JP2001132220A - Floor covering material, its manufacturing method, and mansion - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor covering material having excellent soundproof performance and superior walking feeling and a method for easily manufacturing the floor covering material. SOLUTION: A hard plate-shaped body is used as a surface layer and a hard foam and a soft foam are laminated in the floor covering material, and the floor covering material in which the hard foam has an expansion ratio of 7-30 times, the means value of 1.5-2.5 of the aspect ratio Dz/Dxy of included bubbles and the means value of 500 μm or more of Dxy, the mansion in which the floor covering material is stuck directly on a floor slab, and the manufacture of the floor covering material in which a sheet-shaped substance capable of inhibiting foaming force in the in-plane direction generated when a foamed sheet is foamed is laminated on one surface of the foamed sheet obtained by shaping a foamed composition containing a modified resin, in which an polyolefin resin and a monomer for modification are reacted, and a pyrolysis type foaming agent to a sheet and the soft foam and the hard foam as the surface layer are laminated on the hard foam obtained by heating the acquired foamed composite sheet are provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material, and more particularly to a flooring material having good soundproofing performance and excellent walking sensation, an apartment using the same, and a method of manufacturing the flooring material.

[0002]

2. Description of the Related Art Conventionally, a sound-insulating flooring material is obtained by laminating and integrating a buffer layer such as a resin foam or nonwoven fabric for sound insulation on the back surface of a plywood having a thickness of about 8 to 10 mm with a wood grain on the surface. Also known as And the superiority of the soundproofing performance depends on the above-mentioned buffer layer, and the improvement has been promoted.

For example, the flooring described in Japanese Utility Model Publication No. 4-53387 has improved soundproofing performance by using two kinds of foams having different compression characteristics. However, in this method, even if the soundproof performance can be improved, a so-called "sickness sickness phenomenon" occurs when a person walks on the flooring material, and the walking feeling deteriorates. Such a phenomenon occurs because a specific buffer layer having a thickness of about 5 mm or more is used to improve the soundproof performance.

In Japanese Patent Application Laid-Open No. 10-266545, a bubble having a spindle-shaped major axis oriented substantially in the thickness direction is formed on the back surface of a hard plate-like body, and the ratio of the major axis to the minor axis is 2 or more. A flooring in which a certain rigid foam and a soft foam are laminated is disclosed.

[0005]

However, according to the study by the present inventors, the floor material described in the above publication also forms a pillar because the number of cells increases when the cell diameter of the hard foam decreases. In some cases, the thickness of the cell wall was reduced, the compressive strength was not sufficiently increased, and a feeling of "fluffy" occurred.

[0006] In the method for producing a rigid foam used for a flooring material, a water crosslinking method using silane is adopted. Therefore, after the resin composition for the rigid foam is once extruded into a sheet, it is subjected to another step. Cross-linking, and further through a heating and foaming step, and thereafter, since the hard plate-like body and the soft foam are laminated, there has been a problem that the manufacturing method as a floor material becomes complicated. .

[0007] The present invention solves the above-mentioned problems of the conventional flooring material and the method of manufacturing the same. The flooring material has excellent soundproofing performance, does not "fluffy" even when a human walks, and has a good walking feeling. It is an object of the present invention to provide a manufacturing method capable of easily manufacturing a material. Another object of the present invention is to provide a condominium with a good feeling of living using the floor material.

[0008]

Means for Solving the Problems In order to achieve the above object, the present invention according to claim 1 (hereinafter sometimes referred to as “the present invention 1”) uses a hard plate-like body as a surface layer, A floor material in which a foam and a soft foam are laminated, wherein the rigid foam has an expansion ratio of 7 to 30 times, and an average value of the aspect ratio Dz / Dxy of the intrinsic cells is 1.5 to 2.5
And a floor material having an average value of Dxy of 500 μm or more. Further, the present invention described in claim 2 (hereinafter, sometimes referred to as “the present invention 2”) provides an apartment in which the floor material according to claim 1 is directly attached to a floor slab.

The present invention described in claim 3 (hereinafter sometimes referred to as “the present invention 3”) provides a modified resin obtained by reacting a polyolefin resin and a modifying monomer with a pyrolytic chemical. A foaming resin composition containing a foaming agent is shaped into a sheet, and on at least one side of the resulting foamable sheet, the in-plane foaming force generated when the foamable sheet is heated and foamed is suppressed. 2. A soft foam and a hard plate as a surface layer are laminated on a hard foam obtained by heating a foamable composite sheet obtained by laminating a sheet-like material that can be obtained. To provide a method for producing a flooring.

Hereinafter, the present invention will be described in more detail. [Hard plate-like body] The hard plate-like body used in the present invention is not particularly limited as long as it is a material that is hard as a surface material of a flooring material and does not easily break or be damaged even under a load. Veneer, (a) plywood, (c) resin plate, (d) fiber-reinforced synthetic resin plate and the like can be mentioned. These may be used alone, but are generally used by decorating the surface.

(A) Single veneer A single veneer usually called a "bare plate", which can be made into a veneer excellent in wood texture only by applying varnish or oil.

(A) Plywood Conventionally used flooring materials (including those called medium density fiberboard “MDF”) can be used. In this case, it is preferable to attach a “sticking board” obtained by thinly slicing a tree to the surface, and it may be painted and colored as needed. The coating method is not particularly limited, for example, an acrylic silicon-based material containing inorganic fine particles such as colloidal silica in order to enhance the surface scratch resistance,
It can be performed by applying a coating material such as an acrylic urethane type, an alkyl silicate type or an epoxy type and drying.

