JP2014224390A - Floor structure and underlay sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor structure in which a floor material is laid without use of an adhesive on an underlay sheet, which can prevent displacement of the laid floor material, and which enables the floor material to be detached with ease.SOLUTION: A floor structure 1 of the present invention includes an underlay sheet 2 that has a sheet body 21 and a surface layer 22 provided on a surface of the sheet body 21, and a floor material 3 that has a floor material body 31 and a backing layer 32 provided on the backside of the floor material body 31. The surface layer 22 is made of an impermeable resin sheet. A plurality of protrusions 41 formed from a resin foam are protrusively provided on the backside of the backing layer 32 of the floor material 3. The floor material 3 is loaded on the underlay sheet 2 in such a manner that the protrusion 41 is brought into contact with the surface layer 22 of the underlay sheet 2.

Description

  The present invention relates to a floor structure in which a floor material is laid on an underlay sheet.

Conventionally, when pets such as dogs, cats, lizards and turtles are raised indoors, the flooring in the room is a normal flooring, for example, flooring, resin flooring, cork flooring, carpet, woven flooring Etc. are used.
In general, the flooring material is slippery, and therefore, a large load is placed on the legs and legs of pets such as dogs and cats, and there is a concern that it may cause hernia due to injury due to falling and burden on the joint for a long time. In order to reduce the load on the pet's legs, it is desirable to use a resin floor material, a cork floor material, a carpet, a woven fabric floor material, etc., which is less slippery than the flooring material. In particular, carpets and woven flooring materials are suitable for flooring when pets are raised indoors because they are not slippery and are warm and have excellent cushioning properties.
However, cork flooring, carpets, and woven flooring can easily infiltrate pet manure from the surface, and when tile-shaped flooring is used, manure enters the joints of adjacent flooring. There is. Pet manure not only causes strong foul odors, but also causes stains and molds and damages buildings. Therefore, there is a demand for a floor structure that can cope with the above-mentioned problems caused by pet manure and can be used around water such as a bathroom, a washroom, and a kitchen.

By the way, generally, a floor structure using a flooring material such as a carpet or a resin flooring material is configured by laying a flooring material on a construction surface. Furthermore, a floor structure is also known in which an underlay sheet is laid on the construction surface and flooring is laid on the underlay sheet for the purpose of reducing the impact sound caused by walking or passing of wheels. Yes.
Such a flooring is usually fixed to the underlay sheet using an adhesive. However, when the flooring is laid on the underlay sheet using an adhesive, it is difficult to remove the flooring. Therefore, it is difficult to remove the flooring and clean the flooring, wash it, sun-dry it, dry it, etc. when it becomes dirty with pet manure. In addition, it is not possible to easily change the floor design (such as renewing a new flooring or rearranging an existing flooring).
In addition, when a flooring is laid on the underlay sheet, manure that has entered the joints often enters the interior from the surface of the underlay sheet, and removal thereof is often difficult.

Patent Document 1 discloses a sheet-like base material for loose-lay construction (formerly formed by forming a synthetic resin protrusion independent of a non-woven fabric impregnated with a synthetic resin and forming a groove other than the protrusion forming portion in the horizontal direction. Lay sheet) is disclosed, and it is disclosed that this sheet-like base material is laid on a construction surface without using an adhesive.
However, since the floor finishing material (floor material) laid on the sheet-like base material of Patent Document 1 is bonded to the base material using an adhesive, only the floor finishing material cannot be removed. When changing the floor design, the floor finishing material must be removed together with the sheet-like base material.
Further, Patent Document 2 discloses a floor finishing material (floor material) that can be laid on a construction surface without using an adhesive, but even in this document, when using an underlay sheet, It is disclosed to fix an underlay sheet and a floor finish using an adhesive.
These documents do not disclose that the floor material is stably fixed to the underlay sheet without using an adhesive. Furthermore, it is not disclosed that only the flooring is easily removed from the underlay sheet.

Japanese Patent No. 3300631 Japanese Patent No. 3606368

A first object of the present invention is a floor structure in which a floor material is laid on an underlay sheet without using an adhesive, and the displacement of the laid floor material can be prevented and the floor material can be easily removed. It is possible to provide a floor structure that can be easily cleaned.
The second object of the present invention is to provide an underlay sheet used for the floor structure.

  The floor structure of the present invention includes an underlay sheet having a sheet main body and a surface layer provided on the surface of the sheet main body, and a flooring having a flooring main body and a backing layer provided on the back surface of the flooring main body. The surface layer is made of a water-impermeable resin sheet, and a plurality of protrusions formed from foamed resin are provided on the back surface of the backing layer of the flooring, and the surface layer of the underlay sheet The flooring is placed on the underlay sheet so that the convex portions are in contact with each other.

In a preferred floor structure of the present invention, the water-impermeable resin sheet is a polyester sheet.
In a preferred floor structure of the present invention, the foamed resin is a foamed acrylic resin.
As for the preferable floor structure of this invention, the hardness of the said convex part is 35-70.
In a preferred floor structure of the present invention, the plurality of convex portions are arranged with an interval of 5 mm to 35 mm.

According to another aspect of the present invention, an underlay sheet is provided.
The underlay sheet of the present invention has a sheet body and a surface layer provided on the surface of the sheet body, the sheet body has a foamed urethane resin sheet, and the surface layer is a water-impermeable polyester. It consists of a sheet.

Since the floor structure of the present invention can be constructed simply by placing the floor material on the underlay sheet without using an adhesive, it can be easily constructed. And since the laid flooring is difficult to shift, there is no possibility of becoming an obstacle when walking. On the other hand, the flooring can be easily removed by peeling off the laid flooring in the vertical direction of the underlay sheet. For this reason, it is possible to easily remove a floor material soiled by pet manure and perform cleaning, round washing, sun drying, drying and the like, and also easily change the floor design. Moreover, since the water-impermeable resin sheet is provided on the surface of the underlay sheet, it is possible to prevent the pet's excrement from permeating.
In addition, since the floor structure of the present invention hardly permeates the water as described above, the floor structure can be suitably used for water such as a bathroom, a washroom, and a kitchen.

The schematic sectional drawing of the floor structure of the present invention. Sectional drawing of the underlay sheet | seat of this invention. The top view which looked at the flooring which concerns on one example of this invention from the back surface side. IV-IV sectional view taken on the line of FIG. The top view which looked at the flooring which concerns on another example of this invention from the back surface side. VI-VI sectional view taken on the line of FIG. The schematic diagram which shows each process of the 1st manufacturing method of an underlay sheet. (A) is the VIIIa-VIIIa sectional view taken on the line of FIG. 7, (b) is the VIIIb-VIIIb sectional view taken on the line of FIG. IX-IX sectional view taken on the line of FIG. The schematic diagram which shows each process of the 2nd manufacturing method of an underlay sheet. (A) is a schematic diagram which shows the manufacturing process of a flooring, (b) is XIb-XIb sectional view taken on the line (however, a doctor plate is not represented by the cross section). Sectional drawing of the flooring produced in Example 6 and 7 (however, the center part is abbreviate | omitted). Reference diagram showing the procedure of a peel test.

Hereinafter, the present invention will be specifically described with reference to the drawings.
However, in each figure, it should be noted that dimensions such as thickness are different from actual ones. In addition, the description “PPP to QQQ” means “PPP or more and QQQ or less”.

