JP7342393B2 - Building materials for floors - Google Patents

Description

The present invention relates to building materials for floors.

BACKGROUND ART Sheet flooring materials, in which a decorative sheet is attached to the surface side of a wood base material such as plywood, MDF, or particle board, are becoming popular as flooring materials. Techniques related to sheet flooring materials include those described in Patent Document 1 and Patent Document 2, for example.
The background to this is that if the surface is conventionally made of veneer, problems such as the color of the surface layer not matching will occur at the construction site, and if you want a veneer with a higher design, you will need to use high-quality materials, which is extremely expensive. This is due to the fact that the flooring material becomes expensive.

As sheet flooring materials have become more widespread, the issue of inconsistent quality due to variations in the impact resistance and caster resistance of wood-based base materials has become more important. Therefore, specifications have been put on the market in which a backer material such as a polyethylene terephthalate film or a resin sheet containing wood powder is attached to the back side of the decorative sheet with a thickness of about 0.1 mm to 0.5 mm. Among them, specifications using a resin sheet containing wood flour as the backer material are widely used.

On the other hand, common flooring materials have C-surfaces and V-grooves formed at the ends and center using a router or the like. Conventional flooring materials with veneer laminated to the surface layer were colored on the C-side and V-grooves, and the surface was further protected with UV-curable resin, but this required additional steps and was time-consuming. On the other hand, for flooring materials that use wood flour-containing resin sheets as backer materials, pigments are blended into the wood flour-containing resin sheets to create colored wood flour-containing resin sheets that match the color of the decorative sheet on the surface layer. By forming C-surface and V-grooves that do not reach the wood-based base material on the back side of the sheet, the coloring process and surface protection process are omitted.

However, wood flour, which is a natural product, has a large variation in color, and once the pigment composition is determined to produce the desired color, the quality is not stable, and the color tone adjustment is required each time, which is very time-consuming. .

JP 8-142150 JP 10-195305

The present invention has been made to solve these problems, and an object of the present invention is to provide a non-combustible floor building material that stably produces a desired color and that An object of the present invention is to provide a building material for floors with stable quality, that is, a building material for floors that is nonflammable and can ensure stable color tone quality.

One aspect of the present invention is a floor building material formed by laminating a thermoplastic resin molded body on a wood base material, wherein the thermoplastic resin molded body contains a thermoplastic resin, an inorganic material, and a coloring pigment. The content of the inorganic material is within a range of 15% by mass or more and 90% by mass or less based on the mass of the thermoplastic resin molded body, and the content of the colored pigment is within the range of 15% by mass or more and 90% by mass or less with respect to the mass of the thermoplastic resin molded body. This is a building material for floors, characterized in that the content is in the range of more than 0% by mass and 10% by mass or less with respect to the mass of.

With the floor building material according to one aspect of the present invention, it is possible to ensure stable color tone quality while being nonflammable.

FIG. 1 is an explanatory diagram showing a cross-sectional structure of a floor building material according to an embodiment of the present invention.

<Configuration>
Hereinafter, embodiments of the present invention will be described in detail based on the drawings. FIG. 1 shows a cross-sectional structure of a floor building material according to an embodiment of the present invention. The floor construction material according to the present embodiment includes at least a decorative sheet 1, a thermoplastic resin molded body 2, and a wood base material 3, which are appropriately provided from the front side.
Here, the drawings are schematic, and the relationship between thickness and planar dimension, the ratio of the thickness of each layer, etc. differ from the actual one. In addition, the embodiments shown below illustrate configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is that the materials, shapes, structures, etc. of the component parts are It is not something specific. The technical idea of the present invention can be modified in various ways within the technical scope defined by the claims.

In addition, the content of various materials mentioned below means the content ratio (mass %) with respect to the mass of the whole corresponding member in a dry state. For example, the content of the inorganic material in this embodiment, which will be described later, means the content ratio (mass %) with respect to the mass of the entire thermoplastic resin molded body 2 in a dry state. In addition, the content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the surface anchor layer (first anchor layer) 4a, which will be described later, is the mass of the entire surface anchor layer 4a in a dry state. It means the content ratio (mass%) with respect to In addition, the content of the urethane resin containing salt-vinyl acetate or the acrylic resin containing salt-vinyl acetate in the back anchor layer (second anchor layer) 4b, which will be described later, is the mass of the entire back anchor layer 4b in a dry state. It means the content ratio (mass%) with respect to

In addition, in this embodiment, non-flammability means that (i) The total calorific value for 20 minutes after the start of heating is 8 MJ/ ^m2 or less, (ii) the maximum heat generation rate does not exceed 200kW/ ^m2 for 10 seconds or more for 20 minutes after the start of heating, and (iii) heating It is non-combustible, with no cracks or holes penetrating to the back surface that are detrimental to fire protection for 20 minutes after starting.

(Decorative sheet 1)
The decorative sheet 1 provided as appropriate is not particularly limited, and for example, a decorative sheet conventionally used for the surface of a flooring material can be used. Specifically, those made of conventionally known polyvinyl chloride resins or polyolefin resins can be used. In consideration of environmental issues, it is preferable to use a polyolefin resin that is free from the possibility of generating harmful substances such as hydrogen chloride or dioxins during combustion. The layer structure of the decorative sheet 1 is not particularly limited, and for example, a pattern may be printed on a resin base material, and a transparent resin layer and a surface protection layer may be laminated thereon. Note that it is also possible to provide a colored resin layer without a picture pattern. Hereinafter, each layer of the surface protection layer, transparent resin layer, pattern, and resin base material that constitute the decorative sheet 1 will be briefly described.

