JP2020183627A - Anti-fouling floor material - Google Patents

Abstract

To provide a floor material having a preferable anti-slip property and an anti-fouling property against general fouling due to sediment, and an anti-fouling property against gray dotted fouling.SOLUTION: In a floor material using synthetic resin as a main material, (1) a front surface of the floor material is formed of roughly flat basement regions and crest parts protruded upward from the basement regions, (2) the basement regions have irregularities and level differences between bottoms of recesses and peaks of protrusions are 40 μm or less, (3) in the crest parts, heights from the peaks of the crests to the bottoms of the recesses of the basement regions are 50 μm or more, and (4) the crest parts in plant view of the floor surface show an island shape, and all the basement regions are practically communicated with each other.SELECTED DRAWING: Figure 1

Description

The present invention relates to a novel antifouling flooring material.

Flooring materials used in houses, commercial facilities, etc. are processed to prevent slipping in order to prevent pedestrians from tipping over. In particular, higher anti-slip properties are required on floor surfaces that get wet with tap water, rain, or the like, such as toilets, outer stairs, and outer corridors.

Various floor materials have been developed as floor materials capable of exhibiting such anti-slip properties. For example, wood grain printing with urethane ink on a raw sheet made of a polyolefin-based sheet, and wood grain conduit embossing made of a polyolefin resin with a depth of 5 μm to 150 μm and a spacing of 5 μm to 5 mm on the wood grain printing. The wood grain conduit embossed surface is provided with a large number of fine convex portions and a surface protective layer having a layer thickness of 1 to 7 μm made of an ultraviolet curable resin or a heat curable resin, and the height h of the convex portions is 10 to 100 μm. Yes, the width w of the convex portion from any side end of the convex portion to the opposite side end is 15 to 300 μm, and the distance from one point of the arbitrary convex portion to one point of the other convex portion at the shortest distance. There is known an anti-slip decorative sheet characterized in that d is 50 to 1000 μm and the point density of the convex portion is 1 to 300 points / mm2 (Patent Document 1).

Further, for example, the ultraviolet curable resin layer, the resin film layer, and the base material layer are bonded and integrated in this order, and embossing is performed from the ultraviolet curable resin layer side to give an uneven shape. A flooring material for around water has been proposed (Patent Document 2).

In addition, for example, in a sheet composed of a surface layer 2, an intermediate layer 3, and a lower layer 4 and having an embossed surface, the surface layer 2 is a thermoplastic resin layer having a weather resistance of 3rd grade or higher, or the surface layer 2. An outdoor sheet has been proposed, which has an intermediate layer 3 having a pattern having a weather resistance of 3rd grade or higher, and is provided with embossing of 0.1 mm or more and 2 mm or less on the surface (Patent Document). 3).

As described above, in the prior art, desired anti-slip property is imparted by forming predetermined irregularities on the surface. In this case, if, for example, the embossing is deepened in order to further enhance the anti-slip property, dirt is likely to accumulate in the recess, and the anti-fouling property is lowered. For this reason, the size of the unevenness is set in consideration of the balance between anti-slip property and anti-fouling property.

JP-A-2016-186215 Japanese Unexamined Patent Publication No. 2016-89472 Japanese Unexamined Patent Publication No. 2000-129855

These stains on the floor surface are different from general stains on the floor surface due to earth and sand, dust, dust, etc., and on the floor surface such as toilets and washrooms, there are stains peculiar to the environment around water. More specifically, earth and sand and water combine to form muddy water, which enters the recesses on the floor surface and causes spot-like black spot stains (also referred to as "sesame salt stains") as shown in FIG. ..

There are two methods for removing such stains: wet cleaning and dry cleaning. Wet cleaning is cleaning that uses a deck brush, detergent, or the like to scrape off dirt while flowing water on the floor, assuming that a drainage port is provided on the floor. Dry cleaning is cleaning that wipes off dirt with a dry or damp mop, rag, etc. without running water on the floor.

However, in recent years, from the viewpoint of hygiene, the number of toilets, washrooms, etc. that can only be used for dry cleaning has tended to increase, and since there is no drainage port in these facilities, wet cleaning that allows water to flow to the floor cannot be performed. Therefore, on the floor surface where wet cleaning cannot be performed, even if sesame salt stains occur, there is a problem that the sesame salt stains remain because only dry cleaning can be performed. For this reason, there is a demand for a flooring material that does not easily generate sesame salt stains, or a flooring material that can be removed relatively easily by dry cleaning even if sesame salt stains occur, but such flooring materials are still being developed. The current situation is that it has not reached.

Therefore, a main object of the present invention is to provide a flooring material capable of exhibiting good anti-slip property and antifouling property against general dirt caused by earth and sand, as well as antifouling property against sesame salt stain or easy cleaning.

As a result of intensive research in view of the problems of the prior art, the present inventor has found that the above object can be achieved by adopting a flooring material having a specific surface shape, and has completed the present invention.

That is, the present invention relates to the following antifouling flooring material.
1. 1. A flooring material whose main material is synthetic resin.
(1) The floor material surface is composed of a substantially flat base region and a mountain portion protruding upward from the base region.
(2) The basal region has irregularities on the surface, and the height difference between the bottom of the concave portion and the apex of the convex portion is 40 μm or less.
(3) The height of the mountain part from the apex of the mountain part to the bottom of the recess in the base region is 50 μm or more.
(4) When the surface of the floor material is viewed in a plan view, the mountain parts exist in an island shape independent of each other, and the base regions are substantially all connected.
An antifouling flooring material that is characterized by this.
2. Item 2. The antifouling flooring material according to Item 1, wherein the width of the basal region between adjacent mountain portions is 1.3 mm or more and 15 mm or less.
3. 3. Item 3. The antifouling flooring material according to Item 1 or 2, which is used as a flooring material for a toilet or a washroom.

