JP2000226933A - Floor material and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material made of olefin-based resin which has a laminated structure whose respective layers are bonded together with a sufficient strength and which can be easily produced by extrusion molding or the like. SOLUTION: This floor material is provided with a surface resin layer 1 chiefly composed of ethylene-based ionomer resin, an intermediate resin layer 2 laminated at the underface side of the surface resin layer 1 and composed of a copolymer of ethylene and unsaturated carboxylic acid as a chief component, and a backing resin layer 4 laminated at the underface side of the intermediate resin layer 2 and composed of olefin-based resin as a chief component. Further, the material is provided with a nonwoven fabric layer 3 between resins interposed in a state that it is pregmated with the resin components of both resin layers and composed of nonwoven thermoplastic resin layer fabric and a nonwoven fabric layer 5 of the rear face laminated at the underface side of the backing resinlayer 4 in a state that it is impregnated with the resin component of the resin layer and composed of nonwoven thermoplastic fabric.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material containing a polyolefin resin as a main component and having excellent combustion safety and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as interior flooring materials for stores, offices, hospitals, and the like, those containing polyvinyl chloride (PVC) resin are often used.
Poor quality due to reduced flexibility, and toxic gas is generated at the time of incineration, which poses problems such as disaster prevention in the event of fire, environmental pollution during disposal, and adverse effects on incinerators. .

[0003] In recent years, instead of the PVC resin, a technique of applying an olefin-based resin, which generates less toxic gas during combustion, to the flooring has been advanced. However, ordinary olefin-based resins are inferior in abrasion resistance and also have too high rigidity and poor adaptability to a floor substrate, so that it is difficult to apply them to floor materials and the like.

Under these circumstances, among olefin resins which generate little toxic gas during combustion, they are excellent in wear resistance, chemical resistance, stain resistance, and flexibility and are suitable as resin materials for flooring. , Ie, an ionomer of a copolymer of ethylene and methacrylic acid (ethylene ionomer)
The technology of applying resin to flooring is disclosed, for example, in Japanese Patent Publication No. Hei 9-504.
No. 482, Japanese Translation of PCT International Publication No. 9-504584, and JP-A-10-5
It has been proposed in, for example, US Pat.

[0005]

Generally, a resin-based flooring material has a laminated structure in which a plurality of resin layers are laminated, but the above-mentioned ethylene ionomer resin is different from a resin having a different composition. Is poor in adhesiveness.

[0006] For this reason, technical development of flooring using an ethylene-based ionomer resin is basically carried out on the premise that laminating resins having the same composition are compatible with each other. Will be composed of the resin material
There is a problem in that the flexibility of the material selection is lacking, for example, the cost is increased, and sufficient performance as a floor material cannot be provided.

On the other hand, flooring materials in which an olefin resin layer having a different composition is laminated on an ethylene ionomer resin layer have been conventionally proposed. However, this flooring material may be subjected to, for example, corona treatment to enhance adhesive strength. Activation treatment such as plasma treatment, flame treatment, etc. is performed in advance, or after lamination on olefin resin of different composition, heat treatment is performed, or specific adhesion with good adhesion to both layers between both layers Or performing complicated processing such as interposing a resin layer for use. For this reason, there is a problem that a special manufacturing apparatus is required, the manufacturing process becomes complicated, manufacturing becomes difficult, and the cost increases.

The present invention solves the above-mentioned problems of the prior art, has a laminated structure in which each layer is bonded with sufficient strength, and uses a general-purpose device such as a well-known extrusion device for manufacturing resin flooring. , It can be easily manufactured, cost can be reduced, and toxic gas is not generated during combustion.
An object of the present invention is to provide a flooring material excellent in abrasion resistance, chemical resistance, stain resistance, dimensional stability, shape stability, flexibility and construction adhesion, which are indispensable as a flooring material, and a method for producing the same.

[0009]

Means for Solving the Problems The present inventor has carried out intensive research and, as a result of intensive efforts, has found an optimum configuration as a flooring material capable of achieving the above object and a method of manufacturing the same. Reached.

That is, the flooring material of the present invention has a surface resin layer mainly composed of an ethylene-based ionomer resin, and is laminated on the lower surface side of the surface resin layer, and mainly contains a copolymer of ethylene and an unsaturated carboxylic acid. An intermediate resin layer, a backing resin layer laminated on the lower surface side of the intermediate resin layer and containing an olefin-based resin as a main component, and a resin between these two layers between the intermediate resin layer and the backing resin layer. Interposed in a state in which the components are impregnated, the inter-resin non-woven fabric layer made of a thermoplastic resin non-woven fabric, and laminated on the lower surface side of the backing resin layer in a state in which the resin component of the backing resin layer is impregnated. The gist of the present invention includes a back non-woven fabric layer made of a non-woven fabric made of a plastic resin.

