JP4539297B2 - Flooring - Google Patents

Description

  The present invention absorbs and absorbs moisture in the ambient air when the humidity is high, and dissipates the moisture absorbed in the ambient air when the humidity is low, thereby reducing moisture fluctuations in the ambient air. The present invention relates to materials, and particularly to floor materials for use on indoor floors in buildings such as detached houses, condominiums, apartments, recreational facilities, office buildings, and stores.

  At present, wood flooring materials are most prevalent as floor materials for indoor floors in buildings such as detached houses. Specifically, the wooden flooring material has a thickness of about several hundred μm to several mm on a wooden base material such as a solid plate of natural wood having a thickness of about 5 to 15 mm or a laminated plywood having a thickness of about 5 to 15 mm. It is a thing stuck with a veneer of natural wood, or a painted product thereof.

  These wood-based flooring materials using natural wood have been widely accepted by consumers since the design of the surface is the most natural, familiar and beautiful design of natural wood. However, it is easy to discolor when exposed to sunlight, and when it gets wet, it tends to swell, crack, warp, corrode, peel off the veneer, etc. It has been pointed out that there are problems in use, and that the quality, price, and supply amount of color tone and grain shape are unstable because it is a natural material.

  Particularly in recent years, as social interest in global environmental protection issues has increased, mass consumption of natural timber that leads to environmental destruction has become a perception, and the use of recycled resources in the field of building materials such as flooring The approach to has come to be required. However, it is extremely difficult to recycle the wood flooring material as a flooring material, both technically and economically, and at most it is only crushed and recycled as a raw material for particleboard. This is also due to the lack of progress in application development in response to the rapid increase in supply in recent years, so there is an excess inventory, and recycling is in a deadlock situation, and most of the final disposal is done by landfill or incineration. .

  Therefore, there is a strong social demand for the development of a recyclable flooring that can be reused as a raw material for the same kind of flooring after use. In order to meet these demands, the present inventors have already made a thermoplastic resin similar to the thermoplastic resin contained in the wooden resin molded body on the surface of the wooden resin molded body containing the thermoplastic resin and the wooden filler. A flooring made by laminating decorative sheets mainly composed of resin has been proposed (see Patent Document 1).

  Since this flooring is mainly composed of thermoplastic resin, it has excellent water resistance and weather resistance, and it can supply a large quantity of products with stable quality in terms of physical properties and design, such as cutting and nailing. The processability is equivalent to that of the wood-based flooring material, and it has excellent recyclability such that it can be pulverized as it is after use and reused as a molding material for the wood resin molding.

  Further, the present inventors further made a wood resin foam molded body obtained by foaming the wood resin molded body for the purpose of improving the heat insulating property that gives a warm touch similar to natural wood and the elasticity that gives a pleasant walking feeling. A flooring material using the above as a base material has already been proposed (see Patent Document 2).

  However, because these flooring materials are molded from thermoplastic resin, they lack the warmth of wood, and the outermost surface is covered with a thin film of thermoplastic resin, so it does not absorb moisture, and the surface becomes sticky when humid, There were problems such as condensation on the surface when sudden temperature changes occurred.

  On the other hand, modern buildings are remarkably airtight compared to former Japanese architecture due to the spread of reinforced concrete structures and prefabricated construction methods, new building materials made of synthetic materials such as resin-processed plywood, and the development of metal sashes on doors and windows. It is considered to be a problem that it may cause condensation on walls, ceilings, floors, etc. and generation of mold.

The prior art document information related to the present invention will be listed below.
JP 2001-353815 A Japanese Patent Application No. 2002-120347

  This invention is made | formed in order to solve the said problem, and the place made into the subject is to provide the flooring which possessed the humidity control function.

  The present invention has been made to solve the above-mentioned problems. That is, the invention according to claim 1 is a wood resin foam molded article obtained by foam molding a wood resin composition comprising a thermoplastic resin and a wood filler. A flooring material comprising the activated carbon in the wood resin composition and having a cutting part on the surface of the wood resin foam molded article.

  According to the first aspect of the present invention, it is possible to prevent moisture condensation by containing activated carbon and having a humidity control function and by providing a cutting portion on the surface so that the foamed portion of the wood resin foam molded body appears on the surface. It becomes. Furthermore, it has a deodorizing effect, and is also effective in adsorbing chemical substances such as formaldehyde and toluene that cause sick house syndrome.

