JP2017020248A - Manufacturing method of floor material and floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a floor material capable of easily joining an upper side resin layer and a lower side resin layer to a glass sheet.SOLUTION: A manufacturing method of a floor material of the present invention comprises a process of preparing a glass sheet 6M with resin having a glass sheet 4M including a plurality of glass fibers and a joining resin 5M stuck to the glass sheet 4M, that is, the glass sheet 6M with the resin being 320 g/mor more in a basis weight of the joining resin, and a process of integrating an upper side resin layer 2M, the glass sheet 4M and a lower side resin layer 6M by heating-pressurizing, by laminating the upper side resin layer 2M on an upper surface of the glass sheet 6M with the resin and laminating the lower side resin layer 3M on an undersurface of the glass sheet 6M with the resin.SELECTED DRAWING: Figure 14

Description

  The present invention relates to a method for producing a flooring material having a glass sheet as a reinforcing layer, and the flooring material.

Conventionally, a flooring in which a glass sheet containing glass fibers as a reinforcing layer is embedded in an intermediate portion in the thickness direction of a synthetic resin layer is known (Patent Document 1).
Such a flooring can be obtained by laminating resin layers on the upper and lower surfaces of the glass sheet, passing the laminated body between hot rolls and heating under pressure, and integrating the layers.
However, since the glass sheet containing a resin layer and glass fiber is difficult to join, it is necessary to prevent peeling between the resin layer and the glass sheet.
In particular, when the resin layer is made of a suspension vinyl chloride resin, the bondability to the glass sheet is poor, and the resin layer may be separated up and down with the glass sheet as a boundary.

Japanese Patent No. 5634987

  The objective of this invention is providing the manufacturing method and flooring of a flooring which can join an upper resin layer and a lower resin layer to a glass sheet easily.

The flooring manufacturing method of the present invention is a glass sheet with a resin having a glass sheet containing a plurality of glass fibers and a bonding resin attached to the glass sheet, and the basis weight of the bonding resin is 320 g / m ^2. The step of preparing a glass sheet with resin as described above, an upper resin layer is laminated on the upper surface of the glass sheet with resin, a lower resin layer is laminated on the lower surface of the glass sheet with resin, and the upper resin layer is heated and pressed. And integrating the glass sheet and the lower resin layer.

In a preferred method for producing a flooring material of the present invention, the basis weight of the bonding resin of the glass sheet with resin is 630 g / m ² or less.
In a preferred method for producing a flooring material according to the present invention, the bonding resin includes a paste vinyl chloride resin, and at least one of the upper resin layer and the lower resin layer includes a suspension vinyl chloride resin.

According to another aspect of the present invention, a flooring is provided.
The flooring of the present invention comprises an upper resin layer, a lower resin layer, and a glass sheet laminated between the upper resin layer and the lower resin layer, the glass sheet including a plurality of glass fibers. And a bonding resin is adhered to the glass sheet, and the upper resin layer and the lower resin layer are bonded via the bonding resin.

  According to the manufacturing method of the present invention, a glass sheet, an upper resin layer, and a lower side are formed by laminating an upper resin layer and a lower resin layer on a glass sheet to which a predetermined amount of bonding resin is attached and heating and pressing. It is possible to easily join the resin layer and obtain a flooring material having excellent interlayer strength.

The top view of the flooring which concerns on 1st Embodiment of this invention. The expanded sectional view which cut | disconnected the flooring with the II-II line | wire of FIG. FIG. 3 is a reference cross-sectional view in which a part of FIG. 2 is further enlarged, and is a reference cross-sectional view schematically showing a first example of a bonding state between a bonding resin and an upper resin layer and a lower resin layer. FIG. 3 is a reference cross-sectional view further enlarging a part of FIG. 2, schematically showing a second example of the joined state. FIG. 3 is a reference cross-sectional view in which a part of FIG. 2 is further enlarged, and is a reference cross-sectional view schematically showing a third example of the joined state. The expanded sectional view of the flooring concerning a 2nd embodiment (cutting in the same portion as the II-II line of Drawing 1). The expanded sectional view of the flooring concerning a 3rd embodiment (cutting in the same portion as the II-II line of Drawing 1). The expanded sectional view of the flooring concerning a 4th embodiment (cutting in the same portion as the II-II line of Drawing 1). The expanded sectional view of the flooring concerning a 5th embodiment (cutting in the same portion as the II-II line of Drawing 1). The top view of a glass nonwoven fabric. The expanded reference sectional view cut | disconnected by the XI-XI line of FIG. The top view of a glass woven fabric. The expanded reference sectional view cut | disconnected by the XIII-XIII line of FIG. The schematic side view of each process in the manufacturing method of the flooring which concerns on 1st Embodiment of this invention. The schematic side view of each process in the manufacturing method of the flooring which concerns on 2nd Embodiment of this invention.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In this specification, the “upper surface” or “upper” of a layer refers to the surface or direction far from the floor surface on which the flooring is laid, and the “lower surface” or “lower” refers to the opposite side (the flooring The surface or direction on the side near the floor to be laid.
In the present specification, a numerical range represented by “to” means a numerical range including numerical values before and after “to” as a lower limit value and an upper limit value.
In addition, it should be noted that dimensions such as thickness and size in each drawing are different from actual ones.

[Laminated structure of flooring]
FIG. 1 is a plan view of the flooring material of the first embodiment, FIG. 2 is an enlarged cross-sectional view of the flooring material, and FIGS. 3 to 5 show a glass sheet and an upper resin layer with a bonding resin interposed therebetween. It is the further expanded reference sectional view which represented typically the joined state with a lower resin layer. 3 to 5 show various examples in which the modes of the bonding resin are different.
As shown in FIG. 1, the flooring 1 is formed in a long band shape in plan view. In the present specification, the long band shape is a rectangular shape in which the length in one direction is sufficiently longer than the length in the other direction (the other direction is perpendicular to the one direction). Is at least twice as long as the length in the other direction, preferably at least four times. The long belt-like flooring 1 is usually wound around a roll and stored and transported, and is cut into a desired shape and used at a construction site. But the flooring 1 of this invention is not restricted to a elongate strip | belt-shaped sheet | seat, The tile formed in sheet shape, such as planar view square shape, may be sufficient (not shown).

The long belt-like flooring 1 is formed to have a predetermined length such as a width of 800 mm to 4000 mm, for example, and the length is, for example, 2 m to 300 m. For example, the floor material formed in a sheet form has a length and width of 100 mm to 4000 mm, respectively. The sheet-like flooring is generally a square in plan view with a side length of 50 cm, but may be a rectangular shape of 10 cm in length and 90 cm in width, a hexagonal shape, and the size and shape are not particularly limited. .
The top surface of the flooring 1 may be embossed (not shown) as needed to give a concavo-convex pattern. Moreover, the embossing may be given to the lower surface of the flooring 1 or the upper surface and lower surface of the flooring 1 as needed.

As shown in FIGS. 1 to 5, the flooring 1 of the present invention includes an upper resin layer 2, a glass sheet 4 including fibers 41, a bonding resin 5 attached to the glass sheet 4, and a lower resin layer. 3. Hereinafter, the glass sheet to which the bonding resin is attached is referred to as a glass sheet 6 with resin. If necessary, the flooring 1 may further include at least one layer selected from a scratch-preventing layer 71, a protective layer 72, a decorative layer 73, a base material layer 74, and the like.
Although the thickness of the flooring 1 of this invention is not specifically limited, For example, it is 1 mm-5 mm, Preferably it is 1.5 mm-3.5 mm.
Specifically, the flooring 1 of the first embodiment shown in FIG. 1 to FIG. 5 is, in order from the top, a scratch prevention layer 71, a protective layer 72, a decorative layer 73, an upper resin layer 2, and a glass sheet 6 with resin. , A laminate composed of the lower resin layer 3 and the base material layer 74. These layers are joined and integrated.

6 thru | or FIG. 9 is sectional drawing of the flooring 1 of 2nd thru | or 5th embodiment. The plan view of the flooring material 1 of the second to fifth embodiments is omitted because it is the same as that of FIG. 1, and the flooring material 1 of the second to fifth embodiments is also omitted with the glass sheet 4 through the bonding resin 5. The bonding state between the upper resin layer 2 and the lower resin layer 3 is the same as that in FIG.
The floor material 1 of 2nd Embodiment shown in FIG. 6 is the damage prevention layer 71, the protective layer 72, the upper resin layer 2 which has the designability, the glass sheet 6 with a resin, the lower resin layer 3, and base | substrate sequentially from an upper side. It is a laminate composed of a material layer 74. These layers are joined and integrated. In addition, in 2nd Embodiment, the flooring 1 which does not have the base material layer 74 may be sufficient.
The flooring material 1 of 3rd Embodiment shown in FIG. 7 is a protective layer 72, the decorative layer 73, the upper side resin layer 2, the glass sheet 6 with resin, the lower side resin layer 3, the base material layer 74, and a backing layer in order from the upper side. A laminate composed of 75. These layers are joined and integrated. Examples of the backing layer 75 include an adsorption layer such as rubber, felt, and a foamed acrylic resin layer.
The flooring 1 of 4th Embodiment shown in FIG. 8 is a laminated body which consists of the protective layer 72, the decorative layer 73, the upper side resin layer 2, the glass sheet 6 with resin, and the lower side resin layer 3 in an order from the upper side. These layers are joined and integrated.
The flooring 1 of the fifth embodiment shown in FIG. 9 is a laminate composed of a protective layer 72, an upper resin layer 2 having design properties, a glass sheet 6 with resin, a lower resin layer 3, and a base material layer 74 in order from the upper side. Is the body. These layers are joined and integrated.

  In each embodiment, the glass sheet 6 with a resin is substantially in the middle of the resin layer composed of the upper resin layer 2 and the lower resin layer 3 by making the thicknesses of the upper resin layer 2 and the lower resin layer 3 substantially the same. Or may be arranged in a portion, or by making the thicknesses of the upper resin layer 2 and the lower resin layer 3 different from each other, rather than a substantially middle portion of the resin layer composed of the upper resin layer 2 and the lower resin layer 3. It may be arranged so as to be biased downward or upward.

In the flooring 1, the flooring 1 with a small warp can be configured by disposing the glass sheet 4 substantially in the middle of the thickness of the flooring 1.
And the joining resin 5 of the glass sheet 6 with a resin laminated | stacked between the upper side resin layer 2 and the lower side resin layer 3 is joined to each of the upper side resin layer 2 and the lower side resin layer 3, and those layers 2 are joined. , 3 to form a resin layer on the upper and lower sides of the glass sheet 4. For this reason, about the glass sheet 6 with resin, by adjusting the thickness of each of the upper bonding resin layer and the lower bonding resin layer, which will be described later, the flooring 1 in which the glass sheet 4 is arranged at a substantially middle portion of the thickness is easily configured. it can.
It should be noted that the glass sheet 4 is disposed at a substantially middle portion of the thickness of the flooring 1 within the range of the thickness of the flooring 1 x 0.35 to the thickness of the flooring 1 x 0.65. The intermediate part of the thickness is said to extend, and preferably, the intermediate part of the thickness of the glass sheet 4 is within the range of the thickness of the flooring material 1 × 0.4 to the thickness of the flooring material 1 × 0.6. It means being extended.
In addition, although not shown, any other layer may be omitted from the flooring 1 of the first to fifth embodiments, or any appropriate layer may be added as a component of the flooring 1. May be.

