JP4993931B2 - Manufacturing method of floor decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flooring decorative sheet which can be easily cleaned against water or dirt, while having a feeling and warmth like cloth carpet material, and can find wide application, and its manufacturing method. <P>SOLUTION: The flooring decorative sheet is formed by laminating a synthetic resin-made foamed layer 2 on a fibrous base material layer 1, and a decorative fibrous cloth 3 impregnated and coated with a transparent resin 4 at least on its surface side on the synthetic resin-made foamed layer 2. The flooring decorative sheet may be manufactured by laminating the transparent resin on the decorative fibrous cloth 3, melting the transparent resin at a temperature beyond the melting point of the resin, to impregnate and coat the decorative fibrous cloth with the resin. <P>COPYRIGHT: (C)2008,JPO&amp;INPIT

Description

The present invention, in spite of there is a cloth specific feel and warm taste, it is easy to wet wipe relates to a process for the preparation of a possible floor cosmetic sheet used in a wide range.

Conventionally, a cushion floor made of a vinyl chloride resin, which can easily wipe off water and dirt, has been used around water in kitchens, toilets, and washrooms.
Cushion floors made of vinyl chloride resin, etc. have cushioning properties and can provide various patterns such as woodgrain, stone, and geometric patterns at low cost, but the problem is that `` the feet cool down in winter etc. '' In order to solve this problem, cloth rugs such as carpets and mats are often laid on the cushion floor.

On the other hand, wooden flooring has been used around the above-mentioned water from the recent genuine orientation.
However, wooden flooring has the same problems as the cushion floor that cause the feet to cool down, as well as problems such as “easy to get scratched” and “hard and easy to get tired”. After all, cloth rugs are placed on this wooden flooring. Often laid.

When such cloth rugs (carpets, mats, etc.) become dirty, it becomes necessary to wash the parts that cannot be removed by wiping.
As a surface treatment of a cloth rug, for example, a water repellent treatment such as a fluorine coat may be performed. This is a technology in which a fluororesin attached to a cloth fiber prevents water penetration by surface tension, and is described above. It is not easy to wipe wet when dirty like a cushion floor made of vinyl chloride resin, and even if it is done, it leads to deterioration of the cloth fiber itself as well as fluororesin.
In addition, a decorative sheet in which a transparent resin layer or a transparent sheet is laminated on the surface of the floor decorative sheet and a designable fibrous cloth is provided between the floor decorative sheet base material and the transparent resin layer or the transparent sheet is also proposed. (e.g., JP-a-2-293131, JP-same 5-26337 2 JP, etc. same 7-109818 JP), which is seemingly is an external approximated to fabric coverings, the function itself, on the surface Since it has a transparent resin layer, it was the same as the conventional cushion floor.

JP-A-2-293131 Japanese Patent Laid-Open No. 5-263372 JP-A-7-109818

The object of the present invention combines the cushioning property of the cushion floor and the ease of cleaning against water and dirt, while having the texture and warm taste of the cloth rug that was not on the cushion floor such as made of vinyl chloride resin, can be used equivalent to vinyl flooring is to provide a method for manufacturing a floor decorative sheet having a wide range of applications.

This onset Ming, synthetic resin foam layer on the fibrous base material layer, the design fibrous cloth impregnated coated fiber at least the surface side transparent resin onto the synthetic resin foam layer, it is stacked A method for producing a floor decorative sheet , wherein the transparent resin has a lower melting point than fibers constituting the designable fibrous cloth, and the transparent resin has a thickness of 5 to 5 before impregnation on the designable fibrous cloth. stacked so as to be 100 [mu] m, and melt at a temperature above the melting point of the resin was impregnated coated decorativeness fibrous cloth impregnated amount of the design of the fibrous fabric of the transparent resin, a product layer of 50 It is characterized by -90%.
At this time, the designable fibrous cloth is preferably a nonwoven fabric, a knitted fabric, or a woven fabric made of at least one of synthetic fibers, natural fibers, and inorganic fibers.
The transparent resin is a polyolefin-based resin, vinyl chloride resin, ester copolymer resin acrylate, urethane resins, it is not preferable comprising at least one or more of the urethane acrylate resin.

