JP5690414B2 - ウッドパターン形態のpla表面層を有する床材 - Google Patents
ウッドパターン形態のpla表面層を有する床材 Download PDFInfo
- Publication number
- JP5690414B2 JP5690414B2 JP2013544395A JP2013544395A JP5690414B2 JP 5690414 B2 JP5690414 B2 JP 5690414B2 JP 2013544395 A JP2013544395 A JP 2013544395A JP 2013544395 A JP2013544395 A JP 2013544395A JP 5690414 B2 JP5690414 B2 JP 5690414B2
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- JP
- Japan
- Prior art keywords
- weight
- layer
- parts
- pla
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
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Images
Classifications
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- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/75—Printability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24066—Wood grain
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Floor Finish (AREA)
- Laminated Bodies (AREA)
Description
透明層の製造
PLA樹脂として2002D(Nature Works製造、溶融指数:3未満)100重量部、ATBC20重量部、アクリル共重合体10重量部、ステアリン酸5重量部、カルボジイミド5重量部を押出機を使用して1次混練し、バンバリーミキサーによって140℃で混練した後、140℃の2本ロールを使用して1次及び2次ミキシングを行った。その後、製造された原料を130℃の温度でカレンダリング加工し、厚さが約0.6mmのシートを製造した。
PLA樹脂100重量部、ATBC30重量部、アクリル共重合体10重量部、ステアリン酸5重量部、ジイソシアネート5重量部及びカルボジイミド5重量部、炭酸カルシウム50重量部、二酸化チタン20重量部を前記透明層の製造過程と同一の過程で加工し、厚さが0.2mmのシートを製造した。
PLA樹脂100重量部、ATBC40重量部、アクリル共重合体10重量部、ステアリン酸5重量部、カルボジイミド5重量部、木粉130重量部、籾殻20重量部、炭酸カルシウム280重量部、二酸化チタン20重量部及び松脂10重量部で構成された厚さ2.8mm程度のシートを製造した。
PLA樹脂100重量部、ATBC20重量部、アクリル共重合体10重量部、ステアリン酸5重量部、カルボジイミド5重量部、炭酸カルシウム150重量部、木粉130重量部、籾殻30重量部、二酸化チタン2重量部及び松脂10重量部を押出機を使用して1次混練し、バンバリーミキサーによって140℃で混練した後、140℃の2本ロールを使用して1次及び2次ミキシングを行った。その後、製造された原料に130℃の温度でカレンダリング加工を行い、厚さが約1.4mmのシートを製造した。
アクリル樹脂100重量部、ATBC60重量部、粘度低下剤15重量部、炭酸カルシウム50重量部及び二酸化チタン5重量部を配合してアクリル系ゾルを製造した。その後、ロールコーターを使用して製造されたアクリル系ゾルをガラス繊維(60g/m2)に含浸処理した後、140℃の温度で3分間乾燥し、厚さが約0.6mmの寸法安定層を製造した。
前記の製造されたチップインレイド層、ガラス繊維含浸層及び非発泡層―裏面繊維層をエンボスロールを用いて熱合板した後、チップインレイド層の表面にワックスを用いて厚さ約0.05mmの表面処理層を形成することによって最終表面層を製造できた。本実施例では、透明層、印刷層、チップインレイド層及び非発泡層がPLA樹脂を基盤にして製造された。
ベニヤ合板層としては、一般的に床材に使用されるベニヤを使用し、通常、南洋材(熱帯産闊葉樹材)を使用するが、本発明は、原木を製材して一定の厚さにスライスしたとき、含水率が12%以下になるように乾燥したものを用いる。
合成樹脂層は、PLA(poly lactic acid)、PE(ポリエチレン)、PP(ポリプロピレン)、PVC(塩化ビニル樹脂)、ゴム(ラバー)、PU(ポリウレタン)などを使用して製造することができる。
下から合成樹脂層、合板層、ウッドパターン形態のPLA表面層を接着剤塗布後に積層して冷圧によって一体化し、表面塗装層を形成した後、実矧ぎ継ぎ(Tongue & Groove)形態で裁断し、ウッドパターン形態を有する床材を製造する。
厚さ及びその他の工程条件を実施例1と同一に行い、合成樹脂層に塩化ビニル樹脂層100重量部を基準にして炭酸カルシウム75重量部を含ませる。
前記実施例2で炭酸カルシウムの添加量を35重量部に低下させ、鉄を塩化ビニル樹脂層100重量部に対比して90重量部だけ添加する。
前記実施例1と同一の条件で形成し、ウッドパターン形態のPLA表面層の代わりに実際のベニヤ板を使用する。
ここで、衝撃強度は、床材の表面上に286gの球形錘を落下させ、表面が破壊される高さである。
Claims (25)
