JP6985874B2 - Flooring material and its manufacturing method - Google Patents

Description

The present invention relates to a flooring material having a laminated structure and having various functions, and a method for manufacturing the same.

Flooring materials used in buildings and the like are generally composed of a laminated structure in which layers having each function are laminated. Such flooring materials are required to have wear resistance, stain resistance, crack resistance and dimensional stability as basic characteristics, and are also required to have characteristics such as impact resistance and caster resistance as necessary. ..

As a material that satisfies the above-mentioned various required characteristics as much as possible, a resin containing an ultraviolet curable urethane acrylate as a main component, a resin in which urethane acrylate is mixed with polyvinyl chloride, etc. are widely used for the outermost surface layer of the laminated structure. (For example, Patent Documents 1 and 2).

As a technique for making the floor material strong, resistant to warping, and excellent in dimensional stability, for example, Patent Document 3 describes glass containing glass fiber in the middle portion in the thickness direction of a laminated structure containing resin as a basic component. Flooring materials containing a sheet as a reinforcing layer have been proposed.

Glass fiber has the characteristics of high strength and small size due to temperature, and in the technique of Patent Document 3, by effectively utilizing such characteristics of glass fiber, high strength and dimensional stability are obtained. Realizes excellent flooring material.

While the glass fiber has the above-mentioned characteristics, the glass sheet containing the resin layer and the glass fiber has a drawback that it is difficult to join.

In the technique of Patent Document 3, in order to solve such a problem, "a plurality of glass sheets laminated between an upper resin layer, a lower resin layer, and the upper resin layer and a lower resin layer" are used. A glass sheet containing the glass fibers of the above and having an opening between the glass fibers, the bonding resin is adhered to the surface of the glass fibers of the glass sheet, and the upper resin layer and the lower resin layer are the bonded. It is bonded to the resin and is directly bonded through the opening. "

Japanese Patent No. 2562554 Japanese Patent No. 2802842 Japanese Unexamined Patent Publication No. 2017-2620

In the conventional technology, in order to make the floor material exhibit various functions, a laminated structure according to the required characteristics has been proposed. However, there is a limit to the characteristics that can be realized with each laminated structure, and the floor has a laminated structure that can fully satisfy the basic characteristics of wear resistance, stain resistance, crack resistance, and dimensional stability. The reality is that the material has not been realized. Further, it has not been possible to realize a flooring material having a laminated structure capable of satisfying the above-mentioned basic characteristics and also having characteristics such as impact resistance and caster resistance.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a flooring material which can sufficiently satisfy the characteristics of wear resistance, stain resistance, crack resistance, and dimensional stability. Another object of the present invention is to provide a flooring material which satisfies the above-mentioned basic characteristics but also has characteristics such as impact resistance and caster resistance. Further, the present invention also includes the realization of a method for manufacturing a flooring material having various characteristics as described above.

As a result of diligent studies, the present inventor has found that the above-mentioned problems can be solved by a flooring material having the following laminated structure, and has completed the present invention by further studies based on such findings.

That is, the floor material according to the present invention is
A flooring material with a laminated structure
From the lower layer side to the upper layer side, the foam layer, the reinforcing layer, the non-foam layer, the transparent resin layer, and the surface reinforcing layer are laminated in this order.
The reinforcing layer comprises a layer obtained by impregnating a non-woven fabric made of glass fiber with paste polyvinyl chloride.
The surface-reinforcing layer is characterized by being composed of a layer mainly composed of urethane acrylate having 1 to 3 functional groups and having a thickness of 0.01 to 0.03 mm.

In the floor material of the present invention, the mass ratio of the amount of resin in the upper layer composed of the surface reinforcing layer, the transparent resin layer and the non-foamed layer and the amount of resin in the lower layer nest composed of the foamed layer (resin amount in the upper layer: resin in the lower layer). The amount) is preferably 60:40 to 40:60.

