JP2533978B2 - Thermoplastic floor material with a grain pattern - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor material made of a thermoplastic resin having a grain pattern, and more specifically, it has a three-dimensional and colorful appearance in which colored chips are dispersed and mixed in a surface sheet having excellent transparency. The present invention relates to a thermoplastic resin floor material having a grain pattern.

[0002]

2. Description of the Related Art Conventionally, a floor material having a grain pattern or a stone pattern using chips or flakes as a surface layer has been widely used. However, in recent years, the designability of plastic floor materials has been emphasized, and the conventional patterns have already become obsolete. Therefore, there is also a method of designing various patterns by backprinting on the back of a transparent film. Has been done. Floor materials simulating natural materials such as sand patterns and stone patterns are very popular.
Even if this grain pattern was printed by the back print method, only a flat pattern could be produced and stones and sand could not be expressed three-dimensionally.

Further, conventional thermoplastic resin flooring materials having a grain-like pattern are those in which a thermoplastic resin chip is softened, melted and pressed to form a surface layer as it is, or inside a vinyl chloride paste. A surface sheet has been used in which chips of a thermoplastic resin are dispersed, coated on a base material, heated and gelled to form a surface sheet.

[0004]

These conventional thermoplastic resin flooring materials which form a surface layer by pressing while melting and melting chips and flakes of a thermoplastic resin are known.
The chip lacks design in a crushed pattern, and the method of forming the surface layer by dispersing the chips in a vinyl chloride paste is also a colored vinyl chloride paste or transparent, The sheet formed by applying vinyl chloride paste, heating it and gelling it has poor transparency, so the permeability to the chip is poor.This is because the finer the particles of the chip, the more blurred the design of the chip is. Therefore, it was only possible to express only the sand pattern by using chips as the surface layer.

The present invention provides a three-dimensional and design-rich conventional grain-like pattern, which allows a grain-like pattern composed of finely colored colored chips to be penetrated neatly, and which can be seen as floating. A flooring material having the same is provided.

[0006]

Means for Solving the Problems The present invention is to solve the above-mentioned problems by providing a transparent resin sheet having a transparency in the thickness direction of 80% or more in the visible light transmittance at a wavelength of 550 nm. , The melting temperature is higher than the processing temperature of the thermoplastic resin sheet, and the particle size is 0.1 to 1.0 m.
A transparent surface sheet layer in which two or more colors of synthetic resin chips colored in an arbitrary color and having a size in the range of m and a color corresponding to the color of the colored synthetic resin chips were colored. It is intended to provide a thermoplastic resin flooring material having a grain-like pattern composed of an intermediate colored sheet layer and a backing base material sheet layer provided as the lowermost layer.

[0007]

Embodiments of the invention will be described with reference to the drawings.
The thermoplastic resin flooring material of the present invention comprises a transparent topsheet layer a,
It is made of a thermoplastic resin and comprises an intermediate colored sheet layer b and a backing base sheet layer c.

The surface transparent surface sheet layer a may be a thermoplastic resin which is generally used in the technical field of this kind including a polyvinyl chloride resin, and various compounding agents are added to these, and the calender molding method is used. , Extrusion molding 0.1
Transparent thermoplastic resin sheet 1 molded to ~ 1.0 mm
Two or more colors of synthetic resin colored chips 2 are dispersed and mixed in the transparent portion, and the transparency is 80% or more at a visible light wavelength of 550 nm in the thickness direction of the transparent portion of the layer a. It is not necessarily colorless as long as it has a property, and may be colored. As this transparent thermoplastic resin sheet, for example, polyvinyl chloride resin, ethylene-vinyl acetate copolymer (EVA), ethylene-acrylic acid ester copolymer (EEA), ethylene-methacrylic acid ester copolymer (EMA), Other transparent thermoplastic elastomers (TPE) and the like are not limited to these as long as the sheet has transparency, and other resins can be used. Further, a compounding agent may be appropriately added to these and used.