(C) Resin plate A plate made of a so-called hard resin such as a polyethylene plate (an ultra-high molecular weight polyethylene plate is particularly preferred), a polypropylene plate or a polyvinyl chloride plate is preferably used.

(D) Fiber reinforced synthetic resin plate Thermosetting polyester resin plate, epoxy resin plate reinforced with glass fiber, hard polyurethane plate (foamed 2-3 times as necessary), poly A vinyl chloride plate or the like can be used.

When the thickness of the hard plate is too thin, the strength and rigidity are insufficient, and when it is too thick, the floor impact sound insulation performance is reduced. Therefore, the thickness is preferably 1 to 5 mm, more preferably 2 to 4 mm.
It is.

The surface of the hard plate may be decorated by printing a wood grain pattern, a marble pattern, a granite pattern, etc. in order to enhance the design, and may be used for kitchen and washroom floors. In this case, the surface may be made uneven by providing irregularities.

[Rigid Foam] The rigid foam used in the present invention has an expansion ratio of 7 to 30 times, and the average value of the aspect ratio Dz / Dxy of the intrinsic cells is 1.5 to 2.5. There is no particular limitation as long as the condition is satisfied and the average value of Dxy is 500 μm or more.

The method for producing the rigid foam is not particularly limited, but preferably, as in the present invention 3, a modified resin obtained by reacting a polyolefin resin with a modifying monomer, and a pyrolytic chemical foaming agent Is formed into a sheet, and on at least one surface of the obtained foamable sheet, the in-plane foaming force generated when the foamable sheet is heated and foamed can be suppressed. A method of laminating sheet materials and heating the resulting foamable composite sheet is employed. Here, the in-plane direction refers to a two-dimensional direction of the rigid foam in the longitudinal direction and the width direction. Hereinafter, the present invention 3 will be mainly described. The flooring material of the present invention 1 is obtained by the manufacturing method of the present invention 3.

[Polyolefin Resin] The polyolefin constituting the main component of the polyolefin resin in the present invention 3 is a homopolymer of an olefinic monomer or a copolymer of a main component olefinic monomer and another monomer. Although not to be, for example, low density polyethylene, high density polyethylene, polyethylene such as linear low density polyethylene, homotype polypropylene,
Polypropylene such as random type polypropylene and block type polypropylene, polybutene, ethylene-
Copolymers containing ethylene as a main component such as propylene copolymer, ethylene-propylene-diene terpolymer, eletine-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer, etc. And the like, and a combination of two or more of these may be used. As the polyolefin as the main component of the polyolefin resin in the present invention 3, one or a combination of two or more of the above-mentioned polyethylene and polypropylene is preferable.

The polyolefin resin refers to a resin composition in which the proportion of the polyolefin is 70 to 100% by weight. The resin other than the polyolefin constituting the polyolefin resin is not limited, and examples thereof include polystyrene and styrene elastomer. If the proportion of polyolefin in the polyolefin resin is less than 70% by weight, not only the characteristics of polyolefin such as light weight, chemical resistance, flexibility and elasticity cannot be exhibited, but also it is difficult to secure the melt viscosity required for foaming. This is not preferable because it may result in

The modifying monomer in the present invention 3 is a compound having two or more functional groups capable of radical reaction.
Examples of the functional group include an oxime group, a maleimide group, a vinyl group, an allyl group, and a (meth) acryl group, and a quinone compound.

[Modifying Monomer] Among the modifying monomers which can be used in the present invention 3, the dioxime compound having two oxime groups, that is, the oxime group (chemical formula 1) or the oxime group represented by the following general formula: A compound having two structures (chemical formula 2) in which the hydrogen atom is replaced by another atomic group (mainly a hydrocarbon group) in a molecule, for example, p-quinonedioxime (chemical formula 3), p, p ′ -Dibenzoylquinone dioxime (chemical formula 4) and the like. The dioxime compounds can be used in combination of two or more.

[0023]

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[0024]

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[0025]

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[0026]

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Among the modifying monomers that can be used in the present invention 3, as a bismaleimide compound having two maleimide groups, that is, having two maleimide structures (chemical formula 5) in a molecule, for example, N, N'-p- Examples include phenylene bismaleimide (chemical formula 6), N, N'-m-phenylene bismaleimide (chemical formula 7), and diphenylmethane bismaleimide (chemical formula 8). Bismaleimide compounds can also be used in combination of two or more. In addition, polymaleimide having two or more maleimide structures in a molecule (chemical formula 9) also has the same effect, and thus is included in the category of bismaleimide compounds.

[0028]

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[0029]

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[0030]

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[0031]

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[0032]

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Among the modifying monomers that can be used in the present invention 3, examples of the divinyl compound having two vinyl groups, that is, divinyl benzene (compound 10) represented by the following chemical formula, include: The vinyl group may be in any of ortho, meta and para positions.

[0034]

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Among the modifying monomers that can be used in the present invention 3, examples of the allyl-based polyfunctional monomer having two or more allyl groups, ie, diallyl phthalate (chemical formula 11) represented by the following chemical formula, triallyl cyanurate (Chemical formula 12), triallyl isocyanurate (Chemical formula 13), diallyl chlorendate (Chemical formula 14) and the like are exemplified. The allylic polyfunctional monomer may be used in combination of two or more.