In the floor material of the present invention, a non-woven fabric layer can be further provided as the lowest layer of the laminated structure. By providing such a non-woven fabric layer, when the floor material of the present invention is adhered to the floor base, the adhesive strength between the floor material and the floor base can be increased.

The present invention also includes methods for producing various flooring materials as described above.

According to the present invention, it is possible to provide a floor material having a laminated structure that can sufficiently satisfy the characteristics of wear resistance, stain resistance, crack resistance, and dimensional stability.

FIG. 1 is a schematic cross-sectional view showing an embodiment of the flooring material of the present invention. FIG. 2 is an explanatory diagram schematically showing a process of manufacturing the floor material of the present invention.

The structure of the floor material of the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view showing an embodiment of the floor material 1 of the present invention, in which 2 is a surface reinforcing layer, 3 is a transparent resin layer, 4 is a printed layer, 5 is a non-woven fabric layer, and 6 is. Reinforcing layer, 7 is a foam layer, and 8 is a non-woven fabric layer. That is, in the floor material 1 shown in FIG. 1, in the laminated structure constituting the floor material 1, the foam layer 7, the reinforcing layer 6, the non-foam layer 5, the transparent resin layer 3, and the transparent resin layer 3 are directed from the lower layer side to the upper layer side. The surface reinforcing layer 2 is laminated so as to include it in this order. The printed layer 4 and the non-woven fabric layer 8 shown in FIG. 1 are layers to be arranged as needed.

In the floor material of the present invention, the configurations of the surface reinforcing layer and the reinforcing layer are defined in order to satisfy the characteristics such as wear resistance, stain resistance, crack resistance, and dimensional stability. For the sake of convenience, the layers on the lower layer side to the layers on the upper layer side will be described in this order. Further, the reference numerals of the respective layers shown in FIG. 1 may be omitted.

(Foam layer)
The foam layer is arranged to impart impact resistance (impact absorption) to the floor material. As a specific structure of this foamed layer, for example, a paste polyvinyl chloride having a degree of polymerization of about 1000 to 1500 (hereinafter, may be referred to as "paste PVC") is mainly used, and a blended polyvinyl chloride (hereinafter, referred to as "paste PVC") is used as a main component. It is composed by blending (sometimes referred to as "blended PVC") and further blending a foaming agent.

By blending the foaming agent as described above, a large number of closed cells are formed in the foam layer, and the impact absorption of the floor material is enhanced. Examples of the foaming agent used at this time include pyrolytic organic foaming agents such as azodicarbonamide, azobisisobutyronitrile, benzenesulfonylhodrazide, p-toluenesulfonylhydrazide, and dinitrosopentamethylenetetramine.

The content of the foaming agent is preferably about 0.5 to 5 parts by mass, more preferably about 0.8 to 4 parts by mass with respect to 100 parts by mass of the paste PVC.

In order to exert the above effect by arranging the foamed layer, the foaming ratio in the foamed layer is preferably about 2.5 to 5. The thickness of the foam layer is preferably about 0.5 to 10 mm, more preferably about 1 to 5 mm.

The impact resistance is a characteristic indicating the cushioning property of the floor material, and is evaluated by, for example, the maximum acceleration (G value) measured according to the “floor hardness test” of JIS A 6519.

The foam layer may contain a plasticizer or a filler (strengthening agent), if necessary. By incorporating a plasticizer or a filler in the foam layer, the flexibility and strength of the foam layer can be increased and the impact resistance can be further improved.

In order to exert such an effect, the content of the plasticizer is preferably about 40 to 80 parts by mass, more preferably about 45 to 75 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC. Is. When the filler is contained, the content is preferably 20 to 70 parts by mass, more preferably about 20 to 50 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC.