[Outline of floor structure]
In FIG. 1, a floor structure 1 of the present invention includes an underlay sheet 2 laid on a construction surface X, and a flooring 3 placed on the surface of the underlay sheet 2. On the underlay sheet 2, a plurality of flooring materials 3 are laid with their adjacent edges abutting on each other.
The underlay sheet 2 is fixed to the construction surface X using an adhering means such as an adhesive, a pressure-sensitive adhesive, or a double-sided pressure-sensitive adhesive tape. However, the underlay sheet 2 is not limited to the case where the underlay sheet 2 is fixed using an adhering means such as an adhesive, and may be merely placed on the construction surface X.
The construction surface X is various floor surfaces of a building structure. The construction surface X may be indoor or outdoor. That is, the floor structure 1 of the present invention can be applied indoors or outdoors. The material of the construction surface X is not particularly limited, and examples thereof include concrete, mortar, metal, wood, and synthetic resin.
The underlay sheet 2 includes a sheet main body 21 and a surface layer 22 provided on the surface of the sheet main body 21. The surface layer 22 is formed of a water-impermeable resin sheet such as a water-impermeable polyester sheet. The floor material 3 includes a floor material body 31, a backing layer 32 provided on the back surface of the floor material body 31, and an adsorption layer 4 provided on the back surface of the backing layer 32. The adsorption layer 4 has a plurality of convex portions 41 formed of foamed resin. The convex portion 41 projects downward from the back surface of the backing layer 32. The floor structure 1 of the present invention is constructed by placing the flooring 3 on the underlay sheet 2 so that the convex portions 41 are in contact with the surface layer 22 of the underlay sheet 2.
This will be specifically described below.

[Underlay sheet]
The underlay sheet 2 may be long or single-wafer, but is preferably long in consideration of workability and transportability. The long underlay sheet 2 is formed in a belt shape having a required width (for example, 800 mm to 4000 mm), and the length is, for example, 2 m to 300 m. The sheet-like underlay sheet is, for example, 800 mm to 4000 mm in length and width.
As shown in FIG. 2, the sheet body 21 of the underlay sheet 2 preferably has a foamed resin sheet 211, more preferably a foamed resin sheet 211, and a nonwoven fabric layer 212 provided on the surface thereof. Have On the nonwoven fabric layer 212, a surface layer 22 made of a water-impermeable resin sheet is provided. In the illustrated example, a first adhesive layer 213 for adhering both layers 22 and 212 is provided between the surface layer 22 and the nonwoven fabric layer 212, and both layers 212 are provided between the nonwoven fabric layer 212 and the foamed resin sheet 211. , 211 is provided with a second adhesive layer 214. The underlay sheet 2 having the foamed resin sheet 211 has excellent sound insulation, sound absorption, heat insulation, and shock absorption.
The foamed resin sheet 211 is not particularly limited, and examples thereof include a urethane resin, an olefin resin, an acrylic resin, a styrene resin, polyethylene, polyvinyl chloride, and polyvinyl acetate. Among them, it is preferable to use a urethane resin because it has a high sound insulating property, an appropriate flexibility, and an excellent load dispersion effect.
Although the thickness of the foamed resin sheet 211 is not specifically limited, For example, it is 3 mm-10 mm, Preferably, it is 4 mm-8 mm. If the thickness of the foamed resin sheet 211 is too large, the foamed resin sheet 211 becomes too flexible, and when the load is applied from above the flooring 3, the sinking becomes large and the user feels uncomfortable and the feeling of walking becomes worse. On the other hand, if the thickness is too small, the flexibility is impaired and the elasticity is lowered, and the sound insulation, sound absorption, heat insulation, shock absorption, and the like may be lowered.

The nonwoven fabric layer 212 is not particularly limited, and a nonwoven fabric obtained by entanglement of fibers by a known method such as a spun bond method, a thermal bond method, a chemical bond method, a needle punch method, or a melt blow method can be used. Examples of fibers include synthetic resin fibers made of one or a mixture of two or more of polyester, olefin resin, polyamide, polyvinyl alcohol, acrylic resin, etc .; recycled fibers such as viscose rayon and cupra ammonium rayon; cotton, hemp, Natural fibers such as palm; The fiber may be a single component fiber, a mixture of two or more kinds, or a composite fiber of two or more kinds of components. The fiber may be a short fiber generally used as a non-woven fabric, or may be a long fiber. Especially, since it is excellent in intensity | strength, it is preferable to use the polyester nonwoven fabric or polyolefin nonwoven fabric by a spunbond method, and the polyester nonwoven fabric by a spunbond method is especially more preferable. The non-woven fabric by the spunbond method is a non-woven fabric with a gap between the fibers in which long fibers are overlapped and fixed by heat bonding or the like.
Although the thickness of the said nonwoven fabric layer 212 is not specifically limited, 0.1 mm-1.0 mm are preferable, 0.1 mm-0.7 mm are more preferable, 0.2 mm-0.6 mm are especially preferable. Basis weight of the nonwoven layer 212 is not particularly ^limited, preferably ^{10g / m 2 ~90g / m 2} , 20g / m 2 ~40g / m 2 is more preferable. If the thickness and basis weight are too small, the sound insulation, sound absorption, heat insulation and shock absorption properties will be low, and if the thickness and basis weight are too large, interfacial peeling may occur in the nonwoven fabric layer 212.

  The first and second adhesive layers 213 and 214 are not particularly limited as long as they are adhesive resins. Since it can be applied by melt extrusion laminating and can be firmly bonded by interposing between both layers (surface layer 22 and nonwoven fabric layer 212, nonwoven fabric layer 212 and foamed resin sheet 211), a polyethylene resin such as low density polyethylene can be used. It is preferable to use it.

The water-impermeable resin sheet constituting the surface layer 22 is a sheet having a smooth surface and impervious water.
Examples of the water-impermeable resin sheet include synthetic resin sheets such as a polyester sheet, a polyethylene sheet, a polyamide sheet, a polypropylene sheet, and a polyvinyl chloride sheet. These synthetic resins can easily and inexpensively form a sheet having a smooth surface and excellent water permeability. Among these synthetic resin sheets, it is particularly preferable to use a polyester sheet because it is excellent in surface smoothness and non-water permeability and can effectively prevent displacement of the flooring.
Examples of the polyester sheet include a sheet made of polyester derived from a carboxylic acid mainly composed of an aromatic dicarboxylic acid and an alcohol mainly composed of an aliphatic diol. Preferably, polyester in which 50 mol% or more of the carboxylic acid component is composed of terephthalic acid and 50 mol% or more of the alcohol is composed of an ethylene glycol component is used. The polyester may be a homopolyester, two or more copolyesters, or a mixture thereof. Examples of carboxylic acids other than terephthalic acid include isophthalic acid, naphthalenedicarboxylic acid, oxahydroterephthalic acid, adipic acid, sebacic acid, trimellitic acid, and pyromellitic acid. Examples of alcohols other than ethylene glycol include 1,4-butanediol, propylene glycol, neopentyl glycol, 1,6-hexylene glycol, diethylene glycol, triethylene glycol, glycerol, trimethylolpropane, pentaerythritol, dipentaerythritol, and the like. Is mentioned. Specifically, examples of the polyester include polyethylene terephthalate, polybutylene terephthalate, polyethylene / butylene terephthalate, and polyethylene-2,6-naphthalate. Polyester containing polyethylene terephthalate is preferable, and polyethylene terephthalate is more preferable because of its excellent adsorptivity to the convex portions 41 made of foamed acrylic resin.
The thickness of the surface layer 22 is not particularly limited, and is, for example, 5 μm to 100 μm, preferably 10 μm to 60 μm.

