JP4197766B2 - Non-halogen flooring - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a halogen-free flooring.
[0002]
[Prior art]
Conventionally, synthetic resin flooring has been used to decorate the floor of a building.
This synthetic resin flooring consists of a vinyl chloride resin floor material using vinyl chloride resin and a floor material using halogen-free synthetic resin such as olefin resin and acrylic resin (non-halogen floor material). ).
[0003]
[Problems to be solved by the invention]
By the way, the synthetic resin flooring generally has a structure in which a plurality of types of layers are laminated. Particularly when an olefin-based resin is used, corona discharge treatment and primer treatment are performed when laminating each layer. It is necessary to apply.
That is, since the olefin resin is inferior in adhesiveness as compared with the vinyl chloride resin and the like, the corona discharge treatment and the primer treatment described above are necessary as a treatment for supplementing it.
[0004]
In addition, the above synthetic resin flooring is required to have dimensional stability. In order to satisfy such characteristics, a fibrous base material made of glass fiber or a fibrous base material containing glass fiber (hereinafter referred to as “glass base material”). In many cases, these are collectively referred to as “glass fiber base material”, but normally used glass fiber base materials are excellent in dimensional stability, but are printed directly on this surface and are clear. It was thought that it was virtually impossible to apply a printed pattern.
Therefore, when it is going to give a pattern by printing to the flooring using such a glass fiber base material, this glass fiber base material surface is not printed directly on the glass fiber base material surface. In the case where an olefin resin is used as the synthetic resin for forming the synthetic resin layer, the corona discharge for improving the adhesion of the printing ink is performed. It is necessary to perform treatment and primer treatment.
[0005]
Thus, in producing the above-mentioned non-halogen flooring, particularly non-halogen flooring using an olefin resin, it is necessary to perform corona discharge treatment or primer treatment when laminating each layer or performing printing. Since the process for such a process increases, there exists a problem that a manufacturing process becomes complicated.
[0006]
The present invention has been made to solve the above-described problems, and is a non-halogen floor material using a glass fiber base material having excellent dimensional stability, and is manufactured without performing corona discharge treatment or primer treatment. It is intended to provide a non-halogen flooring that can be used.
[0007]
[Means for Solving the Problems]
The non-halogen floor material of the present invention made in order to solve the above problems has a surface roughness number of 200 to 350/10 mm, an average roughness depth measured using a non-contact type surface roughness meter as a fibrous base material. Using a laminated fibrous base material in which a glass fiber base material is laminated on the back surface of an organic fibrous base material having a thickness of 50 to 80 μm and an intrinsic roughness value in the range of 40000 to 120,000, the surface of the laminated fibrous base material A transparent top layer made of a synthetic resin not containing halogen is formed and a backing layer is formed on the back surface of this laminated fibrous base material . The organic fibrous base material forms a transparent top layer. It has a melting point lower than the temperature, and the organic fibrous base material is melted when the transparent top layer is formed .
[0008]
Laminated fibrous base materials used in the present invention are natural animal or vegetable fibers such as cotton, hemp, silk, wool, etc .; synthetic fibers such as polyethylene, polypropylene, polyamide, acrylic, polyester, vinylon; rayon, sufu, Recycled fibers such as acetate; woven fabrics and knitted fabrics obtained from one or more organic fibers selected from the above, or a mixture of inorganic fibers, inorganic fillers, synthetic resin binders, etc., if necessary Fibers mainly composed of glass fibers (including alone) on the back side of organic fibrous base materials such as cloth, non-woven fabric, paper, or laminates thereof, or, if necessary, organic fibers as described above Glass fiber such as woven fabric, knitted fabric, non-woven fabric, paper, or a laminate thereof obtained from a mixture of inorganic fiber other than glass fiber, inorganic filler, synthetic resin binder, etc. It is obtained by laminating the wood.
In addition, when a low melting point organic fiber is used as a fiber constituting the organic fibrous base material or as a part thereof, the low melting point is formed when the transparent top layer is formed as described later. Since the fibers are melted, there is an advantage that the adhesive strength between the transparent top layer and the laminated fibrous base material is further improved.
[0009]
As a method for obtaining such a laminated fibrous base material, a method for obtaining such a laminated fibrous base material by a two-layer papermaking method, an organic fibrous base material and a glass fibrous base material separately produced, and an olefin Although a method of laminating using an appropriate adhesive such as a system adhesive is mentioned, the method of obtaining such a laminated fibrous base material by a two-layer papermaking method has an advantage that it is not necessary to bond in a subsequent step. .
