JP2017115366A - Floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material not only excellent in surface performance such as scratch resistance, pollution resistance and weatherability but also excellent in unevenness followability.SOLUTION: A floor material includes a thermoplastic resin base material 11 and a decorative sheet 13 provided on the front side 11a of the resin base material 11, a first cushion layer 15 that is provided on the back side 11b of the resin base material 11, and a second cushion layer 17 that is provided between the resin base material 11 and the decorative sheet 13. The decorative sheet 13 has, for example, an olefinic decorative sheet, and an ionomeric clear layer (or an LLDPE-based clear layer and a polyolefinic clear layer) provided on the front side of the olefinic decorative sheet.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a flooring.

  In recent years, flooring materials are often used for indoor or outdoor building floors. Most of the flooring is a veneer coated, but it has a grainy design and natural texture, while it requires surface performance such as scratch resistance, contamination resistance, and weather resistance in practical use. For this reason, many recent flooring materials in which a decorative sheet having such surface performance is attached to a wooden base material are used (see, for example, Patent Document 1).

JP 2003-239517 A

Floor materials using decorative sheets are also used in concrete structures such as condominiums and office buildings. Concrete floors often have irregularities on the surface. For this reason, in addition to surface performance such as scratch resistance, contamination resistance, and weather resistance, the floor material using the decorative sheet is required to have non-land followability to the floor surface.
Therefore, the present invention has been made in view of such circumstances, and provides a flooring material that is excellent in surface performance such as scratch resistance, contamination resistance, and weather resistance, and also has excellent unevenness following ability. For the purpose.

  In order to solve the above-described problems, a flooring according to an aspect of the present invention includes a thermoplastic resin base material, a decorative sheet provided on the front surface side of the resin base material, and a back surface side of the resin base material. And a second cushion layer provided between the resin base material and the decorative sheet.

  According to one embodiment of the present invention, it is possible to provide a flooring material that has excellent surface performance such as scratch resistance, contamination resistance, and weather resistance, and also has excellent unevenness following ability.

It is sectional drawing which shows typically the structural example of the flooring 10 which concerns on 1st Embodiment of this invention. It is sectional drawing which shows the structural example of the decorative sheet 13 typically. It is sectional drawing which shows typically the structural example of the flooring 20 which concerns on 2nd Embodiment of this invention. It is sectional drawing which shows typically the structural example of the flooring 30 which concerns on 3rd Embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, in all the drawings described below, parts corresponding to each other are denoted by the same reference numerals, and description of the overlapping parts will be omitted as appropriate. Further, the embodiment of the present invention exemplifies a configuration for embodying the technical idea of the present invention, and specifies the material, shape, structure, arrangement, dimensions, etc. of each part as follows. Not. Further, the drawings are schematic, and the length and thickness dimensions of each layer in each drawing are different from the actual ones, and their ratios may be different from the actual ones. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

<First Embodiment>
〔Constitution〕
FIG. 1 is a cross-sectional view schematically showing a configuration example of a flooring 10 according to the first embodiment of the present invention.
As shown in FIG. 1, this flooring 10 is provided on a resin base material (backer layer) 11, a decorative sheet 13 provided on the front surface 11 a side of the resin base material 11, and a back surface 11 b side of the resin base material 11. The first cushion layer 15 and the second cushion layer 17 provided between the resin base material 11 and the decorative sheet 13 are provided.

(1) Resin base material The resin base material 11 is a thermoplastic resin base material, and the thickness is 1.5 mm or more and 5 mm or less. The resin base material 11 includes polypropylene (PP) resin, wood powder, talc and the like.
The resin constituting the resin base material 11 is not limited to PP resin, but polyethylene, ethylene-vinyl alcohol copolymer, polymethylene, polymethylbenzene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyarylate, polyethylene naphthalate. -An isophthalate copolymer, polyimide, polystyrene, polyamide, acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene copolymer (AS), etc. may be sufficient.

(2) Decorative sheet The decorative sheet 13 is a decorative sheet for heavy walk floors. Here, a heavy walk floor decorative sheet is a floor decorative sheet for use in harsh environments where there is a large amount of walking, dirt or sand that comes in contact with shoes, and is expected to be transported by a bogie. That is. As such a floor surface, the floor surface of the entrance of a condominium or an office building, the floor surface of a store, etc. are mentioned.

