JP2023175546A - Cigarette resistant floor material - Google Patents

Abstract

To provide a cigarette resistant floor material capable of achieving improvement in production efficiency.SOLUTION: A cigarette resistant floor material 1 includes: a design layer 2 on which design is applied; a coat layer 4 arranged on one side of the design layer 2 in the thickness direction of the design layer 2, and for covering the design layer 2; and a heat radiation layer 5 arranged on the other side of the design layer 2 in the thickness direction, and coming into contact with the design layer 2. The coat layer 4 is a cured object of activated energy beam curable resin. The design layer 2 includes thermoplastic resin. The heat radiation layer 5 includes thermoplastic resin, and a heat radiation material having heat conductivity higher than the heat conductivity of the design layer 2.SELECTED DRAWING: Figure 1

Description

The present invention relates to cigarette-resistant flooring.

Conventionally, architectural decorative laminates have been known that have a printed pattern layer and a core layer made of metal foil and bonded to the pattern layer, and can improve cigarette resistance (for example, , see Patent Document 1 below.)

Japanese Patent Application Publication No. 10-37443

To manufacture the architectural decorative board described in Patent Document 1, a core layer (metal foil) and a pattern layer are bonded together by hot press processing.

In this case, it is necessary to join the core layer and the pattern layer in a batch manner, making it difficult to improve manufacturing efficiency.

The present invention provides a cigarette-resistant flooring material that can improve manufacturing efficiency.

The present invention [1] includes a design layer on which a design is applied, a coat layer disposed on one side of the design layer in the thickness direction of the design layer and covering the design layer, and a coat layer that covers the design layer in the thickness direction. a heat dissipation layer disposed on the other side and in contact with the design layer, the coat layer being a cured product of active energy ray-curable resin, the design layer containing a thermoplastic resin, and the heat dissipation layer being in contact with the design layer; includes a cigarette-resistant flooring material containing a thermoplastic resin and a heat dissipating material having a thermal conductivity higher than that of the design layer.

The present invention [2] includes the cigarette-resistant flooring material of the above [1], wherein the heat dissipating material is at least one selected from talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide.

The present invention [3] includes the cigarette-resistant flooring material of the above [1] or [2], wherein the proportion of the heat dissipation material in the heat dissipation layer is 5% by mass or more.

The present invention [4] provides any one of the above [1] to [3], wherein the heat dissipation layer further contains a filler, and the heat dissipation material has a higher thermal conductivity than the filler. or one cigarette-resistant floor covering.

The present invention [5] includes the cigarette-resistant flooring material of the above [4], wherein the filler is calcium carbonate.

The present invention [6] includes the cigarette-resistant flooring material of the above [4] or [5], wherein the mass ratio of the heat dissipating material to the filler is 10/90 or more and 90/10 or less.

According to the cigarette-resistant flooring material of the present invention, on the other side of the design layer, there is a heat dissipation layer in contact with the design layer. The design layer contains a thermoplastic resin, and the heat dissipation layer contains a thermoplastic resin and a heat dissipation material having a thermal conductivity higher than that of the design layer.

Therefore, the design layer and the heat dissipation layer can be laminated continuously by thermal lamination.

As a result, it is possible to improve the manufacturing efficiency of cigarette-resistant flooring materials.

Furthermore, the cigarette-resistant flooring material of the present invention has a coating layer on one side of the design layer. The coating layer is a cured product of active energy ray-curable resin and has excellent heat resistance.

Therefore, when the surface of the cigarette-resistant flooring material is heated, the coat layer prevents the design layer from discoloring and deteriorating, and allows the heat transmitted to the design layer to be radiated to the heat dissipation layer.

As a result, discoloration and degeneration of the design layer can be suppressed, and the cigarette resistance of the cigarette-resistant flooring material can be improved.

FIG. 1 shows a cross-sectional view of one embodiment of the cigarette-resistant flooring material of the present invention. FIG. 2 is a flowchart for explaining the method for manufacturing the cigarette-resistant flooring material shown in FIG. FIG. 3 is an explanatory diagram for explaining a method of manufacturing a heat dissipation layer in the preparation step of FIG. 2. FIG. 4 is an explanatory diagram for explaining the laminating process, cutting process, coating process, and curing process in FIG. 2.

1. Cigarette-resistant flooring material The cigarette-resistant flooring material of the present invention will be explained.

