JP2015155641A - Floor material and tearing off method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material capable of being easily changed without destroying a base material layer when torn off.

SOLUTION: A floor material according to this invention is a stamped out sheet, in which a base material layer 2 containing fiber, a rear face layer 3 made from resin and a surface layer are laminated in order from bottom to top. The base material layer 2 is impregnated with the resin forming the rear face layer 3. A lower face of the base material layer 2 is scattered with 2a, which are partly exposed parts of the fiber located at the lowest side of the base material layer 2, and 2b, which are partly covered parts with vinyl chloride resin located at the lowest side of the base material layer 2.

COPYRIGHT: (C)2015,JPO&INPIT

Description

  The present invention relates to a flooring that can be easily replaced and a method for peeling the flooring.

  In recent years, renovation has been actively performed in the construction industry. For example, the entire floor material is replaced or only the dirty floor material is replaced. For this reason, there is a demand for a flooring material that can be easily replaced and is so-called excellent in peel-up property.

Conventionally, a base material layer, a foamed resin layer, a pattern layer, a film layer, and a surface protective layer are laminated in order from the bottom, and an uneven pattern is given from the surface protective layer side to the foamed resin layer, and the surface protective layer is 1 or 2 A flooring made of a layer obtained by crosslinking and curing an ionizing radiation curable resin containing a functional silicone (meth) acrylate is known (for example, Patent Document 1).
Patent Document 1 states that such a flooring material is excellent in unevenness followability, has no problem of a step due to thickness, and can be easily replaced and removed.

However, the conventional floor material has a problem that the base material layer is destroyed when the floor material is peeled off.
Specifically, in the base material layer of the floor material, the portion that is weakly adhered to the ground surface peels between the ground surface and the base material layer, but strongly adheres to the ground surface. In the portion where the substrate is present, the base material layer breaks the material (without peeling between the base surface and the base material layer), and the portion of the base material layer remains adhered to the base surface. As described above, a part of the base material layer remaining on the base surface becomes an obstacle when a new flooring material is bonded, and this removal operation must be performed. Since this work requires a lot of labor and time, there has been a problem that the work of replacing the flooring cannot be easily performed.

  On the other hand, if a plasticizer is contained in the flooring material, the plasticizer may bleed and move to the adhesive applied on the base surface. When the plasticizer moves to the adhesive, the adhesive does not harden for a long time, and the curing time of the flooring after construction must be taken long.

JP 2007-92224 A

  An object of the present invention is to provide a flooring that can be easily re-stretched without peeling the base material layer when it is peeled off, and a method for peeling it off.

  The flooring of the present invention is a punched sheet, and in order from the bottom, a base material layer containing fibers, a back surface layer formed from a vinyl chloride resin, and a surface layer are laminated, The base layer is impregnated with a vinyl chloride resin forming a back layer, and a part of the fiber located on the lowermost side of the base layer is exposed on the bottom surface of the base layer and the base A portion of the fiber located on the lowermost surface side of the material layer is scattered with a portion covered with a vinyl chloride resin.

In a preferred flooring material of the present invention, the base material layer is a nonwoven fabric.
Preferred flooring of the present invention, the basis weight of the nonwoven fabric ^{is 30g / m 2 ~50g / m 2} .

According to another aspect of the present invention, a floor material peeling method is provided.
This method includes any one of the above flooring materials, an adhesive, and a ground surface, and the floor material is releasably bonded onto the ground surface via the adhesive. The flooring is peeled off from the base surface at the interface between the lower surface of the base material layer and the base surface.

Since the base material layer is not destroyed when the flooring of the present invention is peeled off from the base surface, it can be peeled off at the interface between the base material layer and the base surface. Therefore, the base material layer hardly remains on the ground surface after the floor material is peeled off, and a new floor material can be applied as it is on the ground surface. Thus, if the flooring of the present invention is used, the flooring can be easily replaced.
Even if the flooring material contains a plasticizer, the flooring material of the present invention can prevent bleeding of the plasticizer. Therefore, the flooring of the present invention does not require a long curing time and can be favorably bonded to the base surface via the adhesive.
Moreover, according to the method of the present invention, the flooring can be peeled off from the base surface without destroying the base material layer.

Sectional drawing of the flooring which concerns on one embodiment of this invention. The reference sectional view which expanded the base material layer and back layer of the flooring.

[Floor material of the present invention and its layer structure]
A preferred embodiment of the flooring of the present invention will be described with reference to the drawings. In each figure, it should be noted that the thickness and size of each layer or member is different from the actual one.

In FIG. 1, a flooring 1 according to one embodiment has a layer structure in which a base material layer 2, a back layer 3 containing a resin, and a surface layer 4 are laminated in order from the bottom.
The surface layer 4 includes a design layer 41, a transparent layer 42, and a surface protective layer 43 in order from the bottom. The surface layer 4 is not limited to the three-layer structure, and can be changed as appropriate. The surface layer 4 may have at least one layer selected from the design layer 41, the transparent layer 42, and the surface protective layer 43, or may have a laminated structure including at least one layer selected from the three layers and other layers.
For example, the surface layer 4 may have a laminated structure having the design layer 41 and the transparent layer 42 in order from the bottom, or a laminated structure having the design layer 41 and the surface protective layer 43 in order from the bottom, or It may be formed only from the design layer 41.
Further, a shape stabilization layer 5 may be provided between the front surface layer 4 and the back surface layer 3.