According to the present invention, it is possible to provide a flooring material capable of exhibiting good anti-slip property and antifouling property against general dirt caused by earth and sand, as well as antifouling property against sesame salt stain. In particular, since the flooring material of the present invention employs a structure in which a mountain portion is provided and a specific base region is continuously formed around the mountain portion, even if dirt adheres to the floor material, it can be removed relatively easily. it can. For this reason, even stains that could only be removed by wet cleaning (especially sesame salt stains) can be relatively easily removed by dry cleaning with existing or commercially available cleaning tools such as mops and rags (especially dry cleaning tools). Can be removed. That is, it is possible to wipe off sesame salt stains relatively easily by dry cleaning with a dry or damp mop, a rag, or the like without flowing a relatively large amount of water on the floor surface.

A flooring material having such characteristics can be suitably used as a flooring material for a facility where wet cleaning is difficult even in an environment where it gets wet with water. In particular, the floor material of the present invention is most suitable as a floor material for toilets, washrooms, etc. in an environment contaminated with muddy water.

It is a schematic diagram which shows the surface shape of the floor material of this invention. It is a schematic diagram when the floor material of this invention is viewed in a plan view. It is a schematic diagram when the floor material of this invention is viewed in a plan view. It is a figure which shows the layer structure of the floor material produced in Example 1. It is a schematic diagram which shows the concept of the height difference (or the height of a mountain part) of the unevenness of the base region in the cross-sectional curve output from the surface roughness measuring machine. It is a schematic diagram which shows the concept of the width of the base region in the cross-sectional curve output from the surface roughness measuring machine. It is a figure which shows the surface property property obtained by molding the embossing roll used in Example 1 with a silicon resin. It is a result (image) of observing the surface of Example 1 with a three-dimensional measurement scanning electron microscope (3D-SEM). It is a figure which shows a part of the cross-sectional curve obtained by measuring the floor material surface of Example 1 with a surface roughness measuring machine. It is a figure which shows a part of the cross-sectional curve obtained by measuring the floor material surface of the comparative example 1 with a surface roughness measuring machine. It is a figure which shows a part of the cross-sectional curve obtained by measuring the floor material surface of the comparative example 2 with a surface roughness measuring machine. It is a figure which shows a part of the cross-sectional curve obtained by measuring the floor material surface of the comparative example 3 with a surface roughness measuring machine. It is a figure which shows a part of the cross-sectional curve obtained by measuring the floor material surface of the comparative example 4 with a surface roughness measuring machine. The appearance of the floor surface in which sesame salt stain is added to the conventional general floor material is shown. The black spots are sesame salt stains.

1. 1. Antifouling flooring material The antifouling flooring material of the present invention (the flooring material of the present invention) is a flooring material whose main material is synthetic resin.
(1) The floor material surface is composed of a substantially flat base region and a mountain portion protruding upward from the base region.
(2) The basal region has irregularities on the surface, and the height difference between the bottom of the concave portion and the apex of the convex portion is 40 μm or less.
(3) The height of the mountain part from the apex of the mountain part to the bottom of the recess in the base region is 50 μm or more.
(4) When the surface of the floor material is viewed in a plan view, the mountain parts exist in an island shape independent of each other, and the base regions are substantially all connected.
It is characterized by that.

A. Surface Structure of Floor Material of the Present Invention The outline of the floor material of the present invention will be described with reference to the illustration. FIG. 1 shows a cross-sectional structure (image) near the surface of the floor material of the present invention. As shown in FIG. 1, the surface of the floor material of the present invention is composed of a base region 11 and a mountain portion 12. The basal region 11 has a substantially flat surface (that is, an uneven surface within a range lower than the top of the mountain portion 12), and is a so-called satin-finished surface. The mountain portion 12 exists in a state of protruding upward from the basal region. As described above, the surface of the floor material has a form as if mountains are scattered in the plain having a satin surface.

Further, FIG. 2 shows a schematic view of the floor material surface over a wide area as viewed from the direction A of FIG. As shown in FIG. 2, the plurality of mountain portions 12 are scattered in an island shape independent of each other, and the basal regions are substantially all connected.

Here, the above-mentioned "island-like shape independent of each other" means that a basal region is formed between each mountain portion, and a plurality of ridges contact each other and do not completely surround the basal region. However, a part of the mountain portions may be in contact with each other within a range that does not interfere with the effect of the present invention.

Further, the above-mentioned "substantially all communicating" means that the base region is connected to one as a whole on the floor material surface, and the base is isolated within a range that does not interfere with the effect of the present invention. It means that some areas may be included. For example, as shown in FIG. 3, an isolated basal region (region completely surrounded by a mountain portion) 21 is allowed within a range that does not interfere with the effect of the present invention, but allows dirt to be discharged smoothly. From this point of view, it is more preferable that the region 21 does not exist on the surface of the floor material. As described above, in the floor material of the present invention, by adopting a configuration in which substantially all the base regions are communicated with each other, even if dirt adheres to the floor material surface, it is easily discharged naturally or at the time of cleaning. Therefore, the floor surface can be maintained in a relatively clean state.