[Floor materials]
The flooring 3 includes a flooring main body 31, a backing layer 32 provided on the back surface of the flooring main body 31, and an adsorption layer 4 having a convex portion 41 formed from a foamed resin.
The floor material 3 may be long or single-wafer (tile). The long flooring 3 is formed in a belt shape having a required width (for example, 900 mm to 4000 mm), and the length is, for example, 10 m to 300 m. The long flooring 3 is cut into a required size during construction. The sheet-like flooring 3 is formed in a desired plan view shape (for example, 500 mm square).
The structure of the flooring main body 31 is not particularly limited, and a conventionally known structure can be adopted.
The flooring body 31 includes a carpet-type flooring body with a pile tuft on the surface, a synthetic resin flooring body with a synthetic resin layer on the surface, a flooring body with natural stones on the surface, and a natural wood surface. The flooring main body etc. which arranged

The flooring 3 in FIGS. 3 and 4 is an example in which a sheet type is used and a carpet type in which a pile 312 is tufted as the flooring main body 31 is used. That is, the flooring 3 of FIGS. 3 and 4 (flooring 3 of the first example) includes a flooring body 31 on which the pile 312 is tufted, a backing layer 32 provided on the back surface of the flooring body 31, and Have
The floor material body 31 of the floor material 3 of the first example is laminated on a base fabric 311, a pile 312 protruding from the upper surface of the base fabric 311 and tufted (planted) on the base fabric 311, and a lower surface of the base fabric 311. An adhesive layer 313.

Since the floor material body 31 of the floor material 3 of the first example is conventionally known, it will be briefly described.
The base material 311 of the flooring main body is provided for tufting the pile 312. The base fabric 311 is not particularly limited, and examples thereof include a nonwoven fabric, a woven fabric, a knitted fabric, and a polypropylene Hessian woven fabric. The base fabric 311 may be coated with a precoat agent such as SBR, MBR, PVC latex, and EVA.
The pile 312 may be a loop pile as shown or a cut pile (not shown). The material of the pile 312 is not particularly limited. For example, a known fiber processed yarn made of polyamide such as nylon, polyester, polypropylene, polyethylene, polyvinyl alcohol, or the like can be used.
The adhesive layer 313 is provided to adhere the base fabric 311 and the backing layer and to fix the tufted pile 312. The adhesive layer 313 is not particularly limited, and for example, a synthetic resin such as polyvinyl chloride, a urethane resin, an ethylene-vinyl acetate copolymer, or SBR can be used.

Moreover, the flooring 3 of FIGS. 5 and 6 is an example in which the flooring body 31 is made of synthetic resin. That is, the flooring 3 (the flooring 3 of the second example) of FIG. 5 and FIG. 6 is provided on a synthetic resin flooring body 31 formed in a rectangular shape in plan view and the back surface of the flooring body 31. A backing layer 32.
The floor material body 31 of the floor material 3 of the second example includes a surface layer 314 and an intermediate layer 315 in order from the top.
In addition, the floor material main body 31 of the first example and the second example is not limited to the above structure, and any layer may be omitted, or an arbitrary layer may be added.

Since the floor material main body 31 of the floor material 3 of the second example is also conventionally known, it will be briefly described.
The surface layer 314 of the floor material body 31 is a layer that protects the surface of the floor material 3. The surface layer 314 is made of a synthetic resin such as polyvinyl chloride. The surface layer 314 may be embossed as necessary. In addition, a decorative print layer (not shown) is provided between the surface layer 314 and the intermediate layer 315 as necessary.
The intermediate layer 315 of the floor material body 31 is a layer that determines the mechanical strength and physical properties of the floor material 3. The intermediate layer 315 is made of a synthetic resin. The synthetic resin may be one or a mixture of thermoplastic resins such as polyvinyl chloride, polyethylene, polypropylene, polystyrene, acrylonitrile / butadiene / styrene, acrylonitrile / styrene, nylon, polyacetal, acrylic resin, polycarbonate, and polyester. Alternatively, two or more kinds of copolymers, reactive resins such as epoxy resins, and the like can be given. These synthetic resins can be used alone or in combination of two or more. Preferably, the intermediate layer 315 is made of polyvinyl chloride. The intermediate layer 315 may be non-foamed or foamed.
Further, a reinforcing layer (not shown) may be embedded in the intermediate layer 315. The reinforcing layer is a layer provided as necessary in order to increase mechanical strength such as dimensional stability and rigidity of the flooring 3. Examples of the reinforcing layer include glass fiber nonwoven fabrics such as glass mats, nonwoven fabrics such as polyester nonwoven fabrics, knitted fabrics such as glass nets, and woven fabrics such as woven fabrics. The reinforcing layer may be one layer or two or more layers. The intermediate layer 315 provided with the two reinforcing layers is configured in the order of synthetic resin / reinforcing layer / synthetic resin / reinforcing layer / synthetic resin, for example.

Examples of the backing layer 32 of the flooring 3 of the first and second examples include nonwoven fabric, felt, woven fabric, rubber layer, synthetic resin layer, nonwoven fabric or woven fabric impregnated with resin or rubber. . Since it becomes easy to remove the placed flooring 3 from above the underlay sheet 2, it is preferable to use a nonwoven fabric as the backing layer 32. As the nonwoven fabric, those exemplified above can be used. Preferably, a polyester nonwoven fabric or polyolefin nonwoven fabric by a spunbond method is used, and a polyester nonwoven fabric by a spunbond method is more preferable.
Moreover, in the carpet-type flooring 3, a felt, a foamed resin layer, or a thick non-woven fabric may be used as the backing layer 32 in order to impart cushioning properties. Felt is relatively soft and excellent in shock absorption, so the carpet-type flooring 3 using felt as a backing layer has unevenness due to the construction surface in the underlay sheet 2 However, it adheres well to the underlay sheet 2 regardless of the unevenness. Furthermore, the flooring 3 having excellent sound absorption and shock absorption can be constituted by the flexibility of the felt and the air in the felt, and the sound absorption and shock absorption are extremely excellent due to the synergistic effect with the underlay sheet 2. A floor structure 1 can be constructed.
Examples of the felt include polyester felt, polypropylene felt, nylon felt, needle punching felt, wool felt, etc. Among them, polyester felt is preferable because of excellent durability and flexibility.
Examples of the synthetic resin layer include acrylic resins such as polyvinyl chloride, polyolefin, ethylene-vinyl acetate copolymer, and ethylene-methacrylate resin, polyamide, polyester, polyolefin elastomer, styrene elastomer, and rubber. Especially, since it is excellent in durability and a softness | flexibility, the synthetic resin layer which consists of polyvinyl chloride is preferable. Note that a sheet material such as jute, glass fiber nonwoven fabric, and spunbond nonwoven fabric may be bonded or embedded in the synthetic resin layer.

On the back surface of the backing layer 32, an adsorption layer 4 made of foamed resin is provided.
The back surface of the adsorption layer 4 is formed in a concavo-convex shape, and accordingly, a plurality of convex portions 41 made of foamed resin are projected from the back surface of the backing layer 31.
The adsorption layer 4 is provided to fix the flooring 3 on the underlay sheet 2 so as to be detachable. The adsorption layer 4 made of foamed resin is flexible and has a porous structure in which a plurality of micropores are opened on the back surface. The porous structure of the adsorption layer 4 may be either an open-cell structure or a closed-cell structure, but an open-cell structure is preferable because it sufficiently exhibits the sucker function.
The adsorbing layer 4 is not particularly limited, and a suction cup with fine pores in which a synthetic resin such as acrylic resin, urethane resin, ethylene-vinyl acetate, polyvinyl alcohol, polyvinyl acetate, epoxy resin, acrylate ester, polyester is foamed. A foamed resin having a function is used. Since the adhesion to the surface layer 22 of the underlay sheet 2 is excellent, it is preferable to use a foamed acrylic resin obtained by foaming an acrylic resin as the adsorption layer 4.