Examples of the plasticizer that can be used in the present invention include phthalates such as di-n-octyl phthalate, di-2-ethylhexyl phthalate, diisooctyl phthalate, isoheptyl phthalate, diisononyl phthalate, and diisodecyl phthalate. Ester plasticizers, trimellitic acid ester plasticizers such as tri-2-ethylhexyl trimellitic acid, dibasic acid ester plasticizers such as di-2-ethylhexyl adipate, diisononyl adipate, diisodecyl adipate, Examples thereof include phosphate ester plasticizers such as tri-2-ethylhexyl phosphite, isodecyldiphenyl phosphite, and tricresyl phosphite, chlorinated paraffins, and polyester plasticizers. These can be used alone or in combination of two or more.

Examples of the filler that can be used in the present invention include calcium carbonate, magnesium carbonate, calcium sulfate, calcium oxide, titanium oxide, aluminum hydroxide, clay, silica and the like.

(Reinforcing layer)
The reinforcing layer exhibits an appropriate rigidity, enhances the dimensional stability of the floor material, and exerts an action of preventing warping. This reinforcing layer consists of a layer obtained by impregnating a non-woven fabric made of glass fiber with paste PVC. Specifically, for example, it is configured by impregnating a glass fiber non-woven fabric as a reinforcing material with paste PVC having a degree of polymerization of about 1000 to 1500.

The glass fiber nonwoven fabric used at this time preferably has a basis weight of ^{about 30 to 80 g / m 2} , and more preferably about 32 to 60 g / m ^2. If the basis weight of the glass fiber non-woven fabric is ^{less than 30 g / m 2} , sufficient dimensional stability and warpage prevention effect may not be obtained, and if the basis weight ^{exceeds 80 g / m 2} , the rigidity of the reinforcing layer may not be obtained. There is a risk that the crack resistance will deteriorate as well as the workability will decrease.

In order to exert the above effect, the coating amount of the reinforcing layer ^{is preferably about 200 to 500 g / m 2} , and more preferably about 250 to 450 g / m ^2. If the coating amount of the reinforcing layer is ^{less than 200 g / m 2} , sufficient dimensional stability and warpage prevention effect may not be obtained, and if the coating amount ^{exceeds 500 g / m 2} , the rigidity is increased and the rigidity of the reinforcing layer is increased. This is not preferable because the workability is lowered and the crack resistance is deteriorated.

The reinforcing layer may contain the above-mentioned plasticizer, if necessary. This plasticizer is effective in imparting appropriate flexibility to PVC and exerting a dimensional stability and a warp prevention effect. In order to exert such an effect, the content of the plasticizer is preferably about 40 to 80 parts by mass, more preferably about 45 to 75 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC. Is. When the content of the plasticizer is less than 40 parts by mass, the viscosity of the paste PVC becomes high and the impregnation property into the nonwoven fabric becomes poor. On the other hand, if the content of the plasticizer exceeds 80 parts by mass, the viscosity becomes low and the plasticizer may not be retained in the nonwoven fabric and may flow.

The dimensional stability means a characteristic that the size of the floor material does not change even after long-term use. This dimensional stability is a characteristic evaluated by the "length and width change test by heating" specified in JIS A 1454.

(Non-foam layer)
The non-foamed layer exerts an action of imparting caster resistance to the floor material. For example, a paste PVC having a degree of polymerization of about 1000 to 1500 is mainly used, and a blended PVC is blended therein, and if necessary, further described above. It is composed by blending the plasticizer.

When the non-foaming layer contains a plasticizer, the content of the plasticizer is preferably about 40 to 80 parts by mass, more preferably 45 to 80 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC. It is about 75 parts by mass. When the content of the plasticizer is less than 40 parts by mass, the flexibility is lost. Further, when the content of the plasticizer exceeds 80 parts by mass, it is too soft.

The non-foaming layer may contain the above-mentioned filler, if necessary. This filler has the effect of increasing the strength of the non-foaming layer and further improving the caster resistance. When the filler is contained, the content is preferably 20 to 70 parts by mass, more preferably about 20 to 50 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC.