In this flooring material, an inter-resin non-woven fabric layer composed of a non-woven fabric is interposed between an intermediate resin layer and a backing resin layer having different compositions, and each resin component of the intermediate resin layer and the backing resin layer is used as an inter-resin non-woven fabric. The layer is impregnated. For this reason,
The intermediate resin layer and the backing resin layer are bonded to each other with sufficient strength by the so-called anchor effect because the resin component is entangled with the non-woven resin layer.

Further, since the surface resin layer and the intermediate resin layer are composed of the same composition, they are bonded with high strength by fusion bonding, and the back non-woven fabric layer made of non-woven fabric has sufficient strength for the backing resin layer by the anchor effect. Glue with

The resin layers constituting the flooring material of the present invention, that is, the surface resin layer, the intermediate resin layer, and the backing resin layer are all materials having a low content of components that generate toxic gas when burned. At times, the generation of toxic gas is reduced as much as possible, resulting in excellent safety.

Further, the flooring material of the present invention uses an ethylene ionomer resin as the surface resin layer and uses a copolymer of ethylene and unsaturated carboxylic acid as the intermediate resin layer, so that the abrasion resistance and the anti-wear property are improved. It has excellent chemical properties, stain resistance and design properties, and has excellent performance as a flooring material. In addition, by forming the non-resin nonwoven fabric layer and the back nonwoven fabric layer, good dimensional stability, form stability and construction adhesiveness can be obtained, and the floor material has more excellent performance.

On the other hand, the flooring material of the present invention can be manufactured by using well-known thermoforming such as extrusion.

That is, in the method for producing a flooring material of the present invention, an intermediate resin layer containing a copolymer of ethylene and an unsaturated carboxylic acid as a main component is provided on the upper surface side of an inter-resin nonwoven fabric layer made of a thermoplastic resin nonwoven fabric. Extrusion coating to obtain a laminate,
A step of extrusion-coating a surface resin layer having an ethylene-based ionomer resin as a main component on the upper surface side of the intermediate resin layer in the laminate, and an olefin resin mainly on the lower surface side of the inter-resin nonwoven fabric layer in the laminate. Extrusion coating of the backing resin layer as a component, and on the lower surface side of the backing resin layer,
And a step of laminating a back non-woven fabric layer made of a non-woven fabric made of a thermoplastic resin.

As described above, the method for manufacturing a flooring material of the present invention utilizes a well-known extrusion lamination method or the like.
For example, it is necessary to separately perform activation treatment such as heat treatment, corona treatment, plasma treatment, and flame treatment, or perform troublesome treatment such as inserting a specific adhesive resin layer between resin layers having different compositions. There is no. Therefore, it can be easily manufactured using a general-purpose extruder or the like, and cost can be reduced.

Hereinafter, the configuration of the present invention will be described in more detail.

As shown in FIG. 1, the flooring (10) of the present invention
The surface resin layer (1), the intermediate resin layer (2), the inter-resin non-woven fabric layer (3), the backing resin layer (4), and the back non-woven fabric layer (5) are sequentially laminated from the upper surface side. It has a laminated structure.

In the present invention, as the surface resin layer (1), a resin composition containing an ethylene ionomer resin as a main component is used.

The carboxyl group of an ethylene ionomer resin such as a copolymer of ethylene and an α, β unsaturated carboxylic acid or a copolymer of ethylene and an α, β unsaturated carboxylic acid ester is a metal salt. A partially or completely neutralized resin.

In the present invention, the α, β unsaturated carboxylic acid includes acrylic acid, methacrylic acid, ethacrylic acid,
Maleic acid, fumaric acid, maleic anhydride and the like can be used, and acrylic acid, methacrylic acid and the like can be particularly preferably used.

As the α, β unsaturated carboxylic acid ester, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, isobutyl acrylate, butyl methacrylate, dimethyl fumarate and the like can be used. Acrylic acid, methacrylic acid esters and the like can be suitably used.

As a specific example of the ethylene ionomer resin, for example, zinc (Zn) or sodium (Na) is allowed to act on an ethylene / methacrylic acid copolymer or ethylene / methacrylic acid ester to form a metal ion bond. Thus, Himilan (trade name) manufactured by Mitsui-Dupont Chemical Co., Ltd., which has been crosslinked, is well known.

The ethylene ionomer resin has the property that it is a transparent resin which is tough, rigid, and excellent in wear resistance due to metal ions.

The ethylene ionomer resin used in the present invention includes MFR (JIS K676)
0) is preferably 0.5 to 20 g / 10 min, more preferably 5 g / 10 min or more.

In the present invention, the content of the ethylene-based ionomer resin is determined by adjusting the total amount of the surface resin layer composition to 10%.
When the amount is 0 parts by weight, the amount is preferably set to 80 to 100 parts by weight, more preferably 90 parts by weight or more.