  In the flooring 1 of each embodiment, the glass sheet 4 uses a glass nonwoven fabric or a glass woven fabric including a plurality of glass fibers. The said glass sheet 4 may be comprised only from the glass fiber, and the fiber component may contain other fibers other than a glass fiber. Examples of the other fibers include natural fibers such as pulp, synthetic resin fibers, and metal fibers. Preferably, natural fibers such as pulp are included as the other fibers. Since natural fibers such as pulp are lighter than glass fibers, the glass sheet containing the natural fibers can reduce the air permeability with a smaller basis weight than a glass sheet made of only glass fibers. Moreover, since natural fibers such as pulp are relatively soft, there is no risk of damaging processing equipment, and the material cost is relatively low. When the glass sheet contains other fibers, the amount is more than 0 and 60% by mass or less, preferably 15% by mass to 50% by mass, when the entire fiber component is 100% by mass. If the proportion of glass fiber is relatively small, the dimensional stability deteriorates.

As shown in FIGS. 10 and 11, the glass nonwoven fabric 4 a has a plurality of fibers 41 including glass fibers that are randomly stacked or entangled in the vertical direction and are bound by a binder such as an adhesive or are bound themselves. Layered together, or although not particularly illustrated, the plurality of fibers 41 overlap or entangle with a certain degree of regularity and are bound by a binder such as an adhesive or themselves Are bound together and layered.
As the binder, those having high bondability to the fibers 41 are preferable, and those having high bondability to the fibers 41 and the bonding resin 5 are more preferable. As such a binder, an adhesive mainly composed of a known resin can be used. For example, a one-component adhesive, a two-component adhesive, a thermosetting adhesive, a hot-melt adhesive, Examples thereof include electron beam curable adhesives such as ultraviolet curable adhesives. Specific examples include one or a mixture of two or more selected from urethane resins, vinyl acetate resins, styrene-butadiene copolymers, acrylic resins, vinyl chloride resins, and epoxy resins.

  The glass nonwoven fabric is, for example, a glass fiber or a fiber mixed with glass fiber and other fibers is formed into a sheet by dispersing the fiber substantially uniformly in water containing a dispersant, a thickener, and the like, and making the paper. It can be obtained by molding and applying or impregnating a binder to the fiber sheet. The coating can be performed by using various coaters such as a roll coater, knife coater, curtain coater, flow coater, spray coater, die coater, etc .; spraying; brush coating; rollers, etc. Etc. The binder is applied or impregnated to a certain thickness, but excess binder is removed by suction with a vacuum knife or the like as necessary. When the amount of the binder per unit area of the glass nonwoven fabric reaches a desired range, the glass nonwoven fabric can be obtained by curing the binder and drying. The amount of the binder can be adjusted by the application or impregnation, suction as required.

As shown in FIGS. 12 and 13, the glass woven fabric 4 b has a layer in which a plurality of fibers 41 are woven with regularity vertically and horizontally, or a plurality of fibers 41 are vertically arranged with regularity vertically and horizontally. They overlap in the direction and are bound by a binder such as an adhesive to form a layer.
In addition, the fiber 41 shows glass fiber, when the glass sheet 4 consists only of glass fiber, and when the glass sheet 4 consists of a mixture of glass fiber and another fiber, those fibers are shown.
A commercial item can also be used as the glass sheet 4.

The glass nonwoven fabric 4a and the glass woven fabric 4b to which the fibers 41 are bound with a certain degree of regularity are oriented in a predetermined direction according to the aligned fibers 41. When the glass sheet 4 having orientation is used, the bonding resin 5 can be relatively uniformly attached, and the fibers 41 are less dropped when the bonding resin 5 is applied.
In addition, in FIG. 3 thru | or FIG. 5, FIG.11 and FIG.13, although 2 or 3 fibers 41 are represented in the state which overlapped in the thickness direction, these figures are reference figures to the last, It should be noted that the glass nonwoven fabric 4a and the glass woven fabric 4b may have more fibers 41 overlapping in the thickness direction.

The glass sheet 4 such as the glass nonwoven fabric 4 a and the glass woven fabric 4 b has innumerable openings A between the fibers 41. Each of the openings A is conceptually formed by continuously connecting gaps between adjacent fibers 41 in the thickness direction of the glass sheet 4. In each of the openings A, the gap between the fibers 41 is continuous substantially in parallel with the thickness direction of the glass sheet 4 and communicates with the upper and lower surfaces of the glass sheet 4 substantially linearly, or the gap between the fibers 41 is the glass sheet 4. The aspect etc. which are connected to the upper and lower surfaces of the glass sheet 4 while being continuously arranged while being inclined, curved, bent, or meandering with respect to the thickness direction are included. The opening of the former aspect is usually an aspect in which things existing on the lower surface side of the glass sheet 4 can be visually recognized when viewed from the upper surface side of the glass sheet 4, and the opening of the latter aspect is Usually, it is an aspect which cannot visually recognize it.
However, you may use the glass sheet which does not have the said opening.

Although the thickness of the glass sheet 4 is not specifically limited, Preferably it is 0.1 mm-0.5 mm, More preferably, it is 0.15 mm-0.4 mm, More preferably, it is 0.20 mm-0.35 mm. Also, the basis weight of the glass sheet 4 is not particularly limited, is preferably from ^{10g / m 2 ~100g / m 2} , more preferably ^{20g / m 2 ~60g / m 2} . If the thickness or basis weight of the glass sheet 4 is too small, the tensile strength and dimensional stability of the flooring 1 cannot be sufficiently improved. On the other hand, if it is too large, the bonding resin 5 is sufficiently within the opening of the glass sheet 4. There is a risk that it does not spread and does not adhere sufficiently to the surface of the fiber 41 in the middle in the thickness direction. Particularly, the glass nonwoven fabric 4a is preferably in the range of the thickness and the basis weight.
The density of the glass sheet 4 is not particularly limited, for ^example, a ^{0.1g / cm 3 ~0.5g / cm 3} .

  Since the glass sheet 4 has an infinite number of openings A, an air passage leading from the upper side to the lower side of the glass sheet 4 or from the upper side to the lower side is secured in the plane of the glass sheet 4. When the opening ratio of the glass sheet 4 is large, the air permeability of the glass sheet 4 is increased. Conversely, when the opening ratio is small, the air permeability of the glass sheet 4 is decreased. In the present invention, in consideration of such points, the aperture ratio is evaluated by measuring the air permeability of the glass sheet 4. The aperture ratio refers to the total opening area occupied per unit area of the upper surface of the glass sheet 4.

Air permeability of the glass sheet 4 having the aperture A is, for example, not more than 350cc ^/ cm 2 · sec exceed zero, preferably ^{30cc / cm 2 · sec~300cc / cm} 2 · sec, more preferably 50cc / Cm ² · sec to 150 cc / cm ² · sec. In order to improve the bondability between the upper resin layer 2 and the lower resin layer 3, it is preferable that the bonding resin 5 easily enters the opening A and is easily held. In this respect, the smaller the air permeability of the glass sheet 4, that is, the opening ratio of the glass sheet 4, the harder the bonding resin 5 enters, and the larger the opening ratio, the harder the bonding resin 5 is held. On the other hand, in order to impart strength, warpage suppression effect, and dimensional change suppression effect by the glass sheet, there is a certain upper limit to the aperture ratio of the glass sheet. From such a viewpoint, the glass sheet 4 preferably has an air permeability in the above range.
In addition, the air permeability of the glass sheet which does not have an opening is zero.
However, in this specification, the air permeability of the glass sheet 4 is measured according to the air permeability test method of JIS L 1096 using a Frazier type air permeability tester manufactured by Toyo Seiki Seisakusho Co., Ltd. It is the value which measured the glass sheet.

In this invention, the glass sheet 6 with resin is comprised by adhering the joining resin 5 to glass sheets 4, such as the said glass nonwoven fabric 4a and the glass woven fabric 4b. It should be noted that the bonding resin 5 is different from the above-described binder constituting the glass nonwoven fabric.
Specifically, as shown in each aspect of FIGS. 3 to 5, the bonding resin 5 is attached to the fibers 41 of the glass sheet 4. However, in FIG. 3 thru | or FIG. 5, the case where a glass nonwoven fabric is used as a glass sheet is shown.

The adhesion mode of the bonding resin 5 to the glass sheet 4 can be roughly classified into the following four modes as viewed from the upper surface side or the lower surface side.
(A) The bonding resin 5 is attached to all of the plurality of fibers 41 constituting the glass sheet 4 when viewed from the upper surface side of the glass sheet 6 with resin.
(B) The bonding resin 5 is attached to at least a part of the plurality of fibers 41 constituting the glass sheet 4 when viewed from the upper surface side of the glass sheet 6 with resin, and at least one of the plurality of fibers 41. It has a part that is not attached to.
(C) The bonding resin 5 is attached to all of the plurality of fibers 41 constituting the glass sheet 4 when viewed from the lower surface side of the glass sheet 6 with resin.
(D) The bonding resin 5 is attached to at least a part of the plurality of fibers 41 constituting the glass sheet 4 and attached to at least one of the plurality of fibers 41 when viewed from the lower surface side of the glass sheet 6 with resin. It has a part that is not.
In this specification, “viewed from the upper surface side (or lower surface side)” refers to viewing from a direction perpendicular to the upper surface (or lower surface) of the layer.
The bonding mode of the bonding resin 5 is one mode selected from the above (a) and (b) and one mode selected from (c) and (d), preferably (a) and (c) It is an aspect or the aspect of (a) and (d).

In (a), almost all of the plurality of fibers 41 are covered with the bonding resin as viewed from the upper surface side of the resin-coated glass sheet 6, and similarly in (c), the lower surface side of the resin-coated glass sheet 6. When viewed from the top, almost all of the plurality of fibers 41 are covered with the bonding resin. 3 to 5 illustrate the modes (a) and (c).
In (b), there is a portion where the fibers 41 are exposed when viewed from the upper surface side of the resin-coated glass sheet 6. Similarly in (d), the fiber sheet 6 is viewed from the lower surface side. The fiber 41 is exposed.

In said (a), seeing from the upper surface side of the glass sheet 6 with resin, the exposure rate of the fiber 41 is substantially 0%.
In said (b), seeing from the upper surface side of the glass sheet 6 with resin, the exposure rate of the fiber 41 is, for example, more than zero and 20% or less, preferably more than zero and 15% or less, more preferably It exceeds zero and is 10% or less.
In said (c), the exposure rate of the fiber 41 is substantially 0% seeing from the lower surface side of the glass sheet 6 with resin.
In said (d), seeing from the lower surface side of the glass sheet 6 with resin, the exposure rate of the fiber 41 is, for example, more than zero and 20% or less, preferably more than zero and 15% or less, more preferably It exceeds zero and is 10% or less.

