JP6904962B2 - 外装パネル及び外装パネルの製造方法 - Google Patents
外装パネル及び外装パネルの製造方法 Download PDFInfo
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- JP6904962B2 JP6904962B2 JP2018536276A JP2018536276A JP6904962B2 JP 6904962 B2 JP6904962 B2 JP 6904962B2 JP 2018536276 A JP2018536276 A JP 2018536276A JP 2018536276 A JP2018536276 A JP 2018536276A JP 6904962 B2 JP6904962 B2 JP 6904962B2
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Description
合成材料と少なくとも1つのフィラー材料とを、混合物の総重量に対して少なくとも20.0重量%のフィラー材料量にて混合する工程であって、上記少なくとも1つのフィラー材料が該フィラー材料の重量基準で少なくとも50重量%のタルクを含み、混合することで混合物が得られる、工程と、
上記混合物を押し出し、それによって基体を得る工程と、
任意に上記基体をアニーリングする工程と、
任意に上層を上記基体に積層する工程と、
を含み、それによって外装パネルが得られる、方法を提供する。
本発明は、例えば機械的連結部によって組み立てられ得る剛性パネル又はタイルで構成される床被覆材等の表面被覆材に関する。考察を簡潔にするために本明細書ではパネル単独について言及されることが多い。本発明の「パネル」について本明細書で言及する場合はいつでも、その記載は、別段の指示のない限り、「タイル」に等しく当てはまると理解され得る。
本発明について用いられる「合成材料」という用語は、1つのポリマー又は2つ以上のポリマーのブレンドを含むものと理解されたい。合成材料は任意の1つ以上のポリマーで構成され得る。例えば、合成材料は、熱可塑性ポリマー又は熱硬化性ポリマーで構成され得る。合成材料は、天然ポリマーと合成ポリマーとの混合物を含む任意のポリマーで構成され得る。合成材料は、例えば熱可塑性ポリマー、熱硬化性ポリマー、ゴム(エラストマー)、又はそれらの任意の組合せとすることができる。さらに、合成材料は、例えば、任意の種のポリマー、例えばホモポリマー、コポリマー、ランダムポリマー、交互ポリマー、グラフトポリマー、ブロックポリマー、星状ポリマー、櫛状ポリマー、架橋ポリマー、及び/又は加硫ポリマーで構成され得る。合成材料は、1つ以上のポリブレンドで構成され得る。合成材料は、例えば熱可塑性エラストマー(TPE)、相互貫入ポリマーネットワーク(IPN);同時相互貫入ポリマーネットワーク(SIN);又は相互貫入エラストマーネットワーク(IEN)で構成され得る。
好ましい実施形態において、本発明は、基体中の上記フィラー材料が、該フィラー材料の総重量に対して少なくとも60重量%、好ましくは少なくとも80重量%のタルクを含む、第1の態様による外装パネルを提供する。より好ましくは、上記フィラー材料は、少なくとも85重量%のタルク、少なくとも90重量%のタルク、少なくとも95重量%のタルクを含む。最も好ましくは、上記フィラー材料はタルクから本質的になる。タルクは、フィラーの利用可能性及び技術的に考慮すべき事項、例えば基体及びパネルの強靭性の改善、寸法安定性の改善、膨張の低減及び湾曲の低減に関して、フィラー材料として好ましい選択肢であることが分かっている。
一実施形態において、パネルは、基体と上層とを含む。一実施形態において、上層は、印刷層又は印刷フィルムと、摩耗層とを含む。上層は、基体の上面に一体として取り付けられる。上層はまた任意に、摩耗層の上部にある印刷デザイン及び保護層の下に下層を有していてもよい。上層(複数の場合もある)は例えば、PVC、オレフィン、ウレタン、アイオノマー、アクリル樹脂、ポリエステル、熱可塑性ポリオレフィン(TPO)、熱硬化性ポリウレタン(TPU)、又はこのタイプの層(複数の場合もある)又は材料に従来使用される他の材料とすることができる。保護層は例えば、熱硬化系、例えば水系ポリウレタン分散系、水系アクリル樹脂若しくはビニルエマルションコーティング、又は放射線硬化型コーティング系、例えばウレタンエポキシ若しくはポリエステルアクリレート、又はこのタイプの層若しくは材料に従来使用される他の材料とすることができる。