When the transparent surface sheet layer a is formed into a sheet by a calendering method, the resin used is limited due to the characteristics of the calendering, and the resin having good transparency is limited. Usually, a polyvinyl chloride resin alone or a blend of other thermoplastic resins, or the EV described above.
A, EEA, EMA, urethane type TPE, etc. are suitable.
Of these, vinyl chloride resins are most preferable among them because of their workability and transparency.

When a sheet is formed by an extrusion method, various resins can be used, but the above resins are suitable as long as they are extrudable at a temperature at which the transparency of the sheet and the colored chips do not melt.

When the colored chips 2 are mixed with the compound of the transparent surface sheet layer a, kneaded, and rolled, the colored chips are fine and fine, and the chips come into contact with each other to easily become agglomerated due to static electricity due to friction. It is preferable to add an antistatic agent to the colored chip 2 because it tends to cause poor dispersion, but it is difficult to impart the antistatic property to the colored chip 2 due to the high processing temperature, and if the antistatic property is imparted, the chip will be deteriorated. Becomes expensive. Therefore, an antistatic agent is added to the compound of the soft synthetic resin sheet 1 in an amount of 0.1
By adding 1.0 part by weight, preferably 0.3 to 0.6 part by weight, static electricity is not generated from the finely divided colored chips, and the particles are sufficiently dispersed during mixing and kneading. It is possible to obtain a transparent surface sheet layer in which is uniformly dispersed.

The colored chip 2 made of synthetic resin is a synthetic resin which does not soften or melt when the transparent surface sheet layer a is formed into a sheet. The desired pattern cannot be obtained because it is crushed or completely compatible with the transparent surface sheet layer). For example, when a polyvinyl chloride resin is used for calendering, the transparent sheet 1 is 150 Since it is rolled at ~ 195 ° C, synthetic resins that do not melt and soften at this temperature, for example, polyester resins such as PET and PBT, thermoplastic resins such as polycarbonate resins and polyamide resins, or polyvinyl chloride are chemically crosslinked. It is possible to use a so-called thermoplastic resin that is cross-linked, and it is possible to use a thermosetting resin. Missing Te easy thing is not preferable. Among these, the above-mentioned thermoplastic resins, whose melting temperature is 30 to 80 ° C. higher than the resin processing temperature of the transparent surface sheet layer, are relatively compatible with the resin of the transparent surface sheet layer, for example, polyvinyl chloride resin. Some are preferable, and the polyester resin, nylon 66, nylon 6, cross-linked polyvinyl chloride, etc. chips are more preferable because they soften slightly during processing.

The amount of the colored chips 2 added is 1 to 10% by weight based on the resin compound of the transparent topsheet layer a.
The amount is preferably 3 to 5% by weight, and when the amount is less than 1% by weight, the amount of particles distributed in the transparent surface sheet layer is small, and a design expressing a grain pattern cannot be obtained. However, the ratio of the transparent portion of the transparent surface sheet layer is reduced and the color pattern of the intermediate colored sheet layer b below the transparent surface sheet layer a becomes invisible, resulting in a desired intermediate colored sheet layer. It is not preferable because the colored chip can be three-dimensionally expressed by the color combination effect with b and the designability cannot be improved. Further, if an amount exceeding 10% by weight is added, the chips may be damaged by contact between colored chip particles during calendar rolling and shearing, resulting in finer particles, and only that part may have the same color.
The transparency is lost in that portion, which is not preferable.

The colored chip 2 is formed by crushing and coloring a colored sheet, and a predetermined colorant is blended by the extrusion molding method, casting method, calendering method or injection molding method using the above synthetic resin. For example, thickness 0.1
A sheet having a size of about mm is formed in plural colors, and the sheet is crushed by a crusher or the like. As a method for obtaining chips having a particle size of 0.1 to 1.0 mm, for example, a method of removing chips having a large particle size with a 16-mesh sieve and removing small chips with a 32-mesh sieve can be used. I can. 0.1-1.0 m obtained by such a method
The colored chips 2 having a particle diameter in the range of m are mixed and dispersed in a transparent surface sheet layer in two or more colors at an appropriate ratio for use.