- PLA(poly lactic acid)樹脂を含む一つ以上の層からなり、ウッドパターン形態のチップインレイド層を含む表面層;
前記表面層の下部に形成され、ベニヤを含む合板層;
前記合板層の下部に形成される合成樹脂層;及び
前記表面層の上部に形成される表面処理層;を含み、
前記チップインレイド層は、前記PLA樹脂に非フタレート系可塑剤、加工助剤としてアクリル系共重合体及び耐加水分解剤のうち一つ以上を含むことを特徴とするウッドパターン形態のPLA表面層を有する床材。 - 前記アクリル系共重合体は、重量平均分子量(Mw)が80万〜600万であることを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記耐加水分解剤は、カルボジイミド又はオキサゾリンであることを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記チップインレイド層は、前記PLA樹脂100重量部に対して、非フタレート系可塑剤5〜100重量部、アクリル系共重合体0.1〜20重量部、滑剤としてステアリン酸及び高級脂肪酸のうち1種以上0.01〜10重量部、耐加水分解剤10重量部以下、木粉及び籾殻のうち1種以上200重量部以下、炭酸カルシウム(CaCO3)500重量部以下、二酸化チタン(TiO2)50重量部以下及び松脂20重量部以下の組成物のうち一つ以上をさらに含むことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記合板層は、3枚以上のベニヤを熱圧着して製造されたことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記ベニヤは、互いに交互に直交するように積層されることを特徴とする、請求項5に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記合成樹脂層は、PLA(poly lactic acid)、PE(ポリエチレン)、PP(ポリプロピレン)、PVC(塩化ビニル樹脂)、ラバー(ゴム)及びPU(ポリウレタン)のうち一つ以上からなることを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記合成樹脂層は、前記塩化ビニル樹脂100重量部を基準にして、75〜90重量部の炭酸カルシウムを含むことを特徴とする、請求項7に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記合成樹脂層は、前記炭酸カルシウム100重量部を基準にして10〜20重量部の麦飯石、玉及び黄土のうち一つ以上をさらに含むことを特徴とする、請求項8に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記合成樹脂層は、前記塩化ビニル樹脂100重量部を基準にして、35〜40重量部の炭酸カルシウム及び45〜60重量部の鉄を含むことを特徴とする、請求項7に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記床材は、実矧ぎ継ぎ(Tongue & Groove)形態で裁断されたことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記表面層は、透明層、非発泡層及び発泡層から選ばれる一つ以上の層を含むことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記表面層は、前記チップインレイド層の下部に寸法安定層をさらに含むことを特徴とする、請求項12に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記寸法安定層は、アクリル樹脂、メラミン樹脂及びPLA樹脂のうち一つ以上の寸法安定バインダー樹脂にガラス繊維が含浸されていることを特徴とする、請求項13に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記ガラス繊維は、30〜150g/m2の面積当たりの単位質量を有することを特徴とする、請求項14に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記寸法安定層は、前記寸法安定バインダー樹脂100重量部に対して、非フタレート系可塑剤40〜150重量部、粘度低下剤30重量部以下、炭酸カルシウム150重量部以下及び二酸化チタン20重量部以下のうち一つ以上をさらに含むことを特徴とする、請求項14に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記透明層は、前記PLA樹脂100重量部に対して、非フタレート系可塑剤5〜50重量部及び加工助剤0.1〜20重量部の組成物のうち一つ以上をさらに含むことを特徴とする、請求項12に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記印刷層は、前記PLA樹脂100重量部に対して、非フタレート系可塑剤5〜60重量部及び加工助剤0.1〜20重量部の組成物のうち一つ以上をさらに含むことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記印刷層は、前記PLA樹脂100重量部に対して、滑剤として高級脂肪酸0.01〜10重量部、鎖延長剤0.01〜10重量部、耐加水分解剤10重量部以下、炭酸カルシウム(CaCO3)100重量部以下及び二酸化チタン(TiO2)50重量部以下の組成物のうち一つ以上をさらに含むことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記透明層は、前記PLA