JP2004084284A - Floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor material which is formed by laminating a decorative sheet on a woody substrate via a thermoplastic resin intermediate layer, ensures its sufficient water resistance even if grooving is carried out from the side of the decorative surface, and is so improved in cutting performance that defective cutting such as burrs, bleeding, and whitening, rarely occurs at the time of grooving. <P>SOLUTION: According to the structure of the floor material, the thermoplastic resin intermediate layer is formed of a mixed thermoplastic resin composition as a main ingredient, containing a thermoplastic resin of 90 to 25 wt% with a glass transition temperature of 0 °C or less, and a thermoplastic resin of 10 to 75 wt% with a glass transition temperature of 45 °C or more. By using the compounded resin in this range, the defective cutting such as burrs, bleeding, and whitening rarely occurs at the time of grooving, to thereby manufacture the floor material of high quality with high productivity. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to flooring materials used for indoor floor surfaces, stair treads, and the like in buildings such as houses, and in particular, when cutting grooves from decorative surfaces, burrs, mustaches, and cutting defects such as whitening hardly occur. And floor materials with improved machinability.
[0002]
[Prior art]
Currently, flooring materials used for indoor floors and the like in buildings such as houses include solid wood of a thickness of about 6 to 15 mm and a wooden base material such as a laminated plywood of a thickness of about 6 to 15 mm. Wood flooring materials, such as those to which a natural wood veneer of about 0.2 to 1 mm is adhered, are most widely used. However, since the wooden flooring material is made of natural wood, its surface is inherently weak in water resistance, and if it is used in places where the floor surface is often wet with water, such as in kitchens and washrooms, water seepage may occur. There is a problem that swelling and peeling of the veneer layer and warping and corrosion of the entire flooring material are liable to occur.
[0003]
Therefore, instead of a conventional natural wood veneer on a wood substrate such as laminated plywood, a thermoplastic resin sheet having excellent water resistance is provided with a design that artificially expresses a wood grain pattern or the like by printing or the like. Floor materials to which a decorative sheet is attached have also been proposed (utility model registration No. 3051530). However, in general, flooring materials are often provided with grooves on the surface to imitate the design of an old parquet floor, but the decorative sheet is a thin sheet at most about 300 μm or less. When a groove is formed with a typical depth (approximately 0.2 mm to 2 mm), the wood base material is exposed in the groove, and the moisture that has permeated there has caused swelling and peeling of the decorative sheet layer and warping of the entire flooring material. And corrosion may occur.
[0004]
In order to solve this problem, a thermoplastic resin plate is interposed between a wood base material such as laminated plywood and a decorative sheet, and a groove is formed to a depth that does not penetrate the thermoplastic resin plate. There is also a proposal of a flooring material which prevents penetration of moisture into a wooden base material and has improved water resistance (Japanese Patent Application Laid-Open No. 2001-191454). However, since the thermoplastic resin plate is made of a thermoplastic resin, unlike a wooden base material, it is softened and stretched due to heat generated by friction with the cutting blade during grooving, causing burrs and whiskers, and cutting portions are generated. There has been a problem that the design of the surface of the flooring material is easily damaged by whitening.
[0005]
[Problems to be solved by the invention]
The present invention has been made in order to solve the above-mentioned problems in the prior art, and can maintain sufficient water resistance even when a groove is formed from a decorative surface, and at the time of forming the groove, generate burrs and beards. It is an object of the present invention to provide a floor material which is hard to generate cutting defects such as whitening and has improved machinability.
[0006]
[Means for Solving the Problems]
In order to solve the above problems, the present invention provides a decorative sheet laminated on a surface of a wooden substrate via a thermoplastic resin intermediate layer, and the thickness of the decorative sheet exceeds the thickness of the decorative sheet from the surface of the decorative sheet. In a flooring material in which a groove is formed to a depth reaching the inside of the intermediate layer, the thermoplastic resin intermediate layer may have a glass transition temperature of 90 to 25% by weight of a thermoplastic resin having a glass transition temperature of 0 ° C. or less. The present invention provides a floor material characterized in that the main component is a thermoplastic resin composition mixed with 10 to 75% by weight of a thermoplastic resin having a temperature of 45 ° C. or higher.
