JP2021095737A - Floor material - Google Patents

Abstract

To provide a floor material having as well as excellent scratch resistance and abrasion resistance, impact resistance and sound insulation, and a good walking feeling while suppressing overall thickness as much as possible.SOLUTION: Provided is a floor material in which: a decorative sheet layer 13 laminated with a base sheet 1 made of a thermoplastic resin, a pattern layer 2, a first adhesive layer 3, a polyester resin layer 4 made of unstretched polyethylene terephthalate, a second adhesive layer 5, a transparent thermoplasticity resin layer 6, and a surface protective layer 7 made of an ultraviolet curable resin; a plywood layer 10; and a soft layer 12 made of first and second soft layers 12A and 12B; are laminated. The transparent thermoplastic resin layer 6 and the surface protective layer 7 are embossed, and a thickness of the polyester resin layer 4 is 150 μm or more and 300 μm or less, a thickness of the transparent thermoplastic resin layer 6 is 50 μm or more and 150 μm or less, and a combined thickness of the polyester resin layer 4 and the transparent thermoplastic resin layer 6 is 250 μm or more and 400 μm or less.SELECTED DRAWING: Figure 1

Description

The present invention relates to a flooring material laid on the floor surface of an indoor or outdoor building or the like.

In recent years, flooring materials are often used for indoor floors. As the flooring material, plywood, medium density fiberboard (MDF), particle board, resin board and the like are known to be painted or laminated with a decorative sheet.

Flooring materials are strongly required to have surface scratch resistance and impact resistance. Therefore, as the base material such as plywood and resin plate, those having higher density and hardness and having excellent scratch resistance and impact resistance have been used. Such a high-density, hard and high-strength base material has a significantly reduced floor impact sound blocking performance (sound insulation).

Further, in high-rise buildings such as hotels, sound insulation is often required for flooring materials in order to avoid troubles between upper-rise residents and lower-rise residents. As a means for improving the sound insulation performance of such a floor material, for example, a means for reducing the rigidity of the floor material by carving a groove in the floor material and providing a soft layer on the entire back surface is known (for example, the following). See Patent Document 1). Further, for example, a means for providing a soft layer such as a resin foam having a high open cell ratio on the back surface of the floor material (see, for example, Patent Document 2 below) is also known.

However, in the conventional means as described above, in order to ensure suitable sound insulation, the soft layer is thickened, or a soft and low elasticity material such as a non-woven fabric or urethane foam is used for the soft layer. Therefore, the cushioning property tends to be large, and the walking ability tends to be difficult.

If the thickness of the soft layer is increased, the amount of subduction when a heavy object such as a refrigerator is placed also increases. In addition, if a soft and low-elasticity material is used for the soft layer, when a heavy object is left to stand for a long period of time, it will settle in the thickness direction, and depending on the joint strength and rigidity of the flooring joint, the sane breaks. It is also possible that the flooring may come off.

Furthermore, in view of recent construction conditions such as an increase in demand for remodeling, it has become possible to avoid an increase in the total thickness of flooring materials. On the other hand, from the viewpoint of ensuring the joint strength and rigidity of the floor material joint portion, the floor material is required to have a certain thickness as the surface material. For this reason, it is difficult to secure sound insulation while reducing the total thickness of the floor material.

For example, Patent Document 3 proposes ensuring sound insulation while suppressing the height level of the floor surface. Since the means described in Patent Document 3 ensure sound insulation by the floor structure, it is suitable for situations and buildings where the structure cannot be easily changed, such as for remodeling applications and high-rise condominiums. Difficult to apply.

Japanese Unexamined Patent Publication No. 3-166462 Japanese Unexamined Patent Publication No. 2007-198084 JP-A-2009-068186

The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to have excellent scratch resistance and abrasion resistance while suppressing the overall thickness as much as possible, and also to have impact resistance. Further, it is an object of the present invention to provide a floor material having a floor impact sound blocking performance (sound insulation) and also having a good walking feeling.

In the floor material according to the present invention for solving the above-mentioned problems, at least a decorative sheet layer and a plywood layer are laminated in this order from the surface side, and at least two soft layers are laminated on the floor surface side. The decorative sheet layer is a pattern layer, a first adhesive layer, a polyester resin layer made of unstretched polyethylene terephthalate, a second adhesive layer, and a transparent thermoplastic resin layer on a base sheet made of a thermoplastic resin. The surface protective layer made of the ultraviolet curable resin and the ultraviolet curable resin is laminated in this order, and at least the transparent thermoplastic resin layer is embossed, and the thickness of the polyester resin layer is 150 μm or more and 300 μm or less. The transparent thermoplastic resin layer has a thickness of 50 μm or more and 150 μm or less, and the combined thickness of the polyester resin layer and the transparent thermoplastic resin layer is 250 μm or more and 400 μm or less. To do.

Further, the flooring material according to the present invention is the above-mentioned flooring material, and the soft layer is the softest layer composed of at least two layers having different compression hardness measured in accordance with Japanese Industrial Standards "JISK 6400-2 D". The compression hardness of the plywood layer is 55 N or more and 70 N or less, the thickness of the plywood layer is 3 mm or more and 7 mm or less, and the thickness of the soft layer composed of at least two layers is 5 mm or more and 7 mm or less. The thickness of is preferably 8 mm or more and 12 mm or less.

Further, in the flooring material according to the present invention, in the above-mentioned flooring material, the soft layer composed of at least two layers has a difference between the compression hardness of the hardest layer and the compression hardness of the softest layer of 50N or more and 100N. It is preferable that it is as follows.

In the floor material according to the present invention, at least two soft layers are laminated on the floor surface side, the thickness of the polyester resin layer is 150 μm or more and 300 μm or less, and the thickness of the transparent thermoplastic resin layer is 50 μm or more. Since the thickness is 150 μm or less and the combined thickness of the polyester resin layer and the transparent thermoplastic resin layer is 250 μm or more and 400 μm or less, the overall thickness is suppressed as much as possible, and the scratch resistance and abrasion resistance are excellent. At the same time, it has impact resistance and floor impact sound blocking performance (sound insulation), and also has a good walking feeling.