Further, in the present invention, a resin other than the ethylene ionomer resin may be mixed with the composition for the surface resin layer. As the mixed resin, it is necessary to use a resin having good compatibility with the ethylene-based ionomer resin, and examples thereof include a copolymer of ethylene and an unsaturated carboxylic acid. Specifically, ethylene
Acrylic acid (EAA), ethylene methyl acrylate (EMA), ethylene acrylamide (EAAM),
Examples include ethylene-methacrylic acid (EMAA), ethylene-methyl methacrylate (EMMA), ethylene-maleic anhydride, and the like. Particularly preferred mixed resins include ethylene-methacrylic acid and copolymers of ethylene-methacrylic acid ester. can do. These mixed resins may be used alone or as a mixture of a plurality of types.

The mixing amount of these mixed resins is 10 parts by weight or less, more preferably 0.5 parts by weight or more, and the upper limit is 2 parts by weight, based on 100 parts by weight of the total amount of the composition for the surface resin layer. It is better to set it below the weight part. If the mixing ratio of the mixed resin is too large, the blending amount of the ethylene ionomer resin is relatively small, and a property unique to the ethylene ionomer resin, that is, a property that is strong, has high rigidity, and has excellent wear resistance is obtained. May not be possible.

In the present invention, a pattern material may be incorporated into the composition for the surface resin layer, if necessary, in order to improve the design.

By mixing the pattern material into the surface resin layer (1), the pattern material is randomly mixed in the transparent or translucent surface resin layer (1), and a deep pattern pattern can be displayed. it can.

As the pattern material, commonly used well-known materials can be used and are not particularly limited. For example, granules made of thermosetting urea resin or thermoplastic polyester resin, cellulose or aluminum A square or flake-shaped handle chip made of cellulose as a main material, and a needle-shaped material of about 0.2 to 2 mm made of cellulose as a main material can be suitably used. These inorganic or fiber pattern materials may be used alone or as a mixture of a plurality of types.

When the pattern material is mixed, the mixing amount is
In the composition for the surface resin layer, the total amount is 100 parts by weight,
It is good to set it to 15 parts by weight or less, more preferably 5 parts by weight or less. That is, when the mixing amount of the pattern material deviates from the above range, it may be difficult to make the surface resin layer (1) exhibit a deep and beautiful pattern with good appearance.

Further, a coloring pigment can be mixed into the composition for the surface resin layer instead of the pattern material or in combination with the pattern material. When mixing this pigment, the mixing amount is 0.1 to 100 parts by weight of the total amount of the composition for the surface resin layer.
It is good to set to 5 parts by weight. In other words, if the amount is too small, the coloring may be insufficient.If the amount is too large, the physical properties of the composition may be deteriorated.
There is a risk of increasing costs.

The surface resin layer (1) has a thickness of 0.1 to 1 m.
It is preferable to adjust to m. That is, when the thickness is too small, the effect peculiar to the ethylene ionomer resin cannot be obtained, and the thickness balance between the resin layers (1), (2), and (4) is disturbed, and harmful warpage is caused. May occur. If the thickness is too large, each resin layer (1)
The thickness balance between (2) and (4) may be disturbed, and harmful warpage may occur.

In the present invention, as the intermediate resin layer (2) laminated on the lower surface side of the surface resin layer (1), a resin composition mainly containing a copolymer of ethylene and an unsaturated carboxylic acid is used. You.

The copolymers of ethylene and unsaturated carboxylic acid are the same as those described above, for example, ethylene acrylic acid (EAA), ethylene methyl acrylate (EM
A), ethylene / acrylamide (EAAM), ethylene / methacrylic acid (EMAA), ethylene / methyl methacrylate (EMMA), ethylene / maleic anhydride, and the like. In particular, ethylene as the surface resin layer (1) From the viewpoint of adhesion to the olefin resin as the base ionomer resin and the backing resin layer (4), it is desirable to use a resin composed of a copolymer of ethylene / methacrylic acid or ethylene / ethacrylic ester.

In the present invention, the content of the copolymer of ethylene and unsaturated carboxylic acid in the intermediate resin layer (2) is defined as 100 parts by weight of the total amount of the composition for the intermediate resin layer.
The content is preferably set to 50 to 95 parts by weight, and more preferably, the lower limit is set to 60 parts by weight or more and the upper limit is set to 80 parts by weight or less.

It is preferable to mix an inorganic filler in the composition for the intermediate resin layer. As the inorganic filler, calcium carbonate, magnesium carbonate, calcium sulfate, calcium silicate, clay, talc, alumina, silica sand, silica, and the like, which can be used well-known fillers for flooring materials, can be used alone. Alternatively, a mixture of a plurality of types may be used.

