JPH0830310B2 - Cushioning heavy walking floor material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a cushioned heavy walking floor material which is excellent in strength and walkability and in which warpage and contraction are suppressed.

[Conventional technology]

As a conventional flooring material, for example, a flooring material consisting of a so-called solid layer formed by laminating a thermoplastic synthetic resin layer on the surface of a base material layer or a surface of a base material layer is sprayed with colored synthetic resin particles and then heated and compressed. Floor materials made of colored synthetic resin sheets are widely used.However, these floor materials leave a hard feeling on the floor surface and have poor walkability, so at least on the surface of the base material layer. A cushioning heavy walking floor material has been proposed in which a thermoplastic synthetic resin layer is laminated and a thermoplastic synthetic resin foam layer formed by chemical foaming is laminated on the back surface of the base material layer.

[Problems to be Solved by the Invention]

However, although a desired walkability (cushioning property) can be obtained with a floor material in which a thermoplastic synthetic resin foam layer formed by chemical foaming is laminated on the back surface of such a base material layer, many Sufficient strength cannot be obtained against external loads such as when people walk, so the surface of the flooring material may wear down and settle down over time, significantly reducing the commercial value of the flooring material. have.

The present invention has been made on the basis of such a conventional technique, and has a cushioning type heavy walking floor material which has excellent strength against external load and also has excellent walking property, and further, warpage and contraction are suppressed. The purpose is to provide.

[Means for solving the problem]

The present invention comprises a laminated structure in which a thermoplastic synthetic resin layer is laminated on at least the surface of a base material layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back surface of the base material layer. The present invention provides a cushioning heavy walking floor material obtained by heating the laminated structure under a heating condition in which the thermoplastic synthetic resin foam layer does not melt.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 shows an example of the cushioning heavy walking floor material of the present invention. A thermoplastic synthetic resin layer 20 is laminated on the front surface, and a thermoplastic synthetic resin foam layer 30 formed by mechanical foaming is laminated on the rear surface of the base material layer 10.

The base material layer 10 used in the present invention may be a single layer or a multi-layered material having two or more layers, as long as it has excellent dimensional stability such as felt-like sheet, woven fabric, knitted fabric and non-woven fabric. Yes, but especially from the aspect of dimensional stability, asbestos sheet,
A sheet in which at least two kinds of inorganic and / or organic fibers such as asbestos, glass fiber, carbon fiber, pulp and polyester fiber are mixed, glass fiber paper, paper and the like are preferable.

Further, a laminated body of a woven fabric and a non-woven fabric made of glass fiber, carbon fiber, synthetic fiber or the like can also be used.

Furthermore, if necessary, in these base material layers 10, a conductive substance such as carbon powder, carbon short fibers, surface-conductive inorganic and organic powders or short fibers (conductive calcium carbonate T130-2500 (Nitto Powder Chemical Co., Ltd., EC-
1, EC-5 (both manufactured by Maruo calcium Co., Ltd.), Dentor WK-100S (manufactured by Otsuka Chemical Co., Ltd.), Thunderon
When the paper is manufactured by impregnating a conductive resin solution containing SS-N (manufactured by Japan Silkworm Dyeing Co., Ltd.), etc., or other non-woven fabrics, glass-blended papers, etc. A conductive powder, a mixture of conductively-treated powder and fibers, and a woven or knitted fabric in which these conductive fibers and conductively-treated fibers are woven or knitted can be used.

The thickness of the base material layer 10 is usually preferably 0.1 to 2 mm, and if the thickness is less than 0.1 mm, the strength of the floor material obtained will be weak, while if it exceeds 2 mm, the cost will be high.

Examples of the main component of the thermoplastic synthetic resin that constitutes the thermoplastic synthetic resin layer 20 of the present invention include vinyl chloride resin, acrylic resin, vinyl acetate resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer resin, urethane resin and the like. However, vinyl chloride resins are preferable in consideration of abrasion resistance and cost.

The vinyl chloride resin in the present invention means polyvinyl chloride resin and vinyl chloride and other monomers such as ethylene, vinyl acetate, vinyl ether, maleic acid ester, (meth) acrylic acid, (meth) acrylic acid ester, acrylonitrile and urethane. A copolymer with
In addition, it also includes a mixture of a polyvinyl chloride resin and another polymer.

