JP3615662B2 - Flooring - Google Patents

Description

【０１５４】
実施例１〜１０、比較例１〜３で得られた床材を以下の評価に供し、その結果を表２に纏めて示した。
【０１５５】
床材の評価
▲１▼沈み込み量
得られた床材を２００×２００ｍｍに切断し、硬質板状体側にφ５０ｍｍの鋼製円柱圧子を載置し、２ｍ／ｍｉｎの速度で８０ｋｇｆの圧縮荷重を負荷したときの沈み込み量を測定した。
【０１５６】
▲２▼防音性能
ＪＩＳ Ａ１４１８に準拠して軽量床衝撃騒音レベルを測定した。
【０１５７】
▲３▼不陸吸収性
床材を３枚平行にならべ、２ｍｍの凹凸部を有する疑似平板に対しての接触度合いを目視にて確認、
以下の基準で４段階評価した。
◎：完全に密接
○：平板と床材の隙間が０．５ｍｍ未満
△：平板と床材の隙間が０．５〜１．５ｍｍ
×：平板と床材の隙間が１．５ｍｍ以上
【０１５８】
【表２】

【０１５９】
【発明の効果】
請求項１記載の床材は、上述の如き構成とされているので、防音性能に優れ、かつ歩行感の良い床材となる。
【０１６０】
請求項２記載の床材は、上述の如き構成とされているので、防音性がさらに良好のものとなる。
【０１６１】
請求項３〜５記載の床材は、上述の如き構成とされているので、歩行感がさらに良好のものとなる。
【０１６２】
請求項６記載の床材は、上述の如き構成とされているので、防音性がさらに良好のものとなる。
【０１６３】
請求項７、８記載の床材は、上述の如き構成とされているので、防音性と歩行感がさらに両立されたものとなる。
【０１６４】
請求項９記載の床材は、上述の如き構成とされているので、防音性がよく且つ施工性に優れたものとなる。
【０１６５】
請求項１０記載の床材は上述の如き構成とされているので、施工性がさらに良好のものとなる。
【０１６６】
請求項１１記載の床材は、請求項１〜１０の床材を直貼りしているので、防音性、歩行に加え、施工性も優れた物となる。
【図面の簡単な説明】
【図１】本発明（請求項１〜１１）に使用され得る発泡性熱可塑性樹脂の製造方法の一例を説明するための工程図である。
【図２】（ａ）〜（ｅ）は、本発明（請求項１〜１１）に使用される得る熱可塑性樹脂発泡体の製造方法の一例を説明するための断面図である。
【図３】実施例１により得られた熱可塑性樹脂発泡体を示す断面図である。
【図４】実施例１により得られた床材を示す断面図である。
【図５】発泡性熱可塑性樹脂粒状体が格子状に配置されている状態を説明するための平面図である。
【図６】発泡性熱可塑性樹脂粒状体が千鳥状に配置されている形態を説明するための平面図である。
【図７】実施例２〜１０により得られた熱可塑性樹脂発泡体を示す断面図である。
【図８】実施例２〜９により得られた床材を示す断面図である。
【図９】実施例１１により得られた床材を示す断面図である。
【符号の説明】
１ 熱可塑性樹脂発泡体
２ 高発泡体
３ 連続発泡層
３ａ連続発泡層
４ 低発泡薄膜
５ 発泡性熱可塑性樹脂シート状体
６ 発泡性熱可塑性樹脂粒状体
７ 発泡性熱可塑性樹脂薄膜
１１ 二軸押出機
１２ Ｔダイ
１３ 賦型ロール
１４ 賦型ロール
１５ シート
１６ シート
２１ 硬質板状体
２２ 不陸層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a flooring, and more particularly to a flooring that has good soundproofing performance and excellent walking feeling and is suitable for being directly attached to a floor slab. In the present invention, the “surface side” of the flooring material and the continuous foamed layer refers to the side exposed to the surface directly or through the decorative sheet, and the “back side” means a concrete slab or the like The side laid on.
[0002]
[Prior art]
Conventionally, carpets, jutans, and the like have been often used as flooring materials for apartment houses. However, since carpets and juts tend to generate mold and mites and are easily soiled, in recent years, there has been an increasing demand for floor materials that are easy to clean and use sanitary hard plates.
However, the floor material using a hard plate-like body has a problem that sound due to impact is likely to be generated, and life sound downstairs, that is, walking sound and falling sound of an object are easily transmitted.
[0003]
As a method for solving the above-described problems, many flooring materials in which a foam or a porous material such as a nonwoven fabric is laminated as a buffer layer on the back surface of a hard plate-like body have been proposed. For example, the flooring described in Japanese Utility Model Publication No. 52-30125 is formed with a soft high foam having a foaming ratio of 3 to 10 times and a soft low foam having a foaming ratio of less than 1.5 to 3 on the back surface of the hard plate. Flooring. In addition, the flooring described in Japanese Utility Model Publication No. 3-21395 has different foaming ratios between the upper and lower buffer layers adjacent to the back surface of the hard plate-like body. It is a flooring which consists of a high foaming layer and a 5-20 times low foaming layer. When subjected to impact force, these buffer layers are deformed and the impact action time is extended, thereby reducing the peak value of impact force and the natural frequency of impact, preventing the propagation of sound and vibration due to impact, and soundproofing However, since the rigidity of the rigid plate-like body is large, it is necessary to increase the thickness of the buffer layer in order to exhibit high soundproofing properties. Therefore, the floor material with high soundproofing has a large sinking with respect to the load, and a new problem has arisen that a strange feeling called “seasickness phenomenon” is felt when walking on the upper surface of the floor material.
[0004]
On the other hand, for example, Japanese Utility Model Publication No. 56-3945 discloses a floor material in which a foam of 20 to 100 mm is laminated on the back surface of a hard plate having a thickness of 0.3 to 15 mm. ing. However, normally used homogeneous foam has mechanical isotropy, and if a high compressive modulus is given to reduce the sinking, the flexural modulus increases naturally and high soundproofing cannot be expected. .
[0005]
[Problems to be solved by the invention]
As described above, there are two contradictory problems of soundproofing and sinking, and in order to provide high soundproofing, it is necessary to increase the thickness of the high-magnification foamed synthetic resin sheet that greatly imparts cushioning properties. However, it has been difficult to achieve both soundproofing and subsidence prevention.
[0006]
An object of the present invention is to solve the above problems and to provide a flooring material having excellent workability while achieving both soundproofing performance and a feeling of walking.
[0007]
[Means for Solving the Problems]
The flooring material according to claim 1 is a flooring material in which a hard plate is laminated on one side of a thermoplastic resin foam, wherein the thermoplastic resin foam comprises a sheet-like continuous foam layer and the continuous foam layer. A plurality of high foam portions disposed on at least one surface of the foam layer, and a low foam thin film covering the entire surface of the high foam portion together with the continuous foam layer,
The high foamed portion covered with the low foamed thin film is formed in a convex shape from the continuous foamed layer, and a concave portion is formed between adjacent high foamed portions, thereby forming irregularities on the back surface of the thermoplastic resin foam. It is what has been.
[0008]
The flooring material according to claim 2 is a flooring material in which a hard plate-like body is laminated on one surface of a thermoplastic resin foam, and the thermoplastic resin foam comprises a sheet-like continuous foam layer and the continuous foam layer. A plurality of high foam portions disposed on the back surface of the foam layer, and a low foam thin film covering the entire surface of the high foam portion together with the continuous foam layer. The high foam portion is formed in a convex shape from the continuous foam layer. The adjacent high foaming portions are formed in a concave shape, and the surface side of the continuous foam layer in contact with each high foaming portion is formed in a concave shape.
[0009]
In the flooring according to the invention described in claim 1 or 2, it is preferable that at least a part of the high foamed portions are connected to each other via the low foamed thin film as described in claim 3. .
[0010]
In the flooring according to the third aspect of the present invention, the low foam thin film may be sequentially bonded to the high foam part. However, as described in claim 4, at least a part of the high foam part is thermally fused. Those that are connected to each other through the attached low foam thin film are preferable.
[0011]
In the flooring material according to any one of the first to fourth aspects of the present invention, as described in the fifth aspect, the plurality of highly foamed portions made of the thermoplastic resin are arranged in a lattice shape or a staggered shape. Is preferred.
[0012]
In the flooring according to any one of the first to fifth aspects of the present invention, it is preferable that the height of the convex forming portion on the high foamed portion side protrudes 3 mm or more from the concave forming portion.
[0013]
In the flooring according to the inventions of the first to sixth aspects, when the flooring is placed on the flat plate with the high foaming portion as the back side, the contact area of the convex forming portion of the high foaming portion with the flat plate is The cross-sectional area of the hard plate is preferably 10 to 70%.
