JP2023125721A - Manufacturing method of floor material and floor material - Google Patents

Abstract

To provide a manufacturing method of a floor material in which a telescopic motion hardly occurs and a warp hardly occurs, and a floor material.SOLUTION: A manufacturing method of a floor material according to one embodiment comprises steps of: mixing at least calcium carbonate and polyvinyl chloride to generate a slurry; extruding the slurry to form a substrate; adhering a transfer film to the substrate; peeling the transfer film off from the substrate; cooling the substrate for a predetermined period; and peeling the transfer film off from the substrate. A back surface layer, a base layer, a design layer, and a surface layer are laminated in this order in the floor material, the base layer comprises the calcium carbonate and the polyvinyl chloride and the design layer is a layer formed by ink coated on the surface of the base layer.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for manufacturing a flooring material and a flooring material.

Today, in the construction industry, the number of housing starts is decreasing, but the demand for renovations of rental properties and existing single-family homes is increasing. BACKGROUND OF THE INVENTION Various types of flooring materials are widely used for floors in various facilities including commercial facilities as well as in general residences. The main flooring materials include resin flooring, wood flooring, stone, and ceramic flooring. Resin flooring materials include resin floor tiles, resin floor sheets, and carpet tiles. Among resin-based flooring materials, flooring materials using polyvinyl chloride (PVC) are particularly widely used. Additionally, in general, for flooring made of polyvinyl chloride, a polyvinyl chloride layer having a printed layer is formed by printing a pattern on the surface of a polyvinyl chloride sheet (for example, see Patent Document 1). .

Japanese Patent Application Publication No. 4-120361

However, PVC flooring tends to expand and contract due to changes in temperature, and shrinkage can create gaps between the flooring materials, and expansion can cause the flooring materials to stick up against each other. There is a problem.

In addition, in flooring materials made of polyvinyl chloride, a polyvinyl chloride layer with a printed layer is formed by printing a design on a polyvinyl chloride sheet; However, there is a problem in that the thermal expansion coefficient and other properties are different from those of the base material, and the flooring material itself may warp. Another problem is that the polyvinyl chloride sheet expands and contracts due to the tension applied to the polyvinyl chloride sheet during printing, and the pattern becomes inconsistent due to the difference in expansion and contraction between the center and both sides of the polyvinyl chloride sheet.

Therefore, the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method for manufacturing a flooring material and a flooring material that is less likely to expand and contract and less likely to warp.

A method for manufacturing a flooring material according to one aspect of the present invention includes the steps of: mixing at least calcium carbonate and polyvinyl chloride to produce a slurry; extruding the slurry to form a substrate; and applying a transfer film to the substrate. The method is characterized by comprising the steps of adhering the transfer film from the substrate, peeling the transfer film from the substrate, cooling the substrate for a predetermined period of time, and peeling the transfer film from the substrate.

According to this configuration, by mixing calcium carbonate and polyvinyl chloride to generate a slurry, a flooring material with a small coefficient of thermal expansion can be manufactured. This makes it difficult for the flooring material to expand and contract due to temperature changes, so the flooring material does not warp or bulge, making it difficult for gaps to form or for the flooring materials to push up against each other.

In addition, by adhering the transfer film to the substrate and peeling it off, only the ink is layered on the substrate, so unlike the conventional method, a layer printed on a sheet of polyvinyl chloride resin or olefin resin is sandwiched between the flooring materials. It is possible to produce a flooring material that does not require warping of the flooring material due to differences in the properties of the layers printed on the substrate and the sheet. Furthermore, by cooling the substrate for a predetermined period of time, internal stress in the flooring material can be alleviated.

Moreover, this method for manufacturing flooring material is characterized in that the step of adhering the transfer film to the substrate is a step of adhering the transfer film while extruding the substrate. According to this configuration, since the transfer film is bonded while extruding the substrate, the transfer film can be bonded to the substrate uniformly and stably.

Further, in the method for manufacturing this flooring material, the step of adhering the transfer film to the substrate is a step of adhering the transfer film wound around the roller to the substrate while the substrate is being pushed out by the roller. Features. According to this configuration, by using the roller, adhesion of the transfer film can be included in a series of manufacturing steps.

Moreover, this flooring manufacturing method is characterized by further comprising the step of creating an embossing on the substrate. According to this configuration, by further including the step of creating embossing on the substrate, it is possible to improve the cushioning properties and manufacture a flooring material that is hard to slip.

Further, in the method for manufacturing this flooring material, the step of creating an emboss on the substrate is a step of forming an emboss on the substrate by the unevenness made on the roller while the substrate is being pushed out by a roller. Features. According to this configuration, the substrate can be uniformly embossed, and the embossing can be included in a series of manufacturing steps.

Further, this method for manufacturing flooring material is characterized in that the step of generating the slurry includes mixing raw materials such as calcium carbonate and polyvinyl chloride, and then storing the mixture for a predetermined period of time to obtain a slurry for extrusion. According to this configuration, by storing the raw materials for a predetermined period of time, the raw materials can be mixed completely and uniformly, and local deformation of the flooring material due to non-uniformity of the materials can be suppressed.

