JP3390714B2 - Olefin resin flooring - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material, particularly a flooring material that can be used as a flooring material for commercial facilities such as stores, and a floor for vehicles such as automobiles and railroads by appropriately flame-retarding. The present invention relates to an olefin resin laminated floor material that can be used as a surface material.

[0002]

2. Description of the Related Art Conventionally, vinyl chloride resin floor materials have been widely used as flooring materials for buildings and condominiums or floor surface materials for vehicles such as automobiles and railways. This vinyl chloride flooring material could not be incinerated because of the generation of hydrogen chloride gas, which is a strong acid, when it was incinerated, so it had to be disposed of as landfill, but recently it has been disposed of as landfill. The places to get are also decreasing rapidly. On the other hand, due to the increasing market needs for environmental protection issues, there is a growing interest in the use of materials that have as little environmental load as possible, and there has been a demand for the development of flooring materials that replace vinyl chloride.

From this point of view, the development of acrylic resin and polyolefin resin flooring materials as alternative materials to vinyl chloride has been studied, but these resins themselves are expensive and are chlorinated in terms of processability. It has a problem that it is difficult to process as compared with vinyl.

For example, as a polyolefin resin, a polypropylene resin floor material has been proposed in which an ethylene-vinyl acetate copolymer is added to give polypropylene flexibility, and an inorganic filler such as calcium carbonate is further added. However, even in the floor material in this case, the filling property of the inorganic filler is not so preferable, and the blended ethylene-vinyl acetate copolymer is around 100 ° C. in the presence of oxygen, 20 without oxygen
Deacetic acid occurs at around 0 ° C, and the thermal stability is not sufficient.

[0005]

Therefore, the present invention is
In view of the above-mentioned current situation, when manufacturing a floor surface material that replaces vinyl chloride resin, the workability has been improved, which has been a problem until now, and the stain resistance, scratch resistance, and flexibility required for the floor material have been improved. It is an object of the present invention to provide an olefin-based resin laminated floor material in which various physical properties such as properties are sufficiently improved.

[0006]

In order to solve the above-mentioned problems, the flooring material according to claim 1 according to the basic aspect of the present invention is a polyolefin, ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate-anhydrous. An upper layer composed of a polyolefin resin chip sintered sheet layer containing a maleic acid copolymer and an inorganic filler, a lower layer composed of a polyolefin resin sheet layer containing an olefin resin and an inorganic filler laminated thereunder, and a lower surface of the lower layer. It is an olefin resin laminated flooring material provided with an organic fiber nonwoven fabric layer.

In the olefin resin laminated floor material according to this basic construction, polyolefin such as polyethylene or polypropylene is used as the olefin resin, but the floor material according to claim 2 is an upper layer. The polyolefin in a certain polyolefin resin chip sintered sheet layer is characterized by being low-density polyethylene, and its compounding amount is 30 to 95 parts by weight, and further, an ethylene-methylmethacrylate copolymer (as a resin component for modification ( 5 to 70 parts by weight of EMMA), and further ethylene-ethyl acrylate-maleic anhydride copolymer (E-EA-).
2 to 20 parts by weight of MAH).

E blended as a resin component for this modification
It is preferable to use MMA having a methylmethacrylate (MMA) content of 5 to 40% by weight, and especially about 20% by weight of methylmethacrylate (MMA).
A) content is preferably used. Further, in the present invention, E-EA-MAH is used in combination as the resin modifying component. The resin modifying components EMMA and E-
EA-MAH has good compatibility with low-density polyethylene, which is a polyolefin resin, improves brittleness with respect to polyethylene, enhances flexibility, and secures a high compounding amount of filler in the inorganic filler. . Especially E-EA-
The blending of MAH imparts a strong polarity to the non-polar polyethylene resin, improves the compatibility with the inorganic filler, and improves the dispersibility of the inorganic filler in the resin component to form a sheet. It has an advantage that whitening at the time of bending can be prevented.

Further, in the olefin resin laminated floor material of the present invention, in order to secure stain resistance and scratch resistance on the surface of the upper layer, an ultraviolet curable resin coating (UV coating), an emulsion type resin coating, A coating of a water-based resin coating or the like is performed, but this EMMA blend enables the coating of a UV coating without the corona discharge treatment, the primer treatment, etc. as the surface treatment of the floor material.

In this case, the compounding amount of EMMA varies depending on the content of methyl methacrylate (MMA), but
It is about 70 parts by weight, and when it exceeds 70 parts by weight, the flooring material itself becomes fragile, and when it is 5 parts by weight or less, the flexibility cannot be ensured.

Further, the compounding amount of E-EA-MAH is 2 to.
It is 20 parts by weight, and even if the amount is more than 20 parts by weight, it is not possible to further impart the polarity to the polyethylene resin, and if it is 2 parts by weight or less, the desired polarity cannot be obtained.