[0014]
In the flooring according to any one of claims 1 to 7, the volume of the thermoplastic resin foam is 50 to 90% (hereinafter, referred to as the volume of the smallest rectangular solid that can circumscribe the thermoplastic resin foam). This ratio is preferably referred to as “filling rate”.
[0015]
In the flooring according to any one of claims 1 to 8, a hard plate-like body is laminated on one surface of the sheet-like body forming the thermoplastic resin foam, and a high foam portion projects from the other surface side. It is preferable.
[0016]
In the flooring according to any one of claims 1 to 9, it is preferable that a non-land absorbing layer is formed on the back surface of the thermoplastic resin foam.
[0017]
When the flooring material according to any one of claims 1 to 10 has a hard plate-like body as a surface, it is preferable that the back surface is directly attached to the floor slab.
[0018]
[Thermoplastic resin used for thermoplastic resin foam]
In the flooring material of the invention according to any one of claims 1 to 11, the thermoplastic resin used for the continuous foam layer, the low foam thin film and the high foam part constituting the thermoplastic resin foam is not particularly limited. As such a thermoplastic resin, for example, low density polyethylene, high density polyethylene, linear low density polyethylene (hereinafter, “polyethylene” means low density polyethylene, high density polyethylene, linear low density polyethylene, or Olefin-based resins such as random polypropylene, homopolypropylene, block polypropylene (hereinafter, “polypropylene” refers to random polypropylene, homopolypropylene, block polypropylene, or a mixture thereof), and the like. These copolymers: polyethylene vinyl acetate, polyvinyl chloride, chlorinated polyvinyl chloride, ABS resin, polystyrene, polycarbonate, polyamide, polyvinylidene fluoride, polyphenylene sulfide, polysulfone, polyether Ketone, and copolymers and the like of these, they can also be used alone, may be used in combination.
[0019]
Among the above thermoplastic resins, olefinic resins such as polyethylene and polypropylene or a mixture thereof are preferable because they are excellent in thermal stability and transferability, and are easy to form irregularities. Surface smoothness and walking of the resulting flooring material are preferable. In order to achieve both prevention of sinking in time, high-density polyethylene, homopolypropylene, or a mixture containing at least one of these is particularly preferable.
[0020]
Further, the thermoplastic resin is preferably partially crosslinked. This is because, by crosslinking, foam breakage during foaming can be prevented, the expansion ratio is increased, and the floor material is reduced in weight.
[0021]
The resin used for the continuous foam layer, the high foam, and the low foam thin film constituting the thermoplastic resin foam does not have to be the same resin, but the obtained flooring is placed when walking and placing heavy objects. It is preferable to use the same kind of resin from the point of being difficult to break. At this time, it is preferable in terms of adhesiveness that the resins used for the high foam and the low foam thin film are formed of the same resin.
[0022]
[Form of thermoplastic resin foam]
The form of the thermoplastic resin foam of the present invention comprises a sheet-like continuous foam layer, a plurality of high foam portions disposed on at least one side of the continuous foam layer, and the surface of the high foam portion together with the continuous foam layer. The high foaming portion is formed in a convex shape with respect to the continuous foamed layer.
[0023]
If the expansion ratio of the thermoplastic resin foam is too low, the floor material cannot be reduced in weight, and if it is too high, the sinking amount of the floor material increases, so 2 to 30 times is preferable, more preferably 3 -20 times, more preferably 5-10 times.
[0024]
If the thickness of the thermoplastic resin foam is too thin, the soundproofing performance is lowered, and if it is too thick, the sinking amount of the flooring increases, so 3 to 50 mm is preferable, more preferably 3 to 30 mm, and particularly preferably 5. -10 mm.
[0025]
If the expansion ratio of the continuous foam layer is too low, it becomes difficult to reduce the weight of the flooring material, and the elastic modulus increases, so that the soundproofing performance decreases, and if it is too high, the sinking amount of the flooring material increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 1.1-10 times are preferable, More preferably, it is 2-8 times, 2-7 times is especially preferable.
[0026]
If the thickness of the continuous foamed layer is too thin, the resulting flooring material tends to break when walking and when a heavy object is placed, and if it is too thick, the proportion of the thermoplastic foam is relatively increased. Since it becomes difficult to reduce the weight of the flooring material and the soundproofing performance decreases, the thickness is preferably 100 μm to 5 mm, more preferably 300 μm to 3 mm, and particularly preferably 500 μm to 2 mm.
The thickness of the continuous foam layer does not need to be uniform and may be non-uniform. Moreover, the continuous foam layer does not need to be a complete flat plate, and may have some unevenness. Here, the thickness of the continuous foam layer refers to the average thickness of the continuous foam layer having a cross section parallel to the thickness direction of the thermoplastic resin foam.
[0027]
If the expansion ratio of the high foam is too low, it becomes difficult to reduce the weight of the flooring material, and the elastic modulus increases, so that the soundproofing performance decreases, and if it is too high, the amount of sinking of the flooring increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 2-100 times are preferable, More preferably, it is 5-50 times, 10-35 times is especially preferable.
[0028]
If the size of the high foam is too small, it will be difficult to reduce the weight of the flooring, and if it is too large, the resulting flooring will be easily destroyed when walking and placing heavy objects, so 3-50 mm. Preferably, it is 5-30 mm.
Note that the size of the highly foamed portion need not be uniform and may be non-uniform.
Here, the size of the highly foamed portion refers to the maximum value of the size of the cross section parallel to the thickness direction of the thermoplastic resin foam.
[0029]
When the foaming ratio of the low foamed thin film is too low, it becomes difficult to reduce the weight of the flooring material, and the elastic modulus increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 1.1 to 10 times is preferable, 1.2 to 7 times is more preferable, and 1.2 to 5 times is particularly preferable.
[0030]
If the thickness of the low-foamed thin film is too thin, the high foam portion is relatively large, the compressive strength of the resulting flooring material is reduced, and if it is too thick, the soundproofing performance is reduced, so 30-500 μm is preferable. Preferably it is 40-400 micrometers, and 50-400 micrometers is especially preferable.
In addition, the thickness of the low foam thin film does not need to be uniform, and may be non-uniform. Here, the thickness of the low foamed thin film refers to the average thickness of the cross section of the thermoplastic resin foam parallel to the thickness direction of the thermoplastic resin foam.
[0031]
The highly foamed part is generally disposed on one side of the continuous foam, but may be disposed on both sides.
[0032]
The highly foamed part is formed in a convex shape with respect to the continuous foamed layer.
Since the height of the convex portion of the high foamed portion is too low, a high soundproofing performance cannot be obtained. Therefore, the height is preferably 1 mm or more, more preferably 2 mm or more, further preferably 3 mm or more with respect to the continuous surface. It is.
[0033]
The back side of the continuous foam corresponding to each highly foamed part is preferably formed in a concave shape, and when formed in a concave shape, it is difficult to express high compressive strength if the depth of the concave part is too large. Then, the amount of sinking is increased, and if it is too low, sufficient soundproofing properties cannot be obtained, so 1 to 5 mm is preferable, and 1 to 3 mm is more preferable.
[0034]
What the at least one part of the said high foaming part is mutually connected via the low foaming thin film is preferable. When connected to each other at least partially via the low foam thin film, the adhesion of the individual high foam portions via the individual low foam thin films is improved, and heavy objects are loaded on the flooring. This is preferable because it is difficult to break.
[0035]
As a method of connecting at least a part of the high foamed portions to each other via a low foamed thin film, adhesion by an adhesive is conceivable. However, since it is formed of a thermoplastic resin, The wearing is most preferable from the viewpoint of the formability of the flooring.
[0036]
In order to improve the thickness accuracy and weight accuracy of the thermoplastic resin foam and to reduce the variation in compressive strength, it is preferable that the plurality of high foams be arranged substantially uniformly in a plane in the cross-sectional direction of the foam. However, the aspect in which the plurality of high foams are arranged substantially uniformly in a plane is not particularly limited, and may be arranged in a lattice shape or in a staggered manner.
[0037]
When multiple high foams are arranged in a grid, each high foam has a quadrangular prism shape, and the amount of sinking is reduced when formed on a flooring. Are preferably arranged in a grid.
[0038]
In addition, when a plurality of high foams are arranged in a staggered manner, a plurality of hexagonal columnar high foams are heat-sealed through a low foam thin film, and a honeycomb-like thermoplastic resin foam as a whole This is particularly preferable because the flooring material has a particularly low sinking amount.