It is sectional drawing which shows the schematic structure of the main embodiment of the flooring material which concerns on this invention.

Although the embodiment of the flooring material according to the present invention will be described with reference to the drawings, the present invention is not limited to the following embodiments described based on the drawings.

<Main embodiment>
A main embodiment of the flooring material according to the present invention will be described with reference to FIG.

In FIG. 1, the base sheet 1 is made of a thermoplastic resin, and various thermoplastic resins other than vinyl chloride resin (PVC) can be used. However, in consideration of pollution-free property, price, performance, ease of coloring, and the like, a polyolefin resin material such as polypropylene resin (PP) to which a filler and a coloring pigment is added can be preferably used. The base sheet 1 preferably has a thickness of 40 μm or more and 100 μm or less.

A printed pattern layer 2 is provided on the surface (upper surface) of the base sheet 1. The type of the pattern pattern layer 2 is arbitrary and is not particularly limited. For example, a wood grain pattern, a stone grain pattern, a cloth grain pattern, a sand grain pattern, an abstract pattern, a geometric figure, a character or a symbol, or a combination thereof, etc. can be applied as desired.

The type of printing ink used for the pattern layer 2 is not particularly limited, and any printing ink conventionally used for the flooring material can be used. Specifically, for example, for binder resins such as polyvinyl chloride resin type, vinyl chloride-vinyl acetate copolymer resin type, butyral type, acrylic type, urethane type, polyester type, epoxy type, alkyd type, and polyamide type. Various additives such as organic or inorganic dyes or pigments and, if necessary, extender pigments, fillers, tackifiers, dispersants, defoaming agents, stabilizers, etc. are appropriately added, and an appropriate diluting solvent is desired. Any conventionally known printing ink adjusted to the viscosity of.

The first adhesive layer 3 is applied on the pattern layer 2. The first adhesive layer 3 is arbitrarily selected from urethane-based, acrylic-based, polyester-based, and the like.

A polyester-based resin layer 4 is provided on the first adhesive layer 3. As the polyester resin layer 4, polyethylene terephthalate, polybutylene terephthalate, polycyclohexylene dimethylene terephthalate, polyethylene naphthalate, polylactic acid and the like are used, and unstretched polyethylene terephthalate is particularly preferable. The polyester-based resin layer 4 is provided with an easy-adhesive layer, corona treatment, or the like, if necessary, in order to improve the adhesion with the first adhesive layer 3 and the second adhesive layer 5 described later. Is also possible. The polyester-based resin layer 4 has a thickness of 150 μm or more and 300 μm or less.

A second adhesive layer 5 is coated on the polyester resin layer 4. The second adhesive layer 5 is arbitrarily selected from urethane-based, acrylic-based, polyester-based, and the like, depending on the transparent thermoplastic resin layer 6 described later.

A transparent thermoplastic resin layer 6 is provided on the second adhesive layer 5. As the transparent thermoplastic resin layer 6, for example, various thermoplastic resins can be used except for vinyl chloride resin (PVC). The transparent thermoplastic resin layer 6 can be made into a plurality of layers. The transparent thermoplastic resin layer 6 can have four or more layers, but if the number of layers is four or more, the structure of the extruder used at the time of manufacturing becomes complicated and the work becomes complicated. Therefore, 3 layers or less is preferable. The transparent thermoplastic resin layer 6 can be used by appropriately combining various resins with each layer according to the desired characteristics. The transparent thermoplastic resin layer 6 has a thickness of 50 μm or more and 150 μm or less. Further, the combined thickness of the polyester resin layer 4 and the transparent thermoplastic resin layer 6 is 250 μm or more and 400 μm or less.

Preferred polypropylene resins (PP) applied to the flooring material according to the present embodiment include, for example, polypropylene resin (a) to which free-terminal long-chain branching is applied, and polypropylene resin (a) to which free-terminal long-chain branching is not applied. A mixture with b) can be mentioned. In particular, the mixture of the above (a) and the above (b) preferably has a molecular weight distribution Mw / Mn defined as mass average molecular weight / number average molecular weight in the range of 1 or more and 5 or less. In addition, it is more preferable that the mixture of the above (a) and the above (b) has an isotactic index defined as a boiling heptane-soluble residue ratio in the range of 1% or more and 90% or less. .. With such a polypropylene resin, it is possible to prevent whitening, cracking, and the like from occurring when the flooring material is attached to the steel plate base material and bent.

In the molecular weight distribution, when there are Ni molecules having a molecular weight of Mi, the mass average molecular weight Mw = Σ (Ni × Mi ² ) / Σ (Ni × Mi) with respect to the number average molecular weight Mn = Σ (Mi × Ni) / ΣNi. It is a value defined as the ratio Mw / Mn of. The closer the molecular weight distribution Mw / Mn is to 1, the narrower the molecular weight distribution and the higher the uniformity. When the molecular weight distribution Mw / Mn is set to 5 or less, the molecular weight can be made uniform to a necessary and sufficient size, so that whitening and cracking can be suppressed. The molecular weight distribution Mw / Mn can generally be measured by gel permeation chromatography (GPC).

Further, the isotactic index defined as the boiling heptane-soluble residue ratio is useful as an index for examining the crystallinity in the polypropylene resin. Specifically, the sample is extracted with boiling n-heptane for a certain period of time, and the mass percentage (%) of the unextracted portion is obtained to calculate the isotactic index.