Further, when such a laminated fibrous base material is laminated with an organic fibrous base material and a glass fibrous base material separately produced using an olefinic adhesive, it is composed of an olefinic resin in a subsequent step. When the transparent top layer is formed, the adhesive strength of the transparent top layer is improved. That is, when laminating the organic fiber base material and the glass fiber base material, the olefin adhesive is impregnated into the organic fiber base material, and the transparent top layer made of the olefin resin is formed when the transparent top layer is formed. The olefin resin that forms the top layer is impregnated into the organic fibrous base material. Thus, by the olefinic resin (olefinic adhesive) impregnated from the front side and the back side of the organic fibrous base material. The so-called bridge effect improves the adhesive strength between the transparent top layer and the laminated fibrous base material.
[0010]
The laminated fibrous base material used in the present invention having the structure as described above has a number of irregularities on the surface (that is, the surface of the organic fibrous base material) measured using a non-contact surface roughness meter of 200 to 350. Pieces / 10 mm, the average unevenness depth is 50 to 80 μm, and the intrinsic roughness value is 40000 to 120,000.
By using such a laminated fibrous base material, it is possible to print directly on the laminated fibrous base material surface, and in addition, a corona discharge treatment is performed on the laminated fibrous base material surface thus printed. A transparent top layer made of an olefin resin or the like can be laminated without applying a primer treatment or the like.
In addition, said intrinsic roughness value is the numerical value derived from the result of having measured the unevenness | corrugation of the fibrous base material surface using a non-contact-type surface roughness meter, and the fibrous base in the said measurement range (10 mm) This is the sum of absolute values of the difference (μm) between an arbitrary point Y _i on the material surface and the average value Y ₀ of all Y _i .
[0011]
Printing on the surface of the laminated fibrous base material (organic fibrous base material surface) can be performed using a printing machine such as a gravure printing machine, an offset printing machine, a rotary screen printing machine, a flexographic printing machine, and an inkjet printing machine. However, at this time, it is necessary to take care not to impair the above-mentioned properties of the laminated fibrous base material surface (organic fiber base material surface) by impregnating the organic fiber base material with the resin component in the printing ink. There is.
[0012]
A transparent top layer made of a synthetic resin not containing halogen is formed on the surface of the laminated fibrous base material printed as described above.
Synthetic resins that form this transparent top layer include polyethylene, polypropylene, ethylene-vinyl alcohol copolymer resins, ethylene- (meth) acrylate copolymer resins, ethylene-α-olefin copolymer resins, and other olefin-based resins. In addition, an acrylic resin such as a (meth) acrylic acid ester alone or a copolymer resin can be used.
[0013]
As said synthetic resin which forms the transparent top layer in this invention flooring, it is desirable to use what has a melt index in the range of 0.5-30.
By using a material having a melt index in the above range, the adhesive strength between the printed laminated fibrous base material and the transparent top layer is improved, the workability at the time of production is good, and the flooring material is used. It is possible to obtain a non-halogen floor material that is excellent in various required physical properties.
[0014]
Specifically, as a method for forming the transparent top layer, a composition comprising the synthetic resin as described above and various additives to be added as needed is applied as appropriate means such as a calendar method, an extrusion method, an inflation method, and the like. A method of laminating a transparent sheet or a transparent film obtained by forming into a sheet or film on the surface of a laminated fibrous base material on which printing has been performed, and then performing pressure bonding while heating and melting, a synthetic resin composition as described above Examples of the method include a method of spraying a powder made of a product on the surface of a laminated fibrous base material on which printing has been performed and sintering the powder.
In the non-halogen floor material of the present invention, when the transparent top layer is formed as described above, the synthetic resin composition melted between the fibers constituting the laminated fibrous base material (organic fibrous base material). The transparent top layer adheres firmly to the surface of the fibrous base material due to the anchoring effect.
[0015]
After forming the printed fibrous base material surface transparent top layer as described above, a backing layer is formed on the back side of the fibrous base material.
The backing layer is not particularly limited, and is not particularly different from a conventional non-halogen flooring backing layer. Specifically, a foamed or non-foamed synthetic resin backing layer made of a synthetic resin not containing halogen; one or two or more kinds of fibers selected from organic fibers, glass fibers, inorganic fibers, etc. as described above, or Layers of fibrous backing materials (fibrous backing layers) such as woven fabrics, knitted fabrics, nonwoven fabrics, paper, or laminates obtained from a mixture of inorganic fillers and synthetic resin binders; or laminates thereof, etc. It is.
[0016]
What is suitable as the backing layer of the non-halogen flooring of the present invention is an opaque layer made of the same synthetic resin composition as that for forming the transparent top layer having the fibrous backing layer formed on the back surface.