[0039]
Further, the contact area ratio with respect to the flat plate of the portion of the high foamed portion whose outer surface is coated with the low foamed thin film of the present invention is preferably 10 to 70%, and if it is too large, the soundproofing property is lowered, If it is too small, the sinking amount of the flooring will increase.
[0040]
In addition, if the filling ratio of the thermoplastic resin foam of the present invention is too small, high compression strength cannot be exhibited, the amount of subsidence increases, and if it is too large, the soundproofing property decreases, and therefore 30 to 30 90% is preferable, and 50 to 90% is particularly preferable.
[0041]
[Method for producing thermoplastic resin foam]
The method for producing the thermoplastic resin foam is not particularly limited. For example, a foamed thermoplastic resin pellet containing a foaming agent is foamed and the outer surface excluding the fusion surface is made of a thermoplastic resin. A continuous foam layer made of a thermoplastic resin formed in a separate process after molding a plurality of high foam portions made of a thermoplastic resin covered with a foam thin film, heat-sealing them together via a low foam thin film After heat sealing, a method of forming irregularities with a hot press or the like is mentioned, but the foamable thermoplastic resin granules containing a foaming agent, which will be described later, are arranged substantially uniformly in a plane. And foaming the foamable thermoplastic resin sheet in which the foamable thermoplastic resin granules are integrally connected via a foamable thermoplastic resin thin film above the decomposition temperature of the foaming agent. Obtained by foaming Foam is the most preferred method and a step of cooling in the cooling mold having the above gap is completely filled.
[0042]
When the foamable thermoplastic resin sheet is foamed, the portion of the foamable thermoplastic resin granules foams, but at this time, the outer surface of the thermoplastic resin granules is difficult to hold the bubbles generated by foaming, The foaming ratio is lower than that of the film, resulting in a low foamed thin film. As a result, the low foamed thin film covers the outer surface of the high foaming portion having a high foaming ratio inside the granular material. Moreover, the foamable thermoplastic resin thin film which connects the granular material of a foamable thermoplastic resin sheet-like body becomes a continuous foamed layer, and will be in the state by which multiple high foaming parts were arrange | positioned on this continuous foamed layer. Note that the continuous foamed layer is also thin and low in foaming because it is difficult to hold the bubbles. Such a low-foaming thin film is close to the low-foaming thin film of the adjacent granular material and thermally fused by foaming inside the granular material. By setting more than the full filling of the plastic resin sheet, the fusion proceeds only partially, and an uneven thermoplastic resin foam that is not completely filled is obtained.
[0043]
[Thermoplastic resin used for foamed thermoplastic resin sheet]
The thermoplastic resin used for the foamable thermoplastic resin granules and the foamable thermoplastic resin thin film constituting the foamable thermoplastic resin sheet is the same as the resin used for the thermoplastic resin resin foam. Things are used.
[0044]
The thermoplastic resin used for the foamable thermoplastic resin granules and the thermoplastic resin used for the foamable thermoplastic resin thin film do not have to be the same resin, but are in terms of foamability and adhesiveness. Therefore, it is preferable to use the same type of resin.
[0045]
As described in the section of the thermoplastic resin foam, the thermoplastic resin used for the foamable thermoplastic resin sheet can improve the expansion ratio and reduce the weight of the resulting thermoplastic resin foam. It is preferable to use a crosslinked one. The crosslinking method is not particularly limited. For example, (1) a method in which a silane graft polymer is melt-kneaded into a thermoplastic resin, followed by water treatment, and (2) a peroxide is added to the thermoplastic resin. Examples thereof include a method of crosslinking by melting and kneading at a temperature lower than the decomposition temperature of the oxide, followed by heating to a temperature higher than the decomposition temperature of the peroxide, and a method of crosslinking by irradiation with radiation (3). However, in order to obtain a highly crosslinked resin and a low (no) crosslinked resin described later, the crosslinking method using the silane graft polymer (1) is preferred.
[0046]
The silane graft polymer is not particularly limited, and examples thereof include silane graft polyethylene and silane graft polypropylene.
[0047]
The above-mentioned water treatment method includes a method of exposing to water vapor in addition to a method of immersing in water. In such a case, when the treatment is performed at a temperature higher than 100 ° C., the treatment may be performed under pressure.
[0048]
When the temperature of water and water vapor during the water treatment is low, the crosslinking reaction rate decreases, and when it is too high, the foamable thermoplastic resin sticks with heat, so 50 to 130 ° C. is preferable, and 90 to 120 ° C is particularly preferred.
[0049]
Moreover, if the time for water treatment is short, the crosslinking reaction may not proceed completely, so the water treatment time is preferably in the range of 0.5 to 12 hours.
[0050]
The method for mixing the silane graft polymer is not particularly limited as long as it can be uniformly mixed. Examples thereof include a method of supplying a thermoplastic resin and a silane graft polymer to a single or twin screw extruder, melt kneading, a melt kneading method using a roll, and a melt kneading method using a kneader.
[0051]
If the amount of the silane graft polymer added is too large, crosslinking will take place too much, and the foaming ratio of the resulting thermoplastic resin foam will decrease, and if it is too small, the cells will break and a uniform foamed cell will be obtained. Therefore, the added amount of the silane graft polymer is preferably 5 to 50% by weight, particularly preferably 10 to 35% by weight in the total thermoplastic resin.
[0052]
Moreover, when silane crosslinking is performed using a silane graft polymer, a silane crosslinking catalyst may be used as necessary. The silane crosslinking catalyst is not particularly limited as long as it promotes the crosslinking reaction between the silane graft polymers. For example, dibutyltin diacetate, dibutyltin dilaurate, dioctyltin dilaurate, tin octoate, tin oleate, octane Examples thereof include lead tin, zinc 2-ethylhexanoate, cobalt octoate, lead naphthenate, zinc cabrate, and zinc stearate.
[0053]
When the addition amount of the silane crosslinking catalyst is increased, the expansion ratio of the obtained thermoplastic resin foam is decreased, and when it is decreased, the crosslinking reaction rate is decreased, and water treatment takes time. The amount of the silane crosslinking catalyst added relative to parts by weight is preferably in the range of 0.001 to 10 parts by weight, and more preferably 0.01 to 0.1 parts by weight.
[0054]
The foamable thermoplastic resin is not particularly limited as described above, but is composed of a mixture of a foaming agent, a highly crosslinked thermoplastic resin having little compatibility with each other, and a low-crosslinked or non-crosslinked thermoplastic resin. In this case, since a low cross-linked or non-cross-linked resin easily flows during foaming, it is particularly preferable because the uneven portions of the obtained uneven thermoplastic resin foam are easily formed.
[0055]
High cross-linking and low cross-linking in a highly cross-linked thermoplastic resin and a low cross-linked or non-cross-linked thermoplastic resin are relative expressions determined by the magnitude of the degree of cross-linking of both. This thermoplastic resin is called a highly crosslinked thermoplastic resin, and the other is called a low-crosslinked or non-crosslinked thermoplastic resin.
[0056]
As the thermoplastic resins used before the two types of thermoplastic resins having little compatibility with each other (before crosslinking), two types of the thermoplastic resins described above (hereinafter, not the crosslinking performance of the resin itself, A resin that forms a highly crosslinked thermoplastic resin can be appropriately selected and used as a “highly crosslinkable resin”, and a resin that forms a low-crosslinked or non-crosslinked thermoplastic resin is referred to as “low (non) crosslinkable resin”. In order to disperse the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin uniformly and finely without being compatible with each other, the solubility parameter of the thermoplastic resin of the highly crosslinked resin and the low (non) crosslinkable resin is The difference is preferably 0.1 to 2.0, and more preferably 0.2 to 1.5.
[0057]
If the difference in solubility parameter exceeds 2.0, the highly crosslinked thermoplastic resin obtained by crosslinking and the low-crosslinked or non-crosslinked thermoplastic resin are very coarsely dispersed. The magnification decreases. On the other hand, if the difference in solubility parameter is less than 0.1, the compatibility between the highly crosslinked thermoplastic resin obtained by crosslinking and the low-crosslinked or non-crosslinked thermoplastic resin becomes high, and the resulting concavo-convex thermoplastic resin foam is obtained. The surface smoothness is reduced.
[0058]
The solubility parameter refers to a value obtained by σ = ρΣFi / M. Here, 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 suction number of the constituent group of the monomer.