The term "colored chips having a particle diameter of 0.1 to 1.0 mm" as used in the present invention does not necessarily mean that the maximum diameter of the chips falls within this range, but also includes elongated type chips having a diameter within this range. . In the case of elongated chips, the chips must not protrude from the transparent topsheet layer with the chips dispersed in the transparent topsheet layer. When the chips are relatively elongated and longer than the thickness of the transparent topsheet layer, the chips are mixed in a laid state and do not substantially protrude from the surface of the transparent topsheet layer. If the diameter of the chip is larger than the thickness of the transparent surface sheet layer in any part, the chip is exposed from the transparent surface sheet layer, and the colored chip intended by the present invention floats in the transparent surface sheet layer. In addition, it is not preferable that the three-dimensional expression cannot be achieved, and in the case of processing, for example, in the case of molding by calendering, the chips are crushed in the gaps of the calender rolls and chips of the same color are densely packed only in that part.

Therefore, the shape of the chip may be spherical, rod-shaped, angular, or piece-shaped, but the minor axis must be smaller than the thickness of the transparent surface sheet layer. Since calender rolling can form a sheet having a maximum thickness of 0.7 mm, it is necessary that the short diameter of the chip be 0.7 mm or less. When extruded, a sheet of 0.7 mm or more can be formed, but since the problem of transparency of the sheet in the thickness direction and the particle size of natural sand is 1.5 mm or less, a grain-like design is required. For expression, the maximum particle size of the chip is 1.5 mm or less, preferably 1.0 mm or less. In addition, the smallest particle size of the chip is preferably 32 mesh or more so that the shape of the particles can be identified, which is preferable in terms of design, and a desired grain pattern can be expressed. Also, within a range that does not interfere with the color pattern of the intermediate colored sheet layer that is the base,
It is also possible to mix scaly or granular colored chips having a thickness of about 1 to 5 mm with a thickness such that the colored chips are not exposed from the transparent surface sheet layer to a colored chip of 0.1 to 1.0 mm in a very small amount. is there.

Further, the chips are colored by mixing an organic pigment or an inorganic pigment as a colorant into a resin, and a method of coloring with a dye or impregnating and coloring after the chips are produced is a color fading during calendar processing or a plasticizer. It is not preferable because the dye migrates and the transparency of the transparent surface sheet layer is hindered.

The surface of the particles of the colored chips mixed and scattered in the transparent surface sheet layer a as described above is covered with the resin matrix, so that the chips do not fall off, but they are long in a frequently walked place. When used for a period of time, the surface may be worn away and the chips may fall off, so a more transparent protective wear resistant layer 3 may be provided.

The protective wear-resistant layer 3 comprises a curable polyurethane resin, an ultraviolet curable monomer, an oligomer (urethane acrylate, epoxy acrylate, polyester acrylate, etc.) in an amount of 3 to 50 μm, preferably 5 to 20 μm.
Apply so that the coating thickness becomes μm. Usually, urethane is cross-linked, and ultraviolet-cured epoxy, urethane, or acrylic resin is coated. In any case, it is limited to those that are transparent.

The intermediate colored sheet layer b is a synthetic resin layer composed of a vinyl chloride resin and a thermoplastic resin usually used in this technical field, and is an organic or inorganic pigment such as a masterbatch or powder. Is colored by. The intermediate colored sheet layer is for making the colored chips 2 scattered on the transparent surface sheet layer a stand out, and corresponds to the color of the colored chips. What is the color corresponding to the color of the colored chip?
For example, when there are many blue-based chips, the intermediate colored sheet layer is also a blue-based color or a light brown-based color that is a base color that brings out the color of the chip 2, that is, an intermediate colored sheet layer that is a base. Any combination of colors, such as contrasting colors such as white and black, red and blue, etc., may be used as long as the color and the color of the chip are not exactly the same. Further, the surface of the intermediate colored sheet layer b may be printed.