Cigarette-resistant flooring refers to resin flooring that has cigarette-resistant properties. Cigarette resistance refers to the discoloration and deterioration of the flooring due to the heat of the cigarette when a lit cigarette is left on the flooring or a lit cigarette is rubbed on the flooring and extinguished. This refers to the ability to suppress deformation (deformation, etc.). Cigarette resistance is evaluated by the method described in Examples below.

The resin flooring material of the present invention corresponds to, for example, a vinyl flooring material specified in JIS A5705, and includes floor tiles and floor sheets. Examples of the floor tile include multilayer vinyl floor tiles, set-up vinyl floor tiles, thin set-up vinyl floor tiles, and the like. Examples of the floor sheet include multilayer vinyl floor sheets.

Floor tiles are formed into square, rectangular, hexagonal, or other sheet shapes during manufacture, and are transported to a construction site and laid on the floor.

Floor sheets are stored and transported in rolls, and then laid on the floor at the construction site.

From the viewpoint of cigarette resistance, floor tiles are preferable to floor sheets. Floor tiles can be made harder than floor sheets, so they can contain more heat dissipating materials and fillers, have better heat resistance, and are often thicker, making it easier to absorb and disperse heat.

As shown in FIG. 1, the cigarette-resistant flooring 1 includes a design layer 2, a clear layer 3, a coating layer 4, a heat dissipation layer 5, and a backing layer 6. Specifically, the cigarette-resistant flooring 1 includes a backing layer 6, a heat dissipation layer 5, a design layer 2, a clear layer 3, and a coating layer 4 in this order toward one side in the thickness direction.

(1) Design layer The design layer 2 is a layer for imparting a design to the cigarette-resistant flooring material 1. A predetermined design is applied to one side of the design layer 2. Specifically, the design layer 2 is a resin sheet on which a predetermined design is applied. Examples of the design layer 2 include printed films and colored resins. A printed film is a resin material sheet with an arbitrary pattern drawn on it by applying ink. Colored resin is made by adding a coloring agent such as a pigment or dye to a resin such as polyvinyl chloride to form a desired color or pattern. The colored resin may be a single color resin sheet or may include resin chips of multiple colors.

The base resin of the design layer 2 is a thermoplastic resin. In other words, the design layer 2 contains thermoplastic resin. The design layer 2 contains a plasticizer, a pigment, and an additive, if necessary.

Examples of the thermoplastic resin include polyvinyl chloride, polyvinyl acetate, polyethylene, polypropylene, and polymethacrylate. The base resin of the design layer 2 is preferably polyvinyl chloride.

The plasticizer imparts plasticity to the design layer 2. Examples of the plasticizer include polyester plasticizers, glycerin plasticizers, polyvalent carboxylic acid ester plasticizers, and polyalkylene glycol plasticizers. Preferably, the plasticizer includes a polycarboxylic acid plasticizer, and preferably a phthalate ester. Examples of phthalate esters include dioctyl phthalate, bis(2-ethylhexyl) phthalate, and diisononyl phthalate.

The blending ratio of the plasticizer in the design layer 2 is not limited. The proportion of the plasticizer in the design layer 2 is, for example, 3 parts by mass or more, preferably 5 parts by mass or more, and, for example, 25 parts by mass or less, preferably, based on 100 parts by mass of the base resin of the design layer 2. , 20 parts by mass or less.

The pigment imparts hiding properties and design properties to the design layer 2. Examples of pigments include rutile titanium oxide and zinc oxide.

Examples of additives include flame retardants, stabilizers, antioxidants, lubricants, foaming agents, antibacterial agents, and fungicides.

The thickness of the design layer 2 is, for example, 0.03 mm or more, preferably 0.05 mm or more, and, for example, 0.50 mm or less, preferably 0.20 mm or less.

(2) Clear layer The clear layer 3 is arranged on one surface of the design layer 2 in the thickness direction of the design layer 2. The clear layer 3 is arranged between the design layer 2 and the coat layer 4 in the thickness direction of the design layer 2. Clear layer 3 covers design layer 2. The clear layer 3 protects the surface (one side) of the design layer 2 on which the design is applied, and increases the durability as a flooring material. The cigarette-resistant flooring 1 does not need to include the clear layer 3.

The clear layer 3 is made of a transparent or translucent thermoplastic resin, and is preferably transparent. Examples of the thermoplastic resin include the above-mentioned thermoplastic resins. Preferably, the clear layer 3 is made of polyvinyl chloride. The clear layer 3 contains the above-mentioned plasticizer and additives as necessary.

