JP3366162B2 - Floor material - 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 used in a house or the like, and more particularly to a floor material suitable for being laid on a concrete floor surface of a condominium or the like.

[0002]

2. Description of the Related Art In the case of using a carpet as a floor material, since the carpet causes generation of mites, in recent years, a wooden floor material has been often used.

The wooden floor material is generally made by printing grain on the surface of a plywood having a thickness of about 10 mm, or by adhering a veneer made by thinly slicing a good quality wood on the plywood to further improve the resistance. It is formed by applying a ceramic coating for enhancing wear resistance.

However, in concrete structures such as condominiums, the floor material is usually laid directly on the concrete on the floor surface. However, on a floor made of concrete, waviness and unevenness are often generated on the surface. On the other hand, since the above wooden floor material is formed as a whole as a flat surface, it becomes difficult to reliably align the floor material with the floor surface when the undulations and irregularities of the floor surface are large, and it cannot be installed if it is extremely There was even a thing.

In order to solve the above problems, in Japanese Patent Laid-Open No. 5-230984, a large number of cracks are formed on the back surface of a wooden floor material, thereby increasing the flexibility and adapting to a concrete floor surface. It has been proposed to improve the structure. According to this structure, even if there are undulations and irregularities on the floor surface, since the flexibility is enhanced by the cracks, it is possible to reliably follow the wooden floor material to the concrete floor surface. .

[0006] However, there is a problem in that it is necessary to process a large number of cracks on the back surface of the wooden floor material as described above, and therefore the manufacturing process of the floor material becomes complicated. Further, in recent years, natural destruction due to felling of wood has become a problem, and it is desired to reduce the amount of plywood used. Therefore, it has been considered that only the surface phase is made of plywood, and the inside and the back side are made of alternative materials such as synthetic resin materials other than wood. However,
When using the above-mentioned alternative materials for the floor material, from the viewpoint of workability, a material having a weight equal to or less than that of wood is strongly required. Therefore, styrofoam and rigid urethane foam have been studied as alternative materials.

However, when the surface phase made of plywood is laminated on the Styrofoam and it is attempted to be integrated by adhesion, there is a problem that the Styrofoam will be melted if a solvent-based adhesive is used. Further, the styrofoam has a defect that it has poor machinability (difficulty in cutting with high precision), and thus it has hardly been actually used.

On the other hand, foamed hard urethane has poor water resistance, and therefore has a problem that it is deteriorated by moisture gradually generated from concrete. In addition, the foamed hard urethane has a drawback that the end portion is easily broken into powder.
Therefore, foamed hard urethane has hardly been used as the alternative material.

[0009]

An object of the present invention is a flooring material using an alternative material in place of the above-mentioned woody material, which is excellent in flexibility, lightweight property, machinability, solvent resistance and water resistance. To provide floor material.

[0010]

Means for Solving the Problems The present invention has been made to achieve the above objects, and is a relatively highly crosslinked polyolefin-based resin material and a low-crosslinked or non-crosslinked polyolefin-based resin. Granules consisting of a mixture with materials are heated and foamed, and the granules are melted with each other.
And wearing is not formed by a plate-like foam, which is laminated on the plate-like foam, a floor material, characterized in that it comprises a rigid hard plate-shaped body than the plate-like foam.

Further, in the floor material of the present invention, preferably, as described in claim 2, a decorative sheet material is further laminated on the surface of the hard plate material. Hereinafter, the details of the present invention will be described.

Polyolefin Resin Material As described above, according to the present invention, two kinds of polyolefin resins, that is, a relatively highly crosslinked polyolefin resin material and a low or non-crosslinked polyolefin resin material are used. . The two types of polyolefin resins are not particularly limited as long as they can be foamed, and examples thereof include low density polyethylene (LD), linear low density polyethylene (LLD), medium density polyeletin (MD), and high density polyethylene. (HD), random polypropylene, homopolypropylene, block polypropylene and the like can be used.

Of the above two types of polyolefin resin materials, one is a highly crosslinked resin material as described above,
The other is a low-crosslinking or non-crosslinking resin material. The high cross-linking and the low cross-linking are relative ones determined by the degree of cross-linking of both. In the following, regarding the composition of the above two types of crosslinked resins, one is referred to as a highly crosslinked resin composition and the other is referred to as a low crosslinked or non-crosslinked resin composition.

In the present invention, two kinds of resins having different degrees of crosslinking as described above are used. By mixing a low-crosslinking or non-crosslinking polyolefin resin, the fluidity at the time of foaming is increased to form a foam. This is because it is easy to form into a sheet.

That is, in order to improve the moldability of the foam, a low-crosslinking or non-crosslinking polyolefin resin material is mixed with the above-mentioned highly crosslinked polyolefin resin material.

