JP2012241331A - Floor material having excellent adhesive workability - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material having a backing layer of laminated nonwoven fabric, the floor material preventing upward warping of the floor material, the floor material having sufficient adhesive performance, and the floor material having excellent adhesive workability without causing rapid decrease in adhesive strength even with a prolonged open time.SOLUTION: A floor material made of a resin containing no chlorine atom in the chemical structure includes a surface layer, an intermediate layer, a lower layer, and a nonwoven fabric which are laminated and integrated in this order. It has been found that the lower layer contains crystalline resin of 55 to 95 mass% based on the entire resin components of the lower layer, and the nonwoven fabric contains an adhesive resin of 3 to 9 g/mso that the floor material has excellent adhesive workability, thus leading to completion of the present invention.

Description

  The present invention relates to a flooring material excellent in adhesive workability used for flooring materials of vehicles such as ships, railroads, and buses or floor materials of buildings such as buildings, condominiums, houses, and commercial facilities.

  Conventionally, as a flooring material for buildings such as buildings, condominiums, houses, and commercial facilities, a material made of vinyl chloride resin (PVC) is often used. This is because PVC flooring is excellent in wear resistance and can reduce costs.

However, PVC flooring has the problem of causing environmental pollution by incineration, and harmful hydrogen chloride gas is generated during combustion due to a fire. Therefore, if hydrogen chloride gas is inhaled during evacuation, the human body will be adversely affected. There was a problem.

  Therefore, in place of the PVC material, a non-halogen-based flooring that generates little toxic gas during combustion has been proposed. The applicant has disclosed a non-halogen-based flooring backing layer, for example, a flooring in which nonwoven fabrics are laminated and integrated (Patent Document 1), and the backing layer of the nonwoven fabric retains strain that tends to shrink due to heating during lamination. In this state, the floor material can be prevented from warping, and when the floor material is applied, the solvent-based or emulsion-based adhesive applied to the base material and the floor material can be prevented. Adhesive performance could be ensured.

JP 2002-52654 A

  However, in the above prior art, when the time from application of the adhesive to the base material when the flooring is applied until the flooring is bonded (hereinafter referred to as “open time”) becomes longer, Since the adhesive is not impregnated, there is a problem that the adhesive strength is rapidly reduced. In addition, as an adhesive for constructing a flooring material, a solvent-based or emulsion-based adhesive is used, and many adhesives have a polar group.

  The present invention has been made in view of such technical background, and even when a nonwoven fabric is laminated as a backing layer, the floor material is prevented from warping and has sufficient adhesive performance, and has an open time. An object of the present invention is to provide a flooring material excellent in adhesion workability without abruptly lowering the adhesive strength by being long. In addition, the upper curvature of the flooring means a state in which the peripheral portion of the flooring is lifted with respect to the construction surface, and the reverse warping of the flooring means a state opposite to the upper bending.

  In order to achieve the above object, the present invention provides the following means.

[1] In a flooring made of a resin having no chlorine atom in its chemical structure, a surface layer, an intermediate layer, a lower layer, and a nonwoven fabric are laminated and integrated in this order, and the crystalline resin is added to the entire lower layer resin component. The flooring material excellent in the adhesive workability characterized by containing 55-95 mass% with respect to this, and the said nonwoven fabric contains 3-9 g / m < ² > of adhesive resin.

[2] The flooring material excellent in adhesion workability according to the above item 1, wherein the solubility parameter (SP value) of the adhesive resin is 9.0 to 12.0 (cal / cm ³ ) ^1/2 .

  [3] The flooring material excellent in adhesion workability according to item 1 or 2, wherein the crystallinity of the crystalline resin is 45% or more.

[4] The flooring material excellent in adhesion workability according to any one of items 1 to 3, wherein the nonwoven fabric has a basis weight of 20 to 100 g / m ² .