When the backing layer having such a structure is formed, the same synthetic resin layer is formed on the front surface and the back surface of the laminated fibrous base material. Since the fiber backing layer is formed on the back surface, there is an advantage that the adhesive used when applying the non-halogen flooring of the present invention is not particularly restricted.
[0017]
In the above case, in order to improve the adhesive strength between the back surface of the laminated fibrous base material and the opaque layer made of the synthetic resin, the non-contact type surface on the back surface side (the back surface of the glass fiber base material) It is desirable to use a laminated fibrous base material having an unevenness number of 200 to 350/10 mm measured by a roughness meter, an average unevenness depth of 50 μm or more, and an intrinsic roughness value of 40000 or more.
Furthermore, as a fiber base material, when an organic fiber base material and a glass fiber base material are laminated | stacked using an olefin type adhesive agent, it is as mentioned later like the case where said transparent top layer is formed. There is also an advantage that the adhesive strength of the synthetic resin backing layer when the synthetic resin backing layer made of an olefin resin is formed by the method is improved.
[0018]
Specifically, as a method of forming the synthetic resin backing layer on the back surface of the laminated fibrous base material, a synthetic resin composition comprising the above synthetic resin and various additives added as necessary is calendered. A method in which a foamed or non-foamed opaque sheet obtained by forming into a sheet by an appropriate method such as an extrusion method or an inflation method is superimposed on the back surface of the laminated fibrous base material and then pressure-bonded while being heated and melted, as described above A method of spraying powder composed of a synthetic resin composition on the back side of a laminated fibrous base material and sintering it, and spraying foamable synthetic resin particles made of synthetic resin as described above on the back side of the fibrous base material, A method of foaming and sintering this, a method of extruding the above synthetic resin composition from the T-die of the extruder onto the back surface of the laminated fibrous base material, pressure bonding and cooling, and laminating using an appropriate adhesive (so-called That may be a dry lamination, a method of may also be) a wet lamination, and the like.
[0019]
Moreover, as a method of forming the fibrous backing layer on the back surface of the synthetic resin backing layer, the fibrous backing material is stacked and pressure-bonded while the back side of the synthetic resin backing layer formed as described above is heated and melted. After the method, the synthetic resin composition is extruded from the T-die of the extruder as described above, the fibrous backing material is stacked and pressure-bonded while the synthetic resin composition is in a molten state, and the method is cooled. In this way, when the synthetic resin powder spread on the back side of the laminated fibrous base material is sintered, the fiber backing material is overlaid and crimped, and the foamable synthetic resin particles are spread on the back side of the laminated fibrous base material. A method of laminating and pressing a fiber backing material when heat-foaming / sintering, lamination using an appropriate adhesive (so-called dry laminate or wet laminate) To do , And the like.
[0020]
The non-halogen floor material of the present invention obtained as described above is embossed on the surface, improved surface strength, surface gloss adjustment, cigarette resistance improvement, etc., as with conventional synthetic resin floor materials. The intended surface treatment layer can also be formed.
[0021]
【Example】
Although the specific Example of this invention is given to the following, this invention is not limited to the Example shown below.
[0022]
(Example 1)
On the back surface of the polyester nonwoven fabric having a surface roughness number of 296/10 mm, an average roughness depth of 56 μm, and an inherent roughness value of 76,200 measured using a non-contact type surface roughness meter, an olefin-based adhesive (ethylene- Printed on the surface of a laminated fibrous base material obtained by laminating a glass fiber nonwoven fabric via an adhesive mainly composed of a vinyl acetate copolymer resin, and then an ethylene-methyl methacrylate copolymer resin. Powder (30 mesh passed) was sprayed and sintered to form a transparent top layer, and this surface was embossed.
[0023]
Next, the fiber backing material (polyester nonwoven fabric) is pressure-bonded to the back surface side by heating and melting the back surface side to the back surface (surface on the glass fiber nonwoven fabric side) of the above laminated fibrous base material. The polyethylene foam sheet laminated with was laminated using a hot melt adhesive to obtain the non-halogen floor material of the present invention.
[0024]
The resulting non-halogen flooring material has a surface printed pattern that is sharp enough to be commercialized and has excellent adhesion between the surface of the laminated fibrous base material and the transparent top layer. there were.
[0025]
A partially enlarged sectional view of the non-halogen floor material obtained as described above is shown in FIG.
In the figure, reference numeral 1 denotes the non-halogen floor material obtained in Example 1, reference numeral 11 denotes a laminated fibrous base material, reference numeral 11a denotes an organic fibrous base material (polyester nonwoven fabric), 11b denotes a glass fiber nonwoven fabric, and reference numeral 11c denotes an olefin. 11d is a printed pattern, 12 is a transparent top layer, 13 is a backing layer, 13a is a synthetic resin backing layer (polyethylene foam layer), and 13b is a fibrous backing material (polyester nonwoven fabric). ing.
