain an inorganic filler.
The rubber-based sheet is made of natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), or butyl rubber (IIR) .
The thickness of the first cushion layer is in the range of 0.1 mm or more and 3 mm or less.
The second cushion layer is made of a polyurethane-based foam.
The thickness of the foamed resin base material is within the range of 0.5 mm or more and 3 mm or less.
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. Resin base material containing wood powder and
A decorative sheet provided on the surface side of the resin base material containing wood powder and
A first cushion layer provided in contact with the back surface of the resin base material containing wood powder, and
A second cushion layer provided between the wood powder-containing resin base material and the decorative sheet is provided.
The first cushion layer is a rubber-based sheet that is not a resin foam and does not contain an inorganic filler.
The rubber-based sheet is made of natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), or butyl rubber (IIR) .
The thickness of the first cushion layer is in the range of 0.1 mm or more and 3 mm or less.
The second cushion layer is made of a polyurethane-based foam.
The resin base material containing wood powder contains 35% or more and 45% or less of wood powder, 10% or more and 20% or less of talc, and 35% or more and 45% or less of polyethylene by mass ratio.
The thickness of the resin base material containing wood powder is within the range of 0.5 mm or more and 3 mm or less.
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. With a thermoplastic resin base material
A decorative sheet provided on the surface side of the resin base material and
A first cushion layer provided in contact with the back surface of the resin base material and
A second cushion layer provided between the resin base material and the decorative sheet is provided.
The first cushion layer is a resin foam and is
The thickness of the first cushion layer is state, and are within the scope of 0.1mm or 3mm or less,
The second cushion layer is made of a polyurethane-based foam.
The resin base material contains, as the resin constituting the resin base material, polymethylene, polymethylbenzene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyarylate, polyethylene naphthalate-isophthalate copolymer, polyimide, polystyrene, polyamide, etc. Contains acrylonitrile-butadiene-styrene copolymer (ABS), or acrylonitrile-styrene copolymer (AS),
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. Foamed resin base material and
A decorative sheet provided on the surface side of the foamed resin base material and
A first cushion layer provided in contact with the back surface of the foamed resin base material,
A second cushion layer provided between the foamed resin base material and the decorative sheet is provided.
The first cushion layer is a resin foam and is
The thickness of the first cushion layer is state, and are within the scope of 0.1mm or 3mm or less,
The second cushion layer is made of a polyurethane-based foam.
The foamed resin base material contains polypropylene as the resin constituting the foamed resin base material.
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. Resin base material containing wood powder and
A decorative sheet provided on the surface side of the resin base material containing wood powder and
A first cushion layer provided in contact with the back surface of the resin base material containing wood powder, and
A second cushion layer provided between the wood powder-containing resin base material and the decorative sheet is provided.
The first cushion layer is a resin foam and is
The thickness of the first cushion layer is state, and are within the scope of 0.1mm or 3mm or less,
The second cushion layer is made of a polyurethane-based foam.
The resin base material containing wood powder contains 35% or more and 45% or less of wood powder, 10% or more and 20% or less of talc, and 35% or more and 45% or less of polyethylene by mass ratio.
The decorative sheet is
Flooring, characterized in Rukoto which have a amorphous polyethylene terephthalate layer, provided on the back surface side of the decorative sheet. The floor material according to any one of claims 1 to 6, wherein the thickness of the first cushion layer is within the range of 0.5 mm or more and 3 mm or less. The decorative sheet is
Olefin cosmetic sheet and
The flooring material according to any one of claims 1 to 7 , wherein the flooring material has an ionomer-based clear layer provided on the surface side of the olefin-based decorative sheet. The decorative sheet is
Olefin cosmetic sheet and
The flooring material according to any one of claims 1 to 7 , further comprising a linear low-density polyethylene-based clear layer provided on the surface side of the olefin-based decorative sheet. The decorative sheet is
Olefin cosmetic sheet and
The floor material according to any one of claims 1 to 7 , further comprising a polyolefin-based clear layer having a thickness of 50 μm or more and 200 μm or less provided on the surface side of the olefin-based decorative sheet.

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