In the invention of [1], in the floor material made of a resin having no chlorine atom in the chemical structure, the surface layer, the intermediate layer, the lower layer, and the nonwoven fabric are laminated and integrated in this order, and the crystalline resin is Since it is defined in the range of 55 to 95% by mass with respect to the entire lower layer resin component, the crystalline resin abruptly shrinks at a temperature below the melting point, so that it becomes a reverse warp, so that the floor material can be prevented from warping. it can. Furthermore, since the said nonwoven fabric contains 3-9 g / m < ² > of adhesive resins, it can be set as the floor material excellent in the adhesive construction property which fully improved the adhesive performance.

In the invention of [2], the dissolution parameter (SP value) of the adhesive resin is defined in the range of 9.0 to 12.0 (cal / cm ³ ) ^1/2 and is used when constructing the flooring. Since the compatibility with the adhesive (containing the polar resin) is greatly improved, the adhesion performance can be effectively improved, and a flooring material excellent in adhesion workability can be obtained.

  In the invention of [3], since the crystallinity of the crystalline resin is specified to be 45% or more, the lower layer is rapidly warped because it contracts rapidly at a temperature equal to or lower than the melting point. Prevention can be improved effectively.

In the invention of [4], since the basis weight of the nonwoven fabric is 20 to 100 g / m ² , material destruction of the nonwoven fabric can be suppressed, so that the adhesion performance can be effectively improved.

It is sectional drawing which shows the flooring which concerns on one Embodiment of this invention.

  One embodiment of a flooring (1) according to the present invention is shown in FIG. This flooring (1) is a flooring made of a resin having no chlorine atom in the chemical structure, and the surface layer (2), the intermediate layer (3), and the crystalline resin are combined with the entire lower layer resin component. The crystalline resin lower layer (4) contained in an amount of 55 to 95% by mass and the nonwoven fabric (5) are laminated in this order.

  For the surface layer (2), as the resin component having no chlorine atom in the chemical structure, a resin having no chlorine atom in the chemical structure is used. For example, a polypropylene-ethylene-random copolymer, a homopolypropylene, a urethane resin, a nylon resin, etc. can be mentioned. By laminating such a surface layer (2), it becomes excellent in abrasion resistance and contamination resistance. The thickness of the surface layer (2) is preferably 0.1 to 1 mm.

  Moreover, in order to impart designability to the flooring (1), a printing layer may be formed on the lower surface of the surface layer (2). Although it does not specifically limit as a printing layer, For example, printing techniques, such as gravure printing, offset printing, screen printing, transfer printing, inkjet printing, can be mentioned. The printing ink used for these printings is not particularly limited. For example, pigments, dyes, colorants, fillers, etc. are added to synthetic resins such as acrylic resins, urethane resins, and polyester resins. The mixed thing etc. can be mentioned. It is necessary to provide a primer layer on the lower surface on which the printing layer is formed. Examples of the primer layer include maleic anhydride-modified polypropylene, maleic anhydride-modified polyethylene, and maleic acid-modified polypropylene.

The intermediate layer (3) preferably uses the same resin as the surface resin, and more preferably contains an elastomeric resin. As an elastomer resin,
Although not particularly limited, for example, SEBS (styrene-ethylene-butadiene-styrene copolymer resin), EPR (ethylene-polypropylene rubber) and the like can be mentioned. The content of the elastomeric resin is preferably 20 to 30 parts by mass with respect to 100 parts by mass of the intermediate layer (3) resin. Furthermore, a metal hydroxide can be contained in the intermediate layer (3). Although it does not specifically limit as a metal oxide, For example, aluminum hydroxide, magnesium hydroxide, zinc hydroxide, titanium hydroxide etc. are mentioned. Especially, it is preferable to use magnesium hydroxide at the point which can improve a flame retardance performance.

  It is preferable to use a metal hydroxide that has been treated with a fatty acid or a silane compound. Dispersibility can be improved by treatment with such a substance. The fatty acid is not particularly limited, and examples thereof include stearic acid, aluminum stearate, calcium stearate, magnesium stearate, zinc stearate, and sodium stearate. Of these, stearic acid is preferred. The silane compound is not particularly limited, and examples thereof include amino silane, epoxy silane, and methacryl silane.