The mixing amount of the inorganic filler is preferably set to 20 to 60 parts by weight, with the total amount of the composition for the intermediate resin layer being 100 parts by weight, more preferably the lower limit is 25 parts by weight or more, and the upper limit is 25 parts by weight or more. The value is preferably set to 50 parts by weight or less. If the amount of the inorganic filler is too small, the dimensional stability may be reduced, or a harmful warpage may occur in the product, and the cost may increase.If the amount is too large, on the other hand, The color of the color pigment described below may be adversely affected, and the pigment may become brittle and cause a whitening phenomenon.

It is preferable to mix a coloring pigment for coloring in the composition for the intermediate resin layer. The mixing amount of the pigment is preferably set to 0.1 to 5 parts by weight, with the total amount of the composition for the intermediate resin layer being 100 parts by weight. If the amount is too small, the coloring may be insufficient. On the other hand, if the amount is too large, the physical properties of the resin composition may deteriorate and the cost may increase.

By mixing the color pigment into the intermediate resin layer (2) in this way, the lower backing resin layer (4) and the like are concealed and the colored intermediate resin layer (2) becomes transparent or semi-transparent. An excellent aesthetic appearance can be obtained by being visually recognized through the transparent surface resin layer (1).

Even when a color pigment is mixed in the surface resin layer (1), opacity is imparted by mixing a white pigment or the like in the intermediate resin layer (2). ) Can be enhanced.

The intermediate resin layer (2) has a thickness of 0.1 to 1 m.
It is good to adjust to m. That is, if the thickness deviates from the specified range, the thickness balance between the resin layers (1), (2), and (4) may be disturbed, and harmful warpage may occur.

In the present invention, as the backing resin layer (4), a resin composition containing an olefin resin as a main component is used.

Examples of the olefin-based resin include polypropylene (PP), polyethylene (PE), and ethylene copolymers such as ethylene-vinyl acetate copolymer (EVA) and ethylene-ethyl acrylate copolymer (EEA). Can be suitably used. Among them, EVA and EEA are particularly preferred in consideration of the flexibility and heat sealability required for the floor material.
It is preferable to use an ethylene copolymer such as

The amount of the olefin resin is preferably adjusted to 20 to 60 parts by weight based on 100 parts by weight of the total amount of the composition for the backing resin layer.

It is preferable to mix an inorganic filler in the composition for the backing resin layer. As the inorganic filler, the same as those described above, for example, calcium carbonate, magnesium carbonate, calcium sulfate, calcium silicate, clay, talc, alumina, silica sand, silica, and the like can be suitably used. May be used as a mixture of a plurality of types.

The mixing amount of the inorganic filler is preferably adjusted to 40 to 70 parts by weight based on 100 parts by weight of the total amount of the composition for the backing resin layer. That is, when the amount of the inorganic filler mixed is too large, the inorganic filler becomes brittle and easily cracks, and the rigidity is excessively increased, the flexibility is reduced, and the adaptability to the floor substrate may be reduced. When the amount is too small, not only the dimensional stability and the installation stability are deteriorated, but also the use of a relatively expensive olefin resin increases, which may lead to an increase in cost.

It is preferable to add a plasticizer to the composition for the backing resin layer in order to impart flexibility and elasticity and to further improve processability and moldability. As the plasticizer, for example, ester plasticizers such as phthalic acid ester, phosphoric acid ester, and adipic acid ester can be suitably used.

The amount of the plasticizer added is preferably adjusted to 2 to 10 parts by weight based on 100 parts by weight of the total amount of the composition for the backing resin layer. That is, if the amount of the plasticizer added is too large, there is a possibility that dents and residual dents of products required as flooring products may deteriorate. If the amount of the plasticizer is too small, it may be difficult to obtain good flexibility, elasticity, workability, and moldability.

The backing resin layer (4) has a thickness of 1 to 5 mm.
It is preferred to adjust to. That is, if this thickness is too thin, good installation stability cannot be obtained, and furthermore, the thickness balance between the resin layers (1), (2) and (4) may be disturbed, and harmful warpage may occur. is there. On the other hand, if the thickness is too large, good flexibility cannot be obtained, the adaptability to the floor substrate may be reduced, and harmful warpage may occur due to disorder in the thickness balance of each resin layer.

In the present invention, between the intermediate resin layer (2) and the backing resin layer (4), an inter-resin nonwoven fabric layer (3) made of a thermoplastic resin nonwoven fabric is interposed.

As the non-woven fabric made of a thermoplastic resin, a non-woven fabric made of polypropylene (PP) resin, polyester fiber (PET resin), or nylon (Ny) fiber can be suitably used. In consideration of safety, it is preferable to use a halogen-free PP resin or PET resin. Furthermore, these thermoplastic resins may be used alone to form a nonwoven fabric, or a plurality of thermoplastic resins may be mixed as needed to form a nonwoven fabric.

