JP4225120B2 - Exterior resin floor and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an exterior resin floor used for a veranda such as a house, an apartment, an apartment, and a garden. Furthermore, the present invention relates to an exterior resin floor that can be easily rehomed and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, exterior resin floors that transfer patterns, directly print, and paste printed sheets to veranda tiles with stones and wood pieces affixed to the resin floor surface or resin floor substrates obtained by injection molding, and such manufacturing methods have been It was known.
[0003]
The following are well-known in other well-known literature.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-61151
In Patent Document 1, a 0.2 mm acrylic resin film with a 40 μm UV curable resin wear layer is attached to an acrylonitrile-butadiene-styrene copolymer (hereinafter referred to as ABS) base material. There was a floor unit material (corresponding to the exterior resin floor in the present application).
[0006]
In the embodiment, there is a description of using polypropylene (hereinafter referred to as PP), polyethylene (hereinafter referred to as PE), and ethylene-vinyl acetate copolymer (hereinafter referred to as EVA) instead of ABS.
[0007]
[Patent Document 2]
Japanese Patent Laid-Open No. 2000-291246
Patent Document 1 describes a structure that simplifies the leg structure of the resin base material and aims for mass productivity.
[0009]
[Non-Patent Document 1]
Imamura Kyoto Co., Ltd., “Sera Easy”, [online], October 29, 2002, [January 10, 2003 search], Internet <URL: http: // www. imakyo. co. jp / reform / sera-m. html>
[0010]
Non-Patent Document 1 displays a veranda tile (a thing corresponding to the exterior resin floor in the present application) that can be easily constructed on the veranda with photographs and texts, and that it is easy to renovate and winds such as typhoons. In order to make it difficult to be skipped, there is an indication that connection with an iron fence or the like is necessary. The material is not described.
[0011]
[Problems to be solved by the invention]
However, in the exterior resin floor of Patent Document 1 as described above, the part that is not pasted even if a decorative sheet is stretched on the surface, that is, the exposed part is exposed to direct sunlight, and the resin base material deteriorates in that part, There is a problem that the cosmetics are markedly deteriorated, and the physical properties thereof are fragile and fragile, and when the flower pot is dropped, it is particularly easy in winter.
[0012]
Therefore, in such a technology, there are restrictions such as the use condition that it is not exposed to the sun for use on the veranda.
[0013]
A technique using vinyl chloride resin instead of ABS resin is also conceivable, but this technique has a problem in that dioxin is generated when burned.
[0014]
Therefore, in the present invention, there has been a demand for an exterior resin floor that can be used outdoors, can be used safely even in winter with good impact resistance, is easy to recycle, and has no problem with incineration.
[0015]
[Means for solving the problems]
Means for solving the problem in the present invention according to claim 1 is that 50 to 95% by weight of polyolefin resin and 5 to 50% by weight of ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm. It is an object of the present invention to provide an exterior resin floor having a decorative base material layer made of at least a polyolefin-based resin on a% -dispersed resin base material .
[0016]
In this case, “mainly” means that the majority of the material of the decorative base layer is made of an olefin resin, and has a secondary layer on the upper surface, the lower surface, or an intermediate portion, and further on these multiple portions, or Even if it contains a secondary composition, those layers and compositions do not substantially affect the physical properties such as incineration, recycling, impact resistance, chemical properties such as weather resistance, It means that the layer can be evaluated as an olefin resin as a whole.
[0017]
In this case, “at least” means that the decorative base layer is directly or indirectly on the resin base, but the resin base and the decorative base are in contact with each other. Even if one or a plurality of other layers are interposed between the material layers, or one or a plurality of other layers are further provided on the decorative substrate layer, the resin-based substrate and the decorative substrate It means that one or a plurality of other layers may be interposed between the layers and another layer or a plurality of other layers may be provided on the decorative base layer.
[0018]
The means for solving the problem in the present invention according to claim 2 further provides an exterior resin floor, wherein the decorative base material layer includes a surface protective layer and an easy adhesion layer. is there.
[0019]
In this case, the easy-adhesion layer is configured to be provided on the side opposite to the surface protective layer in the decorative base material.