The overall shape itself as shown in FIG. 2, particularly the above-mentioned "island-like shape independent of each other" and the above-mentioned "substantially all communicating" is known, for example, in a three-dimensional measuring scanning electron microscope (3D-SEM). Alternatively, it can be confirmed with a commercially available analyzer.

Further, it is desirable that the mountain portion 12 is irregularly formed in a plan view of the floor surface surface. Due to lack of regularity or low regularity, anti-slip properties can be exhibited evenly in all directions in the plane direction.

About the basal region The basal region has irregularities to the extent that it becomes a satin surface as described above. More specifically, the upper limit of the height difference is in the range of 40 μm or less, preferably in the range of 30 μm or less. The lower limit is not limited, but is usually 1 μm or more, preferably 5 μm or more. By setting the degree of unevenness in the base region within the above range, more excellent antifouling property and design property can be obtained. Specifically, by forming the unevenness within the above range, dirt-causing substances such as earth and sand come into point contact with each other, making it difficult for the dirt-causing substances to adhere, and even if they do adhere, their removal becomes easy even with dry cleaning. .. In addition, since the light is diffusely reflected by the satin-finished surface due to the unevenness, the gloss like a mirror surface is lost, and the effect of making it difficult to visually recognize the adhesion of dirt can be obtained.

In the present invention, the height difference of the unevenness of the base region is determined by arbitrarily selecting the convex portion of the unevenness in the cross-sectional curve output from the surface roughness measuring machine and determining the lower valley of the valleys on both sides of the convex portion. Refers to the difference between the valley bottom and the apex of the convex part. FIG. 4 schematically shows a part of the cross-sectional curve. As shown in FIG. 4, when there are apex T of the convex portion and valleys V1 and V2 on both sides thereof, V2 is a valley lower than V1, and in that case, the height difference h is obtained. In the present invention, the height difference can also be expressed as an average value of each height difference of 10 points (preferably 100 points) of the convex portion having a height difference of 40 μm or less.

As the surface roughness measuring machine, a commercially available product can also be used. As an example of the commercially available product, product number "SURFCOM 130A-monochrome" (Tokyo Seimitsu ACCRETCH Co., Ltd., stylus: DM43822) can be mentioned. Similarly, such a commercially available product can be used in the measurement of each of the following physical properties.

The width of the basal region between the mountainous portions adjacent to each other is not particularly limited, but is preferably 0.5 mm or more and 15 mm or less, and more preferably 1 mm or more and 10 mm or less. As a result, it is possible to suppress or prevent the retention or adhesion of sesame salt stains while maintaining the anti-slip property.

In the present invention, the width of the basal region between adjacent peaks can be measured by the following procedure. As the first step, as shown in FIG. 2, in the plan view of the floor material surface, an arbitrary mountain portion 12 is selected, and three mountain portions 12a, 12b, 12c at the shortest distance from the mountain portion are selected. Mark all of these. As the second step, the unevenness of the straight line La straddling the vertices of both the mountain portion 12 and the mountain portion 12a is measured by a surface roughness measuring machine, and the cross-sectional curve thereof is output. As a third step, as shown in FIG. 5, the distance Wa between the valley V on the mountain portion 12a side in the mountain portion 12 and the valley Va on the mountain portion 12 side in the mountain portion 12a is measured from the obtained cross-sectional curve. This is the width of the base region. The width of the base region can be conveniently expressed as an average value of the widths of the base regions of 0.5 mm or more and 15 mm or less. In that case, following the above-mentioned third step, as the fourth step, in the relationship between the mountain part 12 and the mountain part 12b, a series of steps of the first step to the third step is carried out in the same manner to carry out the distance Wb. Ask for. As the fifth step, also in the relationship between the mountain portion 12 and the mountain portion 12c, a series of steps from the first step to the third step is carried out in the same manner to obtain the distance Wc. As the sixth step, the average value of the distances Wa, Wb, and Wc obtained in the third to fifth steps is obtained. The average value of the three numerical values thus obtained can be used as the width of the base region in the present invention. Further, the width of the basal region in the present invention can be an average value of 30 sets of combinations consisting of Wa, Wb, and Wc (the number of samples of the measured width is 90 in total).

The cross-sectional shape of the unevenness of the base region is not particularly limited, and may be, for example, a shape having a steep slope or a gentle shape. In particular, in the present invention, it is preferable that neither the shape of the unevenness of the base region in the plan view nor the cross-sectional shape has sharp corners. As a result, dirt adhering to the floor material surface can be more reliably discharged.

Further, in the plan view of the floor material surface, it is preferable that the unevenness of the base region is irregularly arranged. By arranging them randomly in this way, dirt can be uniformly removed regardless of the direction in which a cleaning tool such as a mop comes into contact with the cleaning tool.

About the mountain part The mountain part is higher than the convex part of the unevenness of the base region, and the height from the apex of the mountain part to the bottom of the concave part of the base region is usually 50 μm or more. More specifically, the lower limit of the height is usually 50 μm or more, preferably 60 μm or more, and more preferably 70 μm or more. The upper limit of the height is usually 200 μm or less, preferably 150 μm or less, and more preferably 130 μm or less. If it is at least this lower limit value, the desired anti-slip property can be exhibited, and if it is at least the upper limit value, the desired antifouling property can be exhibited.