The inter-resin nonwoven fabric layer (3) not only provides dimensional stability which is indispensable as a flooring product, but also bonds the intermediate resin layer (2) and the backing resin layer (4) having different compositions with high adhesive strength. Can be. That is, the non-woven fabric layer between resins (3)
Has a structure in which the respective resin components of the intermediate resin layer (2) and the backing resin layer (4) are impregnated and entangled, as described later, and both resin layers (2) ( 4) adheres with sufficient strength.

The non-woven fabric constituting the non-woven fabric layer (3) has a basis weight of 10 to 120 g / m ² , preferably a lower limit of 15 g / m ² or more and an upper limit of 50 g / m ^2.
The following should be used: That is, if the basis weight is too small, not only is it difficult to obtain good dimensional stability, but also the entanglement of the resin components becomes insufficient, and the intermediate resin layer (2) and the backing resin layer (4) May be difficult to adhere with sufficient strength. If the basis weight is too large, impregnation of the resin components of the intermediate resin layer (2) and the backing resin layer (4) becomes insufficient, and the two resin layers (2) and (4) are bonded with sufficient strength. Can be difficult.

Further, in order to further improve the dimensional stability of the flooring (10), a reinforcing member made of a net-like glass fiber is bonded and laminated on the nonwoven fabric of the non-woven fabric layer (3). Is preferred.

In the present invention, the back nonwoven fabric layer (5) is laminated on the lower surface side of the backing resin layer (4). As the non-woven fabric layer (5), the same material as that of the inter-resin non-woven fabric layer (3) can be suitably used. In particular, in consideration of safety during combustion, a non-woven fabric made of PP resin or PET resin is used. Is desired.

The back nonwoven fabric layer (5) is impregnated with an adhesive on the floor substrate at the time of floor material construction, so that the floor material (1) is
The purpose of the present invention is to improve the adhesiveness of the floor material (0) to the floor substrate and to balance the tension between the front and back surfaces of the floor material (10), thereby preventing harmful warpage of the floor material.

As described later, the back nonwoven fabric layer (5)
It has a structure in which the resin component of the backing resin layer (4) is impregnated and entangled, and adheres to the backing resin layer (4) with sufficient strength by an anchor effect.

[0061] As the nonwoven fabric constituting the back side nonwoven fabric layer (5), those having a basis weight of 10 to 100 g / m ^2, preferably, the lower limit is 15 g / m ² or more, the upper limit is 50 g / m ²
The following should be used: In other words, when the basis weight is too small, the center of the back side swells due to insufficient strength, and valley warpage occurs, and the entanglement of the adhesive on the floor base during construction becomes insufficient, and the floor material is applied to the floor base. It may be difficult to secure sufficient adhesiveness. If the basis weight is too large, on the contrary, due to excessive strength, the center of the surface side swells and mountain warpage occurs, and the impregnation of the adhesive on the floor substrate becomes insufficient, and the floor material is applied to the floor substrate. It may be difficult to secure sufficient adhesiveness.

In the present invention, the total thickness of the surface resin layer (1) and the intermediate resin layer (2) is preferably set smaller than the thickness of the backing resin layer (4). In particular,
The thickness of the surface resin layer (1) is “T1”, and the intermediate resin layer (2)
Is T2 (including the impregnated portion of the nonwoven fabric layer between resins) and the thickness of the backing resin layer (4) is "T4 (including the impregnated portion of the nonwoven fabric layer)", T1 + T2 ≧ T3,
More preferably, the thickness of each of the resin layers (1), (2), and (4) is adjusted so that the relationship of T1 + T2> T3 is satisfied. That is, when this relationship is not established, harmful warpage may occur due to disturbance in the thickness balance between the resin layers.

The flooring material (10) of the present invention has the above-described structure, and can be manufactured by using, for example, well-known extrusion molding.

That is, a non-woven fabric of a thermoplastic resin reinforced by glass fiber as needed (inter-resin non-woven fabric layer) is used as a support, and an intermediate resin layer (2)
The composition as a melt-laminated by extrusion lamination,
A first laminate in which the intermediate resin layer (2) is laminated on the non-woven resin layer (3) is obtained.

In this extrusion lamination (extrusion coating), a part of the molten resin component constituting the intermediate resin layer (2) is impregnated into the non-woven fabric layer (3) and entangled, and then cooled in that state. After being solidified, the inter-resin nonwoven fabric layer (3) adheres to the intermediate resin layer (2) with sufficient strength.

Next, using the first laminate as a support, the composition as the surface resin layer (1) is melt-laminated by extrusion lamination on the intermediate resin layer (2) to form a second laminate. Get the body.

As described above, the surface resin layer (1) and the intermediate resin layer (2) are made of a resin having the same composition.
Both layers (1) because they have good compatibility with each other
(2) is adhered with sufficient strength.