In the present invention, it is important that at least the surface side of the designable fibrous cloth laminated on the synthetic resin foam layer is impregnated with a transparent resin.
By covering the fiber surface of the design fiber cloth completely with a transparent resin and soaking the melted resin in the fiber of the design fiber cloth (feeling familiar), the fiber feel (material feel) and warmness of the cloth The entire surface layer of the floor decorative sheet is coated with resin while retaining the taste, so it has cushioning properties, easy to wipe off against wetness, etc., easy to clean, and easy to maintain like conventional cushion floors Floor decorative sheet can be obtained.

According to the present invention, the cushion floor made of vinyl chloride resin or the like has a cloth-like touch and warm taste, and has a cushioning property like the cushion floor and is easy to maintain by being wet wiped and cleaned. A good floor decorative sheet can be provided.
For this reason, conventional cushion floors lacked the texture of cloth rugs (warm taste, warmth, soft comfort, etc.), so they are often used in places where people can relax, such as living rooms and bedrooms. However, the floor decorative sheet of the present invention has both the texture of the cloth rug and the maintenance that can easily wipe off water and dirt. It can be laid on a tatami mat or wooden flooring in a relaxing place as well as around the water in a bathroom or toilet, and has a wide range of uses.

By the way, when placed on a tatami mat, it is easy to wipe off dirt such as spilled food while keeping the warmth and soft comfort as a cloth rug.
Further, when placed on a wooden flooring, a texture like a carpet is obtained, and water and dirt can be easily wiped off from the carpet without damaging the flooring.

An embodiment of the floor decorative sheet of the present invention will be described with reference to the conceptual diagram shown in FIG.
In FIG. 1, a floor decorative sheet 10 includes a synthetic fiber foam layer 2 on a fibrous base material layer 1, and a design fiber material obtained by impregnating at least surface fibers with a transparent resin 4 on the synthetic resin foam layer 2. The cloth 3 is laminated.

The designable fibrous fabric 3 is a non-woven fabric, knitted fabric, or woven fabric made of at least one of synthetic fibers such as acetate, polyester, rayon, silk, hemp, and cotton, natural fibers, and inorganic fibers such as glass. It is preferable that the design is applied, and one having an appearance equivalent to that of a normal cloth rug can be used.
Also, a fibrous cloth having a feeling of unevenness rather than a flat and simple plain weave is preferable. For example, a raised cloth, a flocked cloth, a towel cloth, or the like may be used, or a needle-punched processed cloth may be used.

  As a method for applying a design to a fibrous fabric, the design may be added by using a general printing method such as inkjet printing, gravure printing, screen printing, offset printing, flexographic printing, or dyeing or weaving. Alternatively, a design attaching method may be used for expressing a pattern by braiding, flocking, or the like.

The thickness of the designable fibrous cloth 3 can be appropriately selected according to the desired design and the material feeling of the fibrous cloth. A thickness of about 50 to 100 μm and a thickness of about 300 to 500 μm are preferable.
In addition, the surface feel and appearance of the floor decorative sheet to be obtained can be adjusted by changing the type and amount of the transparent resin to be impregnated and coated even with the same thickness.

Since the transparent resin 4 constitutes the uppermost layer of the floor decorative sheet 10, the design of the designable fibrous cloth 3 in the lower layer can be visually recognized. In the present invention, the transparent resin 4 is not limited to the transparent resin and is translucent. It may be a simple resin or may be colored with a pigment or a dye.
The transparent resin 4 is preferably composed of at least one thermoplastic resin such as polyolefin resin, vinyl chloride resin, acrylate copolymer resin, urethane resin, urethane acrylate resin, and the like. The plastic resin may be an emulsion type or a solvent type, but when impregnated on a fiber cloth, the fiber surface of the fiber cloth is coated without impairing the texture and feel of the fiber cloth. It is preferable to use a resin that is water resistant.
In addition, when said floor decorative sheet 4 is manufactured by the method of this invention, said transparent resin 4 uses a thing whose melting | fusing point is lower than the various fibers which comprise the designable fibrous cloth 3. FIG.