The base material layer 2 is composed of a fiber layer containing innumerable fibers and having gaps between the fibers. The gap between the base material layers 2 can be impregnated with resin.
The back surface layer 3 is made of resin, and a part of the resin impregnates the base material layer 2.
As shown in FIG. 2, a portion 2 a (a portion 2 a) in which a part of the fibers 21 of the base material layer 2 is exposed on the lower surface of the base material layer 2 (the lower surface of the flooring 1 and the surface in contact with the base surface). Hereinafter, a plurality of fiber exposed portions) and a portion 2b where the resin impregnated in the base material layer 2 is exposed (hereinafter also referred to as a resin exposed portion) are scattered in random order.
In FIG. 1 and FIG. 2, the portion where the resin is present is represented by light ink painting.

In addition, as for the base material layer 2 containing the fiber 21, the countless fiber 21 has overlapped in the up-down direction (thickness direction of the base material layer 2). In the flooring 1 of the present invention, when all of the fibers 21 located on the lowermost surface side of the base material layer 2 are exposed, a part of the fibers 21 located on the lowermost surface side are exposed and the fibers 21 are exposed. The case where a part of the substrate is covered with resin (see FIG. 2) is also included.
Further, some or all of the plurality of exposed resin portions 2b are recessed from the exposed fiber portion 2a (recessed from the lower end surface of the exposed fiber portion 2a), preferably a depth equal to or less than the diameter of the fiber 21. It is recessed. By having the resin exposed part 2b that is recessed from the fiber exposed part 2a, the lower surface of the flooring can be secured between the both surfaces without the lower surface of the flooring being in full contact with the underlying surface. The adhesive strength with respect to the above adhesive is further weakened. Therefore, it becomes easy to particularly peel off the flooring 1 from the base surface.

  The flooring is laid on the base surface via an adhesive. A conventionally well-known thing should just be used for the adhesive agent for adhere | attaching a flooring. Examples of the adhesive include an acrylic resin emulsion-based adhesive, and specifically, a trade name “Eco GA Cement” manufactured by Toli Corporation can be used.

The floor material after bonding can be easily peeled off at the interface between the lower surface of the base material layer and the base surface without being destroyed when the base material layer is reformed. Although the mechanism is not clear, the present inventors presume as follows.
That is, since the floor material is impregnated with the resin of the back surface layer in the base material layer, the fibers of the base material layer are firmly bound by the resin. Therefore, when the flooring is peeled off, most of the fibers in the base material layer do not leave the back surface layer, and a part of the base material layer does not remain on the base surface. Further, since the adhesive on the base surface is sucked into the gaps between the fibers of the base material layer and is not impregnated in large quantities, it is possible to prevent the base surface and the base material layer from being firmly bonded. For this reason, the lowermost surface and the base surface of the flooring can be easily peeled off, and it is possible to suppress the peeling between the base material layers when the flooring is peeled off from the base surface.

Furthermore, since the floor material has a fiber exposed portion and a resin exposed portion on its lower surface, when the lower surface is laid on the adhesive on the ground surface, the fiber exposed portion strongly adheres to the adhesive on the ground surface. And it is thought that the said resin exposure part adhere | attaches the adhesive agent on a base surface weakly compared with the adhesion | attachment of the said fiber exposure part and a base surface. Since a plurality of the fiber exposed portions and the resin exposed portions are scattered on the lower surface of the flooring, portions strongly bonded to the adhesive on the base surface and portions bonded weakly are scattered. Therefore, in the flooring of the present invention, the portion that is strongly bonded to the adhesive on the base surface prevents side slipping and misalignment, while the weakly bonded portion is used as the peeling start point when peeling the flooring. Since it functions, it can be stably fixed at the time of laying, but can be easily peeled off at the boundary between the lower surface and the base surface.
In addition, since the flooring of the present invention is strongly bonded to the base surface at the fiber exposed portion, the laid flooring is not displaced. That is, even when a vertical or horizontal local load is applied to the floor surface due to human walking, furniture movement, etc., the floor material does not slide or roll up from the ground surface, and the floor material of the present invention. There is no problem in use.

  Furthermore, in the flooring of the present invention, even if the back layer contains a plasticizer, the base material layer prevents the penetration of the plasticizer, so that the plasticizer bleeds from the lower surface of the flooring. Can be effectively prevented. When such a floor material is laid on the ground surface, the curing of the adhesive on the ground surface is not inhibited by the plasticizer, and therefore the curing time until the floor material is sufficiently adhered on the ground surface is not prolonged.

Although the thickness of the said flooring is not specifically limited, Usually, it is 1.5 mm-2.5 mm, Preferably it is 1.8 mm-2.2 mm, More preferably, it is 1.9 mm-2.1 mm.
If the flooring is too thick, the weight of the flooring per unit area will be heavy, the handling at the time of construction will be poor, and the resin layer such as the back layer will be relatively thick, so the dimensions will change over time There is a risk of causing. On the other hand, if the flooring is too thin, sufficient strength may not be ensured.
In addition, in this specification, the thickness of a flooring and each layer which comprises it can be measured using the microscope measuring instrument made from Keyence Corporation, for example.

