JP2011219977A - Light-weight polyvinyl chloride resin floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a polyvinyl chloride resin floor material that is excellent in light weight, workability and durability.SOLUTION: The polyvinyl chloride resin floor material comprises at least a surface layer 1 and a back layer 2, and the back layer 2 is a foam layer comprising a hollow particle and a foaming agent in a polyvinyl chloride resin. The back layer 2 is the foam layer containing 5-40 pts.wt. of the hollow particle relative to 100 pts.wt. of the polyvinyl chloride resin, and the weight of the polyvinyl chloride resin floor material is 0.8 to 1.8 kg per 1 m.

Description

  The present invention relates to a polyvinyl chloride resin floor material that is lightweight and excellent in durability.

  Conventionally, polyvinyl chloride resins have been widely used in buildings and vehicles because they have excellent physical and chemical properties. In particular, in the fields of vehicles such as automobiles, buses, and trains, aircraft, and ships, speeding up and improvement in fuel efficiency are required, and weight reduction is also desired for flooring materials used there. However, the polyvinyl chloride resin itself has a large specific gravity and often contains a filler to further improve the strength of the material. Since a general filler has a higher specific gravity than a resin, the weight of the molded product is increased.

  As a technique for reducing the weight of a vinyl chloride resin composition, there is a method in which a polyvinyl chloride resin contains a hollow filler and a plate-like filler (Patent Document 1). In addition, the flooring made of thermoplastic resin includes flooring with a foam layer laminated on the back layer as a flooring material for light walks such as indoors, and these flooring materials are lighter than ordinary thermoplastic resin flooring materials. It is.

JP 2005-298762

  Since the vinyl chloride resin composition of Patent Document 1 has a large amount of hollow filler added, there is a problem that the molding means is limited to an extruder in the case of a soft vinyl chloride resin with a large amount of plasticizer. It was. Even when a large amount of hollow filler is added, the hollow filler is broken during processing, and there is a problem that a sufficient light weight effect cannot be obtained.

  In addition, the flooring material with the foam layer laminated on the back layer described above is not lightweight enough, and the strength of the back layer decreases when the foaming ratio is increased to increase the light weight effect. However, in heavy walking applications, there is a problem that durability is insufficient, such as a foamed layer is crushed due to repeated loads, and the floor surface is wavy or swollen.

  The present invention is intended to solve the above-mentioned problems, and an object of the present invention is to provide a polyvinyl chloride resin flooring material that is excellent in lightness and workability and excellent in durability.

  In order to achieve such an object, the polyvinyl chloride resin flooring of the present invention comprises at least two layers of a surface layer and a back layer, and the back layer contains a hollow particle and a foaming agent in the polyvinyl chloride resin. The main feature is that it is a foamed layer.

That is, the present invention is a flooring material comprising at least two layers of a surface layer and a back layer, and the back layer contains 5 to 40 parts by weight of hollow particles per 100 parts by weight of the polyvinyl chloride resin. And a polyvinyl chloride resin flooring material having a weight per 1 m ² of 0.8 kg to 1.8 kg (Claim 1), and the foaming ratio of the foamed layer is 1.3 times to 3.0 times. (Claim 2), the hollow particles have a specific gravity of 0.2 to 0.9, an average particle diameter of 30 μm to 600 μm (Claim 3), and a tensile elastic modulus of the surface layer of 20 MPa to 200 MPa. (Claim 4), and the specific gravity of the molded polyvinyl chloride resin flooring is 0.40 to 0.90 (Claim 5).

The lightweight polyvinyl chloride resin flooring of the present invention is a flooring composed of at least two layers of a surface layer and a back layer, and the back layer has 5 weights of hollow particles with respect to 100 parts by weight of the polyvinyl chloride resin. Part to 40 parts by weight and a flooring material having a weight per 1 m ² of 0.8 kg to 1.8 kg, it is excellent in durability in heavy walking, light weight and workability. A vinyl chloride resin flooring can be obtained.

  Furthermore, the effect which was excellent in durability is acquired by making the foaming ratio of the foaming layer used as the back layer which comprises the lightweight polyvinyl chloride-type resin flooring of this invention into 1.3 times-3.0 times. be able to.