(Solubility of Resin) It is desirable that the difference between the solubility parameters of the polyolefin resins used in the above two resin compositions is within a specific range. Ie 2
If the difference in the solubility parameter of the polyolefin resin of the type is too large, each resin component is dispersed very coarsely,
The expansion ratio of the plate-shaped foam tends to decrease. On the other hand, if the difference in the solubility parameter is too small, the compatibility of the two kinds of resins becomes too high, and the compatibility becomes close to a single component system, and the degree of freedom in shape at the time of foaming decreases. Therefore, in order to form a uniform and fine mixed phase in the plate-like foam, the difference in solubility parameter between the two types of polyolefin-based resins is preferably 0.1 to 2.0, 2 to 1.5
It is more preferable that the range is

The above solubility parameter is

[0018]

[Equation 1]

The value obtained by the above is referred to. In the above formula, ρ is the density of the resin component, M is the molecular weight of the monomer constituting the resin component, and Fi is the molar attraction constant of the group constituting the monomer.

(Melt Index) If the difference in the melt index (MI) between the above-mentioned two types of polyolefin resins is too large, the highly crosslinked resin composition and the low crosslinked or non-crosslinked resin composition are very coarsely dispersed, resulting in plate-like foaming. The foaming ratio of the body tends to decrease. Further, if the difference in MI between the two types of polyolefin-based resins is too small, the compatibility of the two types of resins becomes high, and it is not possible to form a high-crosslinked resin composition and a low-crosslinked or non-crosslinked resin composition. It becomes close to a one-component system, and the degree of freedom in shape during foaming decreases.

Therefore, the difference in MI between the above-mentioned two types of polyolefin resins is preferably in the range of 3 to 15 g / 10 minutes, and the highly cross-linked resin composition and the low-crosslinked or non-crosslinked resin composition are finely and uniformly mixed. 5 to 13 from the viewpoint that a phase can be realized and foaming can be performed at a high expansion ratio.
g / 10 minutes is more preferable, and 7-11 g / 10 minutes is even more preferable. The melt index (MI) in this specification means a value measured according to JIS K7210.

(Mixing Ratio of Polyolefin Resin) Regarding the mixing ratio of the above-mentioned two kinds of polyolefin resins, the highly crosslinked resin composition and the low crosslinked or non-crosslinked resin composition are uniformly dispersed, and the surface smoothness is excellent. In order to obtain a foam, it is desirable to mix the highly crosslinked resin composition and the lowly crosslinked or non-crosslinked resin composition in a weight ratio of 2: 8 to 8: 2, preferably 4: 6 to. 6: 4 is more preferable, and 5: 5 is even more preferable.

(Foaming Agent) In the present invention, a plate-like foam made of a mixed phase of the above-mentioned two kinds of polyolefin resin materials is used. In obtaining the plate-like foam, a pyrolytic foam is used as a foaming agent. Agents can be used. The thermal decomposition type foaming agent is not particularly limited as long as it has a decomposition temperature higher than the melting temperature of the polyolefin resin used, and examples thereof include sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, azide compound, and borohydride. Inorganic thermal decomposition type foaming agents such as sodium fluoride; azodicarbonamide, azobisisobutyronitrile, N, N'-dinitrosopentamethylenetetramine, P, P'-dinitrosopentamethylenetetramine, P, P'- Oxybisbenzenesulfonyl hydrazide, barium azodicarboxylate, trihydrazinotriazine and the like,
It is preferable to use azodicarbonamide, which is easy to adjust the decomposition temperature and decomposition rate, produces a large amount of gas, and is excellent in hygiene.

If the amount of the thermal decomposition type foaming agent added is too large,
Cell breakage may progress and uniform cells may not be formed. If the amount is too small, sufficient foaming may not be achieved. Therefore, the total resin content of the above-mentioned two types of polyolefin-based resin materials is 100 parts by weight. The thermal decomposition foaming agent is preferably used in the range of 1 to 25 parts by weight.

(Method for producing expandable resin) The method for producing the expandable resin used for producing the above-mentioned plate-like foam in the present invention is not particularly limited. For example, a plurality of types of polyolefin-based resin, a thermal decomposition type foaming agent, as well as supplying a coloring agent and the like added as necessary to the extruder, after melt-kneading at a temperature lower than the decomposition temperature of the thermal decomposition type foaming agent, A foamable resin can be obtained by extrusion and cooling.

The shape of the foamable resin may be any suitable shape such as a sheet shape or a granular shape. In the case of forming a sheet, it may be extruded with a sheet die and cooled. Further, in the case of granulating, a sheet made of a foamable resin may be obtained, and then the sheet may be cut to produce granules, or the foamable resin may be extruded in a strand shape and then cooled and cut. You may obtain a granular material by doing so.

When the expandable resin is made into a granular material, its shape is not particularly limited, and for example, it can be an appropriate shape such as a hexagon, a cylinder or a spherical body. In order to make it hard to roll, it is preferable that the outer surface is composed of only a flat surface such as a hexagonal shape, as compared with a curved surface such as a cylinder or a spherical shape.

When the granular material is hexagonal, the length of one side of the hexagonal is not particularly limited, but it is preferably 1 mm to 50 mm and 3 mm in order to improve the handleability after spraying.
A range of up to 20 mm is particularly preferred. The size of the granular material before foaming does not necessarily have to be uniform, and may be non-uniform.