The exposure rate of the said glass fiber is the total area of the fiber 41 exposed per unit area of the glass sheet 6 with resin. For example, a range of 1 cm × 1 cm is arbitrarily extracted from the upper surface (or lower surface) of the glass sheet 6 with resin, and the exposure rate is measured by viewing the area where the fiber 41 can be seen from the upper surface side (or lower surface side). And the formula: exposure rate (%) = total area of exposed fibers / 1 cm ² ) × 100.

Furthermore, in the glass sheet 6 with resin, the bonding resin 5 is layered substantially along the glass sheet 4. 3 to 5, the upper surface 41u and the lower surface 42d of the glass sheet 4 are represented by two-dot chain lines.
For example, as shown in FIGS. 3 to 5, the bonding resin 5 is impregnated into the glass sheet 4, and further forms a layer substantially along the upper surface 41 u of the glass sheet 4 on the upper side of the glass sheet 4. As shown in FIGS. 3 and 4, the bonding resin 5 has a layer substantially along the lower surface 42 d of the glass sheet 4 on the lower side of the glass sheet 4. In the embodiment shown in FIG. 5, the bonding resin 5 forms a layer on the lower side of the glass sheet 4, but the layer penetrates above the lower surface 42 d of the glass sheet 4 in the thickness direction of the sheet 4. It is. Although not particularly illustrated, the bonding resin 5 that forms a layer on the upper side of the glass sheet 4 may be located below the upper surface 41 u of the glass sheet 4 in the thickness direction of the sheet 4.

  In the glass sheet with resin 6, the upper surface and the lower surface of the bonding resin 5 that are layered as described above may be flat or uneven, respectively, or one of them may be flat and the other may be uneven. 3 and 4, the layered bonding resin 5 has a flat upper surface and lower surface. In FIG. 5, the layered bonding resin 5 has a flat upper surface and The case where the lower surface is uneven is illustrated.

Specifically, in FIG. 3 and FIG. 4, when the glass sheet with resin 6 is divided, the glass sheet with resin 6 is layered on the glass sheet 4 impregnated with the bonding resin 5 and the upper surface 41 u of the glass sheet 4. It consists of a bonding resin layer 51 and a lower bonding resin layer 52 that forms a layer on the lower surface 42 d of the glass sheet 4.
In FIG. 5, when the glass sheet with resin 6 is divided, the glass sheet with resin 6 includes a glass sheet 4 impregnated with the bonding resin 5 and an upper bonding resin layer 51 formed as a layer on the upper surface 41 u of the glass sheet 4. And consist of

When the bonding resin 5 is adhered in the above-described manner (a), the upper bonding resin layer 51 is continuously formed on the upper side of the glass sheet 4 as shown in FIGS. Yes. When the bonding resin 5 is attached in the form of (b) above, the upper bonding resin layer 51 has a partly discontinuous portion and forms a layer when viewed as a whole (not shown). ). Similarly, when the bonding resin 5 is adhered in the above-described mode (c), the lower bonding resin layer 52 is a continuous layer on the lower surface side of the glass sheet 4 as shown in FIGS. Is made. When the bonding resin 5 is adhered in the above-described manner (d), the lower bonding resin layer 52 has a discontinuous portion and forms a layer when viewed as a whole (not shown). ).
The upper surface of the upper bonding resin layer 51 may be flat or uneven. The lower surface of the lower bonding resin layer 52 may be flat or uneven.

The upper bonding resin layer 51 and the lower bonding resin layer 52 may have the same thickness or may have a thickness difference. Preferably, the thickness of the upper bonding resin layer 51 is more than 1 and 100 times or less, more preferably 10 to 80 times the thickness of the lower bonding resin layer 52.
Specifically, the thickness of the upper bonding resin layer 51 is, for example, 0.01 mm to 1.2 mm, preferably 0.1 mm to 1.1 mm, and more preferably 0.2 mm to 1 mm. More preferably, it is 0.3 mm to 0.8 mm. The thickness of the lower bonding resin layer 52 is, for example, 0.005 mm to 0.5 mm, preferably 0.01 mm to 0.4 mm, and more preferably 0.01 mm to 0.3 mm.
The thickness of the upper bonding resin layer 51 is the length from the upper surface 41u of the glass sheet 4 to the upper surface of the upper bonding resin layer 51, and the thickness of the lower bonding resin layer 52 is from the lower surface of the glass sheet 4 to the lower bonding resin. This is the length to the bottom surface of the layer 52. When the upper surface of the upper bonding resin layer 51 and / or the lower surface of the lower bonding resin layer 52 is uneven, and the thicknesses of the layers 51 and 52 are not uniform, the thickness and lower bonding of the upper bonding resin layer 51 The thickness of the resin layer 52 is the maximum value.
The thickness of the glass sheet 4 impregnated with the bonding resin 5 is substantially equal to the thickness of the glass sheet 4 itself.

The bonding resin 5 may be attached to the entire surface of the fiber 41, or may be attached to the entire surface of many fibers 41 and a part of the surface of the remaining fiber 41. The surface of the fiber 41 is meant to include the surface of the fiber 41 itself constituting the glass sheet 4 and the surface of the binder when a binder is bonded to the fiber 41.
In the illustrated example, the bonding resin 5 is attached to the entire surface of many fibers 41 among the plurality of fibers 41.

In the glass sheet 6 with resin, most of the openings A of the glass sheet 4 are closed by the bonding resin 5.
The air permeability of the glass sheet 6 with resin is, for example, 0 to 10 cc / cm ² · sec, preferably 0 to 5 cc / cm ² · sec, and more preferably 0 to 3 cc / cm ² · sec. In the glass sheet with resin 6 having such air permeability, since the bonding resin 5 is interposed between the upper resin layer 2 and the lower resin layer 3, the upper resin layer and the lower resin layer are provided on the glass sheet. It becomes easy to join. The air permeability of the glass sheet 6 with resin can be measured in the same manner as the air permeability of the glass sheet 4 after the object to be measured is changed to the glass sheet with resin.
3 to 5 show the case where the bonding resin 5 blocks all the openings of the glass sheet 4, that is, the case where the air permeability is zero. Although not particularly illustrated, the present invention includes a case where the bonding resin 5 is not provided in a small part of the opening. In such a case, the above-described air permeability is not zero.

In the glass sheet 6 with resin, the basis weight of the bonding resin 5 is 320 g / m ² or more, preferably 350 g / m ² or more, more preferably 400 g / m ² or more, and further preferably 450 g. / M ² or more. By using the glass sheet 6 with resin to which the bonding resin 5 is adhered at 320 g / m ² or more, the upper resin layer 2 and the lower resin layer 3 can be easily and satisfactorily bonded to the glass sheet 4.
In the glass sheet 6 with resin, the upper limit of the basis weight of the bonding resin 5 is not particularly limited. However, when a large amount of the bonding resin 5 is attached to the glass sheet 4, processing such as wrinkles occurs when the glass sheet 6 with resin is processed. May cause sex problems. From this viewpoint, the basis weight of the bonding resin 5 is, for example, 630 g / m ² or less, preferably 600 g / m ² or less, and more preferably 550 g / m ² or less.

In the glass sheet 6 with resin, one type of bonding resin may be attached to the glass sheet 4, or two or more types of bonding resin may be attached to the glass sheet 4.
FIG. 3 is a reference cross-sectional view of a flooring material including a glass sheet 6 with a resin in which one type of bonding resin is attached to the glass sheet 4, and FIGS. 4 and 5 show two types of bonding resin on the glass sheet 4. It is a reference sectional view of the flooring containing the glass sheet 6 with resin adhered.
In FIG. 3, the bonding resin 5 is composed of only one type of bonding resin 5a (hereinafter sometimes referred to as a first bonding resin 5a). 3 has a sea-island shape in which the bonding resin 5a is the sea and the fibers 41 are islands in a cross-sectional view.

4 and 5, the bonding resin 5 includes the first bonding resin 5a and a bonding resin 5b different from the first bonding resin 5a (hereinafter sometimes referred to as a second bonding resin 5b). ing. The second bonding resin 5b is attached to the surface of the fiber 41, and the first bonding resin 5a is provided so as to cover the periphery of the second bonding resin 5a.
In FIG. 4, the bonding resin 5 is provided so that the second bonding resin 5b attached to the surface of the fiber 41 is buried in the first bonding resin 5a. 4 has a sea-island shape with the first bonding resin 5a as the sea and the fibers 41 and the second bonding resin 5b as islands in a cross-sectional view.
In FIG. 5, the first bonding resin 5 a enters the upper side in the thickness direction from the lower surface 42 d of the glass sheet 4, and when viewed from the lower side of the glass sheet 4, the first bonding resin 5 a and the surface of the fiber 41 The adhering second bonding resin 5b is mixed. The glass sheet 6 with resin of FIG. 5 has a sea-island shape in which the bonding resin 5 composed of the first bonding resin 5a and the second bonding resin 5b is the sea and the fibers 41 are islands in a cross-sectional view.

The bonding resin 5 of the glass sheet 6 with resin functions as a binder resin for bonding the upper resin layer 2 and the lower resin layer 3 to the fibers 41, respectively. That is, as shown in FIGS. 3 to 5, the upper resin layer 2 and the lower resin layer 3 are bonded to the fiber 41 through the bonding resin 5.
3 to 5, in order to illustrate the bonding resin 5, the upper resin layer 2, and the lower resin layer 3 in an easy-to-understand manner, solid lines are clearly shown around these boundaries. It should be noted that the resin layer 2 and the lower resin layer 3 are both made of a resin material, so that these boundaries do not appear clearly.

In the flooring 1 of the present invention, the glass sheet 4, the upper resin layer 2, and the lower resin layer 3 are bonded to each other through the bonding resin 5. Therefore, it is difficult for the flooring 1 to peel off between these layers. This is because the bonding resin 5 having a basis weight of 320 g / m ² or more is adhered to the glass sheet 4, the bonding resin 5 is interposed between the fiber 41, the upper resin layer 2 and the lower resin layer 3, It is estimated that the upper resin layer 2 and the lower resin layer 3 are firmly bonded to the glass sheet 4.
In particular, when the bonding resin 5 includes a paste vinyl chloride resin and at least one of the upper resin layer 2 and the lower resin layer 3 includes a suspension vinyl chloride resin, the upper resin layer 2 and the lower resin layer 3 are bonded to each other. 5 can be bonded to the glass sheet 4 more firmly.