The blending ratio of the plasticizer in the clear layer 3 is not limited. The blending ratio of the plasticizer in the clear layer 3 is, for example, 10 parts by mass or more, preferably 25 parts by mass or more, and, for example, 50 parts by mass or less, preferably , 35 parts by mass or less.

When the cigarette-resistant flooring material 1 has the clear layer 3, by making the clear layer 3 thicker than the design layer 2, the durability as a flooring material can be improved. The thickness of the clear layer 3 is, for example, 0.05 mm or more, preferably 0.15 mm or more, and, for example, 1.00 mm or less, preferably 0.50 mm or less, more preferably 0.25 mm or less.

(3) Coat layer The coat layer 4 is the outermost layer of the cigarette-resistant flooring material 1. One side of the coat layer 4 is exposed. The coat layer 4 is arranged on one side of the clear layer 3 in the thickness direction of the design layer 2. In other words, the coat layer 4 is arranged on one side of the design layer 2 in the thickness direction of the design layer 2. Coat layer 4 covers clear layer 3 and design layer 2.

The coat layer 4 is a cured product of active energy ray curable resin. When the coat layer 4 is a cured product of active energy ray-curable resin, the coat layer 4 can be formed by sequentially applying, drying, and curing after laminating and cutting each layer, as described below. Can be formed. Therefore, the productivity of the cigarette-resistant flooring material 1 can be significantly improved. Further, the coat layer 4 has a crosslinked structure. Thereby, the coat layer 4 has higher heat resistance than the clear layer 3 and the design layer 2.

Active energy ray-curable resin refers to a resin that has energy quantum capable of crosslinking and polymerizing monomers in charged particle beams or electromagnetic waves, that is, resin that crosslinks and cures by irradiation with electron beams or ultraviolet rays. do. Among active energy ray curable resins, ultraviolet ray curable resins are preferred from the viewpoint of excellent transparency and ease of forming the coating layer 4.

The ultraviolet curable resin is not limited. Examples of the ultraviolet curable resin include urethane acrylate resin, polyester acrylate resin, epoxy resin, epoxy acrylate resin, and silicone acrylate resin.

As UV-curable resins, urethane acrylate resins, polyester acrylate resins, and , silicone acrylate resins are preferred, and urethane acrylate resins are particularly preferred.

Moreover, the ultraviolet curable resin may contain at least one type selected from silicon-modified urethane (meth)acrylate resin and fluorine-modified urethane (meth)acrylate resin.

When the ultraviolet curable resin contains at least one type selected from silicone-modified urethane (meth)acrylate resin and fluorine-modified urethane (meth)acrylate resin, it can be cured by the sliding properties and water/oil repellency of silicone and fluorine. , the adhesion of dirt to the surface of the coating layer 4 can be suppressed, and the dirt adhering to the surface of the coating layer 4 can be easily removed.

Coat layer 4 may contain a filler to improve physical properties. Examples of the filler contained in the coat layer 4 include inorganic particles and organic particles. Examples of inorganic particles include alumina, silica, and glass beads. Examples of organic particles include cellulose.

The coat layer 4 preferably contains inorganic particles because it can impart heat resistance to tobacco heat and durability to the coat layer 4.

The content ratio of the inorganic particles is, for example, 5 parts by mass or more, preferably 20 parts by mass or more, more preferably is 30 parts by mass or more, for example, 50 parts by mass or less, preferably 40 parts by mass or less, more preferably 35 parts by mass or less.

When the cigarette-resistant flooring material 1 has the clear layer 3, the coat layer 4 is thinner than the clear layer 3, for example. The thickness of the coat layer 4 is, for example, 0.01 mm or more, preferably 0.02 mm or more, and, for example, 0.05 mm or less, preferably 0.04 mm or less.

(4) Heat dissipation layer The heat dissipation layer 5 is arranged on the other surface of the design layer 2 in the thickness direction of the design layer 2. In other words, the heat dissipation layer 5 is arranged on the other side of the design layer 2 in the thickness direction of the design layer 2 . The heat dissipation layer 5 is arranged on the opposite side of the coat layer 2 with respect to the design layer 2 in the thickness direction of the design layer 2. The heat dissipation layer 5 is arranged between the design layer 2 and the backing layer 6 in the thickness direction of the design layer 2. The heat dissipation layer 5 is in contact with the design layer 2. When the temperature of the design layer 2 increases, the heat dissipation layer 5 removes heat from the design layer 2. In other words, the heat of the design layer 2 is radiated to the heat radiation layer 5. Thereby, the heat dissipation layer 5 suppresses the temperature of the design layer 2 from increasing.

