JP2023157378A - Flooring material for building interior finishing and manufacturing method of flooring material for building interior finishing - Google Patents

Abstract

To provide a flooring material for building interior finishing hard to be peeled between PVC layers even when forming a coloring decorative surface layer with inkjet ink between the PVC layers.SOLUTION: A flooring material 1 for building interior finishing of the present invention includes a surface layer 2 having a first PVC layer 21 containing a vinyl chloride-based resin, a coloring decorative surface layer 23 formed from inkjet ink, an adhesion layer 24 containing an ionized radiation curable resin or a thermosetting resin, and a second PVC layer 22 containing a vinyl chloride-based resin in this order.SELECTED DRAWING: Figure 3

Description

The present invention relates to a flooring material for architectural interiors provided with a colored decorative layer and a method for manufacturing the same.

BACKGROUND ART Conventionally, flooring materials for building interiors have been provided on the market, in which colored decorative layers of various designs are provided on the surface layer containing vinyl chloride resin.
Such a surface colored decorative layer is generally formed by performing plate printing such as rotary screen printing or gravure printing on a resin layer containing a vinyl chloride resin or the like. However, while plate printing is suitable for printing the same design in large quantities, it is not suitable for small-lot printing, and the designs formed by plate printing are repeats of the patterns expressed on the roll plate. The repetition of the design also depends on the circumference of the roll plate.
In this regard, plateless printing such as inkjet printing makes it possible to easily manufacture flooring materials for architectural interiors of any design, and is also suitable for manufacturing flooring materials in small lots.

Patent Document 1 discloses a flooring material having a print layer made of inkjet ink. Specifically, Patent Document 1 describes, in order from the back side, a base sheet 23 made of vinyl chloride resin, a printing film 25 made of vinyl chloride resin, an ink-receiving layer 6, a print layer 5 made of inkjet ink, and a polyurethane-based sheet. A flooring material having a layered structure of a hot melt resin sheet 24/a transparent top sheet 22 made of vinyl chloride resin is disclosed. The polyurethane hot melt resin sheet 24 functions as an adhesive layer and adheres the print layer 5 and the transparent top sheet 22.

Patent No. 3921382

However, since the flooring material of Patent Document 1 uses a polyurethane hot melt resin sheet to bond between the print layer 5 and the transparent top sheet 22, the hot melt resin softens when exposed to relatively high temperatures for a long time. However, there is a risk that the delamination strength will decrease.

An object of the present invention is to provide a flooring material for architectural interiors in which PVC layers do not easily peel off even when a colored decorative layer is formed between the PVC layers using inkjet ink, and a method for manufacturing the same.

The architectural interior flooring material of the present invention comprises a first PVC layer containing a vinyl chloride resin, a colored decorative layer formed from an inkjet ink, an adhesive layer containing an ionizing radiation curable resin or a thermosetting resin, and a vinyl chloride resin. and a second PVC layer containing a system resin, in this order.

In the preferred building interior flooring material of the present invention, the inkjet ink contains a colorant and an ionizing radiation-curable resin or a thermosetting resin.
In the preferred building interior flooring material of the present invention, the adhesive layer does not contain any pigment.
In the preferred architectural interior flooring material of the present invention, the second PVC layer contains fine particles.
In a preferred building interior flooring material of the present invention, the first PVC layer and the second PVC layer have an interlayer peel strength of 30 N/50 mm or more.

According to another aspect of the present invention, a method for manufacturing flooring for architectural interiors is provided.
The manufacturing method of the present invention includes the step of preparing a decorative sheet having a first PVC sheet containing a vinyl chloride resin, a colored decorative layer formed on the first PVC sheet, and an adhesive layer formed on the colored decorative layer. , a step of preparing a second PVC sheet containing a vinyl chloride resin, and by integrating the decorative sheet and the second PVC sheet under heating conditions, a laminate consisting of the first PVC sheet/colored decorative layer/adhesive layer/second PVC sheet is formed. forming a body, the colored decorative layer is formed by printing inkjet ink on the first PVC sheet using an inkjet printer, and the adhesive layer is made of ionizing radiation curable resin or thermosetting resin. It is formed by applying a coating liquid containing a mold resin onto the colored decorative layer and curing it.

In the architectural interior flooring material of the present invention, since the colored decorative layer is formed using inkjet ink, a desired design can be easily expressed. Further, a first PVC layer and a second PVC layer containing a vinyl chloride resin are provided on both sides of a colored decorative layer formed from an inkjet ink, and an ionizing radiation-curable resin or thermosetting resin is used between the colored decorative layer and the second PVC layer. Since the adhesive layer containing mold resin is interposed, it becomes difficult for the PVC layers to separate.

FIG. 1 is a plan view of a flooring material for architectural interior according to a first embodiment. FIG. 2 is a plan view of a building interior flooring material according to a second embodiment. FIG. 1 is a cross-sectional view showing a first example of a layered structure of flooring material for architectural interiors. FIG. 3 is a cross-sectional view showing a second example of the same layer configuration. FIG. 7 is a cross-sectional view showing a third example of the same layer configuration. The reference side view which shows the 1st example of the formation process of a laminated structure at the time of manufacturing the flooring material for architectural interiors. The reference side view which shows the 2nd example of the formation process of the same laminated structure.

The present invention will be described below with reference to the drawings as appropriate.
In this specification, the "surface" of a flooring material for architectural interiors or the "surface" of any layer constituting it refers to the surface far from the construction surface on which the flooring material for architectural interiors is installed, and the "back surface" , refers to the opposite side (the side closer to the construction surface of the flooring material for architectural interiors). Planar view refers to viewing the flooring material from a direction perpendicular to the surface of the flooring material for architectural interior use.
In this specification, the numerical range expressed as "more than or equal to the lower limit value and less than or equal to the upper limit value" means that an arbitrary lower limit value and an arbitrary upper limit value can be selected and "more than or equal to the arbitrary lower limit value and less than or equal to the arbitrary upper limit value" can be set. shall be.
Also, it should be noted that dimensions such as thickness and size in each figure are different from the actual ones.

[Overview of flooring materials for architectural interiors]
FIG. 1 is a plan view of a building interior flooring material 1 according to a first embodiment, and FIG. 2 is a plan view of a building interior flooring material 1 according to a second embodiment. Hereinafter, "flooring materials for architectural interiors" may be simply referred to as "flooring materials."
Referring to FIG. 1, flooring 1 is formed into a long strip shape when viewed from above. The long strip shape refers to a substantially rectangular shape in plan view where the length in the longitudinal direction is sufficiently longer than the length in the transverse direction, for example, the length in the longitudinal direction is 3 times or more, preferably 5 times the length in the transverse direction. That's all. As specific dimensions of the long strip, for example, the length in the transverse direction is 500 mm or more and 3000 mm or less, and the length in the longitudinal direction is 2 m or more and 500 m or less. The flooring material 1 formed in the shape of a long strip is usually rolled up for storage and transportation, and then cut into a desired shape and used at a construction site.

Referring to FIG. 2, the flooring material 1 is formed into a substantially square leaf shape when viewed from above. However, the sheet-shaped flooring material 1 may be formed into a substantially rectangular shape in a plan view, a substantially hexagonal shape in a plan view, etc. (not shown). Specific dimensions of the floor material 1 having a substantially square shape or a substantially rectangular shape in plan view include, for example, length x width = 200 mm or more and 1000 mm or less x 200 mm or more and 1000 mm or less. The sheet-shaped flooring material 1 as shown in the illustrated example is stored and transported in a state in which a plurality of sheets are stacked on top of each other or in a state in which they are individually wound into a roll.