(Method for preparing a mixture of plural kinds of polyolefin resins having different degrees of cross-linking) As a method for preparing a mixture of a highly cross-linked resin composition and a low cross-linked or non-cross-linked resin composition having almost no compatibility, A method of mixing different types of resins and preferentially crosslinking one resin component, a method of crosslinking using radiation, a method of crosslinking using a peroxide, and the like can be used.

As a method of preferentially crosslinking only one resin component, for example, only one resin component (a) or the other resin component (b) is preferentially crosslinked to the resin component (a). Method of crosslinking using a crosslinking agent, in the first step, a crosslinkable resin component (c) of the same type as the resin component (a) having a crosslinkable functional group is mixed with the resin component (a) and crosslinked, After forming the highly crosslinked resin composition, in the second stage,
Examples thereof include a method of mixing the resin component (b).

However, the resin components (a) and (b) having a fine and uniform particle size can be formed, the resin component (a) can be preferentially crosslinked, and the resin constituting the foam can be easily prepared. From the standpoint of the ability to form the resin component (a), the resin has the same melt index as that of the resin component (a), has a crosslinkable functional group, and has the same crosslinkable resin component (c) as the resin component (a). Most preferred is a method in which the components (a) and (b) are mixed and then crosslinked.

The resin component (a) has almost the same melt index as that of the resin component (a) and has a crosslinkable functional group. Further, the same crosslinkable resin (c) as the resin component (a) has a reactive functional group. It is not particularly limited as long as it is a resin which has and can crosslink the above polyolefin-based resin, and examples of the crosslinkable resin (c) include unsaturated groups such as vinyl group, allyl group and propylene group, and hydroxyl group. , Carboxyl group,
The above-mentioned polyolefin resin having an epoxy group, an amino group, a silanol group, a silanate group and the like can be mentioned.

Specific examples of the crosslinkable resin (c) include:
Examples thereof include maleic acid-modified polyethylene, maleic acid-modified polypropylene, silane-modified polyethylene, silane-modified polypropylene and the like.

It is easy to preferentially crosslink the resin component (a) alone or to the resin component (a) over the resin component (b), and it is easy to crosslink after mixing. The crosslinkable resin (c) is preferably silane-modified polyethylene or silane-modified polypropylene.

If the difference in melt index between the resin component (a) and the crosslinkable resin (c) is too large, the resin component (a)
It is difficult to preferentially crosslink the resin component (a) over the resin component (b) alone or the resin component (b), and therefore the difference in the melt index is preferably 2 g / 10 min or less, and 1 g / 10 min. The following is more preferable.

The cross-linking method using the cross-linkable resin (c) may be a cross-linking method using an isocyanate, a cross-linking method using an amine, a water-crosslinking method after hydrolyzing a reactive functional group, and the like. Among them, the method of hydrolyzing the reactive functional group and then water-crosslinking is most preferable because crosslinking after mixing is easy.

The unsaturated silane compound used for the silane modification is generally

[0038]

[Chemical 1]

It is represented by In the above formula (1), R is an alkenyl group such as a vinyl group, an allyl group, a propenyl group and a cyclohexenyl group; a glycidyl group; an amino group; a methacryl group; a γ-chloroethyl group,
Organic functional groups such as halogenated alkyl groups such as γ-bromoethyl group, R ′ is an aliphatic saturated hydrocarbon group such as methyl group, ethyl group, propyl group and decyl group, and Y
Is a hydrolyzable organic functional group such as a methoxy group, an ethoxy group, a formyloxy group, a propionoxyarylamino group, and n is 0, 1 or 2.

Since the cross-linking reaction is fast, especially CH ₂ =
CHSi (OA) ₃ (where A is an aliphatic saturated hydrocarbon group having 1 to 8 carbon atoms, preferably 1 to 4 carbon atoms) is preferable,
For example, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriacetoxysilane and the like can be mentioned.

As a method for producing the silane graft polymer such as the above-mentioned silane-modified polyethylene or silane-modified polypropylene, a general method can be used and is not particularly limited. For example, polyethylene, RR '
SiY ₂ (In the formula, R is an olefinically unsaturated monovalent hydrocarbon group or a hydrocarbonoxy group,
Each Y is a hydrolyzable organic group and R ′ is R or Y. ) And an organic peroxide are reacted to obtain a silane-modified polyethylene.

The silane graft polymer having a silyl group, for example, when Y is a methoxy group, is hydrolyzed by contact with water to form a hydroxyl group, and hydroxyl groups of different molecules react with each other to form Si- O-Si bonds are formed, and the silane graft polymers are crosslinked with each other.

The method for adding the silane graft polymer is as follows.
The method is not particularly limited as long as it can be added uniformly. For example, a method of supplying the above-mentioned polyolefin resin and silane graft polymer to a uniaxial or biaxial extruder and melt-kneading, a method of melt-kneading using a roll, a method of melt-kneading using a kneader and the like can be mentioned. .

The water treatment method includes a method of immersing in water and a method of exposing to water vapor.
When the treatment is performed at a temperature higher than 0 ° C., it is preferable to perform it under pressure.

When the temperature of water and water vapor during the water treatment is low, the crosslinking reaction rate is low, and when the temperature is too high, the particles are fused to each other. Therefore, the temperature of the water and steam is 50 to 13
The range of 0 ° C is preferable, and the range of 90 to 120 ° C is particularly preferable.