[0026]
(Example 2)
A non-halogen floor material was obtained in the same manner as in Example 1 except that the laminated fibrous base material was changed to one obtained by a two-layer papermaking method so that the front side was a polyester fiber nonwoven fabric and the back side was a glass fiber nonwoven fabric. The laminated fibrous base material had a number of surface irregularities of 313/10 mm, an average irregularity depth of 52 μm, and an inherent roughness value of 74700 as measured using a non-contact type surface roughness meter.
The resulting non-halogen flooring material has a surface printed pattern that is sharp enough to be commercialized and has excellent adhesion between the surface of the laminated fibrous base material and the transparent top layer. there were.
[0027]
A partially enlarged cross-sectional view of the non-halogen floor material obtained as described above is shown in FIG.
In the figure, reference numeral 2 denotes the non-halogen floor material obtained in Example 2, reference numeral 21 denotes a laminated fibrous base material, reference numeral 21a denotes an organic fibrous base material (polyester nonwoven fabric), 21b denotes a glass fiber nonwoven fabric, and reference numeral 21c denotes printing. Reference numeral 22 denotes a transparent top layer, 23 denotes a backing layer, 23 a denotes a synthetic resin backing layer (polyethylene foam layer), and 23 b denotes a fibrous backing material (polyester nonwoven fabric).
[0028]
(Comparative Example 1)
An organic fibrous base material (polyester nonwoven fabric) used as a laminated fibrous base material has a surface roughness number of 352/10 mm, an average roughness depth of 54 μm, and an inherent roughness measured using a non-contact type surface roughness meter. A non-halogen floor material was obtained in the same manner as in Example 1 except that the value was changed to a polyester nonwoven fabric having a value of 31800.
The resulting non-halogen flooring had a printed pattern on the surface with a sharpness sufficient for commercialization, but the adhesion between the laminated fibrous base material surface and the transparent top layer was extremely inferior and easily I peeled off.
[0029]
(Comparative Example 2)
An organic fibrous base material (polyester nonwoven fabric) used as a laminated fibrous base material has a surface roughness of 373/10 mm, an average roughness depth of 50 μm, and an inherent roughness measured using a non-contact surface roughness meter. A non-halogen floor material was obtained in the same manner as in Example 1 except that the value was changed to a polyester nonwoven fabric having a value of 46700.
The obtained non-halogen flooring material was excellent in adhesiveness between the surface of the laminated fibrous base material and the transparent top layer, but the printed pattern on the surface was poor and unsuitable for commercialization. It was.
[0030]
【The invention's effect】
As described above, since the non-halogen floor material of the present invention uses a specific fibrous base material, it is not only excellent in dimensional stability, but also the formation of an undercoat layer that is generally performed conventionally. Direct printing can be performed without performing the process, and no corona discharge treatment or the like is required when forming the transparent top layer on the surface.
Therefore, although it is a non-halogen floor material, it can be manufactured by a simple manufacturing process.
[Brief description of the drawings]
FIG. 1 is a partially enlarged cross-sectional view showing an embodiment (Example 1) of a non-halogen floor material of the present invention.
FIG. 2 is a partially enlarged cross-sectional view showing another embodiment (Example 2) of the non-halogen floor material of the present invention.
[Explanation of symbols]
1, 2, Non-halogen flooring 11, 21, Laminated fibrous base material 12, 22 Transparent top layer 13, 23 Backing material

Claims (4)

A non-halogen floor material in which a transparent top layer made of a synthetic resin not containing halogen is formed on the surface of a printed fiber base material, and a backing layer is formed on the back surface of the fiber base material. Organic whose substrate has a surface roughness of 200 to 350/10 mm, an average roughness depth of 50 to 80 μm, and an inherent roughness value of 40000 to 120,000 as measured using a non-contact surface roughness meter laminated fibrous substrate der laminated glass fibrous base material on the back surface of the fibrous base material is, at the time of forming the transparent top layer, non-halogen flooring, characterized in that the organic fibrous substrate is melted.   The non-halogen flooring material according to claim 1, wherein the synthetic resin forming the transparent top layer is an olefin resin having a melt index of 0.5 to 30.   The non-halogen floor material according to claim 1 or 2, wherein the laminated fibrous base material is obtained by a two-layer papermaking method.   The non-halogen flooring according to claim 1 or 2, wherein the laminated fibrous base material is obtained by laminating a glass fibrous base material on the back surface of the organic fibrous base material using a polyolefin-based adhesive.

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