The method for manufacturing this flooring material further includes the steps of applying UV coating to the surface of the substrate to which the ink has been transferred by the transfer film, and cooling the substrate whose surface has been coated with UV coating for a predetermined period of time. It is characterized by being prepared. According to this configuration, a flooring material with high wear resistance can be manufactured by applying UV coating to the surface of the substrate onto which the ink has been transferred. Furthermore, by cooling the substrate whose surface has been coated with UV coating for a predetermined period of time, the heat generated during the application of UV coating can be cooled, the internal stress can be alleviated again, and the stability of the flooring material can be increased.

Moreover, this method for manufacturing a flooring material is characterized in that, before the step of cooling the substrate for a predetermined period of time, the method further includes the step of cutting the substrate and dividing it into substrates of a predetermined size. By dividing the substrate into predetermined size substrates, the substrate can be cooled efficiently.

Moreover, this method of manufacturing flooring material is characterized by further comprising a step of applying UV coating to the back surface of the substrate, and a step of cooling the substrate whose back surface is coated with UV coating for a predetermined period of time. According to this configuration, a flooring material with high wear resistance can be manufactured by applying UV coating to the back surface of the substrate to which the ink has been transferred. Furthermore, by cooling the substrate with UV coating on the backside for a predetermined period of time, the heat generated during UV coating can be cooled, the internal stress can be alleviated again, and the stability of the flooring material can be increased.

Moreover, this flooring manufacturing method is characterized by further comprising a step of dividing the substrate into flooring size pieces, and a step of chamfering the divided substrate. According to this configuration, by chamfering the divided substrates, it is possible to alleviate steps caused by unevenness of the subfloor.

In addition, this flooring material has a back layer, a base layer, a design layer, and a surface layer laminated in this order, the base layer containing calcium carbonate and polyvinyl chloride, and the design layer coated on the surface of the base layer. It is characterized by being a layer formed of a modified ink.

According to this configuration, by mixing calcium carbonate and polyvinyl chloride, the coefficient of thermal expansion of the flooring material can be reduced. This makes it difficult for the flooring material to expand and contract due to temperature changes, so the flooring material does not warp or bulge, making it difficult for gaps to form or for the flooring materials to push up against each other. It also becomes a flooring material with excellent load-bearing properties.

In addition, since the design layer is formed by ink applied to the surface of the base layer, there is no need to sandwich the layer printed on a sheet of polyvinyl chloride resin or olefin resin between the flooring materials. , it is possible to prevent the occurrence of warping of the flooring material caused by the difference in characteristics between the base layer and the layer printed on the sheet.

Moreover, this flooring material is characterized in that the design layer is a layer formed by transfer to the base layer. According to this configuration, since the design layer is a layer formed by transfer, a clear design can be easily and reliably provided.

Further, this flooring material is characterized in that the polyvinyl chloride is present in an amount of 40 to 60 parts by mass based on 100 parts by mass of the calcium carbonate. According to this configuration, by blending polyvinyl chloride in an amount of 40 to 60 parts by mass per 100 parts by mass of calcium carbonate, it is possible to obtain a significant effect of suppressing the coefficient of thermal expansion.

In addition, the base layer of this flooring material includes stabilizers, plasticizers, colorants, lubricants, mold release agents, crosslinking agents, antistatic agents, surfactants, flame retardants, foaming agents, antibacterial and antifungal agents, impact Contains one or more reinforcing agents. According to this configuration, the coefficient of thermal expansion can be further suppressed by adding an additive.

Further, in this flooring material, the additive is contained in an amount of 10 to 20 parts by mass based on 100 parts by mass of the calcium carbonate. By setting it within the above range, the physical properties of the flooring material can be improved and the coefficient of thermal expansion can be suppressed.

Further, this flooring material is characterized in that the back layer and the surface layer are formed of UV paint. According to this configuration, since the back layer and the surface layer are formed of UV paint, the abrasion resistance of the flooring material can be improved. Moreover, cracking can be effectively prevented. In addition, since the back layer and the front layer are formed using the same UV paint, when different materials are used for the back layer and the front layer, this prevents the flooring material from warping due to differences in the characteristics of each material. be able to.

Moreover, this flooring material is characterized in that the shape of the surface corner portion of the flooring material is a chamfered shape. According to this configuration, the shape of the surface corners of the flooring material is chamfered, so when replacing the flooring material, the installer can use a hook jig such as a cutter or a perforator between the flooring materials. You can remove the flooring by hooking it on. Therefore, reupholstery work becomes easy. Furthermore, differences in level due to unevenness of the subfloor can be reduced.

Further, this flooring material is characterized in that the thickness of the flooring material is 1.5 mm or less. This allows it to be placed over existing flooring without interfering with areas such as under doors. Since the thickness of the floor material is as thin as 1.5 mm or less, it is easy to cut with a cutter or the like. Moreover, since the flooring material becomes heavy, it becomes difficult to carry it when packing and transporting a plurality of flooring materials.

Moreover, it is preferable that the base layer of this flooring material is colored. By coloring the base layer with a pigment similar to that of the design layer, it is possible to suppress the sense of discomfort caused by the difference in color and improve the aesthetic appearance of the product.

According to the present invention, it is possible to provide a method for manufacturing a flooring material that is less likely to expand and contract and less likely to warp, and a flooring material that is less likely to warp.