Specifically, the cylindrical filter paper is dried at 110 ± 5 ° C. for 2 hours, left in a room at a constant temperature and humidity for 2 hours or more, and then 8 g or more and 10 g or less of a sample (powder or flakes) is placed in the cylindrical filter paper and weighed. Weigh accurately using a cup and tweezers. Set this on the top of the extractor containing about 80 cc of heptane, and assemble the extractor and cooler. This is heated in an oil bath or an electric heater and extracted for 12 hours. The heating is adjusted so that the number of drops from the cooler is 130 drops or more per minute. Subsequently, the cylindrical filter paper containing the extraction residue is taken out, placed in a vacuum dryer, and dried at 80 ° C. and a vacuum degree of 100 mmHg or less for 5 hours. After drying, the mixture is left in a constant temperature and humidity for 2 hours and then precisely weighed to calculate an isotactic index ((P / Po) × 100). Here, Po is the sample mass (g) before extraction, and P is the sample mass (g) after extraction.

By setting the isotactic index to 90% or less, the seat rigidity due to the polypropylene crystals can be suppressed. As a method for lowering the isotactic index, for example, a method using an amorphous polypropylene component (for example, syndiotactic polypropylene, adaptive polypropylene, etc.) as a part, or an olefin monomer such as ethylene or α-olefin is used. One or more random copolymerization methods and various rubber components (eg ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM), styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), butadiene Examples thereof include a method of adding rubber (BR), isoprene rubber (IR) and other components).

The mixture of the above (a) and the above (b) preferably has a melting tension in the range of 100 mN or more and 500 mN or less. If the melt tension exceeds 500 mN, the melt viscosity becomes too high and it becomes difficult to form a stable film. On the other hand, if the melt tension is less than 100 mN, the long chain branching component becomes insufficient, and it becomes difficult to obtain the desired performance. The melt tension is the tension required when extruding at a temperature of 230 ° C. and 60 mm / min and taking it up at 2 mm / min using a nozzle capillary rheometer having a diameter of 2.0 mm.

The mixture of the above (a) and the above (b) is said to have a melt flow rate at 230 ° C. of 5 g / 10 min or more and 50 g / 10 min or less, which is defined in the Japanese Industrial Standards "JIS K 6760". It is preferably in the range of 10 g / 10 min or more and 30 g / 10 min or less, and particularly preferably in the range of 10 g / 10 min or more and 25 g / 10 min or less.

If the melt flow rate exceeds 50 g / 10 min, the effect (neck-in) that the resin melt-extruded from the T-die tends to gather in the center during melt-extrusion by the T-die becomes large, and T The thickness of the end of the resin melt-extruded from the die increases. If the thickness of the end portion of the resin is increased, the cooling efficiency is lowered and the thickness stability in the width direction is affected, which makes it difficult to form a stable film.

On the other hand, if the melt flow rate is less than 5 g / 10 min, the draw resonance of the molten resin deteriorates, and the velocity of the molten resin immediately after exiting the T-die (initial velocity) and the velocity of the resin immediately after touching the cooling roll. The molten resin cannot cope with the gap between the resin and the resin, which makes it difficult to form a stable film.

By doing so, the mixture of the above (a) and the above (b) can easily form a stable film with a molecular weight of a certain value or more.

It is also possible to add an ultraviolet absorber to the transparent thermoplastic resin layer 6. The ultraviolet absorber is appropriately selected from benzotriazole type, triazine type, benzophenone type and the like.

Examples of benzotriazole-based ultraviolet absorbers include 2- (2-hydroxy-5-t-butylphenyl) -2H-benzotriazole, 2- (5-methyl-2-hydroxyphenyl) benzotriazole, and 2- [2- [2- Hydroxy-3,5-bis (α, α-dimethylbenzyl) phenyl] -2H-benzotriazole, 2- (3,5-di-t-butyl-2-hydroxyphenyl) benzotriazole, 2- (3-t -Butyl-5-methyl-2-hydroxyphenyl) -5-chlorobenzotriazole, 2- (3,5-di-t-butyl-2-hydroxyphenyl) -5-chlorobenzotriazole, 2- (3,5) -Di-t-amyl-2-hydroxyphenyl) benzotriazole, 2- (2'-hydroxy-5'-t-octylphenyl) benzotriazole and the like, and mixtures, modified products, polymers, derivatives and the like thereof. be able to.

Examples of triazine-based ultraviolet absorbers include 2- (4,6-diphenyl-1,3,5-triazine-2-yl) -5-[(hexyl) oxy] -phenol and 2- [4-[(2). −Hydroxy-3-dodecyloxypropyl) oxy] -2-hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, 2- [4-[(2-hydroxy) -3-Tridecyloxypropyl) Oxy] -2-Hydroxyphenyl] -4,6-bis (2,4-dimethylphenyl) -1,3,5-triazine, 2,4-bis (2,4-dimethyl) Phenyl) -6- (2-hydroxy-4-iso-octyloxyphenyl) -s-triazine and the like, mixtures, modified products, polymers, derivatives and the like thereof can be mentioned.

Examples of the benzophenone-based ultraviolet absorber include octabenzone, a modified product thereof, a polymer, and a derivative thereof.

It is particularly preferable that the ultraviolet absorber contains a hydroxyl group because it can be bonded to the resin component by cross-linking due to the addition of isocyanate. The number of copies of the ultraviolet absorber is appropriately set according to the desired weather resistance. Usually, it is 0.1% by mass or more and 50% by mass or less, preferably 1% by mass or more and 30% by mass or less, based on the resin solid content.

It is also possible to add a light stabilizer to the transparent thermoplastic resin layer 6. As a light stabilizer, bis (1,2,2,6,6-pentamethyl-4-piperidyl) [[3,5-bis (1,1-dimethylethyl) -4-hydroxyphenyl] methyl] butylmalo Ester, bis (1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, methyl (1,2,2,6,6-pentamethyl-4-poperidinyl) sebacate, bisdecanedioate (2,2) , 6,6-Tetramethyl-1 (octyloxy) -4-piperidinyl) ester and the like, and mixtures, modified products, polymers, derivatives and the like thereof.