The height of the mountain portion is the dimension from the highest apex of the mountain portion to the bottom of the recess in the base region. Specifically, in the base region between two adjacent peaks, the concave and convex recesses of the base region are arbitrarily selected, and the dimension with the apex of the peak is measured. As a more specific measurement method, the same method as the above-mentioned method for measuring the height difference of the unevenness of the base region may be used. That is, assuming that the apex T of the cross-sectional curve of FIG. 4 is the apex of the mountain part, the height difference h between the apex T of the mountain part and the lower valley V2 of the valleys V1 and V2 on both sides of the apex T of the mountain part is set. The height. In the present invention, 10 points (preferably 50 points) of a mountain portion having a height of 50 μm or more can be measured, and the average value thereof can be conveniently used as the height of the mountain portion.

The shape of the mountain portion in a plan view is not particularly limited, and may be, for example, a substantially circular shape, a substantially rectangular shape, an indefinite shape, or the like. The cross-sectional shape of the mountain portion is not particularly limited, and may be a shape having a steep slope or a gentle shape. In this case, the hem width of the mountain portion is usually about 0.5 mm to 2.0 mm, and can be particularly 0.7 mm to 1.5 mm, but is not limited thereto. As shown in FIG. 4, for example, the hem width of the mountain portion can be specified by the horizontal distance between the bottom points of V1 and the bottom points of V2 on both sides of the mountain portion. This can also be expressed as an average value in the same way as the height of the mountain.

In particular, in the present invention, it is preferable that neither the shape of the mountain portion in the plan view nor the cross-sectional shape has a sharp corner portion. As a result, dirt adhering to the surface of the floor material can be more reliably discharged. Further, in a plan view, it is preferable that each mountain portion is irregularly arranged. By arranging them randomly in this way, dirt can be uniformly removed regardless of the direction in which a cleaning tool such as a mop comes into contact with the cleaning tool. Such a shape can be confirmed based on, for example, a cross-sectional curve obtained by a surface roughness measuring device.

The abundance density of the mountain portion in the floor material of the present invention is not limited, but is generally preferably about 20 to 90 pieces / cm ² from the viewpoint of antislip and antifouling properties, and particularly 30 to 70 pieces. It is more preferable to set it to about / cm ² . By adjusting within the above range, more excellent anti-slip property and anti-fouling property can be ensured. For the above-mentioned abundance density, while checking the height of each mountain part with a surface roughness measuring device, arbitrarily select three 1 cm × 1 cm visual fields in the plan view of the floor material surface, and visually, with an optical microscope, and a magnifying glass. It is the average value of the number of peaks observed in each field of view.

Further, as shown in FIG. 2, the floor material surface is occupied by the base region and the mountain portion, and the ratio of both in the plan view of the floor material surface should be appropriately set according to the desired anti-slip property and the like. Can be done. For example, with the floor material surface as 100%, the area ratio (%) is within the range of base area: mountain part = 50:50 to 90:10, and further within the range of base area: mountain part = 60:40 to 90:10. However, it is not limited to this. These ratios can be controlled, for example, by appropriately changing the surface shape and pattern of the embossed roll used in the production of the floor material of the present invention.

The total thickness of the floor material of the present invention is not limited, but is usually about 0.5 mm to 10 mm, and particularly preferably 1 mm to 5 mm.

B. Layer structure of the floor material of the present invention The layer structure of the floor material of the present invention itself may be any one mainly made of synthetic resin, and examples thereof include those containing a resin-containing base material layer. The resin-containing base material layer can be used not only as a single layer as the flooring material of the present invention, but also as a laminate formed by laminating with another layer. As the layer structure itself as the laminated body, a layer structure similar to that of a known or commercially available floor material can be adopted. For example, a laminate including a resin-containing base material layer, a design layer, and a clear layer can be adopted in this order from the lower layer. In this laminated body, other layers (adhesive layer, surface protective layer, etc.) may be included as required.

Examples of the resin-containing base material layer include a layer containing at least one synthetic resin such as a vinyl chloride resin, a polyolefin resin, a polyurethane resin, and an acrylic resin. In particular, at least one of a vinyl chloride resin, a vinyl chloride-vinyl acetate copolymer resin, a polypropylene resin and the like can be preferably used in that high hardness can be obtained. A resin-containing base material layer can be formed by a resin composition containing these synthetic resins as a main material. In this case, the resin composition may contain other components as long as the effects of the present invention are not impaired. Examples thereof include plasticizers, fillers, stabilizers, processing aids, fungicides, flame retardants, antioxidants, lubricants, colorants and the like. In the present invention, "included as a main material" means that the content of the component exceeds 50% by weight, preferably 70% by weight or more, more preferably, when the whole composition is 100% by weight. It means that it is 80% by weight or more.

Further, the resin-containing base material layer may be a single layer, or may be composed of a plurality of layers in which two or more layers of the resin-containing base material layer are laminated. The single layer includes a single resin layer from the front surface to the back surface. Examples of the multi-layer include a single-layer sheet in which vinyl chloride resin chips are mixed and heated and pressurized to be integrated. Further, it may be a resin-containing base material layer composed of a plurality of layers in which an upper layer, a reinforcing layer and a lower layer are laminated in this order as described later, or a resin-containing base material layer formed by laminating a plurality of resin layers having different compositions. good. In the case of multiple layers, the composition of each layer may be the same or different from each other.

The resin-containing base material layer may contain a fibrous sheet as a reinforcing layer, if necessary. Such fibrous sheets include a) a woven or non-woven sheet of organic fibers or inorganic fibers (hereinafter, also referred to as “fiber sheet”) and b) the fiber sheet and the resin component of the soft resin-containing layer. At least one of the containing composite materials can be preferably used.

