JPH0411082A - Cushiony floor material for heavy walking - Google Patents

Abstract

PURPOSE:To provide the subject cushiony floor material having excellent strength and walkability by laminating a thermoplastic synthetic resin layer on one surface of a substrate layer and a thermoplastic synthetic resin fromed layer on the back surface. CONSTITUTION:Preferably a polyvinyl chloride resin paste is coated on and impregnated into one surface of a substrate layer comprising e.g. an asbestos sheet or glass fiber paper and subsequently thermally gelled. If necessary, a colored vinyl chloride resin layer is further formed on and laminated to the coated surface. A mechanically foamed liquid synthetic resin composition is coated to the back surface and gelled to laminate the foamed and gelled layer to the back surface, thus providing a walking cushiony floor material having excellent strength and walkability.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a cushioned heavy walking flooring material with excellent strength and walkability.

[Conventional technology]

Conventional flooring materials include, for example, flooring materials that consist of only a so-called solid layer, in which a thermoplastic synthetic resin layer is laminated on the surface of a base material layer, or colored synthetic resin particles are sprinkled on the surface of the base material layer and then heated and compressed. Flooring materials made of colored synthetic resin sheets are widely used, but these flooring materials leave a hard feeling on the floor surface and have poor walkability, so at least the surface of the base material layer is A cushioning heavy walking floor material has been proposed in which a thermoplastic synthetic resin layer is laminated, and a thermoplastic synthetic resin foam layer formed by chemical foaming is laminated on the back side of the base layer.

[Problems to be Solved by the Invention] However, with a flooring material in which a thermoplastic synthetic resin foam layer formed by chemical foaming is laminated on the back side of such a base layer, the desired walkability (cushioning properties) cannot be obtained. of things,
The flooring material does not have sufficient strength to withstand external loads such as when many people walk on it, and as a result, the surface of the flooring material wears out and weakens over time, reducing its commercial value as a flooring material. This has the problem of significantly reducing the

The present invention was made against the background of such conventional technology, and an object of the present invention is to provide a cushioned heavy walking floor material that has excellent strength against external loads and is also excellent in walkability.

[Means to solve the problem]

The present invention provides a cushioning cushioning material in which a thermoplastic synthetic resin layer is laminated on at least the surface of a base material layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back surface of the base material layer. It provides flooring materials.

Hereinafter, the present invention will be described in detail based on the drawings.

FIG. 1 shows an example of the cushioning heavy walking flooring material of the present invention, and the cushioning heavy walking flooring material A has a thermoplastic synthetic resin layer 20 laminated on at least the surface of the base material layer 10, A thermoplastic synthetic resin foam layer 30 formed by mechanical foaming is laminated on the back surface of the base material layer 10.

The base material layer 10 used in the present invention may be a single layer or a multilayer of two or more layers as long as it has excellent dimensional stability such as a felt sheet, woven fabric, knitted fabric, or nonwoven fabric. However, from the viewpoint of dimensional stability, asbestos sheets,
Preferable materials include sheets, glass fiber paper, and paper made by mixing at least two types of inorganic and/or organic fibers such as asbestos, glass fibers, carbon fibers, bulbs, and polyester fibers.

Furthermore, a laminate of woven fabrics and nonwoven fabrics made of glass fibers, carbon fibers, synthetic fibers, etc. can also be used.

Furthermore, if necessary, conductive substances such as carbon powder, carbon short fibers, inorganic and organic powders or short fibers subjected to surface conductivity treatment [conductive calcium carbonate T13O-2500 (Nitto powder), etc. (Made by Chemical ■), E
C-1, EC-5 (both made by Maruo Calcium ■),
Dentol WK-10O3 (manufactured by Otsuka Chemical), Thunderon 5S-N (manufactured by Nippon Silk Hair Dying)], etc. are impregnated with conductive resin liquid, and other paper-making methods are used to make non-woven fabrics, glass-mixed paper, etc. When manufacturing paper, conductive fibers, conductive powder, conductive treated powders and fibers are mixed, and these conductive fibers and conductive treated fibers are woven or knitted into fabrics. Knitted fabric etc. can be used.

In addition, the thickness of this base material layer 10 is usually 0.1 to 211
11 is preferable, and if the thickness is less than 0.1 m, the strength of the resulting flooring material will be weak, while if it exceeds 2 WI, the cost will increase.

Examples of the thermoplastic synthetic resin as the main component constituting the thermoplastic synthetic resin layer 20 of the present invention include vinyl chloride resin, acrylic resin, vinyl acetate resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer resin, urethane resin, etc. However, in consideration of wear resistance and cost, vinyl chloride resin is preferable.