The number of copies of the light stabilizer is appropriately set according to the desired weather resistance. Usually, it is 0.1% by mass or more and 50% by mass or less, preferably 1% by mass or more and 30% by mass or less, based on the resin solid content.

Additives other than the above, such as a heat stabilizer, a flame retardant, and an anti-blocking agent, can be added to the transparent thermoplastic resin layer 6.

Examples of the heat stabilizer include pentaerythrityl-tetrax [3- (3,5-di-t-butyl-4-hydroxyphenyl)]-propionate and 2,4-bis- (n-octylthio) -6- (4). -Hydroxy-3,5-di-t-butylanilino) -1,3,5-triazine, octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate, 1,3,5- Trimethyl-2,4,6-tris (3,5-t-butyl-4-hydroxybenzyl) benzene, 1,3,5-tris (4-t-butyl-3-hydroxy-2,6-dimethylbenzyl) Hindered phenolic antioxidants such as isocyanuric acid, phenols such as 2,2'-methylenebis (4-ethyl-6-t-butylphenol) and 2,2'-methylenebis (4-methyl-6-t-butylphenol) Antioxidants, phosphorus antioxidants typified by tris (2,4-di-t-butylphenyl) phosphite, and mixtures thereof, that is, one type or a combination of two or more types. Can be mentioned.

Examples of the flame retardant include inorganic compounds such as aluminum hydroxide, magnesium hydroxide, calcium carbonate and magnesium carbonate, and organic compounds such as phosphoric acid ester.

Examples of the blocking inhibitor include inorganic compounds such as aluminum silicate, silicon oxide, hydrotalcite and calcium carbonate, and organic compounds such as fatty acid amide.

A surface protective layer 7 is provided on the transparent thermoplastic resin layer 6. The surface protective layer 7 improves physical properties such as abrasion resistance, scratch resistance, and solvent resistance of the outermost surface of the flooring material. The surface protective layer 7 is an ultraviolet curable resin such as a (meth) acrylic resin, a silicone resin, a polyester resin, a urethane resin, an amide resin, and an epoxy resin. The surface protective layer 7 preferably has a thickness of 3 μm or more and 20 μm or less in view of the balance between the physical characteristics and the flexible surface. Embossing E is formed on the transparent thermoplastic resin layer 6 and the surface protection layer 7.

In order to impart various functions to the surface protective layer 7, various functions such as a gloss adjuster, a lubricant, an antistatic agent, a dew condensation inhibitor, an antibacterial agent, a fungicide, an anti-friction agent, a colorant, and a filler are provided. It is also possible to add sex additives. Further, if necessary, an ultraviolet absorber, a light stabilizer, a heat stabilizer, or the like as described above can be added to the surface protective layer 7.

Further, a mold release agent having a silicone skeleton can be added to the surface protective layer 7 when anti-contamination performance and adhesive tape releasability are required. In this case, the type of the mold release agent is not particularly limited, but by using a silicone mold release agent having a terminal functional group that is reactive with the resin composition, durability such as antifouling performance and adhesive tape releasability can be achieved. The sex can be improved.

In addition, the surface protective layer 7 can be composed of two or more layers of the same type or different types. For example, a second layer that does not contain such particles is provided on the first layer that contains high-hardness wear-resistant particles such as silica, alumina, and silicon carbide to provide wear resistance, scratch resistance, and surface gloss. In order to achieve both surface smoothness and surface smoothness, a second layer with a different gloss state is provided in an arbitrary pattern on the first layer provided on the entire surface to visually change the gloss. It is possible to express a three-dimensional effect.

A primer layer 8 is provided on the back surface (lower surface) of the base sheet 1. For the primer layer 8, for example, a polyester resin, a polyurethane resin, a mixture thereof, or the like is preferably applied. The primer layer 8 preferably has a thickness of 1 μm or more. If the thickness is less than 1 μm, it may dissolve and disappear depending on the type of solvent of the third adhesive layer 9, which will be described later, which causes difficulty in improving the adhesiveness.

Further, it is preferable that the primer layer 8 is, for example, a two-component type of a polyol and an isocyanate because it can improve the adhesion to the base sheet 1 and its own cohesive force. Examples of the polyol include an acrylic polyol and a polyester polyol. Examples of the isocyanate include aromatic systems such as tolylene diisocyanate and 4,4'-diphenylmethane diisocyanate, and aliphatic systems such as hexamethylene diisocyanate, isophorone diisocyanate, and xylene diisocyanate. Aromatic type is preferable in consideration of quick reactivity, heat resistance and the like.

A third adhesive layer 9 is provided on the lower surface (back surface) of the primer layer 8. The third adhesive layer 9 is appropriately provided as needed. The third adhesive layer 9 is not particularly limited as long as it can adhere the plywood layer 10 described later to the base sheet 1. Examples of the third adhesive layer 9 include a two-component urethane aqueous adhesive, a one-component vinyl acetate resin emulsion adhesive, a moisture-curable urethane resin hot-melt adhesive, and the like, and in particular, a moisture-curable type. A urethane resin-based hot melt adhesive is preferable. The thickness of the third adhesive layer 9 after drying is preferably 10 μm or more and 100 μm or less.

A plywood layer 10 is provided on the lower surface (back surface) of the third adhesive layer 9. Once the setting conditions and the like are determined, the plywood layer 10 can be obtained by adjusting a desired one by using conventionally known materials, manufacturing techniques, and the like. The plywood layer 10 has a thickness of 3 mm or more and 7 mm or less. The most typical material of the plywood layer 10 is a wood base material such as laminated plywood.

Laminated plywood is formed by laminating and adhering a plurality of (usually odd-numbered) wood veneers with their fiber directions orthogonal to each other. Examples of the wood veneer grade include broad-leaved wood such as lauan wood, softwood such as pine (pine), and a mixture thereof. As the outermost wood veneer, for example, if it is a hard and highly durable South Sea material containing silica such as kluin material, capul material, and mencran material, the surface strength and caster resistance will be further improved. Excellent and particularly suitable.