  The flooring of the present invention preferably has flexibility. Since the floor material having flexibility can be peeled off while being curved, it can be particularly easily peeled off from the base surface. Moreover, the floor material which has a softness | flexibility can be constructed also on a flexible base surface like a cushion floor. Although the flexible base surface is deformed during walking, the floor material having flexibility can follow the deformation of the base surface even if it is applied to the base surface, so that cracking of the floor material can be prevented. Therefore, a flexible flooring can be constructed on a flexible base surface.

Stiffness at 20 ° C. for flooring, preferably ^{20kgf / cm 2 ~80kgf / cm 2} , more preferably from ^{30kgf / cm 2 ~70kgf / cm 2} , more preferably 40kgf ^/ cm 2 ~60kgf ^/ cm ² . The rigidity at 20 ° C. is the rigidity in at least one of the vertical direction and the horizontal direction of the flooring measured at 20 ° C. in accordance with JIS K7106. If the rigidity at 20 ° C. is too high, it is difficult to peel off the floor material while curving the floor material, and it may be difficult to change the floor material. On the other hand, if the rigidity is too low, the flooring material becomes too soft, and the shape of the base surface may appear on the flooring surface. The flooring of the present invention may be laid on a base surface having joints such as flooring. In such a case, if the rigidity is too low, the joints appear on the flooring surface after construction. There is a risk of damage.

Stiffness at 5 ° C. for flooring, preferably ^{60kgf / cm 2 ~150kgf / cm 2} , more preferably from ^{70kgf / cm 2 ~140kgf / cm 2} , more preferably 80kgf ^/ cm 2 ~130kgf ^/ cm ² . The degree of rigidity at 5 ° C. is the degree of rigidity in at least one of the vertical direction and the horizontal direction of the flooring measured at 5 ° C. in accordance with JIS K7106. The flooring material having the rigidity at 5 ° C. can be peeled off from the ground surface while being bent even when the re-covering is performed under a low temperature condition (for example, in a cold region or in winter).
A specific method for measuring the rigidity of the flooring is as in the following examples.

[Base material layer]
A base material layer is a layer located in the lowest part of a flooring, Comprising: It has the effect | action which prevents the curvature of a flooring. In addition, when the back layer contains a plasticizer, the base material layer also has an action of preventing the plasticizer from bleeding.
The base material layer is not particularly limited as long as it contains fibers, and examples thereof include non-woven fabrics (including felt), woven fabrics, and papers, preferably non-woven fabrics or woven fabrics, and more preferably non-woven fabrics. . By using a non-woven fabric or a woven fabric, warping of the flooring can be effectively prevented. In addition, when the nonwoven fabric is peeled off, the fiber is easily broken and broken, but according to the present invention, even when the nonwoven fabric is used as the base material layer, the base material layer is impregnated with the resin of the back surface layer. Since it is firmly bonded, the destruction can be prevented.

Examples of the nonwoven fabric include spunbond nonwoven fabric, thermal bond nonwoven fabric, chemical bond nonwoven fabric, needle punch nonwoven fabric, and spunlace nonwoven fabric. These can be used alone or in combination of two or more. Among these, it is preferable to use a spunbond nonwoven fabric. A spunbond nonwoven fabric is a nonwoven fabric with gaps in which long fibers are overlapped and fixed by thermal bonding or the like.
Moreover, although the fiber of a nonwoven fabric may be either a short fiber or a long fiber, a long fiber is preferable from a viewpoint of curvature prevention. The length of the long fiber is, for example, 100 mm or more.
The material of the fibers constituting the nonwoven fabric and the woven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; natural fibers and the like. Among these, the base material layer is preferably a non-woven fabric made of polyester fibers. The polyester nonwoven fabric shrinks over time, so it balances against the upward warping of the floor material due to the shrinkage of the surface layer that occurs over time, and the end of the floor material warps upward. In particular, it can be prevented. That is, even if a shrinkage force is generated on the surface layer or the like, the base material layer is also shrunk correspondingly, so that the floor material can be prevented from warping after construction without losing dimensional stability.

  The nonwoven fabric may be one in which the fibers are intertwined randomly, or may be one in which the fibers are bonded with a certain degree of regularity. Examples of the nonwoven fabric in which the fibers are bonded with a certain degree of regularity include, for example, a first layer of a plurality of long fibers arranged in approximately one direction, and a plurality of elements arranged in approximately the other direction (a direction orthogonal to the one direction). Examples thereof include a nonwoven fabric in which second layers of long fibers are alternately stacked on top and bottom and the intersections of the fibers of the first layer and the second layer are combined.