[Surface protective layer]
The material of the surface protective layer is not particularly limited in this embodiment, and for example, from the viewpoint of various surface properties, it is desirable to use a curable resin. Specifically, for example, thermosetting resins such as urethane resins, aminoalkyd resins, melamine resins, epoxy resins, unsaturated polyester resins, urea resins, phenolic resins, and unsaturated polyester resins. Ionizing radiation-curable resins such as , acrylate resins, methacrylate resins, etc. can be used. Among them, two-component curable urethane resins, such as acrylic polyol or A thermosetting resin made of acrylic polyether as a main ingredient and cross-linked and cured by adding an isocyanate curing agent is most suitable for the purpose of the floor building material according to the present embodiment. The thickness of the surface protective layer is not particularly limited in this embodiment, but from the viewpoint of physical properties and flexibility, it is usually appropriate to set it within the range of 3 μm or more and 20 μm or less.

The surface protective layer may contain UV absorbers, light stabilizers, heat stabilizers, gloss adjusters, lubricants, antistatic agents, anti-condensation agents, antibacterial agents, anti-mold agents, anti-friction agents, and colorants as necessary. , fillers, and other additives may be added. Further, the surface protective layer may be composed of two or more layers of the same type or different types, for example, on a first layer containing high hardness wear-resistant particles such as silica, alumina, silicon carbide, etc. A second layer that does not contain the resin may be provided to achieve both abrasion resistance and scratch resistance as well as surface gloss and surface smoothness. In addition, a second layer with a different gloss state can be provided in an arbitrary pattern on top of the first layer, which is provided on the entire surface, for applications such as expressing a visual three-dimensional effect by changing the gloss. is also possible.

[Transparent resin layer]
The transparent resin layer can be made of conventionally known polyvinyl chloride resin or polyolefin resin, and is not particularly limited. It is preferable to use a polyolefin resin that is free from the possibility of generating harmful substances. The total thickness of the transparent resin layer is preferably in the range of 70 μm or more and 120 μm or less.

[Picture pattern]
The picture pattern is provided by printing or the like for the purpose of imparting a desired design picture. There are no restrictions on the type of pattern, constituent materials, forming method, etc. Generally, the pattern is, for example, a wood grain pattern, a stone grain pattern, a cloth grain pattern, an abstract pattern, a geometric pattern, letters or symbols, or a combination thereof, but it is of course possible to use a single color (solid color). do not have. As the constituent material, printing ink or paint in which a colorant such as a dye or a pigment is dispersed in a color vehicle such as a synthetic resin is generally used. Examples of methods for forming the pattern include known printing methods such as gravure printing, offset printing, gravure offset printing, screen printing, flexo printing, letterpress printing, inkjet printing, and transfer printing, as well as solid printing methods. For example, gravure coating method, microgravure coating method, roll coating method, knife coating method, air knife coating method, die coating method, lip coating method, comma coating method, dip coating method, flow coating method, spray coating method. A known coating method such as the like can be used. Further, an adhesive layer (not shown) may be provided between the picture pattern and the surface protective layer on the front side thereof or a transparent resin layer provided as appropriate to increase the interlayer adhesive strength.

[Resin base material]
As the resin base material, conventionally known polyvinyl chloride resins or polyolefin resins can be used and are not particularly limited, but in consideration of environmental issues, hydrogen chloride, dioxins, etc. It is preferable to use a polyolefin resin that is free from the possibility of generating harmful substances. The thickness is sufficient as long as it can be printed on, and is preferably in the range of 70 μm or more and 120 μm or less.

(Thermoplastic resin molded body 2)
The thermoplastic resin molded body 2 in this embodiment contains a thermoplastic resin, an inorganic material, and a coloring pigment, and the content of the inorganic material is 15% by mass or more with respect to the mass of the thermoplastic resin molded body. The coloring pigment content is within the range of 90% by mass or less, and the content of the colored pigment is within the range of more than 0% by mass and 10% by mass or less based on the mass of the thermoplastic resin molded body. Hereinafter, the structure of the thermoplastic resin molded body 2 will be explained in detail.

The content of the inorganic material in this embodiment may be within the range of 15% by mass or more and 90% by mass or less, and within the range of 20% by mass or more and 80% by mass or less, based on the mass of the thermoplastic resin molded body 2. It is more preferable if it is within the range of 60% by mass or more and 80% by mass or less. If the content of the inorganic material is less than 15% by mass with respect to the mass of the thermoplastic resin molded body 2, the proportion of the thermoplastic resin will be relatively large, making it difficult to obtain nonflammability or flame retardance. be. Further, when the surface of the thermoplastic resin molded body 2 is scratched using a Hoffman scratch tester, visible scratches may occur, that is, sufficient surface hardness may not be obtained. On the other hand, when the content of the inorganic material exceeds 90% by mass with respect to the mass of the thermoplastic resin molded body 2, the proportion of the thermoplastic resin becomes relatively small. For this reason, when the surface of the thermoplastic resin molded body 2 is coated with an anchor layer, which will be described later, etc., so-called "powder blowing" may occur on the surface of the thermoplastic resin molded body 2. Here, "powder blowing" refers to the inorganic material contained in the thermoplastic resin molded body 2 coming out onto the surface of the thermoplastic resin molded body 2. Furthermore, if the content of the inorganic material exceeds 90% by mass with respect to the mass of the thermoplastic resin molded body 2, when the thermoplastic resin molded body 2 is bent and opened again, cracks may occur at the bent portion. , inorganic materials may fall.

As described above, the content of the inorganic material of the present embodiment is 15% by mass or more and 90% by mass or less, preferably 20% by mass or more and 80% by mass or less, more preferably 60% by mass or less, based on the mass of the thermoplastic resin molded body 2. If it is within the range of 80% by mass or more, it is possible to obtain nonflammability or flame retardancy, reduce the occurrence of powder blowing, and reduce the occurrence of cracks at the folded portion of the sheet, and moreover, surface hardness can be obtained.

