JP2001096689A - Sheet for building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a non-halogen type sheet for a building material having good adhesion to an adhesive used at applying the sheet to a floor or wall surface, good in productivity and suitable as a substitute of a vinyl chloride resin type sheet for a building material. SOLUTION: In a sheet for a building material consisting of a base sheet made of a polyolefinic resin, the surface material provided on one surface thereof and the backing material provided to the opposite surface of the base sheet, a sheetlike member having the heat fusibility with the base sheet at least on its back sheet side and having the easy adhesion to an adhesive at least on its opposite side is thermally fused to the base sheet at the time of formation of the base sheet to provide the backing material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet for building materials such as non-halogen type floor tiles and wall panels, and more particularly, it has good adhesiveness to an adhesive used when applied to floors or walls. The present invention relates to a polyolefin-based building material sheet which has good productivity and is suitable as a substitute for a vinyl chloride resin-based floor tile or a wall panel, which is a source of environmental pollution.

[0002]

2. Description of the Related Art Conventionally, as floor tiles and wall panels, those made of vinyl chloride resin have been used because of their good flexibility and good workability. However, the use of wood is inevitably restricted for forest protection. On the other hand, vinyl chloride resin floor tiles have poor durability (resistance to abrasion, scratching, dents, etc.), poor cleaning properties, and generate harmful chlorine and dioxin when incinerated. In addition, the plasticizer contained therein is liable to bleed, resulting in poor appearance. Therefore, there has been a demand for a building material sheet which does not use a vinyl chloride resin, has good workability, and has excellent durability and cleanability. For this reason, in recent years, research on non-halogen type building material sheets has been actively conducted, and various floor tiles using, for example, a polyolefin resin as a backer material have been developed (JP-A-2-301434, JP-A-2-4-2).
24842, JP-A-7-125145, JP-A-10-102748, etc.). Since floor tiles are desired to have appropriate elasticity, polyolefin resins used for the backer material include, for example, low-density polyethylene, ethylene-vinyl acetate copolymer, and ethylene-propylene copolymer (EPR). , An ethylene-butene copolymer (EBM), or a mixture thereof, or a mixture thereof with a crystalline polypropylene resin. However, polyolefin-based resins generally have poor adhesive properties, and therefore, when a floor tile or a wall panel using this polyolefin-based resin as a backer material is adhered to a floor or a wall surface with an adhesive, there is a problem that the polyolefin-based resin is easily peeled off. Occurs. So, in order to solve such a problem,
For example, a method has been attempted in which a back surface of a polyolefin resin backer material is subjected to corona discharge treatment or sand blast treatment to improve the adhesiveness with an adhesive, but in this case, a new process is required, and the operation is complicated. Therefore, productivity is low and manufacturing costs are inevitable. By the way, in recent years, ionomer resins obtained by partially or completely neutralizing a copolymer of an α-olefin and an α, β-unsaturated carboxylic acid with a metal ion to form an intermolecular cross-linking have been improved in abrasion resistance and Because of its excellent surface properties such as stain resistance and good environmental pollution, it has attracted attention as a surface layer of decorative boards such as floor tiles and wall panels. Accordingly, various decorative boards having the ionomer resin layer on the surface layer and not using a vinyl chloride resin have been developed. For example, (1) a first resin layer sequentially printed on a backer material, a second resin layer composed of a copolymer of olefin and methacrylic acid, and having a carboxyl group cross-linked between molecular chains by hydrogen bonding, and an ionomer resin (Japanese Unexamined Patent Publication No. 8-254004), a pattern material and an adhesive resin layer are sequentially provided on at least one surface of a first resin layer made of an ionomer resin. (3) An upper layer made of an ionomer resin, and a lower layer made of a backer layer mainly composed of an acrylate-based copolymer resin via a picture layer and a primer layer on the back surface thereof. (Japanese Patent Laid-Open No. 9-20)
No. 7276) and the like. Since these decorative boards do not use vinyl chloride resin and the surface layer is an ionomer resin layer, they have good surface properties such as scratch resistance, abrasion resistance, and stain resistance. It does not cause environmental pollution caused by chlorine. However, none of these decorative panels mentions the adhesiveness between the back surface of the backer material and the adhesive, and as described above, the decorative panel is installed on the floor or wall using the adhesive. In this case, the adhesiveness between the adhesive and the back surface of the backer material is poor, and there is a possibility that peeling may occur over time.