As the plywood layer 10, in addition to the laminated plywood, various conventionally known wood-based boards such as a single-plate laminated material, an oriented board, a particle board, and a high-density fiber board can be arbitrarily applied. Further, the plywood layer 10 is not only a wood base material, but also an inorganic base material such as ceramics and a concrete plate, a metal base material such as iron, aluminum, brass, and stainless steel, and a deformed extruded body of a thermoplastic resin. , Synthetic resin-based base materials such as fiber reinforced plastic (FRP) can also be applied.

A fourth adhesive layer 11 is provided on the lower surface (back surface) of the plywood layer 10. The fourth adhesive layer 11 is appropriately provided as needed. The fourth adhesive layer 11 is not particularly limited as long as it can adhere the soft layer 12 described later to the plywood layer 10. Examples of the fourth adhesive layer 11 include a two-component urethane aqueous adhesive, a one-component vinyl acetate resin emulsion adhesive, a moisture-curable urethane resin hot-melt adhesive, and the like, and in particular, a moisture-curable type. A urethane resin-based hot melt adhesive is preferable. The thickness of the fourth adhesive layer 11 after drying is preferably 10 μm or more and 100 μm or less.

A soft layer 12 is provided on the lower surface (back surface) of the fourth adhesive layer 11. The soft layer 12 is composed of two layers, a first soft layer 12A and a second soft layer 12B, which have different compression hardness measured in accordance with the Japanese Industrial Standard "JISK 6400-2 D". In the soft layer 12, the softest layer (for example, the second soft layer 12B) has a compressive hardness of 55 N or more and 70 N or less, and the hardest layer (for example, the first soft layer 12A) and the softest layer are compressed hard. The difference is 50N or more and 100N or less. The soft layer 12 has a thickness of 5 mm or more and 7 mm or less.

The soft layer 12, that is, the first and second soft layers 12A and 12B can be obtained by adjusting desired ones by using conventionally known materials, manufacturing techniques, etc., once the setting conditions and the like are determined. Specifically, for example, it is preferable that the sheet is made of a foamed polyurethane-based sheet having a foaming ratio of 20 times or more and 70 times or less.

In the present embodiment, the base sheet 1, the pattern layer 2, the first adhesive layer 3, the polyester resin layer 4, the second adhesive layer 5, the transparent thermoplastic resin layer 6, the surface protection layer 7, etc. The decorative sheet layer 13 is configured by the above.

That is, in the flooring material according to the present embodiment, the decorative sheet layer 13, the primer layer 8, the third adhesive layer 9 and the plywood layer 10 are laminated in this order from the surface side (upper surface side in FIG. 1), and the floor surface side. A soft layer 12 composed of first and second soft layers 12A and 12B is laminated on the lower surface side in FIG. 1 via a fourth adhesive layer 11. The decorative sheet layer 13 is formed on the base sheet 1 with a pattern layer 2, a first adhesive layer 3, a polyester resin layer 4, a second adhesive layer 5, a transparent thermoplastic resin layer 6, and a surface protective layer. 7 are laminated in this order. The flooring material according to this embodiment has an overall thickness of 8 mm or more and 12 mm or less.

In such a floor material according to the present embodiment, the soft layer 12 composed of the first and second soft layers 12A and 12B is laminated on the floor surface side (lower surface side in FIG. 1), and the thickness of the polyester resin layer 4 is increased. The thickness is 150 μm or more and 300 μm or less, the thickness of the transparent thermoplastic resin layer 6 is 50 μm or more and 150 μm or less, and the combined thickness of the polyester resin layer 4 and the transparent thermoplastic resin layer 6 is 250 μm or more and 400 μm or less. Therefore, it can have scratch resistance and abrasion resistance that can withstand use on shoes, impact resistance and sound insulation, and can have a cushioning property with a good walking feeling.

As a result, it is possible to suppress the amount of subduction when a heavy object such as a refrigerator is placed, and to suppress the settling in the thickness direction when the heavy object is left to stand for a long period of time.

Therefore, according to the flooring material according to the present embodiment, while suppressing the overall thickness as much as possible, it is excellent in scratch resistance and abrasion resistance, and also has impact resistance and sound insulation, and provides a good walking feeling. You can have it together.

Further, the soft layer 12 is composed of first and second soft layers 12A and 12B having different compressive hardness, the compressive hardness of the second soft layer 12B is 55 N or more and 70 N or less, and the thickness of the soft layer 12 is 5 mm or more. Since it is 7 mm or less, the thickness of the plywood layer 10 is 3 mm or more and 7 mm or less, and the total thickness of the flooring material is 8 mm or more and 12 mm or less, the above-mentioned effect can be obtained more reliably.

If the difference in compressive hardness between the first soft layer 12A and the second soft layer 12B is less than 50 N, the soft layer 12 may become too soft and may cause difficulty in walking, which is less preferable. Absent. On the other hand, if the difference in compressive hardness between the first soft layer 12A and the second soft layer 12B exceeds 100 N, it may become too hard and cause difficulty in sound insulation, which is not very preferable.

<Other Embodiments>
In the above-described embodiment, the case of the flooring material to which the soft layer 12 composed of the two layers of the first soft layer 12A and the second soft layer 12B is applied has been described, but the present invention is not limited to this. As another embodiment, for example, even a flooring material to which a soft layer composed of three or more layers is applied can exhibit the same effects as in the above-described embodiment.

In the above-described embodiment, the case where the primer layer 8 is provided between the base sheet 1 and the plywood layer 10 has been described, but the present invention is not limited to this. As another embodiment, for example, the primer layer 8 can be omitted if there is no particular problem in the adhesion between the base sheet 1 and the plywood layer 10.

Examples of the flooring material according to the present invention will be specifically described, but the present invention is not limited to the examples described below.