Further, the inorganic material of this embodiment is preferably in powder form (powder shape), and preferably has an average particle size in the range of 1 μm or more and 3 μm or less, and a maximum particle size of 50 μm or less. . If the average particle size and maximum particle size of the inorganic material are within the above numerical ranges, the flatness of the surface of the thermoplastic resin molded body 2 can be maintained while improving the dispersibility of the inorganic material in the thermoplastic resin. When the average particle diameter of the inorganic material is less than 1 μm, the cohesive force between the inorganic materials increases, and the dispersibility in the thermoplastic resin described below may decrease. Furthermore, if the average particle diameter of the inorganic material exceeds 3 μm, the flatness of the surface of the thermoplastic resin molded body 2 will decrease, and the thickness of the surface anchor layer 4a or the back surface anchor layer 4b, which will be described later, may become uneven or uneven. Chips may occur. Furthermore, if the maximum particle size of the inorganic material exceeds 50 μm, the flatness of the surface of the thermoplastic resin molded body 2 will decrease, and the thickness of the surface anchor layer 4a or the back surface anchor layer 4b, which will be described later, may become uneven or uneven. Chips may occur. In addition, in this embodiment, "average particle diameter" means a mode diameter. In addition, it is preferable that the particles having the maximum particle size are in the range of 5% by mass or more and 30% by mass or less of the entire inorganic material.

The inorganic material is, for example, a powder containing at least one of calcium carbonate and calcium carbonate salt. The powder containing at least one of calcium carbonate and calcium carbonate salt preferably contains 50% by mass or more and 100% by mass or less. That is, the purity of the powder containing at least one of calcium carbonate and calcium carbonate salt is preferably in the range of 50% by mass or more and 100% by mass or less of calcium carbonate. If the powder contains at least one of calcium carbonate and calcium carbonate salt containing 50% by mass or more of calcium carbonate, etc., sufficient nonflammability or sufficient flame retardance will be imparted to the thermoplastic resin molded body 2. It is possible to provide sufficient mechanical strength.

In addition to powders containing at least one of the calcium carbonate and calcium carbonate salts, examples of inorganic materials include silica (especially hollow silica), alumina, antimony trioxide, antimony soda, zirconium silicate, and zirconium oxide. compounds, such as magnesium hydroxide, aluminum hydroxide, basic magnesium carbonate, borax, zinc borate, molybdenum trioxide or complexes of antimony dimolybdate and aluminum hydroxide, complexes of antimony trioxide and silica, antimony trioxide Examples include at least one of complexes of zirconium and zinc white, silicic acid of zirconium, complexes of zirconium compounds and antimony trioxide, and salts thereof. In particular, calcium carbonate and calcium carbonate salts are easy to control particle size and compatibility with thermoplastic resin through manufacturing methods, and are also inexpensive in terms of material cost, making the thermoplastic resin molded body 2 less expensive. It is also suitable from the viewpoint of

Further, the inorganic material may be a powder material having crystallinity, a so-called crystalline powder, or a powder material having no crystallinity, a so-called amorphous type powder material. If the inorganic material is a powder material with crystallinity, the powder itself is homogeneous and has isotropy, so the mechanical strength of the powder itself improves, and the scratch resistance and durability of the thermoplastic resin molded body 2 tend to improve. There is. In addition, if the inorganic material is an amorphous type powder material, it is possible to adjust the electrical conductivity and thermal conductivity of the powder itself, as well as the light transmittance and light absorption rate, resulting in variations in texture, gloss, etc. This makes it possible to provide a rich variety of designs.

The thermoplastic resin of this embodiment preferably contains at least one of polypropylene, polyethylene, and polyester, and more preferably contains polypropylene. By using at least one of polypropylene, polyethylene, and polyester as the thermoplastic resin, the dispersibility of the inorganic material is improved. Further, by using polypropylene as the thermoplastic resin, the dispersibility of the inorganic material is further improved. Note that polystyrene can also be used as the thermoplastic resin.

Further, the total content of the thermoplastic resin and the inorganic material is preferably in the range of 90% by mass or more and 99% by mass or less based on the mass of the thermoplastic resin molded body 2. If the total content of the thermoplastic resin and the inorganic material is within the above numerical range, it is possible to obtain sufficient nonflammability or sufficient flame retardance while reducing cracks that occur in the folded portion of the sheet. If the total content of the thermoplastic resin and the inorganic material is less than 90% by mass based on the mass of the thermoplastic resin molded body 2, sufficient nonflammability or sufficient flame retardance may not be obtained. Additionally, cracks may occur at the folded portion of the sheet.

In addition, when the total content of the thermoplastic resin and the inorganic material is 99% by mass with respect to the mass of the thermoplastic resin molded body 2, the content of the thermoplastic resin is 9% by mass or more and 84% by mass. The content of the inorganic material is preferably within the range of 15% by mass or more and 90% by mass or less. Further, it is more preferable that the content of the thermoplastic resin is within the range of 20% by mass or more and 80% by mass or less, and the content of the inorganic material is within the range of 19% by mass or more and 79% by mass or less. Further, it is more preferable that the content of the thermoplastic resin be within the range of 20% by mass to 40% by mass, and the content of the inorganic material be within the range of 59% by mass to 79% by mass. If the total content of the thermoplastic resin and inorganic material is within the above numerical range, sufficient nonflammability or sufficient flame retardance can be obtained while reliably reducing cracks that occur at the folded portion of the sheet. I can do it.