[0003]

SUMMARY OF THE INVENTION Under such circumstances, the present invention has good adhesiveness with an adhesive used when applied to a floor or a wall surface, and has good productivity. An object of the present invention is to provide a polyolefin-based building material sheet suitable as a substitute for a vinyl chloride resin-based building material sheet that is a source of environmental pollution.

[0004]

Means for Solving the Problems The present inventor has conducted intensive studies to develop a polyolefin-based building material sheet which has good adhesiveness with an adhesive and high productivity. Backing material that has a surface material on one side of the material sheet and a sheet-like member having heat-fusibility and easy-adhesion-adhesiveness that is heat-sealed on the opposite side during the production of the base sheet. It has been found that a sheet for building materials having the following can be suitable for the purpose, and based on this finding, the present invention has been completed. That is, the present invention provides (1) a polyolefin-based resin base sheet, a surface material having a single-layer or laminated structure provided on one surface thereof, and a surface material provided on the opposite surface of the base sheet. In a building material sheet having a backing material, at least the base sheet side has a heat-sealing property with the base sheet, and at least the opposite side has a sheet-like member having easy adhesive adhesion, at the time of base sheet production A sheet for a building material, wherein the backing material is provided by heat-sealing the sheet; and (2) at least the base sheet has a heat-sealing property with the base sheet, and at least the opposite side has easy adhesion. A sheet-like member having agent adhesion is a paper, a woven or knitted fabric, a nonwoven fabric, an adhesive plastic sheet, a foamed plastic sheet having an opening communicating with the outside air, or a metal sheet provided with a heat-sealing layer. That building materials sheet as set forth in claim 1, wherein, there is provided a.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION A sheet for building material of the present invention comprises a base sheet (backer material) made of a polyolefin resin, a surface material provided on one surface thereof, and a surface material provided on the opposite side of the base material sheet. And a backing material provided on the surface,
The polyolefin resin used for the base sheet is not particularly limited, and examples thereof include α-olefins such as ethylene, propylene, butene-1, 3-methylbutene-1, 3-methylpentene-1, and 4-methylpentene-1. And copolymers thereof, and copolymers thereof with other copolymerizable unsaturated monomers. Representative examples include high-density, medium-density, low-density polyethylene, linear low-density polyethylene, ultra-high-molecular-weight polyethylene, ethylene-vinyl acetate copolymer, polyethylene such as ethylene-ethyl acrylate copolymer, and propylene alone. Polypropylenes such as polymers, propylene-ethylene block copolymers and random copolymers, propylene-ethylene-diene compound copolymers, and polybutene-
1, poly 4-methylpentene-1 and the like. Among the above polypropylenes, crystalline polypropylene resins are often used. Examples of the crystalline polypropylene resins include isotactic propylene homopolymer having crystallinity and ethylene-propylene having a low ethylene unit content. A random copolymer, a propylene block copolymer composed of a homo part composed of a propylene homopolymer and a copolymer part composed of an ethylene-propylene random copolymer having a relatively high content of ethylene units, and the propylene block copolymer. A crystalline propylene-ethylene-α-olefin copolymer or the like in which each homo part or copolymer part in the block copolymer is further obtained by copolymerizing an α-olefin such as butene-1 is exemplified. This polyolefin-based resin may be used alone or in combination of two or more. Recycled products can also be used. For example, when a building material sheet is used as a floor tile, a base material is used. It is preferable that the sheet has an appropriate elasticity. Therefore, low-density polyethylene, ethylene-vinyl acetate copolymer, ethylene-propylene copolymer (EPR), ethylene-butene copolymer (EBM), a mixture thereof, or a mixture thereof is preferred. And a mixture of a crystalline polypropylene resin and the like. In addition, when a building material sheet is used as a wall panel, a crystalline polypropylene-based resin is preferable because appropriate rigidity is required. The base sheet preferably contains an inorganic filler at a ratio of 20 to 85% by weight, particularly preferably 30 to 75% by weight. If the content is less than 20% by weight, cutting workability and rigidity are insufficient, and if it exceeds 85% by weight, sheet formability and impact resistance are reduced, and the weight is increased, which is not preferable. Here, examples of the inorganic filler include calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, kaolin, silica, perlite, calcium sulfate, barium sulfate, calcined alumina, calcium silicate, talc, mica, and the like. These may be used alone or in combination of two or more.