[Preparation of test body and comparative body]
<Example 1>
≪Cosmetic sheet layer 13≫
A 55 μm polyolefin-based inorganic filling sheet (“OW (model number)” manufactured by Riken Technos Co., Ltd.) was used as the base sheet 1, and the pattern layer 2 was provided by printing a wood grain pattern on the surface side by a gravure printing method. ..

Next, the first adhesive layer 3 and the polyester-based resin layer 4 are provided by dry-laminating 200 μm unstretched polyethylene terephthalate (“Lumilar (registered trademark)” manufactured by Toray Industries, Inc.) that has been subjected to corona treatment in advance. It was. Subsequently, a urethane resin-based adhesive was applied onto the polyester-based resin layer 4 and dried with warm air to provide a second adhesive layer 5.

Then, the transparent thermoplastic resin layer 6 was provided by extruding the two layers of the transparent thermoplastic resin melted from the T-die with a multi-axis extruder and laminating them on the second adhesive layer 5.

Here, in the transparent thermoplastic resin layer 6, transparent maleic acid-modified polypropylene (manufactured by RIKEN Vitamin Co., Ltd.) is used for the first layer, and a phenolic antioxidant (manufactured by BASF Japan Ltd.) is used for the second layer. IRGANOX1010 (registered trademark) ") by 0.2 parts by weight, hindered amine light stabilizer ("TINUVIN622 (registered trademark)" manufactured by BASF Japan Ltd.) by 0.3 parts by weight, benzotriazole ultraviolet absorber (BASF Japan Co., Ltd.) A polypropylene resin obtained by adding 0.5 parts by weight of "TINUVIN326 (registered trademark)" manufactured by the company) was used. The transparent thermoplastic resin layer 6 had a first layer having a thickness of 15 μm and a second layer having a thickness of 85 μm.

Then, the laminate of the base sheet 1, the pattern layer 2, the first adhesive layer 3, the polyester resin layer 4, the second adhesive layer 5, and the transparent thermoplastic resin layer 6 is nipped with the conduit embossed plate and the rubber roll. Then, embossing and laminating were performed at the same time.

Next, after surface treatment was performed on the embossed transparent thermoplastic resin layer 6, 10 parts by weight of a curing agent (“UR150B varnish (trade name)” manufactured by Toyo Ink Co., Ltd.) was added to the urethane resin ( 0.5 parts by weight of benzotriazole-based ultraviolet absorber (BASF Japan Co., Ltd. "TINUVIN326 (registered trademark)") in "URV238 varnish (trade name)" manufactured by Toyo Ink Co., Ltd., and hindered amine-based light stabilizer (BASF) A surface protective layer is coated by adding 1 part by weight of "TINUVIN622 (registered trademark)" manufactured by Japan Co., Ltd. as a topcoat resin and coating it with a gravure coat so that ^{the coating amount after drying is 5 g / m 2.} 7 was provided.

≪Primer layer 8≫
Subsequently, after surface treatment is performed on the back surface of the base sheet 1, 10 parts by weight of silica is added to 100 parts by weight of a polyol (“Lamister EM (registered trademark)” manufactured by Toyo Ink Co., Ltd.). Add 3 parts by weight of isocyanate (“LPNYB curing agent (trade name)” manufactured by Toyo Ink Co., Ltd.) to the prima coating liquid, and gravure so that ^{the coating amount after drying is 3 g / m 2.} The prime layer 8 was provided by coating with a coat.

≪Plywood layer 10≫
As the plywood layer 10, a base material for a floor material made of laminated plywood having a length of 300 mm, a width of 600 mm, and a thickness of 6 mm, whose side surfaces were actually processed, was prepared. The plywood layer 10 had a flexural modulus of 786 MPa as a result of measuring the flexural modulus in accordance with the Japanese Industrial Standards "JISK 7171".

≪Soft layer 12≫
As the first soft layer 12A, a polyurethane foam sheet with a compression hardness of 150 N and a thickness of 2 mm measured in accordance with the Japanese Industrial Standards "JIS K 6400-2 D"("RL2.0t (model number)" manufactured by Bridgestone Corporation) I prepared. As the second soft layer 12B, a foamed polyurethane sheet (“CF4.0t (model number)” manufactured by Bridgestone Corporation) with a compression hardness of 60N and a thickness of 4mm measured in accordance with the Japanese Industrial Standards “JISK 6400-2 D” is used. I prepared it. By laminating the first soft layer 12A and the second soft layer 12B, a soft layer having a thickness of 6 mm was obtained.

≪Floor material≫
A third adhesive layer 9 was provided by applying a moisture-curable urethane resin-based hot melt adhesive (“Tyforce (registered trademark)” manufactured by DIC Corporation) to the primer layer 8 so as to have a thickness of 50 μm. The third adhesive layer 9 and the surface (upper surface) of the plywood layer 10 are bonded and bonded. Next, a moisture-curable urethane resin-based hot melt adhesive (“Tyforce (registered trademark)” manufactured by DIC Corporation) is applied to the first soft layer 12A so as to have a thickness of 50 μm, thereby forming a fourth adhesive layer. 11 was provided. The fourth adhesive layer 11 and the back surface (lower surface) of the plywood layer 10 are bonded and bonded. As a result, a test piece 1 of a flooring material was obtained.

<Example 2: Thickness A1 of polyester resin layer 4>
A test body 2 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 was set to 300 μm in Example 1 described above.

<Example 3: Thickness A2 of polyester resin layer 4>
A test body 3 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 was set to 150 μm in Example 1 described above.

<Example 4: Thickness A1 of transparent thermoplastic resin layer 6>
A test body 4 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the transparent thermoplastic resin layer 6 was set to 150 μm in Example 1 described above.

<Example 5: Thickness A2 of transparent thermoplastic resin layer 6>
A test body 5 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the transparent thermoplastic resin layer 6 was set to 50 μm in Example 1 described above.