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
As shown in FIG. 1, the flooring material of the present invention comprises a thermoplastic resin having excellent water resistance on a surface of a wooden base material 1 made of laminated plywood or the like via a thermoplastic resin intermediate layer 2 having excellent water resistance. A decorative sheet 3 made of a sheet for imparting the design property is laminated, and a groove is formed from the surface of the decorative sheet 3 to the inside of the thermoplastic resin intermediate layer 2 to a depth that does not reach the wood substrate 1. The floor material is provided with the groove portions 4 formed thereon, and at the time of groove processing for forming the groove portions 4, the thermoplastic resin intermediate layer 2 is stretched by cutting heat to remove burrs, whiskers, whitening, and the like. The thermoplastic resin intermediate layer 2 has a glass transition temperature of 90 to 25% by weight of a thermoplastic resin having a glass transition temperature of 0 ° C. or less, and a glass transition temperature of 45 ° C. or more, so that the glass transition temperature does not easily occur and good design properties can be obtained after groove processing. Mainly comprising a thermoplastic resin composition mixed with 10 to 75% by weight of a thermoplastic resin. It is characterized in that it has configuration Te.
[0008]
As a thermoplastic resin having a glass transition temperature of 0 ° C. or less, which is the first component of the mixed thermoplastic resin composition constituting the thermoplastic resin intermediate layer 2, for example, low-density polyethylene (glass transition temperature of about −125 ° C.) A second component such as high-density polyethylene (about -125 ° C), polypropylene (about -10 to -20 ° C), polybutene (about -25 ° C), polybutadiene (about -100 ° C), etc. Examples of the thermoplastic resin having a glass transition temperature of 45 ° C. or higher include polyethylene terephthalate (about 67 to 82 ° C.), polybutylene terephthalate (about 60 ° C.), polyethylene naphthalate (about 112 to 120 ° C.), 1,4 -Cyclohexane dimethanol copolymerized polyethylene terephthalate (about 78 ° C), polycarbonate (about 150 ° C), polystyrene (about 98 ° C) Acrylonitrile-butadiene-styrene copolymer (about 100 to 110 ° C.), polyamide resin (about 45 to 70 ° C.), ethylene-vinyl alcohol copolymer (about 55 to 65 ° C.), polymethyl methacrylate ( About 90 to 105 ° C.) can be used alone or in any combination of two or more.
[0009]
As described above, the principle of improving the machinability of the thermoplastic resin intermediate layer 2 by mixing a thermoplastic resin having a glass transition temperature of 0 ° C. or lower and 45 ° C. or higher is not necessarily clear, but this mixing is not clear. In the resin composition, when viewed microscopically, the resin having a low glass transition temperature and the resin having a high glass transition temperature are not uniformly mixed, and a portion made of a resin having a low glass transition temperature and a glass transition temperature are low. It is considered that the part composed of high resin is constituted by an aggregate randomly arranged, and the thermal softening behavior due to frictional heat with the cutting blade during grooving differs between the two, so that the entire resin composition It is considered that the elongation is not uniform and the elongation is hindered, and as a result, the occurrence of burrs, whiskers, and whitening is suppressed.
[0010]
Therefore, it is necessary to select the mixing ratio from the range in which the difference in thermal softening behavior between the two significantly affects the thermal softening behavior of the entire resin composition. In the mixing ratio region mainly comprising a thermoplastic resin having a low glass transition temperature and a thermoplastic resin having a high glass transition temperature, it is easy to take a form in which the particles of the latter are dispersed in the matrix of the former. Even if the ratio is relatively small, the latter is likely to be a hindrance to the deformation of the former in the heat-softened state, so that if the latter is mixed at 10% by weight or more, the effect of improving the machinability is exhibited. On the other hand, in the mixing ratio region mainly based on the latter, the former particles are easily dispersed in the latter matrix, and the thermal softening behavior of the resin composition as a whole is substantially due to the thermal softening behavior of the latter. Therefore, it is considered that a remarkable effect of improving the machinability is exhibited in a mixing ratio range in which the latter matrix takes a form appropriately divided by the former, that is, in a range in which the latter is 75% by weight or less. Can be
[0011]
In mixing and using a plurality of resins having different glass transition temperatures, if the compatibility (interfacial adhesion) between the resins is poor, the mechanical strength is reduced, the brittleness is liable to be broken, and the surface required as a floor material is required. The strength and impact resistance may be insufficient. In order to avoid this problem, a compatibilizing agent such as a styrene-butadiene copolymer or an unsaturated carboxylic acid-modified polyolefin resin represented by maleic anhydride graft-modified polypropylene is added to the mixed resin composition. It is desirable. The amount of the compatibilizer is generally about 0.05 to 10 parts by weight per 100 parts by weight of the mixed resin composition.