[0006] Among these inorganic fillers, calcium carbonate, talc, aluminum hydroxide and magnesium hydroxide are preferred from the viewpoint of machinability and economy, and calcium carbonate is particularly preferred. The calcium carbonate is not particularly limited, and any of precipitated calcium carbonate, heavy calcium carbonate, light calcium carbonate and the like can be used. The average particle size of the calcium carbonate is usually in the range of 0.05 to 200 μm, preferably 0.5 to 20 μm. In the base sheet, if desired, various additional components such as antioxidants, heat stabilizers, ultraviolet absorbers, light stabilizers, chlorine scavengers, flame retardants, flame retardant assistants, lubricants, release agents,
A coloring agent, a plasticizer, a softening agent such as process oil or liquid paraffin, and other thermoplastic resins and thermoplastic elastomers can be appropriately contained. In order to produce this base sheet, first, the above-mentioned polyolefin resin and preferably 20 to 85 based on the total amount of the molding material are used.
% By weight of an inorganic filler such as calcium carbonate, and various additives used as desired, and then mixed with a tumbler blender or a Henschel mixer, or after mixing, use a single-screw extruder or a multi-screw extruder. The mixture is melt-kneaded and granulated to prepare a polyolefin-based molding material. Next, the polyolefin-based molding material is molded by a known method, for example, a method such as cast molding or extrusion sheet molding to prepare a base sheet.
The polyolefin-based molding material may be foamed in an extruder to produce a foamed base sheet having an appropriate expansion ratio. The thickness of the base sheet is generally selected in the range of 0.08 to 10.0 mm, preferably 0.1 to 6.0 mm, depending on the use of the building material sheet. For example, when a building material sheet is used as a floor tile, the thickness of the base sheet is preferably 1.5 to 6.0 mm, more preferably 2.5.
When used as a wall panel, the thickness of the base sheet is preferably 1.0 to 10.0 m.
m, more preferably in the range of 2.5 to 6.0 mm. In the building material sheet of the present invention, the surface material provided on one surface of the base material sheet may have any one of a single-layer structure and a laminated structure of two or more layers. There is no limitation, and any structure conventionally known as a surface material of floor tiles and wall panels may be used, and any material can be used. On the other hand, in the building material sheet of the present invention, as the backing material provided on the surface of the base material sheet opposite to the above (back surface of the base material sheet), at least the base material sheet side has a heat-sealing property with the base material sheet. And a sheet-shaped member having at least the opposite side having easy adhesive adhesion. In the present invention, the productivity is improved by providing the backing material by thermally fusing the sheet-shaped member to the base sheet at the time of preparing the base sheet. The sheet-like member constituting the backing material is not particularly limited as long as at least the base material sheet side has heat-fusibility and at least the opposite side has easy adhesive adhesion, and is not particularly limited. A member can be used. Here, the term “heat-fusing property” refers to a property of being able to be laminated with good adhesion to a substrate sheet whose surface is in a molten or softened state without using an adhesive. Examples of the sheet-shaped member having the above properties include paper, woven or knitted fabric, nonwoven fabric, an adhesive plastic sheet, a foamed plastic sheet having an opening communicating with the outside air, and a metal sheet provided with a heat-sealing layer. it can. Here, as papers, for example, thin paper, bleached or unbleached kraft paper, high-quality paper, inter-sheet reinforced paper, mixed paper mixed with synthetic resin, titanium paper, linter paper, paperboard, gypsum board paper, noncombustible paper, etc. Is mentioned.

