JP5733730B2 - 床材及びその製造方法 - Google Patents
床材及びその製造方法 Download PDFInfo
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- JP5733730B2 JP5733730B2 JP2012529654A JP2012529654A JP5733730B2 JP 5733730 B2 JP5733730 B2 JP 5733730B2 JP 2012529654 A JP2012529654 A JP 2012529654A JP 2012529654 A JP2012529654 A JP 2012529654A JP 5733730 B2 JP5733730 B2 JP 5733730B2
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Description
前記アクリル系加工助剤は、酸無水物及び/又はエポキシ基で変性され、1分子あたり2〜15個の極性基を含み、かつ前記ポリ乳酸100重量部に対して0.5重量部〜20重量部で前記樹脂組成物中に含まれる床材を提供する。
寸法安定層(繊維強化樹脂層)の製造
アクリル樹脂100重量部、ジイソノニルフタレート(DINP)120重量部及び二酸化チタン5重量部を配合し、アクリル系ゾルを製造した。続いて、ガラス繊維で製造された不織布(坪量:60g/m2)にロールコーターを使用してアクリル系ゾルを含浸処理した後、140℃の温度で3分間乾燥して寸法安定層を製造した。
(1)印刷物層の製造
ポリ乳酸(PLA)100重量部、クエン酸アセチルトリブチル(ATBC)30重量部、加工助剤5重量部及び二酸化チタン10重量部を含む樹脂組成物を使用して印刷物層を製造した。前記ポリ乳酸としては、Nature Works社の2002D(溶融指数:3未満)を使用し、加工助剤としては、マレイン酸無水物がグラフトされたアクリル系樹脂を使用した。以下、実施例でポリ乳酸と加工助剤の種類は前記に示す通りである。具体的には、前記各成分を押出器を使用して1次混練し、バンバリーミキサーで140℃で混練した後、140℃の2本ロールを使用して1次及び2次ミキシングをした。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0.3mmであるシートを製造した。
ポリ乳酸(PLA)100重量部、クエン酸アセチルトリブチル(ATBC)40重量部、加工助剤5重量部及び木粉10重量部を含む樹脂組成物を使用したことを除いては、前記印刷物層の製造と同一の方式で厚さが0.3mmである間紙層を製造した。
ポリ乳酸(PLA)100重量部、クエン酸アセチルトリブチル(ATBC)35重量部、炭酸カルシウム10重量部、オキシビスベンゼンスルホニルヒドラジド(OBSH)12重量部及び加工助剤10重量部を含む樹脂組成物を使用して弾性発泡層を製造した。
ポリ乳酸(PLA)100重量部、クエン酸アセチルトリブチル(ATBC)30重量部及び加工助剤5重量部を含む樹脂組成物を使用したことを除いては、前記印刷物層の製造と同一の方式で厚さが0.5mmである透明層を製造した。
前記の製造された寸法安定層上に印刷物層を150℃の温度で熱合板した後、グラビア印刷を通してパターンを付与して印刷物含浸寸法安定層を製造した。一方、製造された間紙層及び弾性発泡層は140℃のヒーティングドラムに通過させて予熱した後、エンボスロールに通過させて熱合板させることによって積層物を製造した。その後、前記積層物を165℃の発泡オーブンに8m/分の速度で通過させ、約150秒間発泡させた(発泡倍率:約200%)。続いて、前記の製造された印刷物含浸寸法安定層及び透明層を約160℃のヒーティングドラムで圧着させて予熱した後、前記発泡物と共にエンボスロールに通過させて熱合板することによって、厚さが約3mmである積層物を製造した。その後、製造された積層物の透明層の表面にウレタンアクリレート系UV硬化型塗料を塗布し、紫外線を照射して表面処理層を形成することによって床材を製造した。
実施例1で裏面層に使用された間紙層及び弾性発泡層の代わりに弾性層を適用したことを除いては、実施例1と同一の方式で床材を製造した。このとき、弾性層は、ポリ乳酸(PLA)100重量部、クエン酸アセチルトリブチル(ATBC)40重量部、木粉10重量部及び加工助剤5重量部を押出器で1次混練し、140℃でバンバリーミキサーで混練した後、140℃の2本ロールを使用して1次及び2次ミキシングをした後、続いて、カレンダリング方式で厚さが約1mmであるシートに製造した。