Examples of the fiber sheet of a) include synthetic fibers made of high molecular weight organic compounds, as well as woven fabrics or non-woven fabrics such as natural fibers, glass fibers, carbon fibers and metal fibers. The non-woven fabric also includes, for example, spunbond, felt and the like. Examples of the composite material of b) include a material in which the fiber sheet of b) is impregnated with a synthetic resin. Further, a material or the like in which the foam material sheet-like body of the a) and the fiber sheet of the b) are laminated can also be used. Commercially available products can also be used for these. Therefore, for example, a commercially available glass mat or the like can be suitably used as the reinforcing layer.

The thickness of the reinforcing layer can be appropriately set according to the type of material constituting the reinforcing layer and the like, but usually it may be in the range of about 0.2 to 1 mm.

As a method for forming the reinforcing layer, a preformed reinforcing layer sheet may be laminated at a predetermined position. Lamination may be carried out by bonding with an adhesive layer, or by heat-sealing (heat-sealing) a reinforcing layer sheet containing a resin component having a heat-sealing property as a resin component to another layer. You can also.

The thickness of the resin-containing base material layer is not limited, but is usually about 0.5 mm to 2 mm, and particularly preferably 0.7 mm to 1.5 mm. This thickness is a value including the thickness of the reinforcing layer when the resin-containing base material layer includes the reinforcing layer.

The method for forming the resin-containing base material layer is not particularly limited, and for example, a) a method using a preformed sheet, and b) a coating liquid in which a resin component is dissolved or dispersed in a fiber sheet to be a reinforcing layer. Any method such as applying (paste) can be adopted.

The design layer has a function of expressing a predetermined design such as a pattern, a pattern, a pattern, a character, etc., and imparting a design property to the floor material of the present invention.

The design layer is preferably formed of a composition containing a thermoplastic resin that can be easily bonded to the upper layer or the lower layer thereof. Examples of the thermoplastic resin include vinyl chloride resin, olefin resin, ethylene-vinyl acetate copolymer, acrylic resin such as ethylene-methacrylate resin, amide resin, ester resin, vinyl acetate, olefin elastomer, and styrene. Examples thereof include various elastomers such as elastomers and at least one of rubbers and the like. In particular, it is preferable that the design layer is formed by a composition containing a vinyl chloride resin as a main material. As a result, excellent flexibility is exhibited, and various designs can be easily formed by mixing a colorant or printing, so that the design layer can be formed inexpensively and easily.

Various additives are blended in the composition forming the design layer. Examples of the additive include at least one such as a filler, a plasticizer, a flame retardant, a stabilizer, an antioxidant, a lubricant, a colorant, and a foaming agent. As these, known or commercially available ones can be used.

The thickness of the design layer is not particularly limited, but is usually about 30 μm to 2.00 mm, particularly preferably 50 μm to 1.50 mm, and more preferably 70 μm to 1.00 mm.

The method of forming the design layer is not particularly limited. For example, a) a method of forming a pattern by directly printing a pattern on the upper surface of a thermoplastic resin sheet by a known printing method, and b) laminating a printed pattern film on the upper surface of a thermoplastic resin sheet. Method of forming, c) Method of rolling a chip of thermoplastic resin to form a pattern, d) Method of forming with a thermoplastic resin containing a colorant, e) A method of forming a thermoplastic resin containing a colorant of a different color. Examples thereof include a method of forming by preparing a plurality of them and kneading them.

The above-mentioned printing method is not limited, and for example, a method using various devices such as gravure printing, screen printing, flexographic printing, and printing using a transfer sheet can be adopted. In addition, a method of laminating a printing film having a design layer formed on a resin film in advance can also be used.

The clear layer is formed on the design layer to protect the design layer. The clear layer is formed from, for example, a resin composition containing a resin component as a main material. The resin component is not particularly limited, and the same resin component as the known clear layer of the floor material can be adopted. For example, at least one of vinyl chloride resin, polyolefin resin, acrylic resin, polyester resin and the like can be mentioned. More specifically, thermoplastic resins such as polyvinyl chloride, low-density polyethylene, high-density polyethylene, polyester, and ethylene-vinyl acetate copolymer; unsaturated polyesters such as a condensate of unsaturated dicarboxylic acid and polyhydric alcohol, etc. At least one of. Among these, vinyl chloride-based resins are preferable because they are excellent in processability and strength.

Further, if the clear layer is transparent or translucent, it is preferable that the clear layer is more transparent because the distinctiveness of the design layer formed under the clear layer can be further enhanced.

The thickness of the clear layer is not particularly limited, but may be, for example, about 0.15 mm to 1.0 mm, and particularly preferably 0.2 mm to 0.8 mm.

The surface protective layer has a function of protecting the upper layer from the outside. Therefore, it is desirable that the surface protective layer is formed as the uppermost layer of the clear layer or the like as the outermost surface layer of the floor material of the present invention.

The surface protective layer is formed from, for example, a resin composition containing a resin component as a main material. The resin component that can be used is not particularly limited. Specific examples thereof include ionizing radiation curable resins such as ultraviolet curable resins. For example, at least one kind of ultraviolet curable resin such as methacrylates such as polyester methacrylate, polyether methacrylate, polyol methacrylate and melamine methacrylate, and acrylates such as polyester acrylate, epoxy acrylate, urethane acrylate, polyether acrylate, polyol acrylate and melamine acrylate. Can be mentioned. These can also be used in violations. Such an ionizing radiation curable resin can be coated by, for example, various coater methods, printing methods, etc., and then cured by irradiating with ionizing radiation such as ultraviolet rays to form a surface protective layer.

