JP3158100B2 - Synthetic resin flooring and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a synthetic resin flooring in which a synthetic resin foamed backing layer is laminated on the back surface of a surface decorative layer and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, synthetic resin flooring has been used as one of decorative materials for decorating floors of buildings.
Among the above-mentioned synthetic resin flooring materials, there are known synthetic resin flooring materials in which a synthetic resin foamed backing layer is laminated on the back surface of the surface decorative layer for the purpose of improving cushioning properties and imparting impact sound absorbing properties. Have been.

[0003]

When an olefin resin is used as the synthetic resin constituting the synthetic resin foamed backing layer as described above, a foam which satisfies the physical properties of the backing layer of the flooring material is obtained. However, there is a problem that appropriate equipment is required. In particular, a wide foam is required to be used as a backing layer of a synthetic resin flooring, but a large facility is required to obtain such a wide foam.
That is, when obtaining a foam of an olefin resin,
Generally, after the olefin resin is crosslinked, it undergoes a process of foaming. In this way, the physical properties as a backing layer of the flooring material are satisfied, and a wide foam is obtained. Requires precise management of manufacturing conditions and large-scale equipment.

[0004] The present invention has been made to solve the above problems, and requires a large-scale equipment even when an olefin resin is used as a synthetic resin for forming a foamed backing layer. The present invention provides a synthetic resin flooring formed with a synthetic resin foamed backing layer having no physical property and having suitable physical properties as a backing layer of the flooring material, and a method for producing the same.

[0005]

Means for Solving the Problems The synthetic resin flooring material of the present invention made to solve the above-mentioned problems is provided by a foamable synthetic resin comprising a synthetic resin composition containing a foaming agent on the back surface of a surface decorative layer. After forming the powder into a sheet by heating and pressing,
It has a synthetic resin foamed backing layer obtained by heating and foaming. Further, the method for producing a synthetic resin flooring material of the present invention includes the steps of: placing an expandable synthetic resin powder made of a synthetic resin composition containing a foaming agent on the back surface of the surface decorative layer; After the body is heated and pressed to form a sheet, the body is heated and foamed to form a synthetic resin foamed backing layer.

The decorative layer on the surface of the synthetic resin flooring material of the present invention is the same as the synthetic resin flooring material conventionally used. For example, a desired printing is performed on the surface of a colored synthetic resin layer or the like, and a synthetic resin chip or a transparent synthetic resin layer mixed with ceramic particles or the like is formed thereon, if necessary. It is generally formed by heating and pressurizing, and further forming a transparent synthetic resin layer as described above as necessary thereon, but the present invention is not limited to this.

The synthetic resin constituting the surface decorative layer is a synthetic resin conventionally used for forming a surface decorative layer of a flooring made of synthetic resin, specifically, a vinyl chloride resin, an olefin resin or the like. Resins, acrylic resins, synthetic resins selected from urethane resins, etc., or a mixture of two or more resins selected therefrom, among which vinyl chloride resins and olefin resins are common. . In forming the decorative surface layer in the synthetic resin flooring material of the present invention, it is also possible to use a paste sol such as a vinyl chloride resin, an acrylic resin or an emulsion of an ethylene-vinyl acetate copolymer. Needless to say.

Examples of the vinyl chloride resin include polyvinyl chloride, which is a homopolymer of vinyl chloride, and other monomers copolymerizable with vinyl chloride, such as ethylene, propylene, vinyl acetate, and (meth) acrylic. A copolymer with an acid ester, acrylonitrile, or the like, or a mixture thereof can be used.

Examples of the olefin resin include polyethylene such as low-density polyethylene, linear low-density polyethylene, ultra-low-density polyethylene, medium-density polyethylene, and high-density polyethylene; ethylene-vinyl acetate copolymer, ethylene-
(Meth) acrylic acid ester copolymer, ethylene-α-
Ethylene copolymers such as olefin copolymers; polypropylene (including random polypropylene which is a random copolymer of propylene and ethylene, and block polypropylene which is a block copolymer of propylene and ethylene); polybutene and butene-α- Resins selected from butene-based polymers such as olefin copolymers; crosslinked or non-crosslinked olefinic thermoplastic elastomers (TPO); and mixtures thereof, and the like can be used.

[0010] The above-mentioned synthetic resin may contain a plasticizer, a stabilizer, an antistatic agent, an antioxidant, a lubricant,
Various additives such as flame retardants, foaming agents, ultraviolet absorbers, light stabilizers such as hindered amine compounds, antibacterial and antifungal agents, deodorants, conductive materials such as carbon black and metal fibers, fillers, coloring agents, etc. Is added and molded by an appropriate means to form each of the synthetic resin layers constituting the surface decorative layer.