Further, the thickness of the thermoplastic synthetic resin layer 20 is preferably 0.1 to 5.0 mm, and if the thickness is less than 0.1 mm, the thermoplastic synthetic resin layer is abraded in a short time due to walking of a person and the life of the floor material is shortened. On the other hand, if it exceeds 5.0 mm, the floor material itself becomes hard, which is inconvenient for construction, and warpage and shrinkage easily occur.

Further, the thermoplastic synthetic resin layer 20 may be a single layer or multiple layers, and in the case of forming multiple layers, for example, the thermoplastic synthetic resin layer
The upper layer 20a is the uppermost layer 20a and the intermediate layer 20b is disposed below the upper layer 20a.
And the printing layer 20 between the upper coating layer 20a and the intermediate layer 20b.
You may interpose c.

Furthermore, in this case, the upper coating layer 20a, when the transparent or semi-transparent one is the intermediate layer 20b and the printing layer 20c is colored,
The design effect can be produced more effectively. Further, the thickness of the overcoat layer 20a is preferably 0.05 to 1 mm. This is because if the thickness is less than 0.05 mm, the abrasion resistance is poor, while if it exceeds 1 mm, the floor material tends to warp to the surface side and the price becomes high.

In addition, this surface layer can also be used as a floor material whose design is improved by using colored synthetic resin chips.

Further, it is also possible to thickly print a vinyl chloride resin paste or the like on the surface of the thermoplastic synthetic resin layer 20 by a rotary screen printing method or the like to improve the design.
It is also possible to form irregularities by an embossing method (embossing may be carried out before forming the thermoplastic synthetic resin foam layer by mechanical foaming or after forming it).

Furthermore, an antifouling paint such as an acrylic antifouling paint may be applied to the surface of the thermoplastic synthetic resin layer (including this when thick printing is performed) for the purpose of preventing stains.

Furthermore, the thermoplastic synthetic resin layer 20, if necessary,
It can also be formed by incorporating an antistatic plasticizer and / or an antistatic agent.

As the antistatic plasticizer mixed in the thermoplastic synthetic resin layer 20, tributoxyethyl phosphite (manufactured by Daihachi Chemical Co., Ltd., TBXP), butyldiglycol adipate (manufactured by Daihachi Chemical Co., Ltd., BXA), Sansosizer C-1100
(Manufactured by Shin Nihon Rikagaku Co., Ltd.), HA-100, AM-801, AM-80
1A are all manufactured by Sekisui Chemical Co., Ltd., etc., and some or all of general-purpose plasticizers such as dioctyl phthalate, dibutyl phthalate, butylbenzyl phthalate, dioctyl adipate, dihexyl phthalate, and diisononyl phthalate are substituted according to the purpose. The compounding amount is usually 5 to 1 with respect to 100 parts by weight of the synthetic resin.
00 parts by weight is preferred.

Examples of the antistatic agent mixed in the thermoplastic synthetic resin layer 20 include cation-based, anion-based, nonion-based and other commonly used antistatic agents, and the amount thereof is usually thermoplastic synthetic. 0.2 to 100 parts by weight of resin
10 parts by weight is preferred. The above compounding agents may be used alone or in combination of two or more.

In addition, other compounding agents such as plasticizers, stabilizers, fillers, viscosity modifiers, foaming agents, mildew-proofing agents, and colorants can be added to the thermoplastic synthetic resin layer 20 if necessary. Is.

When the thermoplastic synthetic resin layer 20 is formed as a single layer, particles of thermoplastic synthetic resin such as vinyl chloride resin particles are laid on a base material, and heated and melted or softened to flatten the emboss roller. Can be formed by pressure sintering.

As the thermoplastic synthetic resin particles, those having a transparent thermoplastic synthetic resin layer formed on the surface of the colored synthetic resin particles main body, colored synthetic resin particles having a disordered flow pattern containing a plurality of colored synthetic resins, and colored synthetic resin particles Any generally used one can be used, such as one having a conductive thermoplastic synthetic resin layer containing carbon black formed on the surface of the main body.

Further, it is possible to use a material in which thermoplastic synthetic resin strips are arranged on a base material, matrix resin powder or solution is filled between the thermoplastic synthetic resin strips, and heat-sintered or gelled.