[0007] The types of fibers constituting the woven or knitted fabric or the nonwoven fabric include, for example, cotton, jute, cellulose fibers, and the like.
Organic fiber such as nylon fiber, aromatic polyamide fiber, polyester fiber, polypropylene fiber, glass fiber,
Examples thereof include inorganic fibers such as carbon fiber, aluminum fiber, stainless fiber, copper fiber, brass fiber, nickel fiber, and silicon carbide fiber. Examples of the adhesive plastic sheet include an adhesive laminated sheet and a maleic acid-modified polyolefin sheet, and an adhesive laminated sheet is particularly preferable. As the adhesive laminated sheet, for example, a sheet obtained by sequentially providing a primer layer and optionally an adhesion reinforcing layer on one side of a polyolefin synthetic paper formed by mixing calcium carbonate and titanium oxide with polypropylene or polyethylene and forming a film, etc. Can be mentioned. Further, examples of the foamed plastic sheet having an opening communicating with the outside air include a foamed sheet having a base material of polypropylene or an ethylene-vinyl acetate copolymer, for example. Further, examples of the metal-based sheet provided with the heat-sealing layer include a metal sheet such as aluminum, an aluminum alloy, and stainless steel provided with a layer made of the same plastic as the base sheet on one surface thereof. . In the present invention, the sheet-like member constituting the backing material may be a single layer, or may have a laminated structure of two or more layers of the same type or different types. The thickness of the sheet-shaped member is usually from 0.08 to 10.0 mm, preferably from 0.1 to 6.0 mm.
The range is 0 mm. FIG. 1 shows a construction material sheet 1 of the present invention.
FIG. 1 is a cross-sectional view of the example. As shown in FIG. 1, a building material sheet 1 has a surface material 4 laminated on one surface of a base material sheet 2 and another surface of the base material sheet 2. It has a structure in which the backing material 3 is laminated. The method for manufacturing the building material sheet of the present invention is not particularly limited, as long as it is a method in which a backing material is provided by heat fusion at the time of producing the base material sheet. As the heat fusion method, any of a batch method by a continuous press method by a roll method can be used. Since the sheet for building materials of the present invention has easy adhesive adhesion on the side of the backing material that comes into contact with the floor surface or wall surface, it is difficult to peel when the building material sheet is applied to the floor surface or wall surface using an adhesive. It works. In addition, since the backing material is provided on the base sheet by heat fusion at the time of producing the base sheet, the productivity can be improved.

[0008]

