JP2008285874A - Dynamic load resistant floor material and its floor structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a soft vinyl chloride resin floor material of superior dynamic load resistance prevented from breaking of its joint surface to backing under load of casters of a carrier or chair, and a floor structure of superior dynamic load resistance formed by constructing the floor material on the backing with a specific adhesive. <P>SOLUTION: The soft vinyl chloride resin floor material of superior dynamic load resistance is formed by laminating a surface layer with a Shore A hardness of 80 or higher containing polyvinyl chloride resin as a main component, and a back layer formed by adding 50-300 pts.wt. of spindle-shaped or cubic light calcium carbonate to 100 pts.wt. of polyvinyl chloride resin. The floor structure of excellent dynamic load resistance is formed by constructing this floor material on the backing using a curable adhesive with a Shore A hardness after cured of 85 or higher. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a flooring material having excellent dynamic load resistance when bonded to a base, and particularly to a dynamic load resistance that does not cause the flooring to peel from an adhesive against a load caused by a carrier or a caster of a chair. The present invention relates to a soft polyvinyl chloride floor material having excellent resistance. Furthermore, the present invention relates to a floor structure having excellent dynamic load resistance obtained by bonding the floor material to a base with a specific adhesive.

  Conventional soft polyvinyl chloride flooring materials include a laminate with a surface layer mainly composed of polyvinyl chloride resin and a back layer mainly composed of an inexpensive filler such as heavy calcium carbonate, A laminate of a base fabric is well known. And these flooring materials were affixed on the foundation | substrate with the various adhesive agent.

However, the joint surfaces of these floor materials have a problem in that the fracture strength against repeated loads such as casters is inferior when they are joined to the base. For example, when a repeated load of about 0.5 N / mm ² or a temporary local load higher than that is applied from a transporter or a caster of a chair, the flooring is peeled off from the bonding agent. Further, when a soft bonding agent is used, or when a bonding agent having poor compatibility with the polyvinyl chloride resin is used, there is a problem that the floor material is also peeled off due to repeated load.

  From the above viewpoints, it has been practiced to provide a dynamic load resistance by providing a foam layer that defines a foaming ratio on the back layer of the flooring. (For example, refer to Patent Document 1). Although this method has a dynamic load resistance performance with respect to a wide caster, the surface may be recessed due to the repeated load of the narrow caster, and it cannot be said that the durability performance is sufficient.

  In addition, there is a method of integrally molding a hard sheet intermediate layer on the floor material, but this also has a problem that the fracture strength of the joint surface is not sufficient, and it peels off from the adhesive due to the repeated load of the caster. (For example, see Patent Document 2). Under such circumstances, it has been desired to develop a soft flooring material that has long-term dynamic load resistance against repeated loads of casters.

Japanese Patent No. 3184093 Utility Model Publication No. 05-430

  The present invention provides a soft vinyl chloride resin floor material excellent in dynamic load resistance in which a joint surface with a base is not broken with respect to a load by a caster of a transport vehicle or a chair, and the floor material is specified. An object of the present invention is to provide a floor structure excellent in dynamic load resistance, which is constructed on a base with an adhesive.

In order to solve such a problem, the means taken by the present invention is to form a spindle shape with respect to a surface layer having a Shore A hardness of 80 or more mainly composed of a polyvinyl chloride resin and 100 parts by weight of the polyvinyl chloride resin. It is to make a soft vinyl chloride resin-based flooring material excellent in dynamic load resistance by laminating a back layer formed by adding 50 to 300 parts by weight of cubic light calcium carbonate (Claim 1). In other words, the floor structure is excellent in dynamic load resistance and is applied to the base using a curable adhesive having a Shore A hardness of 85 or more after curing.

  ADVANTAGE OF THE INVENTION According to this invention, the flooring which can exhibit dynamic load resistance effectively can be provided. In addition, since this flooring is applied to the base with a specific adhesive, it has excellent breaking strength against repeated loads such as casters and can be used stably for a long period of time in a factory or the like.