As the thermoplastic synthetic resin as the main component constituting the thermoplastic synthetic resin foam layer 30, the same one as in the case of the thermoplastic synthetic resin layer 20 can be used, and as a means for forming the foam layer, a vinyl chloride resin is used. Means for mechanically mixing gas (air, gas, etc.) with a foam stabilizer added to the paste, etc., means for dissolving gas at high pressure in vinyl chloride resin paste, and expanding this gas at normal pressure In addition, an inert gas such as carbon dioxide gas or nitrogen gas can be used as the gas.

As the foam stabilizer, any commonly used foam stabilizer can be used. For example, a silicon-based foam stabilizer such as methylsiloxane emulsion, methylsiloxane, and xylene solution, a fluorine-based foam stabilizer, a fatty acid condensate, Alkylallyl sulfonates, metal soaps of oleic acid sericinoleic acid, guanidine salts, quaternary ammonium compounds, aldehyde-amine condensation products and the like can be used.

Further, the addition amount of the foam stabilizer is not particularly limited, may be appropriately adjusted as necessary, usually, to 100 parts by weight of the thermoplastic resin constituting the thermoplastic synthetic resin foam layer 30. , 0.1 to 25 parts by weight.

The expansion ratio of the thermoplastic synthetic resin foam layer 30 is usually 1.2 to 5 times, preferably 1.5 to 3 times.

Further, the thermoplastic synthetic resin foam layer 30 can be formed by mixing an antistatic plasticizer and / or an antistatic agent, if necessary, similarly to the thermoplastic synthetic resin layer 20, and other plasticizers, It is also possible to add compounding agents such as stabilizers, fillers, viscosity modifiers, foaming agents, antifungal agents and colorants.

Furthermore, the thickness of the thermoplastic synthetic resin foam layer 30 is 0.5 to 5
mm is preferable, and if it is less than 0.5 mm, good cushioning properties cannot be obtained and the walking property tends to deteriorate, while if it exceeds 5 mm, warping or shrinkage is likely to occur, which is not so preferable.

The total thickness of the cushioning heavy walking floor material A is 1 to 5 mm.
It is preferred that

Next, an example of a method for manufacturing the cushioning heavy walking floor material of the present invention will be described. A glass nonwoven fabric as a base material is coated and impregnated with a liquid synthetic resin composition such as a vinyl chloride resin paste, which is then gelled by heating. , Then apply a colored liquid synthetic resin composition such as a colored vinyl chloride resin paste on the surface side and then heat it to gel, and then apply gravure printing, screen printing (including rotary screen printing) to this surface After printing with any printing method and heating and drying, a transparent liquid synthetic resin composition such as a transparent vinyl chloride resin paste is further applied to this surface and then heated to gel, while mechanical foaming is applied to the back surface of the glass nonwoven fabric. A liquid synthetic resin composition such as the above-mentioned vinyl chloride resin paste is applied and gelled by heating. Next, the cushioned heavy walking floor material of the present invention is obtained by heating the obtained laminated structure under a heating condition in which the mechanically foamed thermoplastic synthetic resin layer does not melt. In this way, by heating the laminated structure, the cushioning heavy walking floor material is prevented from warping and contracting.

Further, in the cushioned heavy walking floor material of the present invention, a vinyl chloride resin sheet may be further laminated on the back surface of the thermoplastic synthetic resin layer mechanically foamed. In this case, after applying the mechanically foamed liquid synthetic resin composition to the back surface side of the glass nonwoven fabric, a vinyl chloride resin sheet may be attached and gelled by heating before the liquid synthetic resin composition does not gel. Alternatively, after gelling, a vinyl chloride resin sheet may be attached (either a dry laminating method or a wet laminating method may be used).

When a vinyl chloride resin sheet is attached, warp of the cushioned heavy walking floor material can be further suppressed.

As described below, according to the cushioning heavy walking floor material of the present invention, since the thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back surface of the base material layer, the conventional chemical foaming is used. Compared to the cushioning heavy walking floor material in which the formed thermoplastic synthetic resin foam layer is laminated, there is almost no permanent distortion of the thermoplastic synthetic resin foam layer even under continuous load, and the desired walkability is obtained. (Cushioning property) and sufficient strength against external load such as when a person walks on the floor material, so that the floor material may get tired over time. And a cushioning type heavy walking flooring material having excellent strength and walking ability, and the commercial value as a flooring material can be further improved.