[0012]
In order to provide the flooring material of the present invention with sufficient surface strength (scratch resistance, indentation resistance, caster resistance) as a flooring material, a thermoplastic resin is used to enhance the mechanical strength of the thermoplastic resin intermediate layer 2. An appropriate filler can be added to the mid layer 2. Specifically as the filler, for example, calcium carbonate, talc, clay, glass powder, glass fiber, glass beads, mica powder, inorganic fillers such as metal powder, wood powder, paper powder, chaff, wood pulp, Organic fillers such as synthetic resin beads can be used arbitrarily. The amount of the filler is usually about 5 to 400 parts by weight per 100 parts by weight of the mixed thermoplastic resin composition. However, a high filling is required to enhance the surface hardness, and more preferably 150 to 400 parts by weight. It is desirable to add about part of the filler.
[0013]
The thermoplastic resin intermediate layer 2 may be colored in an appropriate color. In particular, if the groove 4 in the flooring material is colored in a desired color, the step of coating the groove 4 after the groove processing is omitted. There are advantages that can be. The coloring is usually performed by adding a coloring agent such as an inorganic pigment such as titanium oxide, iron oxide, carbon black, and cobalt blue, and an organic pigment such as anthraquinone, isoindolinone, quinacridone, and phthalocyanine. In addition, when wood flour is added as a filler, the wood flour also gives a color similar to wood and also gives a woody feeling such as a fibrous feeling and a shining feeling similar to wood. It is particularly suitable in the case of a wood-grain floor material using the wood-grain decorative sheet 3.
[0014]
The thickness of the thermoplastic resin intermediate layer 2 is not particularly limited, but is required to be at least the thickness obtained by subtracting the thickness of the decorative sheet 3 laminated on the surface from at least the depth of the groove 4 formed by the groove processing to be performed from the surface. In addition, it is desirable to select a thickness such that the remaining thickness at the bottom of the groove 4 is at least 0.2 mm or more, and usually selected from a range of about 0.5 to 5 mm.
[0015]
As the wood substrate 1, various conventionally known wood-based boards such as a laminated plywood, a veneer laminate, an oriented board, a particle board, a high-density fiber board and the like can be arbitrarily used 2. Among them, the most typical is a laminated plywood, which is obtained by laminating and bonding a plurality of (usually an odd number) of veneers with their fiber directions alternately orthogonal to each other. The seed may be any of hardwood such as rawan and softwood such as pine or a mixture thereof. As the outermost timber veneer, for example, using a hard and durable Nanyo-based material containing silica, such as Klein, Kapoor, and Menclane, a flooring material with more excellent surface strength can be obtained. be able to.
[0016]
The thickness of the wooden base material 1 is not particularly limited, but the total thickness of the flooring material is generally selected from a range of about 6 to 15 mm. Therefore, the thickness of the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are subtracted from this. The thickness is set and usually designed within a range of about 2.5 to 12 mm.
[0017]
The decorative sheet 3 is provided to impart a desired design and surface properties such as abrasion resistance, scratch resistance, solvent resistance, weather resistance and oil resistance to the surface of the flooring material. May be a paper-based decorative sheet having a surface printed with a pattern printed and a surface protective coat layer. However, from the viewpoint of the surface physical properties described above, it is most preferable to use the decorative sheet 3 made of a thermoplastic resin. desirable.