The thickness of the base material layer is not particularly limited, but is preferably 0.1 mm to 0.5 mm, more preferably 0.2 mm to 0.4 mm, and further preferably 0.25 mm to 0.35 mm. . If the base material layer is too thin, the plasticizer contained in the back surface layer may penetrate the base material layer and may not effectively prevent the plasticizer from bleeding from the lower surface of the flooring (the lower surface of the base material layer). . On the other hand, if the substrate layer is too thick, the substrate layer may not be sufficiently impregnated with the resin of the back surface layer.
Non-woven fabric of basis weight is not particularly limited, it is preferably ^{30g / m 2 ~50g / m 2} . If the basis weight is less than 30 g / m ² , the plasticizer may not be sufficiently prevented from bleeding. On the other hand, if it exceeds 50 g / m ² , the base material layer may be destroyed when the flooring is peeled off from the base surface, and may remain on the base surface.

[Back layer]
A back surface layer is a layer laminated | stacked on the upper surface side of a base material layer, Comprising: It is a layer which couple | bonds a base material layer and a surface layer.
The back layer includes a resin as a main component. The resin is not particularly limited as long as it can be impregnated into the base material layer, and a conventionally known resin can be used, and a thermoplastic resin is generally used.

Examples of the thermoplastic resin include: vinyl chloride resin; olefin resin; vinyl acetate resin such as ethylene-vinyl acetate copolymer; acrylic resin such as ethylene-methacrylate resin; amide resin; ester resin; Examples include various elastomers such as elastomers and various elastomers such as styrene-based elastomers; rubbers and the like.
A vinyl chloride resin is preferable from the viewpoint of excellent flexibility. A flooring material having a back layer mainly composed of a vinyl chloride resin has excellent flexibility, and thus has a good walking feeling and can be easily peeled off from the base surface while being curved. In addition, vinyl chloride resin is inexpensive, and when it is used, flooring can be easily manufactured.

The back layer may be non-foamed or foamed. The back layer is preferably formed from a foamed resin from the viewpoint that a good cushioning property can be imparted to the flooring.
When the back layer is a foamed resin, the expansion ratio is not particularly limited, but is preferably 2 to 5 times. If the expansion ratio is too low, the flooring material cannot be substantially cushioned. On the other hand, if the expansion ratio is too high, there is a risk of breaking at the interface between the back layer and the base material layer when the flooring is peeled off. When the substrate breaks at the interface, the base material layer remains on the base surface.

The back layer usually contains various additives in addition to the above resin.
As the additive, conventionally known additives can be used, and examples thereof include a filler, a plasticizer, a flame retardant, a stabilizer, an antioxidant, a lubricant, a colorant, and a foaming agent.

The filler is not particularly limited, and examples thereof include calcium carbonate, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica.
The plasticizer is not particularly limited, and examples thereof include dioctyl phthalate (DOP), dibutyl phthalate (DBP), and butyl octyl phthalate (BOP).
Although content of a filler is not specifically limited, Usually, they are 75 mass parts-105 mass parts with respect to 100 mass parts of resin.
If the content of the filler is too large, the weight of the flooring becomes heavy and the back surface layer becomes relatively hard, so that it may be difficult to peel off the flooring while curving the flooring. On the other hand, if the content of the filler is too small, the amount of resin and other additives used is relatively increased, which is disadvantageous in terms of cost.
Moreover, although content of a plasticizer is not specifically limited, Usually, it is 20 mass parts-100 mass parts with respect to 100 mass parts of resin, Preferably it is 30 mass parts-80 mass parts. When the content of the plasticizer is too large, the back surface layer becomes too soft and causes a decrease in strength, and the plasticizer becomes easy to bleed. On the other hand, when there are too few plasticizers, a back surface layer will become hard.

  Although the thickness of a back surface layer is not specifically limited, Preferably it is 0.35 mm-0.75 mm, More preferably, it is 0.45 mm-0.65 mm, More preferably, it is 0.5 mm-0.6 mm. If the back layer is too thin, there is a risk of breaking between the base material layer and the surface layer when the flooring is peeled off. On the other hand, when the back surface layer is too thick, the flexibility of the flooring material is lowered, and it may be difficult to bend the flooring material when the flooring material is peeled off.

[Surface layer and shape stabilization layer]
The surface layer is a layer laminated on the upper surface side of the back surface layer and is a layer constituting the upper surface of the flooring.
The surface layer has a layer containing a resin as a main component. For example, the surface layer has at least one layer selected from three layers of a design layer, a transparent layer, and a surface protective layer.

(Design layer)
The design layer is a layer that imparts design properties to the flooring.
The design layer can be formed of a thermoplastic resin. Examples of the thermoplastic resin include those exemplified in the column of the back layer, and a vinyl chloride resin is preferably used.
The design layer may be formed from a thermoplastic resin layer in which a colorant is mixed, or formed from a thermoplastic resin layer in which a colorant and a resin chip exhibiting a color other than the color of the colorant are mixed. May be.
In addition, the design layer may be formed by printing directly on the upper surface of the thermoplastic resin layer or by laminating a printed resin film, or may be formed only from the printed resin film. May be.
Although the thickness of a design layer is not specifically limited, Preferably it is 0.35 mm-1.0 mm, More preferably, it is 0.45 mm-0.80 mm, More preferably, it is 0.5 mm-0.6 mm.