[0020]
Further, in this case, the surface protective layer and the easy-adhesion layer form a part of the decorative base layer, but since the majority of the material of the decorative base layer is made of an olefin resin, it is a secondary layer. It is not necessary to consist of an olefin resin.
[0021]
Further, the surface protective layer means a layer for weather resistance, scratch resistance, abrasion resistance, and gloss adjustment, and any surface protective layer may be used.
[0022]
The easy-adhesion layer is a layer for improving the adhesion of the decorative base layer to the resin base material, or if there is another layer between the decorative base material layer and the resin base material. Yes, even if the easy-adhesive layer itself does not have adhesive performance, it is sufficient if it is a layer that adheres when it is adhered with an adhesive, but of course it may have adhesive performance.
[0023]
The means for solving the problem in the present invention according to claim 3 further provides an exterior resin floor in which the decorative base layer has a wrapping structure .
[0024]
The wrapping structure means that the surface of the resin base material has a planar shape, and when the recesses, holes, grooves, and edges that are not planar are shaped like joints or real parts, The decorative base material layer does not cover the surface, but goes around to the concave portion, hole, groove, end, etc., and the decorative base material layer to the surface near the flat surface of the concave portion, hole, groove, end, etc. Indicates a structure covering the surface, and not only a normal wrapping structure covering a considerably deep part but also a soft wrapping structure covering a flat part to a shallow part may be used.
[0025]
The means for solving the problem in the present invention according to claim 4 is that the ethylene-propylene copolymer rubber fine particles having an average particle diameter of 0.1 to 0.5 μm are 5 to 50% by weight of the polyolefin resin. A method for producing an exterior resin bed, comprising: injection molding a resin dispersed by 50% by weight, forming a resin base material, and then wrapping a decorative base material layer made of a polyolefin resin on the resin base material. It is to provide.
[0026]
Lapping is a coating or laminating method for achieving the above wrapping structure. Specifically, not only pressing the surface with a single roll, but also using an auxiliary roll corresponding to the wraparound portion, other than the plane portion This technology is also used to cover the part of the material. Even if the material is pressed with a single roll, soft wrapping is possible so that the roll itself can be deformed using a material that can be deformed, even if there is a slight unevenness. Shall be included.
[0027]
As for injection molding, a method of manufacturing by injection molding for forming a normal flat plate is also conceivable, but a different shape may be used.
[0028]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below as a representative example in which a resin base material is formed by injection molding, and then a decorative base material layer is bonded by lapping with a one-component moisture-curable adhesive by transfer. Needless to say, in-mold lamination, transfer, and makeup by ink jet can be applied simultaneously with molding.
[0029]
It is also natural that after extrusion with a profile forming machine, or after extrusion, lapping with a one-component moisture-curing adhesive, it is simply cut into lengths, and further, actual processing and grooving can be processed using a router. is there.
[0030]
Various types of resin base materials 1 can be selected in response to required performance and price. For example, polyolefin resins such as polypropylene resins and polyethylene resins can be used. Ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm in a homopolypropylene resin of 50 to 95% by weight in order to soften the base material and further give impact resistance When the initial elastic modulus of 100 to 1000 MPa is dispersed by 5 to 50% by weight, the machinability and walking feeling are improved, and heat shrinkage occurs even when the surface temperature becomes about 60 or 70 ° C. due to direct sunlight in summer. Absorbing is preferable because the dimensional stability is increased. Moreover, due to the excellent elastic action of the ethylene-propylene copolymer rubber fine particles, there is moderate elasticity even in the severe winter season, and furthermore, moderate elasticity can be maintained even under direct sunlight in midsummer due to the entropy elasticity.
[0031]
Although the decorative base material layer 8 is provided on the upper part of the resin base material 1, since the joint part and the real part are exposed to direct sunlight, it is preferable to apply a weather resistance prescription to the resin base material 1. When blended with an ultraviolet absorber, general-purpose benzotriazole (basic skeleton absorption maximums of around 300 nm and 340 nm), benzophenone based on compatibility with the resin (basic skeleton absorption maximums of around 290 nm and 330 nm), triazine System (basic skeleton absorption maximums around 280 nm and 340 nm), ogizanide, salicylate, cyanoacrylate, etc., light stabilizer (hindered amine light stabilizer etc.), etc. are possible. The amount is preferably about 0.1 to 5 parts by weight.