[0059]
When the difference in melt index (MI) between the highly crosslinkable resin and the low (non) crosslinkable resin is large, the highly crosslinked thermoplastic resin obtained by crosslinking and the low crosslinkable or noncrosslinked thermoplastic resin are very different. Since the expansion ratio of the resulting concavo-convex thermoplastic resin foam decreases due to coarse dispersion, the compatibility between the highly crosslinked thermoplastic resin obtained by crosslinking and the low-crosslinked or non-crosslinked thermoplastic resin increases. Since it may be difficult to form the unevenness of the resulting uneven thermoplastic resin foam, the highly crosslinked thermoplastic resin and the low-crosslinked or non-crosslinked thermoplastic resin will not be compatible with each other and will be dispersed uniformly and finely. In order to obtain a thermoplastic resin foam having a high expansion ratio, the difference in MI is preferably 5 to 13 g / 10 minutes, and more preferably 7 to 11 g / 10 minutes.
[0060]
In addition, MI in this specification is a value measured according to JIS K7210.
In order to obtain a high foaming ratio thermoplastic resin foam in which a highly crosslinked thermoplastic resin obtained by crosslinking and a low crosslinked or non-crosslinked thermoplastic resin is uniformly and finely dispersed and surface smoothness is excellent, The mixing ratio of the functional resin and the low (no) crosslinkable resin is preferably 2: 8 to 8: 2 and more preferably 4: 6 to 6: 4 in terms of weight ratio.
[0061]
If the degree of crosslinking of the highly cross-linked thermoplastic resin is too high, cross-linking takes place too much, and the foaming ratio of the resulting concavo-convex thermoplastic resin foam decreases. May not be obtained, the gel fraction serving as an index of the degree of crosslinking is preferably 5 to 40% by weight, more preferably 10 to 30% by weight.
[0062]
If the crosslinking degree of the low-crosslinking or non-crosslinking thermoplastic resin is high, crosslinking is excessively applied, and the fluidity of the resulting concavo-convex thermoplastic resin foam may be lowered, making it difficult to form irregularities. The gel fraction serving as an index is preferably 5% by weight or less, and more preferably 3% by weight or less.
[0063]
In addition, the gel fraction in this specification means the weight percentage with respect to the weight of the crosslinked resin component before xylene immersion of the residue weight after immersing a crosslinked resin component in 120 degreeC xylene for 24 hours.
[0064]
As a method of preparing a mixture of a highly cross-linked thermoplastic resin and a low cross-linked or non-cross-linked thermoplastic resin that have little compatibility with each other, the above two types of thermoplastic resins are mixed, and only the high cross-linkable resin or This is achieved by preferentially crosslinking a highly crosslinkable resin over a low (no) crosslinkable resin.
[0065]
As a method of preferentially crosslinking a highly crosslinkable resin alone or a low crosslinkable resin over a low (no) crosslinkable resin, for example, (1) High crosslinkable resin alone or a high crosslinkability than a low (no) crosslinkable resin A method of cross-linking using a cross-linking agent that preferentially cross-links the resin. (2) In the first step, a high cross-linkable resin having a cross-linkable functional group and a cross-linkable resin of the same kind are mixed and cross-linked to obtain a high cross-link. After forming a thermoplastic resin, the method etc. which mix this with a non-crosslinkable resin at the 2nd step are mentioned.
[0066]
However, the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin can be uniformly and finely dispersed, the highly crosslinked resin can be preferentially crosslinked, and the thermoplastic resin can be easily prepared. The most preferred method is to crosslink a highly crosslinkable resin and the same crosslinkable resin having the same melt index as the crosslinkable resin and having the crosslinkable functional group together with the highly crosslinkable resin and the low crosslinkable resin.
[0067]
As a crosslinkable resin of the same kind as a highly crosslinkable resin having a crosslinkable functional group having almost the same melt index as that of the highly crosslinkable resin, there is a particular limitation as long as it is a thermoplastic resin having a reactive functional group and capable of being crosslinked. Not. Examples of such a functional group include the above-described thermoplastic resins having an unsaturated group such as a vinyl group, an allyl group, or a propenyl group, a hydroxyl group, a carboxyl group, an epoxy group, an amino group, a silanol group, or a silanate group. It is done.
[0068]
Specific examples of the crosslinkable resin include maleic acid-modified polyethylene, maleic acid-modified polypropylene, silane-modified polyethylene, and silane-modified polypropylene. Silane-modified polyethylene and silane-modified polypropylene are the most popular because it is easy to preferentially crosslink highly crosslinkable resins only over highly crosslinkable resins or over low (no) crosslinkable resins, and easy to crosslink after mixing. preferable.
[0069]
If the difference in melt index between the highly crosslinkable resin and the crosslinkable resin is large, it is difficult to preferentially crosslink the highly crosslinkable resin only over the low crosslinkable resin or over the low (no) crosslinkable resin. The difference is preferably 2 g / 10 min or less, more preferably 1 g / 10 min or less.
[0070]
As a method of crosslinking the crosslinkable resin having the above crosslinkable functional group, a method of crosslinking using a peroxide, a method of crosslinking using an isocyanate, a method of crosslinking using an amine, or hydrolysis of a reactive functional group Then, a method of water-crosslinking is mentioned.
[0071]
Since crosslinking after mixing is easy, a method of hydrolyzing a reactive functional group and then water-crosslinking is most preferable.
[0072]
[Foaming agent]
A pyrolytic foaming agent is used as a foaming agent contained in the foamable thermoplastic resin granules and the foamable thermoplastic resin thin film.
[0073]
The pyrolytic foaming agent is not particularly limited as long as it has a decomposition temperature higher than the melting temperature of the thermoplastic resin used. For example, sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, azide compound, Inorganic pyrolytic foaming agents such as sodium hydride; azodicarbonamide, azobisformamide, azobisisobutyronitrile, barium azodicarboxylate, diazoaminobenzene, N, N'-dinitrosopentamethylenetetramine, P- Examples thereof include toluenesulfonyl hydrazide, P, P′-oxybisbenzenesulfonyl hydrazide, trihydrazinotriazine, etc., and azodicarbonamide, which is easy to adjust the decomposition temperature and decomposition rate, has a large amount of gas generation, and is excellent in hygiene, is preferable. .
[0074]
If the amount of the pyrolytic foaming agent added is too large, bubbles are broken and uniform cells are not formed. Conversely, if the amount is too small, foaming may not be sufficiently achieved. It is preferable to make it contain in the ratio of 1-25 weight part with respect to 100 weight part of resin.
[0075]
[Other components that can be added]
In order to increase the strength of the thermoplastic resin foam, the thermoplastic resin used in the foamable thermoplastic resin granules and the foamable thermoplastic resin thin film may include a glass short fiber, a carbon short fiber, Reinforcing materials such as polyester short fibers; fillers such as calcium carbonate, aluminum hydroxide, and glass powder may be added.
[0076]
In addition, when the filler is added, if the addition amount is large, the cell is destroyed at the time of foaming, and a foam having a high expansion ratio cannot be obtained. If the addition amount is small, an effect of reinforcing the obtained foam is obtained. It may not be obtained sufficiently. Therefore, the addition amount of the filler is preferably 100 parts by weight or less, particularly preferably 50 parts by weight or less with respect to 100 parts by weight of the thermoplastic resin.
[0077]
[Foaming thermoplastic resin sheet]
In the foamable thermoplastic resin sheet-like body, the foamable thermoplastic resin granules are arranged substantially uniformly in a plane, and the foamable thermoplastic resin granules are integrated with each other through the foamable thermoplastic resin thin film. It is connected. The shape of the foamable thermoplastic resin granules is not particularly limited, and examples thereof include hexagons, cylinders, and spheres. When the foamable thermoplastic resin granules are foamed, foaming is uniformly performed. A cylindrical shape is most preferable for the purpose.
[0078]
When the foamable thermoplastic resin granule is cylindrical, the diameter is not particularly limited because it varies depending on the foaming ratio, thickness, etc. of the target concavo-convex thermoplastic resin foam, but if it is too large If the foaming rate is too low and the foaming speed is too small, the cylinder melts and deforms due to heating during foaming, is easily deformed, and cannot exhibit primary foaming properties, resulting in large variations in thickness accuracy and weight accuracy. Therefore, when the foamable thermoplastic resin granule is a cylinder, the diameter is preferably 1 to 30 mm, and particularly preferably 2 to 20 mm.
[0079]
When the foamable thermoplastic resin granule is cylindrical, the height is not particularly limited because it varies depending on the foaming ratio, thickness, etc. of the target thermoplastic resin foam, but if it is too high, the foaming If the speed is reduced and it is too low, foaming occurs at the same time as the foamable thermoplastic resin thin film, so that it expands greatly in the width direction and longitudinal direction. Therefore, the height of the columnar foamable thermoplastic resin granules is preferably 1 to 30 mm, more preferably 2 to 20 mm.