[0036]

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[0037]

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[0038]

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[0039]

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The modifying monomer which can be used in the present invention 3 has two or more (meth) acryl groups, that is, (meth)
Examples of the allylic polyfunctional monomer include compounds having 2 to 4 (meth) acryloyloxy groups.

With two (meth) acryloyloxy groups, alkanediol di (meth) acrylate, ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, polypropylene glycol di ( Meth) acrylate, neopentyl glycol di (meth) acrylate, dimethylol tricyclodecane di (meth) acrylate, ethylene glycol adduct di (meth) acrylate of bisphenol A, propylene glycol adduct di (meth) acrylate of bisphenol A, etc. With three acryloyloxy groups, trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate,
Trimethylolpropane ethylene oxide-added tri (meth) acrylate, glycerin propylene oxide-added tri (meth) acrylate, tri (meth) acryloyloxyethyl phosphate, and the like. When four (meth) acryloyloxy groups are used, pentaerythritol tetra (Meth) acrylate, ditrimethylolpropanetetra (meth) acrylate and the like.

Among the modifying monomers usable in the present invention 3, examples of the quinone compound include hydroquinone, p-benzoquinone, tetrachloro-p-benzoquinone and the like.

The amount of the modifying monomer may be appropriately selected according to the type of the monomer, but is generally 0.05 to 5 parts by weight, preferably 0.2 to 5 parts by weight, per 100 parts by weight of the polyolefin resin. ~ 2 parts by weight. If the amount of the modifying monomer is less than 0.05 part by weight, the melt viscosity required for foaming cannot be imparted. If the amount exceeds 5 parts by weight, the degree of cross-linking is too high, and the extrudability is poor (for example, High load is applied and melt fracture occurs).

Furthermore, the foaming agent to be added later cannot be uniformly kneaded in the resin composition, so that the gel fraction is unnecessarily increased, thereby impairing the recyclability. In addition, the foaming pressure at the time of heat foaming becomes too high later, and it becomes impossible to use a sheet-like material having a low tensile strength for suppressing in-plane foaming.

In the present invention 3, an organic peroxide may be used in combination with the modifying monomer. In particular, when a vinyl compound or an allyl compound is used as a modifying monomer, it is preferable to use an organic peroxide in combination. The organic peroxide may be any organic peroxide generally used for polyolefin grafting.

For example, benzoyl peroxide, 2,
4-dichlorobenzoyl peroxide, t-butylperoxyacetate, t-butylperoxybenzoate, dicumyl peroxide, 2,5-dimethyl-2,
5-di (t-butylperoxy) hexane, di-t-butyl peroxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3 and the like,
These are suitably used alone or in combination of two or more. In particular, dicumyl peroxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane,
Di-t-butyl peroxide, 2,5-dimethyl-
One or more of 2,5-di (t-butylperoxy) hexyne-3 and the like are more preferably used.

If the amount of the organic peroxide used is too small, the conversion of the grafting reaction is insufficient, and if it is too large, the so-called β-cleavage of polypropylene occurs remarkably, and the molecular weight of the modified product is too low to deteriorate the physical properties. Alternatively, foaming failure may occur due to a decrease in viscosity. In consideration of these points, the amount of the organic peroxide to be used is preferably 0.001 to 0.5 part by weight, preferably 0.005 to 0.15 part by weight, based on 100 parts by weight of the polyolefin resin. More preferably, there is.

[Modified resin] In order to obtain a modified resin by reacting a polyolefin resin with a modifying monomer, usually,
Using a kneading device such as a screw extruder or a kneader, the polyolefin resin and the modifying monomer are melt-mixed under predetermined conditions and reacted. The reaction temperature at this time is 170 ° C. or higher and not higher than the decomposition temperature of the polyolefin resin, preferably 200 ° C. to 250 ° C. When the reaction temperature is lower than 170 ° C., the denaturation is insufficient, and the expansion ratio of the finally obtained foam may not be sufficiently high. When the reaction temperature is higher than about 250 ° C., the polyolefin resin is easily decomposed.

The apparatus used for the above reaction may be a melt kneading apparatus which can be generally used in plastic molding, in addition to a screw extruder, and examples thereof include a kneader, a rotor and a continuous kneader. Among them, a screw extruder capable of continuous operation is preferable, and a single-screw extruder, a twin-screw extruder, a multi-screw extruder having three or more screws, and the like are all suitably used.

As the single screw extruder, in addition to a general full flight screw, an extruder having a discontinuous flight screw, a pin barrel, a mixing head and the like can be used. Further, as the twin screw extruder, a meshing co-rotating extruder, a meshing different direction rotating extruder, a non-meshing different direction rotating extruder and the like can be suitably used. Providing a vacuum vent at the latter stage of the extruder is effective for preventing volatiles from remaining in the resin composition. When a screw extruder is used, the polyolefin-based resin is usually introduced into the extruder from a hopper, but it is also preferable to use a screw type feeder, a weight control type feeder, or the like in order to increase quantitativeness.

The modifying monomer may be introduced into the extruder from the hopper simultaneously with the polyolefin resin. However, since some of divinylbenzene and allyl-based polyfunctional monomers are liquid at room temperature and pressure, the extruder is preferably used. It is preferable to supply the liquid from a liquid injection hole provided in a downstream part of the molten resin from the position where the polyolefin resin is melted, since this can be uniformly dispersed in the molten resin. At this time, it is desirable that the liquid monomer be sent by a pressure-feeding pump such as a plunger pump.