If the time for water treatment is short, the crosslinking reaction may not proceed completely, and if it is too long, the particles will fuse to each other. Therefore, the time for water treatment may be in the range of 5 minutes to 12 hours. preferable.

If the amount of the above-mentioned silane graft polymer added is too large, crosslinking will take place too much, and the expansion ratio of the resulting foam will be reduced. If it is too small, the cells will be broken and uniform cells cannot be obtained. Therefore, the addition amount of the silane graft polymer is preferably 5 to 50 parts by weight with respect to 100 parts by weight of the resin component of the highly crosslinkable polyolefin resin, and 20
Especially preferred is ˜35 parts by weight.

If necessary, a silane cross-linking catalyst may be added. The silane cross-linking catalyst may be one that promotes a cross-linking reaction between silane graft polymers,
For example, dibutyltin diacetate, dibutyltin dilaurate, dioctyltin dilaurate, tin octoate, tin oleate, lead octoate, zinc 2-ethylhexane, cobalt octoate, lead naphthenate, zinc acrylate, zinc stearate, etc. Can be mentioned.

If the amount of the silane crosslinking catalyst added is too large, the foaming ratio of the resulting foam will decrease, and if it is too small, the crosslinking reaction rate will decrease and the water treatment will take time. Therefore, when the silane crosslinking catalyst is added, the addition amount thereof is 0.0 with respect to 100 parts by weight of the highly crosslinkable polyolefin resin.
The range of 01 to 10 parts by weight is preferable, and 0.01 to 0.1
Part by weight is especially preferred.

In the present invention, in obtaining the two types of polyolefin resins having different degrees of crosslinking, crosslinking may be performed using radiation. The method of cross-linking using radiation can be applied to the case of using a granular material composed of two kinds of resins, a resin that cross-links and a resin that decomposes when irradiated with radiation. The radiation-crosslinkable resin may be a polyethylene resin, and the degradable resin may be a polypropylene resin.

If the irradiation amount of radiation is too large, the crosslinking may be too much and the expansion ratio of the resulting foam may be lowered. If it is too small, the cells may be broken and uniform cells cannot be obtained. . Therefore, the radiation dose is 1 to 20 Mr.
Ad is preferable and 3 to 10 Mrad is particularly preferable.

The method of irradiating with radiation is not particularly limited, and examples thereof include a method of using two electron beam generators, passing a resin between them, and irradiating the resin with an electron beam. .

In the present invention, the method of crosslinking with a peroxide is
It can be applied only when two types of granular materials, a resin that is crosslinked by a peroxide and a resin that is decomposed, are used. Examples of the resin that can be crosslinked with a peroxide include polyethylene resin, and examples of the resin that decomposes include polypropylene resin.

The peroxide used in this method is not particularly limited, and examples thereof include dibutyl peroxide, dicumyl peroxide, tertiary butyl cumyl peroxide and diisopropyl peroxide. Peroxide and tertiary butyl cumyl peroxide are preferable, and dicumyl peroxide is particularly preferable.

If the amount of the peroxide added is too large, the crosslinking will proceed excessively and the foaming ratio of the resulting foam will decrease, and if it is too small, the crosslinking of the resin will be insufficient. Therefore, the amount of the peroxide added is preferably 0.5 to 5 parts by weight, more preferably 1 to 3 parts by weight, based on 100 parts by weight of the resin.

(Gel Fraction of Resin After Crosslinking) In the present invention, when the degree of crosslinking of the highly crosslinked resin composition is high, crosslinking is too much, and the foaming ratio of the resulting foam is lowered, and when it is too low, the cells at the time of foaming However, the cells are broken and a uniform cell cannot be obtained. Therefore, the gel fraction, which is an index of the degree of crosslinking in the highly crosslinked resin composition, is preferably 5 to 40% by weight, and more preferably 10 to 30% by weight.

In the low-crosslinked or non-crosslinked resin composition,
When the degree of cross-linking of the low cross-linking resin composition is high, cross-linking is too much,
Since the fluidity of the obtained foam is lowered, it becomes difficult to form it into a sheet, and the surface smoothness of the foam is lowered, so that the gel fraction which is an index of the degree of crosslinking is preferably 5% by weight or less. It is more preferably less than or equal to wt%.

The gel fraction in the present specification means the weight percentage of the residue weight after immersion of the crosslinked resin component in xylene at 120 ° C. for 24 hours with respect to the weight of the crosslinked resin component before immersion in xylene. .

(Foaming Method) The method for producing the plate-shaped foam used in the present invention is not particularly limited, and for example, (a) a sheet-shaped foamable resin is supplied and heated / foamed, Alternatively, (b) a method may be mentioned in which granules made of a foamable resin are dispersed, heated and foamed, and the granules are heat-sealed to each other to form a sheet-shaped foamed molded article.

In the latter method (b) using the expandable resin particles, the expandable resin particles are dispersed substantially uniformly in order to prevent the expansion ratio of the obtained foam from becoming partially uneven. It is preferable.