FIG. 1 is a longitudinal cross-sectional view of a flooring material according to an embodiment of the present invention. It is a schematic diagram of an extruder provided with five rollers. 2 is a graph showing the relationship between temperature and coefficient of thermal expansion of flooring materials of Example 1 and Comparative Example 1.

Hereinafter, a flooring material according to an embodiment of the present invention will be described in detail. Note that the present invention is not limited to this embodiment. Furthermore, the constituent elements in the embodiments described below include those that can be easily replaced by those skilled in the art, or those that are substantially the same. Furthermore, the configurations described below can be combined as appropriate. Further, various omissions, substitutions, or changes in the configuration can be made without departing from the gist of the present invention.

(Composition of flooring material)
As shown in FIG. 1, the flooring 1 according to the present embodiment has a layer structure in which a back layer 5, a base layer 4, a design layer 3, and a surface layer 2 are laminated in order from the bottom.

The thickness of the flooring material 1 of the present invention is preferably 1.5 mm or less. Since the thickness of the flooring material 1 is as thin as 1.5 mm or less, it does not interfere with the area under the door even if it is placed over the existing flooring, and it is easy to cut with a cutter or the like. Moreover, since the flooring material 1 becomes heavy, it becomes difficult to carry it when packing and transporting a plurality of flooring materials.

The floor material 1 has a chamfered portion 6 at the upper end of its periphery.
By providing a chamfered portion 6 at the upper end of the peripheral portion of the flooring material 1, when the installer tears off the flooring material 1, the installer can hook a hooking jig such as a fingertip or a cutter on the chamfered portion 6 and the side surface of the flooring material 1. peel-up properties can be improved.

Moreover, the floor material 1 of the present invention has a chamfered portion 6 formed at the upper end of its peripheral portion. Therefore, there are no right-angled corners at the boundaries between the flooring materials, and the boundaries between the flooring materials can be made inconspicuous. This allows the difference in level between the flooring materials to be hidden.

That is, by forming the chamfered portions 6, the joints formed between the flooring materials are widened in the upper part, so even if a level difference occurs between the flooring materials, the level difference is not noticeable.

Furthermore, if there is a step between the flooring materials and the upper edge of the periphery of the flooring material 1 is at a right angle, the toes of bare feet or shoes may get caught in the step portion when walking, impairing the feeling of walking, or However, by forming the chamfered portion 6, it is possible to suppress the toes of bare feet or shoes from getting caught when walking.

The chamfered portion 6 of this embodiment is a flat surface. The chamfered portion 6 is provided so that the width is W and the depth is D. It is preferable that the width W is 0.2 to 0.8 mm and the depth D is 0.2 to 0.8 mm. Further, it is more preferable that the width W is 0.4 to 0.6 mm and the depth D is 0.4 to 0.6 mm.

If the width W and depth D are less than 0.2 mm, it will be difficult for the installer to hook a hooking jig such as a cutter or perforator, which may impair the effect of improving peel-up properties and also impair the feeling of walking. , there is a risk of damaging the surface layer of the flooring material. Moreover, if the width W and the depth D are larger than 0.8 mm, cleaning of the joint portion becomes difficult and dirt and dust may easily accumulate.

The angle of each corner of the chamfered portion 6 is preferably 30 to 60 degrees. Further, it is more preferable that the temperature is 40 to 50 degrees. If the angle is less than 30 degrees, when the flooring material 1 is laid down, the width of the joints formed by the chamfered portions 6 will be too wide, causing unevenness on the floor surface, which may impair the feeling of walking. Furthermore, there is a risk that the toes may get caught during walking and damage the surface layer of the flooring 1.

Furthermore, if the angle is less than 30 degrees, the joint will be shallow and it will be difficult for the installer to hook the hooking jig, such as a fingertip, a cutter, or a perforator, and there is a risk that the peel-up property will be impaired. Furthermore, if the angle is greater than 60 degrees, the width of the joint will become narrower, impairing the cleaning performance, and it will be difficult for the installer to hook a hooking jig such as a cutter, perforator, etc., thereby impairing the peel-up performance. Moreover, the joints become deep, and when the flooring material 1 is laid, the boundary portion of the flooring material 1 becomes noticeable, which may impair the aesthetic appearance.

The surface layer 2 is laminated on the uppermost surface of the flooring 1 and is a layer that protects the surface of the flooring 1.
By providing the surface layer 2, the flooring material 1 has high scratch resistance and wear resistance that can withstand use in homes and offices.

The surface layer 2 is formed of UV paint.
Examples of UV paints include paints made of isocyanate and a main ingredient made of oligomers, monomers, photopolymerization initiators, and other additives.

The thickness of the surface layer 2 is preferably 0.05 to 0.20 mm, more preferably 0.10 to 0.15 mm. If the thickness of the surface layer 2 is less than 0.05 mm, the surface of the flooring 1 may not be sufficiently protected. Furthermore, if the thickness of the surface layer 2 is greater than 0.20 mm, the design layer 3 may be difficult to visually recognize.

The design layer 3 is a layer that expresses a desired design, such as a picture, a design, a pattern, a character, etc., and gives the flooring material 1 design properties. By providing the design layer 3, a desired design can be easily and inexpensively imparted to the flooring material 1.