Further, since the suspension vinyl chloride resin is harder and superior in strength compared to the paste vinyl chloride resin, even if the thicknesses of the upper resin layer 2 and the lower resin layer 3 are relatively small (that is, the floor Even if the thickness of the material 1 is reduced, a flooring 1 having excellent mechanical strength and small warpage can be obtained. For example, when both the upper resin layer 2 and the lower resin layer 3 include a suspension vinyl chloride resin and the bonding resin 5 includes a paste vinyl chloride resin, the thickness of the flooring 1 is compared while maintaining the interlayer bonding force. It can be made smaller.
Since the flooring 1 according to the present invention hardly causes delamination as described above, it can be constructed with a good finish without framing the edges when laid on the floor surface. Moreover, when replacing the already laid flooring 1, the existing flooring 1 can be peeled off without causing delamination. For this reason, it is unlikely that a part of the existing flooring 1 (mainly the lower part) remains attached to the floor surface, and the replacement work can be easily performed.
Hereinafter, each layer will be described in detail.

<Upper resin layer and lower resin layer>
The upper resin layer 2 and the lower resin layer 3 are main parts constituting the strength and weight of the flooring 1.
The thicknesses of the upper resin layer 2 and the lower resin layer 3 are not particularly limited and can be set as appropriate. The thickness of the upper resin layer 2 and the thickness of the lower resin layer 3 may be the same, or one of them may be small. For example, the upper resin layer 2 has a thickness of 0.05 mm to 1.0 mm, preferably 0.1 mm to 0.8 mm. The thickness of the lower resin layer 3 is, for example, 0.5 mm to 3.0 mm, preferably 0.7 mm to 2.0 mm.

  In addition, when using the upper resin layer 2 which has the designability like 2nd Embodiment etc., you may set the thickness of the upper resin layer 2 comparatively small. For example, the thickness of the upper resin layer 2 having design properties is 0.05 mm to 0.5 mm. The upper resin layer 2 having design properties can itself be a design. The upper resin layer 2 having the design property is (1) when a design is expressed by the color of the upper resin layer itself, (2) a colorant is mixed in the upper resin layer, and the color of the colorant and how to mix the colorant (3) When a resin chip is mixed in the upper resin layer and the design is expressed by the color, shape, dispersion method, etc. of the resin chip, (4) The color of the upper resin layer In the case where different colorants and resin chips are mixed and the design is expressed by their color or mixing method. For the flooring 1 using the upper resin layer 2 having design properties, when the thickness of the upper resin layer 2 is small, the lower resin layer 3 mainly constitutes the strength and weight of the flooring 1.

  The resin components of the resin layers (upper resin layer 2 and lower resin layer 3) are not particularly limited, and conventionally known ones can be used, and generally a thermoplastic resin is used. The resin components of the upper resin layer 2 and the lower resin layer 3 may be the same, the same, or different. The same kind of resin component means that the monomers constituting the main repeating unit of the resin component are the same, and when having a copolymer monomer, the copolymer monomer is different and / or the degree of polymerization is Including different cases. That the resin component is the same means that the repeating unit (and the copolymer monomer, if any) is the same, includes the case where the polymerization degrees are different.

Examples of the thermoplastic resin include vinyl chloride resins such as vinyl chloride and vinyl chloride-vinyl acetate copolymers; polyolefin resins; urethane resins; vinyl acetate resins such as ethylene-vinyl acetate copolymers; Examples thereof include acrylic resins such as resins; polyamide resins; ester resins; various elastomers such as various elastomers such as olefin elastomers and styrene elastomers; and rubbers. These can be used alone or in combination of two or more. Since it has excellent flexibility and can be easily joined to the glass sheet 6 with resin, at least one of the upper resin layer 2 and the lower resin layer 3 has a vinyl chloride resin as a main component resin. A resin layer is preferable, and it is more preferable that both the upper resin layer 2 and the lower resin layer 3 have a vinyl chloride resin as a main component resin. Since the flooring 1 having a resin layer containing a vinyl chloride resin as a main component resin is excellent in flexibility, it has good walking feeling and can be applied to the floor surface while being curved. In addition, the vinyl chloride resin is inexpensive, and when it is used, the production of the flooring 1 is simplified.
When both the upper resin layer 2 and the lower resin layer 3 have a vinyl chloride resin as a main component resin, the vinyl chloride resins of the upper resin layer 2 and the lower resin layer 3 have the same type of monomer and degree of polymerization. However, any one of them may be different.

  In the present specification, the main component resin refers to the largest component (weight ratio) among the resin components (excluding additives) constituting the layer. The amount of the main component resin is more than 50% by mass, preferably 70% by mass or more, and more preferably 80% by mass or more when the entire resin component constituting the layer is 100% by mass. The upper limit of the amount of the main component resin is 100% by mass. When the amount of the main component resin is less than 100% by mass, the resin other than the main component resin contained in the layer is not particularly limited, and a known resin component can be used.

As the vinyl chloride resin, those produced by an emulsion polymerization method, a suspension polymerization method, a solution polymerization method, a bulk polymerization method, or the like can be used. A vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferred because it is easy to process and handle. These vinyl chloride resins may be used alone or in combination of two or more.
Preferably, at least one of the upper resin layer 2 and the lower resin layer 3 includes a suspension vinyl chloride resin as a main component resin, and more preferably, both the upper resin layer 2 and the lower resin layer 3 are main components. Suspension vinyl chloride resin is included as the resin. By forming the upper resin layer 2 and the lower resin layer 3 from suspension vinyl chloride resin, it is possible to obtain the floor material 1 having a relatively small thickness while ensuring the strength of the floor material 1.

The paste vinyl chloride resin is, for example, a paste-like vinyl chloride resin obtained by an emulsion polymerization method, and the viscosity can be appropriately adjusted with a plasticizer. The paste vinyl chloride resin is a fine powder having a particle diameter of 0.1 to 10 μm (preferably 1 to 3 μm) composed of a large number of fine particle aggregates. Preferably, the surface of the fine powder is coated with a surfactant. ing. The average degree of polymerization of the paste vinyl chloride resin is preferably about 1000 to 2000.
The suspension vinyl chloride resin is, for example, a vinyl chloride resin obtained by a suspension polymerization method. The suspension vinyl chloride resin is a fine powder having a particle size of preferably 20 μm to 100 μm. The average degree of polymerization of the suspension vinyl chloride resin is preferably about 700 to 1500, more preferably about 700 to 1100, and still more preferably about 700 to 1000.
However, the particle diameter is the median diameter (D50) in the volume-based particle size distribution.

Each vinyl chloride resin preferably has a K value of about 60 to 95, and more preferably has a K value of about 65 to 80.
The upper resin layer 2 and the lower resin layer 3 usually contain various additives in addition to the resin component. As the additive, conventionally known additives can be used, and examples thereof include a filler, a plasticizer, a flame retardant, a stabilizer, a hygroscopic agent, an antioxidant, a lubricant, a colorant, a foaming agent, and an antifungal agent.

The upper resin layer 2 and the lower resin layer 3 may be independently non-foamed or foamed. For example, one of the upper resin layer 2 and the lower resin layer 3 may be a foamed resin layer and the other may be a non-foamed resin layer, or both may be a non-foamed resin layer or a foamed resin layer. It may be configured.
Although the expansion ratio of the foamed resin layer is not particularly limited, it is preferably 1.05 to 10 times, more preferably 1.1 to 4 times. If the expansion ratio is too low, the flooring 1 cannot be substantially cushioned. On the other hand, if the expansion ratio is too high, the flooring 1 becomes too soft.

<Glass sheet>
The glass sheet 4 is a layer for suppressing a dimensional change of the flooring 1 due to shrinkage or expansion over time. Specifically, the glass sheet 4 has the characteristics of glass fiber that is high in strength and has little dimensional variation due to temperature, enhances mechanical strength such as dimensional stability and rigidity of the flooring 1, and changes in temperature or over time. It is a layer for suppressing dimensional changes and warping due to shrinkage and expansion.
The glass sheet 4 is a layer in which a plurality of fibers 41 overlap each other, and as described above, a glass nonwoven fabric 4a, a glass woven fabric 4b, or the like can be used.
Preferably, the glass nonwoven fabric 4a is used. Since the glass nonwoven fabric 4a is excellent in dimensional stability, it contributes greatly to the dimensional stability of the entire flooring 1, and can improve the bending strength and tensile strength of the flooring 1. Further, the glass woven fabric 4b has fibers 41 arranged in a generally regular manner, so that there is a possibility that a texture appears on the surface of the flooring 1. However, when the glass nonwoven fabric 4a is used, such a woven fabric is used. There is no problem.
The explanation of the glass nonwoven fabric 4a and the glass woven fabric 4b is as described above in the section of [Laminated structure of flooring]. Here, the items that have not been described in the above column will be mainly described.

The thickness of the glass fiber of the glass nonwoven fabric 4a and the glass woven fabric 4b is not specifically limited, For example, it is 5 micrometers-30 micrometers in diameter, Preferably, it is 8 micrometers-20 micrometers in diameter.
The length of the glass fiber of the glass nonwoven fabric 4a is not specifically limited, For example, it is 10 mm-35 mm. The glass fiber of the glass nonwoven fabric 4a may be comprised only from the short fiber, may be comprised only from the long fiber, or may be comprised from the mixture of the short fiber and the long fiber. Although the glass nonwoven fabric 4a comprised only from the short fiber is excellent in dimensional stability, the glass nonwoven fabric 4a comprised from the mixture of a short fiber and a long fiber is excellent also in tensile strength in addition to dimensional stability. . Although the length of the said short fiber is not specifically limited, For example, it is 10 mm-35 mm, and the length of a long fiber is larger than the length of the short fiber. In addition, the glass fiber of the glass woven fabric 4b is normally composed of a fiber that is longer than the long fiber.
Moreover, when a glass sheet contains natural fibers, such as glass fiber and a pulp, the thickness of natural fibers, such as the pulp, is although it does not specifically limit, For example, they are 10 micrometers-30 micrometers. Since natural fibers such as pulp are generally mixed with various fiber lengths and fiber diameters, the thickness of the natural fibers is a central range of the distribution.

<Bonding resin>
The bonding resin 5 is not particularly limited as long as it can be bonded to any of the fibers 41, the upper resin layer 2, and the lower resin layer 3, and a conventionally known resin can be used. Examples of the bonding resin 5 include thermoplastic resins exemplified in the upper resin layer 2 and the lower resin layer 3.
The bonding resin 5 may contain a vinyl chloride resin as a main component resin because it has excellent bondability to the fibers 41 and the upper resin layer 2 and the lower resin layer 3 having a vinyl chloride resin as a main resin. Preferably, a paste vinyl chloride resin is preferably included as the main component resin.
As described above, when two or more kinds of bonding resins 5 are attached to the glass sheet 4, it is preferable that these bonding resins 5 are all thermoplastic resins, both of which are vinyl chloride-based as the main component resin. It is more preferable that the resin is a resin, and it is more preferable that both include a paste vinyl chloride resin as a main component resin.
Two or more types of bonding resins are different bonding resins. For example, when the main component resins are different, the main component resins are the same or the same, and when the compounding amount is different, the main component resins are the same or the same and the compounding amount. Although the same, the composition is the same when the blending amount of additives such as fillers is different, but the viscosity is different.