Hereinafter, specific embodiments of the present invention will be described.
As the composition of the surface layer and the back layer of the flooring material of the present invention, a plasticizer, a stabilizer, an antistatic or dispersing surfactant, a filler, an antibacterial agent, a flame retardant, a coloring agent, etc. What mixed these various additives can be used. Examples of the polyvinyl chloride resin include vinyl chloride homopolymers, vinyl chloride-urethane copolymer resins, vinyl chloride-ethylene copolymer resins, vinyl chloride-vinyl acetate copolymer resins, and the like. Can be used. Moreover, as long as it does not deviate from the performance of the present invention, other resins may be added as processing aids, reinforcing agents and the like. The average polymerization degree of the polyvinyl chloride resin can be 600 to 3000, and more preferably 700 to 1500. If the average degree of polymerization is in the range of 700 to 1500, the strength of the flooring will be improved and the moldability will be good.

  Examples of the plasticizer include phthalic acid esters such as di-2-ethylhexyl phthalate, diisononyl phthalate, diisodecyl phthalate, and butyl benzyl phthalate, adipic acid esters such as diisononyl adipate and di-2-ethylhexyl adipate, trimellitic acid ester, and phosphoric acid Examples thereof include esters, polyester plasticizers, chlorinated paraffins, and epoxidized soybean oil, which can be used alone or in combination.

  Examples of the stabilizer include metal soap stabilizers such as barium stearate, calcium stearate, and zinc stearate, and organic tin stabilizers such as dioctyltin laurate, dibutyltin maleate, and dibutyltin β-mercaptopropionic acid alkyl ester. Phosphite stabilizers such as monotridecyl diphenyl phosphite and tetraphenyl dipropylene diphosphite, hydrotalcite stabilizers such as perchloric acid-treated hydrotalcite, β diketones such as dibenzoylmethane, pentaerythritol, etc. These polyols can be used, and these can be used alone or in combination.

  These polyvinyl chloride resin-based compositions can be processed into a sheet shape by a calendar molding machine, an extrusion molding machine, a press molding machine, or the like, and the sheet can also be processed into a tile shape.

The surface layer and the back layer of the flooring of the present invention may be a single layer or a plurality of layers of two or more layers. It is also possible to laminate a substrate such as a knitted fabric or a woven fabric for the purpose of improving dimensional stability on the back surface and / or the middle. When laminating on the back surface, the substrate is laminated so that the substrate is buried in the back layer. It is necessary to expose the joint surface of the back layer. Moreover, you may provide a design by mixing the lamination | stacking of a design film or a polyester chip on the surface layer side. The thickness may be the same as that of a normal flooring material, and is generally about 1.0 to 5.0 mm. The Shore A hardness as a flooring after laminating the surface layer and the back layer is preferably 80 or more, and more preferably 85 or more, from the viewpoint of caster runnability and difficulty of dents.
Here, the Shore A hardness is a hardness after 15 seconds from the start of pressurization measured by a type A durometer defined in ASTM D2240, and the measurement temperature at this time is 20 ° C. The following hardness measurements were also performed by this method.

The surface layer of the flooring of the present invention has a Shore A hardness of 80 or more, more preferably 85 or more. When the hardness is less than 80, the caster is inferior in running performance, and the dent due to the caster load becomes remarkable. Further, it is preferable that the hardness of the surface layer is 95 or less because the flooring material becomes flexible and can follow the unevenness of the ground, and it is easy to remove wrinkles when the rolled and stored one is spread. This surface layer may be subjected to a surface treatment, and a curable paint can be applied.
In the vinyl chloride resin composition, the Shore A hardness is affected by the type of polyvinyl chloride resin including the degree of polymerization, the type of filler, and the amount added, but the effect of the plasticizer addition is the largest. To make the A hardness 80 or more, there are some variations depending on the type of polyvinyl chloride resin, the type of filler, and the amount added, but the amount of plasticizer is generally about 100 parts by weight of the polyvinyl chloride resin. The addition amount may be 50 parts by weight or less. Similarly, in order to make the Shore A hardness 95 or less, the amount of plasticizer added is generally 25 parts by weight or more with respect to 100 parts by weight of the polyvinyl chloride resin.