In the olefin resin laminated floor material of the present invention, the lower polyolefin resin sheet layer preferably uses an olefin resin as its resin component.
Such olefin resins include methacrylic acid,
Examples thereof include low-density polyethylene modified with maleic anhydride or acrylic acid, high-density polyethylene, polypropylene, ethylene-vinyl acetate copolymer (EVA), and the like.

Further, in the olefin resin laminated flooring material of the present invention, both the upper polyolefin resin chip sintered sheet layer and the lower polyolefin resin sheet layer are filled with an inorganic filler in order to ensure flame retardancy. The material is mixed. As such an inorganic filler, various conventionally known inorganic fillers can be used, and among them, one of the inorganic fillers selected from calcium carbonate, calcium hydroxide, aluminum hydroxide or magnesium hydroxide or It is preferable to mix two or more kinds.

The amount of the inorganic filler compounded in the upper polyolefin resin chip sintered sheet layer is preferably 20 to 200 parts by weight with respect to 100 parts by weight of the resin component, and the lower layer polyolefin resin. In the sheet layer, 50 to 50 parts by weight of the resin component is used.
It is preferable to add 500 parts by weight. In the compounding of this inorganic filler, if the respective compounding amounts are exceeded, the floor material itself becomes brittle, and if it is the respective compounding amounts or less, the flame retardancy and the dimensional stability of the floor material are lowered, which is not preferable. Absent.

Further, in the olefin resin laminated flooring material of the present invention, the organic fiber nonwoven fabric layer is laminated on the lower back surface. In the flooring material according to claim 5, the organic fiber nonwoven fabric is made of polyester. It is a non-woven fabric layer.

The olefin resin laminated flooring material of the present invention is characterized in that a glass cross cloth is arranged between the upper layer polyolefin resin chip sintered sheet layer and the lower layer polyolefin resin sheet layer. . By disposing such a glass cross cloth, the olefin resin laminated floor material is provided with further excellent dimensional stability.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Specific embodiments of the olefin resin laminated floor material of the present invention will be described in detail below with reference to the drawings.

FIG. 1 is a schematic sectional view of an olefin resin laminated floor material according to an embodiment of the present invention. 1 in the figure
Is the olefin resin laminated floor material of the present invention, and the floor material is provided on the back surface of the polyolefin resin chip sintered sheet layer which is the upper layer 2, the polyolefin resin sheet layer which is the lower layer 3, and the lower layer 3. It has a structure in which the organic fiber nonwoven fabric layer 4 is laminated.

The upper layer 2 is preferably low-density polyethylene and EMMA, E which is a resin for modifying it.
-A polyolefin resin chip sintered sheet layer containing EA-MAH and an inorganic filler,
The lower layer 3 is composed of a polyolefin resin sheet layer containing EVA and an inorganic filler.

Particularly, the polyolefin resin chip sintered sheet layer which is the upper layer 2 is made of low density polyethylene of 30 to 95.
Parts by weight, EMMA 5 to 70 parts by weight, E-EA-MAH
2 to 20 parts by weight and 10 to 100 parts by weight of an inorganic filler are mixed, and a preferable thickness thereof is 0.
It is about 5 to 2.0 mm, but is not particularly limited.

The upper layer 2 of the flooring material of the present invention is formed by heating and sintering olefin resin chips containing a plurality of pigments in order to form various designs as a floor surface layer. Chip size is 0.2-2 mm
It may be a chip of a certain degree.

The lower layer 3 is composed of a polyolefin resin sheet layer containing EVA and an inorganic filler. In this case, EVA has a vinyl acetate content of about 5 to 40% by weight, especially 30% by weight. It is better to use EVA with vinyl acetate content before and after. The preferable thickness of the lower layer 3 is about 0.5 to 2.0 mm, but is not particularly limited.

The olefin resin laminated floor material 1 of the present invention is
Basically, the upper layer 2 and the lower layer 3 are laminated, and further the lower layer 3
Although the organic fiber nonwoven fabric layer is provided on the back side of
The organic fiber nonwoven fabric is preferably polyester fiber nonwoven fabric.

Such an olefin resin laminated floor material comprising the upper layer 2 and the lower layer 3 and the organic fiber main woven fabric layer 4 on the lower surface of the lower layer can be produced, for example, by the following method.

First, the polyolefin resin sheet layer as the lower layer 3 is manufactured by extrusion lamination. That is, for example, EVA as an olefin resin and 5 as an inorganic filler, for example, with respect to 100 parts by weight of a resin component.
0 to 500 parts by weight of calcium carbonate is mixed and mixed, and a polyester nonwoven fabric which is an organic fiber nonwoven fabric is laminated by an extruder, and the lower layer 3 is wound up. EV in this case
The compounding amount of both A and the inorganic filler is approximately 50: by weight.
A blending amount of 50 is preferable.