Subsequently, using the second laminate as a support,
The composition as the backing resin layer (4) is melt-laminated by extrusion lamination on the lower surface side of the inter-resin nonwoven fabric layer (3), and at the same time, the back surface nonwoven fabric layer is formed on the lower surface side of the molten backing resin layer (4). The nonwoven fabric as (5) is attached.

At the time of lamination, a part of the molten resin component constituting the backing resin layer (4) is impregnated into the inter-resin nonwoven fabric layer (3) and the back nonwoven fabric layer (5) and becomes entangled. Is cooled and solidified. Therefore, the backing resin layer (5) adheres to the intermediate resin layer (2) with sufficient strength via the inter-resin nonwoven fabric layer (3), and the back nonwoven fabric layer (5) adheres to the backing resin layer (5). Adhere with sufficient strength.

Thus, the flooring (10) of the present invention is manufactured.

As described above, the flooring material of the present invention can be produced by using a well-known T-die extruder which usually produces films and sheets, that is, without using any special equipment or complicated steps. In addition, it can be easily manufactured and cost can be reduced.

In addition, each layer (1) to
Since (5) are adhered to each other with sufficient strength, high quality can be obtained as a floor material.

Further, in the present invention, since an ethylene ionomer resin is used as the surface resin layer (1) and a copolymer of ethylene and an unsaturated carboxylic acid is used as the intermediate resin layer (2), good results are obtained. Abrasion resistance, chemical resistance, stain resistance and design can be obtained, and it has excellent performance as a floor material. Further, by forming the inter-resin nonwoven fabric layer and the back nonwoven fabric layer, good dimensional stability, form stability and construction adhesiveness can be obtained, and more excellent quality as a flooring material can be obtained.

As the resin layers (1), (2) and (4),
Because non-halogen olefin resin is used,
The generation of toxic gas during combustion can be suppressed to a low level, the combustion safety is excellent, the recycling is possible, and it is possible to sufficiently cope with environmental problems.

[0075]

EXAMPLES Examples related to the present invention and comparative examples for verifying the effects will be described below.

[0076]

[Table 1]

Example 1 As shown in Table 1 above, 68 parts by weight of ethylene / methacrylic acid ester (trade name "Nucrel" manufactured by Mitsui / Dupont Chemical Co., Ltd.) as an ethylene / unsaturated carboxylic acid copolymer And a composition for an intermediate resin layer, in which 30 parts by weight of calcium carbonate as an inorganic filler and 2 parts by weight of a coloring pigment are compounded, is extruded by a well-known extruder into a sheet having a thickness of 400 μm. ,
It was melt-laminated on one surface (upper surface) of an inter-resin nonwoven fabric layer made of a polyester fiber nonwoven fabric having a basis weight of 40 g / m ² to obtain a first laminate.

Ethylene ionomer resin (trade name “HIMILAN” manufactured by Mitsui / Dupont Chemical Co., Ltd.) 98
The composition for the upper surface resin layer, in which 2 parts by weight of a square pattern material made of cellulose as a main raw material (trade name “Nazi flake” manufactured by Dia Kogyo Co., Ltd.) was added to parts by weight, was thickened by a well-known extruder. Extruded into a 300 μm sheet, melt-laminated on the intermediate resin layer in the first laminate,
Was obtained.

Ethylene-vinyl acetate copolymer (EVA)
35 parts by weight of calcium carbonate 59 as an inorganic filler
Parts by weight, 5 parts by weight of dioctyl phthalate (DOP),
The composition for the backing resin layer to which 1 part by weight of the pigment has been added is extruded into a sheet having a thickness of 1300 μm by a well-known extruder, and the other surface of the inter-resin nonwoven fabric layer in the second laminate is formed. At the same time as being melt-laminated on the (lower surface), a polyester fiber non-woven fabric having a basis weight of 20 g / m ² as a back non-woven fabric layer was bonded to the lower surface of the extruded backing resin layer and pressure-bonded to obtain a floor material sample of Example 1. Was.

Example 2 The same procedure as in Example 1 was carried out except that a polyester fiber nonwoven fabric having a basis weight of 40 g / m ² in which a reinforcing member made of a net-like glass fiber was laminated and integrated was used as the non-woven fabric layer between resins. Similarly, a floor material sample of Example 2 was obtained.

Comparative Example 1 A floor material sample of Comparative Example 1 was obtained in the same manner as in Example 1 except that the back nonwoven fabric layer was omitted.

Comparative Example 2 A floor material sample of Comparative Example 2 was obtained in the same manner as in Example 1 except that the non-resin nonwoven fabric layer was omitted.

[Evaluation Test] For each of the above floor material samples,
The following tests were performed.

1. Abrasion resistance According to the friction test method for building materials and building components according to JIS A 1453, using a wear wheel on which a predetermined abrasive paper is wound around the surface of each floor material sample, a taper abrasion tester is used. After rotation, the weight loss (g) was measured.