Among these, it is preferable to use an ultraviolet curable resin because it has surface hardness, transparency and the like. If the surface protective layer is transparent or translucent, the distinctiveness of the design layer formed under it can be further enhanced.

The thickness of the surface protective layer is not particularly limited, but may be, for example, about 0.01 to 0.05 mm, and particularly preferably 0.015 to 0.030 mm.

As a method for forming the surface protective layer, for example, it can be formed by applying a coating liquid containing the above-mentioned resin component and then curing it. The curing method may be appropriately selected according to the type of resin component and the like, and can be carried out by, for example, aging, drying, ultraviolet irradiation, heating and the like.

2. Manufacturing Method of Antifouling Floor Material The manufacturing method of the flooring material of the present invention is not limited, but for example: 1) A step of pressing an embossing roll from the design layer side of a laminated sheet containing a resin-containing base material layer and a design layer. A manufacturing method including (embossing step) and 2) a step of forming a surface protective layer on the design layer (surface protective layer forming step) can be preferably adopted. The method for forming each layer may be carried out by the method described above.

Embossing step In the embossing step, the embossing roll is pressed from the design layer side of the laminated sheet including the resin-containing base material layer and the design layer. By embossing, it is possible to create a surface in which the mountain portion and the unevenness of the base region are integrally formed.

As the laminated sheet to be embossed, for example, a laminated sheet composed of a resin-containing equipment layer / design layer, a laminated sheet composed of a resin-containing equipment layer / design layer / clear layer, or the like can be adopted. In these cases, the resin-containing base material layer may or may not contain a reinforcing layer.

The pressing itself by the embossing roll may be performed in the same manner as the embossing process on a known floor material. Therefore, known or commercially available embossed rolls (embossed plates) and devices can be used.

However, in order to create a surface shape peculiar to the floor material of the present invention, an embossed roll corresponding to the surface shape is used. Further, the embossing step is not limited to one pressing by the embossing roll, and may be two or more pressing by the embossing roll having different surface patterns. Further, the embossing step may be a continuous method using a plurality of embossing rolls.

In the production of the flooring material of the present invention, the groove of the embossed roll corresponds to the convex portion of the mountain portion or the base region, but about 40 to 50% of the depth of the embossed roll (groove depth) is reflected at the time of transfer. Will be done. This is said to have an embossed transfer rate of about 40 to 50%. Therefore, by designing the depth of the emboss roll by calculating back from the height difference of the convex portion of the desired ridge or base region, the target basal region and ridge can be formed more reliably.

Specifically, it is preferable that the embossed roll has gentle recesses such as 20 μm, 40 μm, 70 μm, and 250 μm. For example, when the transfer rate is 50%, theoretically, the 250 μm recesses of the embossed roll form the peaks of the floor material, and the 20 μm, 40 μm, and 70 μm recesses form the unevenness of the base region. Will be. In this embossing roll, when the embossing transfer rate is 50%, the height of the mountain portion of the floor material is theoretically 125 μm.

In the present invention, it is particularly preferable to use an embossed roll in which the groove portion is formed by etching. As a result, the above-mentioned gentle unevenness can be more reliably formed on the floor material surface. That is, as a result of being able to impart a groove portion that is generally rounded and has no sharp corners to the emboss roll, it is possible to efficiently form a basal region and a mountain portion that do not substantially include the sharp corners. The method for etching is not particularly limited, and the embossed roll can be etched with a known or commercially available corrosive solution according to, for example, a known method.

Surface protective layer forming step In the surface protective layer forming step, a surface protective layer is formed on the design layer. In this case, when the clear layer is formed on the surface of the design layer, the surface protective layer is formed on the surface of the clear layer, and the surface protective layer becomes the outermost surface layer of the floor material.

As a method for forming the surface protective layer, it may be carried out as described above. That is, it can be formed by applying a coating liquid containing a predetermined resin component and then curing the coating liquid. The curing method may be appropriately selected according to the type of resin component and the like, and can be carried out by, for example, aging, drying, ultraviolet irradiation, heating and the like.

3. 3. Use of Antifouling Flooring Material The flooring material of the present invention is not limited as long as it is required to have antislip and antifouling properties, and can be used as a flooring material in various places. In particular, it can be suitably used as a floor material for toilets and the like.

The shape of the flooring material of the present invention when used is not particularly limited, and can take various shapes in addition to a substantially rectangular shape (square, rectangle, rhombus, etc.). The size can also be used within a range that fits within a rectangular frame of, for example, about 1 m × 1 m, but the size is not limited to this.

The flooring material of the present invention may be installed according to a normal flooring material construction method. For example, the floor material of the present invention is used by adhering it to a construction surface using an adhesive, and a floor structure composed of the construction surface / adhesive layer / floor material of the present invention can be constructed in order from the bottom.

The adhesive is not particularly limited, and examples thereof include acrylic resin-based adhesives, rubber-based adhesives, urethane resin-based adhesives, epoxy resin-based adhesives, and emulsion-type water-based adhesives such as vinyl acetate. The floor material of the present invention can be applied without any trouble even when a urethane resin-based adhesive or an epoxy resin-based adhesive that generates a relatively large amount of gas is used.

The material of the construction surface is not particularly limited, and for example, a concrete surface, a mortar surface, a gypsum board surface, a wood surface, a synthetic resin surface, a ceramic surface such as a ceramic tile or a ceramic tile, a stone surface, a metal surface such as an iron plate, etc. And so on. The construction surface is preferably a flat surface, and more preferably a flat and relatively hard surface.