The thickness of the heat dissipation layer 5 is not limited. The heat dissipation layer 5 is thicker than the design layer 2, for example. The heat dissipation layer 5 is thicker than the sum of the thicknesses of the design layer 2, the clear layer 3, and the coating layer 4, for example. When the heat dissipation layer 5 is thicker than other layers, the heat dissipation effect is excellent. Therefore, discoloration and degeneration of the design layer 2 can be further suppressed.

The thickness of the heat dissipation layer 5 is, for example, 0.1 mm or more, preferably 0.5 mm or more, and is, for example, 2.0 mm or less, preferably 1.5 mm or less.

The heat dissipation layer 5 contains a thermoplastic resin, a heat dissipation material, and if necessary, a filler, the above-mentioned plasticizer, and the above-mentioned additives.

The blending ratio of the plasticizer in the heat dissipation layer 5 is, for example, 5 parts by mass or more, preferably 10 parts by mass or more, and, for example, 100 parts by mass or less, based on 100 parts by mass of the base resin of the heat dissipation layer 5. Preferably, it is 60 parts by mass or less.

(4-1) Thermoplastic resin Thermoplastic resin is the base resin of the heat dissipation layer 5. Examples of the thermoplastic resin include the above-mentioned thermoplastic resins. The base resin of the heat dissipation layer 5 is preferably polyvinyl chloride.

The proportion of the thermoplastic resin in the heat dissipation layer 5 is, for example, 10% by mass or more, preferably 15% by mass or more, and, for example, 40% by mass or less, preferably 30% by mass or less.

(4-2) Heat dissipation material The heat dissipation material improves the thermal conductivity of the heat dissipation layer 5. The heat dissipation material is dispersed in the base resin of the heat dissipation layer 5.

The thermal conductivity of the heat dissipating material is higher than that of the design layer 2. Therefore, when the temperature of the design layer 2 increases, the heat of the design layer 2 is radiated to the heat radiation layer 5. As a result, discoloration and degeneration of the design layer 2 due to heating can be suppressed, and the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. Further, the thermal conductivity of the heat dissipating material is higher than that of the filler in the heat dissipating layer 5.

The thermal conductivity of the heat dissipating material is, for example, 1 W/m·K or more, preferably 2 W/m·K or more, and, for example, 200 W/m·K or less.

Specifically, the heat dissipation material is at least one selected from talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide. The heat dissipating material is preferably at least one selected from talc and aluminum hydroxide, and more preferably talc. When the heat dissipation material is talc, it has excellent workability, and it is possible to improve cigarette resistance while suppressing an increase in cost. Furthermore, when the heat dissipation material is talc, the heat dissipation layer 5 can be easily formed by calendar molding.

The form of the heat dissipation material is not limited as long as it can be dispersed in the base resin of the heat dissipation layer 5. Specifically, the heat dissipating material is powder. The shape of the particles of the heat dissipating material is also not limited. Examples of the shape of the heat dissipating material particles include spherical, elliptical, and scaly shapes.

In addition, when metal foil is used to exhibit cigarette resistance, as in the architectural decorative board described in Patent Document 1 mentioned above, it is difficult to recycle the leftover materials during manufacturing and the used products. It is often disposed of as industrial waste. This is because recycling scraps from manufacturing or used products requires separating the metal foil from the base material and cutting it into small pieces, which takes time and effort to dispose of.

In this regard, in the cigarette-resistant flooring material 1 of this embodiment, since the heat dissipating material in the heat dissipating layer 5 is powder, the heat dissipating layer 5 can be recycled as is without separating it from other layers.

Therefore, it is possible to suppress scraps from manufacturing and used products from being discarded as industrial waste, and it is possible to reduce the environmental load.

The particle size of the heat dissipating material is, for example, 5 μm or more, preferably 10 μm or more, more preferably 15 μm or more, and, for example, 100 μm or less, preferably 50 μm or less, more preferably 20 μm or less. In addition, in this specification, "particle size" means volume average diameter (MV).