Since the suspension vinyl chloride resin is relatively hard, it is difficult for the resin to adhere firmly to the glass sheet 4. However, the paste vinyl chloride resin has a large amount of plasticizer and is relatively soft. It is easy to work and adheres firmly to the fiber 41. Further, since the paste vinyl chloride resin is excellent in compatibility with the suspension vinyl chloride resin, the bonding resin 5 including the paste vinyl chloride resin is also applied to the upper resin layer 2 or the lower resin layer 3 including the suspension vinyl chloride resin. It comes to join firmly.
The paste vinyl chloride resin contained in the bonding resin 5 is a fine powder having a particle diameter of 0.1 to 10 μm (preferably 1 to 3 μm) composed of a large number of fine particle aggregates, preferably on the surface of the fine powder. Surfactant is coated. The average degree of polymerization of the paste vinyl chloride resin is preferably about 1000 to 2000, and the K value is preferably about 60 to 95, more preferably about 65 to 80.
Note that the bonding resin 5 usually includes various additives. Examples of the additive include those exemplified above.

  Moreover, it is preferable that the bonding resin 5 is substantially solid without any voids inside. The substantially solid state means that the bonding resin 5 is not formed so as to generate a void, and when the bonding resin 5 is attached to the glass sheet 4, a void that is inevitably generated or accidentally generated is allowed. . However, voids may be formed inside the bonding resin 5 as long as the interlayer strength is not impaired. This void can be formed, for example, by a method of blending the bonding resin 5 with foamable microcapsules, a hollow filler, or chemically foaming the bonding resin 5. By forming voids in the bonding resin 5, weight reduction, flexibility, workability, and the like can be improved.

  In the case of using a paste vinyl chloride resin, as shown in FIGS. 4 and 5, when the first bonding resin 5a and the second bonding resin 5b are attached to the glass sheet 4, the first bonding resin 5a is The paste is preferably a paste vinyl chloride resin in which the amount of the filler is larger than that of the second bonding resin 5b. For example, the first bonding resin 5a includes a filler and the content thereof is larger than that of the second bonding resin 2b. The second bonding resin 5b contains substantially no filler or contains a filler, but its content is smaller than that of the first bonding resin 2a.

<Makeup layer>
The decorative layer 73 is a layer that imparts a design to the flooring 1. The decorative layer 73 is provided as necessary.
Examples of the decorative layer 73 include a transfer layer, a design printing layer, a design printing sheet, and a thermoplastic resin layer to which design properties are imparted. However, the decorative layer 73 is not limited to these exemplary layers, and any other layer can be used as long as it can express the design.
The transfer layer is composed of a transfer film formed by printing and solidifying a printing ink on a base material such as release paper and then peeling the solidified printing ink. The decorative layer 7 made of the transfer layer is formed by transferring to the upper surface of the upper resin layer 2 or the lower surface of the protective layer 72. The design print layer is composed of a layer in which printing ink is directly printed and solidified on the upper surface of the upper resin layer 2 or the lower surface of the protective layer 72. The decorative layer 73 made of a design printed sheet is formed by joining a sheet on which design printing has been performed in advance to the upper surface of the upper resin layer 2 or the lower surface of the protective layer 72.

The thermoplastic resin layer imparted with designability is a layer that itself can be designed. The thermoplastic resin layer has (1) a design property imparted by the color of the resin itself, (2) a colorant is mixed, and the design property is imparted by the color of the colorant and how it is mixed. (3) When resin chips are mixed and design properties are given by the color, shape, dispersion method, etc. of the resin chips, (4) Colorants having different colors and resin chips are mixed, When designability is imparted depending on the color or mixing method, etc. The decorative layer 73 made of a thermoplastic resin layer is formed by laminating and bonding the thermoplastic resin layer to the upper surface of the upper resin layer or the like.
Examples of the resin component of the thermoplastic resin layer to which the design property is imparted include those exemplified in the section of the above <upper resin layer and lower resin layer>, and the upper resin layer 2 and the protective layer 72 are strong. A thermoplastic resin is preferable because it is bonded to the substrate. In particular, when the upper resin layer 2 and the protective layer 72 are made of vinyl chloride resin, a resin mainly composed of vinyl chloride resin is preferable.
Although the thickness of the said decorative layer 73 is not specifically limited, For example, they are 0.5 micrometer-1 mm, Preferably they are 0.01 mm-0.8 mm. In particular, the thickness of the decorative layer 73 made of a transfer layer or a design printing layer is 0.5 μm to 0.5 mm.

<Protective layer>
The protective layer 72 is a layer provided in order to make it possible to easily remove dirt adhering to the flooring 1. That is, the protective layer 72 imparts stain removal properties to the flooring 1. The protective layer 72 is provided as necessary. The protective layer 72 may be transparent or opaque, but in order to make the design of the decorative layer 73 provided below the protective layer 72 visible (when the decorative layer 73 is not provided, the upper resin layer In order to make the coloring of 2 visible), it is preferably transparent.
The protective layer 72 is formed of a resin material. Examples of the resin material include those exemplified in the above section <Upper resin layer and lower resin layer>. Since the resin material is firmly bonded to the decorative layer 73 or the upper resin layer 2, a vinyl chloride resin is used. A resin having a main component is preferred.
The thickness of the protective layer 72 is not specifically limited, For example, it is 0.03 mm-1 mm.

<Scratch prevention layer>
The scratch-preventing layer 71 is a layer that is provided to provide the floor material 1 with dirt removal properties together with the protective layer 72, and further to impart wear resistance and scratch resistance to the upper surface of the floor material 1. The scratch preventing layer 71 is provided as necessary. The scratch preventing layer 71 may be transparent or opaque, but is preferably transparent for the same reason as the protective layer 72.
Although the resin material which forms the damage prevention layer 71 is not specifically limited, It is preferable to form from the comparatively hard resin layer. As the resin material of the scratch-preventing layer 71, it is preferable to use a curable resin from the viewpoint of good workability, and more preferably, an ionizing radiation curable resin is used because the protective layer 72 is hardly damaged by heat. It is more preferable to use an ultraviolet curable resin because of its versatility. Examples of the curable resin include thermosetting resins and resins that are cured by non-ionizing radiation, in addition to ionizing radiation curable resins such as ultraviolet curable resins.

Specifically, the scratch-preventing layer 71 includes a curable resin obtained by polymerizing at least one of a curable monomer and an oligomer, and includes other components as necessary.
Examples of the curable monomer or oligomer that forms the ionizing radiation curable resin and that is cured by ionizing radiation include a curable monomer or oligomer that is cured by ultraviolet rays or electron beams. Hereinafter, a curable monomer or oligomer that is cured by ionizing radiation is referred to as an ionizing radiation curable monomer or oligomer.
Examples of the ionizing radiation curable monomer or oligomer include monomers or oligomers having a polymerizable unsaturated bond group such as a (meth) acrylate group or a (meth) acryloyloxy group or an epoxy group in the molecule.

Specific examples of the ionizing radiation curable monomer include styrene monomers such as α-methylstyrene, methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, dipentaerythritol hexa (meth) acrylate, dipenta Examples include erythritol penta (meth) acrylate, urethane (meth) acrylate, and a polyol compound having two or more thiol groups in the molecule. Specific examples of the ionizing radiation curable oligomer include acrylates such as urethane (meth) acrylate, polyester (meth) acrylate, and epoxy (meth) acrylate, unsaturated polyester, and epoxy. These curable monomers or oligomers can be used alone or in combination of two or more.
In these, it is preferable to use the monomer or oligomer which has a (meth) acrylate group in a molecule | numerator as an ionizing radiation-curable monomer or oligomer, and it is more preferable to use urethane (meth) acrylate.
Although the molecular weight of the said curable monomer or oligomer is not specifically limited, For example, 200-10000 etc. are mentioned.

A photopolymerization initiator is usually added to the ionizing radiation curable monomer or oligomer. Examples of the photopolymerization initiator include 2,2-dimethoxy-2-phenylacetophenone, acetophenone, benzophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4′-dimethoxybenzophenone, benzoinpropyl ether, benzyl Dimethyl ketal, N, N, N ′, N′-tetramethyl-4,4′-diaminobenzophenone, 1- (4-isopropylphenyl) -2-hydroxy-2-methylpropan-1-one, other thioxanthates Compound etc. are mentioned.
Further, the scratch-preventing layer 71 may contain components other than the resin component. Examples of the components include solvents, leveling agents, fine particles, fillers, dispersants, plasticizers, ultraviolet absorbers, Surfactants, antioxidants, thixotropic agents, antifungal agents and the like can be mentioned.
Although the thickness of the damage prevention layer 71 is not specifically limited, For example, they are 1 micrometer-100 micrometers, Preferably they are 5 micrometers-70 micrometers, More preferably, they are 10 micrometers-50 micrometers.

<Base material layer>
The base material layer 74 is a layer located on the lowermost side of the flooring 1, and increases the adhesive strength with an adhesive (hereinafter referred to as a flooring adhesive) that adheres the flooring at the time of laying to the floor surface, This is a layer intended to suppress warping of the flooring 1 and the like. Therefore, when the flooring 1 is laid, the lower surface of the base material layer 74 is mainly in contact with the floor surface. However, other layers such as the backing layer 75 can be laminated on the lower surface of the base material layer 74, and the lowermost surface of the flooring 1 having such a layer structure is not configured by the base material layer 74. The base material layer 74 is provided as necessary.
Although it does not specifically limit as the said base material layer 74, For example, conventionally well-known sheet materials, such as a nonwoven fabric, a woven fabric, paper, a felt, can be used. The material of the fibers constituting the nonwoven fabric or 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 base material layer 74 is provided, the floor surface adhesive is sufficiently impregnated into the base material layer 74 when the floor material 1 is laid, and the floor material 1 is firmly fixed to the floor surface by the anchor effect. Moreover, since at least a part of the fibers of the base material layer 74 is exposed from the lowermost surface of the flooring 1 by arranging the base material layer 74 on the lowermost side, the floor adhesive is entangled with the fibers. The flooring 1 is firmly fixed to the floor surface.

The woven fabric is not particularly limited, but from the viewpoint of various physical properties such as dimensional stability, cold chill is preferable, and a plain woven fabric of polyester fibers is more preferable. The cold chill is a woven fabric made of fibers such as polyester fibers. Since the woven fabric is made into a cloth shape by weaving fibers, it is less likely to stretch in the vertical and horizontal directions than the nonwoven fabric, and the floor material 1 can be effectively prevented from stretching. Therefore, when the base material layer 74 is made of a woven fabric, the flooring 1 having a small warp can be obtained without increasing the overall rigidity.
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. Especially, since it is thin and strong, a spunbond nonwoven fabric is preferable, and a polypropylene spunbond nonwoven fabric is more preferable.
The thickness of the base material layer 74 is not particularly limited, but is, for example, 0.1 mm to 0.5 mm, and preferably 0.2 mm to 0.4 mm. Also, the basis weight of the base layer 74 is not particularly limited, for ^example, a ^{30g / m 2 ~50g / m 2} . If the thickness or basis weight of the base material layer 74 is too small, the warping of the flooring 1 may not be sufficiently suppressed. On the other hand, if the thickness is too large, the resin material of the lower resin layer 3 is sufficiently contained in the base material layer 74. May not impregnate.

