JP2002225201A - Expanded decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a non-polyvinyl chloride expanded decorative material excellent in performance. SOLUTION: The expanded decorative material comprises an expanded resin layer containing no chlorine and a composite film which is laminated on the expanded layer. The composite film consists of an upper ionomer layer and a lower film layer which is more flexible than the upper layer and contains no chlorine. The expanded decorative material has functions such as flexibility, resistance to warpage and good workability.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a chlorine-free foam decorative material suitable for interior materials such as floor materials and wall materials.

[0002]

2. Description of the Related Art Japanese Unexamined Patent Publication No. 9-59880 discloses a non-halogen floor material in which the upper layer is simply a single-layer ionomer. In this configuration, the lamination force was low, and whitening occurred. Further, the sheet was expensive and the rigidity of the sheet was high, making it difficult to construct.

Japanese Patent Application Laid-Open No. 10-280284 discloses a non-PVC flooring material in which a composite film having an upper layer and a lower layer softer than the upper layer is formed in a non-PVC foam layer. However, the above flooring is wrinkled, warped, scratch resistant,
There were problems with whitening and workability.

[0004]

SUMMARY OF THE INVENTION The present invention provides a foamed decorative material such as a flooring material containing no chlorine and having high durability such as scratch resistance.

[0005]

The present invention is characterized in that a composite film comprising an ionomer upper layer and a chlorine-free film lower than the upper layer is laminated on a chlorine-free resin foam layer. And foam decorative material,
Is the gist.

In the present invention, a composite film comprising an upper layer and a lower layer is laminated on a foam layer. The laminated film may have two layers or three layers. The upper layer is an ionomer, and the polar polymer having a negative ion functional group is Zn, Li,
It is a structure cross-linked by metal ions such as Mg and Na. As an ionomer, the MFR is 1 to 15 g /
Desirably, it is 10 min. Share D as hardness
Hardness of 50 or more is desirable. The thickness is preferably at least 20 μm, more preferably at least 30 to 200 μm. The ionomer portion of the obtained composite film is a mixture of crystallinity and amorphousness, and is soft and does not whiten. The ionomer is commercially available as Himilan (manufactured by Du Pont-Mitsui Polychemicals) and is used for packaging. This resin is suitably used as a surface film. The obtained composite film is laminated on a non-PVC foam.

The lower layer is a film that is softer than the ionomer. Examples of the film include an ionomer softer than the upper layer, EVA, nylon, an acrylic film, and a polyolefin. MFR of lower layer is 0.1-20g
/ 10 min is preferred.

[0008] A composite film in which the upper layer and the lower layer are laminated is obtained. These films have a thickness of 20-300μ.
m is preferred. In the present invention, the composite film has a configuration in which an upper layer is laminated on the surface side of a lower layer, and the total thickness of the composite film is preferably 50 to 500 μm, and the ratio of the thickness of the upper layer to the lower layer is preferably 1:20 to 20: 1. The composite film having the above configuration is free from scratches by nails,
High wear resistance. Since the lower film is softer than the upper film, it has good adhesion to the foam layer.

[0009]

FIG. 1 is a sectional view of a foam decorative material according to the present invention. 1 is an upper layer, 2 is a lower layer, 3 is a composite film, 4 is a printing layer, and 5 is a foam layer. A fiber layer 6 such as a nonwoven fabric or a net may be interposed immediately below the printing layer to provide dimensional stability.

On a non-combustible paper, a chlorine-free synthetic resin sheet, a glass fiber woven or non-woven fabric substrate 1, a resin containing no chlorine atoms in the components, for example, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl An acrylate copolymer, a polyacrylate, a polymethacrylate, a foamable resin such as a polyolefin is extruded from an extruder into a mold.
１．０1.0 mm thick, and a fiber layer 6 is laminated thereon,
Preheating is performed in a preheat oven, a pattern is formed on the resin layer surface by transfer with a transfer roll, and heating and foaming are performed in a main oven at 120 to 250 ° C. The expansion ratio is 1.3 to 20 times. Thus, the foam decorative material 7 of the present invention
Is obtained.

Polyolefins (mainly PE) polymerized with a metallocene catalyst are also suitable. A general metallocene catalyst is composed of a metallocene complex and an aluminoxane. This metallocene-catalyzed PE is
It has a sharp molecular weight distribution and composition distribution, and has excellent low-temperature heat sealability.

Examples of the blowing agent include dinitrosopentamethylenetetramine, benzenesulfonylhydrazide, p-toluenesulfonylhydrazide, p, p'-oxybis (benzenesulfonylhydrazide), 3,3'-disulfonehydrazidephenylsulfone, azobisisobutylnitrile, Examples include azodicarbonamide and the like, and examples of the foaming accelerator include urea ethanolamine, zinc white, lead carbonate, lead stearate, zinc stearate, and glycol. Examples of the filler include aluminum hydroxide, heavy calcium carbonate, light calcium carbonate, clay, and talc.