  Hereinafter, the flooring of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a cross-sectional structure of an embodiment of the flooring of the present invention. The wood resin foam molding 1 includes a thermoplastic resin 2, a wood filler 3, and activated carbon 4, which is foamed to have bubbles 5 and a cutting portion 6 provided on the surface.

  The resin used for the thermoplastic resin 2 in the present invention can be appropriately selected from resins such as polyolefin, polystyrene, polycarbonate, polyester, polyamide, polyvinyl alcohol, acrylic, polyvinyl chloride, etc., but generation or filling of dioxins during incineration In order to satisfy the performance such as outflow of environmental hormones such as time, weather resistance and heat resistance as a member, and weather resistance against chemicals and solvents, a polyolefin resin is desirable.

  Examples of the polyolefin resin include polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, ethylene-ethyl. An acrylate copolymer, an acid-modified one of these for the purpose of improving adhesiveness, an ionomer, or the like can be selected as appropriate, and a single type or a mixture of plural types may be used.

  Among them, polypropylene, such as homopolypropylene, random polypropylene, block polypropylene, and propylene-α-olefin copolymer, in terms of rigidity, surface hardness, and dimensional stability (low linear expansion coefficient) required for flooring. Resin is most suitable.

  In particular, in order to increase the adhesion, for example, the blend ratio of the acid-modified resin such as polyethylene or polypropylene obtained by graft copolymerization with an unsaturated carboxylic acid such as maleic acid or its anhydride is increased, and the resin itself It is desirable to impart polarity to the wood and to improve the adhesion to the wood filler.

  Moreover, in this invention, since it is necessary to make the wood resin foam molded object 1 foam as mentioned later, the thermoplastic resin 2 is required to have foamability. In general, in order to improve foamability, it is desirable that the thermoplastic resin 2 has a high melt tension, and in particular, when long gas filling occurs when the wood-based filler 3 is highly filled, long chains due to electron beam crosslinking are used. It is desirable to adjust the melt tension as necessary by a known method such as the use of a grade with branching introduced, the control of the molecular weight distribution, or the blend of a fluorine-based additive that increases the melt tension.

  The wood-based filler 3 in the present invention can be selected without particular limitation as long as it is wood, but in general, the wood is broken by a cutter mill or the like, and this is pulverized by a ball mill or impeller mill or the like. Then, a fine powder (wood powder) or the like is used.

  The average particle diameter of the wooden filler 3 is preferably 1 to 200 μm, more preferably 10 to 150 μm. Those having an average particle size of less than 1 μm are difficult to handle, and especially when the amount of the wood-based filler is large, if the dispersion into the resin is poor, the mechanical strength of the wood-resin foamed molded product to be produced Decrease occurs. On the other hand, if it is larger than 200 μm, the homogeneity, flatness and mechanical strength of the molded product are lowered.

  The activated carbon 4 in the present invention can be selected without any particular limitation. Generally, the activated carbon is broken by a cutter mill or the like, and this is pulverized by a ball mill or an impeller mill to obtain a fine powder. Use things.

  The average particle size of the activated carbon 4 is preferably 1 to 200 μm, more preferably 10 to 150 μm. Those having an average particle size of less than 1 μm are difficult to handle, and especially when the amount of activated carbon is large, if the dispersion into the resin is poor, the mechanical strength of the wood resin foam molded article is reduced. appear. On the other hand, if it is larger than 200 μm, the homogeneity, flatness and mechanical strength of the molded product are lowered.

  If the total amount of the wood filler 3 and the active material 4 is too large, the bending elastic modulus of the flooring will increase and the flexibility will be lost. Deteriorates or becomes easy to break when bent. On the other hand, if the amount is too small, the coefficient of linear expansion will increase and the dimensional stability will decrease, which may cause a gap between the flooring materials or a lift due to the thrusting of the flooring materials due to temperature changes. Become. Therefore, with respect to 100 parts by weight of the thermoplastic resin 1, 30 to 500 parts by weight can be combined with the blending amount of the activated carbon 4, but 50 to 300 parts by weight with the blending amount of the activated carbon 4 is preferable, More preferably, the blending amount of the activated carbon 4 is 50 to 150 parts by weight.