The flooring material 1 of the present invention may have flexibility, or may be relatively hard without flexibility. The degree of flexibility of the flooring material 1 is such that, for example, the flooring material 1 can be wound in a roll around a winding core having a diameter of 10 cm with the back side of the flooring material 1 facing the winding core.
The overall thickness of the floor material 1 is not particularly limited, and is, for example, 0.5 mm or more and 10 mm or less, preferably 1 mm or more and 8 mm or less, and more preferably 1.5 mm or more and 5 mm or less.

[Layer composition of flooring materials for architectural interiors]
The flooring material 1 has a surface layer 2 including a colored decorative layer. The color of the colored decorative layer is exposed on the surface of the flooring 1. The design of the flooring material 1 is configured by the color of the colored decorative layer. The surface of the surface layer 2 constitutes the surface of the flooring material 1. Therefore, the flooring material 1 of the present invention does not have pile yarn or cloth on its surface, and the surface of the flooring material 1 is composed of a PVC layer.
The architectural interior flooring material 1 of the present invention may be composed of only the surface layer 2, or may be composed of the surface layer 2 and a back layer laminated on the back side thereof.
The surface layer 2 includes a first PVC layer containing a vinyl chloride resin, a colored decorative layer formed from an inkjet ink, an adhesive layer containing an ionizing radiation curable resin or a thermosetting resin, and a first PVC layer containing a vinyl chloride resin. 2 PVC layers in this order. In the surface layer 2 having the first PVC layer, colored decorative layer, adhesive layer, and second PVC layer in this order, the first PVC layer may constitute the surface of the surface layer 2, or the second PVC layer may constitute the surface layer 2. may constitute the surface of The first PVC layer and the colored decorative layer are directly and strongly adhered to each other, and the colored decorative layer and the second PVC layer are strongly adhered to each other through an adhesive layer.

3 to 5 show first to third examples of the layer structure of the flooring material 1 for architectural interiors. 3 to 5 are cross-sectional views taken along line III--III in FIGS. 1 and 2.
The flooring material 1 of FIG. 3 has a surface layer 2 and a back layer 3 in order from the surface side. The surface layer 2 includes, in order from the surface side, a first PVC layer 21 containing a vinyl chloride resin, a colored decorative layer 23 formed from an inkjet ink, and an adhesive layer 24 containing an ionizing radiation curable resin or a thermosetting resin. A second PVC layer 22 containing a vinyl chloride resin. In this case, the first PVC layer 21 constitutes the outermost surface of the flooring 1. The back layer 3 includes, in order from the front side, a first resin layer 31, a second resin layer 32, and a third resin layer 33. Note that the back layer 3 may have four or more resin layers.

The floor material 1 of FIG. 4 has the layer structure of FIG. 3 in that the surface layer 2 includes, in order from the surface side, a second PVC layer 22, an adhesive layer 24, a colored decorative layer 23, and a first PVC layer 21. Different from the example. In this case, the second PVC layer 22 constitutes the outermost surface of the flooring 1.
The PVC layer provided on the surface side of the colored decorative layer 23 may be relatively thick in order to sufficiently protect the colored decorative layer 23. In this regard, when the second PVC layer 22 is disposed on the surface side of the colored decorative layer 23 as described above, the thickness of the first PVC layer 21, which serves as the supporting base material of the colored decorative layer 23, can be reduced. Therefore, when a decorative sheet in which a colored decorative layer and an adhesive layer are formed on a first PVC sheet is manufactured in advance, it becomes easier to store and transport this decorative sheet, especially when the decorative sheet is rolled into a roll. Storage and transportation become easier.

The flooring material 1 in FIG. 5 has the following features: the back layer 3 includes a first resin layer 31 and a second resin layer 32, and a scratch prevention layer 25 is provided on the surface of the surface layer 2. , which is different from the layer structure examples shown in FIGS. 3 and 4. In this case, the scratch prevention layer 25 is a layer that constitutes the outermost surface of the flooring 1 and is provided to provide the flooring 1 with wear resistance, scratch resistance, and stain resistance. The scratch prevention layer is formed of, for example, an ultraviolet curing resin. The thickness of the scratch prevention layer 25 is not particularly limited, but is, for example, 1 μm or more and 150 μm or less, preferably 5 μm or more and 100 μm or less, and more preferably 10 μm or more and 50 μm or less. In addition, in FIG. 5, the layer structure shown in FIG. 3 is shown as the surface layer 2 (first PVC layer 21 / colored decorative layer 23 / adhesive layer 24 / second PVC layer 22 in order from the surface side), but as shown in FIG. The layer structure may be (in order from the surface side, second PVC layer 22/adhesive layer 24/colored decorative layer 23/first PVC layer 21).

Although not particularly illustrated, the back layer 3 may be composed only of the first resin layer 31, or may have a fiber layer such as cheesecloth on the middle and/or the backmost surface of the back layer 3.
Although not particularly shown, the layer configurations of the back layer 3 shown in FIGS. 3 to 5 may be combined or replaced as appropriate. Further, although not particularly illustrated, some layers of the back layer 3 may be omitted, or another functional layer may be added to the back layer 3. For example, a suction part or an adhesive part may be provided on the back surface of the back layer 3 (not shown). The suction part or the adhesive part is a part that adheres to a construction surface such as a floor in a releasable state. Examples of the material for forming the suction part include a very soft foamed resin, and examples of the material for forming the adhesive part include a peel-up adhesive.

[surface]
<First PVC layer>
The first PVC layer 21 is a layer that serves as a support base material for the colored decorative layer 23. That is, by inkjet printing on the first PVC layer 21, the colored decorative layer 23 is formed on the first PVC layer 21. The colored decorative layer 23 formed on the first PVC layer 21 is firmly adhered to the first PVC layer 21.
The first PVC layer 21 contains a vinyl chloride resin, and may contain a plasticizer, a filler, and any suitable additives as necessary.

Vinyl chloride resin is a polymer formed by polymerizing at least a vinyl chloride monomer (chloroethylene). Vinyl chloride resins include not only polymers made by homopolymerizing chloroethylene (homopolymers), but also copolymers (copolymers) and homopolymers of chloroethylene and other monomers that can be copolymerized with chloroethylene. and copolymers, as well as mixtures of two or more copolymers. In addition, a mixture means a homopolymer and a copolymer, or a polymer in which copolymers are kneaded without substantially polymerizing each other. Vinyl chloride-based resins include vinyl chloride polymer (homopolymer); chlorinated vinyl chloride; partially cross-linked vinyl chloride; vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, vinyl chloride-propylene copolymer , vinyl chloride-styrene copolymer, vinyl chloride-isobutylene copolymer, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-butadiene copolymer, vinyl chloride-isoprene copolymer, vinyl chloride-chlorinated propylene copolymer Copolymers containing vinyl chloride such as polymers; mixtures of homopolymers and one or more types of copolymers; mixtures of two or more types of copolymers; and the like. Preferably, a vinyl chloride polymer (homopolymer) is used. These vinyl chloride resins may be used alone or in combination of two or more.

As the vinyl chloride polymer (homopolymer), those manufactured by emulsion polymerization, suspension polymerization, solution polymerization, bulk polymerization, etc. can be used, and paste vinyl chloride resin or/and suspension vinyl chloride polymer can be used. It is preferable to use a resin based on the resin.
The paste vinyl chloride resin is, for example, a paste vinyl chloride resin obtained by an emulsion polymerization method, and its viscosity can be adjusted as appropriate with a plasticizer. The paste vinyl chloride resin is a fine powder with a particle size of 0.1 to 10 μm (preferably 1 μm to 3 μm) consisting of a large number of fine particle aggregates, and preferably a surfactant is coated on the surface of the fine powder. Coated. The average degree of polymerization of the paste vinyl chloride resin is preferably about 1000 or more and 2000 or less.
The suspension vinyl chloride resin is, for example, a vinyl chloride resin obtained by a suspension polymerization method. The suspension vinyl chloride resin is a fine powder having a particle size of preferably 20 μm or more and 100 μm or less. The average degree of polymerization of the suspension vinyl chloride resin is preferably about 700 or more and about 1,500 or less, more preferably about 700 or more and about 1,100 or less, and even more preferably about 700 or more and about 1,000 or less.