Further, the thickness of the thermoplastic resin molded body 2 may be within the range of 50 μm or more and 1000 μm or less, preferably within the range of 50 μm or more and 250 μm or less, and more preferably within the range of 70 μm or more and 200 μm or less. . If the thickness of the thermoplastic resin molded body 2 is within the above numerical range, it is possible to reliably obtain sufficient nonflammability or flame retardance while reducing cracks that occur at the folded portion of the sheet. If the thickness of the thermoplastic resin molded body 2 is less than 50 μm, it tends to be difficult to obtain sufficient nonflammability or flame retardance. Furthermore, if the thickness of the thermoplastic resin molded body 2 exceeds 250 μm, cracks may occur at the folded portion of the sheet.
Moreover, it is preferable that the thermoplastic resin molded body 2 is a uniaxially stretched or biaxially stretched thermoplastic resin molded body. If the thermoplastic resin molded body 2 is a monoaxially stretched or biaxially stretched thermoplastic resin molded body, the versatility of the floor building material 10 can be increased.

The coloring pigment of this embodiment may be added by blending pigments such as isoindolinone, polyazo, and phthalocyanine so as to develop a desired color tone. The content of the coloring pigment of the present embodiment may be in the range of more than 0% by mass and not more than 10% by mass, and in the range of more than 0% by mass and not more than 8% by mass, based on the mass of the thermoplastic resin molded body 2. It is more preferable if it is within the range of 4% by mass or more and 6% by mass or less. If the content of the colored pigment is 0% by mass with respect to the mass of the thermoplastic resin molded body 2, it is not possible to impart a desired color tone to the thermoplastic resin molded body 2. Furthermore, if the content of the colored pigment exceeds 10% by mass based on the mass of the thermoplastic resin molded body 2, the proportion of inorganic material will be relatively small, so it will tend to be difficult to obtain nonflammability or flame retardancy. .

Note that the thermoplastic resin molded body 2 of this embodiment is not limited to the above configuration. For example, the thermoplastic resin molded body 2 may contain paper powder. The paper powder to be included in the thermoplastic resin molded body 2 is, for example, fine powder with an average particle size in the range of 10 μm or more and 50 μm or less, such as virgin pulp, cut pieces at the paper manufacturing stage, processing loss at the processing stage, Bleeds from the printing stage or waste paper such as used paper can be used, but in consideration of the stability of the coloring effect, paper powder made by pulverizing a certain type of paper is preferable. If the paper powder particle size exceeds 50 μm, the cross section of the thermoplastic resin molded body 2 will have a visually recognizable sea-island pattern between the paper powder portion and the resin portion, which is not desirable in terms of design. Furthermore, if the paper powder particle size is less than 10 μm, handling becomes difficult and work efficiency may decrease. Note that the above-mentioned "average particle diameter" means the mode diameter.

On at least one of the front surface (first surface) and back surface (second surface) of the thermoplastic resin molded body 2, for example, a surface anchor layer (first anchor layer) 4a and a back surface anchor layer (second Before forming the anchor layer) 4b, it is preferable to perform surface treatment such as corona treatment or plasma treatment. Here, "the surface (first surface) of the thermoplastic resin molded body 2" means the surface on the decorative sheet 1 side. Here, the "back surface (second surface) of the thermoplastic resin molded body 2" means the surface on the opposite side to the decorative sheet 1, that is, the surface on the side of the wood base material 3. In addition, by performing surface treatment such as corona treatment or plasma treatment on at least one of the front and back surfaces of the thermoplastic resin molded body 2, the surface anchor layer 4a and the back anchor layer 4b and the thermoplastic resin molded body 2 can be bonded. Adhesion (adhesion) is improved.
In addition, before forming the front anchor layer 4a and the back anchor layer 4b, for example, at least one of the front and back surfaces of the thermoplastic resin molded body 2 is brushed and powdered inorganic material, such as calcium carbonate and calcium carbonate salt, is used. Powder containing at least one of these may be dropped in advance.

(Surface anchor layer 4a)
The surface anchor layer 4a is a layer formed to cover the entire surface of the thermoplastic resin molded body 2, and is a layer for preventing the inorganic material contained in the thermoplastic resin molded body 2 from falling off. When applying an adhesive layer (not shown) for laminating (adhering) the decorative sheet 1 to the thermoplastic resin molded product 2, the inorganic material contained in the thermoplastic resin molded product 2 may be contained in the coating system. If powder falls off in the printing coating equipment, it may contaminate the coating system. Further, if the inorganic material contained in the thermoplastic resin molded body 2 falls off, problems such as the adhesive layer for adhering the decorative sheet 1 to the adhesive layer may come off. Here, "dropout of the adhesive layer" means that the adhesive layer for adhering the decorative sheet 1 is not partially applied. If the adhesive layer for adhering the decorative sheet 1 is cracked, the adhesion between the thermoplastic resin molded body 2 and the decorative sheet 1 may deteriorate.

The surface anchor layer 4a preferably contains a urethane resin containing vinyl acetate or an acrylic resin containing vinyl acetate. Here, "salted vinyl acetate" means a copolymer of vinyl chloride and vinyl acetate. In addition, "urethane resin containing salt vinyl acetate" is a composition containing salt vinyl acetate and urethane resin, and the ratio of the content of salt vinyl acetate to the content of urethane resin (salt vinyl acetate content and urethane resin content) Bi content (mass)/urethane resin content (mass)) may be within the range of 80/20 to 1/99, preferably within the range of 50/50 to 5/95, and 20 It is more preferable if it is within the range of /80 to 10/90.
Further, the "urethane resin containing salt vinyl acetate" may contain a curing agent in addition to the salt vinyl acetate and urethane resin described above. This hardening agent is added to reliably harden the urethane resin containing vinyl acetate, and its content is not particularly limited. For example, the ratio of the content of urethane resin containing salt vinyl acetate to the content of curing agent (content (mass) of urethane resin containing salt vinyl acetate/content (mass) of curing agent) is 99 It may be within the range of /1 to 1/99, preferably within the range of 99/1 to 50/50, and more preferably within the range of 95/5 to 90/10.