If the expansion ratio of the plate-shaped foam according to the present invention is too low, the foam has high strength and poor flexibility. Further, if the expansion ratio is too high, it is likely to break. Therefore, the expansion ratio of the plate-like foam is preferably 5 to 30 times, more preferably 7 to 15 times.

A specific method of foaming the above-mentioned (a) sheet-like foamable resin will be described. That is, the method of foaming the sheet-shaped foamable resin is not particularly limited, and for example, the sheet-shaped foamable resin is supplied between two plate-shaped bodies to keep the distance between the plate-shaped bodies constant. Foaming method, a sheet-like foamable resin is sandwiched between two plate-like bodies, and then the sheet-like foaming resin is expanded while increasing the distance between the plate-like bodies to a certain length. A method may be mentioned in which the resin is sandwiched between two plate-shaped bodies and then heated, and the foaming pressure at the time of foaming is used to increase the distance between the plate-shaped bodies to a certain length.

Further, (b) in the method for obtaining a sheet-shaped foamed molded article by using the granular material made of the expandable resin, first, the granular material made of the expandable resin is dispersed substantially uniformly. In this case, the method of substantially uniformly distributing the particles is not particularly limited, and a plurality of rectangular parallelepiped particles A and B having the minimum sides of the particles having substantially the same height are dispersed, and high frequency vibration is performed. To form a single layer by rolling so that the minimum side is aligned with the thickness direction, a method of spraying cubic particles having almost the same height and applying high frequency vibration to form a single layer, or A method in which a plurality of cubic particles having substantially the same height and scattered together are made into a single layer by using a coater or the like can be preferably used, but in some cases, the particles have substantially the same height. A method of arranging individual particles so that they do not overlap each other can also be adopted.

If the ratio of the sum of the actual dispersion areas of the granular material made of the expandable resin to the area of the portion surrounded by the outer edge of the entire dispersion area is too high, air bubbles are entrained during foaming,
Voids are generated in the foam, and if it is too small, holes are formed in the foam, so 10 to 60% is preferable, and 12 to 45% is particularly preferable.

The term "substantially the same height" in the above description of the granular material in the present specification does not mean that the particles have substantially the same size but that they have substantially the same size. Further, the above-mentioned height means a dimension in a direction orthogonal to a spraying surface of each granular material which is oriented when the granular material is sprayed.

The method for heating the granular material made of the expandable resin is not particularly limited as long as it can be heated to the decomposition temperature of the above-mentioned thermal decomposition type foaming agent or higher. For example, electric heater, far infrared heater,
A method of heating using a heating device that circulates a heating medium such as heated oil or air can be used.

The method of foaming and fusing the granular material made of the expandable resin is not particularly limited, and for example, the granular material may be dispersed between two plate-shaped bodies so that the space between the plate-shaped bodies is increased. A method of foaming while holding it constant, a method of spraying granules, sandwiching them between two plate-like bodies, and then expanding them while increasing the distance between the plate-like bodies to a certain length, or granules After spraying and sandwiching it between the two plate-shaped bodies, a method of increasing the distance between the plate-shaped bodies to a certain length by utilizing the foaming pressure when the granular material foams can be used. .

At the time of molding the plate-like foam of the present invention, glass paper, a sheet-like product or expandable resin granules made of the above-mentioned expandable resin, glass paper,
By supplying a reinforcing material such as a chopped strand mat, a sheet made of a thermoplastic resin or a thermosetting resin, a fiber reinforced thermoplastic resin sheet, or a sheet made of a metal, the strength of the obtained floor material can be more effectively improved. If a sheet having a cushioning property such as a non-woven fabric is supplied in the same manner as the above-mentioned reinforcing material, the flexibility of the floor material can be increased, and the familiarity with the concrete floor surface can be further improved. it can.

That is, according to the application, a hard plate-like body,
An appropriate reinforcing material, cushioning material, or the like can be interposed between the plate-like foam and the supply of these materials.
As described above, it can be achieved simultaneously with the lamination with the hard plate in the step of forming the plate foam.

Hard Plate In the present invention, a hard plate is laminated on the plate foam. The hard plate-shaped body functions as a layer that disperses the load. When the floor material is constructed using only the above-mentioned plate-shaped foam, if a large load is locally applied by the feet of a chair or the feet of a piano, when the load is removed, a depression due to the large load is generated. It may not recover, that is, permanent set may occur. Therefore, in order to disperse such a load, hard plate-shaped bodies are laminated.

As the material that can be used to form the hard plate-like material, any material can be used as long as it is harder than the plate-like foam and can disperse the load, and examples thereof include plywood, resin plate and fiber. A reinforced synthetic resin (FRP) board etc. can be mentioned.

As the plywood, those conventionally used for floor materials can be used, but in the present invention,
Since the above-mentioned plate-like foam is used, the plywood that can be used as the hard plate-like member may be as thin as about 1 to 4 mm, and therefore the amount of wood material used can be extremely reduced.

As the resin plate, a plate made of so-called hard resin such as polypropylene plate, polyethylene plate or vinyl chloride plate is preferably used. Further, as the FRP plate, a thermosetting polyester resin plate reinforced with glass fiber, reinforced with glass fiber, and 2 to
It is possible to use a hard urethane plate that has been foamed about three times, or a vinyl chloride plate reinforced with glass fibers.