好ましい実施形態において、本発明は、上記上層が印刷層又は印刷フィルムを含む、第1の態様による外装パネルを提供する。
摩耗層は、高分子膜又はオーバーレイ紙等のかかる摩耗層を作製するのに好適な当該技術分野で既知の任意の材料から作られ得る。摩耗層は例えば、透明なポリ塩化ビニル層とすることができる。このPVC摩耗層の乾燥膜厚は、好ましくは約0.10 mm〜約1.00 mm、より好ましくは約0.25 mm〜約0.70 mmである。この摩耗層の他の例としては、アクリルポリマー、ポリオレフィン等が挙げられるが、これらに限定されない。摩耗層は、可塑化若しくは剛性ポリ塩化ビニル組成物、及び/又はクリアポリマー等の他のポリマーとすることができる。
好ましい実施形態において、本発明は、上記基体が、ISO 4590に従って求められる場合、10容量%〜70容量%の空隙容量を伴って構成される、第1の態様による外装パネルを提供する。上記基体は、30容量%〜50容量%、より好ましくは35容量%〜45容量%の空隙容量を伴って構成されることが好ましい。上記基体は、約40容量%の空隙容量を有することが最も好ましい。最適化されたフィラー含有率及び高い空隙容量を有する剛性の外装パネルの提供は、パネルの機械的耐久性に負の影響を及ぼすことなく軽量の外装パネルを可能にする。このことは、輸送及び設置中に上記パネルが軽量であることが有利であるとともに、優れた機械特性によってパネルに耐久性がもたらされることから有益である。
本明細書で同義語として使用される「起泡剤」又は「発泡剤」という用語は、通例、熱の作用下で起泡プロセスを介して、幅広い種類の材料中に気泡質構造を形成することができる化合物を指す。かかる気泡質構造は通例、材料の密度を下げ、通例、材料の体積の膨張をもたらす。発泡プラスチック系材料中の発泡剤は、化学的発泡剤、物理的発泡剤、又はそれらの混合物から選択される少なくとも1つを含み得る。物理的発泡剤は通例、液相で材料に添加され、その後、温度を上昇させることにより、発泡剤をその気相へと変換させ、こうして気泡質構造の形成及び材料の膨張がもたらされるが、気相状態の物理的発泡剤を材料に直接添加してもよい。化学的発泡剤は熱の作用下で化学反応を経ることにより、気泡質構造を形成する気体生成物を形成する。特定の温度で分解して、気体を発生させることが可能なものであれば、いずれの化合物を化学的発泡剤として使用してもよく、その例としては、アゾジカルボンアミド、アゾジ−イソブチロ−ニトリル、ベンゼンスルホンヒドラジド、4,4-オキシベンゼンスルホニル−セミカルバジド、p-トルエンスルホニルセミカルバジド、バリウムアゾジカルボキシレート、N,N'-ジメチル-N,N'-ジニトロソテレフタルアミド、トリヒドラジノトリアジン、重炭酸ナトリウム、重炭酸カリウム、重炭酸アンモニウム、炭酸ナトリウム、炭酸アンモニウム、及び上記の任意の誘導体、又は上記の任意の組合せが挙げられ得る。さらに、物理的発泡剤の例としては、無機発泡剤、例えば二酸化炭素、窒素、酸素、アルゴン、水、空気、ヘリウム等、若しくは有機発泡剤、例えば、メタン、エタン、プロパン、n-ブタン、イソブタン、n-ペンタン、イソペンタン、ネオペンタン、シクロブタン及びシクロペンタンを含む炭素数1〜9の脂肪族炭化水素;炭素数1〜5の完全及び部分的にハロゲン化されたアルカン及びアルケン、好ましくは塩素を含まないもの(例えば、ジフルオロメタン(HFC-32)、ペルフルオロメタン、フッ化エチル(HFC-161)、1,1-ジフルオロエタン(HFC-152a)、1,1,1-トリフルオロエタン(HFC-143a)、1,1,2,2-テトラフルオロエタン(HFC-134)、1,1,1,2-テトラフルオロエタン(HFC-134a)、ペンタフルオロエタン(HFC-125)、ペルフルオロエタン、2,2-ジフルオロプロパン(HFC-272fb)、1,1,1-トリフルオロプロパン(HFC-263fb)、1,1,1,2,3,3,3-ヘプタフルオロプロパン(HFC-227ea)、1,1,1,3,3-ペンタフルオロプロパン(HFC-245fa)、及び1,1,1,3,3-ペンタフルオロブタン(HFC-365mfc);完全及び部分的にハロゲン化されたポリマー及びコポリマー、望ましくはフッ化ポリマー及びコポリマー、更に好ましくは塩素を含まないフッ化ポリマー及びコポリマー;炭素数1〜5の脂肪族アルコール、例えばメタノール、エタノール、n-プロパノール及びイソプロパノール;カルボニル含有化合物、例えばアセトン、2-ブタノン及びアセトアルデヒド;エーテル含有化合物、例えばジメチルエーテル、ジエチルエーテル、メチルエチルエーテル、並びにカルボキシレート化合物、例えばギ酸メチル、酢酸メチル、酢酸エチル及びカルボン酸、又は上記の任意の組合せが挙げられ得る。