Those having a wear loss of 0.3 g or less were evaluated as acceptable "O".

2. Stain resistance According to the stain test of the vinyl flooring material according to JIS A 5705, 2 m of the soiling material was applied to the surface of each floor material sample.
After dripping, let stand for 24 hours, wash with water containing a neutral detergent, further wash with alcohol, wipe off with gauze, leave for 1 hour, and visually change the color, gloss and swelling of the dropped portion Was observed.

A sample which did not change by the observation was evaluated as “good”.

3. Flexibility Each of the above floor material samples is cut into a size of 5 cm × 15 cm to obtain sample pieces. Each sample piece is left in a standard state (20 ± 2 ° C., 65 ± 2% RH) for 24 hours or more. At room temperature conditions of 20 ± 2 ° C., as shown in FIG. 2A, fulcrums (21) and (21) having a diameter of 12 mm and arranged at intervals of 13 cm in the long side direction of the sample piece (20).
Place on top. Subsequently, as shown in FIG. 2 (b), a pressurizer (22) at the center between the fulcrums (21) and (21) is used to move the sample piece (20) from the top of the sample piece (20) at a speed of 50 mm / min.
It was compressed by 0 mm and the strength at that time was measured.

Those having a strength of 0.4 kgf or less were judged as acceptable "O".

4. Dimensional stability According to the length change test of vinyl flooring by heating according to JIS A 5705, each flooring sample was heated at 80 ° C. for 6 hours, then allowed to stand in a room for 1 hour, and the length before heating. Was measured.

A sample with a length change rate of 1.0% was evaluated as good (pass), and a sample with a length change rate of 0.5% or less was evaluated as excellent (pass). 1.0-2.0
% Was evaluated as defective (failed) “△”.

[0092] 5. Peel strength Each of the floor material samples was cut into a size of 5 cm × 15 cm to obtain sample pieces, each sample piece was peeled off from one end of its long side by 5 cm, and the peeled portion was gripped by a tensile tester. , And pulled at a speed of 200 mm / min, and the strength at that time was measured.

Those having a strength of 5 kgf or more under normal conditions were evaluated as "good", and those having a strength of less than 5 kgf were evaluated as "poor".

6. Product shape Each of the above floor material samples is cut into a square of 50 cm × 50 cm to obtain sample pieces. Each sample piece is placed on a stainless steel plate having a thickness of 3 mm or more, placed horizontally, and placed in a standard state (20 ± 2 ° C.). , 65 ± 2% RH) for 24 hours or more, placed on a horizontal test table, and measured the size of the gap between the four corners of each sample and the test table.

A sample having a total of gaps of 4 cm or less at the four corners of each sample piece to the front side or the back side was judged as acceptable (○), and one with less than 2 cm was judged as unacceptable (X).

7. According to the 90-degree peeling test method according to JIS A 5536, each floor material sample is cut into a size of 25 mm x 200 mm to obtain a sample piece, and each sample piece is thickened to a size of 70 mm x 150 mm. Specimens bonded to an asbestos slate (flexible plate) having a thickness of 5 to 8 mm with an adhesive were prepared. Further, the remaining of the bonded part was about 25 so that the peel angle was 90 ± 10 degrees.
mm at a pulling speed of 200 mm / min.
The strength was measured.

Those having a strength of 2.5 kgf or more under normal conditions were evaluated as "good", and those having a strength of less than 2.5 kgf were evaluated as "poor".

[0098]

[Table 2]

[Evaluation] The results of the above-mentioned tests are shown in Table 2 above.

As shown in Table 2 above, in Examples 1 and 2 related to the present invention, excellent evaluation was obtained in any of the tests and high quality as a flooring material was obtained. I understand. In particular, it can be seen that the product of Example 2 is more excellent in dimensional stability, and has higher quality.

On the other hand, those of Comparative Examples 1 and 2, which deviate from the gist of the present invention, have dimensional stability, peel strength, product shape,
It turns out that it is inferior to evaluation of construction adhesiveness.

[0102]

As described above, according to the flooring material of the first aspect of the present invention, each layer is adhered with sufficient strength, and can be easily manufactured using a general-purpose device such as a well-known extruder. Cost reduction can be achieved, and less toxic gas is generated during combustion. In addition, abrasion resistance, chemical resistance, stain resistance, dimensional stability, shape stability, flexibility, construction, which are indispensable as flooring materials There is an effect that the adhesiveness is excellent.

In the first invention, when each resin layer is formed of a composition of a specific component, there is an advantage that the above effects can be obtained more reliably.

Further, in the first invention, when the nonwoven fabric layer is made of a specific material, there is an advantage that the above effects can be obtained more reliably.