<Example 6: Difference in compressive hardness of the first and second soft layers 12A and 12B A1>
A test body 6 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the compressive hardness of the second soft layer 12B was set to 50 N in Example 1 described above.

<Example 7: Difference in compressive hardness A2 between the first and second soft layers 12A and 12B>
A test body 7 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the compressive hardness of the first soft layer 12A was 110 N in Example 1 described above.

<Example 8: Thickness A1 of the first and second soft layers 12A and 12B>
A test body 8 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the first soft layer 12A was set to 3 mm in Example 1 described above.

<Example 9: Thickness A2 of first and second soft layers 12A and 12B>
Specimen 9 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the second soft layer 12B was set to 3 mm (compressive hardness 70N) in Example 1 described above. It was.

<Comparative Example 1: Thickness B1 of Polyester Resin Layer 4>
A flooring material is produced in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 is 350 μm and the thickness of the transparent thermoplastic resin layer 6 is 50 μm in Example 1 described above. A comparative body 1 was obtained.

<Comparative Example 2: Thickness B2 of Polyester Resin Layer 4>
A flooring material is produced in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 is 125 μm and the thickness of the transparent thermoplastic resin layer 6 is 150 μm in Example 1 described above. 2 was obtained.

<Comparative Example 3: Thickness B1 of Transparent Thermoplastic Resin Layer 6>
A flooring material is produced in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 is 150 μm and the thickness of the transparent thermoplastic resin layer 6 is 200 μm in Example 1 described above. A comparative body 3 was obtained.

<Comparative Example 4: Thickness B2 of Transparent Thermoplastic Resin Layer 6>
A flooring material is produced in the same manner as in Example 1 described above, except that the thickness of the polyester resin layer 4 is 300 μm and the thickness of the transparent thermoplastic resin layer 6 is 25 μm in Example 1 described above. A comparative body 4 was obtained.

<Comparative Example 5: Difference in compressive hardness B1 between the first and second soft layers 12A and 12B>
Comparative body 5 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the compressive hardness of the second soft layer 12B was set to 40 N in Example 1 described above.

<Comparative Example 6: Difference in compressive hardness B2 between the first and second soft layers 12A and 12B>
Comparative body 6 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the compressive hardness of the first soft layer 12A was set to 100 N in Example 1 described above.

<Comparative Example 7: Thickness B1 of the first and second soft layers 12A and 12B>
In Example 1 described above, the floor is the same as in Example 1 described above, except that the thickness of the first soft layer 12A is 3 mm and the thickness of the second soft layer 12B is 5 mm (compression hardness 40N). By producing the material, a comparative body 7 was obtained.

<Comparative Example 8: Thickness B2 of First and Second Soft Layers 12A and 12B>
Comparative body 8 was obtained by producing a flooring material in the same manner as in Example 1 described above, except that the thickness of the second soft layer 12B was set to 2 mm (compressive hardness 70N) in Example 1 described above. It was.

[Test method]
<A. Abrasion resistance>
Test bodies 1 to 9 and comparative bodies 1 to 8 are tested in accordance with the wear resistance test specified by the Japanese Agricultural Standards (JAS) for flooring, and the number of rotations until the pattern disappears is confirmed. did. The worn paper was replaced every 500 rotations. The results are shown in Tables 1 and 2 below. In the test results, "◎" indicates no pattern disappearance at 8000 rotations, "○" indicates that the pattern disappears at 5001 to 8000 rotations, "△" indicates that the pattern disappears at 3001 to 5000 rotations, and "x" indicates that the pattern disappears. It shows that the handle disappears at 3000 rpm or less.

<B. Scratch resistance>
Test bodies 1 to 9 and comparative bodies 1 to 8 were tested in accordance with the pencil hardness test specified in the Japanese Industrial Standards "JIS K 5600" to confirm how they were scratched. The results are shown in Tables 1 and 2 below. In the test results, "◎" means no scratches at 7H or higher, "○" means no scratches at 4H to 6H, "△" means no scratches at H to 3H, and "x" means no scratches at a softer level than H. Is shown.

<C. Impact resistance>
Test bodies 1 to 9 and comparative bodies 1 to 8 are tested in accordance with the floor hardness test at the time of a fall collision specified in the Japanese Industrial Standards "JIS A 6519", and the fall impact value (Gs value) is obtained. ) Was measured. The results are shown in Tables 1 and 2 below. In the test results, "○" indicates 100 or more, and "x" indicates less than 100.

<D. Sound insulation>
Lightweight floor impact sound levels were measured for the test bodies 1 to 9 and the comparative bodies 1 to 8 by a method conforming to the Japanese Industrial Standards "JIS A 1418". The results are shown in Tables 1 and 2 below. In the test results, "⊚" indicates the permissible level LL-40, 45, "○" indicates the permissible level LL-50, and "x" indicates the permissible level LL-55.

<E. Walking feeling ＞
Test bodies 1 to 9 and comparative bodies 1 to 8 were constructed on a concrete slab using double-sided tape, and the testers (10 people) actually walked on it, causing floor noise, walking feeling, and floor. A sensory evaluation was performed on the softness of the concrete. The results are shown in Tables 1 and 2 below. In the test results, "◎" is a good evaluation for all 10 people, "○" is a good evaluation for 8-9 people, "△" 5-7 people are good evaluations, and "×" is a bad evaluation for more than half. Is shown.

<F. Productivity of transparent thermoplastic resin layer 6>
When the test bodies 1 to 9 and the comparative bodies 1 to 8 were produced, the productivity when the transparent thermoplastic resin layer 6 was extruded and laminated was confirmed. The results are shown in Tables 1 and 2 below. In the test results, "◎" indicates stable production, "○" indicates somewhat stable production, "△" requires careful production, and "×" indicates that production is extremely difficult. Shown.