  In addition, the hollow particles to be blended in the back layer have a specific gravity of 0.2 to 0.9 and an average particle diameter of 30 μm to 600 μm, thereby minimizing cracking of the hollow particles during sheet molding, Good processability can be obtained.

  By setting the tensile modulus of the surface layer constituting the lightweight polyvinyl chloride resin flooring of the present invention to 20 MPa to 200 MPa, the walking layer has excellent walking stability, and the back layer has a dent when subjected to a dent load due to walking or the like. Can be promptly restored without hindering the restoration of the surface layer, and the change in the appearance of the surface layer can be prevented.

  By setting the specific gravity of the lightweight polyvinyl chloride resin floor material molded according to the present invention to 0.40 to 0.90, a lightweight floor material suitable for a floor material of a vehicle such as a vehicle can be obtained.

Sectional view of the flooring according to the present invention Sectional view of the flooring according to the present invention Sectional view of the flooring according to the present invention Sectional view of the flooring according to the present invention Sectional view of the flooring according to the present invention Electron microscope observation photograph of cross section after repeated load test of backing layer according to the present invention (foaming magnification: 2 times) Electron microscope observation photograph of cross section after repeated load test of backing layer according to the present invention (foaming ratio 3 times)

  Hereinafter, preferred embodiments of the present invention will be described in detail.

  The lightweight polyvinyl chloride resin flooring of the present invention comprises at least two layers, a surface layer and a back layer. The back layer is a foamed layer containing 5 to 40 parts by weight of hollow particles and a foaming agent with respect to 100 parts by weight of the polyvinyl chloride resin.

  Examples of the polyvinyl chloride resin used in the present invention include polyvinyl chloride, ethylene-vinyl chloride copolymer, propylene-vinyl chloride copolymer, vinyl chloride-acrylic resin copolymer, and vinyl chloride-urethane copolymer. , Vinyl chloride-vinylidene chloride copolymer, vinyl chloride-vinyl acetate copolymer, and the like. These may be used singly or in combination of two or more. Among these polyvinyl chloride resins, polyvinyl chloride is preferable in terms of processability and cost. Polyvinyl chloride resins used for the back layer have low melt tension when the average degree of polymerization is low, so the foam cells tend not to be uniform during foam molding, and those with a high average degree of polymerization have a high melt viscosity. Since the molding process tends to be difficult, the average degree of polymerization of the polyvinyl chloride resin used for the back layer is preferably in the range of 400 to 2200 where the foamed cells are relatively uniform and the molding processability is excellent.

  Examples of the hollow particles used in the present invention include glass balloons, shirasu balloons, fly ash balloons, micro balloons, silica balloons, alumina balloons, and carbon balloons as inorganic particles. Examples of the organic hollow particles include substances made from phenol resin, epoxy resin, and urea resin as raw materials. Among the above-mentioned hollow particles, an inorganic type having a small shape change is preferable during molding of the back layer, that is, the foam layer, and when forming the foam cell, and among them, a chemically stable glass balloon and fly ash balloon are preferable. preferable.

  The content of the hollow particles is 5 to 40 parts by weight with respect to 100 parts by weight of the polyvinyl chloride resin. When the content is less than 5 parts by weight, a sufficient light weight effect cannot be obtained. When the content is more than 40 parts by weight, not only the molding process becomes difficult, but also the hollow particles are destroyed during the molding process, resulting in sufficient The light weight effect cannot be obtained. A more preferable range is 10 to 20 parts by weight from the balance between light weight effect and workability.

  In the present invention, any hollow particles of the above types can be used. In general, hollow particles having a small specific gravity tend to be easily broken due to stress applied during molding because the thickness of the hollow sphere tends to be thin and the pressure strength is small. It is necessary to add a large amount because the effect of light weight is small when the same amount is added as compared with a small amount. Therefore, the specific gravity of the hollow particles is preferably 0.2 to 0.9, more preferably 0.4 to 0, in order to achieve an excellent light weight effect and an excellent molding processability by reducing the addition amount. .8.