The thickness of the non-foamed layer is preferably, for example, about 0.1 to 1.5 mm, more preferably about 0.12 to 1.0 mm. When the thickness of the non-foamed layer is thinner than 0.1 mm, the caster resistance deteriorates. On the other hand, when the thickness of the non-foamed layer is thicker than 1.5 mm, the flexibility is lost.

The caster resistance is a characteristic required for a floor material used in a place where a device with casters moves, and means the resistance of the floor material surface to the torsional force of the casters. This caster resistance is a characteristic evaluated by the "caster resistance test A-1 method" specified in JIS A 1455.

(Transparent resin layer)
The transparent resin layer exerts an action of supporting the surface reinforcing layer and preventing the surface reinforcing layer from being scratched or the like. Further, if an attempt is made to exert the function as a reinforcing layer only by the surface reinforcing layer without providing the transparent resin layer, the thickness of the surface reinforcing layer becomes too thick, the surface reinforcing layer becomes hard, and the cost increases. It also becomes.

As a specific structure of this transparent resin layer, for example, a paste PVC having a degree of polymerization of about 1000 to 1500 is mainly used, a blended PVC is blended therein, and if necessary, a plasticizer as described above is further blended. Will be done.

When the transparent resin layer contains a plasticizer, the content of the plasticizer is preferably about 40 to 80 parts by mass, more preferably 45 to 80 parts by mass with respect to 100 parts by mass of the total of the paste PVC and the blended PVC. It is about 75 parts by mass. When the content of the plasticizer is less than 40 parts by mass, the flexibility is lost. Further, when the content of the plasticizer exceeds 75 parts by mass, it becomes too soft.

The thickness of the transparent resin layer is preferably, for example, about 0.1 to 1.5 mm, more preferably about 0.12 to 1.0 mm. When the thickness of the transparent resin layer is thinner than 0.1 mm, the scratch prevention effect is lost. On the other hand, if the thickness of the transparent resin layer is thicker than 1.5 mm, it becomes too hard and the crack resistance deteriorates.

(Surface strengthening layer)
The surface reinforcing layer is composed mainly of urethane acrylate having 1 to 3 functional groups, and its thickness needs to be 0.01 to 0.03 mm.

Urethane acrylate is a resin that has appropriate flexibility and is less likely to crack (that is, has good crack resistance). The flexibility of urethane acrylate is influenced by the number of functional groups. As the number of functional groups increases, the surface reinforcing layer becomes hard and brittle, and the crack resistance deteriorates. In order to give appropriate flexibility to the surface reinforcing layer and improve crack resistance, the number of functional groups of urethane acrylate needs to be 1 to 3.

The surface reinforcing layer containing urethane acrylate as a main component is preferably formed by using a solvent-free coating agent. By using a solvent-free coating agent, it is possible to form a coating layer having a smooth surface while exhibiting good coatability without causing phase separation of the coating agent.

The coating agent containing urethane acrylate as a main component is applied as the outermost surface layer (surface strengthening layer) of the floor material in a molten state. This coating agent contains a photopolymerization initiator and is irradiated with ultraviolet rays to polymerize and cure the urethane acrylate to become a coating layer as a surface reinforcing layer of the floor material of the present invention.

In order to exert such an effect, the content of the photopolymerization initiator is preferably 1 part by mass or more with respect to 100 parts by mass of the urethane acrylate. More preferably, it is 3 parts by mass or more. However, even if the content of the photopolymerization initiator becomes excessive, the effect is saturated, so the content is preferably 8 parts by mass or less. More preferably, it is 7 parts by mass or less.

Examples of the photopolymerization initiator used in the present invention include benzophenone, benzoin ethyl ether, 2,2-dimethoxy-2-phenylacetophenone, acetophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4'-dimethoxy. Bezophenone, N, N, N', N'-tetramethyl-4,4'-diaminobenzophenone, benzoinpropyl ether, benzyldimethylketal, 1- (4-isopropylphenyl) -2-hydroxy-2-methylpropane Examples thereof include -1-one and 1-hydroxycyclohexylphenyl ketone. One or more of these can be used.

