JP2007107241A - Floor decorated material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor decorated material capable of having difficulty in attaching a depression etc., having the excellence in a take-up aptitude of a decorative sheet, facilitating the adjustment of a color tone, having caster resistance, impact resistance, flame resistance, etc., being easily manufactured and also having the excellence in a work aptitude. <P>SOLUTION: In the floor decorated material constituted by laminating a thermoplastic resin decorative sheet on a wooden base material, it is characterized that a fiber reinforced thermoplastic resin intermediate layer consisting of a Random fiber reinforced member and/or one direction fiber reinforced member is provided between the wooden base material and the thermoplastic resin decorative sheet. When it is shocked, energy absorption occurs by an interfacial separation between a reinforced fiber and a thermoplastic resin so that strength of surface can increase. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a decorative material for floors used in houses, stores, offices, gymnasiums, ships and the like. More specifically, it is excellent in impact resistance, caster resistance, dimensional stability, roll-up property of decorative sheets, surface strength such as dents, and in particular, a decorative material for floors used for applications where the material is required to be flame retardant. About.

  A board-like decorative material for floors made of a wood-based base material is known in which a veneer is attached to a plywood, grooved with a woodworking machine, the groove is colored, and an ultraviolet curable paint is applied and cured. It has been. However, because the veneer is a natural wood, the colors vary and it is difficult to harmonize the color with the walls, ceiling, and furniture.

  Also, a concave groove is provided on the surface of the wood base material, and a synthetic resin paint for coloring a conduit is applied to the surface. After removing the paint other than the concave groove, a conduit recess having a grain pattern is formed, and the woody material other than the concave groove is formed. A method of applying a transparent synthetic resin paint to the surface of a base material is known. However, because of the construction made of a wood-based base material and a synthetic resin paint, it is difficult to provide scratch resistance by a chair with casters, so-called caster resistance. In addition, there is a problem that once the dent is made, it is difficult to restore.

  Further, a flooring decorative material in which a thermoplastic resin decorative sheet is laminated on a wooden base material is also known. However, if the thermoplastic resin decorative sheet is too thick, it will be difficult to wind in a wave shape (rolled state), and sheet cutting will be difficult on the line during continuous lamination with a woody base material. Therefore, since the productivity does not increase, when laminating the thermoplastic resin decorative sheet and the wooden base material, prepare a thermoplastic resin decorative sheet that has been cut in the same size as the wooden base material in advance. It was necessary to take a method such as laminating one by one using the leaf method.

  Furthermore, since a wood-based base material is used as the constituent material, the problem of lack of flameproofing is evident so that it is clearly found that the self-extinguishing property is inferior when performing a combustion test by flame heating, especially when foaming. was there.

For imparting flame retardancy, usually, a method of adding a halogen-based, phosphorus-based organic or inorganic flame retardant at the time of molding is used. However, when it is intended to impart a higher degree of flame retardancy, simply increasing the amount of flame retardant added is not necessarily sufficient to improve flame retardancy, but as a flooring base material. There are various problems such as a decrease in mechanical properties, a decrease in molding speed due to a decrease in flow characteristics during molding of a wood resin composition, a bleedout of a flame retardant during aging after molding, especially when foam molding is performed. It is not always appropriate as a method for improving flame retardancy.
JP 52-76409 A JP 2004-17590 A JP 2001-353815 A JP 2002-120347 A

  The present invention has been made to solve the above-mentioned problems, and the problem is that it is difficult to have a dent, is excellent in winding up of a decorative sheet, is easy to adjust the color tone, and is resistant to damage. An object of the present invention is to provide a floor decorative material that has caster properties, impact resistance, flame retardancy, etc., can be easily manufactured, and has excellent processability.

  The present invention solves this problem, that is, the invention according to claim 1 is a floor decorative material in which a thermoplastic resin decorative sheet is laminated on a wooden base material, and the wooden base material and the thermoplastic resin. A floor decorative material comprising a fiber reinforced thermoplastic resin intermediate layer made of a random fiber reinforced member and / or a unidirectional fiber reinforced member provided between a resin decorative sheet.

  According to the first aspect of the present invention, when the fiber reinforced thermoplastic resin intermediate layer is provided, energy absorption occurs due to interfacial debonding between the reinforced fiber and the thermoplastic resin when subjected to an impact. Therefore, even if it receives an impact, it is difficult to dent, and even when the room temperature rises in summer or when the surface temperature of the flooring rises when the summer sun hits it, it has the effect of being difficult to change dimensions.

  In addition, it can be easily wound up when manufacturing decorative sheets, so it has the effect of facilitating roll-to-roll production. Furthermore, when heavy objects are dropped on the floor, they are impact resistant and when heavy pianos are placed. It becomes possible to obtain a flooring material having good creep resistance.

  Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 shows a cross-sectional structure of the floor decorative material of the present invention. A fiber-reinforced thermoplastic resin intermediate layer 3 is provided on a wooden substrate 1 via an adhesive layer 2, and a thermoplastic resin decorative sheet 4 is provided. Further, a surface protective layer 5, a transparent thermoplastic resin layer 6, a U-shaped groove 10, and a V-shaped groove 11 may be provided as appropriate. Although not shown, a pattern layer may be provided between the thermoplastic resin decorative sheet 4 and the transparent thermoplastic resin layer 6.

  As the woody base material 1, south plywood plywood, particle board, medium density fiber board (hereinafter MDF), or normal plywood stipulated in Japanese Agricultural Standard can be used. Moreover, the base material which consists of wood powder addition olefin resin can also be used. The thickness is preferably about 3 to 25 mm.

As the adhesive used for the adhesive layer 2, a known aqueous adhesive composed of a two-component urethane-modified vinyl resin, a one-component vinyl acetate resin emulsion-based adhesive, a moisture-curable urethane resin-based hot melt adhesive, or the like can be used. It is. A thermoplastic resin hot melt adhesive can also be used. The weight of the coating after drying is preferably about 3 to ²⁰ g / m ² from the viewpoint of adhesiveness.

  As the fiber used for the fiber reinforced thermoplastic resin intermediate layer 3, glass fiber, para-aramid fiber, carbon fiber, boron fiber, metal fiber, liquid crystal polymer fiber, polyester fiber, polyamide fiber, or the like can be used. The fiber reinforced thermoplastic resin intermediate layer 3 in the present invention is impregnated with random fiber reinforced members in which monofilaments of 1 to 50 μm of these fibers are randomly dispersed in the thermoplastic resin and / or unidirectional fibers in the thermoplastic resin. It is made of a unidirectional fiber reinforced member.

  The volume ratio of the random fiber reinforced member to the thermoplastic resin intermediate layer is appropriately adjusted depending on the thermoplastic resin used, but 10 to 30% is desirable in terms of fluidity and impact resistance during the entire molding. Similarly, the volume ratio of the unidirectional fiber reinforced member is preferably 10 to 90%.

  Examples of the thermoplastic resin used for the fiber-reinforced thermoplastic resin intermediate layer 3 include styrene / acrylic resin, amorphous polyester resin, amorphous crystalline polyester resin, polybutylene terephthalate resin and polytrimethylene terephthalate resin. Mixtures of these can be used. The thickness of about 50 to 200 μm is desirable because it balances each item of impact resistance, surface strength, dimensional stability, and winding property as a decorative sheet.

  In addition, an additive such as a flame retardant can be appropriately added to the fiber reinforced thermoplastic resin intermediate layer 3. Examples of flame retardants include organic flame retardants such as phosphate esters and condensed phosphate esters, boric acid compounds such as magnesium hydroxide, aluminum hydroxide and zinc borate, and inorganic flame retardants such as antimony trioxide and antimony pentoxide. A flame retardant can be used.

  The thermoplastic resin decorative sheet 4 includes a single layer or a plurality of layers made of an amorphous polyester resin, an amorphous crystalline polyester resin, a biaxially stretched polyester resin, a polypropylene resin, a polyethylene resin, an acrylic resin, or the like. Are preferably used. In particular, there may be mentioned a method in which a colored thermoplastic resin layer is provided in the lower layer, a pattern layer (not shown) is provided, and then the transparent thermoplastic resin layer 6 is provided on the upper surface. The thickness of the thermoplastic resin decorative sheet 4 is preferably 50 to 200 μm in consideration of caster resistance, impact resistance, scratch resistance, handling properties, blade abrasion, and the like. Although not shown, as the pattern layer, a known two-component urethane resin binder made of an opaque inorganic or organic pigment, a gravure ink made of an acrylic resin and a vinyl chloride-vinyl acetate resin copolymer, or the like can be used.

In addition, as the surface protective layer 5, an application amount of 6 to 15 g / m ^{2 is} applied to an ultraviolet curable resin or a two-component urethane resin to which a known ultraviolet absorber, light stabilizer, glass beads, etc. are added in consideration of slipperiness. You may do it. In this case, it is desirable to adjust the surface hardness in consideration of the resilience of the impact resistance test and caster resistance test.

  Further, the U-shaped groove 10, the V-shaped groove 11, or the like may be applied by pressing an embossed plate made of a metal roll or the like when the thermoplastic resin decorative sheet 4 is produced or after the flooring material is formed. When coloring the groove part of a recessed part, the recessed coloring ink layer can use the gravure ink which consists of a well-known opaque inorganic and organic pigment 1 liquid, or a 2 liquid urethane type resin binder.