  The shape of the light calcium carbonate used for the back layer of the flooring of the present invention is a spindle shape or a cubic shape. With this shape, when light calcium carbonate and polyvinyl chloride resin are kneaded and formed into a sheet, the structure is such that light calcium carbonate is wrapped in a polyvinyl chloride resin matrix, and the bonding strength between the two is high. It becomes. As a result, the joint strength of the back layer improves the breaking strength against repeated loads such as casters. On the other hand, if amorphous heavy calcium carbonate, flake-shaped talc and magnesium hydroxide, etc. are mixed with a polyvinyl chloride resin and formed into a sheet shape, irregular heavy calcium carbonate or flakes Inorganic fillers such as shaped talc and magnesium hydroxide are easily peeled off from the interface of the joining portion of the back layer, and the breaking strength is poor. For the back layer of the flooring of the present invention, light calcium carbonate having a spindle shape or a cubic shape is used. However, the addition of other fillers is not limited, and other types are not limited within the scope of the present invention. A filler may be used in combination.

  The amount of light calcium carbonate added is in the range of 50 to 300 parts by weight, more preferably 80 to 200 parts by weight, based on 100 parts by weight of the polyvinyl chloride resin. If the light calcium carbonate is less than 50 parts by weight, the adhesiveness to the adhesive is lowered, and particularly the adhesiveness at a low temperature is remarkably lowered. If it exceeds 300 parts by weight of light calcium carbonate, the processability is poor and molding becomes difficult.

The average particle size of the light calcium carbonate is preferably 1 to 5 μm. If the average particle diameter of light calcium carbonate is 1 μm or more, the kneading property becomes better and the material cost can be suppressed. When the average particle size is 5 μm or less, the smoothness of the joining surface of the back layer is improved, and the fracture strength against the load of casters is more excellent. Moreover, in order to improve smoothness, it is preferable that the standard deviation of the particle size distribution of light calcium carbonate is 2.0 or less and the maximum particle size is 15 μm or less. That is, if the average particle size is 5 μm or less, the standard deviation of particle size distribution is 2 or less, and the maximum particle size is 15 μm or less, a smooth joint surface can be formed. As for the smoothness, it is preferable that the arithmetic average roughness specified in JIS B 0601 is 2.5 μm or less and the maximum height is 20 μm or less. Bubbles are not present at the interface between the surface and the bonding agent, and as a result, the breaking strength against loads such as casters is improved.
The average particle shape and particle size distribution of the light calcium carbonate were measured with a laser particle size analyzer. For the smoothness of the joint surface, the standard value described in JIS B 0601 was used for the cut-off value, the evaluation difference length, and the reference length when measuring the arithmetic average roughness and the maximum height. The arithmetic average roughness and the maximum height are obtained by averaging measured values at five or more locations.

  This light calcium carbonate may be subjected to surface treatment such as higher fatty acid, higher fatty acid ester, silane coupling agent, etc. in order to improve dispersibility.

  The adhesive used for the floor structure of the present invention is preferably a reactive curable adhesive having a Shore A hardness of 85 or more after curing. A reactive curable adhesive having a hardness of 85 or more is hardly broken by a caster load or the like, and there is almost no dent. As the reactive curable adhesive, it is preferable to use a urethane resin-based or epoxy resin-based adhesive because it is available at a low cost and has excellent breaking strength and water resistance.

The adhesive used in the floor structure of the present invention preferably contains 5% by weight or more of an organic solvent having a solubility parameter of 8 to 10. When the organic solvent having a solubility parameter of 8 to 10 is contained in an amount of 5% by weight or more, the bonding surface of the flooring material and the adhesive can exhibit a high adhesive force even at a low temperature. The main reason for this is considered that the organic solvent dissolved the polyvinyl chloride resin layer on the back surface joining surface of the flooring material and improved the wettability of the adhesive resin component and light calcium carbonate.
Examples of these organic solvents include acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, cyclohexane, alkylmethyl cyclohexane, ethyl acetate, butyl acetate, isobutyl acetate, and dimethyl carbonate. These can be used alone or in combination of two or more. Of these, dimethyl carbonate, acetone, methyl ethyl ketone, and alkylcyclohexane are preferred because of low toxicity and low odor.