[Manufacturing method of flooring]
Next, the manufacturing method of the flooring of this invention is demonstrated.
However, the flooring 1 of the present invention is not limited to the one produced by the following production method, and can be produced by other production methods.

The method for producing a flooring of the present invention is a step of preparing a glass sheet with resin, laminating an upper resin layer on the upper surface of the glass sheet with resin, laminating a lower resin layer on the lower surface of the glass sheet with resin, A step of heating and pressurizing to integrate the upper resin layer, the glass sheet with resin, and the lower resin layer, and may include other steps as necessary.
Lamination and integration of the upper resin layer, the glass sheet with resin, and the lower resin layer may be performed simultaneously or sequentially. Examples of the lamination and integration include the following procedures (1) to (3).
(1) A laminate including a laminate of the upper resin layer, the glass sheet with resin, and the lower resin layer is heated and pressed to be integrated.
(2) The first laminate including the laminate of the upper resin layer and the glass sheet with resin is integrated by heating and pressing, and the second laminate including the laminate of the first laminate and the lower resin layer is further heated. Press to integrate.
(3) The first laminate including the laminate of the lower resin layer and the glass sheet with resin is integrated by heating and pressing, and the second laminate including the laminate of the first laminate and the upper resin layer is further heated. Press to integrate.

  In a specific embodiment, a protective layer, a base material layer, and the like are laminated in addition to the upper resin layer, the glass sheet with resin, and the lower resin layer. (3) The upper resin layer, the glass sheet with resin, and the lower resin layer may be laminated and integrated at the same time, or the upper resin layer as described in (1) to (3) above. It may be appropriately performed before or after the lamination and integration of the glass sheet with resin and the lower resin layer.

Each of these steps may be performed in series on one production line, or one or more steps selected from the above steps may be performed on one line and the remaining steps may be performed on another one or Two or more lines may be used. Further, all of the steps may be performed by one practitioner, or one or more steps selected from the steps may be performed by one practitioner, and the remaining steps may be performed by another practitioner. The person may go.
Hereinafter, a specific description will be given with reference to FIGS.

FIG. 14 is a schematic side view schematically showing each step of the manufacturing method according to the first embodiment, in which the upper resin layer, the glass sheet with resin, and the lower resin layer are stacked and integrated simultaneously. It is a form.
FIG. 15 is a schematic side view schematically showing each step of the manufacturing method according to the second embodiment. First, a first laminate including a laminate of an upper resin layer and a glass sheet with resin is heated and pressurized. In this embodiment, the second laminate including the first laminate and the lower resin layer is integrated by heating and pressing.
The production line used in the production method of each illustrated example is a case where a series of steps from the preparation step of a glass sheet with resin to the production of a long strip flooring is performed.

<Preparation process of each layer>
By attaching a bonding resin 5M to the glass sheet 4M, a glass sheet 6M with resin is prepared.
As the glass sheet 4M, a glass nonwoven fabric or a glass woven fabric (preferably a glass nonwoven fabric) as described in the above-mentioned [Laminated Floor Structure] and <Glass Sheet> column is used.
The bonding method of the bonding resin 5M to the glass sheet 4M is not particularly limited, and a coating method in which the bonding resin is applied to the glass sheet using various coaters such as a roll coater and a knife coater, and a resin tank filled with the bonding resin is made of glass. Examples include a dipping method through which a sheet is passed, and a combination of the coating method and the dipping method.
When preparing the glass sheet 6M with resin in which two or more kinds of bonding resins 5a and 5b as shown in FIGS. 4 and 5 are attached to the glass sheet 4M, the second bonding resin 5b is attached to the glass sheet 4M. After that, the first bonding resin 5a is further adhered thereto.

14 and 15 illustrate a coating method using a knife coater. 14 and 15, a long strip-shaped glass sheet 4M formed to a predetermined width is conveyed in the length direction. The bonding resin 5M is applied to the upper surface of the glass sheet 4M by the knife coater 81 arranged in the middle of the conveyance. The bonding resin 5M applied to the upper surface of the glass sheet 4M travels through the surface of the glass fiber and moves through the opening of the glass sheet 4M, and also moves to and adheres to the lower surface side of the glass sheet 4M.
By appropriately adjusting the viscosity of the bonding resin 5M, the distance between the knife coater 81 and the upper surface of the glass sheet 4M, the adhesion amount of the bonding resin 5M to the glass sheet 4M and the coating thickness can be set to desired ranges.

In the above description, only the knife coater 81 is used as a method for attaching the bonding resin 5M to the glass sheet 4M. For example, first, the bonding resin is applied using a roll coater and then overlapped using the knife coater. You may apply (not shown). In this case, the same bonding resin may be applied repeatedly, or the second bonding resin 5b may be applied with a roll coater and then the first bonding resin 5a may be applied with a knife coater.
The adhesion amount of the bonding resin 5M is 320 g / m ² or more, preferably 350 g / m ² or more, more preferably 400 g / m ² or more, and further preferably 450 g / m ² or more. The upper limit of the basis weight of the bonding resin 5M is not particularly limited, but is, for example, 630 g / m ² or less, preferably 600 g / m ² or less, and more preferably 550 g / m ² or less.

The bonding resin 5M is not particularly limited, but a resin material mainly composed of a vinyl chloride resin, particularly a paste vinyl chloride resin is preferable. The viscosity of the bonding resin 5M mainly composed of a paste vinyl chloride resin is, for example, 100 mPa · s to 30,000 mPa · s, preferably 500 mPa · s to 15,000 mPa · s, more preferably 1, 000 mPa · s to 5,000 mPa · s. By using a paste vinyl chloride resin having such a viscosity, it can be satisfactorily adhered to the glass sheet 4M. In the present specification, the viscosity is a viscosity at 20 ° C., and is a value measured at 60 rpm using a BM viscometer.
When two or more types of bonding resins are attached to the glass sheet, the first bonding resin 5a may be a low-viscosity paste vinyl chloride resin, such as a viscosity of 100 mPa · s to 50,000 mPa · s. s, preferably 300 mPa · s to 30000 mPa · s vinyl chloride resin can be used. As the second bonding resin 5b, a low-viscosity paste vinyl chloride resin can be used. For example, a vinyl chloride resin having a viscosity of 100 mPa · s to 3000 mPa · s, preferably 300 mPa · s to 1500 mPa · s is used. Can do.

The paste vinyl chloride resin includes a plasticizer, and further includes a filler as necessary. Specifically, the paste vinyl chloride resin includes 50 to 100 parts by mass of a plasticizer and, if necessary, 0 to 300 parts by mass of a filler with respect to 100 parts by mass of the vinyl chloride resin. More preferably, in addition to the plasticizer and the filler, those containing 1 part by mass to 10 parts by mass of additives other than the plasticizer are more preferable.
When two or more types of bonding resins are adhered to the glass sheet, the first bonding resin 5a is, for example, 50 to 100 parts by mass of a plasticizer and 0% of a filler with respect to 100 parts by mass of a paste vinyl chloride resin. The one containing ~ 400 parts by mass is used, and the second bonding resin 5b contains, for example, 50 to 100 parts by mass of plasticizer and 0 to 100 parts by mass of filler with respect to 100 parts by mass of the paste vinyl chloride resin. Is used. Preferably, the first bonding resin 5a is a vinyl chloride resin having a larger amount of filler than the second bonding resin 5b. In the first bonding resin 5a and the second bonding resin 5b, the amount of filler of 0% by mass is a case where no filler is included.
The plasticizer is not particularly limited, and examples thereof include dioctyl phthalate (DOP), dibutyl phthalate (DBP), and butyl octyl phthalate (BOP). The filler is not particularly limited, and examples thereof include calcium carbonate, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica.

When the bonding resin 5M adhered to the glass sheet 4M has high fluidity and dripping occurs, the bonding resin 5M may be forcibly dried using a heating means (not shown) such as a heater or an oven. preferable. By the drying, the glass sheet 6M with resin can be obtained without dripping the bonding resin 5M attached to the glass sheet 4M. The resulting glass sheet 6M is coated resin, little have openings, the air permeability is 0~10cc ^/ cm 2 · sec, preferably 0~5cc ^/ cm 2 · sec, more preferably 0 ~ 3cc / cm ² · sec.

Further, in attaching the bonding resin 5M to the glass sheet 4M, the thickness of the bonding resin on the upper side of the glass sheet 4M (that is, the thickness of the upper bonding resin layer) and the thickness of the bonding resin on the lower side of the glass sheet 4M (that is, By appropriately adjusting the thickness of the lower bonding resin layer, the glass sheet 4 can be disposed at a substantially middle portion of the thickness of the flooring 1. These thicknesses can be adjusted in consideration of the thicknesses of the upper resin layer, the lower resin layer, and other layers. For example, when the thickness of the upper resin layer is smaller than the thickness of the lower resin layer, it is warped by preparing a glass sheet with resin in which the thickness of the upper bonding resin layer is adjusted to be larger than the thickness of the lower bonding resin layer. Small flooring.
The upper resin layer is often limited in the thickness setting range by factors such as surface embossing and durability. Furthermore, the layer widths of the layers such as the decorative layer, the protective layer, and the scratch-preventing layer that are laminated above the upper resin layer are often limited in order to exhibit their functions. Therefore, in the floor material, the thickness beyond the upper resin layer is practically determined to some extent, and the set width is small. Even in such a case, according to the present invention, it is possible to arrange the glass sheet at a substantially middle portion of the thickness of the flooring material only by adjusting the thickness of the upper bonding resin layer and the like of the resin-coated glass sheet. Small flooring can be obtained.

Separately, a protective layer 72M, a decorative layer 73M, an upper resin layer 2M, a lower resin layer 3M, and a base material layer 74M are prepared. These layers 72M, 73M, 2M, 3M, and 74M are in the form of long strips having a predetermined width, and are preferably prepared in the form of long strips having substantially the same width as the glass sheet 4M. Note that the decorative layer 73M is omitted when the upper resin layer having design properties is used.
At least one of the upper resin layer 2M and the lower resin layer 3M is formed of a resin whose main component is suspension vinyl chloride resin, and preferably both are formed of a resin whose main component is suspension vinyl chloride resin. The
The formation method of these layers 72M, 73M, 2M, and 3M is not particularly limited, and can be appropriately selected according to the material for forming them. Examples thereof include a calendering method, a melt extrusion method, and a solution casting method.