[0080]
The distance between the foamable thermoplastic resin granules is not particularly limited because it varies depending on the foaming ratio, thickness, etc. of the target thermoplastic resin foam, but if the distance is too long, the foaming heat When the plastic resin granular material is foamed, there is a possibility that a large amount of insufficient filling will occur, and if it is too short, it will be completely filled. Accordingly, the center-to-center distance between the foamable thermoplastic resin granules is preferably 2 to 50 mm, more preferably 3 to 30 mm.
[0081]
In order to improve the thickness accuracy and weight accuracy of the finally obtained thermoplastic resin foam, and to make the uneven shape and expansion ratio uniform, the foamable thermoplastic resin granular material is a foamable thermoplastic resin sheet. It is necessary to arrange substantially uniformly in a plane. But the aspect which arrange | positions a thermoplastic resin granular material substantially uniformly planarly is not specifically limited, You may arrange | position to a grid | lattice form and may arrange | position to a zigzag form. When the foamable thermoplastic resin granules are arranged in a lattice shape, the high foamed portion obtained by foaming the individual foamable thermoplastic resin granules becomes a quadrangular prism shape, and uneven thermoplastic resin foaming Since the cushioning property of the body becomes uniform and the compressive strength becomes a sufficient value, the foamable thermoplastic resin granules are preferably arranged in a lattice shape.
[0082]
In addition, when the foamable thermoplastic resin granules are arranged in a staggered manner, the high foamed portion obtained by foaming each foamable thermoplastic resin granule has a hexagonal column shape, so that it is simulated. A simple honeycomb structure is formed. Therefore, the obtained uneven thermoplastic resin foam has a uniform buffer property and a sufficient compressive strength. Therefore, preferably, the foamable thermoplastic resin granules are arranged in a staggered manner.
[0083]
The thickness of the foamable thermoplastic resin thin film is not particularly limited because it varies depending on the foaming ratio, thickness, etc. of the target thermoplastic resin foam, but if it becomes too thick, the foamable thermoplastic resin during foaming When the granular material is moved, the expansion in the width direction and the longitudinal direction increases, and if it is too thin, the foamable thermoplastic resin granular material cannot be retained. Therefore, the thickness of the foamable thermoplastic resin thin film is preferably 0.05 to 3 mm, more preferably 0.1 to 2 mm.
[0084]
[Method for producing foamable thermoplastic resin sheet]
The method for producing the foamable thermoplastic resin sheet is not particularly limited. For example, 1) a thermoplastic resin and a foaming agent constituting the foamable thermoplastic resin sheet are supplied to an injection molding machine. Examples of the method include melting and kneading at a temperature lower than the decomposition temperature of the pyrolytic foaming agent, and injecting into a mold having a concave portion corresponding to the shape of the foamable thermoplastic resin granule, followed by cooling. The thermoplastic resin and foaming agent that make up the thermoplastic resin sheet are supplied to the extruder, melt-kneaded at a temperature lower than the decomposition temperature of the pyrolytic foaming agent, and then the sheet-like foaming thermoplastic in the softened state Introducing a resin into a pair of shaping rolls having a clearance narrower than the thickness of the sheet-like foamable thermoplastic resin and rotating in different directions in which a large number of recesses are uniformly arranged on at least one outer peripheral surface; In the recess After press-fitting the part of the sheet-shaped foamable thermoplastic resin state, cooling method for releasing being most preferred.
[0085]
The method 2) will be described in more detail.
First, in order to obtain a sheet-like foamable thermoplastic resin in a softened state, there are usually a method of melt-kneading and extruding a foamable thermoplastic resin with an extruder and a method of melting using a calender roll. The melting used is most preferable from the viewpoint of continuous weight accuracy and quantitativeness.
[0086]
The form of the foamable thermoplastic resin in the softened state is not particularly limited as long as it can be continuously molded, and examples thereof include a sheet form and a large number of strand forms. From the viewpoint, the sheet form is most preferable.
[0087]
The concave portions on the outer peripheral surface of the shaping roll are preferably disposed substantially uniformly in order to improve the weight accuracy and thickness accuracy of the foamable thermoplastic resin sheet. The arrangement of the recesses on the outer peripheral surface of the shaping roll is not particularly limited as long as it is uniform over the entire outer peripheral surface of the shaping roll, but it is most preferable that it is arranged in a lattice or a staggered manner because it is more uniform. .
[0088]
The shape of the concave portion on the outer peripheral surface of the shaping roll is not particularly limited, and examples thereof include hexagonal shape, columnar shape, spherical shape, etc., but it is easy to form the concave portion, and the foamable thermoplastic resin granules are uniform. The columnar shape is most preferable because it is easy to mold and is easy to release after cooling.
[0089]
When the shape of the concave portion on the outer peripheral surface of the shaping roll is cylindrical, the diameter of the column is not particularly limited because it varies depending on the shape of the desired foamable thermoplastic resin sheet. Is difficult to release, the foamable thermoplastic resin thin film is torn, and if it is too small, the foamable thermoplastic resin granules are destroyed at the time of mold release after cooling, so that 1 mm to 30 mm is preferable, and 2 mm to 20 mm is particularly preferable.
[0090]
When the shape of the concave portion on the outer peripheral surface of the shaping roll is a columnar shape, the height of the column is not particularly limited because it varies depending on the shape of the target foamed thermoplastic resin sheet, but if it is too high, it will be cooled. It is difficult to perform subsequent release, the foamable thermoplastic resin thin film is torn, and if it is too low, a foamable thermoplastic resin sheet that can perform one-dimensional foaming cannot be formed, preferably 1 mm to 30 mm, particularly preferably 2 mm to 20 mm. .
[0091]
The clearance of the shaping roll needs to be narrower than the thickness of the soft sheet-like foamable thermoplastic resin. Therefore, if it is within this range, it changes depending on the shape of the desired foamable thermoplastic resin sheet, and is not particularly limited. However, if it is too thick, a foamable thermoplastic resin sheet that can perform one-dimensional foaming is formed. When it becomes impossible and it is too thin, the foamable thermoplastic resin thin film is easily broken at the time of mold release after cooling, so 0.05 mm to 3 mm is preferable, and 0.1 mm to 2 mm is particularly preferable.
[0092]
The method of press-fitting a part of the softened sheet-like foamable thermoplastic resin into the recesses is to form the roll into the softened sheet-like foamable thermoplastic resin by not changing the clearance of the pair of shaped rolls. It is accomplished by applying pressure from.
[0093]
The method for cooling the softened sheet-like foamable thermoplastic resin that has been partially pressed and shaped is not particularly limited as long as it can be lowered below the melting point of the foamable thermoplastic resin. There are methods such as flowing water.
[0094]
[Hard plate]
The hard plate-like body used in the present invention 1 to 11 is not particularly limited as long as it is a material that is not easily broken or damaged by a load normally applied to the flooring material.
1) Wood materials such as wood veneer, plywood, particle board, medium density fiber board (MDF), high density fiber board (HDF), hard board, parallel plywood (LV),
2) Resin materials made of thermoplastic resins such as polyethylene, polypropylene and polyvinyl chloride, thermosetting resins such as polyester and epoxy resins,
3) Composite materials such as fiber reinforced thermosetting resin, fiber reinforced thermoplastic resin,
Etc.
[0095]
If necessary, a surface decorative material such as a veneer, a synthetic resin or a synthetic resin foam sheet, decorative paper, or a synthetic resin impregnated sheet may be adhered to and laminated on the hard plate-like body. Furthermore, printing, painting, coloring, coating, and the like may be performed in order to impart designability, wood texture, scratch resistance, and the like.
[0096]
The hard plate-like body may be provided with a concave groove extending in an arbitrary direction on the laminated surface with the thermoplastic resin foam, thereby further reducing the bending rigidity of the hard plate-like body and further improving soundproofing. It is possible to improve. The shape of the concave groove is usually formed in a U-shape, V-shape, U-shape or the like, the groove width is 1 to 5 mm, and the groove depth is about 1 to 5 mm.
[0097]
The hard plate-like body may be subjected to processing for a conventionally known joining method, such as actual rowing or phase notch, on all or a part of the periphery thereof.
[0098]
If the thickness of the rigid plate-like body is too thin, it is easy to break when walking or placing a heavy object, and if it is too thick, the soundproofing property is reduced, so 2 to 12 mm is preferable, more preferably 2 to 9 mm. Preferably it is 2-6 mm.
[0099]
The ratio of the thickness of the hard plate to the thickness of the thermoplastic resin foam is such that if the thickness of the hard plate is too thick compared to the thickness of the thermoplastic resin foam, the rigidity of the flooring will increase and soundproofing When the thickness is too thin, it is likely to be destroyed when walking or placing a heavy object. Therefore, the thickness of the hard plate is preferably 1 to 10 times, more preferably 1 to 5 times, most preferably Preferably it is 1-3 times.