When an organic peroxide is used in combination with the modifying monomer, the organic peroxide is preliminarily mixed with the modifying monomer and they are simultaneously charged, or the organic peroxide is separated before and after the monomer is added. The method of charging can be applied.

The modified resin may be melt-blended with an unmodified polyolefin resin of the same or different type (hereinafter collectively referred to as a resin for blending) for the purpose of improving the fluidity of the modified resin. By using a blend of such a modified resin and a blending resin, the flowability of the foamable resin composition to be obtained is improved, whereby an extremely thin raw foam can be molded, and as a result, a thin composite foam Production of sheets becomes possible. Moreover, the fluidity favors the formation of spindle-shaped bubbles, and consequently,
It is also possible to obtain a foam having higher compression strength. The unmodified polyolefin resin may be the one described above in the definition of the polyolefin resin before the modification of the modified resin.

The type and amount of the resin for blending are determined according to the moldability, appearance, and adhesion to the sheet-like material of the foamable composite sheet to be obtained, and the expansion ratio, mechanical properties, thermal properties, and thermal properties of the composite foam obtained therefrom. It is appropriately adjusted depending on physical properties, cell shape and the like. In particular, it is preferable to newly melt-blend 50 to 200 parts by weight of the same or different unmodified polyolefin-based resin with respect to 100 parts by weight of the modified polyolefin-based resin. More preferably, 70 to 130 parts by weight are blended. If the proportion of the resin for blending is too large, the melt tension required for foaming cannot be maintained, so that the foaming ratio is reduced and a good foam cannot be obtained.

[Thermal decomposition type chemical foaming agent] The thermal decomposition type chemical foaming agent used in the present invention is not particularly limited as long as it generates a decomposition gas by heating. Representative examples of the thermal decomposition type chemical blowing agent are azodicarbonamide, benzenesulfonyl hydrazide, dinitrosopentamethylenetetramine, toluenesulfonyl hydrazide, and 4,4-oxybis (benzenesulfonyl hydrazide). These may be used alone or in combination of two or more.

Among them, azodicarbonamide is particularly preferably used. Thermal decomposition type chemical blowing agent is modified resin 1
1 to 50 parts by weight, preferably 2 to 50 parts by weight,
It is used in an appropriate amount in the range of 35 parts by weight depending on the desired expansion ratio.

[Kneading] In order to obtain a foamable resin composition by adding a thermally decomposable chemical foaming agent to a modified resin obtained from the above-mentioned polyolefin-based resin and a modifying monomer, it is usually necessary to use the above-mentioned melting reaction. Using a kneading device and a separate melt-kneading device for mixing the blowing agent (the structure may be the same as that of the reaction kneading device for reaction), the maximum blowing agent is not substantially decomposed. Mix both below the temperature. The mode of the melt kneading is as follows.

(A) In a batch or continuous melt-kneading apparatus for reaction, a polyolefin resin and a modifying monomer are melt-mixed and reacted, and the resulting modified resin is taken out of the melt-kneading apparatus and solidified. After granulation and the like, the resin composition is transferred to a batch-type or continuous-type kneading device for mixing a foaming agent, and a foaming agent is added thereto and both are melt-kneaded to obtain a foamable resin composition. (B) In a batch-type melt-kneading apparatus for reaction, a polyolefin resin and a modifying monomer are melt-mixed and reacted, and the obtained modified resin is heated in the kneading apparatus at a temperature at which the foaming agent does not decompose in a large amount. After cooling, a foaming agent is added thereto, and the two are melt-kneaded to obtain a foamable resin composition.

(C) In a reaction screw extruder (continuous melt kneading apparatus), the polyolefin resin and the modifying monomer are melt-mixed at a temperature of 170 ° C. or higher to carry out a reaction. After the temperature is lowered to a temperature at which the foaming agent does not decompose in a large amount, the foaming agent is further charged from a supply port provided in the middle of the screw extruder, and the two are melt-kneaded to obtain a foamable resin composition. (D) In another mode of the continuous operation, two screw extruders and the like are connected, and a polyolefin-based resin and a modifying monomer are melt-mixed and reacted in the first unit. After lowering the temperature in the same manner as above, the same resin composition is transferred to a second unit, a foaming agent is charged therein, and the two are melt-kneaded to obtain a foamable resin composition. The foamable resin composition obtained by kneading the mixture with a thermal decomposition type chemical foaming agent is shaped into a sheet. Extrusion molding, press molding,
Methods generally performed in plastic molding such as blow molding, calendering molding, and injection molding can be applied.

In particular, the foamable resin composition obtained according to the above-mentioned methods (a) and (b) is taken out from a batch-type kneading apparatus for mixing a foaming agent, and is put into a screw extruder to be continuously fed. Forming into sheet shape, or
According to the above methods (a), (c) and (d), a method of directly shaping the foamable resin composition discharged from the screw extruder is preferable from the viewpoint of productivity.

[Sheet-like Material] In the present invention 3, a sheet-like material capable of suppressing the in-plane foaming force generated when the foamable resin sheet is heated and foamed is formed on at least one side of the foamable resin sheet. Because it is laminated and integrated
When the foamable resin sheet is heated and foamed, foaming in the in-plane direction is suppressed, and the cells formed by the suppressed amount have a shape in which the long axis is oriented in the thickness direction, thereby compressing the obtained rigid foam. Strength is increased. In addition, even after foaming, since the above-mentioned sheet-like material is laminated and integrated, the strength of the entire rigid foam is increased also by the reinforcing effect of the sheet-like material itself.