In the first invention, when each resin layer is adjusted to a specific thickness, the balance between the front surface side and the rear surface side of the flooring material is achieved, and no harmful warpage occurs. There is an advantage that form stability can be further improved.

The method for manufacturing a flooring material according to the second aspect of the present invention specifies one aspect of the process for manufacturing a flooring material according to the first aspect of the invention, and can produce a flooring material having the above-described effects. This has the effect.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing a floor material related to the present invention.

FIG. 2 is a side view for explaining a flexibility evaluation test method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Surface resin layer 2 ... Intermediate resin layer 3 ... Inter-resin nonwoven fabric layer 4 ... Backing resin layer 5 ... Backside nonwoven fabric layer 10, 20 ... Floor material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 27/32 B32B 27/32 E // B29K 23:00 701: 12 B29L 31:10 F term (reference) 4F100 AA01B AA01C AA08H AG00D AH02H AJ04A AK01D AK01E AK03C AK03D AK03E AK04B AK04D AK04J AK07D AK07E AK24B AK24D AK24J AK41D AK41E AK68 AK70A AL01B AL01D BA05 BA07 CA04 CA04C CA13A CA13B CA23 CA23B CA23C DG01D DG01E DG15D DG15E EC032 EG002 EH152 EH172 EK01 GB07 JA20D JA20E JB16D JB16E JL02 JL10B JL11 YY00D YY00E 4F207 AA03 AA04E AA20E AA22 AB11 AB12 AB16 AB25 AD16 AG02 AG03 AH48 KA01 KA17 KB13 KB26 KK81

Claims (11)

[Claims] A surface resin layer mainly composed of an ethylene ionomer resin; an intermediate resin layer laminated on a lower surface side of the surface resin layer and mainly composed of a copolymer of ethylene and an unsaturated carboxylic acid; A backing resin layer laminated on the lower surface side of the intermediate resin layer and containing an olefin-based resin as a main component; and a state in which the resin components of both layers are impregnated between the intermediate resin layer and the backing resin layer. Interposed between the non-woven fabric layers made of thermoplastic resin non-woven fabric, and on the lower surface side of the backing resin layer, laminated with the resin component of the backing resin layer impregnated, from the thermoplastic resin nonwoven fabric A floor material comprising a back non-woven fabric layer. 2. The copolymer of ethylene and an unsaturated carboxylic acid having a total amount of 100 parts by weight, wherein
The flooring material according to claim 1, comprising a composition containing not more than 15 parts by weight, not more than 15 parts by weight of a pattern material, and not more than 5 parts by weight of a pigment. 3. The intermediate resin layer, wherein the total amount is 100 parts by weight, the inorganic filler is 20 to 60 parts by weight, and the pigment is 0.1% by weight.
The flooring material according to claim 1, comprising a coloring composition contained in an amount of from 5 to 5 parts by weight. 4. The backing resin layer comprises 50 to 70 parts by weight of an inorganic filler and 1 part by weight of a plasticizer based on a total amount of 100 parts by weight.
4. The composition according to claim 1, wherein the composition contains 0 parts by weight or less.
The flooring material according to any of the above. 5. The non-woven fabric layer between resins has a basis weight of 10 to 12.
Floor material according to any one of claims 1 to 4 consisting of 0 g / m ² nonwoven fabric. 6. The flooring material according to claim 1, wherein the non-woven fabric layer includes a reinforcing member made of glass fiber. 7. The back nonwoven fabric layer has a basis weight of 10 to 100.
Floor material according to any one of claims 1 to 6 consisting of g / m ² nonwoven fabric. 8. The flooring material according to claim 1, wherein the nonwoven fabric as the inter-resin nonwoven fabric layer and the back nonwoven fabric layer is made of a polypropylene resin or polyester fiber. 9. The thickness of the surface resin layer is 0.1 to 1 m.
m, the thickness of the intermediate resin layer is set to 0.1 to 1 mm, and the thickness of the backing resin layer is set to 1 to 5 mm.
9. The flooring material according to any one of items 1 to 8. 10. The flooring material according to claim 1, wherein a total thickness dimension of the surface resin layer and the intermediate resin layer is set smaller than a thickness dimension of the backing resin layer. 11. An intermediate resin layer containing a copolymer of ethylene and an unsaturated carboxylic acid as a main component is extrusion-coated on the upper surface side of an inter-resin non-woven fabric layer made of a non-woven fabric made of a thermoplastic resin to form a laminate. Obtaining, a step of extrusion-coating a surface resin layer mainly composed of an ethylene ionomer resin on the upper surface side of the intermediate resin layer in the laminate, and an olefin on the lower surface side of the inter-resin nonwoven fabric layer in the laminate. Extrusion coating a backing resin layer containing a base resin as a main component, and laminating a backside nonwoven fabric layer made of a thermoplastic resin nonwoven fabric on the lower surface side of the backing resin layer.