The surface-reinforced layer may contain a resin other than urethane acrylate in a part thereof (for example, up to about 40% by mass with respect to the entire urethane acrylate layer). Examples of such a resin include acrylic resin, vinyl chloride resin, polyethylene resin, polypropylene resin and the like.

Since the surface-reinforced layer of the present invention can be a layer having a smooth surface as described above, it also has excellent stain resistance. In the present invention, the stain resistance was evaluated by the heel mark resistance. The heel mark resistance means, for example, that if the outermost surface layer has fine irregularities or fine scratches, the black rubber on the sole of the shoe adheres and stains called "heel marks" tend to adhere. However, if the surface is smooth, it is difficult for such stains to adhere, and it means that the stains can be easily removed by simple maintenance such as wiping.

The surface-reinforced layer as described above is a layer having excellent wear resistance, stain resistance, crack resistance, etc., but in order to effectively exert these characteristics, the thickness of the surface-reinforced layer is also within an appropriate range. Must be. That is, the thickness of the surface reinforcing layer needs to be 0.01 to 0.03 mm, and by setting the thickness of the surface reinforcing layer within this range, the above-mentioned characteristics are effectively exhibited.

When the thickness of the surface reinforcing layer is thinner than 0.01 mm, not only the wear resistance is deteriorated, but also the smoothness of the surface is lowered due to the influence of the surface texture of the lower layer, and the stain resistance is also deteriorated. On the other hand, when the thickness of the surface reinforcing layer is thicker than 0.03 mm, the toughness of the surface reinforcing layer is lowered and the crack resistance is deteriorated. The upper limit of the thickness of the surface reinforcing layer is preferably 0.02 mm or less.

An antibacterial agent, a deodorant, or the like may be contained in the surface reinforcing layer as long as the object of the present invention is not impaired. Antibacterial agents include nitrile compounds, pyridine compounds, haloalkylthio compounds, organic iodine compounds, thiazole compounds, benzimidazole compounds, wasabi components (allyl isothiocyanate), and inorganic compounds such as silver, zinc, and copper. And so on. The deodorant includes an inorganic compound and an organic compound, and the inorganic compound includes a silicate compound having silver ion and zinc ion, a phosphate compound having silver ion and zinc ion, and silver ion and zinc ion. Examples thereof include calcium phosphate compounds having the above, activated charcoal, calcium hydroxide obtained by calcining scallop shells, and the like. When these are contained, the antibacterial agent is preferably about 0.1 to 5 parts by mass, more preferably about 0.5 to 1 part by mass with respect to 100 parts by mass of urethane acrylate. The deodorant is preferably about 5 to 15 parts by mass, more preferably about 5 to 10 parts by mass with respect to 100 parts by mass of urethane acrylate.

The floor material of the present invention has a transparent resin layer, a non-foamed layer, and a foamed layer in addition to the surface reinforcing layer and the reinforcing layer. The effects of these layers are as follows.

The floor material of the present invention is configured by laminating each layer as described above, but may be provided with a non-woven fabric layer (reference numeral "8" shown in FIG. 1) as the lowest layer, if necessary. .. This non-woven fabric layer is arranged to increase the adhesive strength between the floor material and the floor base when the floor material of the present invention is adhered to the floor base (see FIG. 1 above). This non-woven fabric layer is composed of, for example, a non-woven fabric layer made of polyethylene terephthalate (PET) fiber. The coating amount of the nonwoven fabric layer is preferably about ^{10 to 50 g / m 2.}

Further, in the floor material of the present invention, a printed layer (reference numeral "4" shown in FIG. 1) may be provided between the transparent resin layer and the non-foamed layer. This printing layer is arranged to give color and decoration to the floor material, and is configured by printing decoration such as wood grain on the surface of a thermoplastic resin sheet, for example.