[0032]
Furthermore, you may add antistatic agents, such as a well-known heat stabilizer, anti-algae, an antifungal agent, and a quaternary ammonium salt. Moreover, in order to improve the adhesiveness with the decorative substrate layer, the surface after molding may be subjected to corona treatment, plasma treatment or the like.
[0033]
The decorative base layer 8 is mainly made of polyolefin resin such as polypropylene resin and polyethylene resin, copolymer polyethylene terephthalate (hereinafter referred to as PET) resin system, amorphous PET, polybutylene terephthalate (hereinafter referred to as PBT) resin. And mixtures thereof.
[0034]
For example, the decorative base layer 8 may be configured by a colored lower base layer 3, a pattern ink layer 4, an anchor agent layer 5, a transparent upper base 6, and a surface protective layer 7.
[0035]
In this case, it is preferable to add a known colorant, ultraviolet absorber, light stabilizer and the like to the homopolypropylene resin as the colored lower layer 3. The thickness is preferably about 60 μm to 150 μm, but is preferably 70 μm or more in consideration of concealment and the like. It is preferable to provide the pattern ink layer 4 on the surface, but in this case, a two-component curable urethane resin system is desirable from the viewpoint of adhesion strength. It is desirable that the surface tension be 38 mN / m to 55 mN / m by corona treatment on both sides. It is desirable to provide the primer layer 2 on the back surface by applying silica and a two-component curable urethane resin-based primer in an application amount of 0.5 to ² g / m ² after drying.
[0036]
As the transparent upper base 6, as long as it is a transparent polyolefin resin, polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α Olefin copolymers, ethylene-ethyl acrylate copolymers, acid-modified products thereof, ionomers, and the like are desirable.
[0037]
The surface protective layer 7 may be applied by adding an ultraviolet absorber and a light stabilizer to a two-component urethane-bonded acrylic urethane resin composed of acrylic polyol and isocyanate, and applying a coating amount after drying of 5 to 10 g / m ^2. Conceivable.
[0038]
The anchor agent 5 may be provided later. In this case, it is desirable to apply a two-component curable urethane resin in an application amount of 0.5 to 2 g / m 2 after drying.
[0039]
In addition, when bonding the resin-type base material 1 and the decorative base material layer 8 using a wrapping machine, it is preferable to laminate, extruding the reactive hot-melt adhesive 9 at a temperature thickness of about 120 ° C. and about 50 to 150 μm.
[0040]
【Example】
<Example 1>
One embodiment of the exterior resin plate of the present invention will be described with reference to the partial schematic cross-sectional view of FIG.
[0041]
The resin base material 1 is an ethylene-propylene copolymer rubber having an average particle size of 0.3 μm and 90% by weight of a homopolypropylene resin in order to make the base material soft and flexible to further give impact resistance. Fine particles were dispersed at 10% by weight to obtain an initial flexural modulus of 500 MPa.
[0042]
In addition, a benzotriazole type (absorption maximum of 300 nm and around 340 nm of the basic skeleton) ultraviolet absorber as a weather resistance prescription is added to the resin base material 1 in an amount of 0.5 parts by weight, and further, a known heat stabilizer, Antistatic agents such as algae, fungicides and quaternary ammonium salts were added. Moreover, in order to improve the adhesiveness with the decorative base material layer, the surface after molding was subjected to corona treatment to make the surface 48 mN / m.
[0043]
As the colored base layer 3 of the decorative base layer 8, a homopolypropylene resin having a known colorant, ultraviolet absorber, light stabilizer and the like added thereto having a thickness of 70 μm was used.
[0044]
As the ink for the pattern layer, the pattern ink layer 5 was provided by printing a wood grain pattern with a two-component curable urethane resin system (manufactured by Toyo Ink Manufacturing Co., Ltd.). On the back surface of the colored lower layer 3, a primer layer 2 was provided by applying silica and a two-part curable urethane resin-based primer in an application amount of 0.5 to ² g / m ² after drying.