好ましい実施形態において、本発明は、上記基体が、該基体の総重量に対して6.0重量%未満の量で1つ以上の可塑剤を含む、第1の態様による外装パネルを提供する。上記基体は1つ以上の可塑剤を、5.0重量%未満、2.0重量%未満、1.0重量%未満、又は更に好ましくは0.5重量%未満、最も好ましくは0.1重量%未満の量で含むことが好ましい。
一実施形態において、本発明は、上記基体が補強層を更に含む、本発明の第1の態様による外装パネルを提供する。
補強層は不織ガラス繊維布であってもよい。
代替的な実施形態において、鋼繊維、カーボン繊維、アラミド繊維、ポリエチレン繊維及び/又はポリプロピレン繊維が補強繊維を設けるのに使用される。
好ましい実施形態において、本発明は、上記基体が、好ましくは該基体の総重量に対して0重量%〜10重量%の量の少なくとも1つの衝撃改質剤を更に含む、本発明の第1の態様による外装パネルを提供する。
基体はまた、少なくとも1つの熱安定剤を含むことができる。安定剤は通例、合成材料をベースとする配合物に対して熱安定性及び/又はUV光安定性をもたらす。PVCがポリマーとして使用される場合の非限定的な例として、安定剤はカルシウム−亜鉛安定剤とすることができる。約5.5重量%以上の亜鉛、例えば約6.0重量%〜約10.0重量%の亜鉛を含有するカルシウム−亜鉛安定剤を使用してもよい。亜鉛−カルシウム安定剤の非限定的な具体例は、Baerlocherによって与えられている。安定剤の他の例としては、バリウム−カドミウム安定剤、バリウム−亜鉛安定剤、有機スズ安定剤、エポキシ化ダイズ油等が挙げられるが、これらに限定されない。
付着促進剤若しくは接着剤として又は接着剤層に使用するのに好適な材料は、種々の層で同じであっても又は異なっていてもよい。特定の層を別の層に結合することができる任意の接着剤は本発明の範囲内である。接着剤の効果的な種類及び量は、所与の(フォーム)層/(フォーム)層の組合せについて過度の実験を行うことなく当業者によって決定することができる。
基体(複数の場合もある)配合物は、合成材料と、フィラーと、任意に、好適な潤滑剤及び加工助剤と調合した顔料及び/又は変化に富んだ顔料とを含む。他の一般的な添加剤としては、赤外線減衰剤(例えばカーボンブラック、グラファイト、金属フレーク、二酸化チタン);核形成剤(例えばケイ酸マグネシウム);難燃剤(例えば、臭素化難燃剤、例えば臭素化ポリマー、ヘキサブロモシクロドデカン、リン酸トリフェニル等のリン系難燃剤、並びに例えばジクミル及びポリクミル等の協力剤を含み得る難燃剤パッケージ);溶融粘度を低減し、また透過性を向上させるための内部潤滑剤(例えば、ステアリン酸カルシウム及びステアリン酸バリウム、脂肪アルコール、低エステル化エステル、EVAワックス等);ポリマー溶融物と押出成形型との間の摩擦を低減させるための外部潤滑剤(例えばポリエチレンワックス、酸化ポリエチレンワックス、パラフィン、金属セッケン、高エステル化エステル、アミド、脂肪酸等);酸掃去剤(例えば酸化マグネシウム及びピロリン酸四ナトリウム);UV光安定剤;熱安定剤;及び着色剤、例えば染料及び/又は顔料の任意の1つ又は2つ以上の組合せが挙げられる。
第2の態様において、本発明は、床パネル、壁パネル又は天井パネル等の外装パネルを製造する方法であって、各外装パネルが、少なくとも1つの基体と、任意に上層とを含み、上記少なくとも1つの基体が、合成材料と、少なくとも1つのフィラー材料とを含み、上記方法が、
合成材料と少なくとも1つのフィラー材料とを、混合物の総重量に対して少なくとも20.0重量%のフィラー材料量にて混合する工程であって、上記少なくとも1つのフィラー材料が該フィラー材料の重量基準で少なくとも50重量%のタルクを含み、混合することで混合物が得られる、工程と、
上記混合物を押し出し、それによって基体を得る工程と、
任意に上記基体をアニーリングする工程と、
任意に上層を上記基体に積層する工程と、
を含み、それによって外装パネルが得られる、方法を提供する。