The thickness of the hard plate-like body is determined by the required strength. If it is too thin, the strength will be insufficient, and if it is too thick, the thickness of the plate-like foam will be relatively thin and will not serve its intended purpose. . Therefore, the thickness of the hard plate varies depending on the strength of the material, but is generally 1 to 4 mm.
It is appropriate to set the degree.

The hard plate-like body can be integrated with the plate-like foam by laminating it with an adhesive or a pressure-sensitive adhesive. Examples of the adhesive include vinyl acetate emulsion (for example, Sekisui Chemical Co., Ltd., trade name: Esdyne # 6354), acrylic adhesive (for example, Sekisui Chemical Co., Ltd., trade name: Esdyne # 7850), chloroprene-based adhesive. An adhesive (for example, Sekisui Chemical Co., Ltd., trade name: Esdyne # 280L) can be used.

(Surface decoration) On the surface of the hard plate,
In order to improve the design, it may be decorated by printing a wood grain pattern, a marble pattern, a granite pattern, or the like.

(Decorative Sheet-like Material) Further, in order to decorate the surface, a decorative sheet-like material for enhancing the design is further provided on the surface of the hard plate-like article as in the invention of claim 2. You may laminate. As the decorative sheet material, a synthetic resin sheet on which a wood grain pattern, a marble pattern, a granite pattern or the like is printed, for example, a vinyl chloride sheet or the like can be used. Alternatively, a "veneer" formed by slicing generally commercially available wood may be adhered to the surface of the hard plate as a decorative sheet.

As the adhesive or pressure-sensitive adhesive for adhering the decorative sheet-like material to the hard plate-like material, a commonly used acrylic adhesive or natural or synthetic rubber adhesive can be used. .

(Surface coating) In the flooring material of the present invention, the surface (the surface of a hard plate or a decorative sheet) is added in order to enhance the abrasion resistance of the surface and develop a color luster, if necessary. When the sheet-like article is further laminated, a coating may be applied on the surface of the decorative sheet article. As such a coating method, a method generally called a ceramic coating can be adopted, whereby the abrasion resistance of the surface can be enhanced. The ceramic coating can be performed by applying a coating material such as acrylic silicon-based material, acrylic urethane-based material, or alkyl silicate-based material containing an alkyl group having 10 or less carbon atoms, which contains inorganic fine particles such as colloidal silica, and then dried.

In the flooring material of the present invention, a soundproof sheet made of rubber, non-woven fabric, foamed resin sheet or the like having excellent sound insulation may be interposed between the layers to enhance the soundproof performance. Is possible and preferable. In this case, the soundproof sheet may be interposed between the plate-like foam and the hard plate-like body, or may be provided between the hard plate-like body and the decorative sheet-like product provided as necessary. Good.

Action In the flooring material of the present invention, as described above, the plate-like foamed body obtained by mixing two kinds of polyolefin resins having different degrees of crosslinking is used. Therefore, in this plate-like foam, since the low-crosslinking or non-crosslinking polyolefin resin is dispersed, the fluidity at the time of foaming is enhanced as compared with the foam obtained by uniformly crosslinking the whole, Easy to form into a plate.

In addition, since the obtained plate-like foam is made of a polyolefin resin, it is excellent in solvent resistance and water resistance, and is also excellent in machinability as compared with expanded polystyrene and expanded rigid urethane.

Further, since the plate-shaped foam is a foam having a large number of cells, it has sufficient flexibility to absorb the undulations and irregularities of the concrete surface, and therefore, does not form cracks or the like. , A smooth floor finish can be constructed.

[0084]

EXAMPLES The present invention will be clarified by describing examples of the present invention. (Example 1)

Production of Plate Foam A resin for forming the plate foam was prepared in the following manner. High-density polyethylene (Mitsubishi Chemical Co., trade name: EY4
OH, melt index (MI) = 1.5 g / 10
Min) 50 parts by weight and polypropylene (manufactured by Mitsubishi Chemical Co.,
Product name: MA3, MI = 11 g / 10 min) 50 parts by weight and crosslinkable silane-modified polypropylene (Mitsubishi Chemical Co., trade name: XPM800H, MI = 11 g / 10 min,
20% by weight of gel fraction after crosslinking (60% by weight),
0.1 part by weight of dibutyl tin laurate as a crosslinking catalyst, 2 parts by weight of azodicarbonamide (trade name: SO20, manufactured by Otsuka Chemical Co., decomposition temperature 210 ° C.) as a foaming agent, and a brown pigment (Sumika Chemical Co., Ltd.) Color composition, product name: PR912) 2 parts by weight is supplied to a twin-screw extruder having a diameter of 30 mm, melt-kneaded at 180 ° C., and a sheet having a thickness of 2.5 mm and a width of 300 mm. After extruding, the mixture was cooled, cut into a width of 5 mm and a length of 5 mm, immersed in water at 98 ° C. for 2 hours, and then dried to obtain a foamable resin particle.