The design layer 3 is a layer formed by transfer to the base layer 4, and is a layer formed by ink applied to the surface of the base layer 4. As a result, there is no need to sandwich the layer printed on the sheet such as vinyl chloride resin or olefin resin between the flooring materials, and only the ink is laminated on the base layer 4, so the layer printed on the base layer 4 and the sheet It is possible to prevent the flooring material 1 from warping due to differences in its characteristics. Moreover, a clear design can be easily and reliably provided.

The design layer 3 is formed, for example, by heat transfer using a transfer film having a pattern printed with ink on the surface of the base. The solid content of the design layer 3 is preferably 0.1 to 30 g/m ² . By setting the solid content of the design layer 3 to 0.1 to 30 g/m ² , formation by thermal transfer becomes easy and the appearance of the design layer 3 becomes good.

The thickness of the design layer 3 is preferably 0.01 to 0.10 mm, more preferably 0.02 to 0.05 mm.

In this embodiment, the design layer 3 is a layer formed by transfer, but it may also be a printed layer directly formed by gravure printing, flexo printing, screen printing, inkjet printing, etc., and is not particularly limited to this embodiment. It's not something you can do.

The base layer 4 is a layer that serves as a base material.
In this embodiment, the base layer 4 is a layer containing calcium carbonate and polyvinyl chloride, and has the effect of lowering the expansion/contraction rate of the flooring 1.

Examples of the polyvinyl chloride included in the base layer 4 include a polyvinyl chloride homopolymer, a copolymer of a vinyl chloride monomer and a monomer having an unsaturated bond copolymerizable with the vinyl chloride monomer, and a polyvinyl chloride polymer other than vinyl chloride. Examples include graft copolymers obtained by graft copolymerizing vinyl chloride onto other polymers (including copolymers), and these may be used alone or in combination of two or more types.

Examples of monomers having an unsaturated bond copolymerizable with the above vinyl chloride monomer include α-olefins such as ethylene, propylene, and butylene; vinyl esters such as vinyl acetate and vinyl propionate; butyl vinyl ether and cetyl vinyl ether. vinyl ethers such as methyl (meth)acrylate, ethyl (meth)acrylate, butyl acrylate; aromatic vinyls such as styrene and α-methylstyrene; N-phenylmaleimide, N-cyclohexyl Examples include N-substituted maleimides such as maleimide, and these may be used alone or in combination of two or more types.

Other polymers (including copolymers) other than vinyl chloride used in the above graft copolymer are not particularly limited as long as they can graft copolymerize vinyl chloride, but for example, ethylene - Vinyl acetate copolymer, ethylene-vinyl acetate-carbon monoxide copolymer, ethylene-ethyl acrylate copolymer, ethylene-butyl acrylate-carbon monoxide copolymer, ethylene-methyl methacrylate copolymer, ethylene-propylene Examples include copolymers, acrylonitrile-butadiene copolymers, polyurethanes, chlorinated polyethylenes, chlorinated polypropylenes, etc., and these may be used alone or in combination of two or more.

The average degree of polymerization of the above-mentioned polyvinyl chloride is not particularly limited, but if the average degree of polymerization is small, the physical properties of the obtained molded product are likely to deteriorate, and if the average degree of polymerization is high, the melt viscosity increases and molding becomes difficult. Since this tends to be difficult, the average degree of polymerization is preferably within the range of 600 to 3,000, more preferably 700 to 1,500.

As the calcium carbonate contained in the base layer 4, heavy calcium carbonate is used in this embodiment, but light calcium carbonate may also be used, and the particle shape of the powder may be a regular shape such as a spherical shape, or an irregular shape. , whisker shape, etc. Furthermore, the average particle diameter is preferably 0.5 to 5 μm. Furthermore, those surface-treated with fatty acids such as stearic acid, palmitic acid, and lauric acid, and salts of these fatty acids and alkali metals (calcium, etc.) can also be used.

The amount of polyvinyl chloride included in the base layer 4 is 40 to 60 parts by mass based on 100 parts by mass of calcium carbonate. By blending polyvinyl chloride in an amount of 40 to 60 parts by mass per 100 parts by mass of calcium carbonate, it is possible to obtain a remarkable effect of suppressing the coefficient of thermal expansion.

In addition, the base layer 4 may contain one or two of stabilizers, plasticizers, colorants, lubricants, mold release agents, crosslinking agents, antistatic agents, surfactants, flame retardants, foaming agents, and antibacterial and antifungal agents. The above additives are blended. The amount of the additive is preferably 10 to 20 parts by weight, more preferably 15 to 18 parts by weight, based on 100 parts by weight of calcium carbonate.

Examples of the above-mentioned stabilizers include metal soap stabilizers such as barium stearate, calcium stearate, and zinc stearate, and organotin stabilizers such as dioctyltin laurate, dibutyltin maleate, and dibutyltin β-mercaptopropionate alkyl ester. , phosphite stabilizers such as monotridecyl diphenyl phosphite and tetraphenyl dipropylene diphosphite, hydrotalcite stabilizers such as perchloric acid-treated hydrotalcite, β-diketones such as dibenzoylmethane, pentaerythritol, etc. These polyols can be used alone or in combination of two or more types.