(Transparent layer)
The transparent layer is a layer for protecting the design layer while making the design represented in the design layer visible from the surface of the flooring.
The transparent layer is formed of a thermoplastic resin. Examples of the thermoplastic resin include those exemplified in the column of the back layer, and a vinyl chloride resin is preferably used. Although the thickness of a transparent layer is not specifically limited, Preferably it is 0.05 mm-0.30 mm, More preferably, it is 0.1 mm-0.2 mm.

(Surface protective layer)
The surface protective layer is located on the uppermost surface of the flooring and is a layer that further improves the durability of the upper surface of the flooring.
The surface protective layer is not particularly limited as long as it can stably adhere to other layers, and can be formed from the thermoplastic resin exemplified above. The surface protective layer may be, for example, unsaturated polyesters such as unsaturated dicarboxylic acid and polyhydric alcohol condensates; methacrylates such as polyester methacrylate, polyether methacrylate, polyol methacrylate, melamine methacrylate; polyester acrylate, epoxy acrylate, It may be formed from an ultraviolet curable resin such as urethane acrylate, polyether acrylate, polyol acrylate, acrylate such as melamine acrylate; The surface protective layer is preferably formed of an ultraviolet curable resin because it can be more stably adhered to other layers and a strong film can be formed.

  Although the thickness of a surface protective layer is not specifically limited, Preferably it is 0.005 mm-0.040 mm. Moreover, it is more preferable that it is 0.01-0.03 mm, and it is further more preferable that it is 0.015-0.025 mm.

(Shape stabilization layer)
The shape stabilizing layer is a layer for suppressing a dimensional change of the flooring due to shrinkage or expansion over time. The shape stabilizing layer is preferably provided between the back surface layer and the surface layer. By providing the shape stabilizing layer at this position, it is possible to improve the dimensional stability of the flooring and prevent warping of the end of the flooring.

  As the shape stabilizing layer, a nonwoven fabric or a woven fabric can be used. The material of the fibers constituting the nonwoven fabric and the woven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; natural fibers and the like. Since the dimensional stability of the flooring can be increased, the dimensional fluctuation is extremely small compared to organic fibers, and the compatibility with the resin is good. Therefore, it is preferable to use a glass fiber nonwoven fabric as the shape stabilizing layer. Further, when a glass fiber nonwoven fabric is used as the shape stabilizing layer and a nonwoven fabric made of polyester fiber is used as the base material layer, the glass fiber nonwoven fabric greatly contributes to the dimensional stability of the entire flooring and the polyester fiber nonwoven fabric warps the surface layer. Therefore, it is possible to obtain a stable flooring that does not cause warping after construction without losing dimensional stability.

  Although the thickness of a shape stabilization layer is not specifically limited, Preferably it is 0.1 mm-0.5 mm, More preferably, it is 0.2 mm-0.4 mm, More preferably, it is 0.25 mm-0.35 mm. . If the shape stabilizing layer is too thin, the dimensional stability of the flooring material will not be sufficiently improved. On the other hand, if the shape stabilizing layer is too thick, there is a risk of breaking the layer when the flooring material is peeled off. .

[Method for producing flooring of the present invention]
The flooring of the present invention can be produced, for example, through the following steps.
(Process A)
Step A is a step of laminating a base material layer containing fibers on one surface of the film of the back surface layer forming resin paste.
The resin paste for forming the back surface layer is made of, for example, a thermoplastic resin and an additive as described in the column of the back surface layer.
By applying this resin paste onto an appropriate development substrate (including a development film), a film of the back layer forming resin paste is formed.
When the flooring has the shape stabilizing layer, the resin paste is applied directly on the shape stabilizing layer, so that the resin paste film for forming the back layer can be formed on the shape stabilizing layer. Good.

The base material layer is placed on one surface of the film.
The film of the resin paste for forming the back surface layer on which the base material layer is laminated preferably has a viscosity of 8 Pa · s to 10 Pa · s. Such a resin pace is easily impregnated between the fibers of the base material layer.
The viscosity can be measured at 20 ° C. using a viscometer manufactured by Rion Co., Ltd. (trade name “Bisco Tester”).

(Process B)
Step B is a step of impregnating the base material layer with the resin paste for forming the back surface layer by the weight of the base material layer or by applying a load to the base material layer.
The base material layer placed on one surface of the resin paste film sinks into the resin paste by its own weight. Due to the weight of the base material layer and the fluidity of the resin paste, when the substrate layer is not sufficiently submerged by its own weight, the non-mounting surface of the base material layer (the surface placed on the resin paste film) Apply the load from the opposite side. For example, a load can be applied while pressing a base material layer by rolling a rubber roller on the non-mounting surface of the base material layer.
When the resin paste oozes out on the non-mounting surface of the base material layer, the process proceeds to the next step.

(Process C)
Step C is a step of pre-gelating the back surface layer forming resin paste.
When the resin paste for forming the back layer is a vinyl chloride resin paste, it can be pregelled by heating. Although a heating means is not specifically limited, For example, an electric heater etc. are mentioned.
The heating temperature is appropriately set according to the resin paste. In the case of a vinyl chloride resin paste, it is preferably 135 ° C to 155 ° C, more preferably 140 ° C to 150 ° C. If the heating temperature is too low, pre-gelation is not sufficiently performed and there is a risk of damage in the next step. If the heating temperature is too high, the surface of the resin paste film may be completely cured, and the surface layer may not be integrally laminated and bonded in the next step.