EXAMPLES Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. Example 1 Floor tile (1) Preparation of surface material A corona discharge treatment was applied to the back surface of an acrylic resin film having a thickness of 250 μm, and a primer mainly composed of a polyurethane resin was applied to the treated surface by a gravure coating method. Was 2 μm to form a primer layer. On the other hand, calcium carbonate and titanium oxide are blended with high-density polyethylene to form a film having a thickness of 100%.
One side of a synthetic paper having a thickness of μm was coated with a primer mainly composed of a polyurethane resin by a gravure coating method so that a dry thickness became 2 μm, and a primer layer was provided. Next, a marble pattern was printed on the primer layer by a gravure rotary press using a plurality of inks of different colors to provide a picture layer having a thickness of 6 μm. Next, the synthetic paper and the acrylic resin film were heat-fused so that the picture layer and the primer layer faced each other, thereby producing a surface material. (2) Preparation of floor tile 65 parts by weight of ethylene-vinyl acetate copolymer resin (ethylene unit: 90% by weight, weight average molecular weight: about 110,000, melt index (MI): 3.0 g / 10 minutes), average particle size: 2.4
225 parts by weight of μm calcium carbonate powder, 5 parts by weight of diisononyl phthalate as a plasticizer, 2.5 parts by weight of zinc stearate as a lubricant, 2.5 parts of a phosphate ester-based metal roll release agent
After the dry blending of 0.5 parts by weight of the hindered phenolic antioxidant and 0.5 parts by weight of the hindered phenolic antioxidant, a molding material for a base sheet was prepared using a twin-screw kneader. Next, a 3.0 mm-thick base sheet was prepared by extrusion sheet molding using this molding material, and the surface material obtained in the above (1) was applied to one surface of the base sheet. A polyethylene terephthalate non-woven fabric having a thickness of 30 g / m ² was brought into contact with the base sheet and the other surface of the base sheet was brought into contact with the base sheet at a temperature of 1 g / m ^2.
Sheets for building materials (floor tiles) having the structure shown in FIG. 1 by laminating by thermal fusion by pressing at 50 ° C.
Was prepared. The adhesion of the floor tile to the adhesive was evaluated as follows. <Evaluation of Adhesiveness with Adhesive> A flexible board having a thickness of 3.0 mm is coated with an acrylic adhesive, a predetermined comb is inserted, and a floor tile cut into a width of 50 mm is pressed on the flexible board with a roller. Four days later, the 90 ° peel strength was measured. As a result, the adhesive strength was 8.0 kg / 50 mm. Comparative Example 1 A floor tile material was prepared in the same manner as in Example 1 except that the backing material was not laminated, and the adhesion to the adhesive was evaluated. As a result, the adhesive strength was 0.5 kg / 50 mm. Example 2 Wall Panel Homopolypropylene (weight average molecular weight about 320,000, MI
3.1 g / 10 min) 45 parts by weight, 55 parts by weight of calcium carbonate powder having an average particle size of 1.0 μm and 0.2 parts by weight of a hindered phenolic antioxidant are dry-blended,
The mixture was melt-kneaded with a twin-screw kneader to obtain pellets. Then
Using the pellets, a substrate sheet having a thickness of 3.0 mm was formed by extrusion molding. Hereinafter, in the same manner as in Example 1,
A wall panel material was prepared, and the adhesion to the adhesive was evaluated as described below. As a result, cohesive failure of the adhesive occurred at 1.9 N / mm ² . <Evaluation of adhesion to adhesive> 20 mm x 2
A sample having a size of 0 mm was cut out, and the back surface of the sample was adhered to a steel plate using a urethane-based adhesive. After standing for 7 days, a plane tensile test was performed.

[0009]

The building material sheet of the present invention is a non-halogen type, has good adhesiveness to an adhesive used when applied to floors and walls, has good productivity, and is a source of environmental pollution. As a substitute for the vinyl chloride resin-based building material sheet.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of one example of a building material sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Building material sheet of this invention 2 Base material sheet 3 Backing material 4 Surface material

Continued on the front page F-term (reference) 4F100 AA08H AB01C AK01C AK03A AK05 AK25 AK42 AK51G AK68 AT00B AT00C BA03 BA10B BA10C CB00C DC11C DG10C DG12C DG13C DG15C DJ01C EC03 EH17 J12JJB11 GB11

Claims (2)

[Claims] 1. A base sheet made of a polyolefin resin, a surface material having a single layer or a laminated structure provided on one surface thereof, and a backing material provided on a surface opposite to the base material sheet. In the sheet for building materials having, the sheet-like member having at least the base sheet side having a heat-sealing property with the base sheet, and at least the opposite side having easy adhesive adhesion, is heat-sealed to the base sheet at the time of making the base sheet. A sheet for building material, wherein the backing material is provided. 2. A sheet-like member having at least the base sheet side having heat-fusibility with the base sheet and having at least the opposite side having easy adhesive adhesion, paper, woven or knitted fabric, non-woven fabric, adhesive plastic The sheet according to claim 1, wherein the sheet is a sheet, a foamed plastic sheet having an opening communicating with the outside air, or a metal sheet provided with a heat-sealing layer.