In the present invention 3, if the strength of the sheet-like material for suppressing the in-plane foaming is too low, the sheet-like material will be torn during foaming, and the foaming of the foamable resin sheet in the in-plane direction will occur. Cannot be sufficiently suppressed, and if the strength is too high, the flexibility of the obtained foaming property decreases. Therefore, as the sheet-like material for suppressing the in-plane foaming, for example, when the expansion ratio is less than 5 times, the tensile strength is 100 to 400 N / m, and when the expansion ratio is 5 to 15 times, When the tensile strength is 300 to 6000 N / m and the expansion ratio exceeds 15 times, the tensile strength is 5000 to 5,000 N / m.
Those having a range of 10,000 N / m are preferably used. These ranges are suitably used especially for polyolefin foams.

The rigid foam, which will be described in detail later, is usually 7 to 30 times, and preferably 8 to 30 times, from the viewpoint that a floor material having a good walking feeling and a high soundproofing property can be obtained (particularly from the viewpoint of walking feeling). 2
It is set to 0 times. If it is smaller than 7 times, the soundproofing will be worse,
In addition, it feels hard when walking. In the method of the present invention in which foaming is carried out only in the thickness direction, those having a size of more than 30 times are extremely difficult to produce and are not industrially useful.

The material constituting the sheet-like material is not particularly limited. However, when the foamable resin sheet is laminated and integrated when foamed, it exhibits a certain degree of adhesiveness with the foamable resin sheet. Desirable ones include, for example, surface glass mats obtained by making glass fibers, glass cloth woven with glass rovings, paper, woven fabrics and nonwoven fabrics made of organic fibers and inorganic fibers, and the like.

The surface mat may contain a binder for binding short glass fibers. Examples of the binder include thermoplastic resins such as polyvinyl alcohol, saturated polyester and acrylic resin, and thermosetting resins such as epoxy resin and unsaturated polyester.

The organic fibers constituting the woven or nonwoven fabric include polyester fibers, cotton, acrylic fibers, nylon fibers, and the like.
Examples include carbon fiber and aramid fiber.

The method of laminating and integrating the sheet-like material on the foamable resin sheet is not particularly limited as long as the foamable resin sheet and the sheet-like material are fixed. For example, a method of heating the foamable resin sheet to a molten state and heat-sealing the foamable resin sheet to the sheet-like material, and a method of bonding the foamable resin sheet and the sheet-like material with an adhesive can be used.

More specifically, the sheet is passed through a pair of opposed cooling rolls in a state where the sheet-like material is lightly laminated on at least one side of the substantially molten foamable resin sheet immediately after being extruded from the T-die. A preferred method is to integrate the two with a pressing force of 1. In addition, the above-mentioned lamination and integration means that when the foamable resin sheet and the sheet-like material are to be peeled off at the interface between them, the two are fixed to such an extent that the material is destroyed at a high rate. Shall mean.

[Heat Foaming] The foamable composite sheet thus obtained can be foamed to a desired foaming ratio under normal pressure or constant pressure by heating under an appropriate temperature condition. The heating is usually performed in a temperature range from the decomposition temperature of the thermal decomposition type chemical foaming agent to the decomposition temperature + 100 ° C. In particular, as a continuous foaming apparatus, in addition to a take-up foamer that foams while taking out a foam at an outlet side of a heating furnace, a belt-type foamer, a vertical or horizontal foaming furnace, a hot air thermostat, or an oil bath, metal A hot bath such as a bath or a salt bath is used.

[About the Bubble] The rigid foam according to the present invention 1 or 3 has a sheet shape, and the foam sheet has a diameter D in the sheet thickness direction of the bubbles contained in the foam.
The average value of the ratio Dz / Dxy between z and the diameter Dxy in the in-plane direction is 1.5 to 2.5. That is,
Many bubbles are spindle-shaped. [Direction] In-plane direction (xy direction): means any direction within the sheet surface of the foam sheet. Including length direction and width direction. (Sheet) Thickness direction (z direction): direction perpendicular to the in-plane direction.

[Regarding Dz and Dxy] A 10-times enlarged photograph of an arbitrary cross section parallel to the sheet thickness direction (referred to as the z direction) of the foam sheet is taken, and a fixed direction of at least 50 randomly selected cells is taken. The maximum diameter is measured in the following two directions, and the number average value is calculated. As shown in FIGS. 1 (a) to 1 (c), the shape of the cells of the rigid foam sheet 1 shows that there are naturally some cells whose major axis direction and thickness direction do not coincide with each other.
(C) schematically illustrates the case. Dz: The maximum diameter of the cells in the foam sheet parallel to the z direction. Dxy: Maximum diameter of bubbles in the foam sheet parallel to the sheet width or length direction (xy direction). When the average value of the aspect ratio Dz / Dxy is greater than 1, a foam having a high compressive strength is obtained, but this is because a force is applied in the long axis direction (z direction) of the spindle.