  The heating time is appropriately set according to the resin paste. In the case of a vinyl chloride resin paste, it is preferably 50 seconds to 65 seconds, and more preferably 55 seconds to 60 seconds. If the heating time is too short, the pregelling is not sufficiently performed and may be damaged in the next step. If the heating time is too long, the surface of the resin paste film may be completely cured.

[Step D]
Step D is a step of applying a resin paste for forming a surface layer to the opposite surface of the pregelled resin paste film.
After pregelling in the process C, the upper and lower surfaces of the film of the resin paste for forming the back surface layer impregnated with the base material layer are reversed.
When the film of the resin paste for forming the back layer is applied on the development substrate, after peeling this film from the development substrate, the upper and lower surfaces of this film are reversed (or after the reversal, the development substrate) ).
When the film of the resin paste for forming the back surface layer is applied on the shape stabilizing layer, the upper and lower surfaces are inverted as they are.

  A resin paste for surface layer formation (a resin composition for forming a design layer, a resin composition for forming a transparent layer and / or a surface protective layer) is formed on the opposite surface of the resin paste film (or on the shape stabilization layer on the opposite surface). A resin composition for forming) is applied.

[Step E]
Step E is a step of curing the back surface layer forming resin paste and the front surface layer forming resin paste.
When the back surface layer forming resin paste and the front surface layer forming resin paste are vinyl chloride resin pastes, they can be cured by heating. Although a heating means is not specifically limited, For example, a gas heater etc. are mentioned.
The heating temperature is appropriately set according to the resin paste. When it is a vinyl chloride resin paste, it is preferably 198 ° C to 205 ° C, more preferably 199 ° C to 204 ° C. If the heating temperature is too low, the resin will not be cured sufficiently, while if the heating temperature is too high, the resin paste will be too hard and the flooring may be too hard.

  The heating time is appropriately set according to the resin paste. In the case of a vinyl chloride resin paste, it is preferably 2 minutes 40 seconds to 3 minutes 10 seconds, and more preferably 2 minutes 45 seconds to 3 minutes 5 seconds. If the heating time is too short, the resin will not be cured sufficiently, while if the heating time is too long, the resin paste will be cured too much and the flooring material may become too hard.

In addition, when the said resin composition for surface protection layer formation is an ultraviolet curable resin, an ultraviolet-ray is further irradiated.
According to the production method of the present invention, the gap between the base material layers can be impregnated by laminating the base material layer on the film of the back surface layer forming resin paste, and by curing the resin paste, A flooring having a fiber exposed portion and a resin exposed portion on the lower surface can be obtained. Thus, according to the manufacturing method of the present invention, the floor material having the above-mentioned layer structure can be manufactured easily and reliably.

  Examples of the present invention and comparative examples are shown below. However, the present invention is not limited to the following examples.

[Materials Used in Examples and Comparative Examples]
(Resin paste for backside layer formation)
100 parts by mass of vinyl chloride resin paste (vinyl chloride paste having an average degree of polymerization of 2000: vinyl chloride paste having an average degree of polymerization of 950 = 9: 5 (mass ratio)), 96 parts by mass of filler (calcium carbonate), and 60 parts by mass A plasticizer (DOP), 0.4 part by mass of a Pb stabilizer and 0.9 part by mass of a pigment were kneaded.
The viscosity of the resin paste for forming the back surface layer at 20 ° C. was 8 Pa · s.
This viscosity was measured using a viscometer manufactured by Rion Co., Ltd. (trade name “Bisco Tester”).

(Design layer forming resin composition)
100 parts by mass of vinyl chloride resin paste (vinyl chloride paste having an average degree of polymerization of 2000: vinyl chloride paste having an average degree of polymerization of 950 = 48: 25 (mass ratio)), 200 parts by mass of filler (calcium carbonate), and 85 parts by mass A kneaded plasticizer (DOP) and 7.8 parts by mass of a prepared masterbatch (Pb stabilizer: pigment = 3: 68 (mass ratio)) were used.

(Print film)
A vinyl chloride film having a thickness of about 0.13 mm printed with a wood grain pattern was used.

(Transparent layer forming resin composition)
100 parts by mass of vinyl chloride resin paste (vinyl chloride paste having an average degree of polymerization of 2000: vinyl chloride paste having an average degree of polymerization of 950 = 20: 13 (mass ratio)), 50 parts by mass of a plasticizer (DOP), and 3.3 parts by mass What knead | mixed the Ba-Zn type stabilizer of a part was used.

(Resin composition for forming a surface protective layer)
A urethane resin UV curable resin was used.

(Base material layer)
A polyester-based non-woven fabric (spunbond non-woven fabric, basis weight 40 g / m ^2, thickness about 0.3 mm) was used.

(Shape stabilization layer)
A glass fiber nonwoven fabric (weight per unit area 53 g / m ^2, thickness about 0.3 mm) was used.