The foamed acrylic resin is obtained by foaming a resin composed of a polymer compound having an acrylic group, and typical examples thereof include polyacrylic acid or an ester thereof (and polymethacrylic acid or an ester thereof). Among them, a multilayer structure polymer is preferable because it exhibits good flexibility at normal temperature, has bending durability, and is excellent in weather resistance. The acrylic resin of a multilayer structure polymer is a soft resin in which two or more kinds of acrylic polymers form a core-shell type multilayer structure.
The foamed acrylic resin can be obtained by foaming an emulsion containing an acrylic resin by adding a foaming aid, a crosslinking agent, or the like. The expansion ratio is not particularly limited, but is preferably 1.1 to 6 times, more preferably 1.6 to 2 times, and particularly preferably 1.6 to 2 times. If the expansion ratio is too low, the adsorptive power becomes weak, and if it is too high, the adsorbing layer 4 becomes brittle and material destruction may occur.
Moreover, the density of the said foaming acrylic resin is although it does not specifically limit, For example, 0.1-0.5 g / cm < ³ > is preferable. If the density is less than 0.1 g / cm ³ , the strength may decrease and the adsorption layer 4 may have low durability. If the density is greater than 0.5 g / cm ³ , the number of micropores is small. There exists a possibility that it may become the adsorption layer 4, and the adsorption power falls.

  As the foamed resin, a commercially available product may be used as it is. When a foamed acrylic resin is used as the foamed resin, examples of the acrylic resin emulsion include trade names “Boncoat 350”, “Dick Foam F601”, “Dick Foam MF509” (manufactured by DIC Corporation), and trade names “F439C”. ”,“ F439P ”,“ F439M ”(above, manufactured by Etec Corporation), trade name“ Aron NW7020 ”(produced by Toagosei Co., Ltd.), trade names“ AE601C ”,“ AE379A ”,“ AE116 ”(above, JSR) Co., Ltd.), trade names “Ultrazole”, “Crosslen CL-0090”, “Crosslen AC-150” (above, made by Aika Industries), trade name “SH2054S” (above, made by Kuraray Co., Ltd.) Can be used.

The convex portion 41 is provided on the adsorption layer 4 for the purpose of forming the adsorption layer 4 having high adsorption properties with less foamed resin and adjusting the adsorption properties.
In addition, in order to illustrate the formation range of the convex part 41 clearly, in FIG.3 and FIG.5, the convex part 41 is shaded for convenience.
As shown in FIGS. 4 and 6, a recess 42 is formed between the plurality of protrusions 41 corresponding to the protrusion of the protrusion 41. Between the convex portions 41 (the bottom surface of the concave portions 42), the adsorption layer 4 made of foamed resin exists, and the back surface of the backing layer 32 is not completely exposed. That is, the adsorption layer 4 is a layer that is continuous in the surface direction, and is provided over the entire back surface of the backing layer 32. By having such a continuous adsorption layer 4, the flooring 3 having a high shear strength can be configured. In the floor structure in which the flooring 3 is laid on the underlay sheet 2, when a load is applied from above the flooring 3 by walking, both the convex portion 41 and the concave portion 42 are in contact with the surface layer 22 of the underlay sheet 2. Can be sufficiently adsorbed and the displacement of the flooring 3 can be particularly suppressed. On the other hand, in a state where no load is applied from above the flooring 3, the flooring 3 comes into contact with the underlay sheet 2 only at the convex portion 41 (because it is not in contact with the concave portion 42). The floor material 3 can be easily removed from the underlay sheet 2.

The planar view shape of the plurality of convex portions 41 and the arrangement of the convex portions 41 in the surface of the backing layer 32 viewed from the back surface side of the flooring 3 are not particularly limited, and can be appropriately designed. Further, the plurality of convex portions 41 arranged in the surface of the backing layer 32 may all have the same shape or may be different. Furthermore, the plurality of convex portions 41 may be regularly arranged in the surface of the backing layer 32 or may be irregularly arranged.
Specifically, the plurality of convex portions 41 may be provided in the form of dots in the surface of the backing layer 32 as viewed from the back surface side of the flooring 3, or may be provided in a lattice shape (a plurality of strip shapes). 3 and FIG. 5, a plurality of convex portions 41 having a band shape in a plan view may be provided at regular intervals so as to form a stripe shape on the entire back surface. In particular, since a plurality of rows of uniform convex portions can be formed continuously and easily, the convex portions 41 are preferably formed in a band shape in plan view as illustrated. When the convex part 41 is strip | belt shape, it is preferable that the some convex part 41 is arrange | positioned regularly, and it is more preferable that all are the same planar view shapes. If the shape in plan view is the same, when the flooring material is manufactured or when the flooring material 3 is cut into an arbitrary size, a flooring material or a cut piece of the flooring material having substantially uniform shear strength can be obtained. By regularly laying the flooring 3 or the cut piece having substantially the same shear strength on the underlay sheet 2, the difference in adsorption force between the flooring materials is reduced, and construction and maintenance can be easily performed. .
When forming the convex portions 41 in a strip shape, for example, as shown in FIGS. 3 and 5, a plurality of convex portions 41 in a planar view extending in the first direction (vertical direction in the drawing) of the flooring main body 31 are provided. The convex portions 41 are arranged substantially in parallel with an interval in a direction orthogonal to the first direction. Therefore, as shown in FIGS. 4 and 6, a concave portion 42 having a band shape in plan view extending in the first direction is formed between the adjacent convex portions 41.
The cross-sectional shape of the convex portion 41 is not particularly limited, and is usually formed in a semicircular arc shape, a substantially rectangular shape, or a substantially triangular shape. A semicircular arc shape is particularly preferable because the foamed resin can be uniformly applied during production. The cross-sectional shapes of the plurality of convex portions 41 may all be the same, or the cross-sectional shapes of some of the convex portions may be different.

The height H of the convex portion 41 is not particularly limited, but if it is too small, the effect of preventing the displacement of the flooring 3 may not be obtained. If it is too large, the concave portion 42 becomes proportionally larger. There is a risk of creating a gap between the flooring 3 and the underlay sheet 2. From such a viewpoint, the height H of the convex portion 41 is preferably 0.1 mm to 1 mm, and more preferably 0.2 mm to 0.5 mm. In addition, the height of the convex portion 41 is a linear length from the bottom surface of the concave portion 42 to the apex of the convex portion 41 (the straight line is perpendicular to the surface of the flooring main body 31).
The width W1 of the convex portion 41 is not particularly limited. If the width W1 is too small, the effect of preventing the displacement of the flooring 3 may not be obtained. If the width W1 is too large, the placed flooring 3 is removed from the underlay sheet 2. May be difficult. From such a viewpoint, the width W1 of the convex portion 41 is preferably 1 mm to 10 mm, and more preferably 1.5 mm to 8 mm. In addition, when the planar view shape of the said convex part 41 is strip | belt shape, and the width | variety is not uniform, the width W1 of the said convex part 41 corresponds to the width | variety in the largest location. Similarly, even when the shape of the convex portion in plan view is a dot shape, it is the width at the largest portion.
The interval W2 between the plurality of convex portions 41 is not particularly limited. However, if it is too small, the interval width between the concave portions 42 is relatively small, and it is difficult to remove the placed flooring 3 from the underlay sheet 2. If it is too large, there is a risk that the effect of preventing the displacement of the flooring 3 cannot be obtained. From such a viewpoint, the interval W2 between the convex portions 41 is preferably 5 mm to 35 mm, more preferably 10 mm to 25 mm, and particularly preferably 15 mm to 25 mm. The interval W2 between the convex portions 41 is the interval between two adjacent convex portions 41 and corresponds to the width of the concave portion 42.