In the floor decorative sheet of the present invention, such a transparent resin is impregnated and coated on the fiber surface of the aforementioned designable fibrous cloth 3.
This impregnation coating may be formed by impregnating the designable fibrous cloth 3 with a thermoplastic resin as an emulsion or solvent paint, surface coating, drying, and extrusion coating with a transparent resin by the method of the present invention. After being laminated on the fiber surface of the designable fibrous cloth 3 by a known method such as roll coating, calender topping, or placing a previously prepared film, the melting point of the resin is exceeded. By heating at a temperature, the melted resin may be soaked into the fiber surface of the designable fibrous cloth 3 and formed.
For example, in the temperature range of about 100 to 150 ° C. at the time of contact with the designable fibrous cloth during the lamination process such as extrusion, the resin can only be adhered to the designable fibrous cloth 3. In the method of the present invention, for example, a polyolefin resin is heated to about 210 ° C. until it is completely melted in order to sufficiently infiltrate the fibers of No. 3. Thereby, the transparent resin 4 laminated by extrusion or the like on the designable fibrous cloth penetrates between the fibers of the designable fibrous cloth 3 and forms a film on the surface of the designable fiber. The function of the transparent resin 4 can be maintained while leaving the feel of the textured cloth 3.

The amount of impregnation coating depends on the type of resin used and the designable fibrous fabric, but if it is too small, the surface fibers of the designable fibrous fabric will not be completely coated, and water will be removed when wet wiped. The designable fibrous cloth penetrates or is difficult to remove, and if it is too much, the texture and warm taste of the designable fibrous cloth are reduced, and the effects of the present invention cannot be obtained. For example, in the case of applying and impregnating an emulsion or solvent paint, about 300 g / m ² , and in the case of melt impregnation after lamination, the thickness before impregnation may be about 5 to 100 μm.
In addition, the amount of impregnation into the designable fibrous fabric is small depending on the type of resin used and the designable fibrous fabric, both in the case of applying and impregnating an emulsion and solvent paint, and in the case of melt impregnation after lamination. If the amount is too large, the amount of the transparent resin layer remaining on the fiber surface of the designable fibrous cloth will increase, and the fiber texture (feel) and warm taste will disappear. If the amount is too large, the fiber surface of the designable fibrous cloth will disappear. In general, the amount remaining in the transparent resin layer is too small, and the stain resistance of the transparent resin layer is likely to decrease during use as a floor sheet. It shall be the degree.

In the present invention, the synthetic resin foam layer 2 is laminated and integrated on the back surface of the designable fibrous cloth 3 impregnated and coated with the transparent resin 4 in this manner.
Furthermore, the fibrous base material layer 1 can be laminated and integrated on the back surface of the laminated synthetic resin foam layer 2 via an adhesive layer as necessary to obtain the floor decorative sheet 10 of the present invention. it can.

Various methods can be employed to provide the synthetic resin foam layer 2 and the fibrous base material layer 1 on the back surface side of the designable fibrous cloth 3. For example, the following method may be performed.
The raw material of the synthetic resin foam layer 2 described below is kneaded and sheeted and topped on the back side of the designable fibrous cloth 3 to form an unfoamed synthetic resin foam layer 2, which is heated and foamed. The fibrous base material layer 1 is laminated and integrated on the back surface of the synthetic resin foam layer 2 via an adhesive layer.

Examples of the synthetic resin foam layer 2 include polyolefin resins such as polyethylene, polypropylene, ethylene vinyl acetate resin (EVA), and ethylene acrylic copolymer resins (EMA, EMMA, EEA, etc.), vinyl chloride resins, and acrylate esters. A thermoplastic resin comprising at least one of a polymer resin, a urethane resin, and a urethane acrylate resin may be foamed.
The foaming method may be mechanical foaming or chemical foaming using a foaming agent as described below.