If the particle size of the heat dissipation material is equal to or larger than the above lower limit, it is possible to improve workability and handleability when manufacturing the heat dissipation layer 5. If the particle size of the heat dissipation material is below the above upper limit, the dispersibility of the heat dissipation material into the base resin can be ensured, and damage to manufacturing equipment by the heat dissipation material when manufacturing the heat dissipation layer 5 can be suppressed.

The proportion of the heat dissipating material in the heat dissipating layer 5 is, for example, 5% by mass or more, preferably 10% by mass or more, and preferably 15% by mass or more. When the proportion of the heat dissipation material in the heat dissipation layer 5 is 5% by mass or more, the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. When the proportion of the heat dissipation material in the heat dissipation layer 5 is 10% by mass or more, sufficient cigarette resistance can be imparted to the cigarette-resistant flooring material 1.

The proportion of the heat dissipating material in the heat dissipating layer 5 is, for example, 20% by mass or less. When the proportion of the heat dissipating material in the heat dissipating layer 5 is 20% by mass or less, an increase in the material cost of the cigarette-resistant flooring 1 can be suppressed.

(4-3) Filler The filler is dispersed in the base resin of the heat dissipation layer 5 together with the heat dissipation material. The filler improves the workability of the heat dissipation layer 5 and increases its dimensional stability while ensuring the heat dissipation properties of the heat dissipation material.

The thermal conductivity of the filler is lower than that of the heat dissipating material in the heat dissipating layer 5. The thermal conductivity of the filler is preferably higher than that of the design layer 2.

The thermal conductivity of the filler is, for example, 0.1 W/m·K or more, preferably 0.5 W/m·K or more, and, for example, 100 W/m·K or less.

Examples of the filler include inorganic particles other than the above-mentioned heat dissipating material. Examples of inorganic particles include calcium carbonate, magnesium carbonate, magnesium hydroxide, kaolin, silica, perlite, alumina, mica, boron nitride, aluminum nitride, and silicon nitride. Moreover, volcanic ash whose main components are silica and alumina can also be used as the inorganic particles. The filler is preferably calcium carbonate. When the filler is calcium carbonate, dimensional changes in the cigarette-resistant flooring 1 can be suppressed, and an increase in material cost can be suppressed.

The particle size of the filler is, for example, 5 μm or more, preferably 10 μm or more, and, for example, 400 μm or less, preferably 100 μm or less, more preferably 30 μm or less.

Further, the difference between the particle size of the filler and the heat dissipating material is, for example, 200 μm or less, preferably 100 μm or less, and more preferably 30 μm or less. The difference between the particle size of the filler and the particle size of the heat dissipation material may be zero.

If the difference between the particle size of the filler and the heat dissipation material is equal to or less than the above upper limit, it is possible to improve the dispersibility of the filler and the heat dissipation material in the base resin when manufacturing the heat dissipation layer 5. The cigarette resistance of the cigarette-resistant flooring material 1 can be improved.

The proportion of the filler in the heat dissipation layer 5 is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 30% by mass or more, and even more preferably 50% by mass or more. When the heat dissipation material is talc, workability can be improved if the proportion of the filler in the heat dissipation layer 5 is 5% by mass or more. When the heat dissipation material is aluminum hydroxide, workability can be improved if the proportion of the filler in the heat dissipation layer 5 is 10% by mass or more. When the heat dissipation material is magnesium oxide or zinc oxide, workability can be improved if the proportion of the filler in the heat dissipation layer 5 is 30% by mass or more. When the heat dissipation material is carbon, workability can be improved if the proportion of the filler in the heat dissipation layer 5 is 50% by mass or more. Further, when the proportion of the filler in the heat dissipation layer 5 is 30% by mass or more, dimensional changes in the cigarette-resistant flooring 1 can be suppressed, and an increase in material cost can be suppressed.

The upper limit of the proportion of the filler in the heat dissipation layer 5 is not limited as long as the heat dissipation material can be incorporated into the heat dissipation layer 5. The proportion of the filler in the heat dissipation layer 5 is, for example, 80% by mass or less, preferably 60% by mass or less, more preferably 55% by mass or less. When the proportion of the filler in the heat dissipation layer 5 is 80% by mass or less, the blending proportion of the heat dissipation material can be ensured, and the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. When the proportion of the filler in the heat dissipation layer 5 is 60% by mass or less, the blending proportion of the heat dissipation material can be further ensured, and the cigarette resistance of the cigarette-resistant flooring material 1 can be further improved. When the proportion of the filler in the heat dissipation layer 5 is 55% by mass or less, a sufficient blending proportion of the heat dissipation material can be ensured, and sufficient cigarette resistance can be imparted to the cigarette-resistant flooring material 1.