FIG. 14 shows a case where the protective layer 72M, the upper resin layer 2M having design properties, the lower resin layer 3M, and the base material layer 74M are separately prepared, and are laminated and integrated in a laminating process described later. .
FIG. 15 shows a case where a protective layer 72M, a decorative layer 73M, an upper resin layer 2M, a lower resin layer 3M, and a base material layer 74M are separately prepared, and sequentially laminated and integrated in a laminating process described later. Yes.
In FIG. 14, a decorative layer and an upper resin layer may be prepared instead of the upper resin layer having design properties. In FIG. 15, instead of the decorative layer 73M and the upper resin layer 2M, an upper resin layer having design properties may be prepared. In this case, the lamination of the decorative layer 73M is omitted as necessary.
Further, as described above, the lamination of layers other than the upper resin layer, the glass sheet with resin, and the lower resin layer is not limited to the lamination process described later, and can be performed at any time.
For example, in the preparation step, a base material layer 74M is provided on the lower surface of the lower resin layer 3M, and the lower resin layer 3M with the base material layer is laminated on the glass sheet 6M with resin in the laminating step described later. Also good. Alternatively, a protective layer 72M is provided on the upper surface of the laminate of the upper resin layer 2M and the decorative layer 73M or the upper surface of the upper resin layer having design properties, and the upper resin layer 2M with the protective layer is resinated in a laminating process described later. It may be laminated on the attached glass sheet 6M. In addition, any two or more layers may be laminated in advance and integrated, and a lamination process described later may be performed.

<Lamination process>
As shown in FIG. 14, an upper resin layer 2M having design properties is laminated on the upper surface of the glass sheet with resin 6M, and a lower resin layer 3M is laminated on the lower surface of the glass sheet with resin 6M. A protective layer 72M is laminated on the upper surface of the resin layer 2M and a base material layer 74M is laminated on the lower surface of the lower resin layer 3M, and heated and pressed between a pair of rolls 84 and 85, whereby each layer 72M, 2M, 6M, 3M and 74M are integrated.
As shown in FIG. 15, the upper resin layer 2M is laminated on the upper surface of the resin-coated glass sheet 6M, and the decorative layer 73M and the protective layer 72M are laminated on the upper surface of the upper resin layer 2M. The layers 72M, 73M, 2M, and 6M are integrated by heating and pressurizing the first laminated body to form the first laminated body, and the lower surface of the first laminated body (the lower surface of the glass sheet 6M with resin) Each layer 72M, 73M, 2M, 6M, 3M, by laminating the resin layer 3M and heating and pressing between the pair of rolls 842, 852 while laminating the base material layer 74M on the lower surface of the lower resin layer 3M, 74M is integrated.

Specifically, in the case of FIG. 14, the protective layer 72M, the decorative layer 73M having design properties, the upper resin layer 2M, the glass sheet with resin 6M, the lower resin layer 3M, and the base material layer 74M are overlapped in order from the upper side. The laminated body is heated and pressurized by passing the laminated body between the pair of heating rolls 84 and 85 (or the heating roll 84 and the resin roll 85), and the layers 72M, 2M, 6M, 3M, and 74M are joined. .
In the case of FIG. 15, the first laminated body in which the protective layer 72 </ b> M, the decorative layer 73 </ b> M, the upper resin layer 2 </ b> M, and the glass sheet 6 </ b> M with resin overlap in order from the upper side is paired with a pair of heating rolls 841 and 851 (or a heating roll 841. By passing between the resin rolls 851), the first laminate is heated and pressurized, and the layers 72M, 73M, 2M, and 6M are joined. Next, in order from the upper side, the first laminated body, the lower resin layer 3M, and the second laminated body in which the base material layer 74M are overlapped are paired with a pair of heating rolls 842 and 852 (or a heating roll 842 and a resin roll 852). By passing between the layers, the second laminate is heated and pressurized, and the layers 72M, 73M, 2M, 6M, 3M, and 74M are joined.
Note that, as described above, for example, in the preparation step, in the case where a layer in which two or more arbitrary layers are stacked is prepared, the stack of two or more layers is used in FIGS. 14 and 15.

Examples of the bonding method of each layer by heat and pressure include a laminating method, a calendering method, and a continuous pressing method. Among them, the method of continuously joining the laminate by heating and pressing with a roll, such as a laminating method and a calendering method, is preferable because many products can be manufactured at one time. In particular, the laminating method can be most suitably applied in the present invention because many laminated bodies can be joined at one time. The heating temperature and pressure of the laminating method are appropriately set according to a known processing method. For example, the heating temperature of the laminate is 140 ° C. to 200 DEG ° C., the pressure between the rolls ^{is 20kgf / cm 2 ~100kgf / cm 2} .
The flooring shown in the second to fifth embodiments can be obtained by omitting the lamination of appropriate layers among the layers shown in FIGS. 14 and 15 or adding appropriate layers.

<Embossing process>
An embossing process is performed as needed in order to form an unevenness | corrugation in the upper surface or lower surface of the said laminated body. By passing the laminate 1M in which the layers are integrated through the rolls 84, 85, 841, 851, 842, and 852 between the embossing roll 86 and the receiving roll 87, irregularities are formed in the laminate 1M. According to the present invention, it is excellent in embossing and a good embossed shape can be formed on the upper surface of the flooring.

<Scratch prevention layer forming process>
This step is performed as necessary in order to form an anti-scratch layer on the upper surface of the protective layer 72M.
On the upper surface of the laminate 1M, for example, an ionizing radiation curable monomer or oligomer (scratch prevention layer forming material 71M) is applied using a roll coater 88 or the like, and an ionizing radiation irradiation device 89 is used for ionization. By irradiating with radiation, the flooring 1 in which the damage prevention layer is formed on the uppermost surface is obtained.
The obtained long belt-like flooring 1 is wound up on a roll as necessary, and is stored and transported. Further, when the flooring 1 of the present invention is a single-leaf tile, the long strip-like flooring is cut into an appropriate size by punching, cutting, etc. Provided for transportation.

  In general, it is difficult to bond a glass sheet and a resin layer. In particular, when the resin layer is made of a vinyl chloride resin, it is difficult to enhance the bondability to the glass sheet. In particular, the suspension vinyl chloride resin is difficult to penetrate between the fibers of the glass sheet, and therefore has low bondability. In this regard, a method of increasing the processing temperature at the time of joining the resin layer and the glass sheet is also conceivable. However, the resin layer may be deteriorated, or if the heat is not applied uniformly, the resin may be locally stretched to impair the design. This is not preferable. Conventionally, flooring materials using suspension vinyl chloride resin have laminated suspension vinyl chloride resin layers on the upper and lower surfaces of the glass sheet, and the laminate is heated and pressed between rolls to integrate the layers. Can be obtained by so-called laminating. However, it is difficult to adjust the heating temperature of the laminate during processing and the pressure between the rolls without excess or deficiency. When the heating temperature is too low or the pressure is too weak, peeling easily occurs between the resin layer and the glass sheet. On the other hand, when the heating temperature is too high or the pressure is too strong, the resin of each layer is deteriorated or the glass sheet is easily broken. If adjustment at the time of such processing is mistaken, the subject that manufacturing efficiency and product quality fall will arise.

According to the manufacturing method of the present invention, the upper resin layer 2M and the lower resin layer 3M are laminated on the glass sheet 6M with resin to which the bonding resin 5M having a predetermined basis weight is previously attached. The resin layer 3M is bonded to the bonding resin 5M, and is easily bonded to the glass sheet 4M through the bonding resin 5M. The flooring obtained by the production method of the present invention is excellent in interlayer strength.
In particular, by constituting at least one of the upper resin layer 2M and the lower resin layer 3M with a suspension vinyl chloride resin, the flooring 1 having a relatively small thickness while having sufficient mechanical strength can be constructed. Further, since the paste vinyl chloride resin is excellent in compatibility with the suspension vinyl chloride resin, the bonding resin 5M is made of the paste vinyl chloride resin, and the upper resin layer 2M and the lower resin layer 3M are made of the suspension vinyl chloride resin. By comprising resin, it is possible to obtain a flooring 1 that is difficult to delaminate, has excellent mechanical strength, and has a relatively small thickness.
Furthermore, by using the first bonding resin 5a and the second bonding resin 5b as the bonding resin, a flooring material having excellent interlayer strength can be obtained even if the basis weight of the bonding resin is reduced.

  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.

[Materials used]
First glass nonwoven fabric (trade name “Grabest” manufactured by Olivest Co., Ltd.). Nonwoven fabric width: 193 cm, length: 3000 m, thickness: 0.25 mm. Glass fiber and pulp mixed nonwoven fabric. Thickness of glass fiber: diameter of about 18 μm, length of glass fiber: about 13 mm, basis weight of glass fiber: 25.1 g / m ² . Pulp thickness: 10 μm to 30 μm, pulp weight per unit area: 6.4 g / m ² . Weight per unit area of the nonwoven fabric including glass fiber, pulp and a binder for binding them: 37.0 g / m ² . The air permeability of the first glass nonwoven fabric was 295 cc / cm ² · sec.

Second glass nonwoven fabric (trade name “Grabest” manufactured by Olivest Co., Ltd.). Nonwoven fabric width: 193 cm, length: 3000 m, thickness: 0.25 mm. Glass fiber and pulp mixed nonwoven fabric. Thickness of glass fiber: diameter of about 18 μm, length of glass fiber: about 13 mm, basis weight of glass fiber: 31.5 g / m ² . Pulp thickness: 10 μm to 30 μm, pulp weight per unit area: 5.5 g / m ² . Weight per unit area of the nonwoven fabric including glass fiber, pulp and a binder for binding them: 45.0 g / m ² . The air permeability of this second glass nonwoven fabric was 199 cc / cm ² · sec.

-Paste vinyl chloride resin Trade name "Kane Vinyl" manufactured by Kaneka Corporation. Degree of polymerization: 1150, K value: 69.
-Suspension vinyl chloride resin The product name "Kane Vinyl" manufactured by Kaneka Corporation. Degree of polymerization: 1050, K value: 67.

[Example 1]
The viscosity of the paste vinyl chloride resin was adjusted to 2000 mPa · s by mixing 100 parts by mass of the paste vinyl chloride resin with 73 parts by mass of dioctyl phthalate as a plasticizer and 150 parts by mass of calcium carbonate as a filler. . This resin was used as the first bonding resin. The viscosity was measured at 20 ° C. and 60 rpm using a BM viscometer (trade name “BII viscometer-BMII” manufactured by Toki Sangyo Co., Ltd.).
Using a general-purpose roll coater on the top surface of the first glass nonwoven fabric, the first bonding resin is applied so that the basis weight of the first bonding resin is about 350 g / m ^2. A glass sheet was prepared.
The air permeability of this glass sheet with resin was 0 cc / cm ² · sec.
In addition, the measurement of each air permeability of the 1st glass nonwoven fabric and the glass sheet with resin was performed as described above.

Separately, the suspension vinyl chloride resin is calendered using a general-purpose calender molding machine to produce a resin layer having a width of 193 cm, a length of 3000 m, and a thickness of 0.5 mm. Layered. A design printing layer having a thickness of about 1 μm was formed on the upper surface of the upper resin layer using a known ink by a known printing method.
Similarly, the suspension vinyl chloride resin was extruded to produce a resin layer having a width of 193 cm, a length of 3000 m, and a thickness of 1.45 mm, and this was used as the lower resin layer.