As shown in FIG. 1, the surface 13 a of the decorative sheet 13 may be provided with irregularities. When the surface 13a of the decorative sheet 13 is uneven, the anti-slip performance of the surface 13a can be enhanced. This unevenness can be formed by embossing.
2A and 2B are cross-sectional views schematically showing a configuration example of the decorative sheet 13. As shown in FIG. 2A, the decorative sheet 13 includes an olefin-based decorative sheet 131 and a surface protective layer 133 provided on the surface 131a side of the olefin-based decorative sheet 131. Although not shown, a pattern layer such as wood grain may be provided on the surface 131a side of the olefin-based decorative sheet 131. Further, the pattern layer (not shown) may be covered with the surface protective layer 133.

  The surface protective layer 133 is preferably transparent to such an extent that the surface 131a (or a picture layer (not shown)) of the olefinic decorative sheet 131 located therebelow can be seen through. The surface protective layer 133 is preferably colorless and transparent, but may be colored and transparent or translucent, and may contain a colorant or a filler. The term “transparent” refers to a degree of transparency that allows the back to be visually recognized from the front.

The surface protective layer 133 is an ionomer-based clear layer. The total thickness of the decorative sheet 13 having the olefin-based decorative sheet 131 and the ionomer-based clear layer is 150 μm or more and 500 μm or less, and particularly preferably 300 μm or more and 400 μm or less.
Alternatively, the surface protective layer 133 may be a linear low density polyethylene (hereinafter, LLDPE) clear layer. The total thickness of the decorative sheet 13 having the olefin-based decorative sheet 131 and the LLDPE-based clear layer is preferably 150 μm or more and 500 μm or less, and particularly preferably 300 μm or more and 400 μm or less.

Alternatively, the surface protective layer 133 may be a polyolefin-based clear layer. The total thickness of the decorative sheet 13 having the olefin-based decorative sheet 131 and the polyolefin-based clear layer is preferably from 100 μm to 300 μm, and particularly preferably from 120 μm to 200 μm.
Note that an amorphous polyethylene terephthalate (hereinafter, A-PET) layer may be provided on the back surface 13b (see FIG. 1) side of the decorative sheet 13. For example, as shown in FIG. 2B, an A-PET layer 135 may be attached to the back surface 131 b of the olefin-based decorative sheet 131.

(3) First Cushion Layer The first cushion layer 15 shown in FIG. 1 is a resin foam having a thickness of 0.1 mm to 10 mm (more preferably 0.5 mm to 3 mm). Here, the resin foam refers to one in which a large number of cavities exist on the surface and inside of the resin, and the entire resin is molded into a porous shape. As an example of the resin foam constituting the first cushion layer 15, a polyethylene (PE) -based foam can be cited.

In addition, the resin foam which comprises the 1st cushion layer 15 is not limited to PE type foam, A polyurethane (PUR) type foam, a polystyrene (PS) type foam, a polypropylene (PP) type foam It may be.
The first cushion layer 15 may not be a resin foam but may be a rubber sheet having a thickness of 0.1 mm to 10 mm (more preferably 0.5 mm to 3 mm). For the rubber sheet, natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), styrene butadiene rubber (SBR), chloroprene rubber (CR), butyl rubber (IIR), urethane rubber (U), etc. are used. be able to.

(4) Second Cushion Layer The second cushion layer 17 shown in FIG. 1 is a resin foam having a thickness of 0.1 mm to 10 mm (more preferably 0.5 mm to 3 mm). As an example of the resin foam constituting the second cushion layer 17, a polyethylene (PE) -based foam can be cited. In addition, the resin foam which comprises the 2nd cushion layer 17 is not limited to PE type foam, A polyurethane (PUR) type foam, a polystyrene (PS) type foam, a polypropylene (PP) type foam It may be.

[Effects of First Embodiment]
The first embodiment of the present invention has the following effects (1) to (6).
(1) The flooring 10 includes a thermoplastic resin base material 11, a decorative sheet 13 provided on the front surface 11a side of the resin base material 11, and a first cushion provided on the back surface 11b side of the resin base material 11. A layer 15 and a second cushion layer 17 provided between the resin base material 11 and the decorative sheet 13. By covering the surface 11 a of the resin base material 11 with the decorative sheet 13, it is possible to realize a flooring material having excellent surface performance such as scratch resistance, contamination resistance, and weather resistance in addition to being able to impart desired design properties. it can.

  Further, the back surface 11 b of the resin base material 11 is covered with the first cushion layer 15. Thereby, even when the flooring 10 is arranged on a floor surface with unevenness such as a concrete floor surface, the first cushion layer 15 can be deformed according to the unevenness, and the back surface of the resin base material 11 It is possible to prevent a gap from being generated between 11b and the floor surface. Thereby, the back surface side of the flooring 10 can be adhered to the floor surface.