[0018]
The decorative sheet 3 made of the thermoplastic resin is, specifically, an opaque base sheet made of a thermoplastic resin provided with a pattern layer on the surface, or a transparent base sheet made of a thermoplastic resin, The decorative sheet may be a single-layer decorative sheet such as a sheet provided with a pattern layer on its surface, or a sheet provided with a surface protective layer on its surface. However, in consideration of various required qualities such as design properties, adhesive suitability, weather resistance, solvent resistance and abrasion resistance, on a base sheet made of a transparent or opaque thermoplastic resin, a transparent It is most preferable to use a decorative sheet having a multilayer structure in which a transparent resin layer made of a thermoplastic resin is provided. The picture layer may be provided between the base sheet and the transparent resin layer, or may be provided on the front surface of the transparent resin layer or on the back surface of the base sheet when the base sheet is transparent.
[0019]
As the thermoplastic resin constituting the base sheet, the transparent resin layer, and the like, which is the main component of the decorative sheet 3, for example, a polyolefin resin, a polyester resin, an acrylic resin, a polystyrene resin, a polyamide resin, or the like is used. Can be. In particular, in consideration of the surface physical properties as a floor material, workability, economy, disposability (including incineration), and the like, it is desirable to use a polyolefin resin and / or a polyester resin as the material of the decorative sheet 3. . Further, in consideration of the treatment of waste materials generated after the use of the floor material or during processing, if the same resin as that contained in the thermoplastic resin intermediate layer 2 is used, the thermoplastic resin intermediate layer 2 and the decorative sheet 3 can be used. Can be reused as a raw material of the thermoplastic resin intermediate layer 2 without separation.
[0020]
There are no particular restrictions on the type of pattern in the pattern layer applied to the decorative sheet 3, and any type of pattern, such as a wood pattern, a stone pattern, or an abstract pattern, may be used as desired. Further, the decorative sheet 3 is required to have a concealing property in order to conceal undesired colors, color unevenness, defects and the like on the surface of the wooden base material 1 and / or the thermoplastic resin intermediate layer 2 to enhance the design. Often. In order to provide the decorative sheet 3 with hiding properties, titanium oxide, zinc oxide, carbon black, iron oxide, or the like is applied to the thermoplastic resin layer on the back side from the picture layer, that is, the base sheet in the multi-layer decorative sheet described above. It is most effective to add an opaque pigment of the formula (1) and color the film in a concealing property. In addition, a concealing layer can be formed on the back side of the picture layer with an opaque printing ink containing an opaque pigment, or these can be used in combination.
[0021]
In addition to the above, if necessary, the decorative sheet 3 may be embossed on its surface, filled with a coloring agent by a wiping method in the recesses of the embossed surface, or may have a top coat layer which also has gloss control and surface protection on the surface. Or by providing a resin layer having a different gloss state as the top coat layer to express a visual three-dimensional effect by gloss difference, or adding a lubricant to the top coat layer to improve abrasion resistance and scratch resistance. Alternatively, a primer layer may be provided on the back surface to improve the adhesiveness with the thermoplastic resin intermediate layer 2. Further, it is possible to arbitrarily improve the weather resistance by adding an ultraviolet absorber, a light stabilizer, or the like to the transparent resin layer and / or the top coat layer in the decorative sheet 3.
[0022]
In the production of the flooring material of the present invention, the laminating method of the wood substrate 1 and the thermoplastic resin intermediate layer 2 and the laminating method of the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are not limited at all. Without, for example, a wet lamination method or a dry lamination method via an appropriate adhesive, a heat lamination method with or without an adhesive, a sand lamination method through an extruded layer of a molten thermoplastic resin, an ultrasonic fusion method, The method can be arbitrarily selected from any conventionally known lamination methods such as a high-frequency fusion method.
[0023]
In addition, the order of lamination of these three layers is not particularly limited, and after the wooden base material 1 and the thermoplastic resin intermediate layer 2 are laminated in advance, the decorative sheet 3 is placed on the surface of the thermoplastic resin intermediate layer 2 side. Alternatively, the wooden substrate 1 may be laminated on the surface of the thermoplastic resin intermediate layer 2 side after the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are laminated in advance. Of course, three layers of the wood substrate 1, the thermoplastic resin intermediate layer 2, and the decorative sheet 3 may be simultaneously laminated.