Examples and comparative examples are shown below, and the features of the present invention will be described more specifically. However, the scope of the present invention is not limited to the examples.

Example 1
An antifouling floor material 10 made of a laminated body as shown in FIG. 6 was produced. First, a sheet which can be a resin-containing base material layer 41 in which a lower layer 41b is formed under a glass mat 41c to be a reinforcing layer and an intermediate layer 41a is laminated on a glass mat 41c is prepared. More specifically, the "lower layer" paste shown in Table 1 is applied to the underside of a commercially available glass mat (weight: 40 g / m ² ), and heated in an oven at 140 ° C. for 1 minute to pregel. It was. Next, the "middle layer" paste shown in Table 1 was applied to the upper side of the glass mat and heated in an oven at 140 ° C. for 1 minute to pregel.

Next, a printing film is laminated on the pregelled intermediate layer 41a to form the design layer 42, and then the “clear layer” paste shown in Table 1 is applied onto the design layer, and then in an oven. Each layer was gelled by heating at 200 ° C. for 3 minutes to form a clear layer 43 and integrated.

The following components were used for each component in Table 1.
Vinyl chloride resin: Product name "Kaneka Vinyl" manufactured by Kaneka Corporation. K value: 94.
Plasticizer: Dioctyl phthalate Filler: Calcium carbonate Stabilizer: Ba-Zn stabilizer Antibacterial agent: Zeomic KM10D (manufactured by Sinanen Zeomic)

The emboss roll was pressed from above the clear layer 43 of the laminated sheet thus obtained. In this embossing step, an embossing roll having a groove portion with a depth of 30 to 250 μm having a pattern corresponding to a predetermined base region and mountain portion was used. For reference, FIG. 7 shows a surface state formed by molding the embossed roll used with a silicone resin. FIG. 7 shows a state where the embossing transfer rate is 100%. Therefore, when the surface embossing of the antifouling floor material is formed by the same embossing roll, if the embossing transfer rate is 50%, the mountain part and the base The height of the unevenness of the area is about half. After embossing, the surface of the clear layer 43 of the laminated sheet that has undergone such a process is coated with a coating liquid containing an ultraviolet curable resin, and then irradiated with ultraviolet rays to form the surface protective layer 44.

In this way, an antifouling floor material made of the laminated body 10 as shown in FIG. 6 was produced. In FIG. 6, the unevenness due to embossing is omitted. The laminated body 10 had a clear layer of 0.20 mm, a design layer of 0.15 mm, an intermediate layer of 0.30 mm, and a reinforcing layer + a lower layer, totaling 1.4 mm. The size of the laminated body in a plan view was 30 cm in length × 30 cm in width. FIG. 8 shows the results of cutting the obtained laminate into 1 cm in length × 1 cm in width and observing the surface texture of the surface (surface of the surface protective layer) with a three-dimensional measuring scanning electron microscope (3D-SEM). Furthermore, when the number of peaks on the surface of the obtained laminate was measured, the abundance density of the peaks was about 57.

Test Example 1
The surface texture of the floor material obtained in Example 1 was examined by a surface roughness measuring machine. More specifically, 1) the presence or absence of a mountain portion of 50 μm or more, 2) whether or not the requirement that the unevenness of the base region is 40 μm or less is satisfied, and 3) the requirement that the width of the base regions adjacent to each other is 30 μm or more. It was confirmed whether or not it was satisfied, and 4) whether or not the basal region and the mountain part had rounded irregularities. As the measuring device, a surface roughness measuring machine (product number "SURFCOM 130A-monochrome" (Tokyo Seimitsu ACCRETECH Co., Ltd., stylus: DM43822)) was mainly used. The results are shown in Table 2. Comparison is shown in Table 2. The results of similarly examining the surface properties of commercially available flooring materials as Examples 1 to 4 are also shown. Further, each flooring material of Example 1 and Comparative Examples 1 to 4 was output from the surface roughness measuring machine. A part of the cross-sectional curve is shown in FIGS. 9 to 13, respectively.

As is clear from the results of Table 2 and FIGS. 9 to 13, it can be seen that the floor material of Example 1 has peaks scattered in a specific base region on the surface thereof. Further, while the cross-sectional curves of the flooring materials of Comparative Examples 3 and 4 have sharp corners, in Example 1, there are no sharp corners, and both the ridges and the unevenness of the base region are smooth without sharp corners. You can see that it draws a nice curve.

Test Example 2
The antifouling property and the like of the floor materials of Example 1 and Comparative Examples 1 to 4 were examined. The results are shown in Table 3. The method of each test was carried out as follows.

(1) Tokyo Institute of Technology Test The flooring materials of each example and comparative example were examined for stain adhesion to the surface and stain removal property according to the stain test method of Tokyo Institute of Technology. The specific test method is as follows.
The flooring materials of each Example and Comparative Example were cut into a rectangular shape having a length of 15 cm and a width of 15 cm, and three samples were prepared for each of the Examples and Comparative Examples. The surface of these three samples opposite to the surface protective layer is a regular hexagonal columnar hollow container (hexagonal column 6) of a rotary tester (manufactured by Yasuda Seiki Co., Ltd., trade name: Tokyo Institute of Technology stain tester). A double-sided tape was used to attach the two side surfaces to the inner walls of the side surfaces having a size of vertical (axial direction) x horizontal (circumferential direction) = 16.0 cm x 16.3 cm. In this hollow container, 150 g of silicon carbide (No. 80), 2 g of powdered pastel and 10 iron balls having a diameter of 3 cm were placed, and the container was rotated for 3 minutes (rotation speed: 20 rotations / minute).
After the rotation was stopped, each sample was taken out from the container, and the dirty state of the surface (the surface of the surface protective layer in the case of the example and the surface of the surface layer in the case of the comparative example) was visually observed.
Subsequently, the surface of each sample was wiped with a cloth (dry wipe) in a dry state and wiped with a cloth (wipe with water) in a state of being wet with water, and the state of each stain after wiping was visually observed. This water wipe is intended for dry cleaning with a mop or rag moistened with water.
The color difference ΔE from that before the stain was attached was measured with a color difference meter for each of the initial adhered stain, the cloth wipe, and the water wipe.