The first PVC layer 21 preferably contains a suspension vinyl chloride resin.
The first PVC layer 21 may contain other resins or may not contain other resins, provided that it contains vinyl chloride resin as the main component resin.
Here, in this specification, the main component resin of a certain layer is 60% by weight or more, preferably 80% by weight based on the entire resin component contained in the layer (assuming the entire resin component is 100% by weight). The above refers to a resin that more preferably accounts for 90% by weight or more.

The plasticizer is blended mainly for the purpose of improving the flexibility of the vinyl chloride resin. Examples of the plasticizer include polyester plasticizers, glycerin plasticizers, polyvalent carboxylic acid ester plasticizers, and polyalkylene glycol plasticizers. Preferably, as the plasticizer, a polyhydric carboxylic acid plasticizer is used, more preferably a phthalate ester is used, and particularly preferably dioctyl phthalate is used.
The amount of plasticizer is not particularly limited, and is, for example, 15% by weight or more and 50% by weight or less, preferably 20% by weight or more and 45% by weight or less, with the entire first PVC layer being 100% by weight.

Fillers are blended primarily for the purpose of improving processability and physical properties, and lowering product costs. Fillers are added as necessary.
Fillers may be opaque, transparent or translucent. Examples of the opaque filler include calcium carbonate, titanium oxide, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica. Examples of the transparent or translucent filler include resin beads and glass beads. Resin beads are particularly preferred, and acrylic beads are preferably used, for example.
As shown in FIG. 3, when the first PVC layer 21 constitutes the surface of the flooring 1, the filler is preferably transparent or translucent. This allows the color of the colored decorative layer 23 on the back side to be exposed.

When blending a filler, the amount thereof is not particularly limited, and is, for example, 3% by weight or more and 30% by weight or less, preferably 10% by weight or more and 25% by weight or less, with the entire first PVC layer 21 being 100% by weight. It is. When forming the transparent first PVC layer 21, if the amount of filler is too large, the transparency of the first PVC layer 21 may decrease even if the filler is transparent or translucent.
In particular, as shown in FIG. 4, when the first PVC layer 21 is disposed on the back side, the first PVC layer 21 and the colored decorative layer 20 can be separated by containing a filler such as calcium carbonate. The adhesion between the two can be further improved.
Note that since the colored decorative layer 23 is formed by adhering inkjet ink to the first PVC layer 21, even if the first PVC layer 21 does not substantially contain a filler, the colored decorative layer 23 is formed using the first PVC layer 21. It firmly adheres to layer 21. Of course, even if the first PVC layer 21 contains the above-mentioned filler such as calcium carbonate, the colored decorative layer 23 firmly adheres to the first PVC layer 21. If necessary, an ink-receiving layer may be provided on the printing side surface of the first PVC layer 21.

As the additives, conventionally known ones can be used, and examples thereof include colorants, flame retardants, stabilizers, antioxidants, lubricants, antibacterial agents, fungicides, surfactants, and the like.
When blending additives, the amount thereof is not particularly limited, and is, for example, 0.1% by weight or more and 5% by weight or less, assuming that the entire first PVC layer 21 is 100% by weight.
As shown in FIG. 3, when the first PVC layer 21 constitutes the surface of the flooring 1, the first PVC layer 21 is made of a colorless transparent or colored layer in order to bring out the color of the colored decorative layer 23 on the back side. It is considered transparent. On the other hand, as shown in FIG. 4, when the first PVC layer 21 is placed on the back side, it may be colorless and transparent, colored and transparent, or opaque.
When the first PVC layer 21 is placed on the back side, it is preferable that the first PVC layer 21 is opaque because it can hide the back layer 3 and form a background in which the color of the colored decorative layer 23 becomes clear. The color when the layer is opaque can be selected as appropriate. For example, white opaque is preferably used because it has excellent concealment of the back layer 3 and color development of the colored decorative layer 23.
Further, the first PVC layer 21 may be a foamed material, but is preferably a non-foamed material.

The thickness of the first PVC layer 21 is not particularly limited, but is, for example, 0.5 μm or more, preferably 1 μm or more, and more preferably 10 μm or more so that inkjet printing can be performed well.
There is no particular upper limit to the thickness of the first PVC layer 21, but as shown in FIG. 3, when the first PVC layer 21 forms the surface of the flooring 1, the thickness is, for example, 2 mm or less, preferably 1 mm or less be. Further, as shown in FIG. 4, when the first PVC layer 21 is arranged on the back side, its thickness is, for example, 9 mm or less, preferably 0.5 mm or less. In particular, when the flooring 1 consists of only the surface layer 2 and the first PVC layer 21 is arranged on the back side, the first PVC layer 21 having a large thickness is used.

<Second PVC layer>
The second PVC layer 22 contains a vinyl chloride resin, and may contain a plasticizer and any suitable additives as necessary. Furthermore, the second PVC layer 22 may contain particulates.
As the vinyl chloride resin for the second PVC layer 22, those explained in the section of <First PVC layer> above are used.
When the second PVC layer 22 contains a paste vinyl chloride resin, the degree of freedom in processing during manufacturing, such as foaming the second PVC layer 22, can be increased. Further, when the second PVC layer 22 contains a suspension vinyl chloride resin, it can be processed even with a reduced amount of plasticizer, and the second PVC layer 22 can be obtained with excellent durability. It is preferable that the second PVC layer 22 contains a suspension vinyl chloride resin because it is strongly adhered to the adhesive layer 24.

As the plasticizer for the second PVC layer 22, those explained in the section of <First PVC layer> above are used.
Although the amount of plasticizer is not particularly limited, by blending a relatively large amount of plasticizer, adhesive layer 24 and second PVC layer 22 can be firmly bonded. From this point of view, the amount of plasticizer is, for example, 5% by weight or more, preferably 8% by weight or more, more preferably 10% by weight or more, based on 100% by weight of the entire second PVC layer. . On the other hand, if too much plasticizer is included, the second PVC layer may become too soft, so the amount of plasticizer is, for example, 25% by weight or less, preferably 20% by weight or less. be.
As will be described later, since the adhesive layer 24 contains an ionizing radiation-curable resin or a thermosetting resin, it becomes relatively hard after curing. Since the second PVC layer 22 contains a vinyl chloride resin, the second PVC layer 22 can be made more flexible than the adhesive layer 24 if the amount of plasticizer is at least the lower limit. Thereby, the second PVC layer 22 and the adhesive layer 24 can be easily and firmly integrated under heating conditions. Since vinyl chloride resin plasticizes at a relatively low temperature among thermoplastic resins, deterioration due to heat during processing of the colored decorative layer 23 and adhesive layer 24 can be suppressed. Moreover, the second PVC layer 22 can exhibit the strength necessary for the flooring material because the amount of plasticizer is equal to or less than the above-mentioned upper limit.

As additives for the second PVC layer 22, those explained in the section of <First PVC layer> above are used. When blending additives, the amount thereof is not particularly limited, and is, for example, 0.1% by weight or more and 5% by weight or less, assuming that the entire second PVC layer is 100% by weight.