As foaming agents used for chemical foaming, thermal expansion foaming agents such as microcapsules, heat such as azodicarboxylic acid (ADCA), dinitroso / pentamethylene / tetramine (DPI), oxybisbenzene / sulfonyl hydrazide (OBSH), etc. Any of the decomposable foaming agents can be used.
The heating temperature and heating time at the time of foam molding can be appropriately selected depending on the selected production method and material such as resin.

The fibrous base material layer 1 is provided in the lowermost layer of the floor decorative sheet 10.
The fibrous base material layer 1 is a non-woven fabric, knitted fabric or woven fabric made of at least one of synthetic fibers, natural fibers and inorganic fibers, or a mixed paper obtained by mixing these with a synthetic resin binder and a pulp material. be able to. Examples of the synthetic resin binder include acrylic resin and styrene butadiene rubber.
The fibrous base material layer 1 may be composed of a plurality of layers. For example, rayon fiber nonwoven fabric and mixed paper may be alternately laminated.

In the present invention, a stabilizer, an antistatic agent, a lubricant, a sterilizer are used in the fibrous base material layer 1, the synthetic resin foam layer 2, and the transparent resin 4 as long as they do not impair the characteristics of the present invention. Various additives such as agents, insect repellents, and coloring agents can be added as appropriate.
As these additives, ordinary additives blended in ordinary floor decorative sheets can be used.

  The total thickness of the floor decorative sheet of the present invention is about 1.0 to 5.0 mm, preferably 1.5 to 3.0 mm.

Example 1
A polyethylene resin as a transparent resin is extruded and laminated with a thickness of 80 μm using an extruder on the surface of a cotton material design woven (cotton cloth), and the surface is further melted until the polyethylene resin is completely melted. By heating, the resin was soaked in cotton fabric by about 80% of the lamination amount and integrated to form a transparent resin layer on the cotton fabric fibers. At this time, a transparent resin layer may be formed between the fibers as long as the texture of the cotton cloth is not impaired. Thereby, a designable fibrous cloth impregnated with a transparent resin was obtained (first process product).
Next, a mechanically foamed paste made of a vinyl chloride resin was applied, gelled, and cured on the back surface of the obtained designable fibrous cloth to be laminated and integrated (second process product).
Thereafter, a mechanically foamed vinyl chloride resin paste was thinly applied as an adhesive layer to the back surface of the second process product, and a rayon fiber nonwoven fabric was laminated and integrated to obtain a floor decorative sheet having a thickness of 2.0 mm.

Reference example 2
The surface coating was applied to the surface of the same cotton material as in Example 1 (cotton cloth) with a urethane acrylate oil paint applied at 150 g / m ^2, and 80% of this was impregnated. This was carried out in the same manner as in Example 1 except that the dried and integrated one was used, and a floor decorative sheet having a thickness of 2.0 mm was obtained.

Example 3
Except for using a polyester nonwoven fabric dyed and gravure-printed and designed as a designable fibrous fabric, and using a surface that is laminated and impregnated with a polyethylene resin in the same manner as in Example 1. Was carried out in the same manner as in Example 1 to obtain a floor decorative sheet having a thickness of 1.8 mm.

Reference example 4
The same polyester non-woven fabric as in Example 3 was dyed and gravure-printed and used as a designable fibrous cloth, and the surface side was impregnated with a urethane acrylate oil paint and surface-coated in the same manner as in Reference Example 2. This was carried out in the same manner as in Example 1 except that the dried and integrated one was used to obtain a floor decorative sheet having a thickness of 1.8 mm.

Comparative Examples 1-3
As shown in FIG. 2, a vinyl chloride cushion floor 20 (consisting of glass mixed paper 21, foamed vinyl chloride resin layer 22, printed design layer 23, and transparent vinyl chloride resin layer 24) as shown in FIG. It was.
Further, a woody flooring having a thickness of 15 mm was set as Comparative Example 2, and a fibrous carpet having a thickness of 9 mm was set as Comparative Example 3.