The content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the surface anchor layer 4a is within the range of 15% by mass or more and 100% by mass or less based on the mass of the surface anchor layer 4a. It is preferably in the range of 80% by mass or more and 100% by mass or less, and even more preferably in the range of 85% by mass or more and 95% by mass or less. If the content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the surface anchor layer 4a is within the above numerical range, the interlayer between the surface anchor layer 4a and the thermoplastic resin molded body 2 It is possible to form a uniform surface anchor layer 4a without unevenness or chipping while maintaining sufficient strength. If the content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the surface anchor layer 4a is less than 15% by mass with respect to the mass of the surface anchor layer 4a, the surface anchor layer 4a The interlaminar strength with the thermoplastic resin molded body 2 may become insufficient. Furthermore, if the content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the surface anchor layer 4a is less than 80% by mass with respect to the mass of the surface anchor layer 4a, there is no problem in use. Although there is no problem, the penetration ratio of the surface anchor layer 4a into the thermoplastic resin molded body 2 may be reduced, and the interlayer strength between the surface anchor layer 4a and the thermoplastic resin molded body 2 may be slightly reduced. Note that if the content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the surface anchor layer 4a is 100% by mass or less with respect to the mass of the surface anchor layer 4a, there will be no problem in use. However, if it exceeds 95% by mass, more precisely 98% by mass, the surface anchor layer 4a may be chipped due to insufficient curing, and the interlayer strength between the surface anchor layer 4a and the thermoplastic resin molded body 2 may decrease. Sometimes.

In addition, the content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the surface anchor layer 4a is the same as the content of the urethane resin containing vinyl acetate or vinyl acetate in the back anchor layer 4b, which will be described later. It may be the same as the content of the acrylic resin containing. That is, the content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the front anchor layer 4a is the same as the content of the urethane resin containing vinyl acetate or vinyl acetate in the back anchor layer 4b. The content may be 1.0 times (within a range of 0.95 times or more and 1.04 times or less) the content of the acrylic resin. The content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the front anchor layer 4a is higher than that of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the back anchor layer 4b. When the resin content is the same, the physical properties of the front anchor layer 4a and the back anchor layer 4b are almost the same, so that the thermoplastic resin molded body 2 has the front anchor layer 4a and the back anchor layer 4b. In this state, the occurrence of distortion, warping, etc. can be reduced. Therefore, the occurrence of distortion, warping, etc. of the thermoplastic resin molded body 2 as a whole can be reduced. In addition, since the coating liquid for forming the front surface anchor layer 4a and the coating liquid for forming the back surface anchor layer 4b can be shared, manufacturing costs are reduced and work efficiency is improved. be able to.

Further, the content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the front anchor layer 4a is the same as the content of the urethane resin containing vinyl salt or vinyl acetate in the back anchor layer 4b. The content may be greater or less than the content of the acrylic resin. The content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the front anchor layer 4a is higher than that of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the back anchor layer 4b. If the content is higher or lower than the resin content, the physical properties of the front anchor layer 4a and the back anchor layer 4b will be different, so that the thermoplastic resin molded body 2 with the front anchor layer 4a and the back anchor layer 4b may , distortion, warpage, etc. can be applied. In this way, by imparting distortion, warping, etc. to the thermoplastic resin molded body 2 including the front anchor layer 4a and the back anchor layer 4b, the thermoplastic resin molded body 2 can be applied to a base material etc. with a curved surface. Can be pasted without any gaps. For example, the content of the urethane resin containing vinyl acetate or the acrylic resin containing vinyl acetate in the front anchor layer 4a is the same as the content of the urethane resin containing vinyl acetate or vinyl acetate in the back anchor layer 4b. The content of the acrylic resin may be 1.1 times or more and 10 times or less, or 0.1 times or more and 0.9 times or less.

The thickness of the surface anchor layer 4a is, for example, in the range of 0.5 μm or more and 20 μm or less, preferably in the range of 0.5 μm or more and 10 μm or less. Moreover, the thickness of the front surface anchor layer 4a may be the same as the thickness of the back surface anchor layer 4b. When the thickness of the front anchor layer 4a is the same as the thickness of the back anchor layer 4b, the physical properties of the front anchor layer 4a and the back anchor layer 4b are almost the same, so the thermoplastic resin molded body 2 becomes the front anchor. In the state provided with the layer 4a and the back anchor layer 4b, the occurrence of distortion, warpage, etc. can be reduced.

Moreover, the thickness of the front surface anchor layer 4a may be thicker or thinner than the thickness of the back surface anchor layer 4b. By making the thickness of the front anchor layer 4a and the back anchor layer 4b different, a difference in gloss is generated, so that the front side and the back side of the thermoplastic resin molded body 2 can be easily recognized visually. By doing so, the decorative sheet 1 can be laminated on the surface of the thermoplastic resin molded body 2 without forming, for example, an identification mark or the like indicating that it is a laminated surface. As a result, product loss caused by laminating the decorative sheet 1 on the back surface (non-laminated surface) side of the thermoplastic resin molded body 2 can be reduced.

(Backside anchor layer 4b)
The back anchor layer 4b is a layer formed to cover the entire back surface of the thermoplastic resin molded body 2, and is a layer for preventing the inorganic material contained in the thermoplastic resin molded body 2 from falling off. When applying an adhesive layer (not shown) for laminating (adhering) the wood-based base material 3 to the thermoplastic resin molded product 2, the inorganic material contained in the thermoplastic resin molded product 2 is deposited within the coating system. Specifically, if the powder falls off in a printing coating device, it may contaminate the coating system.
The back anchor layer 4b preferably contains a urethane resin containing vinyl acetate or an acrylic resin containing vinyl acetate.