Examples of the fine particles include inorganic fine particles and organic fine particles. Examples of the inorganic fine particles include calcium carbonate, titanium oxide, silica, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica. Examples of organic fine particles include fine particles made of various synthetic resins.
The fine particles are incorporated to firmly adhere the second PVC layer 22 to the adhesive layer 24. Inorganic fine particles are preferred because they can further improve the adhesion between the two, and among them, calcium carbonate and talc are more preferred, and calcium carbonate is particularly preferred.
The shape of the fine particles may be a fixed shape such as a substantially spherical shape or a substantially acicular shape, or may be an amorphous shape whose shape cannot be specified. The shape of the fine particles is preferably amorphous because it can further improve the adhesion between the two. In particular, adhesiveness can be improved by using amorphous calcium carbonate.

The size of the fine particles is not particularly limited. Since the adhesion between the second PVC layer 22 and the adhesive layer 24 can be further improved, it is preferable to use fine particles with an average particle size of 0.1 μm or more and 50 μm or less, and more preferably fine particles with an average particle size of 0.1 μm or more and 25 μm or less. It is more preferable to use fine particles with an average particle size of 1 μm or more and 10 μm or less, and it is particularly preferable to use fine particles with an average particle size of 1.5 μm or more and 7 μm or less. Adhesion can be improved by using calcium carbonate having an average particle size within the above range.
The average particle diameter is a value measured by a laser diffraction scattering method, and specifically refers to the particle diameter at 50% cumulative volume of the particle size distribution measured using a laser diffraction particle size distribution device (D50).
Particularly, as shown in FIG. 3, when the second PVC layer 22 is disposed on the back side, the second PVC layer 22 contains fine particles, which improves the adhesiveness between the second PVC layer 22 and the adhesive layer 24. can be further improved.

When fine particles are added to the second PVC layer 22, the amount of the fine particles such as calcium carbonate is not particularly limited. Since the adhesion between the second PVC layer 22 and the adhesive layer 24 can be further improved, it is preferable that the fine particles are contained in an amount of 15% by weight or more and 80% by weight or less, based on 100% by weight of the entire second PVC layer 22, and further, The content is more preferably 25% by weight or more and 75% by weight or less, and even more preferably 40% by weight or more and 73% by weight or less.

As shown in FIG. 4, when the second PVC layer 22 constitutes the surface of the flooring 1, the second PVC layer 22 is made of a colorless transparent or colored layer in order to bring out the color of the colored decorative layer 23 on the back side. It is considered transparent.
On the other hand, as shown in FIG. 3, when the second PVC layer 22 is placed on the back side, it may be colorless and transparent, colored and transparent, or opaque. When the second PVC layer 22 is arranged on the back side, it is preferable that the second PVC layer 22 is opaque because it can hide the back layer 3 and form a background in which the color of the colored decorative layer 23 becomes clear. The color when the layer is opaque can be selected as appropriate. For example, white opaque is preferably used because it has excellent concealment of the back layer 3 and color development of the colored decorative layer 23. For example, by incorporating calcium carbonate as fine particles, the second PVC layer 22 which is white and opaque can be formed.

The thickness of the second PVC layer 22 is not particularly limited, but is, for example, 0.5 μm or more, preferably 1 μm or more, and more preferably 10 μm or more in order to adhere evenly to the entire colored decorative layer 23.
There is no particular upper limit to the thickness of the second PVC layer 22, but as shown in FIG. 4, when the second PVC layer 22 constitutes the surface of the flooring 1, the thickness is, for example, 2 mm or less, preferably 1 mm or less. be. Further, as shown in FIG. 3, when the second PVC layer 22 is arranged on the back side, its thickness is, for example, 9 mm or less, and preferably 0.5 mm or less. In particular, when the flooring 1 consists of only the surface layer 2 and the second PVC layer 22 is arranged on the back side, the second PVC layer 22 having a large thickness is used.

<Colored makeup layer>
The colored decorative layer 23 is a layer that imparts a design to the flooring 1.
The design of the colored decorative layer 23 is composed of one color or two or more colors. In addition, in arbitrary one color or two or more colors provided to the colored decorative layer 23, shading may be applied.
The colored decorative layer 23 is formed from inkjet ink. In other words, the colored decorative layer 23 is made of an ink solidified layer of inkjet ink. The colored decorative layer 23 is formed on the first PVC layer 21 by inkjet printing.

The inkjet ink contains a resin and a colorant, and if necessary, any suitable additives. At least three types of inkjet ink, cyan (C), magenta (M), and yellow (Y), are usually used, and black (BK) or other colors may be used in combination as necessary.
Inkjet inks can be categorized by solidification methods, such as water-based inks, solvent-based inks, ionizing radiation-curable inks such as ultraviolet-curable inks, thermosetting inks, and the like. Since inkjet printing is performed on PVC sheets as described later, solvent-based inks, ionizing radiation-curable inks, or thermosetting inks are preferred, and ionizing radiation-curable inks require almost no drying time and have excellent durability. Ink or thermosetting ink is more preferred, and ultraviolet curable ink is even more preferred since it can be printed with a general-purpose printer.
The inkjet ink is applied to the first PVC layer 21 in an uncured state, and then, when cured, becomes a colored decorative layer 23 firmly adhered to the first PVC layer 21. On the other hand, it is known that once the inkjet ink is cured to form the colored decorative layer 23, it is difficult to firmly adhere the layer to the second PVC layer 22 even if it is subsequently laminated with the second PVC layer 22 under heat and pressure. In particular, when the inkjet ink contains a pigment, even if the colored decorative layer 23 and the second PVC layer 22 are laminated under heat and pressure, they will not adhere sufficiently and their interlayer peel strength will be low.

The colored decorative layer 23 formed from the ionizing radiation curable inkjet ink, such as the ultraviolet ray curable type, contains a colorant and an ionizing radiation curable resin, and if necessary, any suitable additives.
Further, the colored decorative layer 23 formed from the thermosetting inkjet ink contains a colorant and a thermosetting resin, and, if necessary, any appropriate additives.
The colorant imparts color to the colored decorative layer 23. The coloring agent may be either a dye or a pigment, or a combination of a dye and a pigment may be used. Dyes have the advantage of excellent color development and the ability to express beautiful designs. Pigments have the advantage of being excellent in light resistance and durability, and can maintain good design over a long period of time.

Examples of dyes include oil-soluble dyes with chromophores or chromogens such as azos, anthraquinones, indigoids, phthalocyanines, carboniums, quinoneimines, methines, xanthenes, nitros, and nitrosos; Examples include disperse dyes, acid dyes, reactive dyes, cationic dyes, and direct dyes.
The pigment may be either organic or inorganic, or a combination of organic and inorganic may be used. Examples of organic pigments include nitrosos, dyeing lakes, azo lakes, insoluble azos, monoazos, disazos, condensed azos, benzimidazolones, phthalocyanines, anthraquinones, perylenes, quinacridones, and dioxazines. , isoindolines, azomethines, pyrrolopyrroles, and the like. Examples of inorganic pigments include oxides, hydroxides, sulfides, ferrocyanides, chromates, carbonates, silicates, phosphates, carbon (carbon black), and metal powders. Examples include.
The content of the colorant in the inkjet ink is 0.01% by weight or more and 10% by weight or less. If it is above the lower limit, color can be sufficiently imparted, and if it is below the upper limit, good ejection properties in inkjet printing can be obtained.

The ionizing radiation-curable resin contains a polymerizable monomer or/and a polymerizable oligomer (photopolymerizable prepolymer), preferably further contains a polymerization initiator, and, if necessary, any suitable additive.
The ionizing radiation curable resin may be of a radical polymerization type, a cationic polymerization type, or a mixture of radical polymerization and cationic polymerization types.
As the ionizing radiation curable resin, conventionally known resins can be used.
As the ionizing radiation curable resin, those containing polymerizable monomers and/or oligomers that can be polymerized by irradiation with ionizing radiation such as ultraviolet rays or electron beams can be used, and if necessary, any suitable additives may be used. can use things.