<Thermoplastic resin decorative sheet>
A wood grain pattern was printed on one side of a colored polypropylene film having a thickness of 70 μm (“Rivester TPO” manufactured by Riken Technos Co., Ltd.) with gravure ink (“Lamister” manufactured by Toyo Ink Manufacturing Co., Ltd.) using a gravure printing machine. Thereafter, a two-component urethane primer resin containing silica powder on the surface opposite to the printed surface was applied with a gravure so that the thickness after drying would be 1 μm. On the printed surface, a two-component urethane resin adhesive of polyester polyol as an anchor agent and isophorone diisocyanate as a curing agent is applied so that the coating amount after drying becomes 1 g / m ^2. A polypropylene resin obtained by modifying maleic acid by adding 0.5 parts of an ultraviolet absorber, 0.5 parts of a hindered amine light stabilizer and 0.2 parts of a heat stabilizer to a mixture of 50 parts of homopolypropylene and 50 parts of random polypropylene. The thickness after drying was 80 μm, and at the same time, the adhesive resin was co-extruded while spraying ozone gas so that the thickness after drying was 10 μm, and a thermoplastic resin decorative sheet was obtained. .
<Surface protective layer>
On the co-extrusion laminate surface of the thermoplastic resin decorative sheet, a recoat layer made of a two-component urethane resin is provided so that the thickness after drying becomes 1 g / m ^2, and then urethane acrylate (manufactured by Daicel Usbi Co., Ltd.). "Ebecryl 4858") 100 parts, pentaerythritol tetraacrylate (Daicel Usubi Co., Ltd. "PETA-K") 20 parts, benzophenone photoinitiator (Daicel Usubi Co., Ltd. "Ebecryl BZO") 0.5 parts A UV curable resin to which 0.5 parts of a benzotriazole UV absorber, 0.5 parts of a hindered amine light stabilizer and 2 parts of glass beads were added was applied to a thickness of 5 μm, and irradiated with UV light from a metal halide lamp. A surface protective layer was provided by curing.
<Lamination with intermediate layer>
A coating amount after drying a two-component urethane resin adhesive (“TM-593” manufactured by Toyo Morton Co., Ltd.) on the side opposite to the surface provided with the surface protective layer of the thermoplastic resin decorative sheet is 10 g / m ^2. It was applied to become. On this surface, as a fiber reinforced thermoplastic resin intermediate layer, 100 parts by weight of polybutylene terephthalate, 10 parts by weight of a random fiber reinforced member made of random glass fibers having a monofilament diameter of 24 μm 4000 tex (4000 g / 1000 m JIS10101-1978), a flame retardant ( A sheet having a thickness of 0.17 mm composed of 10 parts by weight of aluminum hydroxide was bonded. These could be bonded together in-line and rolled up with a roll.
<Lamination with wood base>
Lauan plywood with a thickness of 12 mm x 303 mm x 1818 mm was used as the wood-based substrate, and a two-liquid aqueous emulsion adhesive ("Rikabond" manufactured by Chuo Rika Kogyo Co., Ltd. (BA-10L / BA-11B = 100/5) was used on this surface. )) Is applied in a wet state to 100 g / m ² , and then bonded to the fiber reinforced thermoplastic resin intermediate layer side of the thermoplastic resin decorative sheet with a laminator. After curing for 12 hours, actual processing of the end portion and wood A V-groove process reaching the base material was performed, and finally the V-groove was colored with a two-component urethane resin-based colorant to form a joint, which was used as a flooring decorative material.
<Comparative Example 1>
A flooring decorative material was produced in the same manner as in Example 1 except that the fiber-reinforced thermoplastic resin intermediate layer 3 was not provided in Example 1.
<Comparative example 2>
A flooring decorative material was produced in the same manner as in Example 1 except that no fiber was added to the reinforced thermoplastic resin intermediate layer 3 in Example 1.
<Performance evaluation>
As a caster resistance test, a polycarbonate double caster (diameter 40 mm, 1 wheel width 9 mm, 2 wheel width 18 mm) was loaded with a weight of 25 kg (about 245 N), 10,000 times (1 stroke 20 cm or more, 5,000 reciprocations), and the caster was moved on the floor decorative material at a speed of 20 cm / sec. The subsequent traces were observed.

  As the impact resistance test, the test was conducted in accordance with the DuPont falling ball test (JIS_K5400), which is originally a coating film evaluation method. However, as an evaluation method, the dent amount of the flooring was measured.

  As a cold heat repetition test, −20 ° C. for 2 hours and 80 ° C. for 2 hours were performed for 4 cycles. The results are shown in Table 1.

  The floor decorative material of the present invention can be particularly suitably used in places where impact resistance, caster resistance, dimensional stability, and the like are required, such as houses, stores, offices, and gymnasiums.

It is explanatory drawing which shows the structure of the cross section of one Example of the decorative material for floors of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Wood type base material 2 ... Adhesive layer 3 ... Fiber reinforced thermoplastic resin intermediate layer 4 ... Thermoplastic resin decorative sheet 5 ... Surface protection layer 6 ... Transparent thermoplastic resin layer 10 ... U-shaped groove 11 ... V-shaped groove

Claims (1)

  A floor decorative material in which a thermoplastic resin decorative sheet is laminated on a wooden base material, a random fiber reinforced member and / or a unidirectional fiber reinforced member between the wooden base material and the thermoplastic resin decorative sheet. A floor decorative material comprising a fiber-reinforced thermoplastic resin intermediate layer comprising:

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