The average value of Dz / Dxy needs to be 1.5 to 2.5. If it is less than 1.5, the bubbles become substantially spherical, and the improvement in compressive strength due to the spindle shape cannot be obtained. On the other hand, if it exceeds 2.5, the compression elastic modulus becomes too high, and especially when walking, it is hard. The average value of Dxy needs to be 500 μm or more. 500 μm
If the ratio is less than, the thickness of the foam cell wall becomes thin, and as a result, improvement in compressive strength cannot be obtained.

The thickness of the rigid foam is preferably 55 mm or less so as to prevent a step difference from a tatami mat (usually a thickness of 10 to 55 mm) when used as a flooring material. 3 mm or more is preferable because it also serves as reinforcement.

The soft foam used in the present invention 1 is not particularly limited as long as it is relatively softer than the above-mentioned hard foam. For example, a polyethylene foam manufactured by Sekisui Chemical Co., Ltd. having a magnification of 20 to 40 times is used. And a urethane foam having a magnification of 20 to 40 times manufactured by Bridgestone Corporation are preferably used. This layer not only acts as a buffer layer for soundproofing, but also acts as an unevenness-adjusting layer for absorbing irregularities when directly attached to concrete. If the thickness of the flexible foam is too thick, it will be "fluffy" when walking,
m or less, and particularly preferably 1 to 2 mm.

The flooring material of the present invention 1 is obtained by laminating the hard foam and the soft foam on the hard plate as a surface layer. The floor material is preferably in the order of hard plate / hard foam / soft foam in order to obtain a good walking sensation, but in the order of hard plate / soft foam / hard foam / soft foam. A structure in which a soft foam is sandwiched between a hard plate and a hard foam (in this case, the two soft foams do not need to be of the same type), or between the hard plate and the hard foam, If a layer made of a material having a vibration damping effect, such as rubber, soft elastomer, and nonwoven fabric, is inserted, the soundproof performance is further improved. The floor material may be formed by laminating a hard plate on one side and a soft foam on the other while the sheet-like material used in claim 3 is laminated on both surfaces of the rigid foam.

Further, when the soft foam is thin, the sound insulation performance can be exhibited without impairing the walking feeling even when the hard plate-like body / soft foam / hard foam is laminated in this order.
Rigidity can also be improved by sandwiching a hard foam with a hard plate, such as a hard plate / hard foam / hard plate / soft foam.

The method of laminating the hard plate, the hard foam and the soft foam is not particularly limited. For example, they can be integrated by laminating using an adhesive or a pressure-sensitive adhesive. As an adhesive, vinyl acetate emulsion (for example, trade name “ESDINE # 635” manufactured by Sekisui Chemical Co., Ltd.)
4 "), an acrylic adhesive (for example, product name" Esdine # 7850 "manufactured by Sekisui Chemical Co., Ltd.), and a chloroprene-based adhesive (for example, product name" Esdine # 280L "made by Sekisui Chemical Co., Ltd.) be able to.

When an olefin resin is used as the rigid foam, auxiliary means such as corona treatment may be used because of poor adhesiveness. May be improved. Rigid urethane foam is preferred because paper can be laminated on the surface during foaming.

The condominium according to claim 2 is equivalent to claim 1
Is directly attached to a floor slab.
The condominium here refers to a high-rise apartment house made of reinforced concrete. In condominiums, sound insulation is particularly important,
The flooring material of the present invention is suitable because the flooring material is directly stuck on the floor slab.

The floor material is directly adhered to a floor slab such as concrete of an apartment with an adhesive or an adhesive.
In general, the thickness of the floor material is suitably 5 to 20 mm.
2 mm and 15 mm are frequently used as standard sizes. In this case, the thickness of the rigid foam is preferably 5 to 10 mm.

(Function) The flooring material of the present invention is a flooring material in which a hard plate-like body is used as a surface layer and a hard foam and a soft foam are laminated. Since the average value of the ratio Dz / Dxy is 1.5 to 2.5 and the average value of Dxy is 500 μm or more, a cell structure that is strong against a compressive force from above is obtained. Further, when the cell diameter is 500 μm or more, the thickness of the cell wall becomes thick, the compression elastic modulus can be improved even at a high magnification, and since the expansion ratio is 7 to 30 times, the elasticity in the in-plane direction is increased. The rate is reduced, resulting in easier bending. As a result, the flexural modulus can be reduced while securing the necessary compressive modulus as a floor material, so that the soundproofing performance can be improved without using a thick cushioning material. Even if it is not "fluffy", it is a good flooring with good walking feeling.

The condominium according to the second aspect of the present invention is excellent in a feeling of living in that the condominium according to the present invention is provided with a floor which has a good soundproof performance and a good walking feeling because the flooring material of the present invention is directly attached to the floor slab. It will be.

In the method for producing a flooring material according to the third aspect of the present invention, the polyolefin resin is reacted with a modifying monomer, the viscosity of the resin in the molten state is increased by the modification, and even when the foaming agent is decomposed at a high temperature, the foaming energy is increased. Use a denatured resin that does not cause bubble breakage. For this reason, thermal decomposition type foaming becomes possible without going through an electron beam crosslinking or water crosslinking step.

[0084]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail with reference to examples. (Example 1) (1) Preparation of modified polyolefin-based resin A BT40 (plastic engineering laboratory) co-rotating twin-screw extruder was used as a screw extruder for modification. It has a self-wiping double-start screw with an L / D of 35 and a D of 39 mm. The cylinder barrel is composed of first to sixth barrels from upstream to downstream of the extruder. The die is a three-hole strand die, and a vacuum vent is installed in the fifth barrel to collect volatile components.
The operating conditions are as follows.