The vinyl chloride resin in the present invention refers to polyvinyl chloride resin, vinyl chloride, and other monomers such as evaporated ethylene,
Vinyl acetate, vinyl ether, maleate ester, (
It also includes copolymers with meth)acrylic acid, (meth)acrylic acid esters, acrylonitrile, urethane, etc., and mixtures of polyvinyl chloride resin and other polymers.

Moreover, the thickness of the thermoplastic synthetic resin layer 20 is 0.1 to 5.
A value of 0-1 is preferable; if it is less than 0.1 lll, the thermoplastic synthetic resin layer will wear out in a short time due to people walking, shortening the lifespan of the flooring material, while if it exceeds 5.01 lll, the floor material will deteriorate. The material itself is hard (which makes it inconvenient to install, and it also tends to warp and shrink).

Further, the thermoplastic synthetic resin layer 20 may be a single layer or a multi-layer. In the case of a multi-layer, for example, the thermoplastic synthetic resin layer 20 is formed of an uppermost layer 20a and an intermediate layer 20b disposed below the uppermost layer 20a. The printing layer 20c may be interposed between the top layer 20a and the intermediate layer 20b.

Furthermore, in this case, if the top layer 20a is made transparent or translucent, the design effect can be more effectively produced when the intermediate layer 20b and the printed layer 20c are colored. Moreover, the thickness of this upper layer 20a is preferably 0.05 to 111 Im. This is because a flooring material with a thickness of 0.05 maz without grooves has poor abrasion resistance, and if it exceeds the - direction h1, the flooring material tends to warp toward the surface side and also becomes expensive.

Moreover, this surface layer can also be made into a flooring material with improved design by using colored synthetic resin chips.

Furthermore, the design can be improved by thickly printing vinyl chloride resin paste or the like on the surface of the thermoplastic synthetic resin layer 20 using a rotary screen printing method or the like.
The unevenness can also be formed by an embossing method (the embossing may be performed before or after forming the thermoplastic synthetic resin foam layer by mechanical foaming).

Furthermore, an antifouling paint such as an acrylic antifouling paint may be applied to the surface of the thermoplastic synthetic resin layer (including this in the case of thick printing) for the purpose of preventing stains.

Furthermore, the thermoplastic synthetic resin layer 20 may include, if necessary,
It can also be formed by incorporating an antistatic plasticizer and/or an antistatic agent.

Examples of antistatic plasticizers mixed into the thermoplastic synthetic resin layer 20 include tributoxyethyl phosphate (manufactured by Otona Kagaku, TBXP), butyl diglycol adipate (
Manufactured by Otona Kagaku ■, BXA), Sansocizer C-1100
(manufactured by Shin Nihon Rikagaku Co., Ltd.), HA-100, AM-801,
AM-801A (all manufactured by Tanezu Kagaku ■) is preferred, and general-purpose plasticizers such as dioctyl phthalate, dibutyl phthalate, butylbenzyl phthalate, dioctyl adipate, dioctyl phthalate, and diisononyl phthalate can be partially or fully substituted depending on the purpose. The compounding amount is usually preferably 5 to 100 parts by weight per 100 parts by weight of the synthetic resin.

Further, the antistatic agent mixed into the thermoplastic synthetic resin layer 20 includes commonly used antistatic agents such as cationic, anionic, and nonionic antistatic agents. 0.0 for 100 parts by weight of resin.
Zero or more compounding agents, preferably 2 to 10 parts by weight, may be used alone or in combination of two or more.

In addition, other compounding agents such as plasticizers, stabilizers, fillers, viscosity modifiers, foaming agents, antifungal agents, colorants, etc. can be added to the thermoplastic synthetic resin layer 20 as necessary. It is.

When the thermoplastic synthetic resin layer 20 is formed as a single layer, thermoplastic synthetic resin particles such as vinyl chloride resin particles are laid on the base material, and then heated and melted or softened to form a flat embossing roller. It can be formed by pressure sintering.

Thermoplastic synthetic resin particles include colored synthetic resin particles with a transparent thermoplastic synthetic resin layer formed on the surface of the main body, colored synthetic resin particles with a flow pattern in which multiple colored synthetic resins are mixed together, and colored synthetic resin particles. Any commonly used material can be used, such as one in which a conductive thermoplastic synthetic resin layer containing carbon black is formed on the surface of the main body.

Alternatively, a material in which thermoplastic synthetic resin strips are arranged on a base material, matrix resin powder or solution is filled between each thermoplastic synthetic resin strip, and heated and sintered or gelled can be used.