The surface decorative layer may have a fibrous base material at an arbitrary position, specifically, at one or more positions between the layers constituting the surface decorative layer or on the back surface. As the fibrous base material, those conventionally used as a base material for synthetic resin flooring materials, for example, natural animal or vegetable fibers such as cotton, hemp, silk, wool; polyester, polyamide, polyethylene , Polypropylene, acrylic,
Synthetic fiber such as vinylon; regenerated fiber such as rayon, suf, acetate, etc .; glass fiber; pulp; asbestos; rock wool; one or more fibers selected from the like, or, if necessary, an inorganic filler , A woven fabric, a knitted fabric, a nonwoven fabric, a paper, or a laminate thereof obtained from a mixture of a synthetic resin hinder and the like can be used.

A foamed backing layer made of synthetic resin is formed on the back of the surface decorative layer. In the synthetic resin flooring material of the present invention, a foaming agent and various additives are added to the above synthetic resin. It is formed using an expandable synthetic resin powder made of a synthetic resin composition to which is added. In addition, as a foaming agent blended in the above-mentioned foamable synthetic resin powder, a thermal decomposition type chemical foaming agent generally used conventionally, such as azodicarbonamide, can be used.

As a method for obtaining the above-mentioned foamable synthetic resin powder, for example, a synthetic resin composition obtained by adding a foaming agent and various additives to the above-mentioned synthetic resin is formed into pellets, which are pulverized. A method of forming a synthetic resin composition obtained by adding a foaming agent and various additives to a synthetic resin as described above, into a sheet, and pulverizing the sheet, and the like, but are not limited thereto. Absent. In addition, in order to pulverize what is formed into a pellet or the like, it may be pulverized at room temperature or may be pulverized as a frozen state, but on the surface of the synthetic resin powder obtained by pulverization, It is necessary to set the compounding of the synthetic resin composition and the pulverization conditions for obtaining the powder, taking care not to form countless whiskers. Countless whiskers formed on the surface of the synthetic resin powder are intertwined with each other, and when coating or spraying the synthetic resin powder as described later, the powder is uniformly coated or sprayed. You will not be able to do it.

The foamable synthetic resin powder is, for example,
On the back side of the surface decorative layer set so that the back side is on the production line, it is coated using a doctor knife coater or the like or sprayed using a sprayer as appropriate, and thus the surface decorative layer is The foamable synthetic resin powder placed by being coated or sprayed on the back surface is heated and pressed to form a sheet (the foamable synthetic resin powder is heated and pressed on the back surface of the decorative surface layer). The resulting synthetic resin layer is formed). Then, heated again, foamed the synthetic resin layer obtained by molding the foamable synthetic resin powder obtained as described above into a sheet, and by applying pressure again if necessary, A synthetic resin foam backing layer is formed.

In forming the synthetic resin foamed backing layer in the present invention, as described above, the foamable synthetic resin powder is directly coated or sprayed on the back surface of the surface decorative layer, and heated and pressed to form a sheet. Forming into a shape is easier than laminating a synthetic resin foam backing layer separately manufactured using a releasable carrier as described later in the post-process, and the process is simplified with the surface decorative layer. It is preferable because it has an excellent sense of unity with the resin foam backing layer.

Further, as described above, instead of directly coating or spraying the foamable synthetic resin powder on the back surface of the surface decorative layer, it is coated or sprayed on a release carrier such as release paper, and heated and dispersed. After forming into a sheet by pressing, or after heating and foaming the sheet, it may be laminated with the surface decorative layer. Of course, at this time, an appropriate adhesive can be used as needed. The release carrier is peeled off before or after lamination with the surface decorative layer.

The synthetic resin flooring and the method for producing the same according to the present invention use an expandable synthetic resin powder to form a synthetic resin foamed backing layer, and heat the expandable synthetic resin powder first. The most characteristic feature is that after pressurizing to form a sheet (forming a synthetic resin layer), it is heated again to foam it. Further, in this way, even if an olefin resin is used as the resin constituting the synthetic resin foam backing layer, no large-scale equipment is required, and the backing layer of the synthetic resin flooring material is used. This makes it possible to form a synthetic resin foam backing layer that can satisfy physical properties. If the foamable synthetic resin powder is coated or sprayed, then the foamable synthetic resin powder is foamed at the same time as heating and pressing, and then the synthetic resin foam backing layer is formed by applying pressure. The foam state of the foam backing layer becomes uneven,
A synthetic resin foamed backing layer that satisfies the physical properties of the backing layer of the synthetic resin flooring material cannot be formed.

Regarding the particle size of the foamable synthetic resin powder,
Although not particularly limited, generally, the average particle size is about 50 to 3000 μm, particularly 100 to 2000 μm.
m is desirable. Further, in the case of coating the expandable synthetic resin powder using a doctor knife coater or the like, the particle size of the expandable synthetic resin powder is too large, or the particle size of the expandable synthetic resin powder has a large variation. And it becomes difficult to coat uniformly,
In particular, it is desirable to use a powder having an average particle diameter of 2000 μm or less and containing no powder having a particle diameter exceeding 3000 μm.