Examples of the plasticizer include phthalic acid esters such as di2-ethylhexyl phthalate, diisononyl phthalate, diisodecyl phthalate, and butylbenzyl phthalate, adipic acid esters such as diisononyl adipate and di2-ethylhexyl adipate, trimellitic acid esters, and phosphoric acid esters. Examples include esters, polyester plasticizers, chlorinated paraffins, and epoxidized soybean oil, and these may be used alone or in combination of two or more.

As the coloring agent, for example, various natural and synthetic dyes, and various inorganic and organic pigments can be arbitrarily used. By adding a coloring agent, the base layer 4 is colored in a color similar to that of the design layer 3, thereby suppressing the discomfort caused by the difference in color and improving the aesthetic appearance of the product.

Examples of the lubricant include waxes, oils, caprics, higher fatty acids such as lauric acid, myristic acid, palmitic acid, margaric acid, stearic acid, arachidic acid, and behenic acid, or metal salts thereof, ie, lithium salts, Calcium salt, sodium salt, magnesium salt, potassium salt, etc., aliphatic alcohols such as palmityl alcohol, cetyl alcohol, stearyl alcohol, caproic acid amide, caprylic acid amide, capric acid amide, lauric acid amide, myristic acid amide, palmitin Examples include aliphatic amides such as acid amide and stearamide, esters of fatty acids and alcohols, fluorine compounds such as fluoroalkylcarboxylic acids or their metal salts, and fluoroalkylsulfonic acid metal salts, which may be used alone or in combination. Two or more types can also be used in combination.

Examples of the above waxes include mineral waxes such as montan wax, peat wax, ozokerite/ceresin wax, petroleum wax, polyolefin waxes such as polyethylene wax and polypropylene wax, Fischer-Tropsch wax, chemically modified hydrocarbon waxes, and substituted amide waxes. Examples include synthetic waxes such as wax, vegetable waxes, animal waxes, and the like.

Examples of the oil agent include natural and synthetic oils such as aromatic oils, naphthenic oils, paraffinic oils, mineral oils, vegetable oils, and silicone oils. As the silicone oil, dimethylpolysiloxane having a viscosity of 10 to 5000 cSt, preferably 500 cSt can be used.

Examples of the mold release agent include lower (C1-4) alcohol esters of higher fatty acids (butyl stearate, etc.), polyhydric alcohol esters (C4-30) of fatty acids (hydrogenated castor oil, etc.), glycol esters of fatty acids, Examples include liquid paraffin, and these may be used alone or in combination of two or more types.

Examples of the crosslinking agent include (H1) aromatic alcohols such as N,N-bis(2-hydroxypropyl)aniline, hydroquinone-bis(β-hydroxyethyl)ether, and resorcinol-bis(β-hydroxyethyl)ether. (H2) aliphatic alcohol crosslinking agents such as ethylene glycol, 1,3-butanediol (1,3-butylene glycol), 1,4-butanediol, octanediol, trimethylolpropane, triisopropanolamine, etc. ; Phenylene diamine, tolylene diamine, diphenyl diamine, 4,4'-diaminodiphenylmethane, 3,3'-dichloro-4,4'-diaminodiphenylmethane, 1,2-bis(2-aminophenylthio)ethane, trimethylene Examples include (H3) aromatic amine crosslinking agents such as glycol-p-aminobenzoate; and (H4) aliphatic amine crosslinking agents such as ethylene diamine, propylene diamine, hexamethylene diamine, and diethylene triamine, which may be used alone or in combination. More than one type can also be used together.

Examples of the antistatic agent include cationic surfactants, anionic surfactants, amphoteric surfactants, and nonionic surfactants.

Examples of the above-mentioned surfactants include acetylene glycol surfactants, fluorine surfactants, silicone surfactants, and the like.

As the flame retardant, for example, halogen flame retardants, phosphorus flame retardants, nitrogen-containing flame retardants, and antimony flame retardants can be used.

Various chlorine-based and bromine-based flame retardants can be used as the above-mentioned halogen-based flame retardants. From the side, pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, hexabromocyclododecane, hexabromobenzene, pentabromoethylbenzene, hexabromobiphenyl, decabromodiphenyl, hexabromodiphenyl oxide, octabromodiphenyl oxide , decabromodiphenyl oxide, pentabromocyclohexane, tetrabromobisphenol A, and its derivatives [e.g., tetrabromobisphenol A-bis(hydroxyethyl ether), tetrabromobisphenol A-bis(2,3-dibromopropyl ether), tetrabromobisphenol A-bis(hydroxyethyl ether), tetrabromobisphenol A-bis(2,3-dibromopropyl ether), Bromobisphenol A-bis(bromoethyl ether), tetrabromobisphenol A-bis(allyl ether), etc.], tetrabromobisphenol S, and its derivatives [e.g., tetrabromobisphenol S-bis(hydroxyethyl ether), tetrabromobisphenol S-bis(2,3-dibromopropyl ether), etc.], tetrabromophthalic anhydride, and derivatives thereof [e.g., tetrabromophthalimide, ethylenebistetrabromophthalimide, etc.], ethylenebis(5,6-dibromonorbornene-2, 3-dicarboximide), tris-(2,3-dibromopropyl-1)-isocyanurate, adduct of Diels-Alder reaction of hexachlorocyclopentadiene, tribromophenyl glycidyl ether, tribromophenyl acrylate, ethylene bistribromophenyl Ether, ethylene bispentabromophenyl ether, tetradecabromodiphenoxybenzene, brominated polystyrene, brominated polyphenylene oxide, brominated epoxy resin, brominated polycarbonate, polypentabromobenzyl acrylate, octabromonaphthalene, hexabromocyclododecane, bis Brominated flame retardants such as (tribromophenyl)fumaramide and N-methylhexabromodiphenylamine; chlorinated flame retardants such as chlorinated paraffin are preferably used.