When the foamed layer is made of EVA, the composition of the foamable resin is as follows: EVA100PHR, foaming agent 1 to 10
PHR, foaming accelerator 0.1-5PHR, pigment 1-20P
HR, fillers 0 to 100 PHR are preferred. The flooring material obtained in this way does not generate toxic gas during combustion,
In terms of strength, it was useful as compared with a floor material using PVC.

In the above production process, the resin containing no chlorine atom, which is contained in the foamable resin applied to the substrate by using an extruder, is preferably EVA (MFR of 0.1 or less).
~ 20 g / 10 0 min. Preferably, MFR is 1.0
-10 g / 10 min), vinyl acetate (VAc amount 5-4)
0 wt%). The MFR is a value indicating the fluidity of the resin, and the larger the number, the higher the fluidity. (ASTM D-1238 revised)

Further, the foamed resin layer is laminated with a composite film immediately before heating and foaming in an oven, and after heating and foaming, pressure embossing is performed with an embossing roll to obtain a flooring material of the foamed decorative material of the present invention.

FIG. 2 is a sectional view of the foam decorative material of the present invention. 1 is an upper layer, 2 is a lower layer, 3 is a composite film, 8
Is a printing layer, and 5 is a foam layer. In order to provide dimensional stability near the floor base of the foam layer, a thickness of 0.1 to 0.5 mm,
A fiber layer 9 such as a nonwoven fabric or a net having a basis weight of 30 to 200 g / m ² may be interposed. In this way, another foam decorative material 10 of the present application is obtained. The flooring material thus obtained was useful because it did not generate toxic gas during combustion and was comparable in strength to flooring materials using PVC.

[0017]

【Example】

Example 1 A foamable resin mixed with a composition shown in Table 2 was applied to a glass nonwoven fabric substrate of 50 g / m ^{2 so} as to have a thickness of about 0.3 mm by an extruder, and heated in a preheat oven. After transferring the pattern, a composite film consisting of an upper layer and a lower layer of “Table 3” was laminated on the surface, and then heated and foamed in a main oven (200 ° C.). A foam flooring material was obtained. The obtained flooring material had effects such as flexibility, no warpage, no whitening, good workability, good wear resistance, and good scratch resistance.

(Table 2) EVA resin 1 100 (unit: PHR) (MFR 2 g / 10 min, VAc 28%) Azodicarbonamide foaming agent 3.0 Zinc stearate 1.0 Colorant (TiO 2) 2.0

(Table 3) Extruded sheet = resin layer 0.3 mm Surface film (two-layer structure) Two layers co-pressed Upper layer Ionomer 1 MFR 5 g / 10 min 50 μm Lower layer Ionomer 1 MFR 14 g / 10 min 50 μm

[0020]

Example 2 The upper layer of "Table 4" on the foamable layer of Example 1
After laminating the lower three-layer composite film, it was heated and foamed to obtain a foamed floor material.

(Table 4) Extruded sheet = resin layer 0.5 mm Surface layer film (three-layer configuration) Three-layer inflation Upper layer Ionomer 2 MFR 1 g / 10 min Middle layer Ionomer 2 + EVA2 = 20: 80 Lower layer EVA2 (Va 28% MFR 6 g / 10 min ) Each layer 40μm (total thickness 120μm)

[0022]

COMPARATIVE EXAMPLE The composite film of Table 5 was laminated on the foamable layer of Example 1 and foamed to obtain a foamed floor material. (Table 5) Extruded sheet = Resin layer 0.5 mm Surface layer film (three-layer configuration) Three layers co-pressed Upper layer PP / Intermediate layer PE / Lower layer EVA Each layer 35 μm (total thickness 105 μm)

[Table 1]

Bending whitening 90 ° bending on the surface side,
The same line was bent 90 degrees to the back side, and the one where the bent part was whitened was ×, and the one that was not whitened was ○ Workability. ○ No problem △ End work hardly workability Scratch resistance Surface rubbed with a cloth, no scratches ○, scratched white x

Table 1 shows the performance of the obtained foamed floor material. According to Table 5, at 20 ° C. and at 5 ° C., the examples are more flexible than the comparative examples, and the examples show about 60% of the heating warpage of the comparative examples.
Low and excellent in dimensional and morphological stability. In addition, bending whitening resistance and workability were excellent. Furthermore, while the abrasion resistance of the comparative example was 0.20 mm, the abrasion resistance of the example of the present application was 0.09 mm, which is half or less, and the abrasion resistance was excellent.

[0025]

Effect of the Invention Be flexible. 2. There is no warpage. 3. Does not whiten Good workability. 5. Good wear resistance. 6. Good scratch resistance.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of the foam decorative material of the present invention.

FIG. 2 is a cross-sectional view of the foam decorative material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Upper layer 2 Lower layer 3 Composite film 5 Foam layer 7,10 Foam decorative material

Claims (2)

[Claims] 1. A foam decorative material comprising a composite film comprising an ionomer upper layer and a chlorine-free film lower than the upper layer, laminated on a chlorine-free resin foam layer. 2. The foam decorative material according to claim 1, wherein the film constituting the lower layer is one of an ionomer, an ethylene-vinyl acetate copolymer, nylon, an acrylic resin, and a polyolefin.