In the floor material of the present invention, it is also useful to balance the strength of the entire laminated structure. From this point of view, the mass ratio of the resin amount of the upper layer portion (that is, the surface reinforcing layer, the transparent resin layer and the non-foamed layer) and the lower layer portion (that is, the foamed layer) (the resin amount of the upper layer portion) with the reinforcing layer as a boundary. : The amount of resin in the lower layer) is preferably in the range of 60:40 to 40:60. If it is out of this range, the warp tends to be large, and it is difficult to prevent it with the reinforcing layer.

The floor material of the present invention is adhered to the surface of the floor base with an adhesive 9 (see FIG. 1 above) to form a floor structure having at least excellent wear resistance, stain resistance, crack resistance, dimensional stability, and the like. ..

In order to manufacture the flooring material of the present invention, for example, it can be manufactured according to the process diagram shown in FIG. In the process shown in FIG. 2, the case where the print layers are not laminated is shown, but in the case of laminating the print layers, a step of laminating the print layers may be added in the middle of the series of steps.

FIG. 2 is an explanatory diagram schematically showing a process of manufacturing the floor material of the present invention. A resin solution 11a of polyvinyl chloride (PVC) is applied to both sides of a long glass fiber nonwoven fabric 10 cut to a predetermined width and wound by a pickup roll 12a, a coating roll 13a and a supply roll 14a. The resin liquid 11 is impregnated into the glass fiber nonwoven fabric 10 to form the reinforcing layer 6 (reinforcing layer forming step A). After that, the resin liquid 11b which is the material of the foam layer 7 is applied to the lower surface side of the reinforcing layer 6 by the pickup roll 12b to form the foam layer 7 (foam layer forming step B), and further, the lower surface of the foam layer 7 is formed. The non-woven fabric 15 is attached to the side to form the non-woven fabric layer 8 (nonwoven fabric layer forming step C).

Subsequently, the resin liquid 11c, which is the material of the non-foaming layer 5, is applied to the surface opposite to the surface on which the non-foaming layer 8 is formed (that is, the upper side surface of the foaming layer 7) by the coating roll 13b and the supply roll 14b. While forming the non-foaming layer 5 (non-foaming layer forming step D), the resin liquid 11d, which is the material of the transparent resin layer 3, is applied to the upper surface of the non-foaming layer 5 by the coating roll 13c and the supply roll 14c to make it transparent. The resin layer 3 is formed (transparent resin layer forming step E).

Finally, the resin liquid 11e, which is the material of the surface reinforcing layer, is applied to the upper surface side on which the transparent resin layer 3 is formed by the coating roll 13d and the supply roll 14d to form the surface reinforcing layer 2 (formation of the surface reinforcing layer). Step F), a floor material 1 having a laminated structure is obtained.

Although not shown in FIG. 2, the coating amount of each of the resin liquids 11a to 11e can be adjusted by arranging a doctor blade or the like. Further, if necessary, heating and pressurization may be performed in the middle of the above process or in the final stage to integrate each layer. In the step shown in FIG. 2, the resin liquid 11 is impregnated into the glass fiber nonwoven fabric 10 by roll coating, but other known methods such as depping, barcoting, and spray coating can also be used.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to any examples.

The details of each component used in this example are as follows.

(Surface strengthening layer)
-Trifunctional urethane acrylate-Five-functional urethane acrylate-Photopolymerization initiator: 1-hydroxycyclohexylphenylketone-Antibacterial agent: Ag-Cu-based compound-Deodorant: Zinc ion-bearing silicate compound (transparent resin layer)
-Paste PVC with a degree of polymerization of 1000 to 1500
・ Blend PVC
-Plasticizer: DOP (dioctyl phthalate)
(Non-foam layer)
-Paste PVC with a degree of polymerization of 1000 to 1500
・ Blend PVC
-Plasticizer: DOP (dioctyl phthalate)
・ Filler: Heavy calcium carbonate (reinforcing layer)
-Paste PVC with a degree of polymerization of 1000 to 1500
-Plasticizer: DOP (dioctyl phthalate)
-Reinforcing material: Non-woven fabric made of glass fiber (foam layer)
-Paste PVC with a degree of polymerization of 1000 to 1500
・ Blend PVC
-Plasticizer: DOP (dioctyl phthalate)
・ Filler: Heavy calcium carbonate ・ Foaming agent: ADCA (azodicarbonamide)
(Non-woven fabric layer)
PET fiber non-woven fabric