The hardness (Asker C) of the convex portion 41 is not particularly limited, but is preferably 35 to 70. However, the hardness (Asker C) is a value measured by a durometer (spring type hardness meter) defined in SRIS0101 (Japan Rubber Association Standard).
In order to prevent the flooring 3 from being damaged during storage or transportation, a protective sheet may be provided on the back surface of the adsorption layer 4 to protect the adsorption layer 4 as necessary. This protective sheet is formed from a synthetic resin such as polypropylene. The protective sheet, like so-called release paper, is peeled off from the adsorption layer 4 when the flooring 3 is laid.

The adsorption layer 4 of the flooring 3 is a continuous layer over the entire back surface of the backing layer 32, but a part of the back surface of the backing layer 32 is exposed or the adsorption layer is not exposed on the bottom surface of the recess 42. Thus, the adsorption layer 4 may be provided. For example, the backing layer 32 may be exposed at a portion corresponding to the recess 42 (no foamed resin is provided). Alternatively, the adsorption layer 4 having a plurality of convex portions 41 may be formed as a continuous layer over the entire back surface of the backing layer 32, and the bottom surface of the concave portion 42 may be covered with a masking material.
In this case, only the plurality of convex portions 41 made of foamed resin are formed on the back surface of the backing layer 32, and thus the adsorption layer 4 is composed of the convex portions 41. Thus, when the adsorption layer 4 consists only of the convex part 41, it becomes easy to remove the mounted flooring 3 from the underlay sheet 2. FIG. However, in this case, since the effect of suppressing the displacement of the flooring 3 is reduced, for example, (a) by increasing the amount of foamed resin of the convex portion 41, the adsorption force of the convex portion 41 is improved. It is preferable to compensate for the effect of suppressing the displacement of the flooring 3 by making at least the exposed surface of the backing layer a non-slip material such as a felt material.

By placing the flooring 3 on the surface of the surface layer 22 of the underlay sheet 2 while facing the back surface of the flooring 3 (the surface on which the convex portions 41 are formed), the present invention as shown in FIG. The floor structure 1 can be constructed.
The construction of the floor structure 1 of the present invention can be completed simply by laying the flooring 3 on the underlay sheet 2 without using an adhering means such as an adhesive. It is very easy because it can. Further, according to the present invention, it is possible not only to save the trouble of applying the adhesive when constructing the floor structure 1, but also to eliminate the open time of the adhesive, and dramatically shorten the construction time. Can do.
A surface layer 22 made of a polyester sheet or the like is provided on the surface of the underlay sheet 2 of the present invention, and an adsorption layer 4 having a convex portion 41 made of foamed acrylic resin or the like is provided on the back surface of the flooring 3. . Since the convex portions 41 are in close contact with the surface layer 22, even when walking on the floor material 3, the floor material 3 is difficult to shift (that is, the floor material 3 is difficult to move in the surface direction of the underlay sheet 2). ). Specifically, in the floor structure 1, when a person or the like walks on the floor structure 1, when a load is applied from above the flooring 3, air comes out from each micropore of the adsorption layer 4 made of foamed resin, and the adsorption layer 4 is drowned. Like a suction cup, it exerts a sufficient suction force for the underlay sheet 2. For this reason, the flooring 3 becomes difficult to shift.

On the other hand, when the placed flooring 3 is turned in the vertical direction of the underlay sheet 2, the flooring 3 can be easily detached from the underlay sheet 2. For this reason, the replacement of a new flooring 3 or the replacement of an existing flooring 3 can be easily performed, and the floor design can be easily changed. In particular, since the adsorption layer 4 has the convex part 41, the flooring 3 can be removed easily.
Moreover, since the surface layer 22 is non-permeable, the underlay sheet 2 can be prevented from passing through the underlay sheet 2 even if the pet manure, beverages, etc. are spilled on the flooring 3. Since the flooring 3 of the floor structure 1 of the present invention can be easily removed, it is possible to easily remove the flooring 3 soiled with manure, etc., wash the contamination, or replace the flooring. Also, contamination of the surface of the underlay sheet 2 can be easily wiped off.
Thus, the floor structure 1 of the present invention is difficult to slip when the load is applied to the laid flooring 3 due to the interaction between the adsorption layer 4 and the surface layer 22 of the underlay sheet 2. When no load is applied, the flooring 3 can be easily removed.

[Underlay sheet manufacturing method]
The underlay sheet can be produced, for example, as follows. However, the production method of the underlay sheet of the present invention is not limited to the following method.
(First production method of underlay sheet)
Drawing 7 is a mimetic diagram of the manufacturing process of the 1st manufacturing method of an underlay sheet.
In the first manufacturing method, two underlay sheets 2 in which the surface layer 22 made of a polyester sheet or the like is laminated on the surface of the sheet body 21 can be formed simultaneously.

In FIG. 7, a first polyester sheet 71a (a water-impermeable resin sheet as a surface layer of the underlay sheet) is pulled out from the sheet supply roll 51a, and an adhesive resin 72a (first adhesive layer) such as polyethylene is melted on the back surface thereof. Extrude and apply. Next, the 1st nonwoven fabric 73a is laminated | stacked from the nonwoven fabric supply roll 52a on the back surface of the adhesive resin 72a. Further, an adhesive resin 74a (second adhesive layer) such as polyethylene is melt-extruded and applied to the back surface of the nonwoven fabric 73a. And from the back side of the first laminate 75a laminated in the order of polyester sheet 71a / first adhesive layer 72a / nonwoven fabric 73a / second adhesive layer 74a, using a punching machine 54a having a needle portion 53a, A hole penetrating in the thickness direction of the stacked body 75a is formed. The needle portion 53a of the punching machine 54a is not heated, and the temperature thereof is approximately room temperature. By piercing the needle portion 53a from the back surface side of the laminate 75a, a hole 76a penetrating the laminate 75a is formed as shown in FIG. 8A, and a burr projecting outward around the hole 76a is formed. 77a is produced.
Although the magnitude | size of the said hole 76a is not specifically limited, For example, it is 0.3 mm-1 mm in diameter, Preferably, it is 0.5 mm-0.9 mm. A plurality of holes 76a are formed, and the interval between adjacent holes 76a and 76a is 5 mm to 20 mm (preferably 8 mm to 12 mm) in the longitudinal direction of the sheet 71a, and 3 mm to 15 mm (preferably in the width direction of the sheet 71a). 5 mm to 10 mm).
The formation of the hole 76a is not limited to the case where the hole 76a is formed on the laminated body 75a. The hole 76a may be formed after the first polyester sheet 71a is pulled out and before the first adhesive layer 72a is applied. The formation time of the hole 76a is not limited as long as the hole 76a is formed in the first polyester sheet 71a and the burr 77a generated by the hole 76a can protrude outward from the polyester sheet 71a.