[0100]
The thickness of the flooring is not particularly limited, but if it is too thick, the ceiling of the room becomes low and the sinking during walking increases, so it is preferably 65 mm or less.
[0101]
The flooring material of the present invention 9 is a flooring material in which a hard plate-like body is laminated on the surface opposite to the surface on which the high foaming portion of the continuous foaming layer is disposed, but such flooring material has soundproofing properties. It is further improved and more preferable.
[0102]
[Other laminated materials]
For example, the flooring according to any one of claims 1 to 9 is laminated between a hard plate-like body and a hard foam to improve buffering, vibration control, sound insulation, etc., if necessary. A resin sheet, a woven fabric, a non-woven fabric, or a foamed sheet may be laminated.
[0103]
Examples of the resin sheet laminated for improving the above-described buffering property, vibration damping property, sound insulation property, etc. include thermoplastic resins such as polyethylene, polypropylene, polyethylene vinyl acetate, and polyvinyl chloride, and resin sheets of these copolymers: Resin sheet of thermosetting resin such as unsaturated polyester, urethane, epoxy, etc., vulcanization of isoprene rubber, butadiene rubber, styrene-butadiene rubber, butyl rubber, nitrile rubber, ethylene-propylene rubber, etc., resin sheet of non-vulcanized rubber, etc. Is mentioned.
The resin sheet also includes a composite resin sheet in which the resin is filled with an inorganic, organic, or metal material.
[0104]
If the resin sheet is too thick, the sinking of the flooring material will increase, and if it is too thin, the effects of buffering, damping, and sound insulation cannot be exhibited. Most preferred is ˜3 mm.
[0105]
The woven fabric or non-woven fabric laminated to improve buffering, damping properties, sound insulation, etc. is composed of inorganic fibers such as glass fibers and carbon fibers, organic fibers such as polypropylene, polyester, nylon and aramid. Things.
[0106]
If the woven fabric or non-woven fabric is too thick, sinking of the flooring material becomes large, and if it is too thin, effects such as buffering properties, vibration damping properties, and sound insulation properties cannot be exhibited, so 30 to 1000 g / m. ² Is preferred, 50-800 g / m ² Is more preferable, 80-500 g / m ² Is most preferred.
[0107]
Foamed sheets that are laminated to improve buffering, vibration damping, sound insulation, etc., include resins such as polyethylene, polypropylene, polyethylene vinyl acetate, polyvinyl chloride, unsaturated polyester, urethane, and copolymers thereof. The thing which becomes.
[0108]
If the foamed sheet is too thick, the sinking of the flooring material becomes large. If the foamed sheet is too thin, the effects of buffering, damping, and sound insulation cannot be exhibited. Most preferred is ˜3 mm.
[0109]
In the flooring material according to claim 10, a non-land absorbing layer is formed on the back surface of the thermoplastic resin foam.
[0110]
The uneven absorption layer adjusts unevenness with the floor slab, and is preferably a soft foam, and is particularly limited as long as it has a relatively low compression modulus relative to the thermoplastic resin foam. For example, a polyethylene foam having an expansion ratio of 10 to 30 times, a polyurethane foam having an expansion ratio of 20 to 40 times, and the like can be given.
[0111]
The compression elastic modulus of the soft foam (C) is not particularly limited, but if it is too small, the feeling of walking decreases (the above-mentioned “fluffy” state), and if it is too large, the soundproofing performance decreases, so 0.2-3 kg. / Cm ² Is preferred.
[0112]
If the thickness of the non-land absorbing layer is too thick, the sinking of the flooring material becomes large, and if it is too thin, the non-land absorbing effect cannot be expressed. Therefore, the thickness is preferably 300 μm to 10 mm, more preferably 500 μm to 5 mm, and most preferably 1 to 3 mm. preferable.
[0113]
[Lamination method of thermoplastic resin foam, hard plate and other laminated materials]
Examples of a method for laminating the thermoplastic resin foam and the hard plate-like body include a laminating method using an adhesive or a pressure-sensitive adhesive. Examples of the adhesive used include vinyl acetate-based and vinyl ester-based adhesives and chloroprene-based adhesives, and examples of the pressure-sensitive adhesive include acrylic pressure-sensitive adhesives.
[0114]
In order to improve adhesiveness and tackiness, it is also preferable to perform corona treatment or primer treatment on at least one surface of the thermoplastic resin foam.
[0115]
[Construction method for flooring]
The flooring material according to claims 1 to 10 is a flooring material that is directly bonded or adhered to a floor base material such as concrete, but in addition, on the upper surface of a plywood or particle board laid on joists or pillars. You may construct with an adhesive or an adhesive.
[0116]
A flooring material according to an eleventh aspect is one in which the flooring material according to the first to tenth aspects is directly laminated on a floor slab.
[0117]
The floor material is directly attached to a floor slab such as concrete of a collective food house directly with an adhesive or an adhesive. The thickness of the flooring is generally 5 to 20 mm, and 12 mm and 15 mm are frequently used as standard sizes.
[0118]
The thickness of the floor slab on which the floor material is laminated is suitably 100 to 250 mm.
(Function)
[0119]
The flooring material according to claim 1 is a flooring material in which a hard plate is laminated on one side of a thermoplastic resin foam, wherein the thermoplastic resin foam comprises a sheet-like continuous foam layer and the continuous foam layer. A plurality of high foam portions disposed on at least one surface of the foam layer, and a low foam thin film covering the entire surface of the high foam portion together with the continuous foam layer,
The high foamed portion covered with the low foamed thin film is formed in a convex shape from the continuous foamed layer, and a concave portion is formed between adjacent high foamed portions, thereby forming irregularities on the back surface of the thermoplastic resin foam. As a result, the back surface of the thermoplastic resin foam is uneven, so that even if it has a high compression modulus, the flexural rigidity does not increase, so an impact was given on the flooring. Even when the buffer layer is thin, the impact action time can be extended, and a small amount of compressive deformation and high soundproofing can be exhibited. In addition, since the continuous foam layer connects the individual high foams, destruction during walking or loading of heavy objects hardly occurs. Therefore, the “sea sickness phenomenon” at the time of walking can be eliminated, and the flooring material has excellent soundproofing performance and good walking feeling.
[0120]
The flooring material according to claim 2 is a flooring material in which a hard plate-like body is laminated on one surface of a thermoplastic resin foam, and the thermoplastic resin foam comprises a sheet-like continuous foam layer and the continuous foam layer. A plurality of high foam portions disposed on the back surface of the foam layer, and a low foam thin film covering the entire surface of the high foam portion together with the continuous foam layer. The high foam portion is formed in a convex shape from the continuous foam layer. Since the adjacent high foamed portions are formed in a concave shape, and the surface side of the continuous foamed layer in contact with each high foamed portion is formed in a concave shape, the rigid plate-like body and the thermoplastic resin foam The contact of the body becomes partial, and the vibration of the hard plate-like body becomes difficult to propagate to the thermoplastic resin foam, and the soundproofing is further improved by the vibration attenuation occurring in the space formed by the recess.
[0121]
The flooring material according to claim 3 is the flooring material according to claim 1 or 2, wherein the high foaming portions are connected to each other via a low foaming thin film, so that the high foaming portions are in close contact with each other. Since the load is integrated and dispersed by improving the property, destruction at the time of walking or loading a heavy object hardly occurs.
[0122]
The flooring material according to claim 4 is the flooring material according to claim 3, in which the adjacent low-foaming thin films are heat-sealed to each other, and the adhesion is further improved.
[0123]
The flooring material according to claim 5 is the flooring material according to any one of claims 1 to 4, wherein the high foamed portions are arranged in a lattice shape or a staggered shape with respect to the continuous foamed layer. The high-foamed foam becomes prismatic or hexagonal, and the thickness accuracy and weight accuracy of the thermoplastic resin foam are small. Therefore, the compressive strength and strength variation are also improved. Is even better.
[0124]
The flooring material according to claim 6 is the flooring material according to any one of claims 1 to 5, wherein the height of the convex forming portion on the side of the high foaming portion protrudes 3 mm or more from the concave forming portion, and the bending rigidity is high. By further lowering, the amount of deformation when an impact is generated on the flooring material is increased, thereby further improving soundproofing.
[0125]
The flooring material according to claim 7 is the flooring material according to any one of claims 1 to 6, wherein when the high foaming portion side of the flooring material is placed on the flat plate, the convex forming portion of the high foaming portion contacts the flat plate. Since the area is 10 to 70% of the cross-sectional area of the hard plate-like body and the contact area is small, the cushioning property is increased, the soundproofing performance can be improved, and the foam can be prevented from being deformed. It becomes a soundproof flooring material that further balances the feeling.