The backing base material sheet layer c is a backing layer which is usually used in this kind of technical field. For example, a synthetic resin backing sheet 4 made of a resin such as polyvinyl chloride resin is used.
Lining material such as linen or paper such as hemp or polyester fiber 5
The synthetic resin backing sheet 4 may be a foamed layer or a non-foamed layer.

These transparent surface sheet layer a, intermediate coloring sheet layer b, and backing base material sheet layer c are laminated by first forming the backing base material sheet layer c by calendering, and then by forming the intermediate coloring sheet layer. The sheet b is calender-rolled and heat-fused with the backing base material sheet layer c at the same time as the sheet is taken out to laminate. Then, the transparent surface sheet layer a in which the colored chips 2 are mixed is molded by a calendaring method or an extrusion method, and laminated on the surface of the intermediate colored sheet layer on which the backing base material sheet layer c is laminated to form a laminated structure.

Next, examples according to specific embodiments of the present invention will be described in detail.

Example 1 (Preparation of Colored Chip) A 0.1 mm thick polybutylene terephthalate (PBT) resin sheet containing each colorant was prepared by extrusion molding. These several color sheets were each crushed by a crusher, passed through a 16-mesh sieve to remove chips with a large particle size, and further removed with a 32-mesh screen to remove fine chips to obtain a particle size of about 0.1 to 1.0 mm. A range of colored chips was obtained.

(Molding of Sheet) Of these colored chips, three types of chips of white, black and blue were blended at a ratio of 1: 1: 1 to prepare P shown in Formulation 1.
5% by weight of the mixed colored chips with respect to the VC compound
A transparent polyvinyl chloride resin sheet in which the compound is added, heated and melted with a Banbury mixer, mixed and calendar-rolled at 190 to 195 ° C., and colored chips are dispersed and mixed inside the sheet having a thickness of 0.4 mm. Got 550n in the thickness direction of the transparent part of this sheet
The visible light transmittance at the m wavelength was 87%.

Next, the polyvinyl chloride resin blended with the blue pigment shown in Formulation 2 is heated and melted with a Banbury mixer or the like and mixed, and calendered to a thickness of 0.3 m.
A blue-colored colored sheet of m was molded and laminated with a backing base sheet to which a polyester fiber base cloth was attached by heating and pressing.

The transparent polyvinyl chloride resin sheet is heated and pressed to be laminated on the colored sheet surface of this laminated sheet, and a curable urethane resin treatment liquid is applied onto the transparent surface sheet layer to cure and harden it. A layer was formed to obtain a grainy polyvinyl chloride resin flooring having a transparent surface sheet layer in which colored chips were dispersed and mixed.

Example 2 (Preparation of Colored Chip) A vinyl chloride paste having a degree of polymerization of 1300 and colored in each color according to the formulation 3 was prepared. These were applied to release paper to form a PVC crosslinkable sheet having a thickness of 0.1 mm.
These were crosslinked at 220 ° C., pulverized with a pulverizer, passed through a 16-mesh sieve, and left on the 32-mesh sieve to obtain colored chips.

(Formation of Sheet) Of these colored chips, three types of white, black and green chips were blended in a ratio of 1: 1: 2, and ethylene containing 25% of methyl acrylate shown in Formula 4 was blended. To the methacrylic acid ester copolymer (EMA) resin, 3.0% by weight of this mixed colored chip was added and blended, and the mixture was fed from a hopper with a feeder to a uniaxial extruder with L / D = 25, and a coating having a width of 1200 mm was applied. Hanger die thickness 0.5
mm sheet was formed. The barrel temperature during molding is 130
Molding was performed at a temperature of 170 ° C and a die temperature of 165 ° C.