樹脂100重量部に対して、滑剤として高級脂肪酸0.01〜10重量部、鎖延長剤0.01〜10重量部及び耐加水分解剤10重量部以下の組成物のうち一つ以上をさらに含むことを特徴とする、請求項17に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記非発泡層は、前記PLA樹脂100重量部に対して、非フタレート系可塑剤5〜60重量部、アクリル系共重合体0.1〜20重量部、滑剤としてステアリン酸及び高級脂肪酸のうち1種以上0.01〜10重量部、耐加水分解剤10重量部以下、木粉及び籾殻のうち1種以上200重量部以下、炭酸カルシウム300重量部以下、二酸化チタン5重量部以下及び松脂20重量部以下の組成物のうち一つ以上を含むことを特徴とする、請求項12に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記表面処理層は、ポリウレタン、ポリウレタンアクリレート及びワックスのうち一つ以上からなることを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記チップインレイド層の下部には、発泡層、非発泡層、寸法安定層、織布のうち1種以上をさらに含むことを特徴とする、請求項1に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記非発泡層の上部に前記発泡層が形成されることを特徴とする、請求項23に記載のウッドパターン形態のPLA表面層を有する床材。
- 前記寸法安定層の上部には非発泡層をさらに含むことを特徴とする、請求項23に記載のウッドパターン形態のPLA表面層を有する床材。
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WO2005052056A1 (ja) * | 2003-11-25 | 2005-06-09 | Asahi Kasei Life & Living Corporation | 艶消しフィルム |
US20050154109A1 (en) * | 2004-01-12 | 2005-07-14 | Minyu Li | Floor finish with lightening agent |
JP2006007728A (ja) * | 2004-06-29 | 2006-01-12 | Dainippon Printing Co Ltd | 化粧シート |
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KR101288213B1 (ko) * | 2007-01-05 | 2013-07-18 | (주)엘지하우시스 | 칩층 내부무늬와 표면엠보가 일치하는 칩 인레이드바닥타일 |
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EP2265439A4 (en) * | 2008-03-24 | 2012-05-16 | Biovation Llc | BIOSTRATIFIED COMPOSITE ASSEMBLY AND ASSOCIATED METHODS |
US8389107B2 (en) * | 2008-03-24 | 2013-03-05 | Biovation, Llc | Cellulosic biolaminate composite assembly and related methods |
US20110123809A1 (en) * | 2008-03-24 | 2011-05-26 | Biovation, Llc | Biolaminate composite assembly and related methods |
US20110287237A1 (en) * | 2008-03-24 | 2011-11-24 | Biovation, Llc | Wear Resistant Biolaminate Composite Assembly and Related Methods |
-
2010
- 2010-12-24 KR KR1020100134467A patent/KR101320265B1/ko active IP Right Grant
-
2011
- 2011-12-15 WO PCT/KR2011/009645 patent/WO2012086960A2/ko active Application Filing
- 2011-12-15 US US13/993,932 patent/US20130266759A1/en not_active Abandoned
- 2011-12-15 JP JP2013544395A patent/JP5690414B2/ja active Active
- 2011-12-15 CN CN2011800626255A patent/CN103299009A/zh active Pending
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KR20120072623A (ko) | 2012-07-04 |
JP2014504341A (ja) | 2014-02-20 |
WO2012086960A3 (ko) | 2012-10-04 |
CN103299009A (zh) | 2013-09-11 |
KR101320265B1 (ko) | 2013-10-29 |
WO2012086960A2 (ko) | 2012-06-28 |
US20130266759A1 (en) | 2013-10-10 |
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