In addition, the second polyester sheet 71b (non-permeable resin sheet as a surface layer of the underlay sheet) is pulled out from the sheet supply roll 51b, and an adhesive resin 72b (first adhesive layer) such as polyethylene is melt-extruded on the back surface thereof. Apply. Next, the 2nd nonwoven fabric 73b is laminated | stacked from the nonwoven fabric supply roll 52b on the back surface of the adhesive resin 72b. Further, an adhesive resin 74b (second adhesive layer) such as polyethylene is melt-extruded and coated on the back surface of the nonwoven fabric 73b. And from the back side of the second laminate 75b laminated in the order of polyester sheet 71b / first adhesive layer 72b / nonwoven fabric 73b / second adhesive layer 74b, using a punching machine 54b having a needle portion 53b, A hole penetrating in the thickness direction of the stacked body 75b is formed. The needle portion 53b of the punching machine 54b is not heated, and its temperature is approximately room temperature. By piercing the needle portion 53b from the back surface side of the multilayer body 75b, a hole 76b penetrating the multilayer body 75b is formed and projecting outward around the hole 76b, similarly to the first multilayer body 75a. A burr 77b is generated.
Although the magnitude | size of the said hole 76b is not specifically limited, For example, it is 0.3 mm-1 mm in diameter, Preferably, it is 0.5 mm-0.9 mm. A plurality of holes 76b are formed, and the interval between adjacent holes 76b and 76b is 5 mm to 20 mm (preferably 8 mm to 12 mm) in the longitudinal direction of the sheet 71b, and 3 mm to 15 mm (preferably in the width direction of the sheet 71b). 5 mm to 10 mm).
The formation of the hole 76b is not limited to the case where the hole 76b is formed on the laminated body 75b. The hole 76b may be formed after the second polyester sheet 71b is pulled out and before the first adhesive layer 72b is applied. The formation time of the hole 76b is not limited as long as the hole 76b is formed in the second polyester sheet 71b and the burr 77b generated by the hole 76b can protrude outward from the polyester sheet 71b.

A foamed resin forming material 78 is placed on the second adhesive layer 74a of the first laminate 75a.
As the foamed resin forming material 78, for example, a mixture made of other raw materials such as urethane chips, binders, and fiber waste can be used.
The urethane chip is made of crushed flexible polyurethane foam. Since the foamed resin sheet having uniform quality can be formed, the urethane chip is preferably crushed to the smallest possible particle size. The flexible polyurethane foam may be either an open-celled foam or a closed-celled foam, but an open-celled foam is preferable. Such a flexible polyurethane foam is generally used as, for example, an automobile seat or a cushion material for a sofa. As the flexible polyurethane foam, a new one may be used, or waste generated at the time of manufacturing the cushioning material or a recycled product of waste after use of the product may be used. From the viewpoint of environment and cost, it is preferable to use scraps and recycled products.
The binder is a moisture curable urethane elastic binder added to the urethane chip. This binder is a solution-type or solvent-free composition comprising a polyurethane prepolymer having an NCO group at the terminal as a main component, and an elastic urethane resin by curing the terminal NCO group by reacting with water. In addition, the urethane chip and the fiber waste are bonded to each other.
As the fiber waste, waste generated at the time of manufacturing a fabric product, a recycled product, or the like can be used.

  As shown in FIG. 7, the foamed resin forming material 78 containing the urethane chip and the binder is kneaded by the mixer 55 and placed on the first laminate 75a. The first laminated body 75a on which the forming material 78 is placed is conveyed by a conveying device having an endless belt 56, and then the second adhesive layer 74b of the second laminated body 75b is formed on the forming material 78. Then, the second laminated body 75b is superposed and passed between the pair of endless belts 57, 57, and the forming material 78 is formed to a required thickness. In this way, an original sheet 81 composed of the second laminate 75b / foamed resin forming material 78 / first laminate 75a as shown in FIG. 8B is obtained.

Steam is applied while passing the raw sheet 81 between a pair of compression belts 59, 59 provided in the steam chamber 58. Since a plurality of holes 76a and 76b are formed in the laminates 75a and 75b, steam spreads into the forming material 78 through the holes 76a and 76b. The polyurethane prepolymer in the binder is wet-cured by the steam, and a foamed polyurethane layer 79 is formed between the pair of laminates 75a and 75b.
Part of the burrs 77a and 77b of the laminates 75a and 75b is crushed by molding with the pair of endless belts 57 and 57 and compression with the pair of compression belts 59 and 59. The holes 76a and 76b are not crushed so as to close the holes.

Next, temperature and pressure are applied to the original sheet 81 from the outside of the original sheet 81 using a pair of heating presses 91 and 91. The temperature and pressure of the hot press machines 91 and 91 are not particularly limited. For example, the temperature is preferably 210 ° C. for 120 seconds and the pressure is preferably 4 MPa. The burrs 77a and 77b are pushed into the holes 76a and 76b while being slightly melted by the heating and pressurization of the hot press machines 91 and 91. Accordingly, as shown in FIG. 9, at least the holes 76a and 76b of the first and second polyester sheets 71a and 72b are closed, and the original fabric having the first and second polyester sheets 71a and 72 which do not allow water to pass through. A sheet 81 can be formed.
In this regard, when a hole is formed using a heated needle portion, burrs are unlikely to occur, and therefore it is difficult to close the hole after steaming. In addition, when the hole is formed so that the burr is generated inside, it is difficult to close the hole even when heated and pressurized after the steam. In the first manufacturing method, by using a needle portion that is not heated and forming a hole so that a burr is formed on the outside, the hole can be closed relatively easily and reliably after steaming.

As shown in FIG. 7, by using a slicer 92, the foamed polyurethane layer 79 of the original fabric sheet 81 is divided into two parts, whereby a first polyester sheet 71a / first adhesive layer 72a / nonwoven fabric 73a / second. From the first underlay sheet 2a composed of the adhesive layer 74a / half of the foamed polyurethane layer 79, and from the second polyester sheet 71b / first adhesive layer 72b / nonwoven fabric 73b / second adhesive layer 74b / half of the foamed polyurethane layer 79 The second underlay sheet 2b is obtained. The obtained first and second underlay sheets 2a and 2b may be compressed by heating and pressing in the thickness direction, if necessary. In addition, the dashed-dotted line of FIG. 9 shows the parting line divided by the slicer 92.
The obtained first and second underlay sheets 2a and 2b are usually wound on a roll. The first and second underlay sheets 2a and 2b have the same structure as the underlay sheet 2 shown in FIG.
As mentioned above, since the 1st manufacturing method can manufacture the underlay sheet used for the floor structure of the present invention by one manufacturing process, it is excellent in manufacturing efficiency. Moreover, since the hole formed in the polyester sheet is finally closed, a water-impermeable underlay sheet can be obtained. Closing this hole means that it does not allow liquid to pass through (non-water-permeable), but close enough to allow water vapor to pass through. However, the hole may be blocked so that liquid and gas are not allowed to pass therethrough.
In the above-described underlay sheet manufacturing method, the case where all the steps are performed in one manufacturing line as illustrated in FIG. 7 is illustrated, but the present invention is not limited to this. For example, the first laminated layer in which the holes 76a are formed. The body 75a may be prepared in a separate process in advance and introduced into the underlay sheet production line.

(Second manufacturing method of underlay sheet)
FIG. 10 is a schematic diagram of the manufacturing process of the second manufacturing method of the underlay sheet.
In the second manufacturing method, one underlay sheet 2 in which the surface layer 22 made of a polyester sheet is laminated on the surface of the sheet main body 21 can be formed.
Hereinafter, the second manufacturing method will be described, but only the parts different from the first manufacturing method will be mainly described, and the same parts as the first manufacturing method will be omitted (assuming that they have been described). In the above, reference numerals are used.

As shown in FIG. 10, in the second manufacturing method, the second laminated body 75b is composed of the nonwoven fabric 73b / second adhesive layer 74b (without the second polyester sheet and the second adhesive layer).
Further, no punching machine is provided, and no holes are formed in the first stacked body 75a and the second stacked body 75b.
The foamed resin forming material 78 is placed on the first laminate 75a in the same manner as in the first manufacturing method, and the second laminate 75b is further laminated on the foamed resin-forming material 78. The polyurethane prepolymer is wet-cured to form a foamed polyurethane layer. In the second manufacturing method, since no hole is formed, steam does not enter through the polyester sheet 71a of the first laminated body 75a, but the second laminated body 75b does not have a polyester sheet. Steam spreads from the nonwoven fabric 73 a on the body 75 b side into the forming material 78. For this reason, polyurethane can be wet cured.