550 nm in the thickness direction of this sheet
At wavelength, the visible light transmittance was 83%.

The obtained sheet was excellent in transparency, and the colored chips in the form of fine particles were uniformly dispersed inside the sheet, and each chip was clearly visible.

EVA resin having a vinyl acetate content of 15% shown in Formulation 5 was calendered to form a green sheet having a thickness of 0.4 mm, which was used as an intermediate colored sheet layer.

The EVA resin shown in Formulation 6 was calendered in the same manner to form a sheet, a glass fiber base cloth was attached thereto, the intermediate colored sheet colored green was further adhered thereto, and the colored chips described above were further laminated thereon. The transparent sheets in which were dispersed were stuck together to form a thermoplastic resin floor material in which the colored chips were dispersed.

[0034]

[Table 1]

[0035]

[Table 2]

[0036]

According to the present invention, the transparency of the transparent portion in the thickness direction is 80 in terms of visible light transmittance at a wavelength of 550 nm.
% Or more, the melting temperature is higher than the processing temperature of the thermoplastic resin sheet, and the particle size is 0.1
A transparent surface sheet layer in which two or more colors of synthetic resin chips colored in an arbitrary color with a size of 1.0 mm are scattered, and a color corresponding to the color of the colored synthetic resin chips. By forming the intermediate colored sheet layer and the backing substrate sheet layer provided as the lowermost layer, the colored chips dispersed in the top, bottom, left, and right inside the surface transparent surface sheet layer are dispersed in fine particles. Despite the fine grain size,
The outline and color of each chip can be seen clearly, and the color of the intermediate colored sheet layer underneath can also be seen clearly, which makes the colored chips appear to be scattered and scattered, giving a very three-dimensional effect. Thus, it is possible to obtain a floor material having a grainy pattern with excellent design.

[Brief description of drawings]

FIG. 1 is a partially cutaway plan view of a flooring material of the present invention.

FIG. 2 Enlarged sectional view

[Explanation of symbols]

a is a transparent surface sheet layer, b is an intermediate colored sheet layer, c is a backing base sheet layer, 1 is a thermoplastic resin sheet, 2 is a synthetic resin colored chip, 2-1, 2-2, 2-3 are colors. Different chips, 3 is a wear resistant layer for protection

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Isao Hirayama 5-3 Higashi Nakanuki-cho, Tsuchiura-shi, Ibaraki Ronshiru Kogyo Co., Ltd. Technical Research Institute (56) Reference JP-A-2-207492 (JP, A) JP-A 1-235634 (JP, A) Actual development Sho 61-64194 (JP, U)

Claims (3)

(57) [Claims] 1. The transparency of the transparent portion in the thickness direction is 5
A thermoplastic resin sheet having a visible light transmittance of 80% or more at a wavelength of 50 nm formed by calendering or extrusion has a melting temperature higher than the processing temperature of the thermoplastic resin sheet and a particle size of 0.1. In the range of ~ 1.0 mm
2 synthetic resin chips of any size and colored in any color
Color or more, 1 for the thermoplastic resin sheet compound
Transparent surface sheet layers interspersed at a ratio of 10 to 10% by weight,
Thermoplastic resin flooring material having a grain pattern, which comprises an intermediate colored sheet layer colored in a color corresponding to the color of the colored synthetic resin chips and a backing base sheet layer provided in the lowermost layer. . 2. The thermoplastic resin composition according to claim 1, wherein 0.1 to 1.0 parts by weight of an antistatic agent is added to 100 parts by weight of the resin in the transparent topsheet layer. Resin floor material. 3. The thermoplastic resin flooring material according to claim 1, further comprising an abrasion resistant resin layer having a visible light transmittance of 80% or more at a wavelength of 550 nm on the transparent surface sheet layer.