The synthetic resin foam backing layer in the synthetic resin flooring material of the present invention may have a fibrous backing material on the back surface. As this fibrous backing material, the same material as the above-mentioned fibrous base material can be used. Means for laminating the fibrous backing material is to coat or scatter the fibrous backing material when heating or pressing the foamable synthetic resin powder coated or sprayed on the back surface of the surface decorative layer. , Placed on the heated foamable synthetic resin powder, pressurizing the foamable synthetic resin powder and simultaneously laminating the fibrous backing material, and then heating and foaming,
A method of laminating by using an appropriate adhesive or the like in a subsequent process can be adopted, but the process is simple, and a feeling of unity between the fibrous backing material and the layer made of the foamable synthetic resin powder is excellent. For this reason, it is desirable to heat and press the powder made of the expandable synthetic resin and to simultaneously laminate the fibrous backing material.

When a synthetic resin foamed backing layer having a fibrous backing material on the back surface is used, the synthetic resin constituting the synthetic resin foamed backing layer may be an olefin-based resin having poor adhesion. Even in this case, there is an advantage that excellent adhesiveness is maintained and workability on a floor surface is improved.

The synthetic resin flooring material of the present invention obtained as described above can be embossed on the surface as required, and can be used for gloss control, surface strength improvement, stain resistance and cigarette resistance. Surface treatment (including formation of a coating film with an ultraviolet curable paint, lamination of a transparent film, etc.) for the purpose of imparting properties can also be performed.

[0022]

EXAMPLES Specific examples will be given below, but the synthetic resin flooring material of the present invention is not limited to the following examples.

A wood pattern is printed on the surface of the polyester nonwoven fabric using a gravure printing machine, and then an ethylene-methyl methacrylate copolymer powder (30 mesh passing) is sprayed and sintered to form a transparent top layer. Then, the surface was embossed to obtain a surface decorative layer.

Next, an expandable synthetic resin powder having the composition shown in Table 1 and having the average particle size shown in Table 2 was coated on the back surface of the surface decorative layer obtained as described above with a doctor knife coater. After heating and pressing the coated foamable synthetic resin powder and forming it into a sheet, or without heating and pressing (as shown in Table 2 with or without heating and pressing), heat and foam the powder. Then, pressure was applied again to form a synthetic resin foamed backing layer to obtain a synthetic resin floor material. About the obtained synthetic resin flooring material, the coating suitability of the expandable synthetic resin powder and the foaming state of the synthetic resin foam backing layer were evaluated based on the following criteria. The results are shown in Table 2.

[Evaluation Criteria] (1) Suitability of coating of foamable synthetic resin powder ○: Good coating suitability Δ: Slightly difficult to coat uniformly ×: Uniform coating practically impossible (2) ) Foaming state of synthetic resin foam backing layer ○: Uniform foaming, extremely good condition △: Slight foaming unevenness, but no hindrance to commercialization ×: Notable foaming unevenness, synthetic resin floor Not suitable as a backing layer for wood

[0026]

[Table 1]

[0027]

[Table 2]

The above Test Example A was conducted except that after heating the foamable synthetic resin powder coated on the back of the surface decorative layer, a polyester nonwoven fabric as a fibrous backing material was placed thereon, and then pressurized. , C, E, and F, synthetic resin flooring materials (Test Examples a, c, e, and f) were obtained.
The obtained synthetic resin flooring material had excellent workability on the floor surface as compared with Test Examples A, C, E and F.

[0029]

As described above, the synthetic resin flooring of the present invention does not require a large-scale facility, even if an olefin resin is used as the resin constituting the synthetic resin foamed backing layer. The synthetic resin foam backing layer thus obtained can satisfy the physical properties of the synthetic resin flooring material as the backing layer. Of course, the above configuration of the synthetic resin flooring material of the present invention is applicable even when a synthetic resin other than an olefin resin such as a vinyl chloride resin is used.

When the method of coating or spraying the foamable synthetic resin powder directly on the back surface of the decorative surface layer (ie, the manufacturing method of the present invention) is adopted as the manufacturing method, the manufacturing process is simplified. In addition, a flooring material excellent in a sense of unity between the surface decorative layer and the synthetic resin foam backing layer can be obtained.

Claims (5)

(57) [Claims] 1. A synthetic resin flooring material having a surface decorative layer and a synthetic resin foam backing layer laminated on the back surface thereof, wherein the synthetic resin foam backing layer comprises a synthetic resin composition containing a foaming agent. A synthetic resin flooring, which is a layer obtained by heating and pressing a foamable synthetic resin powder to form a sheet, followed by heating and foaming. 2. The synthetic resin flooring according to claim 1, wherein the synthetic resin constituting the synthetic resin foam backing layer is an olefin resin. 3. The synthetic resin flooring material according to claim 1, wherein the synthetic resin foamed backing layer has a fibrous backing material laminated on the back surface thereof. 4. A foamable synthetic resin powder comprising a synthetic resin composition containing a foaming agent is placed on the back surface of the surface decorative layer,
A method for producing a synthetic resin flooring, characterized in that the foamable synthetic resin powder is heated and pressed to form a sheet, and then heated and foamed to form a synthetic resin foamed backing layer. 5. The composition according to claim 4, which is placed on the back surface of the surface decorative layer and pressed into a sheet while the fibrous backing material is placed on the heated foamable synthetic resin powder. Manufacturing method of resin flooring.