The expandable resin granules thus obtained were formed into a sheet of fluorinated ethylene resin at a rate of 900 g / m ² ,
Disperse so that the sum of the actual projected areas of the particulate matter is 25% of the total projected area of the area surrounded by the outer periphery of the portion where the particulate matter is dispersed, and the dispersed particulate matter is fluorinated ethylene oxide. A second sheet made of resin is overlaid, sandwiched between a pair of hot plates at 210 ° C., heated for 10 minutes, foamed, and then transferred to a cooling press at 30 ° C., and a sheet made of fluorinated ethylene resin 2 via a spacer. The thickness of the material excluding the thickness of the sheet is 9 mm
And cooled for 10 minutes to obtain a plate-like foam having a thickness of 9 mm.

Preparation of Floor Material The plate-like foam obtained as described above was added to the plate-like foam as a hard plate by thermosetting hard urethane foam (reinforced by Sekisui Chemical Co., Ltd., trade name: NeoLumber). FFU) processed into a thickness of 3 mm was bonded using a chloroprene adhesive (manufactured by Sekisui Chemical Co., Ltd., trade name: Esdyne # 280L). Adhesion is 100 g / m each on both sides of the adhesion interface.
^The above chloroprene-based adhesive was applied at a ratio of ² , the bonded portion was dried at room temperature for about 15 minutes, and then pressure-bonded with a roll.

Further, a veneer (Kinpara Co., Ltd., zelkova grain, 0.3 mm thickness) was adhered to the surface of the hard plate using an adhesive made of vinyl acetate emulsion. At the time of adhesion, an adhesive consisting of vinyl acetate emulsion is applied to the surface of the hard plate at a rate of 100 g / m ² ,
After that, the above-mentioned veneer plates were stacked and pressure-bonded using a roll. The floor material of Example 1 was produced as described above.

(Example 2) Preparation of plate-like foam First, a foaming resin for forming the plate-like foam was prepared by the following procedure. High-density polyethylene (trade name: JY2, manufactured by Mitsubishi Chemical Corporation)
0, MI = 9 g / 10 minutes) and 50 parts by weight of linear low-density polyethylene (manufactured by Mitsubishi Chemical Corporation, trade name: F30H, M
I = 2 g / 10 minutes) 50 parts by weight and crosslinkable silane-modified polyethylene (manufactured by Mitsubishi Chemical Co., trade name: HM600A,
MI = 10 g / 10 minutes, gel fraction after crosslinking 50% by weight)
10 parts by weight, 0.1 part by weight of dibutyltin laurate as a crosslinking catalyst, and azodicarbonamide as a foaming agent (trade name: SO-20, manufactured by Otsuka Chemical Co., Ltd., decomposition temperature 21).
0 ° C.) 2 parts by weight and 2 parts by weight of the brown pigment used in Example 1 as a colorant, a composition having a diameter of 30 m
m twin screw extruder and melt-kneaded at 180 ° C.
It was extruded into a sheet having a thickness of 5 mm and a width of 300 mm. Cool the extruded sheet, width 2 mm and length 2
It was cut into mm, immersed in water at 98 ° C. for 2 hours and then dried to obtain expandable resin particles.

The expandable resin granules obtained as described above were formed into a sheet made of fluorinated ethylene resin at 900 g / m ^2.
Was sprayed. At the time of spraying, the sum of the projected areas of the actually-dispersed particles is 25 with respect to the total projected area of the area surrounded by the outer peripheral edge of the area in which the particles are scattered.
% So that a second sheet made of fluorinated ethylene resin is overlaid on the sprinkled granules.
It was sandwiched between a pair of hot plates at 0 ° C. and heated and foamed for 10 minutes. After that, it was transferred to a cooling press at 30 ° C., and the thickness of the material excluding the thickness of the pair of fluorinated ethylene resin sheets was set to 9 mm through a spacer, followed by cooling for 10 minutes,
A plate-like foam having a thickness of 9 mm was obtained.

Production of Floor Material A hard plate-shaped body was obtained by the same procedure as in Example 1 except that a plywood plate having a thickness of 3 mm was used as the hard plate-shaped body in the plate-shaped foamed body obtained as described above. Then, the veneer used in Example 1 was bonded to the hard plate in the same manner as in Example 1 in the same manner as in Example 1 to obtain the floor material of Example 2.

Comparative Example 1 As Comparative Example 1, a commercially available floor material (made by Yuasa Kenzai Kogyo Co., Ltd., plywood thickness = 12 mm, trade name: Dynafloor-12) was prepared.

(Comparative Example 2) Using the floor material of Comparative Example 1 and using a slicer on the back surface of the floor material according to the technique disclosed in JP-A-5-230984, a width of 0.5 mm and a depth of 0.5 mm are obtained. Cracks of 5 mm were formed at a pitch of 20 mm.

(Comparative Example 3) A floor material of Comparative Example 3 was produced in the same manner as in Example 1 except that styrofoam having an expansion ratio of 10 was used in place of the plate-like foam of Example 1. .

(Comparative Example 4) A floor material of Comparative Example 4 was prepared in the same manner as in Example 1 except that a foamed hard urethane having an expansion ratio of 10 was used in place of the plate-shaped foamed product of Example 1. It was made.