  Content of the said metal hydroxide is 150-300 mass parts with respect to 100 mass parts of resin which does not have a chlorine atom in chemical structure. If it is less than 150 parts by mass, the flame retardancy cannot be sufficiently improved. Moreover, when it exceeds 300 mass parts, a volume fraction will be 0.5 or more, and kneading | mixing will become difficult. Especially, it is preferable that it is 200-250 mass parts.

  Furthermore, a carbonate can be contained in the intermediate layer (3). Examples of the carbonate include calcium carbonate, sodium carbonate, and potassium carbonate.

  Content of the said carbonate is 180-300 mass parts with respect to 100 mass parts of resin which does not have a chlorine atom in chemical structure. If the amount is less than 180 parts by mass, the flame retardancy cannot be sufficiently improved. Moreover, when it exceeds 300 mass parts, a volume fraction will be 0.5 or more, and kneading | mixing will become difficult. Especially, it is preferable that it is 220-250 mass parts.

  The lower layer (4) contains the crystalline resin in an amount of 55 to 95% by mass with respect to the entire resin component of the lower layer (4). Since it is prescribed in the range of 55 to 95% by mass, the crystalline resin rapidly contracts at a temperature below the melting point and thus reverse warping, so that the floor material can be prevented from warping. Examples of the crystalline resin include isotactic polypropylene, syndiotactic polypropylene, high density polyethylene (HDPE), and the like, and it is preferable to use isotactic polypropylene. The crystallinity of the crystalline resin needs to be 45% or more. When the degree of crystallinity is less than 45%, it is impossible to prevent the floor material from warping because the crystalline resin shrinks at a temperature below the melting point.

The nonwoven fabric (5) is not particularly limited, and is a nonwoven fabric composed of synthetic fibers such as polyester fibers, acrylic fibers, polypropylene fibers, polyamide fibers, and viscose fibers, and examples thereof include spunbond nonwoven fabrics and needle punched nonwoven fabrics. . The basis weight of the nonwoven fabric is preferably in the range of ^{20 to} 100 g / m ² . It is not preferable because the basis weight of the nonwoven fabric is a nonwoven fabric is easily torn when flooring molding below the 20 g / m ^2, the adhesive strength tends to occur a material failure becomes insufficient in the adhesion evaluation test exceeds 100 g / m ^2. More preferably, it is the range of 30-60 g / m < ² >. Furthermore, since the said nonwoven fabric contains 3-9 g / m < ² > of adhesive resins, it can be set as the floor material excellent in the adhesive construction property which fully improved the adhesive performance. When the content of the adhesive resin is less than 3 g / m ² , the adhesive strength after construction of the flooring material is weakened, and when it exceeds 9 g / m ² , the adhesive strength between the lower layer (4) and the nonwoven fabric (5) is not sufficient. Disappear. More preferably, it is the range of 5-7 g / m < ² >. The adhesive resin may be attached to the nonwoven fabric by a known method, and examples thereof include a method using a dip, a roll coater, and a doctor coater.

Although it does not specifically limit as said adhesive resin, An acrylic resin, an epoxy resin, and a urethane-type resin can be mentioned. Among these, an acrylic resin is preferable in terms of adhesion workability. The solubility parameter (SP value) of the adhesive resin needs to be in the range of 9.0 to 12.0 (cal / cm ³ ) ^1/2 . If the SP value is less than 9.0 (cal / cm ³ ) ^1/2 , the compatibility with the adhesive used during construction of the flooring is lowered, so it is difficult to ensure the adhesive strength. Even if the SP value exceeds 12.0 (cal / cm ³ ) ^1/2 , the compatibility with the adhesive is lowered, so that it is difficult to ensure the adhesive strength.

  In addition, in any of the surface layer (2) and the intermediate layer (3), various types such as an antioxidant, an ultraviolet absorber, a lubricant, a stabilizer, a light stabilizer, a flame retardant, a colorant, an antistatic agent, and a filler. You may contain an additive suitably.