On the other hand, for example, 30 to 95 parts by weight of low density polyethylene, 5 to 70 parts by weight of EMMA, 2 to 20 parts by weight of E-EA-MAH, and 20 to 200 as an inorganic filler.
Parts by weight of calcium carbonate and an antistatic agent of 0.0
5 to 0.5 parts by weight, a proper amount of plural pigments are mixed, extruded and granulated by a pelletizer, and the obtained pellets are further pulverized to produce a polyolefin resin chip having a size of about 0.2 to 2 mm. .

Next, the lower layer 3 previously wound and molded is unwound as a base material, and the polyolefin resin chip obtained above is applied thereon. Such application is performed by coating or spraying resin chips. Then, the substrate coated with the chips is heated to 150 ° C. to 180 ° C.
The olefin resin laminated flooring material of the present invention is obtained by heating and sintering under a temperature condition of ℃, pressurizing and integrating to form a laminated structure, further applying an ultraviolet curing coating (UV coating) on the surface and then irradiating with ultraviolet rays. Manufactured.

As the ultraviolet curable paint (UV paint) applied to the surface, urethane UV paint, ester UV paint, acrylic UV paint, epoxy UV paint, diene UV paint, silicon UV paint, etc. Can be mentioned.

FIG. 2 shows a schematic sectional view of an olefin resin laminated floor material according to another embodiment of the present invention. 1 in the figure
Is the olefin resin laminated floor material of the present invention, and the floor material is the polyolefin resin chip sintered sheet layer as the upper layer 2 and the polyolefin as the lower layer 3 as in the embodiment shown in FIG. 1 above. Resin sheet layer and lower layer 3
In addition to the organic fiber nonwoven fabric layer 4 provided on the back surface, the upper layer 2 has a structure in which a UV paint layer 5 is provided on the front surface, and a glass cross cloth 6 is provided between the upper layer 2 and the lower layer 3.

The olefin resin laminated floor material in this embodiment has a feature that the dimensional stability of the floor material can be ensured by providing the glass cross cloth provided between the upper layer 2 and the lower layer 3. . In this case, it is preferable to use glass fibers having a glass fiber crossing interval of approximately 1 to 3 mm.

The production of the olefin resin laminated floor material in this embodiment is basically the same as the production method of the floor material of the above-described embodiment, and the lower layer 3 as the base material is extruded and laminated. In the manufacturing process of the base laminate laminate, the resin component, the organic fiber nonwoven fabric,
This is accomplished by laminating a glass cross cloth with an extruder and winding the lower layer.

The ultraviolet curable coating (UV coating) layer 5 laminated on the surface of the upper layer in FIG. 2 is the urethane-based UV coating, ester-based UV coating, acrylic-based U described above.
Examples thereof include V paints, epoxy UV paints, diene UV paints, silicon UV paints, and the like. Such UV
By providing the paint layer 5, a floor material having good stain resistance and scratch resistance is formed, and the film thickness of the paint layer is 0.01 to 0.
It may be about 1 mm.

[0033]

The present invention will be described in more detail with reference to the following examples. a) Production of lower layer (olefin resin sheet layer: base material) As a lower layer portion, 50 parts of EVA (vinyl acetate content: 28%) as an olefin resin and 50 parts of calcium carbonate as an inorganic filler are mixed to form a polyester nonwoven fabric. The base material to be the lower layer portion having a layer thickness of 1.0 mm was wound up by an extrusion laminating machine by unwinding and unwinding with a glass orthogonal cloth.

B) Production of polyolefin resin chip As a polyolefin resin chip component, 65 parts by weight of low density polyethylene, 28 parts by weight of EMMA, 7 parts by weight of E-EA-MAH, and 43 parts by weight of calcium carbonate as an inorganic filler. Then, 0.1 part by weight of an antistatic agent and a pigment were mixed, pellets were granulated with a pelletizer, and further pulverized to obtain chips of about 0.4 to 0.7 mm.

C) Manufacture of flooring The polyolefin resin sheet layer as the lower layer portion wound up in (a) above was unwound, and the chip obtained in (b) above was uniformly coated and applied on the sheet. Next, heating / sintering was performed at a heating temperature of 150 ° C. to 180 ° C., and a base material portion (lower layer) polyolefin resin chip sintered sheet layer was laminated to have a thickness of 0.8 mm. Further, a urethane-based UV paint as an ultraviolet-curable paint is applied to the obtained laminate and cured by UV irradiation, and the floor material is wound up by a winder, and the olefin resin laminate of the present invention having a layer thickness of 2 mm. I got the flooring. The flooring material thus obtained was excellent in flexibility, flame retardancy, stain resistance, and scratch resistance.