Examples of the above-mentioned phosphorus flame retardants include tris(chloroethyl) phosphate, tris(2,3-dichloropropyl) phosphate, tris(2-chloropropyl) phosphate, tris(2,3-bromopropyl) phosphate, tris(bromopropyl) phosphate, and tris(bromopropyl) phosphate. Halogen-containing phosphoric acids such as chloropropyl) phosphate, 2,3-dibromopropyl-2,3-chloropropyl phosphate, tris(tribromophenyl) phosphate, tris(dibromophenyl) phosphate, and tris(tribromoneopentyl) phosphate Ester flame retardants; aliphatic phosphate esters such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate; triphenyl phosphate, cresyl diphenyl phosphate, dicresyl phenyl phosphate, tricresyl phosphate, tricresyl phosphate nyl phosphate, xylenyl diphenyl phosphate, tri(isopropylphenyl) phosphate, isopropylphenyl diphenyl phosphate, diisopropylphenyl phenyl phosphate, tri(trimethylphenyl) phosphate, tri(t-butylphenyl) phosphate, hydroxyphenyl diphenyl phosphate, octyldiphenyl phosphate non-halogenated phosphate ester flame retardants such as aromatic phosphate esters; aluminum phosphinate flame retardants such as aluminum dimethylphosphinate and aluminum diethylphosphinate; these may be used alone or in combination of two or more. You can also do it.

Examples of the nitrogen-containing flame retardants include melamine cyanurate, isocyanuric acid, tris(2-hydroxyethyl)isocyanurate, triallylisocyanurate, tris(2,3-epoxypropyl)isocyanurate, guanidine hydrochloride, guanidine nitrate, and phosphoric acid. Guanidine, guanidine sulfate, guanidine sulfamate, guanidine tetraborate, guanidine carbonate, guanylurea phosphate, guanylurea sulfate, melamine, melamine/melam/melem, melamine cyanurate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, polyphosphorus Examples include acid melamine, melam, melem, melamine sulfate, and the like, and these can be used alone or in combination of two or more types.

Examples of the antimony-based flame retardant include antimony oxide, antimony trioxide, antimony pentoxide, antimony tetroxide, and sodium antimonate, and these can be used alone or in combination of two or more types.

Examples of the above-mentioned blowing agents include azo compounds, ammonium carbonate, ammonium bicarbonate, ammonium nitrite, and the like, and these can be used alone or in combination of two or more types.

Examples of the antibacterial and fungicidal agents include benzimidazole compounds, mercaptopyridine-N-oxide compounds, isothiazolone compounds, and benzothiazole compounds, and these can be used alone or in combination of two or more.

The thickness of the base layer 4 is preferably 1.0 to 1.4 mm, more preferably 1.2 to 1.3 mm. If the thickness of the base layer 4 is less than 1.0 mm, it may not be possible to effectively suppress warping of the floor material 1 or size changes due to temperature changes, and if it is greater than 1.4 mm, the rigidity of the floor material 1 may be reduced. The rate increases, making it difficult to bend or warp.

The back layer 5 is a layer that is laminated on the lowermost surface of the flooring material 1 and is in contact with the underlying surface.
By providing the back layer 5, the back surface of the flooring 1 can be protected.

The back layer 5 is formed of UV paint.
Since the surface layer 5 is formed of UV paint, the wear resistance of the floor material 1 can be improved. Moreover, cracking can be effectively prevented.

Examples of UV paints include paints made of isocyanate and a main ingredient made of oligomers, monomers, photopolymerization initiators, and other additives.

In addition, since the back layer 5 is formed of the same UV paint as the front layer 2, when different materials are used for the front layer 2 and the back layer 5, warping of the flooring 1 due to the difference in the characteristics of each material can be avoided. This can be prevented from occurring.

The thickness of the back layer 5 is preferably 0.05 to 0.20 mm, more preferably 0.10 to 0.15 mm. If the thickness of the back layer 5 is less than 0.05 mm, the back surface of the flooring 1 may not be sufficiently protected. Furthermore, if the thickness of the back layer 5 is greater than 0.20 mm, there is a risk that the manufacturing cost will increase and the handling of the flooring 1 will decrease.

(Manufacturing method of flooring material)
Next, a method for manufacturing the flooring material 1 according to this embodiment will be explained.
The flooring material 1 according to this embodiment can be manufactured by the following steps.