The content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the back anchor layer 4b is, for example, in the range of 15% by mass or more and 100% by mass or less based on the mass of the back anchor layer 4b. It is preferably in the range of 80% by mass or more and 100% by mass or less, and even more preferably in the range of 85% by mass or more and 95% by mass or less. If the content of the urethane resin containing salt-vinyl acetate or the acrylic resin containing salt-vinyl acetate in the back anchor layer 4b is within the above numerical range, a uniform back anchor layer 4b without unevenness or chipping is formed. be able to. If the content of the urethane resin containing salt-vinyl acetate or the acrylic resin containing salt-vinyl acetate in the back anchor layer 4b is less than 15% by mass with respect to the mass of the back anchor layer 4b, powder falling cannot be prevented. Sometimes it's not enough. In addition, if the content of the urethane resin containing salt-vinyl acetate or the acrylic resin containing salt-vinyl acetate in the back anchor layer 4b is less than 80% by mass with respect to the mass of the back anchor layer 4b, there is no problem in use. Although there is no problem, the biting ratio of the back anchor layer 4b into the thermoplastic resin molded body 2 may be reduced, and the interlayer strength between the back anchor layer 4b and the thermoplastic resin molded body 2 may be slightly reduced. Note that if the content of the urethane resin containing vinyl acetate salt or the acrylic resin containing vinyl acetate salt in the back anchor layer 4b is 100% by mass or less with respect to the mass of the back anchor layer 4b, there will be no problem in use. However, if it exceeds 95% by mass, more precisely 98% by mass, the back anchor layer 4b may be chipped due to insufficient curing, and the interlayer strength between the back anchor layer 4b and the thermoplastic resin molded body 2 may decrease. Sometimes.

Further, the thickness of the back anchor layer 4b is, for example, in the range of 0.5 μm or more and 20 μm or less, preferably in the range of 0.5 μm or more and 10 μm or less.
In addition, as mentioned above, although the embodiment demonstrated the case where both the front surface anchor layer 4a and the back surface anchor layer 4b were provided, this invention is not limited to this. For example, at least one of the front anchor layer 4a and the back anchor layer 4b may be provided, or both the front anchor layer 4a and the back anchor layer 4b may not be provided.
By using this thermoplastic resin molded body 2, the total calorific value and heat generation rate with respect to time for the floor building material 10 are determined based on the corn calorie combustion test based on ISO5660-1. (i) the total calorific value for 20 minutes after the start of heating is 8 MJ/ ^m2 or less, and (ii) the maximum heat generation rate exceeds 200kW/ ^m2 for 20 minutes after the start of heating for 10 seconds or more. (iii) It is possible to impart non-combustibility that satisfies the fact that there are no cracks or holes that penetrate to the back surface which are harmful in terms of fire protection for 20 minutes after the start of heating.

(Wood base material 3)
The wood base material 3 is, for example, plywood, particle board, medium density wood fiberboard (MDF), or hardboard. The thickness of the wood base material 3 is, for example, 1 mm or more and 50 mm or less.
In addition, as the wood-based base material 3, for example, a wood-based base material whose dimensional change per 1% change in moisture content is larger than 0.02% and whose average moisture content is 6 to 10% by mass is used. It's okay. Such a wood base material 3 may be, for example, one of medium-density wood fiberboard (MDF), high-density wood fiberboard (HDF), particle board (PB), softwood plywood, and fast-wood plywood, or one of these. An example is a base material formed by laminating two or more selected plates.

In addition, as the adhesive when pasting the wood base material 3 and the thermoplastic resin molded body 2, any type of adhesive such as thermoplastic resin adhesive, thermosetting resin adhesive, rubber (elastomer) adhesive, etc. can be used. It is also possible. These can be used by appropriately selecting known ones or commercially available ones. Examples of thermoplastic resin adhesives include polyvinyl acetate resin, polyvinyl alcohol, polyvinyl acetal (polyvinyl formal, polyvinyl butyral, etc.), cyanoacrylate, polyvinyl alkyl ether, polyvinyl chloride, polyamide, polymethyl methacrylate, and nitrocellulose. , cellulose acetate, thermoplastic epoxy, polystyrene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, etc., and thermosetting resin adhesives include urea resin, melamine resin, etc. , phenolic resin, resorcinol resin, furan resin, epoxy resin, unsaturated polyester resin, polyurethane resin, polyimide resin, polyamideimide, polybenzimidazole, polybenzothiazole, and the like. Rubber adhesives include natural rubber, recycled rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, butyl rubber, polysulfide rubber, silicone rubber, polyurethane rubber, stereo rubber (synthetic natural rubber), ethylene propylene rubber, and blocks. Examples include copolymer rubbers (SBS, SIS, SEBS, etc.).
Moreover, the above-mentioned adhesive can also be used as an adhesive when pasting the decorative sheet 1 and the thermoplastic resin molded body 2 together.

(Example 1)
Commercially available polystyrene, silica (content 15% by mass) with an average particle diameter of 0.8 μm, 10% by mass of coloring pigment, and 1% by mass of calcium stearate were mixed and extruded using a twin-screw extruder, and the mixture was extruded to a thickness of 0. The thermoplastic resin molded body 2 was formed by molding into a rectangular cross-sectional shape with a cross section of .5 mm and a width of 450 mm, and corona discharge treatment was performed on the front and back surfaces thereof.
Then, on the surface side of this thermoplastic resin molded body 2, a decorative sheet 1 (manufactured by Toppan Cosmo Co., Ltd.: "Eco Sheet") made of olefin resin with a thickness of 160 μm and provided with a pattern printing layer is applied with a PUR adhesive of 50 μm. (thickness) was applied and adhered. Thereafter, a vinyl acetate adhesive of 30 μm (thickness) is applied to the back side of the thermoplastic resin molded body 2, and lauan ordinary plywood is used as the wood base material 3, and these are bonded together to form the floor building material of Example 1. Obtained.