Examples of the polymerizable monomer or oligomer include monomers or oligomers having a polymerizable unsaturated bond group such as a (meth)acrylate group or a (meth)acryloyloxy group or an epoxy group in the molecule.
Specific examples of the polymerizable monomer include methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol penta(meth)acrylate, and urethane (meth)acrylate. ) acrylates, polyol compounds having two or more thiol groups in the molecule, and the like.

Specific examples of the polymerizable oligomer include radical polymerizable oligomers such as urethane acrylate oligomers, epoxy acrylate oligomers, and polyester acrylate oligomers, cationic polymerizable oligomers such as vinyl ether oligomers, and alicyclic epoxy oligomers (resins). can be mentioned.
Specific examples of the polymerizable monomer include acrylate monomers, vinyl ether monomers, styrene monomers such as α-methylstyrene, urethane (meth)acrylates, and polyol compounds having two or more thiol groups in the molecule. It will be done. Examples of the acrylate monomer include pentaerythritol triacrylate, neopentyl glycol diacrylate, and phosphoric acid-containing (meth)acrylate. Examples of the phosphoric acid-containing (meth)acrylate include monomers such as acryloyloxyethyl acid phosphate and bis(2-(meth)acryloyloxyethyl)acid phosphate. Examples of the vinyl ether monomer include 2-hydroxyethyl vinyl ether (HEVE), diethylene glycol monovinyl ether (DEGV), and 4-hydroxybutyl vinyl ether (HBVE).
Examples of the polymerization initiator include photoradical polymerization initiators such as benzophenone, benzoin alkyl ether (benzoethyl ether, benzobutyl ether, etc.), benzyl dimethyl ketal, acetophenone, and cationic photopolymerization initiators.
Further, the molecular weight of the polymerizable monomer or oligomer is not particularly limited, but may be, for example, in the range of 200 or more and 10,000 or less.
For example, when an ultraviolet curable resin is used as an ionizing radiation curable resin in an inkjet ink, the amount of polymerizable oligomer is 5% to 40% by weight, and the amount of polymerizable monomer is 55% to 90% by weight. , the polymerization initiator is 1% by weight or more and 10% by weight or less. These blending ratios are appropriately determined in consideration of ejection properties in inkjet printing before curing, hardness after curing, and the like.
Among these, the colored decorative layer 23 containing an acrylic ultraviolet curable resin is preferable because it can form the colored decorative layer 23 firmly adhered to the first PVC layer 21 .

As the thermosetting resin, conventionally known ones can be used.
Examples of thermosetting resins constituting the colored decorative layer 23 include epoxy resins, phenol resins, unsaturated imide resins, cyanate resins, isocyanate resins, benzoxazine resins, oxetane resins, amino resins, unsaturated polyester resins, allyl resins, and dichloromethane resins. Examples include cyclopentadiene resin, silicone resin, triazine resin, and melamine resin. Among these, the colored decorative layer 23 containing at least one thermosetting resin selected from the above examples is preferred because it allows the colored decorative layer 23 to be firmly adhered to the first PVC layer 21 .

The thickness of the colored decorative layer 23 is not particularly limited, and is, for example, 1 μm or more and 50 μm or less, preferably 3 μm or more and 30 μm or less, and more preferably 5 μm or more and 15 μm or less.

<Adhesive layer>
The adhesive layer 24 is a layer for firmly adhering the colored decorative layer 23 and the second PVC layer 22. The adhesive layer 24 formed on the colored decorative layer 23 firmly adheres to the colored decorative layer 23.
The adhesive layer 24 contains an ionizing radiation curable resin or a thermosetting resin, and contains any appropriate additives as necessary. That is, the adhesive layer 24 is composed of a cured resin film containing at least one of an ionizing radiation curable resin and a thermosetting resin, and the cured resin film may contain any additives as necessary. Good too.
As the ionizing radiation-curable resin constituting the adhesive layer 24, those explained in the section of <Colored Decorative Layer> above are used. Examples of polymerizable monomers and/or oligomers that can be polymerized by irradiation with ionizing radiation such as ultraviolet rays and electron beams include those exemplified in the section of <Colored decorative layer> above. The ionizing radiation curable resin constituting the adhesive layer 24 is preferably an ultraviolet curable resin because it can form the adhesive layer 24 with relatively excellent adhesiveness and is versatile.
As the thermosetting resin constituting the adhesive layer 24, those described in the section of <Colored Decorative Layer> above are used. The thermosetting resin constituting the adhesive layer 24 is epoxy resin, phenol resin, unsaturated imide resin, cyanate resin, or isocyanate resin because it can constitute the adhesive layer 24 with relatively excellent adhesiveness and is versatile. , benzoxazine resin, oxetane resin, amino resin, unsaturated polyester resin, allyl resin, dicyclopentadiene resin, silicone resin, triazine resin, and melamine resin.
The ionizing radiation-curable resin or thermosetting resin constituting the adhesive layer 24 is bonded to the second PVC layer 22 after curing, so an ionizing radiation-curable resin or thermosetting resin with high adhesiveness to vinyl chloride resin is selected. By doing so, the interlayer peel strength between the adhesive layer 24 and the second PVC layer 22 can be increased.

For example, when using an ultraviolet curable resin as the ionizing radiation curable resin, it is sufficient that it contains at least one of a polymerizable monomer and a polymerizable oligomer. When forming the adhesive layer 24, in order to lower the viscosity of the coating liquid containing the ultraviolet curable resin and improve the coating properties, the polymerization component of the ultraviolet curable resin may be only a polymerizable monomer or a polymerizable monomer. A mixture of a polymerizable monomer and a polymerizable oligomer is preferable. In the ultraviolet curable resin containing a polymerizable monomer and a polymerizable oligomer, the polymerizable oligomer is 5% by weight or more and 70% by weight or less, the polymerizable monomer is 20% by weight or more and 94% by weight or less, and the polymerization initiator is 1% by weight or more and 10% by weight or less. These blending ratios are appropriately determined in consideration of the applicability before curing, the hardness after curing, and the like.
Above all, it is preferable that the adhesive layer 24 contains the same type of resin as the colored decorative layer 23, in order to ensure strong adhesion between the colored decorative layer 23 and the adhesive layer 24. It is more preferable that it be included. For example, it is preferable that the colored decorative layer 23 and the adhesive layer 24 both contain an acrylic ultraviolet curable resin.
The same type of resin means a case where the adhesive layer 24 and the colored decorative layer 23 both contain an ionizing radiation curable resin, or a case where the adhesive layer 24 and the colored decorative layer 23 both contain a thermosetting resin. . The same type of resin means that the main repeating units of the resin component of the adhesive layer 24 and the main repeating units of the resin component of the colored decorative layer 23 are the same.

As shown in FIG. 4, when the second PVC layer 22 constitutes the surface of the flooring 1, the adhesive layer 24 is made colorless and transparent or colored and transparent in order to bring out the color of the colored decorative layer 23 on the back side. Ru.
On the other hand, as shown in FIG. 3, when the first PVC layer 21 constitutes the surface of the flooring 1 and the second PVC layer 22 is arranged on the back side, the adhesive layer 24 may be colorless and transparent, colored and transparent, or , may be opaque. When the second PVC layer 22 is disposed on the back side, the adhesive layer 24 may be opaque because it hides the back layer 3 and forms a background in which the color of the colored decorative layer 23 becomes clear. The color when the layer is opaque can be selected as appropriate. For example, white opaque is preferably used because it has excellent concealment of the back layer 3 and color development of the colored decorative layer 23. Further, when the second PVC layer 22 is disposed on the back side, the adhesive layer 24 may be colorless and transparent, and the second PVC layer 22 may be made opaque. Even in this case, the back layer 3 is hidden and the colored decorative layer is It is possible to construct a background in which the 23 colors are vivid.