First step: This is a step of mixing calcium carbonate, polyvinyl chloride, and additives to form a slurry.
Specifically, calcium carbonate and polyvinyl chloride granules are crushed, put into a blender together with additives, stirred and mixed to form a slurry, and stored for a certain period of time. By storing the product for a predetermined period of time, the raw materials can be mixed uniformly, and the dispersion state of the materials becomes non-uniform, thereby making it possible to avoid local deformation of the product.

Second step: This is a step in which the slurry is extruded to form a substrate, a transfer film is adhered to the extruded substrate, and an embossing is created.
The generated slurry is put into the tip of an extruder, heated and melted, and then extruded from a mold into a plate with a thickness of 1.0 to 1.4 mm. Then, a transfer film is attached to the extruded substrate at high temperature, an embossing is applied, and the substrate is divided into specified size substrates.

As shown in FIG. 2, the extruder of this embodiment includes five rollers 7, as an example. The substrate is extruded by rollers 7A and 7B to form a set thickness, and roller 7C presses the transfer film with transfer device 8 to adhere it to the substrate, and the unevenness provided on rollers 7D and 7E embosses the substrate. can be applied together.

Third step: This is a step of cooling the substrate for a predetermined period of time.
The divided substrates are naturally cooled at room temperature for 72 hours or more. By cooling for 72 hours or more, the substrate can be sufficiently cooled and the internal stress of the substrate can be alleviated. Then, the transfer film is peeled off from the substrate.

Fourth step: This is a step of applying UV coating to the surface of the substrate.
The cooled substrate is put into a UV production line, a UV coating machine coats the surface of the substrate uniformly with UV paint, and an ultraviolet UV curing machine hardens the paint. A hardened UV layer can be applied to the surface of the product to improve its wear resistance.

Fifth step: This is a step of cooling the substrate coated with UV coating.
The substrate on which the cured UV layer is laminated is naturally cooled at room temperature for 24 hours or more. By naturally cooling for 24 hours or more, the amount of heat generated by the ultraviolet UV curing machine can be completely cooled, the internal stress of the substrate can be relaxed again, and the stability of the product can be improved.

Sixth step: This is a step of applying UV coating to the back side of the board.
The cooled substrate is put into a UV production line, a UV coating machine uniformly applies UV paint to the back surface of the substrate, and an ultraviolet UV curing machine hardens the paint. A hardened UV layer can be applied to the surface of the product to improve its wear resistance.

Seventh step: This is a step of cooling the substrate coated with UV coating.
The substrate on which the cured UV layer is laminated is left at room temperature for 24 hours or more. The amount of heat generated by the ultraviolet UV curing machine can be completely cooled down, the internal stress of the substrate can be relaxed again, and the stability of the product can be improved.

Eighth step: This is a step of dividing the substrate into flooring size pieces.
The board is put into a dividing production line, and then divided into the set floor material sizes by a dividing machine. When dividing, remove debris such as chips generated by the dust remover inside the machine.

Ninth step: This is a step of chamfering the divided substrates.
Pass the divided board through a click cutter and chamfer the four sides of the surface. By chamfering, it is possible to reduce the difference in level caused by the unevenness of the subfloor.

Next, specific aspects of this embodiment will be explained in detail with reference to Examples, but the present invention is not limited to these descriptions.

The materials used in Example 1 below were as follows.
[Example 1]
(Surface layer)
UV paint (manufactured by Mile) was used.

(design layer)
A transfer film (manufactured by Kosei) was used.

(base layer)
A mixture of 100 parts by mass of calcium carbonate (manufactured by Keiho), 50 parts by mass of polyvinyl chloride resin (manufactured by Xinfa), and about 17 parts by mass of a stabilizer (manufactured by Maijisen) was used.

(back layer)
UV paint (manufactured by Mile) was used.

The method for manufacturing the flooring material was to crush calcium carbonate and polyvinyl chloride granules, then put them into a blender, stir and mix them to form a slurry, and store it for 3 hours.

Next, the generated slurry was put into the tip of an extruder, heated and melted, and then extruded from a mold into a 1.24 mm thick plate to form a substrate. Further, a transfer film was bonded at 150° C., embossing was applied, and the substrates were divided into 925 mm long and 1060 mm wide substrates. Note that the thickness of the transfer film is 0.02 mm.

Next, the divided substrates were left to cool at room temperature for 72 hours. Then, the transfer film was peeled off from the substrate.

Next, this cooled substrate was put into a UV production line, a UV coating machine was used to uniformly adhere the UV paint to the surface of the substrate, and an ultraviolet UV curing machine was used to harden the paint. The thickness of this surface UV layer is 0.12 mm.

The substrate on which the cured UV layer was laminated was left to cool at room temperature for 24 hours.

Next, this cooled substrate was put into a UV production line, a UV coating machine was used to uniformly adhere UV paint to the back surface of the substrate, and an ultraviolet UV curing machine was used to harden the paint. The thickness of this back UV layer was 0.12 mm.

The substrate on which the cured UV layer was laminated was left to cool at room temperature for 24 hours.

Next, this board was put into a dividing production line, and then divided into the set sizes by a dividing machine. The obtained flooring has a length of 914 mm, a width of 152 mm, and a thickness of 1.5 mm.

The divided flooring material was passed through a click cutter and the four sides of the surface were chamfered. The width and depth of the chamfered portion 6 of the obtained flooring material were 0.5 mm.