Cylinder barrel set temperature: 1st barrel; 180 ° C. 2 to 6 barrels; 220 ° C. die; 220 ° C. Screw rotation speed: 150 rpm The mixture was charged from an end hopper, a mixture of divinylbenzene and an organic peroxide was injected into the extruder from a third barrel, and these were melt-mixed to obtain a modified resin. At this time, the volatile components generated in the extruder were evacuated by a vacuum vent.

The polyolefin resin is a polypropylene random copolymer (“EX6” manufactured by Nippon Polychem, MI;
1.8, density; 900 g / L), and the supply amount is 1
0 kg / h. The modifying monomer was divinylbenzene, and the supply amount was 0.5 parts by weight based on 100 parts by weight of the polyolefin resin. The organic peroxide used was 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3, and the supply amount was 0.1 part by weight based on 100 parts by weight of the polyolefin resin. And The modified resin obtained by melt-mixing a polyolefin resin, divinylbenzene, and an organic peroxide was discharged from a strand die, cooled with water, and cut with a pelletizer to obtain pellets of the modified resin.

(2) Preparation of foamable resin composition and foamable composite sheet The screw extruder for kneading the foaming agent is a TEX-44 type (manufactured by Nippon Steel Works) co-rotating twin screw extruder.
It is equipped with a self-wiping double screw and its L
/ D is 45.5 and D is 47 mm. The cylinder barrel comprises first to twelfth barrels from upstream to downstream of the extruder, and the forming die has a width of 510 mm and a lip interval of 0.8 mm. The temperature setting categories are as follows.

The first barrel is constantly cooled. The first zone; the second to fourth barrels; the second zone; the fifth to eighth barrels; the third zone; the ninth to twelfth barrels; the fourth zone; A side feeder is installed in the sixth barrel, and a vacuum vent is installed in the eleventh barrel to collect volatile components. The operating conditions including the temperature setting are as follows.

[0089] The modified resin obtained as described above and a homo-type polypropylene (“FY4” manufactured by Nippon Polychem, MI;
0, density: 900 g / L) was supplied to the blowing agent kneading screw extruder at a supply rate of 10 kg / h.
In addition, a blowing agent (azodicarbonamide (ADCA))
Was supplied from the side feeder to the same extruder at a supply rate of 0.4 kg / h.

The foamable resin composition thus obtained by kneading the modified resin and the foaming agent is extruded from a T-die, and
A nonwoven fabric made of polyethylene terephthalate (trade name “Spanbond Equle 6301A”, manufactured by Toyobo Co., Ltd., weighing 30 g) above and below the foamable sheet extruded from the die
/ M2, tensile strength 1600 N / m length (approximately 1.6 kg /
cm) and 1200 N / m (approximately 1.2 kg / cm)], and then pass between opposed cooling rolls with an interval of 0.8 mm and a temperature of 90 ° C. to be laminated and integrated. Thus, a foamed laminate was obtained. The size of the foamable resin sheet excluding the nonwoven fabric is 500 mm in width and 0.8 in thickness.
mm.

(3) Preparation of Rigid Foam The foamed laminate obtained as described above was cut at the end and cut in the longitudinal direction to have a width of 450 mm and a length of 1100 mm. It was sandwiched between upper and lower two belts mainly composed of polytetrafluoroethylene (manufactured by Chuko Kasei Kogyo Co., Ltd., trade name "Chukoflow G type belt"), and heated at 230 ° C. for about 8 minutes to foam. After foaming, it is cooled, solidified, peeled from the belt, and has a width of 400 mm x a length of 1100 m
m of rigid foam was obtained.

(4) Evaluation of rigid foam The obtained composite foam was evaluated for the performance of the following items.
The results are shown in Table 1. Expansion ratio: After the surface material was scraped off from the composite foam with a cutter, the expansion ratio of the foam was measured in accordance with JIS K6767. Bubble shape: The foam sheet was cut in the thickness direction (z direction), and a 15-fold enlarged photograph was taken while observing the center of the cross section with an optical microscope. Dz and D of all bubbles in the photo
xy is measured with a caliper, Dz / Dxy is calculated for each bubble,
The number average of Dz / Dxy for 100 bubbles was calculated.
However, during the measurement, bubbles with a Dz (actual diameter) of 0.05 mm or less and bubbles with a diameter of 10 mm or more were excluded.

The major and minor axes of the bubbles were measured as follows. Long axis: the maximum length between any two points of the object. Minor axis: width in the direction perpendicular to the maximum length.

(5) Hard plate-like body A 0.2 mm-thick attached plate (manufactured by Kitasan Co., Ltd.) is adhered to a plywood (2.7 mm thick), an epoxy resin is applied, and the resin is cured by ultraviolet rays. - (6) Soft foam A 30-fold soft urethane foam with a thickness of 2.0 mm manufactured by Bridgestone Corporation was used.

(7) Adjustment and evaluation of flooring material The above hard plate was adhered to one side of the obtained rigid foam, and the soft foam was adhered to the entire surface of the obtained rigid foam with double-sided tape. And The double-sided tape used was a double tack tape (400 mm width) manufactured by Sekisui Chemical Co., Ltd. The floor materials were evaluated by the following methods, and the results are shown in Table 1. Soundproofing performance The lightweight floor impact level was measured in accordance with JIS A1418 and displayed as soundproofing performance LL. Submersion amount A compression terminal with a diameter of 50 mm is placed on the floor (hard plate-like body surface).
The displacement when pressed with a force of 0N was defined as the sinking amount (it is considered that a walking feeling is poor if the sinking is 3 mm or more).