A surface-reinforced layer was produced by the method shown below using each of the above components.

Each layer is formed by the component ratios shown in Tables 1 and 2 (all the numerical values of the components in the table indicate parts by mass), and various types are laminated according to the manufacturing process shown in FIG. 2 to manufacture a flooring material having a laminated structure. did. At this time, for the surface reinforcing layer, various raw materials were mixed at the component ratios shown in Tables 1 and 2 to prepare a solvent-free and uniform coating agent, and a coating agent to be a surface reinforcing layer was prepared. Tables 1 and 2 also show the mass ratio (the amount of resin in the upper layer: the amount of resin in the lower layer), but this value is based on the value calculated in consideration of the thickness of each layer.

The following evaluation tests were performed on the samples (Examples 1 to 6 and Comparative Examples 1 to 8) obtained as described above.

[Abrasion resistance]
A taber wear test was conducted in accordance with JIS K 7204 (load: 9.80 N), and the state of wear marks on the surface of the test piece before and after the test was observed, and the wear resistance was evaluated according to the following criteria.
○: No wear marks, or the extent to which shiny marks appear when the surface is wiped off ×: Wear marks are completely visible

[Stain resistance (heel mark resistance)]
Carbon powder was sprinkled on the test piece after the Taber wear test, and the presence or absence of carbon powder adhering to the surface of the test piece was observed, and the stain resistance was evaluated according to the following criteria.
◯: No carbon powder adhered, or a small amount of carbon powder adhered ×: Carbon powder adhered

[Crack resistance]
A flexibility test was conducted in accordance with JIS A 1454, and crack resistance was evaluated according to the following criteria based on the crack generation status on the surface of the test piece.
○: No cracks occurred ×: Cracks occurred

[Dimensional stability]
In accordance with JIS A 1454 "Test for changing length and width by heating", a 300 mm x 300 mm test piece was kept in an incubator with a stirrer at 80 ° C for 6 hours, then taken out and left to stand indoors for 1 hour for length. The rate of change with respect to the length before the test in the vertical direction and the width direction was measured. When this rate of change is 0.15% or less in any direction, it can be judged that the dimensional stability is good.

[Caster resistance]
The test was carried out in accordance with the "caster resistance test A-2 method" specified in JIS A 1454, and the caster resistance was evaluated according to the following criteria from the swelling occurrence condition of the surface of the test piece after 4 hours.
◯: No swelling occurred △: Slight swelling occurred ×: Swelling clearly occurred

[Impact resistance]
The maximum acceleration (G value) measured according to the floor hardness test of JIS A 6519 was measured, and the impact resistance was evaluated. When the G value is 150 G or less, it can be determined that the impact resistance (impact absorption) is good.

[warp]
In accordance with JIS A 1454, 14 "warp test", a 300 mm x 300 mm test piece was used and left in a constant temperature room at 5 ° C with the surface facing up for 12 hours, and the amount of warp (5 ° C warp amount: mm). Was measured. In the case of downward warpage, (-) was displayed after the measured value.

The above evaluation results are shown in Tables 3 and 4.

From these results, it can be considered as follows. First, the flooring materials (Examples 1 to 6 shown in Tables 1 and 3) satisfying the requirements specified in the present invention were excellent in all of wear resistance, stain resistance, crack resistance and dimensional stability. .. Since these Examples 1 to 6 also satisfy the preferable requirements, they also exhibit excellent characteristics in terms of caster resistance and impact resistance (G value).