Further, the mass ratio of the heat dissipating material to the filler (mass of the heat dissipating material in the heat dissipating layer 5/mass of the filler in the heat dissipating layer 5) is, for example, 10/90 or more, preferably 20/80 or more. When the mass ratio of the heat dissipating material to the filler is 10/90 or more, the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. When the mass ratio of the heat dissipating material to the filler is 20/80 or more, sufficient cigarette resistance can be imparted to the cigarette-resistant flooring material 1.

The mass ratio of the heat dissipation material to the filler (mass of the heat dissipation material in the heat dissipation layer 5/mass of the filler in the heat dissipation layer 5) is, for example, 90/10 or less, preferably 80/20 or less, more preferably, It is 50/50 or less, more preferably less than 30/70. When the mass ratio of the heat dissipating material to the filler is 90/10 or less, the heat dissipating layer 5 can be formed by calendar molding. When the mass ratio of the heat dissipation material to the filler is 80/20 or less, the heat dissipation layer 5 can be easily formed by calendar molding.

If the mass ratio of the heat dissipating material to the filler is greater than or equal to the above lower limit and less than the above upper limit, both heat dissipation performance and workability can be achieved.

(5) Backing layer The backing layer 6 supports the heat dissipation layer 5, the design layer 2, the clear layer 3, and the coating layer 4. The backing layer 6 is arranged on the other surface of the heat dissipation layer 5 in the thickness direction of the design layer 2 . The backing layer 6 is disposed on the opposite side of the design layer 2 with respect to the heat dissipation layer 5 in the thickness direction of the design layer 2. Note that the cigarette-resistant flooring 1 does not need to include the backing layer 6.

The backing layer 6 contains the above-described thermoplastic resin as a base resin, and if necessary, the above-described filler and the above-described plasticizer. The base resin of the backing layer 6 is preferably polyvinyl chloride. The filler in the backing layer 6 is preferably calcium carbonate.

Note that, although FIG. 1 shows an example in which the backing layer 6 is a single layer, the backing layer 6 is not limited to this, and may be composed of a plurality of layers. Furthermore, when the backing layer 6 is composed of a plurality of layers, the backing layer 6 may include a fiber reinforced layer. For example, the fiber reinforcement layer is located at the center of the backing layer 6 in the thickness direction. The fiber reinforcement layer may be a nonwoven fabric or a woven fabric. The fiber-reinforced layer is preferably a nonwoven fabric containing glass fibers, and more preferably a nonwoven fabric containing only glass fibers, since it has excellent heat resistance and a high effect of suppressing dimensional changes.

The thickness of the backing layer 6 is, for example, 1.0 mm or more, preferably 2.0 mm or more, and is, for example, 7.0 mm or less, preferably 5.0 mm or less.

2. Method for manufacturing cigarette-resistant flooring Next, a method for manufacturing cigarette-resistant flooring will be described.

As shown in FIG. 2, the method for manufacturing cigarette-resistant flooring includes, for example, a preparation step (S1), a lamination step (S2), a cutting step (S3), a coating step (S4), and a curing step ( S5).

(1) Preparation Step In the preparation step, the design layer 2, the heat dissipation layer 5, and the backing layer 6 are prepared.

To prepare the design layer 2, for example, a commercially available resin sheet with a predetermined design can be purchased. Note that the purchased design layer 2 may be provided with a clear layer 3. If the purchased design layer 2 is not provided with the clear layer 3, the clear layer 3 described above may be laminated onto the design layer 2. Further, in order to prepare the design layer 2, the design layer 2 may be formed from the above-described material for the design layer 2 by calender molding, which will be described later, and a predetermined design may be applied thereto.

To prepare the heat dissipation layer 5, as shown in FIG. 3, the heat dissipation layer 5 is formed by calendering. Specifically, the materials for the heat dissipation layer 5 described above are mixed in a Banbury mixer 11 while being heated to, for example, 140° C. to 170° C.

Next, the obtained mixture is kneaded using mill rolls 12 while being heated to, for example, 140° C. to 190° C.