When the adhesive layer 24 is colored transparent or opaque, a coloring agent of any color is added to the adhesive layer 24. Colorants include pigments or dyes. From the viewpoint of firmly adhering the adhesive layer 24 and the second PVC layer 22, when forming a colored transparent or opaque adhesive layer 24, it is preferable that the adhesive layer 24 contains no pigment but contains a dye. Note that in the case of the adhesive layer 24 being colorless and transparent, the adhesive layer 24 does not contain a coloring agent such as a pigment or dye.
Since the pigment has higher hardness than the resin constituting the adhesive layer 24, the adhesive layer containing the pigment has a higher surface hardness, which may reduce the adhesiveness between the adhesive layer 24 and the second PVC layer 22. There is.

The thickness of the adhesive layer 24 is not particularly limited, but is, for example, 0.05 μm or more, preferably 0.1 μm or more in order to be interposed between the colored decorative layer 23 and the second PVC layer 22 and bond them together. . Further, there is no particular upper limit to the thickness of the adhesive layer 24, but since the effect does not change even if it is too large, from the viewpoint of cost effectiveness, it is, for example, 200 μm or less, preferably 50 μm or less, and more preferably 30 μm. It is as follows.

[Back layer]
<Resin layer>
The resin layers such as the first resin layer 31, second resin layer 32, and third resin layer 33 of the back layer 3 are layers that mainly constitute the strength and weight of the flooring 1.
The resin layer may be a foamed material or a non-foamed material. When the back layer 3 has a plurality of resin layers, at least one resin layer may be made of a foam and at least one resin layer may be made of a non-foam, or all resin layers may be made of a foam. Alternatively, it may be made of a non-foamed material. Moreover, when the back layer 3 has a plurality of resin layers, the main component resin of each resin layer may be different, or the main component resin of each resin layer may be the same.
The resin component of the resin layer is not particularly limited, and conventionally known resin components can be used. Generally, thermoplastic resins are used, and furthermore, soft thermoplastic resins are used. The thermoplastic resins include vinyl chloride resins; polyolefin resins; urethane resins; vinyl acetate resins such as ethylene-vinyl acetate copolymers; acrylic resins such as ethylene-methacrylate resins; polyamide resins; and ester resins. Examples include resins; various elastomers such as olefin elastomers and styrene elastomers; rubber; and the like. These can be used alone or in combination of two or more. The resin layer preferably contains a vinyl chloride resin as the main resin because it is inexpensive, has excellent flexibility and durability, and also has strong adhesion to the surface layer 2. As the vinyl chloride resin for the resin layer, those explained in the section of <Second PVC Layer> above are used.

When the resin layer of the back layer 3 has a vinyl chloride resin as its main resin, it contains, for example, a vinyl chloride resin, a plasticizer, and a filler, and if necessary, various additives. For example, when the entire resin layer is 100% by weight, the resin layer contains 20% by weight or more and 60% by weight or less of vinyl chloride resin, 5% by weight or more and 15% by weight or less of a plasticizer, and 30% by weight of a filler. 80% by weight or less, and 0.1% by weight or more and 5% by weight or less of additives.
The thickness of the resin layer is not particularly limited, and is, for example, 0.3 mm or more and 9 mm or less, preferably 0.4 mm or more and 7 mm or less. In addition, when the back layer 3 has a plurality of resin layers, the range of the thickness of the resin layer means the total thickness of the plurality of resin layers.

<Fiber layer>
The fiber layer of the back layer 3 is a layer that maintains the dimensional stability of the flooring 1.
Examples of the fiber layer include nonwoven fabrics and woven fabrics. The material of the fibers constituting the nonwoven fabric or woven fabric is not particularly limited, and includes, for example, synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; and natural fibers. In particular, it is preferable to use a glass sheet containing glass fibers as the fiber layer since dimensional changes due to temperature are small.

[Method for manufacturing flooring materials for architectural interiors]
The building interior flooring material 1 of the present invention can be manufactured by the following manufacturing method, but the building interior flooring material 1 of the present invention is not limited to those manufactured by the following manufacturing method.
A method for manufacturing flooring for architectural interiors includes a decorative sheet having a first PVC sheet containing a vinyl chloride resin, a colored decorative layer formed on the first PVC sheet, and an adhesive layer formed on the colored decorative layer. a step of preparing a second PVC sheet containing a vinyl chloride resin; and a step of preparing a second PVC sheet containing a vinyl chloride resin, and integrating the decorative sheet and the second PVC sheet under heating to form a first PVC sheet/colored decorative layer/adhesive layer/second PVC sheet. A step of forming a laminate consisting of.
In the preparation step, the colored decorative layer is formed by printing inkjet ink on the first PVC sheet using an inkjet printer, and the adhesive layer is a coating containing an ionizing radiation curable resin or a thermosetting resin. It is formed by applying a liquid onto the colored decorative layer and curing it.

A flooring material having a back layer can be obtained by forming a back layer on the laminate. For example, a flooring material as shown in FIG. 3 can be obtained by forming a back layer on the side of the second PVC sheet of the laminate opposite to the colored decorative layer. Furthermore, for example, a flooring material as shown in FIG. 4 can be obtained by forming a back layer on the opposite side of the colored decorative layer of the first PVC sheet of the laminate.
The formation of the back layer may be performed simultaneously with the step of forming the laminate, or may be formed on the second PVC sheet or the first PVC sheet in advance before the step of forming the laminate, or After forming the laminate, it may be formed on the second PVC sheet or the first PVC sheet of the laminate. When manufacturing a flooring material having a back layer, it is preferable to form the back layer at the same time as the step of forming the laminate, since the flooring material can be manufactured in one lamination step.
In the following, a case will be described taking as an example a case in which a back layer is formed in the process of forming a laminate.

<Preparation process of decorative sheet>
The first PVC sheet corresponds to the first PVC layer.
The first PVC sheet contains a vinyl chloride resin, as described in the section of <First PVC Layer> above, and may contain a plasticizer, a filler, and any appropriate additives as necessary. The first PVC sheet is obtained by mixing these vinyl chloride resins and forming the mixture into a film using a conventionally known method. The film forming method is not particularly limited, and examples thereof include a calendar method, a melt extrusion method, a solution casting method, and the like.

Print inkjet ink on one side of the first PVC sheet using an inkjet printer.
As the inkjet ink, those explained in the section of <Colored decorative layer> above can be used, preferably ionizing radiation curable ink or thermosetting ink, more preferably ultraviolet ray curable inkjet ink. An ink is used, and more preferably an acrylic ultraviolet curable inkjet ink is used. An inkjet printer can easily represent any design.
A colored decorative layer can be formed on the first PVC sheet by printing an inkjet ink on the first PVC sheet and then solidifying the ink. Since the inkjet ink is directly printed and solidified on the first PVC sheet, the colored decorative layer (ink solidified layer) that is formed firmly adheres to the first PVC sheet. Note that solidification is a concept that includes curing, and in the case of ionizing radiation-curable ink or thermosetting ink, it is generally referred to as curing.
The ink solidification method depends on the ink, for example, drying in the case of water-based or solvent-based inkjet ink, irradiation with a specified ultraviolet ray in the case of ultraviolet ray curing inkjet ink, and solidification method for thermosetting inkjet ink. If necessary, heat to a predetermined temperature.
For ultraviolet irradiation, light beams from conventionally known ultra-high-pressure mercury lamps, high-pressure mercury lamps, low-pressure mercury lamps, carbon arcs, xenon arcs, metal halide lamps, and the like can be used. As the thermosetting type heating, a conventionally known heating method can be used, and heater heating, oven heating, infrared heating, laser heating, etc. can be used.
In addition, in the manufacturing process, the colored decorative layer may be in either a substantially completely solidified state or a semi-solidified state before being coated with the coating liquid described below.
The semi-solidified state is a state in which the coating liquid is solidified to the extent that there is no problem with coating, such as mixing with the inkjet ink when applying the coating liquid described below, but it is not completely solidified. means.