[Example 1]
A film of the back surface layer forming resin paste was formed by applying a back surface layer forming resin paste on the shape stabilizing layer. A base material layer was placed on this film. The substrate layer was pressed with a stainless steel roller (load: about 4 kgf / m ² ). When it was confirmed that the resin paste had slightly exuded from the non-mounting surface of the base material layer, the pressing was stopped.
Next, the resin paste was pregelled by heating the laminate with a ceramic heater at 160 ° C. for 1 minute.

After reversing the upper and lower surfaces of the pre-gelled laminate, a design layer forming resin composition was applied on the shape stabilizing layer. Further, a printing film was placed on the film.
On this printed film, the resin composition for forming a transparent layer was applied.
Next, this laminate was heated at 200 ° C. for 3 minutes using a gas heater, thereby curing the back surface layer forming resin paste, the design layer forming resin composition, and the transparent layer forming resin composition.
Thus, in order from the bottom, the base material layer, the back surface layer having a thickness of about 0.55 mm, the design layer (including the printed film) having a thickness of about 0.68 ± 0.13 mm, and the thickness of about 0.15 ± 0.05 mm The laminated body on which the transparent layer was laminated | stacked was obtained.

Next, a resin composition for forming a surface protective layer was applied on the transparent layer. Using three ultraviolet lamps (mercury lamps (model number: HI40N, HI50N, HI180N)), the surface protective layer is irradiated with ultraviolet rays under the conditions of a peak irradiation intensity of 130 mJ / cm ² and an integrated amount of 795 mW / cm ^2. A surface protective layer (thickness: about 0.02 ± 0.01 mm) was formed on the transparent layer by curing the forming resin composition.
The thickness of the flooring material obtained in Example 1 was 2 mm. Each thickness was measured using a microscope measuring instrument manufactured by Keyence Corporation.
The flooring was punched out to a length of 900 mm and a width of 150 mm using a cutting device.

The floor material of Example 1 had a longitudinal stiffness at 20 ° C. of 57.9 kgf / cm ² and a lateral stiffness of 46.3 kgf / cm ² .
The floor material of Example 1 had a longitudinal rigidity at 5 ° C. of 115.7 kgf / cm ² and a lateral rigidity of 92.6 kgf / cm ² .

Each rigidity was measured according to JIS K7106. Specifically, with an Olsen-type stiffness tester, the distance between supporting points is 4 cm, the sample width is 2.5 cm, the load is 2.0 kg, the load scale reading angle is 6 degrees, the predetermined temperature (5 ° C. or 20 ° C.), and the humidity is 50%. Under the conditions, the load scale was measured. By substituting the result into the following equation, the rigidity of a flooring material having a thickness of 2 mm was calculated.
Formula: E = {(4 × S) / (W × d ³ )} × {(M × reading of load scale) / (100 × φ)} × C
However, E represents rigidity (kgf / cm < ² >), S represents the distance (cm) between fulcrums, W represents the sample width (cm), d represents the thickness (cm) of a sample. , M represents a load (kgf), C represents a constant (C = 2 in the case of vinyl chloride), and φ represents a load scale reading angle (rad).

[Example 2]
Except that the transparent layer and the surface protective layer were not formed (except that the transparent layer forming resin composition and the surface protective layer forming resin composition were not applied), in the same manner as in Example 1, A flooring was prepared. The thickness of the flooring material obtained in Example 2 was 1.83 mm.

The floor material of Example 2 had a longitudinal rigidity at 20 ° C. of 38.0 kgf / cm ² and a lateral rigidity of 26.1 kgf / cm ² .
The floor material of Example 2 had a longitudinal stiffness at 9 ° C. of 96.3 kgf / cm ² and a lateral stiffness of 71.8 kgf / cm ² .

[Example 3]
A flooring was produced in the same manner as in Example 1 except that the surface protective layer was not formed (except that the surface protective layer-forming resin composition was not applied). The thickness of the flooring material obtained in Example 3 was 1.98 mm.

Stiffness in the longitudinal direction at 20 ° C. floor material of Example 3 is 48.0kgf / cm ^2, the rigidity of the lateral was 36.0kgf / cm ^2.
The flooring material of Example 3 had a longitudinal stiffness at 5 ° C. of 105.5 kgf / cm ² and a lateral stiffness of 82.1 kgf / cm ² .

[Comparative Example 1]
A flooring was produced in the same manner as in Example 1 except that the base material layer was not provided. The thickness of the floor material of Comparative Example 1 obtained was 1.7 mm.

The longitudinal stiffness of the flooring of Comparative Example 1 at 20 ° C. was 18.9 kgf / cm ² , and the lateral stiffness was 14.3 kgf / cm ² .
The floor material of Comparative Example 1 had a longitudinal rigidity at 5 ° C. of 59.5 kgf / cm ² and a lateral rigidity of 49.8 kgf / cm ² .

[Comparative Example 2]
A flooring was produced in the same manner as in Example 1 except that the base material layer was not impregnated with the back surface layer forming resin paste.
Specifically, the back layer forming resin paste was applied on the shape stabilizing layer in the same manner as in Example 1 to form a back layer forming resin paste film. The film was heated at 200 ° C. for 3 minutes using a gas heater to cure the resin paste for forming the back layer and form the back layer. A base material layer was bonded onto the back layer via an adhesive.
After reversing the upper and lower surfaces of this laminate, in the same manner as in Example 1, a design layer, a transparent layer and a surface protective layer were formed thereon.
The thickness of the floor material of Comparative Example 2 obtained was 2.2 mm.