[0024]
Also, instead of laminating the thermoplastic resin intermediate layer 2 formed in a plate shape in advance with the wooden base material 1 and the decorative sheet 3, simultaneously with the molding of the thermoplastic resin intermediate layer 2 by an extrusion molding method or an injection molding method, It is also possible to laminate with the wooden substrate 1 and / or the decorative sheet 3 by utilizing the adhesive force in the molten state. For example, in the case of an extrusion molding method, when the thermoplastic resin composition is extruded in a molten state on the surface of the wooden substrate 1 or on the back surface of the decorative sheet 3 or between the layers of the wooden substrate 1 and the decorative sheet 3. At the same time, a method of laminating and cooling and solidifying to form the thermoplastic resin intermediate layer 2 may be adopted.
[0025]
Also, the timing of the cutting process of the groove portion 4 may be at least after lamination of the thermoplastic resin intermediate layer 2 and the decorative sheet 3. In the case of laminating the wooden base material 1 after lamination of both, It may be before or after lamination with the wood substrate 1.
[0026]
In the flooring material of the present invention, similarly to the case of the conventional wooden flooring material, a groove is formed on the back surface of the wooden base material 1 and / or a foam layer and / or fiber is formed on the back surface of the wooden base material 1. It is also possible to add a layer of material to the floor to give the floor base an absorptive property, a soundproofing / soundproofing property, a cushioning property, a heat insulating property, an impact resistance and the like. Further, the foamed layer or the like may be sandwiched between the wooden base material 1 and the thermoplastic resin intermediate layer 2, which improves cushioning and heat insulating properties on the floor material surface, and allows walking when walking with bare feet. It is effective for improving the feeling and eliminating cold touch.
[0027]
【Example】
Example 1
100 parts by weight of a polypropylene resin having a glass transition temperature of −10 ° C. having long chain branching by electron beam crosslinking, 40 parts by weight of a polyethylene terephthalate resin having a glass transition temperature of 65 ° C., and a maleic anhydride graft-modified polypropylene-based compatibilizer Five parts by weight were mixed and pelletized by a twin-screw extruder, and the pellets were charged into a T-type extruder and subjected to corona discharge treatment on both sides while extruding to a thickness of 1 mm, thereby producing a thermoplastic resin intermediate layer.
[0028]
A wood grain pattern is printed with a urethane-based ink on the surface of an 80 μm-thick random polypropylene resin sheet opaquely colored with iron oxide and titanium oxide, and the printed surface is coated with a homopolypropylene resin to a thickness of 100 μm by extrusion lamination. Simultaneously with the lamination, the surface is embossed with a wood grain conduit pattern, and the surface is coated with an ultraviolet-curable resin at an application amount of 6 g / m ² and cured by ultraviolet irradiation to form a top coat layer. Was prepared.
[0029]
The colored sheet surface of the decorative sheet is laminated on the surface of the thermoplastic resin intermediate layer while extruding a reactive hot melt adhesive (YR210-3 manufactured by Hitachi Chemical Co., Ltd.) to a thickness of 100 μm in a molten state at a temperature of 120 ° C. did.
[0030]
On the surface of the laminated plywood having a thickness of 12 mm, the surface of the thermoplastic resin intermediate layer opposite to the decorative sheet laminating surface is coated with a modified vinyl acetate resin emulsion adhesive (Licabond BA-10L, manufactured by Chuo Rika Kogyo Co., Ltd.). 100 parts by weight of BA-11B was mixed with 2.5 parts by weight, and bonded together via a coating amount of 80 g / m ² wet).
[0031]
Finally, a commercially available V-cut machine (RS-105D manufactured by Toyo Radial Industry Co., Ltd., and the cutting blade is a carbide cutter EK-219 for woodworking manufactured by Matsuoka Cutter Manufacturing Co., Ltd. (outer diameter 220 mm, thickness 20 mm, cutting edge angle 90 degrees 30 minutes) V10-shaped groove with a depth of 0.5 mm from the surface of the decorative sheet at a rotation speed of 6000 rpm (the rotation direction of the blade is the same direction as the traveling direction). To produce the flooring material of the present invention.