[0126]
The flooring material according to claim 8 is the flooring material according to claim 1, wherein the filling ratio of the thermoplastic resin foam is 50 to 90%, and high sound insulation and high strength of the foam are achieved by the uneven space. Both can be enhanced, and the soundproof flooring material can achieve both high soundproofing and good walking feeling.
[0127]
The flooring material according to claim 9 is the flooring material according to claim 1, wherein a hard plate-like body is laminated on one surface of the sheet-like body forming the thermoplastic resin foam, and a high foaming is formed on the other surface side. Since the projecting portion is projecting, the convex portion becomes the lower surface when constructed, the contact area with the construction surface is reduced, and the space is formed between the construction surface and the soundproofing is further improved. .
[0128]
The flooring material according to claim 10 is the flooring material according to claim 1, wherein a non-land absorbing layer is formed on the back surface of the thermoplastic resin foam. It can be absorbed and the construction of the flooring becomes easy and the finish is improved.
[0129]
The flooring material according to claim 11 is obtained by directly laminating the flooring material according to claims 1 to 10 on the floor slab. In addition to the compatibility between high soundproofing and gait, workability is also improved.
【Example】
[0130]
The present invention will be described in more detail with reference to examples.
Example 1
Thermoplastic resin foam
High density polyethylene (Mitsubishi Chemical Corporation, trade name “HY340”, MI = 1.5 g
/ 10 minutes) 50% by weight, silane-grafted polypropylene (trade name “XPM800H”, manufactured by Mitsubishi Chemical Corporation, MI = 11 g / 10 minutes, gel fraction 80% by weight after crosslinking) 20% by weight, polypropylene (manufactured by Mitsubishi Chemical Corporation) , Trade name "MA3", melt index (MI) = 11 g / 10 min) 30 wt% thermoplastic resin 100 parts by weight, azodicarbonamide (manufactured by Otsuka Chemical Co., Ltd., trade name: SO-20, decomposition temperature 210 ° C) ) A composition containing 4 parts by weight and 0.1 part by weight of dibutyltin dilaurate as a silane crosslinking catalyst was supplied to the twin-screw extruder 11 shown in FIG.
[0131]
As the biaxial extruder 11, the one having a diameter of 44 mm was used. In the twin-screw extruder 11, the composition was melt-kneaded at 180 ° C., and the sheet-like foamable thermoplastic resin in a softened state was extruded by a T die 12 having a surface length of 500 mm and a lip of 1.0 mm.
[0132]
Furthermore, the number of cylindrical recesses 13a having a depth of about 10 mm and a diameter of 4 mm is 1 / cm. ² The foamable thermoplastic resin sheet is shaped between the rolls 13 and 14 (clearance 0.2 mm) having a diameter of 250 mm and a surface length of 500 mm, which are randomly arranged only on the shaping roll 13 so as to obtain a density of While cooling, the foamed thermoplastic sheet was immersed in 98 ° C. water for 2 hours and then dried, so that the measured height, average 5.5 mm, standard deviation 1 mm; 1 thermoplastic resin granule / cm ² A foamable thermoplastic resin sheet-like body as shown in Table 1 was obtained that was randomly formed so as to have a density of 5%.
[0133]
In the foamable thermoplastic resin sheet 1 obtained as described above, the foamable thermoplastic resin granules 2 are connected by the foamable thermoplastic resin thin film 3, and the foamable thermoplastic resin sheet 1 as a whole. Was configured.
[0134]
The obtained foamable thermoplastic resin sheet-like body 1 is cut into 300 × 900 mm, and disposed on the polyfluorinated ethylene sheet 15 as shown in FIGS. 2 (a) to 2 (e). 16 is arranged on the upper surface, and the thickness between the polyfluorinated ethylene sheets 15 and 16 is 10 mm by hand press and heated and foamed at 210 ° C. for 10 minutes, and then cooled by a 30 ° C. cooling press for 10 minutes. Thus, an uneven thermoplastic resin foam (FIG. 3) having an expansion ratio of 8 times and a thickness of 10 mm was obtained.
[0135]
The foam includes a plate-like continuous foam layer 3, a plurality of high foam portions 2 arranged on one side of the continuous foam layer 3, and a low foam covering the surface of the high foam portion 2 together with the continuous foam layer 3. Consisting of a foamed thin film 4, the high foamed portions 2 are each formed in a convex shape with respect to the continuous foamed layer 3, and the surface side of the continuous foam 3 in contact with each high foamed portion 2 is formed in a concave shape. The part corresponding to the convex part of the foam 3 was cut into a smooth shape.
[0136]
In addition, the expansion ratio of the obtained thermoplastic resin foam and the thickness of the foam were measured by the following methods.
[0137]
(Foaming ratio)
The expansion ratio was measured according to JIS K6767.
(Thickness of foam)
Using calipers, the thickness of the obtained thermoplastic resin foam was measured.
[0138]
(Fabric production)
A laminating plywood with a 0.3 mm thick veneer (made by Kitasansha, trade name “White Oak”) is bonded with an aqueous vinyl urethane resin (trade name “KR120”, produced by Koyo Sangyo Co., Ltd.), and the thickness is 4.0 mm. A hard plate was obtained.
The thermoplastic resin foam adjusted to a thickness of 8 mm using an acrylic pressure-sensitive adhesive (trade name “# 5782” manufactured by Sekisui Chemical Co., Ltd.) is bonded and laminated to the obtained hard plate, and a flooring (thickness of 12 mm) is obtained. (FIG. 4) was obtained.
[0139]
In addition, the whole thickness of the obtained flooring material, the thickness of a foam, the presence or absence of formation of a concave shape, the presence or absence of close contact, arrangement | positioning, the height of a convex part, an area rate, and the filling rate were measured with the following method.
[0140]
(Thickness of the whole flooring, foam, and hard plate)
Using calipers, the individual thicknesses of the resulting flooring were measured.
(Presence / absence of depression, presence / absence of close contact, arrangement)
The produced flooring was visually observed.
(Convex height)
The height of the convex portion with respect to the continuous layer was measured with a caliper.
(Area ratio)
The colored area ratio when the foam convex part of the flooring was colored and transferred to a flat plate was measured.
(Filling rate)
(Arrangement weight (g / m ² ) × foaming ratio) / (foam thickness × 1000) × 100.
[0141]
Examples 2-10
The foamed thermoplastic resin sheet-like material as shown in Table 1 was obtained in the same manner as in Example 1 except that the roll recess arrangement mode was changed to obtain the foamable thermoplastic resin sheet-like material shown in Table 1. It was. In addition, the reason why the roll recess arrangement mode in the table is “random” is that the recess 13a is 1 piece / cm. ² The “lattice” indicates that the recesses 13a are in a grid pattern (see FIG. 5) at the intervals shown in Table 1, and the “staggered” indicates the recesses. It shows that 13a is arrange | positioned at the space | interval shown in Table 1 at zigzag form (refer FIG. 6).
[0142]
In the foamable thermoplastic resin sheet 1 obtained as described above, the foamable thermoplastic resin granules 2 are connected by the foamable thermoplastic resin thin film 3, and the foamable thermoplastic resin sheet 1 as a whole. Was configured.
[0143]
The obtained foamable thermoplastic resin sheet 1 was cut into 300 × 900 mm, and disposed on the polyfluorinated ethylene sheet 15 as shown in FIG. 2, and further the polyfluorinated ethylene sheet 16 was disposed on the upper surface thereof. Then, with a hand press, the polyfluorinated ethylene sheets 15 and 16 are made to have the gaps shown in Table 1 and heated and foamed at 210 ° C. for 10 minutes, then cooled at 30 ° C. for 10 minutes, and the expansion ratio An uneven thermoplastic resin foam (FIG. 7) having a size of 8 times and a thickness of 8 mm was obtained.
[0144]
The foam is composed of a continuous foam layer of a plate-like body, a plurality of high foam portions disposed on at least one side of the continuous foam layer, and a low foam thin film that covers the surface of the high foam portion together with the continuous foam layer. Further, the high foamed portion is formed in a convex shape with respect to the continuous foamed layer, and the surface side 3a of the continuous foam corresponding to each high foamed portion is formed in a concave shape.
[0145]
In addition, the expansion ratio of the obtained thermoplastic resin foam and the thickness of the foam were measured in the same manner as in Example 1.
[0146]
Further, in the same manner as in Example 1, the thermoplastic resin foam obtained as a hard plate was adhered and laminated to the laminated surface shown in Table 1 to obtain the flooring shown in FIG.