<G. Roll laminating workability of decorative sheet layer 13>
In preparing the test bodies 1 to 9 and the comparative bodies 1 to 8, the roll-lamination processability of the decorative sheet layer 13 was confirmed. The results are shown in Tables 1 and 2 below. In the test results, "◎" indicates in-line roll laminating, "○" requires some caution in processing, but in-line roll laminating is possible, and "△" indicates considerable caution in processing. Although it is necessary, in-line roll laminating is possible, and "x" indicates that roll laminating is not possible and only laminating with single leaves is possible.

<H. Burr treatment property of decorative sheet layer 13>
The test bodies 1 to 9 and the comparative bodies 1 to 8 were cut with a circular saw and a cutting test was performed using a hand router to reach the plywood layer 10 on the surface, and burrs on the decorative sheet layer 13 were confirmed. The results are shown in Tables 1 and 2 below. In the test results, "◎" indicates that no burrs are generated, "○" indicates that burrs occur in a very small part but can be easily corrected, and "△" indicates that burrs occur in a part but can be corrected. "X" indicates that burrs are generated on almost the entire surface and it is difficult to correct by hand.

[Test results]
The conditions and test results of the test bodies 1 to 9 are shown in Table 1, and the conditions and test results of the comparative bodies 1 to 8 are shown in Table 2. The "total thickness" is a value obtained by rounding off the second decimal place when expressed in millimeters to the first decimal place.

As can be seen from Table 2, in the comparative body 1, since the polyester-based resin layer 4 is thick, it is excellent in abrasion resistance and scratch resistance, but it is difficult to put into practical use due to poor processability and burr treatment. It was. On the other hand, in the comparative body 2, since the polyester-based resin layer 4 is thin, the processability and the burr processability are excellent, but the wear resistance and the scratch resistance are poor.

In the comparative body 4, since the polyester-based resin layer 4 has a sufficient thickness, it is excellent in abrasion resistance and scratch resistance, but since the transparent thermoplastic resin layer 6 is thin, it is a transparent thermoplastic resin. Wrinkles and rolls were generated in the layer 6, resulting in poor productivity and difficulty in practical use. On the other hand, in the comparative body 3, since the transparent thermoplastic resin layer 6 is thicker than the polyester resin layer 4, not only the wear resistance is deteriorated, but also the productivity is poor and it is difficult to put it into practical use. It became.

In the comparative body 5, the second soft layer 12B is soft, and the difference in compressive hardness between the first soft layer 12A and the second soft layer 12B is large, so that the walking feeling is poor. .. Further, in the comparative body 7, since the soft layer 12 is thick, the sound insulation is excellent, but the difference in compressive hardness between the first soft layer 12A and the second soft layer 12B is large. , The feeling of walking has become bad.

In the comparative body 6, since the difference in compressive hardness between the first soft layer 12A and the second soft layer 12B is small, the impact resistance and sound insulation are poor. Further, in the comparative body 8, since the soft layer 12 is thin, the walking feeling is excellent, but the impact resistance and sound insulation are poor.

On the other hand, in the test bodies 1 to 9, good results could be obtained in all the tests. In particular, in the test body 2 in which the polyester resin layer 4 was made thick enough, excellent wear resistance was exhibited. Further, in the test piece 5 in which the transparent thermoplastic resin layer 6 is made thin enough so as to reduce the ratio of the thickness of the transparent thermoplastic resin layer 6 to the thickness of the polyester resin layer 4, excellent scratch resistance is obtained. showed that. Further, in the test body 8 in which the first soft layer 12A was made thick enough, excellent sound insulation was exhibited. Further, in the test body 3 in which the polyester-based resin layer 4 and the transparent thermoplastic resin layer 6 were thinned to be necessary and sufficient, excellent processability and burr-treatability were exhibited.

From these facts, the flooring material according to the present invention has excellent scratch resistance and abrasion resistance, impact resistance and sound insulation, and a good walking feeling while suppressing the overall thickness as much as possible. It was confirmed that they also have it.

The flooring material according to the present invention has excellent scratch resistance and abrasion resistance, impact resistance and floor impact sound blocking performance (sound insulation), and has good walking, while suppressing the overall thickness as much as possible. Since it also has a feeling, it can be used extremely beneficially in indoor and outdoor buildings.

1 Base sheet 2 Pattern pattern layer 3 First adhesive layer 4 Polyester resin layer 5 Second adhesive layer 6 Transparent thermoplastic resin layer 7 Surface protection layer 8 Primer layer 9 Third adhesive layer 10 Plywood layer 11 Fourth Adhesive layer 12 Soft layer 12A First soft layer 12B Second soft layer 13 Decorative sheet layer

Claims (3)

At least the decorative sheet layer and the plywood layer are laminated in this order from the surface side.
At least two soft layers are laminated on the floor side,
The decorative sheet layer is a pattern layer, a first adhesive layer, a polyester resin layer made of unstretched polyethylene terephthalate, a second adhesive layer, and a transparent thermoplastic resin layer on a base sheet made of a thermoplastic resin. , And a surface protective layer made of an ultraviolet curable resin are laminated in this order, and at least the transparent thermoplastic resin layer is embossed.
The thickness of the polyester resin layer is 150 μm or more and 300 μm or less.
The thickness of the transparent thermoplastic resin layer is 50 μm or more and 150 μm or less.
A flooring material having a total thickness of the polyester resin layer and the transparent thermoplastic resin layer of 250 μm or more and 400 μm or less. The soft layer is composed of at least two layers having different compression hardness measured in accordance with Japanese Industrial Standards "JIS K 6400-2 D", and the softest layer has a compression hardness of 55N or more and 70N or less.
The thickness of the plywood layer is 3 mm or more and 7 mm or less.
The thickness of the soft layer composed of at least two layers is 5 mm or more and 7 mm or less.
The flooring material according to claim 1, wherein the total thickness is 8 mm or more and 12 mm or less. The flooring material according to claim 2, wherein the soft layer composed of at least two layers has a difference between the compression hardness of the hardest layer and the compression hardness of the softest layer of 50 N or more and 100 N or less. ..

Images