A coating containing an ionizing radiation-curable resin or a thermosetting resin, which is a material for forming an adhesive layer, is applied to the surface of the solidified colored decorative layer or the semi-solidified colored decorative layer (the surface opposite to the first PVC sheet). Apply the liquid.
As the ionizing radiation-curable resin or thermosetting resin, those explained in the <adhesive layer> section above can be used, preferably an ultraviolet-curable resin, more preferably an acrylic ultraviolet-curable resin. Resin is used.
The method for applying the coating liquid is not particularly limited, and various coating methods such as a roll coater, blade coater, and curtain coater, and various printing methods such as screen printing, gravure printing, and inkjet printing can be used.
An adhesive layer can be formed on the colored decorative layer by applying a coating liquid onto the colored decorative layer and then curing the coating liquid. Since the coating liquid is applied directly to the colored decorative layer and cured, the formed adhesive layer firmly adheres to the colored decorative layer. In particular, by applying a coating liquid to the semi-solidified colored decorative layer and curing it, it is expected that the formed adhesive layer will adhere more firmly to the colored decorative layer.
The method of curing the coating liquid depends on the resin, for example, in the case of a coating liquid containing an ultraviolet curable resin, it is irradiated with a specified ultraviolet ray, and in the case of a coating liquid containing a thermosetting resin, it is heated to a specified temperature. Heat. As the ultraviolet ray irradiation and heating method, the above-mentioned methods can be adopted.
In this way, a decorative sheet in which the first PVC sheet/colored decorative layer/adhesive layer are integrated can be obtained.

<Preparation process of second PVC sheet>
The second PVC sheet corresponds to the second PVC layer.
The second PVC sheet contains a vinyl chloride resin, as described in the section of <Second PVC Layer> above, and may contain fine particles, a plasticizer, and any appropriate additives as necessary. A second PVC sheet is obtained by mixing a vinyl chloride resin or the like and forming the mixture into a film using a conventionally known method. The film forming method is not particularly limited, and examples thereof include a calendar method, a melt extrusion method, a solution casting method, and the like.

<Preparation process for back layer>
For the back layer, various combinations of layers can be considered, as explained in the above section [Layer structure of flooring material for architectural interior].
Prepare the resin layer and fiber layer according to the back layer you want to form. As the resin layer, for example, a resin sheet formed into a film can be used. In the case of a resin layer whose main component is vinyl chloride resin, as explained in the <Resin layer> section above, the vinyl chloride resin, plasticizer, filler, etc. are mixed and formed into a film. A resin sheet is obtained.

<Lamination process>
As shown in FIG. 6, by overlapping the decorative sheet 4 (first PVC sheet 51, colored decorative layer 53, and adhesive layer 54), second PVC sheet 52, and back layer forming material 6 in this order from the front side, the stack 71 form. Note that the decorative sheet 4 is stacked on the second PVC sheet 52 so that the adhesive layer 54 of the decorative sheet 4 faces the second PVC sheet 52. A laminated structure 72 is formed by heating this stack 71 to adhere adjacent sheets and layers. In FIG. 6, the back layer forming material 6 is made by stacking a resin sheet 61, a fiber layer 64, and a resin sheet 62 in order from the front side, and by bonding these to each other, the resin layer 31/fiber Back layer 3 consisting of layer 34/resin layer 32 is formed. The heating temperature is higher than the temperature at which the vinyl chloride resin melts, for example, 140°C or higher and 200°C or lower. In order to bond the layers more firmly, it is preferable to press the stack 71 in the thickness direction. The pressing method is not particularly limited, and may include a method of passing the accumulated material 71 through pressure rollers 81 and 82 as shown in the illustrated example, a method of pressing a press plate from above and below the accumulated material 71 (not shown), etc. can be mentioned. The pressurizing pressure is not particularly limited, and is, for example, 0.5 MPa or more and 10 MPa or less, preferably 1 MPa or more and 5 MPa or less. Heating and pressurization may be performed simultaneously, or pressure may be applied after heating. When heating and pressing are performed simultaneously, a heated pressure roller or the like is used.

The obtained laminated structure 72 consists of the first PVC layer 21 / colored decorative layer 23 / adhesive layer 24 / second PVC layer 22 / back layer 3 in order from the front side, and is used as a flooring material for building interiors. If necessary, after forming the laminated structure 72, an arbitrary process such as embossing the surface and/or back surface of the laminated structure 72 or forming a scratch prevention layer on the surface of the laminated structure 72 is performed. , this may be used as a flooring material for architectural interiors. The scratch prevention layer can be formed, for example, by coating the surface of the laminated structure 72 with a paint containing an ultraviolet curable resin.

In FIG. 6, the decorative sheet 4 (first PVC sheet 51, colored decorative layer 53, and adhesive layer 54), second PVC sheet 52, and back layer forming material 6 are stacked in this order from the front side. As shown, the second PVC sheet 52, the decorative sheet 4 (adhesive layer 54, colored decorative layer 53, and first PVC sheet 51), and the back layer forming material 6 may be stacked in this order from the front side to form an aggregate 73. good. In this case as well, the second PVC sheet 52 is stacked on the decorative sheet 4 so that the adhesive layer 54 of the decorative sheet 4 faces the second PVC sheet 52. Afterwards, in the same manner as in FIG. 6, heating is performed, preferably heating and pressure is applied to form a laminate consisting of second PVC layer 22/adhesive layer 24/colored decorative layer 23/first PVC layer 21/back layer 3 in order from the front side. A structure 74 can be formed. The laminated structure 74 can be used as it is as a flooring material for building interiors, and, similarly to the above, the laminated structure 74 may be embossed on the front and/or back surfaces of the laminated structure 74 if necessary. An arbitrary process such as forming a scratch-preventing layer on the surface of 74 may be performed, and this may be used as a flooring material for building interiors.

[Usage of flooring materials for architectural interiors]
The flooring material of the present invention is particularly suitable as a flooring material for buildings where peel strength is required, for example, as an interior flooring material for various buildings such as condominiums, buildings, gymnasiums, and general houses.
The flooring material of the present invention is laid directly on a construction surface such as a floor surface, or is laid on a construction surface using an adhesive or a pressure-sensitive adhesive.

In the flooring material of the present invention, since the colored decorative layer on the surface layer is formed from inkjet ink, the colored decorative layer can be formed by inkjet printing, and a desired design can be easily displayed. In addition, since the surface layer has the first PVC layer containing vinyl chloride resin, the colored decorative layer, the adhesive layer, and the second PVC layer containing vinyl chloride resin in this order, the adhesion between each layer is excellent, and the first PVC layer and Peeling becomes difficult at the interface of the colored decorative layer, the interface of the colored decorative layer and the adhesive layer, and the interface of the adhesive layer and the second PVC layer.
In particular, as is clear from the examples below, when a vinyl chloride resin containing a plasticizer is used and the adhesive layer does not contain a pigment, a surface layer that is difficult to delaminate can be formed.

The interlayer peel strength of the flooring material of the present invention is, for example, 30 N/50 mm or more, preferably 35 N/50 mm or more, and more preferably 40 N/50 mm or more. If the interlayer peel strength is at least the above value, the flooring material will have sufficient durability as a flooring material and can be stably used for a long period of time after construction.
The interlayer peel strength refers to the peel strength between the first PVC layer and the second PVC layer. The interlayer peel strength refers to the strength required to separate the bonded layers, and is a measure of how strongly the layers are bonded.
The interlayer peel strength can be measured, for example, as follows. A sample piece was prepared by cutting the flooring material to 200 mm x 50 mm (length x width), and the first PVC layer and the second PVC layer were forcibly peeled off at one end in the longitudinal direction. %RH), the force required to peel the separated first PVC layer and the second PVC layer by pulling them at an angle of 180 degrees with a commercially available precision universal testing machine was measured, and the force was measured. The maximum value of is taken as the delamination strength.