Thereafter, the raw fabric sheet 81 is not passed through a heating press machine (however, it may be heated and pressurized after steaming as in the first manufacturing method), and the foamed polyurethane layer 79 of the raw fabric sheet 81 is removed by using a slicer 92. The first underlay sheet 2a composed of the first polyester sheet 71a / first adhesive layer 72a / nonwoven fabric 73a / second adhesive layer 74a / half foamed polyurethane layer 79, and / nonwoven fabric 73b / A third underlay sheet 2c composed of the second adhesive layer 74b / half of the polyurethane foam layer 79 is obtained.
The obtained first and third underlay sheets 2a and 2c are usually wound on a roll. The first underlay sheet 2a has substantially the same structure as the underlay sheet 2 shown in FIG. That is, the underlay sheet 2a obtained by the second production method is the same as the underlay sheet obtained by the first production method, except that not only liquid but also gas such as water vapor is not passed. On the other hand, unlike the underlay sheet 2a, the third underlay sheet 2c has a structure that allows water to pass through.
As described above, the underlay sheet 2 used in the floor structure of the present invention can also be manufactured by the second manufacturing method. In the second manufacturing method, underlay sheets having different structures can be manufactured simultaneously.

[Production method of flooring]
The flooring can be produced, for example, as follows. However, the manufacturing method of the flooring of the present invention is not limited to the following method.
A backing layer 32 and a floor material body 31 are prepared. As the backing layer 32, as exemplified above, a nonwoven fabric or the like can be used. As exemplified above, the floor material body 32 may be a carpet type, a synthetic resin material, or the like. Since the manufacturing method of the floor material main body 31 is conventionally well-known, the description is abbreviate | omitted.
In one manufacturing method of the flooring material, after the adsorption layer 4 having the convex portions 41 is formed on the back surface of the backing layer 32, the backing layer 32 is integrated with the flooring body 31. In another method for producing a flooring material, after the backing layer 32 is integrated with the flooring body 31, the adsorption layer 4 having the convex portions 41 is formed on the back surface of the backing layer 32. Hereinafter, the former production method will be described.

Fig.11 (a) is a schematic diagram of the manufacturing process of a flooring.
In Fig.11 (a), the nonwoven fabric 61 (backing layer) is pulled out from a roll to a production line, and an adsorption layer is formed in the middle.
For example, an acrylic ester copolymer emulsion is used as a resin component, and an adsorbent layer forming material is prepared by blending an appropriate amount of an auxiliary agent such as a crosslinking agent, a filler, a foaming agent, a thickener, and a water repellent into the emulsion. To prepare. When an acrylic ester copolymer emulsion is used, an epoxy resin as the crosslinking agent, aluminum hydroxide as the filler, ammonium stearate as the foaming agent, sodium polyacrylate as the thickening agent, and a fluorosurfactant as the water repellent Etc. can be used. In order to further increase the strength, a crosslinking agent is added to the adsorbing layer forming material, and this is foamed by stirring and foaming while blowing air with a foaming machine. The obtained foam-forming material contains bubbles, has viscosity and adhesiveness, and has microbubbles even after drying.
The foam-forming material 62 obtained in this way is applied onto the strip-shaped nonwoven fabric 61 using a rotary screen coating machine. In order to form a convex portion in the coating layer of the foam forming material 62, the surface thereof is formed in an irregular shape. For example, as shown in FIG. 11B, a doctor blade 63 having a plurality of notches 631 formed below is applied to the surface of the nonwoven fabric 61 in the middle of the production line. After passing the doctor blade 63 by conveying the nonwoven fabric 61 coated with the foam-forming material 62 at a predetermined speed on the production line, the coating layer of the foam-forming material 62 is shown in FIG. Thus, it is formed in an uneven shape (a plurality of convex portions are formed in the longitudinal direction of the nonwoven fabric). Thereafter, the nonwoven fabric 61 having the coating layer of the foam-forming material 62 formed in an uneven shape is passed through a dryer 64, dried at 120 ° C. to 200 ° C. for about 3 minutes to 5 minutes, and then cooled. By this step, moisture contained in the forming material evaporates, and the acrylic ester copolymer and the crosslinking agent chemically react to crosslink the polymer, so that the forming material is cured in a state having microbubbles. In this way, an adsorption layer having a porous structure in which a plurality of micropores are opened can be integrally formed on the nonwoven fabric 61.
A non-woven fabric 61 (backing layer) on which an adsorbing layer is formed (which may be wound into a roll if necessary) is bonded to the floor material body to obtain a floor material 3 as shown in FIGS. be able to.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the present invention is not limited to the following examples.

[Example 1]
(Fabric production)
A polyester fiber spunbonded nonwoven fabric was used as the base fabric, and a nylon yarn made of 2289 dtex 362 filament twisted yarn was tufted with a tufting machine to prepare a base fabric with a loop pile (pile basis weight 900 g / m ² ).
Separately, foamed acrylic resin (manufactured by DIC Corporation, trade name “Dick Foam MF509”) is foamed 1.8 times as an adsorption layer forming material, and this is used as a backing layer for polyester fiber needle punch nonwoven fabric (thickness 1). (9 mm, basis weight 200 g / m ² ) with a coating amount of 80 g / m ² , this coating layer has a notch portion as shown in FIG. The surface of the coating layer was formed in a concavo-convex shape by passing it through a doctor blade. Finally, the coating layer was dried at 180 ° C. for 3 minutes to produce a backing layer with an adsorbing layer having a plurality of strip-shaped convex portions as shown in FIG.
And after apply | coating the adhesive layer which consists of polyvinyl chloride to the said backing layer with an adsorption layer, and bonding the back surface of the said base fabric with a loop pile to this adhesive layer, heating at 120 to 200 degreeC for 15 minutes Thus, the adhesive layer was cured. The bonded product was cooled and then cut into a 40 cm square to prepare a carpet-type flooring.
When the height and width of the convex part of the adsorption layer of this flooring material and the interval between adjacent convex parts were measured, the height was about 0.3 mm, the width was about 3.0 mm, and the distance was about It was 20 mm.
In addition, the height, width, and space | interval of the said convex part measured the cut surface of the flooring material visually using the ruler.

(Preparation of underlay sheet)
The underlay sheet was produced according to the second manufacturing method.
Specifically, a polyethylene terephthalate sheet having a thickness of 12 μm (trade name “E5102” manufactured by Toyobo Co., Ltd.) is drawn from the sheet supply roll, and linear low density polyethylene is melt-extruded on the back surface thereof to obtain a polyethylene having a thickness of 15 μm. A layer (adhesive resin) was applied.
After laminating a polyester spunbonded non-woven fabric (product name “3251AD” manufactured by Toyobo Co., Ltd.) having a basis weight of 25 g / m ² on the back surface of the polyethylene layer, the same linear low density polyethylene as described above was formed on the back surface of the non-woven fabric. Was melt-extruded and a polyethylene layer (adhesive resin) having a thickness of 15 μm was applied. Thus, the 1st laminated body which consists of PET / PE / nonwoven fabric / PE was prepared.
On the other hand, the same linear low density polyethylene as described above was melt-extruded on the back surface of the same polyester spunbond nonwoven fabric as described above, and a polyethylene layer (adhesive resin) having a thickness of 15 μm was applied. Thus, the 2nd laminated body which consists of a nonwoven fabric / PE was prepared.