(Example 2)
Example 2 was carried out in the same manner as in Example 1, except that the content of the inorganic material (silica) was 80% by mass, the content of colored pigment was 5% by mass, and the content of calcium stearate was 3% by mass. Obtained building materials for floors.
(Example 3)
A floor building material of Example 3 was obtained in the same manner as in Example 2 except that the average particle diameter of the inorganic material (silica) was 1 μm.

(Example 4)
A floor building material of Example 4 was obtained in the same manner as Example 2 except that the average particle diameter of the inorganic material (silica) was 3 μm.
(Example 5)
A floor building material of Example 5 was obtained in the same manner as Example 2 except that antimony trioxide was used as the inorganic material.

(Example 6)
A floor building material of Example 6 was obtained in the same manner as Example 2 except that zircon oxide was used as the inorganic material.
(Example 7)
A floor building material of Example 7 was obtained in the same manner as Example 2 except that calcium oxide was used as the inorganic material.

(Example 8)
A floor building material of Example 8 was obtained in the same manner as in Example 1 except that commercially available polypropylene was used as the thermoplastic resin.
(Example 9)
A floor building material of Example 9 was obtained in the same manner as in Example 1 except that commercially available polyethylene was used as the thermoplastic resin.

(Example 10)
A floor building material of Example 10 was obtained in the same manner as in Example 1 except that commercially available polyester was used as the thermoplastic resin.
(Example 11)
A floor building material of Example 11 was obtained in the same manner as in Example 1 except that the total content of the thermoplastic resin and inorganic material was 90% by mass.

(Example 12)
A floor building material of Example 12 was obtained in the same manner as in Example 1 except that the total content of the thermoplastic resin and inorganic material was 99% by mass.
(Example 13)
A floor building material of Example 13 was obtained in the same manner as in Example 1 except that anchor layers were formed on both sides of the thermoplastic resin molded body 2 using a urethane resin containing salt-vinyl acetate.

(Example 14)
A floor building material of Example 14 was obtained in the same manner as in Example 1 except that anchor layers were formed on both sides of the thermoplastic resin molded body 2 using an acrylic resin containing salt and vinyl acetate.
(Example 15)
The inorganic material is calcium carbonate, the content is 80% by mass, the average particle diameter is 2 μm, the thermoplastic resin is polypropylene, the total content of the thermoplastic resin and the inorganic material is 90% by mass, and the thermoplastic Anchor layers were formed on both sides of the resin molded body 2 using a urethane resin containing vinyl acetate, the content of the coloring pigment was 5% by mass, and the content of calcium stearate was 3% by mass, but in the same manner as in Example 1. Thus, the floor building material of Example 15 was obtained.

(Example 16)
A floor building material of Example 16 was obtained in the same manner as Example 15 except that anchor layers were formed on both sides of the thermoplastic resin molded body 2 using an acrylic resin containing salt and vinyl acetate.
(Comparative example 1)
A floor building material of Comparative Example 1 was obtained in the same manner as in Example 1 except that the content of the inorganic material was 13% by mass.

<Performance evaluation>
The performance of Examples 1 to 16 and Comparative Example 1 described above was evaluated for the following four items.
Coloring effect on cut cross section: The decorative material with a wood-like pattern printed layer was prepared, V-grooves were cut using a V-cut radial saw, and the coloring effect on the grooves was visually confirmed.
○: The color is comparable to the surface of the pattern printing layer/base material layer.
Δ: Slight whiteness is observed, and a slight difference between the surface of the pattern printing layer and the base material layer can be confirmed.
×: Strong whiteness, and the difference between the surface of the pattern printing layer and the base material layer is greatly noticeable.
In the above evaluation, "○" and "△" were regarded as passing.

Non-combustible performance test: It was evaluated whether the following requirements were met in a heat generation test using a cone calorimeter tester in accordance with ISO5660-1.
1. Total calorific value is 8MJ/ ^m2 or less 2. Maximum heat generation rate does not exceed 200kW/ ^m2 for 10 seconds or more 3. No cracks or holes penetrating the back surface, which are harmful in terms of fire protection, will occur. Note that gypsum board was used as the noncombustible base material. Moreover, the evaluation criteria are as follows.
○: All of the above requirements are met. ×: At least one of the above requirements is not met. In each of the above evaluations, a sheet with an evaluation of "x" was judged as a failure as a whole.

Moldability: Ease of molding was confirmed when the thermoplastic resin molded body 2 was mixed and extruded using a twin-screw extruder.
○: Good moldability △: Slightly poor molding stability, poor dimensional stability, etc. ×: Unable to mold In the above evaluation, "○" and "△" were regarded as passing.

Thermal stability: The coefficient of linear expansion in the temperature range of 0°C to 40°C was calculated using a thermomechanical analyzer TMA.
〇: Less than 7×10E-5 △: 7×10E-5 to less than 10×10E-5 ×: 10×10E-5 or more In the above evaluation, “○” and “△” were regarded as passing.

Adhesion: After pressing Nichiban's cellophane tape onto the surface of the decorative sheet 1 of the floor construction material, peel it off strongly with a certain force and visually check whether there is any peeling between the layers of the decorative sheet 1 and the thermoplastic resin molded body 2. It was evaluated. The evaluation criteria are as follows.
◎: When peeled off with a force of 15N (Newtons), no separation occurs between the decorative sheet 1 and the thermoplastic resin molded body 2.○: When peeled off with a force of 10N, no separation occurs between the decorative sheet 1 and the thermoplastic resin molded body 2. No peeling occurred between the layers of the thermoplastic resin molded body 2 △: When peeled off with a force of 10 N, peeling occurred in a part of the layer between the decorative sheet 1 and the thermoplastic resin molded body 2 ×: Cellophane The decorative sheet 1 adhered to the entire surface of the tape, and significant peeling occurred between the layers of the decorative sheet 1 and the thermoplastic resin molded body 2. In the above evaluation, "◎", "○", and "△" were judged as passing.
The above results are shown in Table 1.