100部の合成材料(PVC、又は11%のPVAc含有率を有する70:30重量比のPVCとPVC/PVAcコポリマーとの混合物)を、1つ以上のフィラーと、4部の安定剤(BaeropanMC 90060P)と、加工助剤と、衝撃改質剤と、2部の潤滑剤(Baerolub L-PL、Baerlocher)との混合物と表1に示される比率で配合することによって造粒物を形成する。別段の指示がない限り、剛性PVC化合物をもたらすために、可塑剤は造粒物に配合しない。実施例1、実施例3及び実施例4では、起泡剤も添加する。実施例1、実施例2及び実施例4による組成物は、チョークとタルクとの比率が1:1〜1:38の範囲を示している。実施例3及び実施例5の組成物はフィラーとしてタルクのみを含有する。
押出供給物は、23.0重量%のPVCと、22.0重量%のタルクと、52.3重量%のリサイクル熱可塑性材料と、2.7重量%の添加剤とで構成される。
Claims (15)
- 少なくとも1つの基体と、任意に上層とを含む外装パネルであって、
前記基体が合成材料と、少なくとも1つのフィラー材料とを含み、
前記フィラー材料が前記基体中、該基体の重量に対して35重量%〜45重量%の量で存在し、前記少なくとも1つのフィラー材料が、該フィラー材料の総重量に対して少なくとも50重量%の量でタルクを含み、該外装パネルが70℃でDIN EN ISO 23999に従って求められる場合、-0.20%〜+0.20%の範囲内の寸法安定性を有し、前記合成材料がPVCを含むことを特徴とする、外装パネル。 - 前記フィラー材料が、該フィラー材料の総重量に対して少なくとも80重量%のタルクを含む、請求項1に記載の外装パネル。
- 前記フィラー材料がタルクからなる、請求項1又は2に記載の外装パネル。
- 前記フィラー材料が、重量%基準として1:1より大きいタルク:他のフィラー(複数の場合もある)の比率で、タルクと少なくとも1つの他のフィラーとの混合物で構成される、請求項1又は2に記載の外装パネル。
- 前記フィラーは、粒子の少なくとも95%が、ISO 13317-3に従って測定される5.0 μm〜200.0 μmの粒径を有する粒子を含む、請求項1〜4のいずれか一項に記載の外装パネル。
- 前記基体が、ISO4590に従って求められる10容量%〜70容量%若しくは30容量%〜40容量%の空隙容量を伴って構成される、請求項1〜5のいずれか一項に記載の外装パネル。
- 前記基体が、該基体の総重量に対して6.0重量%未満の量で1つ以上の可塑剤を含む、請求項1〜6のいずれか一項に記載の外装パネル。
- 前記基体が可塑剤を実質的に含まない、請求項1〜6のいずれか一項に記載の外装パネル。
- 前記合成材料がリサイクル熱可塑性ポリマーを含む、請求項1〜8のいずれか一項に記載の外装パネル。
- 前記少なくとも1つのフィラー材料が天然繊維を含む、請求項1、2及び4〜9のいずれか一項に記載の外装パネル。
- 前記上層が補強層を含む、請求項1〜10のいずれか一項に記載の外装パネル。
- 前記上層が弾性層を含む、請求項1〜11のいずれか一項に記載の外装パネル。
- 前記上層が印刷層又は印刷フィルムを含む、請求項1〜12のいずれか一項に記載の外装パネル。
- 前記基体が、1.0 mm〜5.0 mm、若しくは1.5 mm〜4.0 mm、若しくは2.0 mm〜3.5 mmの厚さを有する、請求項1〜12のいずれか一項に記載の外装パネル。
- 外装パネルを製造する方法であって、
各外装パネルが、少なくとも1つの基体と、任意に上層とを含み、前記少なくとも1つの基体が、合成材料と、少なくとも1つのフィラー材料とを含み、前記方法が、
PVCを含む合成材料と少なくとも1つのフィラー材料とを、混合物の総重量に対して35重 量%〜45重量%のフィラー材料量にて混合する工程であって、前記少なくとも1つのフィラー材料が該フィラー材料の重量基準で少なくとも50重量%のタルクを含み、混合することで混合物が得られる、工程と、
前記混合物を押し出し、それによって基体を得る工程と、
任意に前記基体をアニーリングする工程と、
任意に上層を前記基体に積層する工程と、
を含み、それによって70℃でDIN EN ISO 23999に従って求められる場合、-0.20%〜+0.20%の範囲内の寸法安定性を有する外装パネルが得られる、方法。
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