Next, the obtained kneaded product is heated to, for example, 140° C. to 170° C. using a calendar roll 13 and formed into a sheet shape to obtain a resin sheet containing a heat dissipating material as the heat dissipating layer 5.

Moreover, in order to prepare the backing layer 6, the backing layer 6 is molded from the above-described material for the backing layer 6 by the above-described calender molding.

(2) Lamination process In the lamination process, the design layer 2, heat dissipation layer 5, and backing layer 6 obtained in the preparation process are laminated by thermal lamination.

Specifically, as shown in FIG. 4, the heat dissipation layer 5 is laminated on the backing layer 6, and then the design layer 2 is laminated on the heat dissipation layer 5.

Note that after laminating the design layer 2 on the heat dissipation layer 5, the clear layer 3 may be laminated on the design layer 2, if necessary.

Since the heat dissipation layer 5 contains the thermoplastic resin, the heat dissipation layer 5 can be joined to the design layer 2 and the backing layer 6 by heating and pressing. In particular, when the thermoplastic resin of the backing layer 6, heat dissipation layer 5, design layer 2, and clear layer 3 is polyvinyl chloride, each layer can be easily bonded by heating and pressing, and the peel strength can be improved. .

In the lamination process, each layer is laminated roll-to-roll. Thereby, the laminate of the backing layer 6, heat dissipation layer 5, design layer 2, and clear layer 3 can be manufactured continuously.

(3) Cutting process The cutting process is carried out, if necessary, after the laminating process and before the coating process. In the cutting step, the obtained laminate is cut into a predetermined shape and size. To cut the laminate, for example, the laminate is cut using a cutting machine 20. Examples of this cutting include circle cut and guillotine cut.

Note that the cutting step before the coating step is necessary when the floor material is a floor tile, but is not necessary when the floor material is a floor sheet. When the flooring material is a floor sheet, after the lamination process, it goes through a coating process and a curing process without being cut, and then is stored in a rolled up state. When the flooring material is a floor sheet, after the curing process and before or after being rolled up, both ends of the floor sheet in the width direction are cut to adjust the width dimension.

(4) Coating process In the coating process, a precursor of the coating layer 4 (a coating liquid containing an active energy ray-curable resin) is applied to the clear layer 3 of the obtained laminate using the coating device 21. do.

Note that the coating device 21 is not limited. Examples of the coating device 21 include a bar coater, a slit die coater, and a roll coater.

(5) Curing process In the curing process, the coating liquid applied to the laminate in the coating process is dried and cured using the ultraviolet irradiation device 22. Thereby, a coat layer 4 is formed on the clear layer 3.

Through the above steps, the production of the cigarette-resistant flooring material is completed.

3. Effects According to the cigarette-resistant flooring material 1, as shown in FIG. 1, the heat dissipation layer 5 is provided on the other side of the design layer 2 and is in contact with the design layer 2. The design layer 2 contains a thermoplastic resin, and the heat dissipation layer 5 contains a thermoplastic resin and a heat dissipation material having a thermal conductivity higher than that of the design layer 2.

Therefore, as shown in FIG. 4, the design layer 2 and the heat dissipation layer 5 can be laminated continuously by thermal lamination.

As a result, it is possible to improve the manufacturing efficiency of the cigarette-resistant flooring material 1.

Furthermore, according to the cigarette-resistant flooring material 1, as shown in FIG. 1, a coating layer 4 is provided on one side of the design layer 2. The coat layer 4 is a cured product of active energy ray-curable resin and has excellent heat resistance.

Therefore, when the surface of the cigarette-resistant flooring material 1 is heated, the coat layer 4 can radiate the heat transmitted to the design layer 2 to the heat dissipation layer 5 while preventing discoloration and degeneration of the design layer.

As a result, discoloration and degeneration of the design layer 2 can be suppressed, and the cigarette resistance of the cigarette-resistant flooring material 1 can be improved.

EXAMPLES The present invention will be described in more detail with reference to Examples below, but the present invention is not limited thereto. Specific numerical values such as blending ratios (content ratios), physical property values, parameters, etc. used in the following description are the corresponding blending ratios (content ratios) described in the above "Details of Carrying Out the Invention". ), physical property values, parameters, etc. can be replaced with the upper limit value (value defined as "less than" or "less than") or lower limit value (value defined as "more than" or "exceeding"). can. Note that "parts" and "%" are based on mass unless otherwise specified.