  The suitable average particle diameter of the hollow particles is 30 μm to 600 μm, more preferably 30 μm to 300 μm. When the average particle size is smaller, foam cells that are more uniform and denser can be formed when the back layer is foamed. Therefore, the strength of the foamed layer is increased and the flooring material is further improved in durability.

  Hollow particles with low pressure strength tend to be destroyed due to stress during molding, tending to make it difficult to obtain a sufficient light weight effect, and those with high pressure strength tend to have high specific gravity. The amount needs to be increased. In order to obtain an excellent light weight effect with a small addition amount while minimizing the breakage of the hollow particles, the pressure resistance of the hollow particles is preferably in the range of 10 MPa to 70 MPa.

  As the foaming agent to be blended in the back layer, a general foaming agent can be used, and among them, an organic chemical foaming agent can be suitably used. Examples of organic chemical foaming agents include azo compounds, nitroso compounds, sulfonyl compounds, sulfonyl semicarbazide compounds, and triazole compounds. Examples of the azo compound include azodicarbonamide (ADCA), azobisisobutyronitrile (AIBN), barium azodicarboxylate, and the like, and examples of the nitroso compound include dinitrosopentamethylenetetramine (DPT), N, N′-dinitroso N, N'-dimethylphthalamide and the like. Examples of the sulfonyl compound include oxybisbenzenesulfonyl hydrazide (OBSH), benzenesulfonyl hydrazide (BSH), and toluenesulfonyl hydrazide (TSH). Organic hollow particles such as those mentioned for the hollow particles can also be used instead of the foaming agent because they expand by heating to increase the volume. Of these, azodicarbonamide is particularly preferable. The addition amount of the foaming agent is preferably 2 to 10 parts by weight with respect to 100 parts by weight of the resin.

  The foaming ratio of the back layer can be set to an arbitrary ratio depending on the amount of foaming agent added and foaming conditions. The back layer of the present invention is a foam layer containing hollow particles, and is superior in durability even in applications where repeated loads such as heavy walking are applied, compared to a foam layer containing no hollow particles of the same weight and thickness. However, if the expansion ratio of the back layer increases, foaming is promoted and the cell wall of the foamed cell becomes thin, so if hollow particles are present on the foamed cell wall during foaming, the growth of the foamed cell is inhibited and bubbles are broken. Then, the cell tends to become coarse, and when a load is repeatedly applied to the flooring material, the cell tends to be crushed and the hollow particles also tend to break. Depending on the type of hollow particles, the inside may be depressurized, and when such hollow particles are used, the hollow particles in the back layer are cracked by the load repeatedly applied to the flooring and returned to atmospheric pressure. If the pressure load is applied to the surroundings, there is a possibility that the back layer may not be restored while being dented.

In the present invention, a weight drop test using an impact deformation tester was adopted as a method for evaluating durability against repeated loads. The test method is to place a test piece such as a flooring material on a receiving base on a DuPont deformation tester, place a shooting mold with a hemispherical tip on it, and put a 300 g weight on the shooting mold of 10 cm. It is to drop 5 times continuously from the height. 6 and 7 are cross-sectional observations of the back layer of the present invention after this test. In FIG. 6, the foaming ratio is 2 times, and the foam after the test is not deformed, and the state before the test is almost maintained. FIG. 7 shows a foaming ratio of 3 times. After the test, the foamed cell was deformed and the foam was slightly recessed, but the durability as a flooring back layer was satisfactory.
The smaller the expansion ratio of the back layer, the better the durability, while the light weight effect tends to decrease. When considering the durability against repeated loads and the light weight, the preferable expansion ratio of the back layer is 1.3-3. The flooring material is lightweight and has excellent durability by setting the expansion ratio within the above range. Furthermore, as a preferable range, it is 1.5 to 2.5 times, More preferably, it is 1.6 to 2.0 times.
In addition, the expansion ratio here is obtained by the following formula 1.
Foaming ratio (times) = Thickness of back layer sheet after foaming (mm) / Thickness of back layer sheet before foaming (mm) (Formula 1)

  Other additives that can be blended in the backing layer include plasticizers, stabilizers, fillers, antibacterial agents, flame retardants, antistatic agents, lubricants, etc., as appropriate to give the necessary physical properties according to the intended use. Can be blended.