[0147]
Furthermore, in Example 10, a non-landing layer made of polyurethane foam (foaming ratio 40 times, 2.5 mm thickness) was adhered and laminated on the surface opposite to the surface on which the rigid plate of thermoplastic resin foam was laminated. The flooring shown in FIG. 9 was obtained.
[0148]
Comparative Example 1
The flooring material was a 12 mm thick hard plate obtained by adhering the same 0.3 mm veneer to Lauan plywood as in Example 1.
[0149]
Comparative Example 2
A soft sheet-like foaming thermoplastic obtained in the same manner as in Example 1 except that azodicarbonamide (trade name: SO-20, decomposition temperature 210 ° C., manufactured by Otsuka Chemical Co., Ltd.) was increased to 5 parts by weight. The resin is cooled between rolls having a diameter of 250 mm and a surface length of 500 mm (clearance: 1 mm) having no recesses, and further immersed in water at 98 ° C. for 2 hours and then dried to obtain a foamable thermoplastic resin having a thickness of 1.0 mm. A resin sheet was obtained.
The obtained foamable thermoplastic resin sheet was foamed in the same manner as in Example 1 to obtain a foam having a thickness of 2.2 mm. Four foams obtained were stacked and laminated, and thermocompression bonded to obtain a thermoplastic resin foam having a thickness of 8.0 mm. The obtained thermoplastic resin foam was adhesively laminated with the thermoplastic resin foam obtained in the same manner as in Example 1 to obtain a flooring material.
[0150]
Comparative Example 3
Azodicarbonamide (Otsuka Chemical Co., Ltd., trade name: SO-20, decomposition temperature 210
The foamed thermoplastic resin sheet is shown in Table 1 in the form of roll recesses in the softened sheet-like foamable thermoplastic resin obtained in the same manner as in Example 1 except that the temperature is increased to 5 parts by weight. A foamable thermoplastic resin sheet-like material as shown in Table 1 was obtained in the same manner as in Example 1, except that it was changed to obtain
[0151]
The obtained foamable thermoplastic resin sheet 1 was cut into 300 × 900 mm, and disposed on the polyfluorinated ethylene sheet 15 as shown in FIG. 2, and further the polyfluorinated ethylene sheet 16 was disposed on the upper surface thereof. Then, with a hand press, the polyfluorinated ethylene sheets 15 and 16 are made to have the gaps shown in Table 1 and heated and foamed at 210 ° C. for 10 minutes, then cooled at 30 ° C. for 10 minutes, and the expansion ratio A thermoplastic resin foam having a size of 8 times and a thickness of 8 mm was obtained.
[0152]
The foam is composed of a continuous foam layer of a plate-like body, a plurality of high foam portions disposed on at least one side of the continuous foam layer, and a low foam thin film that covers the surface of the high foam portion together with the continuous foam layer. Each of the high foamed portions was a flat foam that was heat-sealed through a low foam thin film.
Further, in the same manner as in Example 1, the thermoplastic resin foam obtained as a hard plate was adhered and laminated to the laminated surface shown in Table 1 to obtain a flooring.
[0153]
[Table 1]

[0154]
The flooring materials obtained in Examples 1 to 10 and Comparative Examples 1 to 3 were subjected to the following evaluation, and the results are summarized in Table 2.
[0155]
Evaluation of flooring
▲ 1 ▼ Subduction amount
The obtained flooring was cut to 200 × 200 mm, a steel cylindrical indenter with a diameter of 50 mm was placed on the side of the hard plate, and the amount of sinking was measured when a compression load of 80 kgf was applied at a speed of 2 m / min. .
[0156]
(2) Soundproof performance
The light floor impact noise level was measured according to JIS A1418.
[0157]
(3) Non-land absorption
Visually check the degree of contact with a pseudo flat plate with 2 mm uneven parts by arranging three floors in parallel.
A four-level evaluation was made based on the following criteria.
◎: Completely closely
○: The gap between the flat plate and the flooring is less than 0.5 mm
Δ: The gap between the flat plate and the flooring is 0.5 to 1.5 mm.
X: The clearance between the flat plate and the flooring is 1.5 mm or more.
[0158]
[Table 2]

[0159]
【The invention's effect】
Since the flooring according to claim 1 is configured as described above, the flooring is excellent in soundproofing performance and has a good walking feeling.
[0160]
Since the flooring material according to the second aspect is configured as described above, the soundproofing property is further improved.
[0161]
Since the flooring of Claims 3-5 is set as the above-mentioned structure, a walk feeling becomes still better.
[0162]
Since the flooring material according to the sixth aspect is configured as described above, the soundproofing property is further improved.
[0163]
Since the flooring material of Claims 7 and 8 is configured as described above, the soundproofing and the walking feeling are more compatible.
[0164]
Since the flooring according to claim 9 is configured as described above, it has good soundproofing properties and excellent workability.
[0165]
Since the flooring according to claim 10 is configured as described above, the workability is further improved.
[0166]
Since the flooring material of Claim 11 is directly pasting the flooring material of Claims 1 to 10, it is excellent in workability in addition to soundproofing and walking.
[Brief description of the drawings]
FIG. 1 is a process diagram for explaining an example of a method for producing a foamable thermoplastic resin that can be used in the present invention (claims 1 to 11).
2A to 2E are cross-sectional views for explaining an example of a method for producing a thermoplastic resin foam that can be used in the present invention (claims 1 to 11).
3 is a cross-sectional view showing a thermoplastic resin foam obtained in Example 1. FIG.
4 is a cross-sectional view showing a flooring material obtained in Example 1. FIG.
FIG. 5 is a plan view for explaining a state in which foamable thermoplastic resin granules are arranged in a lattice pattern.
FIG. 6 is a plan view for explaining a form in which foamable thermoplastic resin granules are arranged in a staggered manner.
7 is a cross-sectional view showing a thermoplastic resin foam obtained in Examples 2 to 10. FIG.
FIG. 8 is a cross-sectional view showing a flooring material obtained in Examples 2-9.
9 is a cross-sectional view showing a flooring material obtained in Example 11. FIG.
[Explanation of symbols]
1 Thermoplastic foam
2 High foam
3 Continuous foam layer
3a continuous foam layer
4 Low foam thin film
5 Foamed thermoplastic resin sheet
6 Foamed thermoplastic resin granules
7 Foamed thermoplastic resin thin film
11 Twin screw extruder
12 T-die
13 Forming roll
14 Forming roll
15 seats
16 sheets
21 Hard plate
22 Non-land

Claims (11)

A flooring material in which a hard plate-like body is laminated on one side of a thermoplastic resin foam, wherein the thermoplastic resin foam is disposed in plural on a sheet-like continuous foam layer and at least one surface of the continuous foam layer. And a low foam thin film covering the entire surface of the high foam part together with the continuous foam layer,
The high foamed portion covered with the low foamed thin film is formed in a convex shape from the continuous foamed layer, and concave portions are formed between adjacent high foamed portions, thereby forming irregularities on the back surface of the thermoplastic resin foam. Flooring characterized by being made. A flooring material in which a hard plate-like body is laminated on one side of a thermoplastic resin foam, and a plurality of the thermoplastic resin foams are disposed on a sheet-like continuous foam layer and the back surface of the continuous foam layer. And a low-foamed thin film that covers the entire surface of the high-foamed portion together with the continuous foamed layer. The flooring material is characterized in that it is formed in a concave shape and the surface side of the continuous foamed layer in contact with each highly foamed portion is formed in a concave shape. The flooring according to claim 1 or 2, wherein the high foaming portions are connected to each other through a low foaming thin film. The flooring according to claim 3, wherein the high foamed portions are connected to each other through a low foamed thin film that is heat-sealed. The flooring according to claim 1, wherein the highly foamed portion is arranged in a lattice shape or a zigzag shape with respect to the continuous foamed layer. 6. The flooring material according to claim 1, wherein a height of the convex forming portion on the side of the high foaming portion protrudes from the concave forming portion by 3 mm or more. When the high foamed portion side of the flooring material is placed on a flat plate, the contact area of the convex portion of the high foamed portion with the flat plate is 10 to 70% of the cross-sectional area of the hard plate-like body. The flooring material according to claim 1. The flooring material according to claim 1, wherein the volume of the thermoplastic resin foam is 50 to 90% with respect to the volume of the smallest rectangular parallelepiped that can circumscribe the thermoplastic resin foam. The floor according to claim 1, wherein a hard plate-like body is laminated on one surface of the sheet-like body forming the thermoplastic resin foam, and a high-foaming portion protrudes on the other surface side. Wood. The flooring material according to claim 1, wherein a non-land absorption layer is formed on the back surface of the thermoplastic resin foam. The flooring material according to claim 1, wherein when the hard plate-like body is used as the surface, the back surface is directly attached to the floor slab.

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