1. Manufacturing of polyvinyl chloride sheets (preparation process)
(1) Comparative Example As a comparative example, a normal (that is, not a heat dissipation layer) polyvinyl chloride sheet was manufactured.

In the blended parts shown in Table 1, polyvinyl chloride (thermoplastic resin), calcium carbonate (filler) with a particle size of approximately 13 μm, dioctyl phthalate (plasticizer), and additives (coloring pigment, processing aid) , heat stabilizer) were mixed at 140°C to 170°C using a Banbury mixer.

The resulting mixture was kneaded using a mill roll while being heated to 140°C to 190°C.

The obtained kneaded product was formed into a sheet using a calender roll (temperature: 140° C. to 170° C.) to obtain a polyvinyl chloride sheet with a thickness of 0.7 mm.

(2) Examples 1 to 50
A polyvinyl chloride sheet as a heat dissipation layer was produced in the same manner as in Comparative Example, except that a portion of the calcium carbonate was changed to the heat dissipation material shown in Tables 1 to 5 (each having a particle size of approximately 16 μm).

Ease of manufacturing (workability) when manufacturing the heat dissipation layer was compared with a comparative example and evaluated using the following evaluation criteria.

<Evaluation criteria>
○: Can be manufactured as a sheet as in the comparative example.

Δ: Compared to the comparative example, although it can be molded into a sheet, the processability of the obtained sheet is inferior in terms of surface smoothness.

×: Cannot be manufactured as it cannot be formed into a sheet due to holes.

2. Manufacturing of flooring material: On the backing layer (polyvinyl chloride, thickness: 4 mm), the polyvinyl chloride sheet of the comparative example and each example, the design layer (polyvinyl chloride, thickness: 0.07 mm), and the clear layer ( Polyvinyl chloride (thickness: 0.2 mm) were laminated in this order to obtain a laminate of a backing layer, a polyvinyl chloride sheet of a comparative example and each example, a design layer, and a clear layer (laminate step).

Next, a coating liquid containing an ultraviolet curing resin (Polymedic SK-0910-2, manufactured by DIC Corporation) was applied to the clear layer of the obtained laminate (coating step).

Next, the coating liquid was dried, and the resulting coating film was irradiated with ultraviolet rays to be cured (curing step). Thereby, a coat layer was formed on the clear layer, and a flooring material was obtained.

3. Evaluation of Cigarette Resistance The cigarette resistance of the flooring materials of Comparative Examples and Examples was evaluated by the following method.

A lit cigarette was left on a test piece (9.5 mm x 9.5 mm) cut out from the obtained floor material for 3 minutes (Test A).

In addition, a lit cigarette was rubbed for 5 seconds using a test piece (9.5 mm x 9.5 mm) cut out from the obtained flooring material to extinguish it (Test B).

The condition of the test piece after the test was evaluated using the following evaluation criteria. In the following evaluation criteria, surface change means discoloration and degeneration. The results are shown in Tables 1 to 5.

<Evaluation criteria>
○: There was almost no change in the surface in both Test A and Test B.

Δ: There was a slight change in the surface in either Test A or Test B.

×: In either Test A or Test B, there was a large change in the surface.

1 Cigarette-resistant flooring material 2 Design layer 4 Coating layer 5 Heat dissipation layer

Claims (6)

a design layer on which a design is applied;
a coat layer disposed on one side of the design layer in the thickness direction of the design layer and covering the design layer;
a heat dissipation layer disposed on the other side of the design layer in the thickness direction and in contact with the design layer;
The coat layer is a cured product of active energy ray-curable resin,
The design layer contains a thermoplastic resin,
The heat dissipation layer is
thermoplastic resin;
A cigarette-resistant flooring material comprising a heat dissipating material having a higher thermal conductivity than the design layer. The cigarette-resistant flooring material according to claim 1, wherein the heat dissipation material is at least one selected from talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide. The cigarette-resistant flooring material according to claim 1 or 2, wherein the proportion of the heat dissipation material in the heat dissipation layer is 5% by mass or more. The heat dissipation layer further contains a filler,
The cigarette-resistant flooring according to claim 1, wherein the heat dissipation material has a higher thermal conductivity than the filler. A cigarette-resistant flooring according to claim 4, wherein the filler is calcium carbonate. The cigarette-resistant flooring material according to claim 4 or 5, wherein the mass ratio of the heat dissipating material to the filler is 10/90 or more and 90/10 or less.

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