(2) BHM value <BHM test>
The floor materials of Examples and Comparative Examples were cut into squares having a length of 22 cm and a width of 22 cm, and three samples were prepared for each. The surface of the three samples opposite to the surface protective layer was attached to the inner wall of the regular hexagonal columnar hollow container. Put six cubic rubber pieces 5 cm long x 5 cm wide x 5 cm high in this hollow container, rotate this container clockwise for 15 minutes (rotation speed: 63 rotations / minute), and then counterclockwise. Was rotated for 15 minutes (rotation speed: 63 rotations / minute). After the rotation was stopped, the sample was taken out and the state of dirt on the surface was visually observed.
Subsequently, the surface of each sample was wiped with water in a state of being wet with water, and the state of dirt after wiping was visually observed. This water wipe is intended for dry cleaning with a mop or rag moistened with water.
The antifouling property and decontamination property of the surface after cleaning were visually evaluated according to the following criteria.
◎: No heel mark ○: Heel mark is attached but can be wiped off in a short time by wiping with water △: Heel mark is attached but can be wiped off with water if it takes time ×: Slightly after wiping with water Heel mark remains on

(3) Sesame salt stain <Sesame salt stain test>
A model sample of sesame salt stain was prepared according to the following procedure, and its removal effect was confirmed.
1. 1. A floor sheet is cut into 300 mm squares to prepare a shaku angle sample.
2. Mix 3 g of pastel powder and 0.3 g of water to prepare a mixed solution. Pastel powder is made by crushing pastel pieces into small pieces and sieving them.
3. 3. Apply the mixture to the center of the shaku angle sample, step on it with shoes for 1 minute, and let it blend into the entire surface of the shaku angle sample. Leave it in a room at 3.23 ° C for 3 days to dry it to prepare a dirty sample. ..
4. Prepare a general long-handled "water-wiping mop" and "bucket with mop squeezer". Wet the mop with water and squeeze it with a mop squeezer. The surface of the dirt sample placed on the floor was reciprocated 5 times with a water-wiping mop to remove the dirt on the surface. This water wipe is intended for dry cleaning with a mop or rag moistened with water.
5. The state of dirt removal was visually observed and evaluated as follows.
〇: There was almost no sesame salt stain, and it was removed cleanly.
Δ: Sesame salt stains were slightly seen, but the level was aesthetically pleasing.
X: Many sesame salt stains were observed.

(4) CSR value <CSR test>
Each floor material was cut into a length of 30 cm and a width of 30 cm, and the CSR value in a water + dust sprayed state was determined according to the slipperiness test of JIS A1454.

(5) Sensual slip evaluation <Sensual slip evaluation>
A sample piece of 500 mm square in length and width was prepared. About 200 ml of water was evenly sprinkled on the sample piece in a shower. The evaluator evaluated the degree of slippage by stepping on the sample piece or kicking the sample piece. The evaluator was 10 people. The types of shoes were 4 leather shoes, 3 athletic shoes, and 3 high heels.
[Evaluation criteria]
5 grades from 1 to 5. 1 is good and slippery, and 5 is the least slippery.

As is clear from the results in Table 3, the flooring material of Example 1 has a recess in which sesame salt stains are accumulated because a base region (within a vertical width of 40 μm) having gentle irregularities is formed between each mountain portion. Does not exist, and the basal region is formed with a constant width (30 μm or more), so that sesame salt stains are less likely to accumulate. In addition, since it has a rounded uneven shape as a whole, it can be said that sesame salt stains are less likely to occur from this point of view.
On the other hand, in Comparative Examples 3 and 4, it can be seen that the removal of dirt is poor because the depth of the recess is deep. Further, it can be seen that Comparative Example 3 has poor anti-slip property because the depth is shallow. It can be seen that also in Comparative Examples 1 and 2, since the floor material of the present invention does not have a specific surface shape, the sesame salt stain cannot be sufficiently removed with a moist mop.
As described above, it can be seen that the flooring material of the present invention exhibits high antifouling property especially against sesame salt stains and can exhibit good antislip property.

Claims (3)

A flooring material whose main material is synthetic resin.
(1) The floor material surface is composed of a substantially flat base region and a mountain portion protruding upward from the base region.
(2) The basal region has irregularities on the surface, and the height difference between the bottom of the concave portion and the apex of the convex portion is 40 μm or less.
(3) The height of the mountain part from the apex of the mountain part to the bottom of the recess in the base region is 50 μm or more.
(4) When the surface of the floor material is viewed in a plan view, the mountain parts exist in an island shape independent of each other, and the base regions are substantially all connected.
An antifouling flooring material that is characterized by this. The antifouling flooring material according to claim 1, wherein the width of the base region between the mountain portions adjacent to each other is 1.3 mm or more and 15 mm or less. The antifouling flooring material according to claim 1 or 2, which is used as a flooring material for a toilet or a washroom.