  As the cutting part 6 provided on the surface in the present invention, a method of scraping the surface layer of the surface of the wood resin foam molded body with a single-blade canna or a rotary canna, or a cutting process for applying a metal brush, a sander, a file, etc. to the entire surface. The depth is preferably 10 to 500 μm. Usually, a wood resin foam molded article is covered with a thin thermoplastic resin with a thickness of 3 to 10 μm on the surface for molding. If it is left as it is, it does not absorb water at all and causes condensation. When the cutting thickness is 10 μm or less, the thermoplastic resin film is not torn, and when the thickness is 500 μm or more, the rigidity and surface hardness as a flooring material are insufficient from the normal thickness of the wooden resin foam molded body described later. In addition, scratch resistance and pressure dent resistance are deteriorated.

  The thickness of the woody resin foam molded body 1 in the present invention is generally about 2 to 30 mm, particularly about 3 to 15 mm, as in the case of conventional ordinary flooring.

In addition to the thermoplastic resin 2, the wood filler 3 and the activated carbon 4, the wood resin foam molded body 1 according to the present invention includes a foaming agent for foaming, a heat stabilizer, an acid neutralizer, an ultraviolet ray as necessary. Absorbers, light stabilizers, colorants such as pigments and dyes, fillers, antistatic agents, lubricants, nucleating agents, flame retardants, antiblocking agents, dehydrating agents, light scattering agents for translucency, gloss adjustment An agent or the like can also be added.

  Among these additives, hindered phenols, sulfurs, phosphoruss, etc. as heat stabilizers, stearic acid metal salts, hydrotalcite, etc. as acid neutralizers, benzotriazoles, benzoates as ultraviolet absorbers, etc. Benzophenone, triazine, etc., and light stabilizers include hindered amines.

  Examples of flame retardants include halogen flame retardants, phosphorus flame retardants, and chlorine flame retardants. Fillers include calcium carbonate, silica, titanium oxide, barium sulfate, zinc oxide, alumina, talc, mica, magnesium silicate, and titanium. Examples include potassium acid, aluminum hydroxide, magnesium hydroxide, iron oxide, carbon black, and metal powder.

  As lubricants, hydrocarbon lubricants, fatty acids, higher alcohols, fatty acid amides, metal soaps, esters, fluorines, etc. As nucleating agents, carboxylate metal salts, sorbitol, phosphate ester metal salts, etc. Examples of pigments include condensed azo, insoluble azo, quinacridone, isoindoline, anthraquinone, imidazolone, cobalt, phthalocyanine, carbon, titanium oxide, iron oxide, mica, and other pearl pigments. Generally used in combination.

  Any known technique can be used for the foaming technique of the wood resin foam molded article 1 in the present invention. In general, chemical foaming can be classified into chemical foaming, which generates gas by thermal decomposition or chemical reaction, and physical foaming, which heats low-boiling liquids to vaporize them, and chemical foaming agents include inorganic sodium bicarbonate and ammonium carbonate. Ammonium bicarbonate, ammonium nitrite, sodium borohydride, light metals, azide compounds, etc., and organic foaming agents such as azo, nitroso, hydrazide, etc. can be used in any combination.

  In particular, physical foaming is mainly used for foaming at a high foaming ratio exceeding 2 times, and carbon dioxide gas and aliphatic hydrocarbons are mainly used as foaming agents. In addition, a chemical foaming agent is often used in combination with physical foaming to adjust the cell shape of the foam.

  In the present invention, the kneading of the thermoplastic resin 2, the wood filler 3, the activated carbon 4, the foaming agent and other additives constituting the foamable wood resin composition is not particularly limited, but it is kneaded by a Banbury mixer. In general, a pelletizing method using a pelletizer, a mixing and pelletizing method using a twin-screw extrusion kneader, and the like are generally used. Further, the wood-based filler 3 and the activated carbon 4 cause foaming during pelletization when the water content is large. Therefore, it is desirable to suppress the water content to 8% or less with a dryer or a hopper dryer before kneading.

  In addition, the floor material of the present invention mainly includes a thermoplastic resin similar to the thermoplastic resin 2 contained in the wood resin foam molded body 1 on a part or all of the back surface of the wood resin foam molded body 1. A foam layer (not shown) may be laminated. For example, if a foam layer is laminated on the back side of the flooring, it absorbs the unevenness of the floor surface and prevents rattling, or absorbs the impact sound and walking sound of articles on the floor. There are effects such as preventing.