Evaluation of Examples and Comparative Examples Examples 1 and 2 and Comparative Examples 1 to 1 prepared as described above.
4 floor material, load resistance, machinability, solvent resistance,
The conformability to the concrete floor surface was evaluated in the following manner.

Load resistance: Assuming chair legs, diameter 10 m
The presence or absence of permanent set was visually observed when a circular terminal of m was applied with a load of 30 kg and pressed against a floor material arranged on a horizontal plane. That is, the circular terminal is
After pressing for a minute, it was visually observed whether the recesses on the surface of the floor material after removing the circular terminals remained as permanent set. The case where the permanent set was set was marked with X, and the case where the concave was not set and the recess was recovered by elasticity, the mark was marked, and the results are shown in Table 1 below.

Machinability: The side surface of the floor material was subjected to a shading process, and when the processing was performed smoothly, it was marked with a circle, and when it was not processed, with a cross, the results are shown in Table 1 below. As the processing machine, a dedicated device for Neo-Lumber FFU processing manufactured by Sekisui Chemical Co., Ltd. was used.

Solvent resistance: Styrene was applied to the surface of the plate-like foam, and the presence or absence of melting was visually evaluated. The mark “◯” indicates that the sample did not melt, and the mark “x” indicates that the sample melted. The results are shown in Table 1 below.

Familiarity with the floor surface ... The presence or absence of swelling or waviness of the floor material was visually evaluated when each floor material was spread over the concrete floor surface having a swelling height of 1 mm. When no floating or waviness was observed, a circle was marked, and when a floating or waviness was observed, a cross was marked, and the results are shown in Table 1 below.

In addition, in Table 1, in order to facilitate the comparison of the floor materials of Examples and Comparative Examples, the floor materials (Comparative Example 2) that must be cracked are as follows:
In Table 1, a crack is given in the column of crack processing, and the other Examples 1 and 2 and Comparative Examples 1, 3 and 4 are marked with a circle in the column of crack processing because cracking is not required. Similarly, in Table 1, the amount of wood used in each floor material is based on the thickness of the wood used and is marked with a circle when no wood is used (thickness 0 mm).
A triangle mark is attached to Example 2 using a wood having a thickness of 3 mm, and a cross mark is attached to Comparative Examples 1 and 2 using plywood having a thickness of 12 mm.

[0102]

[Table 1]

As is clear from Table 1, the floor material of Comparative Example 3 using styrofoam as the plate-shaped foam is insufficient in machinability and solvent resistance, and in Comparative Example 4 using foamed hard urethane, It can be seen that the machinability is not sufficient.
On the other hand, the floor materials of Examples 1 and 2 have a structure in which a hard plate-like body is laminated on a plate-like foamed body made of a mixed phase of a plurality of types of polyolefin-based resin materials having different degrees of crosslinking according to the present invention. , Load resistance, machinability, solvent resistance, and conformability to the concrete floor surface all showed good results.

Further, as a matter of course, in Comparative Examples 1 and 2, since the plywood having a thickness of 12 mm is used, it can be seen that a large amount of wood is used. On the other hand, in Examples 1 and 2, it is not necessary to use plywood having such a large thickness, and it can be seen that this can contribute to the saving of wood resources.

Further, in the floor of Comparative Example 2, the crack work was applied to improve the conformability to the concrete floor surface, whereas in Examples 1 and 2, the crack work was not applied. It can be seen that both of them can enhance the compatibility with the concrete floor surface.

[0106]

INDUSTRIAL APPLICABILITY As described above, the flooring material of the present invention is hard as a plate-like foam made of a mixed phase of a relatively highly crosslinked polyolefin resin material and a low or noncrosslinked polyolefin resin material. It has a structure in which plate-like bodies are laminated. Therefore, since it is configured using the plate-shaped foam, the flooring material according to the present invention has sufficient flexibility, and can be suitably applied to a concrete floor surface with undulations and irregularities, thereby It is possible to reliably form a flat floor surface.

Moreover, since the above-mentioned plate-like foam is used, the floor material is relatively light in weight, so that the floor material can be installed as effortlessly as the conventional wooden floor material. In addition, since the plate-shaped foam is made of the above polyolefin-based resin material, it has sufficient solvent resistance and water resistance. Therefore, even if moisture is generated from the concrete after being applied to the concrete floor surface, the durability is unlikely to deteriorate. Further, since it has excellent solvent resistance, it is possible to bond a hard plate to a plate foam using a solvent-based adhesive having excellent workability, so that it is possible to reliably and efficiently produce a floor material. it can.

Further, as in the invention described in claim 2,
By laminating a decorative sheet-like material on the surface of the hard plate of the flooring material of the present invention, it is possible to further improve the design and abrasion resistance.

Claims (2)

(57) [Claims] 1. A granular material comprising a mixture of a relatively highly crosslinked polyolefin resin material and a low or non-crosslinked polyolefin resin material is heated and extruded.
A plate-like foam body made by foaming and heat-sealing the particulate matter to each other ; and a hard plate-like body laminated on the plate-like foam body and harder than the plate-like foam body, Floor material to be used. 2. The flooring material according to claim 1, further comprising a decorative sheet material laminated on the hard plate body.