[0032]
Example 2
In the above Example 1, an acrylonitrile-butadiene-styrene copolymer resin having a glass transition temperature of 100 ° C. was used in place of the polyethylene terephthalate resin during the compounding of the thermoplastic resin intermediate layer. The flooring material of the present invention was produced in the same manner.
[0033]
Comparative Example 1
In the above-mentioned Example 1, the compounding amount of polyethylene terephthalate was changed from 40 parts by weight to 0 parts by weight (not added) during the resin compounding of the thermoplastic resin intermediate layer, and the rest was the same as in Example 1 above. Materials were produced.
[0034]
Comparative Example 2
In Example 1, a floor material was prepared in the same manner as in Example 1 except that the amount of polyethylene terephthalate was changed from 40 parts by weight to 5 parts by weight during the compounding of the thermoplastic resin intermediate layer.
[0035]
Comparative Example 3
In the above Example 2, the amount of the acrylonitrile-butadiene-styrene copolymer resin was changed from 40 parts by weight to 5 parts by weight during the compounding of the thermoplastic resin intermediate layer, and the other points were the same as in the above Example 2. The floor material was produced with.
[0036]
Comparative Example 4
In Example 1, a flooring material was prepared in the same manner as in Example 1 except that the amount of polyethylene terephthalate was changed from 40 parts by weight to 400 parts by weight during the resin mixing of the thermoplastic resin intermediate layer.
[0037]
Comparative Example 5
In the above-described Example 2, the amount of the acrylonitrile-butadiene-styrene copolymer resin was changed from 40 parts by weight to 400 parts by weight during the resin mixing of the thermoplastic resin intermediate layer, and the other points were the same as those in Example 2 above. The floor material was produced with.
[0038]
Evaluation The floor materials of Examples 1 and 2 and Comparative Examples 1 to 5 were visually inspected for the cutability (whether or not a whisker and whitening occurred) of the grooved portion, and the results were as follows.
[0039]
Machinability
Example 1 ○ (almost no beard, no whitening)
Example 2 ○ (partially short beard but no problem)
Comparative Example 1 x (remarkable mustache, with whitening)
Comparative Example 2 △ (whisker)
Comparative Example 3 △ (whisker)
Comparative Example 4 x (remarkable mustache, with whitening)
Comparative Example 5 x (remarkable mustache, with whitening)
[0040]
【The invention's effect】
As described in detail above, the flooring material of the present invention comprises a thermoplastic resin intermediate layer interposed between a wood substrate and a decorative sheet, wherein the glass transition temperature of the thermoplastic resin is 0 ° C. or less 90 to 25% by weight. And a mixture of 10% to 75% by weight of a thermoplastic resin having a glass transition temperature of 45 ° C. or more, so that the depth from the surface of the decorative sheet to the inside of the thermoplastic resin intermediate layer exceeds the thickness of the decorative sheet. When forming the groove by cutting, hardly any cutting defects such as burrs, whiskers, whitening, etc. occur, floor material with excellent surface strength, water resistance and design can be manufactured with stable quality and high productivity. This is a remarkable effect.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view showing an embodiment of a flooring material of the present invention.
[Explanation of symbols]
Reference Signs List 1 wood base material 2 thermoplastic resin intermediate layer 3 decorative sheet 4 groove

Claims (1)

A decorative sheet is laminated on the surface of the wooden base material through a thermoplastic resin intermediate layer, and a groove is formed from the surface of the decorative sheet to a depth exceeding the thickness of the decorative sheet and into the thermoplastic resin intermediate layer. In the floor material to be applied, the thermoplastic resin intermediate layer is composed of 90 to 25% by weight of a thermoplastic resin having a glass transition temperature of 0 ° C or less and 10 to 75% by weight of a thermoplastic resin having a glass transition temperature of 45 ° C or more. A floor material comprising a thermoplastic resin composition mixed with a main component.

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