  The adhesive used in the floor structure of the present invention desirably has few bubbles present inside after being cured. These bubbles include organic solvents originally contained, carbon dioxide generated by the reaction, and air entrained during construction. If these bubbles have a diameter of 0.5 mm or less and the shortest distance from the bubble edge to the edge of the adjacent bubble is 20 mm or more, it is more preferable because the breaking strength against repeated loads such as casters is excellent.

  These adhesives used in the present invention can be applied to the base using a crease stipulated in JIS A5536, and the flooring material is pasted and sufficiently pressed. The floor structure obtained by this construction can improve load resistance because the floor material is not peeled off or deformed by a dynamic load such as a caster.

  The dynamic load resistance can be evaluated based on, for example, a caster test specified in JIS A1454 B method. As test conditions at this time, when a load of 780 N was applied to one caster (made of nylon, diameter 75 mm, width 25 mm) and the caster was rotated counterclockwise every 15 seconds at a speed of 6 rpm, the adhesive was used. If the floor material affixed to the base does not peel or dent, the dynamic load resistance is generally in the range of no problem. Although the conventional flooring generates swelling and dents in less than 1500 revolutions in the above test, the method of the present invention does not cause swelling or dents even at 1500 revolutions or more, and has excellent dynamic load resistance and flooring. Structure.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples. In addition, Examples 1-7 and Comparative Examples 1-7 were evaluated as flooring materials, and Examples 8-10 and Comparative Examples 8 and 9 were evaluated as floor structures.

<Examples 1-7>
The surface layer composition shown in Tables 1 and 2 was roll-formed at 180 ° C. to prepare a vinyl chloride resin surface layer sheet having a thickness of 0.4 mm. Next, the composition of the back layer shown in Table 2 was roll-molded at 180 ° C. to prepare two vinyl chloride resin sheets having a thickness of 0.8 mm. Then, the two backing layers and the surface layer were laminated to obtain a flooring material having a thickness of 2.0 mm. This flooring is made of a one-component reactive curing urethane resin adhesive (Shore A hardness 88 after curing, organic solvent contains 15% by weight of methyl ethyl ketone having a solubility parameter of 9.3) and a slate 8 mm in thickness. It was affixed to a board and allowed to stand for 7 days to obtain a floor structure. The application of the adhesive was performed using a comb-like iron specified in JIS A5536, and a floor material was pasted after a predetermined waiting time, and sufficiently bonded with a roller. The evaluation results are shown in Table 2.
<Comparative Examples 1-7>
About the compound composition of the surface layer shown in Table 1, 3, and the compound composition of the back layer shown in Table 3, it shape | molded by the method similar to Examples 1-7, and obtained the flooring of thickness 2.0mm. This flooring is 8 mm thick using a one-component reaction-curing urethane resin adhesive (Shore A hardness 88 after curing, organic solvent contains 15% by weight of methyl ethyl ketone having a solubility parameter of 9.3). A floor structure was obtained by pasting on a slate plate and allowing to stand for 7 days. The construction at this time was performed in the same manner as in Examples 1-5. In Comparative Examples 6 and 7, the workability was poor and a flooring was not obtained, and the construction was not performed. The evaluation results are shown in Table 3.

<Examples 8 to 10>
The flooring material of Example 2 was stuck to a slate plate having a thickness of 8 mm using five types of adhesives shown in Table 4, and left to stand for 7 days to obtain a floor structure. The construction at this time was performed in the same manner as in Examples 1-7. The evaluation results are shown in Table 4.
<Comparative Examples 8 and 9>
The flooring material of Example 2 was affixed to a slate plate having a thickness of 8 mm using two types of adhesives shown in Table 5, and left for 7 days to obtain a floor structure. The construction at this time was performed in the same manner as in Examples 1-7. The evaluation results are shown in Table 5.