[0036]

EFFECT OF THE INVENTION The olefin resin laminated flooring material of the present invention having the above-mentioned constitution is an olefinic surface flooring material which does not use vinyl chloride resin. Particularly, as its laminated structure, low density polyethylene is used for the upper layer. In addition, ethylene-methyl methacrylate copolymer (EMMA) and ethylene-ethyl acrylate-maleic anhydride copolymer (E-EA-) as the modified resin of this low density polyethylene.
By adding MAH), flexibility and polarity are given to the polyethylene resin. Furthermore, EMMA and E-EA
By blending -MAH, a high filler filling property of the inorganic filler is secured, and it becomes possible to obtain a flooring material having good quality.

Furthermore, this EMMA and E-EA-M
The blending of AH makes it possible to obtain good adhesion to the surface treatment agent in the surface UV paint treatment of the flooring material without performing post-treatment steps such as corona discharge treatment and primer treatment. In particular, in the conventional modification of olefin resin with EVA, the contained EVA causes thermal decomposition to lose the acetic acid group which has the effect of adhering to the surface coating. However, the problem can be solved. Therefore, the manufacturing cost can be reduced.

The EMMA formulation is to avoid generation of acid gas such as acetic acid gas in the heating / sintering process.
It has the advantage that a flooring of very good quality can be produced.

Further, in the case of blending E-EA-MAH, the hydrogen bonding force and the chemical reaction force of the contained maleic anhydride component impart the adhesiveness and affinity to the polar material.
Since the compatibility with the inorganic filler is further improved and the dispersibility of the inorganic filler in the resin component is improved, there is an advantage that whitening at the time of bending when formed into a sheet can be prevented.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of an olefin resin laminated floor material according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view of an olefin resin laminated floor material according to another embodiment of the present invention.

[Explanation of symbols]

1 Olefin resin laminate flooring 2 upper layers 3 lower layers 4 Organic fiber non-woven fabric layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁷ Identification code FI E04F 15/02 E04F 15/02 A // E04F 15/10 104 15/10 104A (56) Reference JP-A-11-335981 ( JP, A) JP 11-158784 (JP, A) JP 11-100456 (JP, A) JP 10-280284 (JP, A) JP 9-143888 (JP, A) JP Flat 9-32258 (JP, A) JP 7-125145 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) D06N ⁷ /00-7/06 B32B 27/12 B32B 27 / 20 B32B 27/28 B32B 27/32 E04F 15/02 E04F 15/10

Claims (6)

(57) [Claims] 1. An upper layer consisting of a polyolefin resin chip sintered sheet layer containing a polyolefin, an ethylene-methyl methacrylate copolymer, an ethylene-ethyl acrylate-maleic anhydride copolymer, and an inorganic filler, and laminated below the upper layer. An olefin resin laminated flooring material having a lower layer composed of a polyolefin resin sheet layer containing an olefin resin and an inorganic filler, and an organic fiber non-woven fabric layer provided on the lower surface of the lower layer. 2. The resin component of the polyolefin resin chip sintered sheet layer, which is the upper layer, contains 30 to 30 low-density polyethylene.
The olefin system according to claim 1, wherein 95 parts by weight, 5 to 70 parts by weight of the ethylene-methyl methacrylate copolymer, and 2 to 20 parts by weight of the ethylene-ethyl acrylate-maleic anhydride copolymer are blended. Resin laminated flooring. 3. The inorganic filler blended in the polyolefin resin chip sintered sheet layer is one or more inorganic fillers selected from calcium carbonate, calcium hydroxide, aluminum hydroxide or magnesium hydroxide. Yes, 2 parts of inorganic filler per 100 parts by weight of resin component
The olefin resin laminated floor material according to claim 1, which is a mixture of 0 to 200 parts by weight. 4. The inorganic filler blended in the lower polyolefin resin sheet layer is one or more inorganic fillers selected from calcium carbonate, calcium hydroxide, aluminum hydroxide or magnesium hydroxide. 50 parts of the inorganic filler with respect to 100 parts by weight of the resin component.
The olefin resin laminated floor material according to claim 1, which is mixed in an amount of ˜500 parts by weight. 5. The olefin resin laminated flooring material according to claim 1, wherein the organic fiber nonwoven fabric layer provided on the back surface is a nonwoven fabric layer made of polyester. 6. The olefin resin laminated floor material according to any one of claims 1 to 5, wherein a glass cross cloth is arranged between the upper layer polyolefin resin chip sintered sheet layer and the lower layer polyolefin resin sheet layer.