  The surface layer of the lightweight polyvinyl chloride resin flooring of the present invention is necessary to maintain the surface properties and durability as a flooring. The surface layer is made of a non-foamed resin composition, and the same polyvinyl chloride resin as the back layer can be used. Since the back layer of the flooring of the present invention is a foamed layer, the amount of dent in the back layer when a load is applied is larger than that of a non-foamed material. Here, the hardness of the surface layer (in the present invention, the tensile elastic modulus is used as an index of hardness) affects the dent characteristics of the flooring. If the surface layer is soft, that is, if the tensile elastic modulus is small, the dent mark after walking will be easy to restore, but the dent will become large, so the mark after placing a heavy object for a long time will be conspicuous or walking There is a tendency for safety to decline, sometimes giving a fluffy and unstable sensation and making it easier for the feet to fall and fall. On the other hand, if the surface layer is hard, that is, if the tensile modulus is large, the appearance of the dent will change, or the hardness of the surface layer will work in a direction that prevents the dent of the back layer from being restored. It may become noticeable. Considering these, the hardness of the surface layer is preferably in the range of 20 to 200 MPa in tensile modulus, more preferably in the range of 40 to 100 MPa, and still more preferably in the range of 40 to 70 MPa. . By setting it as such a tensile elasticity modulus, it can be set as the flooring which is more excellent in walk stability and dent restoration property.

  Additives that can be blended in the surface layer include plasticizers, stabilizers, hollow particles, fillers, antibacterial agents, light stabilizers, UV absorbers, flame retardants, antistatic agents, lubricants, colorants, etc. In order to give a required physical property according to a use, it can mix | blend suitably.

The flooring of the present invention may be laminated with a base material made of woven fabric, non-woven fabric, etc., and the base material used is organic fiber such as cotton, hemp, polyester, acrylic, nylon, carbon fiber, glass, inorganic fiber, etc. And woven fabrics, nonwoven fabrics and the like. The substrate can be laminated between the back layer and the surface layer as the bottom layer below the back layer and as an intermediate layer.
Although the thickness of a base material is not specifically limited, The thing of 0.01 mm-1 mm can be used normally. Substrates such as woven fabrics and nonwoven fabrics generally have a large porosity compared to the resin layer, and the use of a material having a large thickness can provide the effect of reducing the weight of the flooring. Moreover, the weight reduction effect of a flooring can be improved by using the woven fabric and nonwoven fabric of synthetic fibers, such as polyester, an acryl, and nylon, among the said base materials.

The flooring of the present invention can be provided with a design by laminating a design layer such as a colored layer or a printed layer in addition to the base material. When laminating the design layer, the surface layer is preferably a transparent or translucent transparent layer.
In addition, various natural fibers, synthetic fibers, wood flour, resin chips and the like can be added to the surface layer to impart design properties. Further, the surface layer can be embossed to give unevenness.

In the present invention, the weight of the flooring material is 0.8 kg to 1.8 kg per 1 m ^{2. By} using the flooring material having such weight, the flooring material such as a vehicle can be used because of its light weight. It can be used effectively as a material. A more preferable range is 1.0 kg to 1.6 kg, and a more preferable range is 1.2 kg to 1.5 kg.
Moreover, it is preferable that the specific gravity of the whole flooring is 0.40-0.90, More preferably, it is 0.50-0.80, More preferably, it is 0.60-0.75.

  In the present invention, the thickness of the flooring material is preferably 1.5 mm to 3.0 mm. In consideration of durability as a flooring material, walking ability, etc., it is necessary to secure a certain thickness, but if the thickness is too thick, the weight as a whole increases. Therefore, the floor material of the present invention preferably has a thickness in the range of 1.5 mm to 3.0 mm.