In addition, if necessary, by using a conductive material, etc., the static electricity charged to people working on the flooring and various equipment can be effectively removed, and electric shock due to leakage from equipment etc. It is possible to eliminate the danger and obtain a safe floor material.

Furthermore, the cushioning heavy walking floor material of the present invention, when a flexible material is used for the base material layer, enables long winding together with the thermoplastic synthetic resin layer of the surface layer, which is rich in flexibility,
Since it does not break even when bent, it has excellent workability.

Further, in laying the cushioning heavy walking floor material of the present invention, for example, in addition to being used in a long sheet state, a tile state cut into a predetermined width is used as a general construction adhesive (synthetic rubber latex type, acetic acid). It can also be used as a floor surface material for a free access floor by adhering it to the floor surface of the free access floor using a vinyl resin solvent-based, epoxy resin-based, acrylic emulsion-based, EVA emulsion-based, or conductive adhesive. It is possible.

〔The invention's effect〕

In the cushioned heavy walking floor material of the present invention, a thermoplastic synthetic resin layer is laminated on at least the surface of the base material layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back surface of the base material layer. Further, since the laminated structure is heated under a heating condition in which the thermoplastic synthetic resin foam layer formed by mechanical foaming does not melt, it has excellent strength and walking ability, and further warps and shrinks. Is also suppressed.

〔Example〕

 Examples of the present invention will be described below.

Example 1 On a dense glass fiber paper having a fiber structure having a thickness of 0.25 mm,
Apply the vinyl chloride resin paste of formulation example 2 in Table 1 with a doctor knife coater to a thickness of 0.50 mm and in a heating furnace.
It was gelled by heating at 180 ° C for 1 minute.

Then, a predetermined pattern was printed on this surface with a gravure printing machine, and the vinyl chloride resin paste of formulation example 3 in Table 1 was applied with a doctor knife coater to a thickness of 0.1 mm, and at 180 ° C in a heating furnace. It gelled by heating for 1 minute.

Next, on the surface opposite to the surface coated with the vinyl chloride resin paste, compressed air was blown into the vinyl chloride resin paste of Formulation Example 1 in Table 1 and the mixture was stirred with a mixer to obtain a liquid foam in which small bubbles were dispersed throughout. At the doctor knife coater
It is applied with a thickness of 0.50 mm, heated and gelled at 180 ° C for 2 minutes in a heating furnace to form a thermoplastic synthetic resin foam layer, and further heated under heating conditions in which the thermoplastic synthetic resin foam layer does not melt (heating After heating in a furnace at 160 ° C. for 2 minutes, heating with a far infrared heater for 30 seconds), cooling and winding up, a cushioning heavy walking floor material with a total thickness of 1.35 mm was obtained.

The heating method under the heating condition in which the thermoplastic synthetic resin foam layer does not melt is not limited to the above, and for example, in a heating furnace or a similar heating device 13
It may be a method of heating at 0 to 190 ° C. for 0.5 to 10 minutes, a method of heating at a far infrared heater or a similar heating device for 10 to 180 seconds, or a method of using both of them together if necessary.

Next, the abrasion resistance of this cushioning heavy walking floor material was tested by a taper type abrasion test using S-42 sandpaper. As a result, there was almost no abrasion even after 10,000 times, and it was preferable.

In addition, a load of 8 kg / 25 cm ² (load equivalent to 80 kg of body weight) was continuously applied for 12 hours at 10 second intervals, and a strength test was performed for 12 hours without applying a load for 100 days. It did not produce any good cushioning properties.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view of the cushioning heavy walking floor material of the present invention. 10; Base material layer 20; Thermoplastic synthetic resin layer 30; Thermoplastic synthetic resin foam layer

Claims (1)

[Claims] 1. A laminate structure in which a thermoplastic synthetic resin layer is laminated on at least the surface of a base material layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back surface of the base material layer. And a cushioning heavy walking floor material obtained by heating the laminated structure under heating conditions in which the thermoplastic synthetic resin foam layer does not melt.