  From the above, it is possible to provide a flooring material that is excellent in surface performance such as scratch resistance, contamination resistance, and weather resistance, and that is also excellent in unevenness following ability. Moreover, since the 1st cushion layer 15 and the 2nd cushion layer 17 can repeat a deformation | transformation and decompression | restoration and have an impact absorption performance, the flooring excellent also in impact resistance can be provided.

(2) The decorative sheet 13 may be composed of an ionomer-based clear layer / olefin-based decorative sheet, or an LLDPE-based clear layer / olefin-based decorative sheet, or an olefin-based clear layer / olefin-based decorative sheet.
The ionomer-based clear layer can be made of a polymer structure composed of materials such as ethylene, polypropylene, urethane, styrene, and fluorine. It is desirable in terms of cost and material procurement by selecting an ethylene type. As one of these features, one has elasticity and flexibility, so performance such as impact resistance and wear resistance is good. In addition, it is excellent in extrudability and embossability because of easy molding by heating. In addition to having high weather resistance, it is possible to add various weathering agents.

  For the polyolefin-based clear layer, materials such as polyethylene, propylene homopolymer, ethylene-propylene random copolymer, and ethylene-propylene block copolymer can be used. The thickness should just be 50-200 micrometers, and 70-130 micrometers is especially desirable. A polyolefin-based clear layer is relatively inexpensive and available, and has good moldability.

A second surface protective layer may be further provided on the surface side of the surface protective layer. For the second surface protective layer, any one or a plurality of materials of a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin can be used. By this, further surface hardness can be provided.
From the above, it is possible to provide a flooring further improved in wear resistance, scratch resistance (caster resistance), weather resistance and cold shock resistance.

  (3) The decorative sheet 13 may have an A-PET layer 135 on the back side thereof. Thereby, the flooring which further improved (dent restoration property) can be provided. When a load or impact is applied from the surface side of the decorative sheet 13, those stresses can be absorbed by the cushion layer 15, but in some cases, it becomes difficult to restore the recessed shape. Therefore, by providing the A-PET layer 135 on the back side, the toughness of the decorative sheet 13 is increased and the dent can be restored.

(4) The resin base material 11 is thermoplastic. The thermoplastic resin substrate 11 can be repeatedly deformed and restored. For this reason, the flooring which further improved impact resistance, heel mark property, and simple construction nature can be provided. Since it can be easily bent, cut or folded, the flooring can be stored even in a complicated space.
(5) The first cushion layer 15 may be a resin foam or a rubber sheet. The resin foam or rubber sheet can be repeatedly deformed and restored, and has high shock absorption performance and high sound absorption performance. Therefore, when the first cushion layer 15 is a resin foam or a rubber sheet, it is possible to provide a flooring further improved in impact resistance, sound generation property and unevenness following ability.

  (6) The second cushion layer 17 may be a resin foam. The resin foam can be repeatedly deformed and restored, and has high impact absorption performance and high sound absorption performance. For this reason, when the second cushion layer 17 is a resin foam, it is possible to provide a flooring further improved in impact resistance and sound output.

Second Embodiment
FIG. 3 is a cross-sectional view schematically showing a configuration example of the flooring 20 according to the second embodiment of the present invention.
As shown in FIG. 3, the flooring 20 includes a foamed polypropylene (PP) base material 21, a decorative sheet 13 provided on the surface 21 a side of the foamed PP base material 21, and a back surface 21 b side of the foamed PP base material 21. And a second cushion layer 17 provided between the foamed PP base material 21 and the decorative sheet 13. The foamed PP base material 21 contains polypropylene (PP) as a main component. In this specification, a main component is a component with a high ratio in the whole substance, for example, points to the case of 70 mass parts or more when the whole is 100 mass parts. The foamed PP base material 21 is a backer layer, and the thickness thereof is 0.1 mm or more and 10 mm or less (more preferably 0.5 mm or more and 3 mm or less). Even with such a configuration, the same effects as the effects (1) to (6) of the first embodiment described above can be obtained.

  In the second embodiment, as in the first embodiment, the decorative sheet 13 is composed of an ionomer-based clear layer / olefin-based decorative sheet or an LLDPE-based clear layer / olefin-based decorative sheet. 13 may be a heavy walk floor decorative sheet having a total thickness of 150 μm or more and 500 μm or less. The decorative sheet 13 may be a polyolefin-based clear layer / olefin-based decorative sheet, and the decorative sheet 13 may have a total thickness of 100 μm to 300 μm.