Next, a test was conducted on the coefficient of thermal expansion of the flooring using the flooring of Example 1 and a conventional general PVC flooring as Comparative Example 1. Note that the room temperature under the environment in which the test is conducted is 17°C.

In this test, the flooring materials of Example 1 and Comparative Example 1 were used, respectively. I cut it out. Test piece 1 was stored in the open at temperatures of 20°C, 30°C, 40°C, and 50°C for 1 hour, and test piece 2 was stored in a refrigerator at a depth of 35 cm for 1 hour at temperatures of -10°C, 0°C, and 10°C. saved.

Then, the length and width of each flooring material were measured at temperature conditions of -10°C, 0°C, 10°C, 30°C, 40°C, and 50°C, with 20°C as the standard, and the coefficient of thermal expansion was measured. The results are shown in Figure 3.

From the results ^of Example 1 and Comparative Example 1 shown in FIG. It was revealed that the flooring material No. 1 had a coefficient of thermal expansion of 65.5×10 ^-6 /K between -10°C and 50°C.

Therefore, the flooring material of Example 1 was able to suppress the coefficient of thermal expansion to about 1/10 of that of the flooring material of Comparative Example 1, and became a flooring material that was less susceptible to temperature changes. Therefore, the flooring material is less likely to warp or bulge, and unlike the commonly used PVC flooring materials such as Comparative Example 1, there is no need to install the flooring material with gaps, which can occur due to temperature changes after construction. This also makes it difficult for flooring materials to push up against each other. It is also resistant to heat, so it can be installed over floor heating.

As mentioned above, the preferred embodiments of the present invention have been described, but it goes without saying that the present invention is not limited to the above-described embodiments, and various changes or modifications within the scope of the claims can be made. These also belong to the technical scope of the present invention.

1 Floor material 2 Back layer 3 Base layer 4 Design layer 5 Surface layer 6 Chamfered portion 7 Roller 8 Transfer device

Claims (19)

mixing at least calcium carbonate and polyvinyl chloride to produce a slurry;
extruding the slurry to form a substrate;
a step of adhering a transfer film to the substrate;
cooling the substrate for a predetermined time;
Peeling the transfer film from the substrate;
characterized by comprising;
Method of manufacturing flooring. The step of adhering a transfer film to the substrate,
A step of adhering the transfer film while extruding the substrate,
The method for manufacturing a flooring material according to claim 1. The step of adhering a transfer film to the substrate,
a step of adhering the transfer film wound around the roller to the substrate while the substrate is being pushed out by the roller;
The method for manufacturing a flooring material according to claim 2. further comprising the step of creating an embossing on the substrate,
The method for manufacturing a flooring material according to any one of claims 1 to 3. The step of creating an embossing on the substrate,
a step of forming an emboss on the substrate by the unevenness formed on the roller while the substrate is being pushed out by a roller;
The method for manufacturing a flooring material according to claim 4. The step of generating the slurry includes:
After mixing raw materials such as calcium carbonate and polyvinyl chloride,
Store it for a specified period of time and use it as a slurry for extrusion.
The method for manufacturing a flooring material according to any one of claims 1 to 5. applying UV coating to the surface of the substrate to which the ink has been transferred by the transfer film;
cooling the substrate whose surface is coated with UV coating for a predetermined time;
further comprising;
The method for manufacturing a flooring material according to any one of claims 1 to 6. Before the step of cooling the substrate for a predetermined time,
further comprising the step of cutting the substrate into substrates of a predetermined size;
The method for manufacturing a flooring material according to any one of claims 1 to 7. a step of applying UV coating to the back side of the substrate;
cooling the substrate whose back surface is coated with UV coating for a predetermined time;
further comprising;
The method for manufacturing a flooring material according to any one of claims 1 to 8. dividing the substrate into floor material sizes;
a step of chamfering the divided substrate;
further comprising;
The method for manufacturing a flooring material according to any one of claims 1 to 9. The back layer, base layer, design layer, and surface layer are laminated in this order,
The base layer includes calcium carbonate and polyvinyl chloride,
The design layer is a layer formed by ink applied to the surface of the base layer.
flooring. The design layer is a layer formed by transfer to the base layer,
The flooring material according to claim 11. The polyvinyl chloride is present in an amount of 40 to 60 parts by mass based on 100 parts by mass of the calcium carbonate.
The flooring material according to claim 11 or 12. The base layer may contain one or more of stabilizers, plasticizers, colorants, lubricants, mold release agents, crosslinking agents, antistatic agents, surfactants, flame retardants, foaming agents, and antibacterial and antifungal agents. containing agents,
The flooring material according to any one of claims 11 to 13. The additive is 10 to 20 parts by mass based on 100 parts by mass of the calcium carbonate,
The flooring material according to any one of claims 11 to 14. The back layer and the surface layer are formed of UV paint,
The flooring material according to any one of claims 11 to 15. The shape of the surface corner of the flooring material is a chamfered shape,
The flooring material according to any one of claims 11 to 16. The thickness of the flooring material is 1.5 mm or less,
The flooring material according to any one of claims 11 to 17. the base layer is colored;
The flooring material according to any one of claims 11 to 18.

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