EXAMPLES Hereinafter, the present invention will be explained in further detail by showing Examples and Comparative Examples. However, the present invention is not limited to the following examples.

[Example]
<Preparation of decorative sheet>
100 parts by weight of vinyl chloride resin (suspension type vinyl chloride resin, trade name "ZEST-800Z" manufactured by Shin Daiichi PVC Co., Ltd. Degree of polymerization: 820), 29 parts by weight of plasticizer (dioctyl phthalate), After thoroughly mixing 3 parts by weight of Ba-Zn stabilizer, the first PVC sheet was formed into a film with a thickness of about 0.28 mm using a calendar molding machine with a roll temperature of 150°C. Created.
On one side of the first PVC sheet, an inkjet printer equipped with an ultraviolet ray irradiation device is used to print a solid layer of ultraviolet curable inkjet ink, and by curing the ink by irradiating ultraviolet rays, a thick layer is formed on the first PVC sheet. A colored decorative layer of about 10 μm was formed. The inkjet ink was an acrylic ultraviolet curing type containing magenta dye.

Further, on the colored decorative layer, a coating liquid containing an ultraviolet curable resin is applied in a solid manner using a bar coater, and the colored decorative layer is cured by irradiating ultraviolet rays. An adhesive layer having a thickness of approximately 15 μm was formed on top of the adhesive layer. In this way, a decorative sheet consisting of the first PVC sheet/colored decorative layer/adhesive layer was produced. The coating liquid containing the ultraviolet curable resin contained an acrylic ultraviolet curable resin, a polymerization initiator, and the like. The acrylic ultraviolet curable resin was a mixture containing a polymerizable monomer and a polymerizable oligomer.

<Production of second PVC sheet>
100 parts by weight of vinyl chloride resin (suspension type vinyl chloride resin, trade name "ZEST-800Z" manufactured by Shin Daiichi PVC Co., Ltd. Degree of polymerization: 820), 29 parts by weight of plasticizer (dioctyl phthalate), After thoroughly mixing 3 parts by weight of Ba-Zn stabilizer, the second PVC sheet was formed into a film with a thickness of about 0.5 mm using a calendar molding machine with a roll temperature of 150°C. Created.

<Preparation of back layer forming material>
100 parts by weight of vinyl chloride resin (suspension type vinyl chloride resin, trade name "ZEST800Z" manufactured by Shin Daiichi PVC Co., Ltd. Degree of polymerization: 820), 36 parts by weight of plasticizer (dioctyl phthalate), 259 parts by weight 3 parts by weight of a Ca-Zn stabilizer (calcium carbonate, a mixture of the product name "KP200" manufactured by Hitachi Kuraishi Co., Ltd. and the product name "TA074B" manufactured by Chichibu Lime Industry Co., Ltd.), 3 parts by weight of a Ca-Zn stabilizer (Katsuta After thoroughly mixing ``HE-1218G'' (trade name manufactured by Kako Co., Ltd.), 1. Two resin sheets were produced. This single resin sheet was used as a back layer forming material.

<Production of flooring materials for architectural interiors>
A stack of decorative sheets (first PVC sheet/colored decorative layer/adhesive layer)/second PVC sheet/resin sheet is stacked in this order and heated to 140°C using a press while being pressed, thereby forming each sheet. integrated. The pressure applied to the stack by the press was set at approximately 0.8 MPa.
In this way, a building interior flooring material consisting of the first PVC layer/colored decorative layer/adhesive layer/second PVC layer/back layer was produced in order from the front side.

[Comparative example]
A building interior flooring material consisting of the first PVC layer/colored decorative layer/second PVC layer/back layer was produced in the same manner as in the example except that no adhesive layer was formed.

Sample pieces were prepared by cutting the flooring materials of Examples and Comparative Examples into length x width = 200 mm x 50 mm, and a cutter blade was inserted between the first PVC layer and the second PVC layer at one end in the longitudinal direction to cut the first PVC layer. The edges and the edges of the second PVC layer were separated. The separated ends were manually pulled and peeled, and the difficulty of peeling was sensory evaluated. As a result, the flooring material of the example was more difficult to peel than the flooring material of the comparative example.
The reason for this difference is presumed to be as follows.
In the example, the vinyl chloride resin of the second PVC layer, which has plasticity when heated and is relatively flexible at room temperature, bites into the surface of the adhesive layer, and the resin of the adhesive layer, which softens slightly when heated, is the second PVC. It is believed that the adhesion between the adhesive layer and the second PVC layer is enhanced by the mutual anchoring effect due to digging into the surface of the layer. In particular, when the second PVC layer contains fine particles such as calcium carbonate, the fine particles are scattered on the surface of the second PVC layer and form irregularities on the surface, so that the anchor effect can be further enhanced.
On the other hand, in the comparative example, the colored decorative layer and the second PVC layer were directly bonded. The colored decorative layer is often formed with an inkjet ink that has a smooth surface and high surface hardness in order to improve expressiveness. The vinyl chloride resin of the second PVC layer does not easily dig into the surface of the colored decorative layer as described above, and similarly, the surface (high hardness surface) of the colored decorative layer also does not easily dig into the surface of the second PVC layer. Become. For these reasons, it is considered that the comparative example does not have sufficient interlayer peel strength.
In this way, the colored decorative layer is formed taking into consideration the expressiveness and other design factors, so when the colored decorative layer and the second PVC layer are directly bonded together, as in the comparative example, interlayer peeling may occur. There is a limit to how much strength can be improved. On the other hand, as in the example, by interposing an adhesive layer between the colored decorative layer and the second PVC layer, which does not require consideration of the design elements required for the colored decorative layer, the colored decorative layer satisfies the design elements. The delamination strength between the first PVC layer and the second PVC layer can be increased.

1 Flooring material for architectural interior 2 Surface layer 21 1st PVC layer 22 2nd PVC layer 23, 53 Colored decorative layer 24, 54 Adhesive layer 3 Back layer 4 Decorative sheet 51 1st PVC sheet 52 2nd PVC sheet

Claims (6)

A first PVC layer containing a vinyl chloride resin, a colored decorative layer formed from an inkjet ink, an adhesive layer containing an ionizing radiation curable resin or a thermosetting resin, and a second PVC layer containing a vinyl chloride resin. A flooring material for architectural interiors having a surface layer in this order. The architectural interior flooring material according to claim 1, wherein the inkjet ink contains a colorant and an ionizing radiation curable resin or a thermosetting resin. The architectural interior flooring material according to claim 1 or 2, wherein the adhesive layer does not contain a pigment. The architectural interior flooring material according to claim 1 or 2, wherein the second PVC layer contains fine particles. The building interior flooring material according to claim 1 or 2, wherein the first PVC layer and the second PVC layer have an interlayer peel strength of 30 N/50 mm or more. preparing a decorative sheet having a first PVC sheet containing a vinyl chloride resin, a colored decorative layer formed on the first PVC sheet, and an adhesive layer formed on the colored decorative layer;
preparing a second PVC sheet containing a vinyl chloride resin;
A step of forming a laminate consisting of the first PVC sheet/colored decorative layer/adhesive layer/second PVC sheet by integrating the decorative sheet and the second PVC sheet under heating,
The colored decorative layer is formed by printing inkjet ink on the first PVC sheet using an inkjet printer,
A method for producing a flooring material for architectural interiors, wherein the adhesive layer is formed by applying a coating liquid containing an ionizing radiation-curable resin or a thermosetting resin onto the colored decorative layer and curing the coating liquid.

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