  The thickness of the flooring (1) is not particularly limited, but is preferably set to 2.0 to 2.5 mm. When it is 2.0 mm or more, dimensional stability is obtained, and when it is 2.5 mm or less, the lightweight property as the flooring material (1) can be maintained and good handling properties can be secured. Moreover, you may comprise as a tile-like flooring and may comprise as a sheet-like flooring, and it does not specifically limit.

  In addition, the flooring (1) manufacturing method according to the present invention is not particularly limited. For example, the surface layer (2), the intermediate layer (3) and the lower layer ( 4) and a non-woven fabric (5) prepared by impregnating an adhesive resin in a separate process by, for example, a dip method and then drying, and then forming a sheeted surface layer (2), intermediate layer ( 3), the lower layer (4), and the non-woven fabric (5) can be laminated and integrated with a known device, for example, a thermal drum.

  Next, specific examples of the present invention will be described, but the present invention is not particularly limited to these examples. In addition, about the adhesiveness evaluation method and the curvature evaluation method, it tested and evaluated in accordance with the following test method. These evaluation results are shown in Table 1.

<Adhesion evaluation method>
Based on the peel adhesion strength of JIS A5536-2003 of 53.3, the adhesive strength (N / 25mm) of the flooring was measured for each of the open time of 10 minutes and 60 minutes, and based on the following evaluation criteria evaluated. A panel was used instead of the flexile board. An acrylic resin emulsion adhesive was used for bonding the panel and the flooring, and the amount of adhesive applied was 300 g / m ² . An average value of three measurement samples was calculated and evaluated.
“◯”: Normal adhesive strength was 30.0 N / 25 mm or more.
“Δ”: The normal adhesive strength was 10.0 N / 25 mm or more and less than 30.0 N / 25 mm.
“X”: The normal adhesive strength was less than 10.0 N / 25 mm.

<Warpage evaluation method>
The amount of warp (mm) of the flooring was measured based on the warp test of 6.10 of JIS A 1454-2005 and evaluated based on the following evaluation criteria. The measurement was carried out by measuring four corners of the flooring, and calculating and evaluating the average value of the four corners.
“◯”: The amount of warpage was −1.0 mm or more and 0.0 mm or less.
“Δ”: The amount of warpage was more than 0.0 mm and 0.5 mm or less.
“X”: The amount of warpage was more than 0.5 mm. Or the amount of warpage was less than -1.0 mm.

<Example 1>
A surface layer having a thickness of 0.20 mm was obtained from a composition comprising a polypropylene-ethylene-random copolymer using a calendering machine. Next, a calendering process in which a resin composition comprising 60 parts by mass of polypropylene, 20 parts by mass of an ethylene elastomer, 20 parts by mass of EPR (ethylene polypropylene rubber), and 250 parts by mass of calcium carbonate was kneaded with a Banbury mixer and set to 160 ° C. An intermediate layer having a thickness of 1.60 mm was obtained using a machine. Next, a composition comprising 80% by mass of isotactic polypropylene having a crystallinity of 70% and 20% by mass of atactic polypropylene was kneaded with a Banbury mixer, and the thickness was adjusted to 0. 0 mm using a calendering machine set at 160 ° C. A lower layer of 30 mm was obtained. A spunbond nonwoven fabric made of polypropylene fiber having a basis weight of 60 g / m ² is dipped in an acrylic resin emulsion having an SP value of 10.0 (cal / cm ³ ) ^1/2 and dried at 80 ° C. for 5 minutes. A nonwoven fabric containing / m ² was obtained. Finally, the surface layer, the intermediate layer, the lower layer, and the nonwoven fabric are laminated in this order, and compression molding is performed for 5 minutes under the conditions of 160 ° C. and 1.0 MPa using a thermal drum device, thereby a floor material having a thickness of 2.1 mm Got.

<Example 2>
A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that 60% by mass of isotactic polypropylene having a crystallinity of 70% and 40% by mass of atactic polypropylene were used.

<Example 3>
A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that 90% by mass of isotactic polypropylene having a crystallinity of 70% and 10% by mass of atactic polypropylene were used.

<Example 4>
A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1, except that 80% by mass of isotactic polypropylene having a crystallinity of 50% was used.