For Examples 1 and 3, Reference Examples 2 and 4, and Comparative Examples 1 to 3, (A) design diversity, (B) luxury design, (C) surface thermal feeling, (D) cushioning properties, (E ) Maintainability and (F) antifouling property were evaluated in five stages by the following evaluation methods. The results are shown in Table 1.

(A) The diversity of designs was evaluated according to the following criteria.
Diversity: 5, Diversity is somewhat: 4, Neither is: 3, Diversity is not so much: 2, Diversity is not: 1.
(B) The luxury of the design was evaluated according to the following criteria.
There is a sense of luxury: 5, there is a little sense of luxury: 4, cannot be said either: 3, there is not much sense of luxury: 2, there is no sense of luxury: 1.
(C) The surface thermal sensation was evaluated with the following criteria, standing on each surface in a room at room temperature of 20 ° C. with bare feet.
I feel warm taste: 5, I feel warm taste a little: 4, I can say neither: 3, I feel slightly cold: 2, I feel cold: 1.
(D) About cushioning property, it walked on each surface for 3 minutes with bare feet, and evaluated it on the following references | standards.
I don't feel hardness or fatigue: 5, I don't feel much hardness or fatigue: 4, I can't say either: 3, I feel a little hardness or fatigue: 2, I feel hardness or fatigue: 1.
(E) About maintainability, it laid on the toilet in a factory, wiped the surface after using it normally for one week with the wet rag, and evaluated it on the following references | standards.
Dirt is easy to remove: 5, Dirt is somewhat easy to remove: 4, Neither can be said: 3, Dirt is somewhat difficult to remove: 2, Dirt is difficult to remove: 1.
(F) About antifouling property, wiping the surface with a wet rag, drying, and wiping with a wet rag was repeated 30 times and evaluated according to the following criteria.
No contamination at all: 5, Slightly change in fiber shape, but not as much as contamination: 4, Slight contamination: 3, Slight contamination: 2, Clear and very clean Ru often seen in: 1.

The floor decorative sheet of the present invention has a material feeling and warm taste of a cloth rug, has cushioning properties, and easily removes water and dirt by wiping and cleaning, and therefore has excellent maintainability.
For this reason, the floor decorative sheet according to the present invention can be used as a cushion floor for kitchens, toilets, toilets, etc., and can also be used as a cloth rug such as a rug mat, and can be easily wiped off against water and dirt. Since it does not involve construction, it can be placed in various places such as floor tiles such as toilets and washrooms, flooring in dining and living rooms, and tatami mats in bedrooms.

It is a figure which shows notionally the cross section of one Embodiment of the floor decorative sheet of this invention. It is sectional drawing which shows one Embodiment of the conventional vinyl chloride cushion floors.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Fiber base material layer 2 Synthetic resin foam layer 3 Designable fiber cloth 4 Transparent resin layer 10 Floor decorative sheet 20 Vinyl chloride cushion floor 21 Glass mixed paper 22 Foamed vinyl chloride resin layer 23 Printed design layer 24 Transparent vinyl chloride resin layer

Claims (3)

Production of a floor decorative sheet in which a synthetic resin foam layer is laminated on a fibrous base material layer, and on the synthetic resin foam layer, a designable fibrous cloth in which a transparent resin is impregnated and coated on at least the surface side fiber is laminated. A method ,
The transparent resin has a lower melting point than the fibers constituting the designable fibrous cloth, and the transparent resin is laminated on the designable fibrous cloth so that the thickness before impregnation is 5 to 100 μm. and melted at more than the melting point temperature, impregnated coated decorativeness fibrous cloth impregnated amount of the design of the fibrous fabric of the transparent resin, characterized in that 50 to 90% of the product layer weight A method for producing a floor decorative sheet. The floor decorative sheet according to claim 1, wherein the design fibrous fabric is a non-woven fabric, a knitted fabric, or a woven fabric made of one or more of synthetic fibers, natural fibers, and inorganic fibers. Manufacturing method . The floor makeup according to claim 1 or 2, wherein the transparent resin comprises at least one of a polyolefin resin, a vinyl chloride resin, an acrylate copolymer resin, a urethane resin, and a urethane acrylate resin. Sheet manufacturing method .