The floor material of Comparative Example 2 had a longitudinal rigidity at 20 ° C. of 58.0 kgf / cm ² and a lateral rigidity of 45.8 kgf / cm ² .
The vertical stiffness of the flooring of Comparative Example 2 at 5 ° C. was 114.9 kgf / cm ² , and the lateral stiffness was 93.5 kgf / cm ² .

[Confirmation of adhesiveness and destruction of substrate layer]
A slate plate (manufactured by Nippon Test Panel Co., Ltd.) having a smooth surface was prepared as the lower ground. An acrylic resin emulsion adhesive (trade name “Eco GA Cement” manufactured by Toli Co., Ltd.) was applied to the surface of this slate plate at an application amount of 110 g / m ² . On this adhesive, the floor materials of Examples 1 to 3 and Comparative Examples 1 and 2 punched out to 900 mm in length and 150 mm in width were laid. After laying, it was left for 24 hours.
Next, each flooring was peeled off from the ground surface by picking the side edge of each flooring by hand and pulling it upward.
However, the flooring that could not be peeled off by hand was peeled off from the ground surface by turning the side edge upward using a cutter and pulling upward while inserting a metal spatula into that part.
The adhesive on the lower ground after being peeled off was observed visually and with tentacles to confirm the adhesiveness of the flooring. Moreover, the lower ground after peeling was observed visually and with a tentacle, and the presence or absence of adhesion of the base material layer was confirmed. The results are shown in Table 1.

In addition, the column of the adhesiveness of Table 1 and the destruction of a base material layer represents the following matter.
A1: The adhesive on the base surface was hardened to such an extent that it could exert adhesive force.
B1: The adhesive on the base surface was in a liquid state (not solidified) and did not exhibit adhesive strength.
A2: The base material layer did not remain on the base surface.
B2: Many broken base material layers adhered on the base surface.

[Confirmation of easy peeling]
Nine pieces of each of the flooring materials of Examples 1 to 3 and Comparative Examples 1 to 2 punched out to 900 mm in length and 150 mm in width were prepared. An acrylic resin emulsion adhesive (trade name “Eco GA Cement” manufactured by Toli Co., Ltd.) is applied at an application amount of 110 g / m ² so that the nine flooring materials are vertical × horizontal = 3 × 3. Each was laid on the applied water-absorbing substrate surface. The side edge part of the flooring laid in the center part was picked, this flooring was peeled off by hand, and it was confirmed whether it can peel easily.
However, the flooring that could not be peeled off by hand was peeled off using a metal spatula as described above.
The results are shown in Table 1. In addition, the column of ease of peeling in Table 1 represents the following matters.
A3: It was easily peeled by hand.
B3: Could not be peeled by hand.

[Evaluation]
The flooring materials of Examples 1 to 3 did not hinder the adhesive force of the adhesive, could be easily peeled off, and did not break the base material layer when peeled off.
Since the flooring of Comparative Example 1 did not have a base material layer, the adhesive did not exhibit adhesive strength even after curing for 24 hours. In addition, the flooring of Comparative Example 1 that was not adhered to the base surface could be easily peeled off at the interface between the base material layer and the adhesive.
Moreover, since the flooring of the comparative example 2 has a base material layer, the adhesive force of the adhesive was not inhibited. However, since the flooring material of Comparative Example 2 was not impregnated with resin in the base material layer, it could not be easily peeled off and the base material layer was destroyed.

  The flooring of the present invention is used by laying it on the lower ground of ordinary houses, apartments, office buildings and the like.

  DESCRIPTION OF SYMBOLS 1 ... Flooring material, 2 ... Base material layer, 2a ... The part from which some fiber was exposed, 2b ... The part to which resin was exposed, 3 ... Back surface layer, 4 ... Surface layer, 41 ... Design layer, 42 ... Transparent layer, 43 ... Surface protective layer, 5 ... Shape stabilization layer

Claims (4)

It is a punched sheet,
In order from the bottom, a base material layer containing fibers, a back surface layer formed from a vinyl chloride resin, and a surface layer are laminated,
The base material layer is impregnated with the vinyl chloride resin forming the back layer,
On the lower surface of the base material layer, a portion of the fiber located on the lowermost surface side of the base material layer and a portion of the fiber located on the lowermost surface side of the base material layer are covered with a vinyl chloride resin. Floor material characterized by scattered parts.   The flooring according to claim 1, wherein the base material layer is a nonwoven fabric. The flooring according to claim ² , wherein the basis weight of the nonwoven fabric is 30 g / m ^{2 to} 50 g / m ² .   It has the flooring as described in any one of Claims 1 thru | or 3, an adhesive agent, and a base surface, The said floor material is adhere | attached on the said base surface so that peeling is possible through the said adhesive agent. A floor material peeling method comprising: peeling off the floor material in a floor surface structure from the base surface at an interface between a lower surface and a base surface of the base material layer.

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