<Example 5>
In Example 1, a flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that a spunbond nonwoven fabric made of polypropylene fiber having a basis weight of 30 g / m ² was used.

<Example 6>
In Example 1, a flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that a spunbond nonwoven fabric made of polypropylene fiber having a basis weight of 90 g / m ² was used.

<Example 7>
In Example 1, it is desired to use a nonwoven fabric containing 4 g / m ² of acrylic resin by dipping into an acrylic resin emulsion having an SP value of 10.0 (cal / cm ³ ) ^1/2 and drying at 80 ° C. for 5 minutes. Except for the above, a flooring material having a thickness of 2.1 mm was obtained in the same manner as Example 1.

<Example 8>
In Example 1, it is desired to use a nonwoven fabric containing 6 g / m ² of acrylic resin by dipping into an acrylic resin emulsion having an SP value of 10.0 (cal / cm ³ ) ^1/2 and drying at 80 ° C. for 5 minutes. Except for the above, a flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1.

<Example 9>
In Example 1, 80% by mass of high-density polyethylene having a crystallinity of 95% was used instead of isotactic polypropylene having a crystallinity of 70%, and an epoxy system having an SP value of 11.0 (cal / cm ³ ) ^1/2 A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that it was dipped in a resin emulsion, dried at 80 ° C. for 5 minutes, and a nonwoven fabric containing 5 g / m ^{2 of} an epoxy resin was used.

<Comparative Example 1>
A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that 40% by mass of isotactic polypropylene having a crystallinity of 70% and 60% by mass of atactic polypropylene were used.

<Comparative example 2>
A flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1, except that 80% by mass of isotactic polypropylene having a crystallinity of 40% was used.

<Comparative Example 3>
In Example 1, a floor material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that a spunbond nonwoven fabric made of polypropylene fiber having a basis weight of 120 g / m ² was used.

<Comparative example 4>
In Example 1, a flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1 except that a spunbond nonwoven fabric made of polypropylene fiber having a basis weight of 60 g / m ² and containing no adhesive resin emulsion was used.

<Comparative Example 5>
In Example 1, it is desired to use a nonwoven fabric containing 10 g / m ² of acrylic resin by dipping into an acrylic resin emulsion having an SP value of 10.0 (cal / cm ³ ) ^1/2 and drying at 80 ° C. for 5 minutes. Except for the above, a flooring material having a thickness of 2.1 mm was obtained in the same manner as Example 1.

<Comparative Example 6>
In Example 1, it is desired to use a nonwoven fabric containing 5 g / m ² of polypropylene resin by dipping into a polypropylene resin emulsion having an SP value of 7.5 (cal / cm ³ ) ^1/2 and drying at 80 ° C. for 5 minutes. Except for the above, a flooring material having a thickness of 2.1 mm was obtained in the same manner as in Example 1.

  The present invention can be used as a flooring material for vehicles such as ships, railways, and buses, or a flooring material for buildings such as buildings, condominiums, houses, and commercial facilities.

DESCRIPTION OF SYMBOLS 1 ... Floor material excellent in adhesive workability 2 ... Surface layer 3 ... Intermediate layer 4 ... Lower layer 5 ... Nonwoven fabric

Claims (4)

In a flooring made of a resin having no chlorine atom in the chemical structure, a surface layer, an intermediate layer, a lower layer, and a nonwoven fabric are laminated and integrated in this order, and the crystalline resin is added to the entire lower layer resin component. 55 to 95% by mass, and the nonwoven fabric contains 3 to 9 g / m ² of an adhesive resin. The flooring material excellent in adhesive workability according to claim 1, wherein a solubility parameter (SP value) of the adhesive resin is 9.0 to 12.0 (cal / cm ³ ) ^1/2 .   The flooring material excellent in adhesion workability according to claim 1 or 2, wherein the crystallinity of the crystalline resin is 45% or more. Excellent flooring adhesion workability according to any one of claims 1 to 3 weight per unit area of the nonwoven fabric is 20 to 100 g / ^{m 2.}

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