If the surface layer is too thin, the surface layer will be worn by walking for a long time, or the surface layer will be removed when it is damaged by dropping a sharp object etc. Durability may deteriorate. On the other hand, if the thickness of the surface layer is too thick, the back layer becomes thin due to the balance with the overall thickness, which may increase the weight. From the above, the preferable thickness of the surface layer is 0.1 mm to 1.0 mm, more preferably 0.2 mm to 0.7 mm.
The thickness of the back layer is preferably 1.0 mm to 2.0 mm in consideration of the balance with the surface layer for the reasons described above.

  In the present invention, the flooring production method is not particularly limited. For example, the compounding agent is kneaded and formed into a sheet by using various molding machines, a back layer is laminated on the base material, foamed by heat treatment, and then again by various molding machines. It can be manufactured by laminating a sheeted surface layer in-line. Further, the back layer and the surface layer can be separately molded by a molding machine, and the surface layer and the foamed back layer can be laminated after heating and foaming the back layer. Each layer can be produced by a molding method such as extrusion molding, calendar molding, or coating molding. Since the composition of the back layer of the present invention is designed so that the hollow body is not easily broken during processing, it can be processed even by a molding method that applies a high shear force such as calender molding, and has a high degree of freedom in the molding method.

  Specific examples of the present invention will be described.

Tables 1 and 2 show the formulations used for the back layers of Examples and Comparative Examples, and Table 3 shows the formulations and tensile elastic modulus used for the surface layers. In addition, Table 4 shows the base materials used. Specific substance names of each compounding agent are as follows.
Polyvinyl chloride resin: Polyvinyl chloride resin (average polymerization degree (P) is listed in the table)
Plasticizer: Dioctyl phthalate (DOP)
Stabilizer: Ba-Zn metal soap Foaming agent 1: Azodicarbonamide (ADCA)
Foaming agent 2: oxybisbenzenesulfonyl hydrazide (OBSH)
Filler: Calcium carbonate Hollow particles 1: Fly ash balloon
Specific gravity: 0.70
Pressure strength: 12 MPa
Average particle size: 125 μm (JIS M 8801 low tap testing machine)
Hollow particle 2: Glass balloon
Specific gravity: 0.60
Pressure strength: 69 MPa
Average particle size: 30 μm
Hollow particle 3: glass balloon
Specific gravity: 0.37
Pressure strength: 21 MPa
Average particle size: 45 μm

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* Tensile modulus: measured according to JIS-K-7113. The shape of the test piece was a strip having a width of 19 mm and a length of 120 mm, and the measurement was performed under the conditions of a distance between marked lines: 60 mm and a test speed: 10 mm / min.

The flooring materials of Examples and Comparative Examples were produced by combining the surface layer and the back layer shown in Table 5, Table 6, Table 7, and Table 8, respectively. As for the production method, Examples 1 to 6, and Examples 10 to 21 and Comparative Examples were prepared by kneading the back layer composition, laminating the back layer on the base material using a calender molding machine, and forming it into a sheet shape. Then, after foaming to the foaming ratio shown in the table by heat treatment, the surface layer formulation was kneaded again using a calender molding machine and laminated on the back layer side to produce a flooring. Here, the expansion ratio is obtained from the above-described (Formula 1).
In Example 7, after forming a sheet of only the back layer without laminating the base material, a flooring was produced by the above method. In Example 8, the process until the back layer is laminated on the base material and foamed is the same as the above method, and then the polyvinyl chloride colored layer (with the colorant added to B1 in Table 3) is placed on the back layer side. At the same time, a printed pattern was transferred by a transfer sheet to provide a design layer thereon, and a surface layer was further laminated. In Example 9, after laminating a back layer on the base material in the same manner, after foaming what was laminated with another back layer on the base material side, a design layer was provided in the same manner as in Example 8, and a surface layer was laminated. did.