As shown above, by matching the composition of inorganic materials, coloring pigments, and thermoplastic resins within the scope of the embodiments of the present invention, moldability and thermal stability can be ensured, while nonflammability and coloring effects on cut sections can be achieved. It also becomes possible to create floor building materials with excellent interlayer adhesion.

The building material for floors of the present invention can be used for floors in buildings such as detached houses, housing complexes, rental houses, and houses for the elderly.

1... Decorative sheet 2... Thermoplastic resin molded body 3... Wood base material 4a... Surface anchor layer 4b... Back anchor layer 10... Floor building material

Claims (11)

In floor building materials made by laminating thermoplastic resin moldings on wood base materials,
The thermoplastic resin molded article contains a thermoplastic resin, an inorganic material, and a colored pigment,
The content of the inorganic material is within the range of 80% by mass or more and 90% by mass or less with respect to the mass of the thermoplastic resin molded body,
The content of the colored pigment is within the range of more than 0% by mass and not more than 10% by mass, based on the mass of the thermoplastic resin molded body,
A building material for floors, characterized in that the inorganic material is in powder form, has an average particle size in the range of 1 μm or more and 3 μm or less, and has a maximum particle size of 50 μm or less. The building material for floors according to claim 1, characterized in that a decorative sheet is laminated on the surface of the thermoplastic resin molded body. The inorganic materials include antimony trioxide, antimony soda, zircon silicate, zircon oxide, magnesium hydroxide, aluminum hydroxide, basic magnesium carbonate, borax, zinc borate, calcium carbonate, molybdenum trioxide, or antimony dimolybdate and water. Contains at least one of a complex with aluminum oxide, a complex between antimony trioxide and silica, a complex between antimony trioxide and zinc white, a silicic acid of zirconium, a complex between a zirconium compound and antimony trioxide, and a salt thereof. The building material for floors according to claim 1 or 2, characterized in that: The inorganic materials include antimony trioxide, antimony soda, zircon silicate, zircon oxide, magnesium hydroxide, aluminum hydroxide, basic magnesium carbonate, borax, zinc borate, molybdenum trioxide, or antimony dimolybdate and aluminum hydroxide. complexes of antimony trioxide and silica, complexes of antimony trioxide and zinc white, silicic acid of zirconium, complexes of zirconium compounds and antimony trioxide, and salts thereof. The building material for floors according to claim 1 or 2, characterized in that: The building material for floors according to any one of claims 1 to 4 , wherein the thermoplastic resin contains at least one of polypropylene, polyethylene, and polyester. The total content of the thermoplastic resin and the inorganic material is within a range of 90% by mass or more and 99% by mass or less based on the mass of the thermoplastic resin molded body. The floor building material according to claim 5 . a first anchor layer formed on the first surface of the thermoplastic resin molded body;
further comprising a second anchor layer formed on a second surface of the thermoplastic resin molded body that is a surface opposite to the first surface,
Any one of claims 1 to 6 , wherein the first anchor layer and the second anchor layer contain a urethane resin containing vinyl acetate or an acrylic resin containing vinyl acetate. The building material for floors according to item 1. When determining the total calorific value and heat generation rate over time for floor building materials in accordance with the corn calorie combustion test in accordance with ISO5660-1, (i) the total calorific value for 20 minutes after the start of heating is 8 MJ/ ^m2 or less (ii) for 20 minutes after the start of heating, the maximum heat generation rate does not exceed 200kW/ ^m2 for 10 seconds or more; and (iii) for 20 minutes after the start of heating, there are cracks that penetrate to the back surface that are harmful in terms of fire protection. The building material for floors according to any one of claims 1 to 7 , characterized in that it has a noncombustible property that satisfies the absence of holes. In floor building materials made by laminating thermoplastic resin moldings on wood base materials,
The thermoplastic resin molded article contains a thermoplastic resin, an inorganic material, and a colored pigment,
The content of the inorganic material is within the range of 15% by mass or more and 90% by mass or less with respect to the mass of the thermoplastic resin molded body,
The content of the colored pigment is within the range of more than 0% by mass and not more than 10% by mass, based on the mass of the thermoplastic resin molded body,
A building material for floors, characterized in that the inorganic material is in powder form, has an average particle size in the range of 1 μm or more and 3 μm or less, and has a maximum particle size of 50 μm or less. In floor building materials made by laminating thermoplastic resin moldings on wood base materials,
The thermoplastic resin molded article contains a thermoplastic resin, an inorganic material, and a colored pigment,
The content of the inorganic material is within the range of 15% by mass or more and 90% by mass or less with respect to the mass of the thermoplastic resin molded body,
The content of the colored pigment is within the range of more than 0% by mass and not more than 10% by mass, based on the mass of the thermoplastic resin molded body,
A building material for floors, wherein the total content of the thermoplastic resin and the inorganic material is within a range of 90% by mass or more and 99% by mass or less based on the mass of the thermoplastic resin molded body. In floor building materials made by laminating thermoplastic resin moldings on wood base materials,
The thermoplastic resin molded article contains a thermoplastic resin, an inorganic material, and a colored pigment,
The content of the inorganic material is within the range of 15% by mass or more and 90% by mass or less with respect to the mass of the thermoplastic resin molded body,
The content of the colored pigment is within the range of more than 0% by mass and not more than 10% by mass, based on the mass of the thermoplastic resin molded body,
a first anchor layer formed on the first surface of the thermoplastic resin molded body;
further comprising a second anchor layer formed on a second surface of the thermoplastic resin molded body that is a surface opposite to the first surface,
The first anchor layer and the second anchor layer contain a urethane resin containing vinyl acetate or an acrylic resin containing vinyl acetate.

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