  For the method of laminating the foamed layer, a known method can be used. For example, the thermoplastic resin similar to the thermoplastic resin used in the foamable wood resin composition for molding a wood resin foam molded article is used for the above pyrolysis and chemicals. A foamed molded article formed by foaming a sheet with a foaming agent that is either a chemical foaming agent that generates gas by reaction or a physical foaming agent that vaporizes by applying heat to a low-boiling liquid, and is a decorative sheet for a wood resin foam molded body Can be formed by adhering to a part or all of the non-laminated surface.

  When the flooring of the present invention is recycled, a wood-based filler, activated carbon, thermoplastic resin, various additives, etc. are appropriately added as necessary and pelletized again, and this is molded into the wood resin foam molded body 1. It can be reused as a material. Also in this case, the method for kneading the crushed material, the pelletizing method, the forming method, etc. is not particularly limited. Further, instead of re-pelletizing, the crushed material is directly put into a molding machine as a molding material for the wood resin foam molded body 1, or when the wood resin foam molded body 1 is molded, the crushed material and the wooden filler or thermoplastic resin are used. Of course, it is also possible to put in the molding machine at the same time, and molding while kneading in the molding machine.

  Using a homopolypropylene resin having a flexural modulus of 1000 MPa, which is obtained by adding 20% by weight of a maleic acid-modified homopolypropylene resin to a homopolypropylene resin as a thermoplastic resin, 100 parts by weight of this, and breaking the wood with a cutter mill, This was pulverized by a ball mill and mixed with 100 parts by weight of a wood filler having an average particle diameter of 100 μm by a twin-screw extruder kneader and pelletized to prepare a wood resin composition.

  Further, a homopolypropylene resin having a flexural modulus of 1000 MPa, which is obtained by adding 20% by weight of a maleic acid-modified homopolypropylene resin to a homopolypropylene resin as a thermoplastic resin, and 100 parts by weight of this homopolypropylene resin is broken by a cutter mill. Then, 100 parts by weight of activated carbon having an average particle diameter of 100 μm, which was pulverized by a ball mill, was mixed by a twin-screw extrusion kneader and pelletized to prepare a mixture of activated carbon and resin.

  To 100 parts by weight of the wood resin composition and 100 parts by weight of the mixture of activated carbon and resin, 5 parts by weight of a baking soda-citric acid-based foaming agent is added, and the thickness is 5 mm by a Celca process using a single screw extruder. The core member is molded at an average foaming ratio of 1.54 times, and a surface layer portion having a thickness of 1 mm is molded on the surface thereof at an average foaming ratio of 1.4 times, so that the overall cross-sectional rectangular shape has a thickness of 6 mm and a width of 300 mm. Molded to produce a woody resin foam molding.

  The floor material of the present invention was produced by scraping 100 μm of the surface (opposite side of the construction surface) of this woody resin foam molded body with a rotary plane and providing a cutting part.

<Comparative Example 1>
In Example 1, a flooring was produced in the same manner as in Example 1 except that the surface of the wood resin foam molded body was not cut.

<Comparative example 2>
In Example 1, the humidity control floor material of this invention was produced like Example 1 except not having added 100 weight part of the mixture of activated carbon and resin.

<Performance comparison>
Each of the flooring materials of Example 1 and Comparative Examples 1 and 2 prepared as described above was spread in a 1 square meter room, and left for 24 hours in a 40 ° C 90% environment and a 15 ° C 30% environment. The situation of the room was compared. The results are shown in Table 1.

  Since the flooring of the present invention has a deodorizing effect, a chemical adsorption effect, etc. in addition to a humidity control effect, it is particularly suitable for indoor floors in buildings such as detached houses, condominiums, apartments, recreational facilities, office buildings, stores, etc. Is available.

It is explanatory drawing which shows the structure of the cross section of one Example of the flooring of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Wood resin foam molding 2 ... Thermoplastic resin 3 ... Wood type filler 4 ... Activated carbon 5 ... Bubble 6 ... Cutting part

Claims (1)

  In a floor material comprising a wood resin foam molded body formed by foam molding a wood resin composition comprising a thermoplastic resin and a wood filler, the wood resin composition contains activated carbon, and the surface of the wood resin foam molded body A flooring characterized by having a cutting part.

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