On the other hand, the floor materials (Comparative Examples 1 to 8 shown in Tables 2 and 4) that do not satisfy either the requirements specified in the present invention or the preferable requirements are inferior in any of the characteristics. Specifically, Comparative Example 1 is an example in which the content of the plasticizer in the reinforcing layer, the basis weight of the glass nonwoven fabric, and the coating amount of the reinforcing layer are less than the preferable lower limit, and the dimensional stability is deteriorated. Comparative Example 2 is an example in which the content of the plasticizer in the reinforcing layer, the basis weight of the glass nonwoven fabric, and the coating amount of the reinforcing layer exceed the preferable upper limits, and the crack resistance is deteriorated.

Comparative Example 3 is an example in which the foaming ratio in the foamed layer is small and the thickness is thin, and the crack resistance is deteriorated. Comparative Example 4 is an example in which the content of the foaming agent in the foam layer, the expansion ratio is large, and the thickness is large, and the sinking may be large and the upper layer may be damaged, and the caster resistance and impact resistance may be increased. The sex has deteriorated. Further, in this example, (the amount of resin in the upper layer portion: the amount of resin in the lower layer portion) is out of the preferable range, and warpage occurs.

Comparative Example 5 is an example in which the content of the foaming agent in the foam layer is excessive, the foaming ratio is increased, and the thickness is increased, and the caster resistance is deteriorated. Further, in this example, (the amount of resin in the upper layer portion: the amount of resin in the lower layer portion) is out of the preferable range, and warpage occurs. Comparative Example 6 is an example in which the thickness of the surface reinforcing layer is thin, and the wear resistance and the stain resistance are deteriorated.

Comparative Example 7 is an example in which the thickness of the surface reinforcing layer is increased, and although the wear resistance and the stain resistance are good, the crack resistance is deteriorated. Comparative Example 8 is an example in which urethane acrylate having 5 functional groups is mainly used as the surface reinforcing layer, and the flexibility of the surface reinforcing layer is lowered and the crack resistance is deteriorated.

1 Floor material 2 Surface reinforcing layer 3 Transparent resin layer 4 Printing layer 5 Non-foaming layer 6 Reinforcing layer 7 Foaming layer 8 Non-woven fabric layer 10 Glass fiber non-woven fabric 11a to 11e Resin liquid 12a, 12b Pickup roll 13a to 13d Coating roll 14a to 14d Supply roll

Claims (4)

A flooring material with a laminated structure
From the lower layer side to the upper layer side, the foam layer, the reinforcing layer, the non-foam layer, the transparent resin layer, and the surface reinforcing layer are laminated in this order.
The reinforcing layer comprises a layer obtained by impregnating a non-woven fabric made of glass fiber with paste polyvinyl chloride.
The surface reinforcing layer, with the number of functional groups composed of a layer mainly composed of urethane acrylates is 1-3, Ri its thickness 0.01~0.03mm der,
The mass ratio of the amount of resin in the upper layer composed of the surface reinforcing layer, the transparent resin layer and the non-foamed layer to the amount of the resin composed of the foamed layer (the amount of resin in the upper layer: the amount of resin in the lower layer) is 60:40 to 40:60. der Ru flooring. The floor material according to claim 1, further comprising a non-woven fabric layer as the lowest layer. The method for manufacturing the flooring material according to claim 1, wherein the flooring material includes a reinforcing layer forming step, a foaming layer forming step, a non-foaming layer forming step, a transparent resin layer forming step, and a surface reinforcing layer forming step in sequence. Manufacturing method. The method for manufacturing the floor material according to claim 2 , which is a reinforcing layer forming step, a foaming layer forming step, a non-woven layer forming step, a non-foaming layer forming step, a transparent resin layer forming step, and a surface reinforcing layer forming step. A method for manufacturing a flooring material including sequentially.

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