[0045]
A transparent upper base 6 of 80 μm is coextruded with an adhesive resin of 65 μm and maleic acid-modified polyolefin resin at a ratio of 95 parts by weight of IPP (isotactic polypropylene resin) and 5 parts by weight of APP (atactic polypropylene resin). Provided.
[0046]
The surface protective layer 7 was prepared by applying a coating amount after drying of 8 g / m ² using a two-component urethane-bonded acrylic urethane resin composed of acrylic polyol and isocyanate to which an ultraviolet absorber and a light stabilizer were added. Was provided.
[0047]
Furthermore, the coating amount 1g / m < ² > after drying 2 liquid curable urethane resin was apply | coated, and the anchor agent layer 5 was provided.
[0048]
Next, a one-component moisture-curing reactive adhesive (YR210-3 manufactured by Hitachi Chemical Co., Ltd.) is extruded at 120 ° C. to a thickness of 100 μm while being extruded by a profile extrusion molding method using a profile forming machine, and then a length of 600 mm. In addition, actual processing and grooving were processed using a router.
[0049]
The resulting exterior resin floor has an overall cross-sectional shape as shown in Fig. 2 and has good cutting properties and a good feeling of walking. It is easy to recycle and generates dioxins even when incinerated. lost.
[0050]
Furthermore, since the weather resistance is good, the outdoor deterioration is slow. Furthermore, it was no longer damaged by falling objects such as flowerpots.
[0051]
【The invention's effect】
Recycling is easy because it is mainly made of olefin resin. In particular, if the resin base material and the decorative base material are aligned with a polypropylene resin, it is easy to recycle because they are the same resin. In addition, even if it is difficult to recycle, incineration no longer causes problems.
[0052]
In addition to the veranda, it can be used as a stepping stone in the garden. Because it has good weather resistance, it is slow to deteriorate outdoors.
[0053]
In addition, impact resistance has been improved as a countermeasure against falling objects.
[0054]
In the invention of the present application, it is also possible to produce by a profile forming machine. In this case, while extruding or extruding, further lapping with a one-component moisture-curing adhesive and further cutting into unit lengths, Furthermore, actual machining and grooving can be performed using a router, which can improve mass productivity.
[0055]
It is also possible to blend ethylene-propylene copolymer rubber fine particles. In this case, for example, ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm in 50 to 95% by weight of homopolypropylene resin. If the composition is such that 5 to 50 parts by weight is mixed, the machinability and the feeling of walking are improved, and the thermal stability is absorbed even when the surface temperature reaches about 60 or 70 ° C. due to direct sunlight in midsummer. Increase. Moreover, due to the excellent elastic action of the ethylene-propylene copolymer rubber fine particles, there is moderate elasticity even in the severe winter season, and furthermore, moderate elasticity can be maintained even under direct sunlight in midsummer due to the entropy elasticity.
[Brief description of the drawings]
FIG. 1 is a partial schematic cross-sectional view of an embodiment of an exterior resin plate according to the present invention.
2 is an overall schematic cross-sectional view of one embodiment of FIG. 1; (However, the primer layer and reactive hot melt adhesive are omitted)
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Resin-type base material 2 Primer layer 3 Colored base 4 Picture ink layer 5 Anchor agent layer 6 Transparent upper base 7 Surface protective layer 8 Makeup base material layer 9 Reactive hot melt adhesive

Claims (4)

It consists of at least a polyolefin resin on a resin base material in which ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm are dispersed in 50 to 95% by weight of the polyolefin resin. An exterior resin floor having a decorative base layer. The exterior resin floor according to claim 1, wherein the decorative base material layer includes a surface protective layer and an easy adhesion layer. The exterior resin floor according to claim 1 or 2, wherein the decorative base material layer has a wrapping structure. After injection molding a resin in which 5 to 50% by weight of ethylene-propylene copolymer rubber fine particles having an average particle size of 0.1 to 0.5 μm are dispersed in 50 to 95% by weight of a polyolefin resin, and molding the resin base material A method for producing an exterior resin floor, comprising wrapping a decorative base material layer made of a polyolefin resin on the resin base material.

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