製造された床材の最下部に厚さが約1mmである黄麻布を接着剤を用いて付着したことを除いては、実施例2と同一の方式で床材を製造した。
Claims (16)
- 繊維層又は繊維強化樹脂層と、前記繊維層又は繊維強化樹脂層上に形成され、一つ以上の生分解性シートを含む表面層又は裏面層と、を有し、
前記生分解性シートは、加工助剤であるアクリル系加工助剤と、可塑剤であるエポキシ化植物性オイルと、ポリ乳酸とを含む樹脂組成物からカレンダリング方式で製造されるものであり、
前記アクリル系加工助剤は、酸無水物及び/又はエポキシ基で変性され、1分子あたり2〜15個の極性基を含み、かつ前記ポリ乳酸100重量部に対して0.5重量部〜20重量部で前記樹脂組成物中に含まれる床材。 - 前記繊維層は、ガラス繊維、炭素繊維、ポリエステル繊維、ポリアミド繊維、ポリウレタン繊維、アクリル繊維、ポリオレフィン繊維及びセルロース繊維からなる群より選ばれた一つ以上の織布、不織布又はスクリムを含む請求項1に記載の床材。
- 前記繊維強化樹脂層は、ポリ乳酸、アクリル樹脂、ポリ塩化ビニル、ウレタン樹脂、メラミン樹脂、フェノール樹脂、エポキシ樹脂及びポリエステル樹脂からなる群より選ばれた一つ以上の樹脂成分が含浸された織布、不織布又はスクリムを含む請求項1に記載の床材。
- 前記織布、不織布又はスクリムは、坪量が20g/m2〜120g/m2である請求項3に記載の床材。
- 前記繊維層又は繊維強化樹脂層は厚さが0.2mm〜0.8mmである請求項1に記載の床材。
- 前記ポリ乳酸はL―ポリ乳酸を含む請求項1に記載の床材。
- 前記樹脂組成物はフィラーをさらに含む請求項1に記載の床材。
- 前記可塑剤は、エポキシ化大豆油である請求項1に記載の床材。
- 前記可塑剤は、前記ポリ乳酸100重量部に対して5重量部〜70重量部で含まれる請求項1に記載の床材。
- 前記フィラーは有機系フィラー又は無機系フィラーである請求項7に記載の床材。
- 前記フィラーは、前記ポリ乳酸100重量部に対して1重量部〜300重量部で含まれる請求項7に記載の床材。
- 前記樹脂組成物は、発泡剤、滑剤、架橋剤及び紫外線安定剤からなる群より選ばれた一つ以上をさらに含む請求項1に記載の床材。
- 前記表面層は透明層、フィラー層及び印刷層からなる群より選ばれた一つ以上を含む請求項1に記載の床材。
- 前記裏面層は間紙層、発泡弾性層、離紙層、弾性層及び織布層からなる群より選ばれた一つ以上を含む請求項1に記載の床材。
- 繊維層又は繊維強化樹脂層を製造すること、及び前記の製造された繊維層又は繊維強化樹脂層上に、加工助剤であるアクリル系加工助剤と、可塑剤であるエポキシ化植物性オイルと、ポリ乳酸とを含む樹脂組成物からカレンダリング方式で生分解性シートを形成することを含み、
前記アクリル系加工助剤は、酸無水物及び/又はエポキシ基で変性され、1分子あたり2〜15個の極性基を含み、かつ前記ポリ乳酸100重量部に対して0.5重量部〜20重量部で前記樹脂組成物中に含まれる床材の製造方法。 - 前記の製造された繊維層又は繊維強化樹脂層上に生分解性シートを形成することは、(1)前記繊維層又は繊維強化樹脂層の一面に生分解性シートを圧着すること、(2)前記の圧着された生分解性シートの表面にパターンを印刷すること、及び(3)前記パターンが印刷された繊維層又は繊維強化樹脂層と生分解性シートの積層体の一面又は両面に生分解性シートをさらに形成することを含む請求項15に記載の床材の製造方法。
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JP2013504702A (ja) | 2013-02-07 |
KR20110032536A (ko) | 2011-03-30 |
KR101302335B1 (ko) | 2013-08-30 |
WO2011037325A3 (ko) | 2011-06-16 |
CN102470650B (zh) | 2015-04-15 |
WO2011037325A2 (ko) | 2011-03-31 |
US20120128946A1 (en) | 2012-05-24 |
CN102470650A (zh) | 2012-05-23 |
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