About these Examples 1-7 and Comparative Examples 1-7, it evaluated by the following evaluation methods and evaluation criteria regarding the workability of a back layer, the workability of a flooring, and dynamic load resistance. For Examples 8 to 10 and Comparative Examples 8 and 9, the dynamic load resistance was evaluated.
<Evaluation method and evaluation criteria>
[Processability of back layer]
200 g of the back layer blends of Examples and Comparative Examples were put into an 8-inch test roll, and the peelability from the metal roll and the kneadability when kneaded at the above thickness were evaluated.
(Peelability)
○: It can be easily peeled off from the metal roll and the sheet can be taken up.
X: Adhesion is strong with respect to the metal roll and cannot be stably processed.
(Kneadability)
○: The resin bank on the roll gap bites uniformly between the rolls, and the kneadability is good.
Δ: The resin bank on the gap between the rolls bites unevenly between the rolls, but the kneadability is relatively good.
X: The bite between the rolls of the resin bank on the roll gap is not uniform, and the kneadability is inferior.
[Workability]
○: The flooring material is flexible and follows the unevenness of the ground, and it is easy to remove curl, and the workability is good.
(Triangle | delta): If a flooring is a little hard and the unevenness | corrugation of a foundation | substrate is large, it may be unable to follow. In addition, it takes a long time to eliminate curling, but there is no practical problem.
[Dynamic load resistance]
The dynamic load resistance was evaluated based on the caster property test specified in JIS A1454 B method. A load of 780 N was applied to one caster (made of nylon, diameter 75 mm, width 25 mm), and this caster was rotated counterclockwise every 15 seconds at a speed of 6 rpm to measure the number of rotations at which swelling occurred.
○: No swelling occurs when rotating 3000 times, and durability is excellent.
(Triangle | delta): Although it swells or a dent generate | occur | produces below 1500-3000 rotation, it is a range which is not a problem practically.
X: Swells or significant dents occur at less than 1500 revolutions (durability is inferior).

From the results shown in Table 2, the flooring materials of Examples 1 to 3, 5, and 6 did not generate dents or blisters at 3000 rotations in the dynamic load test. In Examples 4 and 7, no dents or blisters occurred at 1500 revolutions, indicating that the flooring of the present invention is excellent. This is an effect obtained by combining the surface layer in which the present invention specifies Shore A and the back layer to which a predetermined amount of light calcium carbonate having a specific shape is added. Further, in Examples 2 to 7, the flooring material was flexible, followed the unevenness of the foundation, easily removed the curl, and the workability was good.
On the other hand, if the surface layer or the back layer specified by the present invention is outside the range, the above effect cannot be obtained. As is apparent from the results of Table 3, the flooring materials of Comparative Examples 1 to 5 have poor dynamic load resistance and are practically used. It was not able to withstand as a dynamic load resistant flooring. Among them, the dents were generated in Comparative Examples 1 and 2, and the dents were particularly remarkable in Comparative Example 2 because the surface layer was soft. In Comparative Examples 6 and 7, there was a problem in workability.
From the results shown in Table 4, the floor structures of Examples 8 and 9 were free from dents and blisters after 3000 rotations in the dynamic load test. Moreover, in the thing of Example 10, a dent and a swelling do not generate | occur | produce even in 1500 rotation, and it turns out that the flooring structure of this invention is excellent. On the other hand, from the results of Table 5, it was found that the floor structures of Comparative Examples 8 and 9 were inferior in dynamic load resistance. In other words, even if it has excellent dynamic load resistance as a flooring material, unless an appropriate adhesive is selected, a floor structure with excellent dynamic load resistance will not be obtained. By constructing with an adhesive, it becomes a floor structure with excellent dynamic load resistance.

  According to the present invention, a floor material and a floor structure excellent in dynamic load resistance can be obtained, and can be widely used in a portion where a load is repeatedly applied to the floor surface from a transporter or a caster of a chair. In particular, it is a flooring material and a floor structure excellent in dynamic load resistance suitable for factories and hospitals where particularly heavy loads are applied, and can be widely used.

Claims (2)

  Add 50-300 parts by weight of spindle-shaped or cubic light calcium carbonate to a surface layer mainly composed of polyvinyl chloride-based resin with a Shore A hardness of 80 or more and 100 parts by weight of polyvinyl chloride-based resin. A flexible load-bearing floor material made of a soft polyvinyl chloride resin, characterized by being laminated with a backing layer.   A floor structure excellent in dynamic load resistance, wherein the floor material according to claim 1 is bonded to a base using a reactive curable adhesive having a Shore A hardness of 85 or more after curing.