In order from the upper side, the upper resin layer provided with the design printing layer, the glass sheet with resin, and the lower resin layer are overlapped, and the laminate is heated to 150 ° C. with a preheater, and each laminate is 50 ° C. By passing between the upper and lower laminating rolls, a long belt-like floor material having a thickness of about 2.3 mm was produced. In addition, the conveyance speed of the laminated body was about 10 m / min, and the pressure applied to the laminated body was 40 kgf / cm ² .
When the obtained flooring material was cut and the cut surface was magnified 50 times and observed, the first glass nonwoven fabric was buried in the first bonding resin, and the structure shown in FIG. 3 was obtained. It was. Furthermore, the thickness from the upper surface of the first glass nonwoven fabric to the upper surface of the bonding resin layer (the thickness of the upper bonding resin layer), the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer (the units of each thickness are mm). The results are shown in Table 1.

[Example 2]
In the same manner as in Example 1, a first bonding resin was prepared.
The viscosity of the paste vinyl chloride resin was adjusted to 1000 mPa · s by mixing 100 parts by mass of the paste vinyl chloride resin with 99 parts by mass of dioctyl phthalate as a plasticizer and 1 part by mass of calcium carbonate as a filler. . A resin not containing this filler was used as the second bonding resin.
After applying the second bonding resin to the upper surface of the first glass nonwoven fabric using a general-purpose roll coater so that the basis weight of the second bonding resin is about 50 g / m ² , On the upper surface side, using a general-purpose knife coater, the first bonding resin was applied so that the basis weight of the first bonding resin was about 300 g / m ² , thereby producing a glass sheet with a resin.
The air permeability of this glass sheet with resin was 0 cc / cm ² · sec. Hereinafter, also in Examples 3 to 9, the air permeability of the glass sheet with resin was 0 cc / cm ² · sec.

Thereafter, in the same manner as in Example 1, a 0.5 mm thick upper resin layer and a 1.45 mm lower resin layer having a design printing layer were laminated on a glass sheet with resin, and heated and pressed to obtain a thickness of about A 2.3 mm long strip-shaped flooring was produced. The thicknesses of the flooring materials of Examples 3 to 9 and Comparative Examples 1 to 4 were all 2.3 mm.
When the obtained flooring was cut, and the cut surface was magnified 50 times and observed, the second resin layer adhered to the surface of the glass fiber, and the first bonding resin was substantially from the upper side of the first glass nonwoven fabric. It existed even in the middle part, and the lower surface of the first glass nonwoven fabric was covered with the second bonding resin. That is, Example 2 had a structure as shown in FIG.
As in Example 1, the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer were measured. The results are shown in Table 1.
The bonding resin was also present in layers on the lower side of the glass nonwoven fabric, but its thickness was about several tens of μm. Hereinafter, also in Examples 3 to 9, the bonding resin was present at a thickness of several tens of μm below the glass nonwoven fabric.

[Example 3]
Similar to Example 1 except that the weight of the first bonding resin was changed to 500 g / m ² and the thickness of the lower resin layer was changed to 1.3 mm when the glass sheet with resin was produced. A flooring was prepared.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 4]
Similar to Example 2 except that the basis weight of the first bonding resin was changed to 500 g / m ² and the thickness of the lower resin layer was changed to 1.25 mm when the glass sheet with resin was produced. A flooring was prepared.
When the obtained flooring was cut and observed, the second resin layer adhered to the surface of the glass fiber, and the first bonding resin was present from the upper side to the lower side of the glass nonwoven fabric. That is, Example 4 had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 5]
A flooring was prepared in the same manner as in Example 3 except that the second nonwoven fabric was used instead of the first glass nonwoven fabric.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 6]
Similar to Example 1 except that the weight of the first bonding resin was changed to 600 g / m ² and the thickness of the lower resin layer was changed to 1.2 mm when the glass sheet with resin was produced. A flooring was prepared.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 7]
Similar to Example 1 except that the basis weight of the first bonding resin was changed to 650 g / m ² and the thickness of the lower resin layer was changed to 1.15 mm when the glass sheet with resin was produced. A flooring was prepared.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 8]
Similar to Example 1 except that the weight of the first bonding resin was changed to 950 g / m ² and the thickness of the lower resin layer was changed to 1.0 mm when the resin-coated glass sheet was produced. A flooring was prepared.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Example 9]
Similar to Example 1 except that the basis weight of the first bonding resin was changed to 1100 g / m ² and the thickness of the lower resin layer was changed to 0.8 mm when the resin-coated glass sheet was produced. A flooring was prepared.
The obtained flooring had a structure as shown in FIG. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Comparative Example 1]
The floor was the same as in Example 1 except that the bonding resin was not adhered to the glass nonwoven fabric, that is, the first glass nonwoven fabric itself was used and the thickness of the lower resin layer was changed to 1.7 mm. A material was prepared.
When the obtained flooring was cut and observed, the glass nonwoven fabric was compressed. From the cut surface, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer were measured. The results are shown in Table 1.

[Comparative Example 2]
Similar to Example 1 except that the basis weight of the first bonding resin was changed to 250 g / m ² and the thickness of the lower resin layer was changed to 1.55 mm when the glass sheet with resin was produced. A flooring was prepared.
When the obtained flooring was cut and observed, the first bonding resin was present from the upper side of the glass nonwoven fabric to the substantially middle portion, but the first bonding resin adhered to the glass fiber on the lower surface of the glass nonwoven fabric. The lower resin layer was directly bonded to the glass fiber on the lower surface of the glass nonwoven fabric. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Comparative Example 3]
Similar to Example 1, except that the basis weight of the first bonding resin was changed to 300 g / m ² and the thickness of the lower resin layer was changed to 1.5 mm when the glass sheet with resin was produced. A flooring was prepared.
When the obtained flooring was cut and observed, it was the same structure as Comparative Example 2. Table 1 shows the results of the thickness of the upper bonding resin layer, the thickness of the glass nonwoven fabric, the thickness of the upper resin layer, and the thickness of the lower resin layer.

[Comparative Example 4]
The bonding resin was not adhered to the glass nonwoven fabric, that is, the first glass nonwoven fabric itself was used, the thickness of the upper resin layer was changed to 2.2 mm, and the lower resin layer was not laminated. Except for the above, a flooring was produced in the same manner as in Example 1.
When the obtained flooring was cut and observed, the glass nonwoven fabric was compressed. From the cut surface, the thickness of the glass nonwoven fabric and the thickness of the upper resin layer were measured. The results are shown in Table 1.

[Interlayer strength test for flooring]
When the delamination strength between the upper resin layer and the glass sheet was measured for the flooring materials of each Example and Comparative Example, it was as shown in Table 1. However, in Examples 8 and 9 and Comparative Example 4, since the result of interlayer strength can be predicted, no actual measurement was performed.
The delamination strength was measured according to the delamination strength test method of JIS A 1454 (polymer-based tension flooring test method).
Specifically, the flooring material is cut into a width of 50 mm and a length of 150 mm to obtain a measurement sample, and a cutter is inserted at the boundary between the upper resin layer and the glass sheet in the end face of the sample, and the sample is divided into two in the thickness direction. And an upper piece and a lower piece were formed on the end face. This sample was measured with a tensile tester by pulling the upper piece at a pulling speed of 200 mm / min.

<Processability>
The processability evaluated the ease of operation | work at the time of apply | coating joining resin to a glass sheet and producing a glass sheet with resin. The results are shown in Table 1. However, in Examples 8 and 9, the results could be predicted, so the workability was not evaluated.
The evaluation of workability in Table 1 is as follows.
○: The glass sheet with resin could be smoothly conveyed using a roll during the production process, and no wrinkles were formed on the finished glass sheet with resin.
(Triangle | delta): Although the glass sheet with resin was able to be conveyed using the roll in the manufacture process, a wrinkle might arise in the completed glass sheet with resin.

<Waring warpage test>
When the warpage of the flooring material of each Example and Comparative Example was measured, it was as shown in Table 1.
The warpage was measured at 5 ° C. in accordance with the warpage test method of JIS A 1454 (polymer-based stretch flooring test method).
Specifically, a flooring material is cut into a width of 303 mm and a length of 303 mm to obtain a measurement sample. A case where the end portion warps downward is represented by minus (mm), and a case where the end portion warps upward is represented by plus (mm). In a flooring, since the accommodation at the time of laying worsens, it is not preferable to warp upward.

From the comparison between Examples 1 to 7 and Comparative Examples 2 and 3 in Table 1, by using a glass sheet with a resin to which a bonding resin is adhered with a basis weight of 320 g / m ² or more, a flooring material having excellent delamination strength is obtained. It can be seen that it can be obtained. Further, it can be seen from the comparison between Examples 1 to 5 and Example 6 that the workability is improved when the basis weight of the bonding resin is 630 g / m ² or less.
Further, from the comparison between Example 1 and Example 2 and the comparison between Example 2 and Example 3, by using the first bonding resin and the second bonding resin, even if the basis weight of the bonding resin is reduced, the interlayer is reduced. It can be seen that a flooring excellent in strength can be obtained.
Further, it can be seen from Examples 1 to 8 that the flooring has a small warpage due to the glass sheet being disposed at a substantially intermediate portion of the thickness of the flooring.
The position of the middle part of the glass sheet can be specified as the thickness of the flooring material × K times, but the K times is K = (the thickness of the upper resin layer + the thickness of the upper bonding resin layer) for the flooring material of this example. + Thickness of glass sheet × 1/2) / thickness of flooring.
For example, in Example 2, the middle part of the thickness of the glass sheet is extended to a location of floor material thickness × about 0.31 times, and in Example 3, the middle part of the thickness of the glass sheet is the floor. In Example 4, the middle portion of the thickness of the glass sheet is extended to a location of floor material thickness × about 0.4 times. Thus, a floor material with small curvature can be obtained by arrange | positioning a glass sheet in the approximate middle part of the thickness of a floor material.

1 Floor material 2,2M Upper resin layer 3,3M Lower resin layer 4,4M Glass sheet 5,5M Bonding resin 6,6M Glass sheet with resin

Claims (4)

A glass sheet with a resin having a glass sheet containing a plurality of glass fibers and a bonding resin attached to the glass sheet, wherein a glass sheet with a resin having a basis weight of the bonding resin of 320 g / m ² or more is prepared. Process,
The upper resin layer is laminated on the upper surface of the glass sheet with resin, the lower resin layer is laminated on the lower surface of the glass sheet with resin, and the upper resin layer, the glass sheet and the lower resin layer are integrated by heating and pressing. A method for producing a flooring having a process. The manufacturing method of the flooring material of Claim 1 whose basis weight of the joining resin of the said glass sheet with resin is 630 g / m < ² > or less. The bonding resin includes a paste vinyl chloride resin,
The method for manufacturing a flooring according to claim 1 or 2, wherein at least one of the upper resin layer and the lower resin layer includes a suspension vinyl chloride resin. An upper resin layer, a lower resin layer, and a glass sheet laminated between the upper resin layer and the lower resin layer, the glass sheet including a plurality of glass fibers,
Bonding resin is attached to the glass sheet,
A flooring in which the upper resin layer and the lower resin layer are bonded via the bonding resin.

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