(Comparative Example 1) In the preparation of the rigid foam, the belt was adjusted from above and below the belt by a press machine so that the clearance between the belts was 3 mm. After heating for 7 minutes, the press was released and about 1 minute. Except that a rigid foam was obtained by heating, the floor material was adjusted and evaluated in the same manner as in Example 1, and the results are shown in Table 1.

(Comparative Example 2) In the preparation of the above-mentioned rigid foam, a pressure of 4.0 MPa was applied from above and below the belt by a press machine, heated for 7 minutes, released, and heated for about 1 minute to foam. A rigid foam and a floor material were obtained and evaluated in the same manner as in Example 1 except that the test was completed, and the evaluation was performed. The results are shown in Table 1.

(Comparative Example 3) In the preparation of the foamable resin composition, a foaming agent (azodicarbonamide (ADCA)) was added in an amount of 0.4 kg /
h from the side feeder to the same extruder, and pass between opposed cooling rolls having a distance of 2.0 mm and a temperature of 90 ° C. to be laminated and integrated to form a foamable laminate. I got a body. The floor material was adjusted and evaluated in the same manner as in Example 1 except that the size of the foamable resin sheet excluding the nonwoven fabric was 500 mm in width and 2.0 mm in thickness, and the results are shown in Table 1.

Comparative Example 4 High Density Polyethylene Resin 1
(Mitsubishi Chemical's trade name "HY340" Density: 952 g
/ L, MI: 1.5 g / 10 min), 25%, high-density polyethylene resin 2 (manufactured by Mitsubishi Chemical Corporation, trade name “JY20”)
(Density: 951 g / L, MI: 9.0 g / 10 min.) 25
%, Polypropylene resin (manufactured by Mitsubishi Chemical Corporation, trade name "MA
3 ", density: 900 g / L, MI: 11 g / 10 min.)
20%, silane-modified polypropylene resin (manufactured by Mitsubishi Chemical Corporation, trade name "XPM800HM", density: 912 g /
L, MI: 11 g / 10 min,) 30%, about 1% by weight of dibutyltin dilaurate in a polypropylene masterbatch (manufactured by Mitsubishi Chemical Corporation, trade name "PZ-10S") and azodicarbonamide (decomposition temperature: 201 ° C) ), 1.5 parts by weight, 4 parts by weight,
The water-crosslinkable composition was obtained by adding parts by weight. This composition is
After extruding into a sheet using an EX-44 type extruder, a nonwoven fabric was laminated in the same manner as in Example 1 to prepare a composite sheet. Next, the obtained composite sheet was immersed in hot water of 99 ° C. for 2 hours, and crosslinked with water to obtain a foamable laminate,
Further, foaming was performed in the same manner as in Example 1 to obtain a foam, and the floor material was adjusted and evaluated in the same manner as in Example 1. The results are shown in Table 1.

[0100]

[Table 1]

[0101]

According to the first aspect of the present invention, the flooring material is constructed as described above, is excellent in soundproofing performance, has a good walking sensation, and has both properties and is of great practical value. Claim 2
The condominium according to the present invention has excellent feeling of living because the floor material according to the first aspect is directly attached to the floor slab. In the method for producing a flooring material according to the third aspect, it is possible to produce a rigid foam by pyrolytic foaming without going through an electron beam crosslinking or water crosslinking step, and thus it is easy to produce the flooring material with a high productivity. Flooring can be manufactured.

[Brief description of the drawings]

FIG. 1 is a view for explaining an aspect ratio of spindle-shaped cells in a rigid foam sheet according to the present invention 1 or 2.
(A) is a perspective view of the entire rigid foam sheet, (b) is a schematic enlarged view of a main part for showing a cell shape of the rigid foam sheet,
(C) is a schematic enlarged view showing one bubble taken out.

[Explanation of symbols]

 1..Rigid foam (sheet)

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F100 AK03 AK07J AK18 AK42 AL03 AL06 AR00A AR00B AR00C BA03 BA07 BA10A BA10C DG15 DJ01B DJ01C EC052 EJ021 EJ421 EJ422 GB08 GB90 JH01 JK12A JK12B JK13C YY00B

Claims (3)

[Claims] 1. A floor material comprising a hard plate-shaped body as a surface layer and a hard foam and a soft foam laminated thereon, wherein said hard foam has an expansion ratio of 7 to 30 times and is intrinsic. A flooring material, wherein the average value of the aspect ratio Dz / Dxy of the bubbles is 1.5 to 2.5 and the average value of Dxy is 500 μm or more. 2. An apartment, wherein the floor material according to claim 1 is directly attached to a floor slab. 3. A foamable resin composition containing a modified resin obtained by reacting a polyolefin-based resin with a modifying monomer and a thermal decomposition type chemical foaming agent is formed into a sheet, and the foamed resin composition is obtained. It is obtained by laminating a sheet-like material capable of suppressing an in-plane foaming force generated when the foamable sheet is heated and foamed on at least one surface of the foamable sheet, and heating the resulting foamable composite sheet. The floor material manufacturing method according to claim 1, wherein a soft foam and a hard plate-like body serving as a surface layer are laminated on the hard foam.