Table 5, Table 6, Table 7, and Table 8 show the evaluation results of the flooring materials of Examples and Comparative Examples. Each evaluation item was evaluated by the following method.
<Lightweight>
The weight of a 10 cm × 10 cm flooring was measured, and the weight per 1 m ² was calculated.
[Evaluation]
◎: 1.5 kg or less ○: More than 1.5 kg and 1.6 kg or less △: More than 1.6 kg and 1.8 kg or less ×: More than 1.8 kg <Restorability of dents>
According to JIS-A-1454, the residual dent ratio was measured by the method A of the residual dent test, and the dent restoration property was evaluated.
Residual dent rate = (thickness of flooring material before test−thickness of flooring material after test) / thickness before test × 100
[Evaluation]
○: Residual dent rate is 15% or less △: Residual dent rate is greater than 15% and less than 25% ×: Residual dent rate is 25% or more <Dentability>
The amount of dents at 20 ° C. was measured according to JIS-A-1454.
[Evaluation]
◎: dent amount of 0.3 mm or more, no change in appearance of surface layer ○: dent amount of less than 0.3 mm, no change of appearance of surface layer Δ: dent amount of less than 0.3 mm, surface appearance slightly changed ×: dent amount of 0. Less than 3mm, large change in appearance of surface layer <Machinability>
The processability of the back layer was evaluated.
[Evaluation]
<1> State around the bank during roll processing ○: Good △: Slightly bad ×: Does not rotate <2> State of winding around the roll ○: Good △: It takes time to wind ×: Does not wind <Repetitive load (Durability)>
Using a JIS K 5600 5-3 DuPont impact deformation tester, place a test piece with a diameter of 29 mm on a cradle with a smooth surface and place it under a shooting mold with a radius of 6.53 mm. The cross section of the test piece when it was dropped 5 times continuously from a height of 10 cm was observed with an electron microscope, and the state of the foam cell and the floor material surface was observed.
[Evaluation]
◎: No change in the shape of the foam cell and no dent in the floor material ○: A slight change in the shape of the foam cell, but the dent in the floor material is not noticeable △: There is a change in the shape of the foam cell, and the dent in the floor material Slightly ×: The shape change of the foam cell is remarkable, and there is a dent in the flooring

From the evaluation of the examples, those having a small amount of hollow particles added are excellent in workability but slightly inferior in weight, and those having a large amount of addition are excellent in lightness but slightly inferior in workability (Examples 1, 2, 5, 19). In addition, the tensile modulus of the surface layer affects the dent restoration and dent properties, and the moderately flexible surface layer does not change its appearance when subjected to dent load, and it restores without disturbing the dent restoration properties of the back layer. (Examples 5, 6, 10, 11). The expansion ratio of the back layer affects the lightness and durability, and becomes lighter as the expansion ratio becomes higher, and the durability improves as the expansion ratio becomes lower (Examples 12 to 17).
In the comparative example, the conventional flooring is not sufficiently lightweight (Comparative Examples 1 and 2), and if the back layer is made to be lightweight only by foaming, the expansion ratio becomes large and the durability becomes insufficient (Comparative Example). 3). When the back layer is unfoamed, the lightness is insufficient even when hollow particles are added (Comparative Examples 4 and 7).

  Since the lightweight polyvinyl chloride resin flooring of the present invention is excellent in durability in heavy walking, it can be widely used as a flooring for vehicles because it is lightweight as well as a building flooring.

DESCRIPTION OF SYMBOLS 1 Surface layer 2 Back layer 3 Base fabric 4 Design layer 5 Surface layer (embossing)

Claims (5)

A flooring made of polyvinyl chloride resin comprising at least a surface layer and a back layer, wherein the back layer is a foamed layer containing 5 to 40 parts by weight of hollow particles with respect to 100 parts by weight of the polyvinyl chloride resin. A lightweight polyvinyl chloride resin flooring material having a weight per 1 m ^{2 of the} polyvinyl chloride resin flooring material of 0.8 kg to 1.8 kg.       The lightweight polyvinyl chloride thermoplastic flooring material according to claim 1, wherein the back layer has an expansion ratio of 1.3 to 3.0 times.       3. The lightweight polyvinyl chloride resin flooring according to claim 1, wherein the hollow particles have a specific gravity of 0.2 to 0.9 and an average particle diameter of 30 μm to 600 μm.       The lightweight polyvinyl chloride resin flooring material according to any one of claims 1 to 3, wherein the surface layer has a tensile elastic modulus of 40 MPa to 200 MPa.       The specific gravity is 0.40 to 0.90. The lightweight polyvinyl chloride resin flooring material according to any one of claims 1 to 4.

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