  In the second embodiment, the foamed PP base material 21 is exemplified as the foamed resin base material, but the resin (material) constituting the foamed resin base material is not limited to polypropylene (PP). In the present invention, as the foamed resin base material, a base material obtained by foaming various resins such as polyurethane (PUR) and polystyrene (PS) may be used.

<Third Embodiment>
FIG. 4 is a cross-sectional view schematically showing a configuration example of the flooring 30 according to the third embodiment of the present invention.
As shown in FIG. 4, the flooring 30 includes an SF base material 31, a decorative sheet 13 provided on the surface 31 a side of the SF base material 31, and a first surface provided on the back surface 31 b side of the SF base material 31. The cushion layer 15 and the second cushion layer 17 provided between the SF base material 31 and the decorative sheet 13 are provided. Here, the SF base material 31 is a wood powder-containing resin base material, and includes, by mass ratio, wood powder of 35% to 45%, talc of 10% to 20%, and polyethylene of 35% to 45%. In addition, the SF base material 31 may include an additive component other than wood powder, talc, and polyethylene. SF base material 31 includes each component such as wood powder, talc, polyethylene, and the like in the above ranges, and each component and the additive component and the like are added to each other so that a value obtained by adding 100% is 100%. Each mass% is adjusted. The SF substrate 31 is a backer layer, and the thickness thereof is 0.1 mm or more and 10 mm or less (more preferably 0.5 to 3 mm). Even with such a configuration, the same effects as the effects (1) to (6) of the first embodiment described above can be obtained.

  Also in the third embodiment, similarly to the first embodiment, the decorative sheet 13 is composed of an ionomer-based clear layer / olefin-based decorative sheet or an LLDPE-based clear layer / olefin-based decorative sheet, and is a decorative sheet. 13 may be a heavy walk floor decorative sheet having a total thickness of 150 μm or more and 500 μm or less. The decorative sheet 13 may be a polyolefin-based clear layer / olefin-based decorative sheet, and the decorative sheet 13 may have a total thickness of 100 μm to 300 μm.

<Others>
The technical idea of the present invention is not limited to the embodiments described above. Based on the knowledge of a person skilled in the art, design changes or the like may be added to each embodiment of the present invention, and each embodiment of the present invention may be arbitrarily combined, and such changes are added. Is also included in the technical idea of the present invention.

10, 20, 30 Floor material 11 Resin base material 11a, 13a, 21a, 31a, 131a Front surface 11b, 13b, 21b, 31b, 131b Back surface 13 Cosmetic sheet 15 First cushion layer 17 Second cushion layer 21 Foamed PP base Material 31 SF base material 131 Olefin-based decorative sheet 133 Surface protective layer 135 A-PET layer

Claims (8)

A thermoplastic resin substrate;
A decorative sheet provided on the surface side of the resin substrate;
A first cushion layer provided on the back side of the resin substrate;
A flooring material comprising: a second cushion layer provided between the resin base material and the decorative sheet. A foamed resin substrate;
A decorative sheet provided on the surface side of the foamed resin substrate;
A first cushion layer provided on the back side of the foamed resin substrate;
And a second cushion layer provided between the foamed resin base material and the decorative sheet. A resin base material containing wood powder,
A decorative sheet provided on the surface side of the resin base material containing wood powder;
A first cushion layer provided on the back side of the resin base material containing wood powder;
A flooring material comprising a second cushion layer provided between the wood powder-containing resin base material and the decorative sheet. The decorative sheet is
An olefin-based decorative sheet;
It has an ionomer type clear layer provided in the surface side of the said olefin type decorative sheet, The flooring as described in any one of Claims 1-3 characterized by the above-mentioned. The decorative sheet is
An olefin-based decorative sheet;
It has a linear low density polyethylene type clear layer provided in the surface side of the said olefin type decorative sheet, The flooring as described in any one of Claims 1-3 characterized by the above-mentioned. The decorative sheet is
An olefin-based decorative sheet;
The flooring according to any one of claims 1 to 3, further comprising a polyolefin-based clear layer having a thickness of 50 µm or more and 200 µm or less provided on the surface side of the olefin-based decorative sheet. The decorative sheet is
It has an amorphous polyethylene terephthalate layer provided in the back surface side of this decorative sheet, The flooring as described in any one of Claims 1-6 characterized by the above-mentioned.   The flooring according to any one of claims 1 to 7, wherein the cushion layer is a resin foam or a rubber sheet.

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