A foamed resin forming material containing a urethane chip, a moisture-curing urethane-based elastic binder and fiber waste is sufficiently kneaded, and this forming material is placed on the polyethylene layer of the first laminate, and the top of the forming material is The polyethylene layer of the second laminate was superposed and this laminate (raw fabric sheet) was passed between a pair of endless belts to form a forming material to a thickness of 16 mm.
Thereafter, the foamed resin forming material is cured by adding steam for 10 to 15 minutes while passing the raw sheet between a pair of compression belts provided in the steam chamber, and the first and second laminations A foamed polyurethane layer having a thickness of 16 mm was formed between the bodies. By dividing the foamed polyurethane layer of the original fabric sheet into two in the thickness direction, a polyethylene terephthalate sheet having a thickness of 12 μm / a polyethylene layer having a thickness of 15 μm / a spunbond nonwoven fabric / a polyethylene layer having a thickness of 15 μm / a foamed urethane layer having a thickness of 8 mm And a second sheet made of a spunbonded nonwoven fabric / a polyethylene layer having a thickness of 15 μm / a foamed polyurethane layer having a thickness of 8 mm. Finally, the foamed polyurethane layer was compressed to 6 mm by hot pressing the first sheet and the second sheet from the vertical direction. The 1st sheet | seat after compression was used as an underlay sheet | seat of an Example.

(Floor structure)
The underlay sheet was fixed on a flat concrete surface using an adhesive. The floor structure of Example 1 was produced by placing the flooring on the underlay sheet.

[Example 2]
A flooring was produced in the same manner as in Example 1 except that the foamed acrylic resin as the adsorption layer forming material was foamed 1.9 times.
In the same manner as in Example 1, this flooring was placed on the fixed underlay sheet to produce the floor structure of Example 2.

[Example 3]
A flooring was produced in the same manner as in Example 1, except that the foamed acrylic resin as the adsorption layer forming material was foamed 2.0 times.
In the same manner as in Example 1, the flooring was placed on the fixed underlay sheet to produce the floor structure of Example 3.

[Example 4]
The foamed acrylic resin as the adsorbing layer forming material was foamed 2.0 times, and a doctor blade having a plurality of cut portions with a spacing of 10 mm was used (the spacing between adjacent convex portions was about 10 mm). Except for the above, a flooring was produced in the same manner as in Example 1.
The floor structure of Example 4 was produced by placing this flooring on the fixed underlay sheet in the same manner as in Example 1.

[Example 5]
The foamed acrylic resin, which is the material for forming the adsorption layer, was foamed by a factor of 2.0, and a doctor blade having a plurality of incisions with an interval of 30 mm was used (the interval between adjacent projections was about 30 mm). Except for the above, a flooring was produced in the same manner as in Example 1.
In the same manner as in Example 1, this flooring was placed on the fixed underlay sheet to produce the floor structure of Example 5.

[Example 6]
As shown in FIG. 12, a sheet-like masking material was affixed to the bottom surface of each concave portion between adjacent convex portions of the floor material produced in the same manner as in Example 2. In such a flooring, the adsorbing layer is not exposed at the bottom surface of the concave portion, and the adsorbing layer is composed only of the convex portion.
In Example 6, a cloth adhesive tape (product number 941 manufactured by Kikusui Tape Co., Ltd.) having a thickness of 0.21 mm was used as a masking material.
The floor structure of Example 6 was produced by placing this flooring on the fixed underlay sheet in the same manner as in Example 1.

[Example 7]
A floor structure was produced in the same manner as in Example 6 except that a packaging OPP tape (provider: ASKUL Corporation) having a thickness of 0.05 mm was used as a masking material.

[Slip resistance test]
A slip resistance test was conducted to confirm the displacement (adsorption strength) of the flooring material relative to the underlay sheet.
Specifically, for the floor structures of Examples 1 to 7, one adult male stepped on the flooring 20 times with almost the same force. After that, a digital force gauge (product name “MODEL DPS-50” manufactured by Imada Co., Ltd.) is attached to one corner of the flooring, and the gauge is 6 m / min in a direction parallel to the surface of the underlay sheet. I pulled. The value when the flooring moved was measured with the force gauge. The results are shown in Table 1.

  From the comparison between Example 3 and Examples 4 and 5, the floor structure using the flooring with the convex spacing of around 20 mm (for example, 15 mm to 25 mm, especially 13 mm to 23 mm) is a floor where the flooring is difficult to slip. It can be seen that the structure can be built. Further, from comparison between Examples 1 and 2 and Example 3, the flooring material has a foaming ratio of less than 2 times (for example, 1.6 times to 1.95 times, particularly 1.7 times to 1.95 times). It can be seen that the floor structure using can build a floor structure in which the flooring is difficult to slip. Furthermore, it can be seen from the comparison between Example 2 and Examples 6 and 7 that the floor structure using the floor material in which the adsorbing layer is exposed also in the recess is difficult to slip.

[Peel test]
In order to confirm the ease of peeling off the floor material from the underlay sheet, a peel strength test was performed.
Specifically, for the floor structures of Examples 1 to 7, one adult male stepped on the flooring 20 times with almost the same force. After that, as shown in FIG. 13A, a digital force gauge (product name “MODEL DPS-50” manufactured by Imada Co., Ltd.) is attached to one corner of the flooring, and the gauge is attached to the underlay sheet. Raised in a direction perpendicular to the surface. And as shown in FIG.13 (b), the value when peeling a flooring to the diagonal line which connected two corners other than the said one corner (value when peeling half of a flooring) is shown. Measured with the force gauge. The results are shown in Table 2.

  If the peel strength is 15 N or less, the flooring can be easily peeled off, and if it is 10 N or less, the flooring can be more easily peeled off. It can be seen that any of the floor structures of Examples 1 to 7 can be peeled with a relatively small force.

[Reference example]
By placing the flooring materials of Examples 1 to 7 on a flat flooring material (trade name “Eco First 3000” manufactured by Toyo Tex Co., Ltd.), a floor structure composed of the flooring material and the flooring material (implementation) Reference examples corresponding to each of Examples 1 to 7 were prepared.
With respect to the floor structure of each reference example, the adsorption strength and peel strength were measured in the same manner as in the slip resistance test and peel test. The results are shown in Table 1 and Table 2, respectively.
From the results of the reference examples, it was confirmed that the floor structure composed of the flooring material of the present invention and the underlay sheet is less likely to slip while maintaining the same ease of peeling as the floor structure composed of the flooring material and the flooring material. did it.

DESCRIPTION OF SYMBOLS 1 Floor structure 2 Underlay sheet 21 Sheet main body 22 Surface layer 3 Floor material 31 Floor material main body 32 Backing layer 41 Convex part 42 Concave part X Construction surface

Claims (6)

An underlay sheet having a sheet body and a surface layer provided on the surface of the sheet body;
A flooring having a flooring main body and a backing layer provided on the back surface of the flooring main body,
The surface layer is made of a water-impermeable resin sheet,
A plurality of protrusions formed from foamed resin are provided on the back surface of the backing layer of the flooring,
A floor structure in which the flooring is placed on the underlay sheet such that the convex portions are in contact with the surface layer of the underlay sheet.   The floor structure according to claim 1, wherein the water-impermeable resin sheet is a polyester sheet.   The floor structure according to claim 1 or 2, wherein the foamed resin is a foamed acrylic resin.   The floor structure as described in any one of Claims 1 thru | or 3 whose hardness of the said convex part is 35-70.   The floor structure according to any one of claims 1 to 4, wherein the plurality of convex portions are arranged with an interval of 5 mm to 35 mm. A sheet body, and a surface layer provided on a surface of the sheet body,
The sheet body has a foamed urethane resin sheet,
An underlay sheet in which the surface layer is made of a water-impermeable polyester sheet.

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