As the thermoplastic synthetic resin as the main component constituting the thermoplastic synthetic resin foam layer 30, the same one as in the case of the thermoplastic synthetic resin layer 20 can be used, and as a means for forming the foam layer, vinyl chloride resin can be used. Methods include adding a foam stabilizer to a paste, etc., and mechanically mixing gas (air, gas, etc.) into it, or methods of dissolving gas into a vinyl chloride resin paste at high pressure and expanding the gas at normal pressure. As the gas, inert gas such as carbon dioxide gas or nitrogen gas can be used.

As the foam stabilizer, any commonly used foam stabilizer can be used, such as silicone foam stabilizers such as methylsiloxane emulsion, methylsiloxane, and xylene solutions, fluorine foam stabilizers, fatty acid condensates, Alkylaryl sulfonates, metal soaps of oleic acid sericinoleic acid, guanidine salts, quaternary ammonium compounds, aldehyde-amine condensation products, etc. can be used.

Further, the amount of the foam stabilizer added is not particularly limited and may be adjusted as necessary, but it is usually based on 100 parts by weight of the thermoplastic resin constituting the thermoplastic synthetic resin foam layer 30. , 0.1 to 25 parts by weight.

Note that the foaming ratio of the thermoplastic synthetic resin foam layer 30 is usually about 1.2 to 5 times, preferably about 1.5 to 3 times.

Furthermore, like the thermoplastic synthetic resin layer 20, the thermoplastic synthetic resin foam layer 30 can be formed by mixing an antistatic plasticizer and/or an antistatic agent as necessary, and in addition, a plasticizer, It is also possible to add compounding agents such as stabilizers, fillers, viscosity modifiers, blowing agents, antifungal agents, and colorants.

Furthermore, the thickness of the thermoplastic synthetic resin foam layer 30 is 0.5
~5-11 is preferable, and if it is less than 0.5+++++++, good traction properties cannot be obtained and walkability tends to be poor, while if it exceeds 5+wa+, warping and shrinkage tend to occur, which is not so preferable.

In addition, the total thickness of the cushioning heavy walking flooring material A is 1 to 511
Preferably, it is 11.

Next, an example of the manufacturing method of the cushioning heavy walking flooring material of the present invention will be described. A liquid synthetic resin composition such as a vinyl chloride resin base is applied and impregnated onto a glass nonwoven fabric as a base material, and this is heated to gel. Next, a colored liquid synthetic resin composition such as a colored vinyl chloride resin paste is applied to the surface side and heated to gel, and then this surface is coated with a gravure printing method, screen printing method (including rotary screen printing), etc. After printing with any printing method and heating and drying, a transparent liquid synthetic resin composition such as a transparent vinyl chloride resin base is applied to the surface and heated to gel, while the back side of the glass nonwoven fabric is mechanically foamed. It is obtained by applying a liquid synthetic resin composition such as a vinyl chloride resin paste and heating it to gel.

In addition, after applying a mechanically foamed liquid synthetic resin composition to the back side of the glass nonwoven fabric, a vinyl chloride resin sheet can also be attached and heated to gel before the liquid synthetic resin composition has gelled. After gelling, a vinyl chloride resin sheet is attached (dry lamination method,
Any wet lamination method may also be used.

When vinyl chloride resin sheets are laminated together, it is preferable because warping of the cushioned heavy walking flooring material can be suppressed.

In addition, by gelling the mechanically foamed liquid synthetic resin composition and then heating the resulting laminated structure under heating conditions that do not melt the mechanically foamed thermoplastic synthetic resin layer, warping can be prevented. It can also suppress shrinkage.

As explained above, according to the cushioning heavy walking flooring material of the present invention, a thermoplastic synthetic resin foam layer formed by mechanical foaming is laminated on the back side of the base material layer, so conventional chemical foaming is not possible. Compared to cushioned heavy walking flooring materials in which the formed thermoplastic synthetic resin foam layer is laminated, there is almost no permanent distortion of the thermoplastic synthetic resin foam layer even under continuous loads, and the desired walkability is achieved. In addition to providing cushioning properties, it also provides sufficient strength against external loads such as those caused by people walking on the flooring, thus preventing the flooring from becoming sagging over time. This makes it possible to create a cushioned heavy walking flooring material that has excellent strength and walkability, thereby further improving its commercial value as a flooring material.

In addition, by using conductive materials as necessary, we can effectively remove static electricity from people working on flooring and various equipment, and prevent electric shocks caused by electrical leakage from equipment. It is also possible to eliminate danger and obtain highly safe flooring materials.

Furthermore, when a flexible material is used for the base layer, the cushioned heavy walking flooring material of the present invention can be rolled up into long lengths in combination with the thermoplastic synthetic resin layer of the surface layer, and has a high level of flexibility. It also has excellent workability because it does not break even when bent.

Furthermore, when laying the laminated sheet of the present invention, in addition to using it in the form of a long sheet, for example, it can be used in the form of a tile cut into a predetermined width using a general construction adhesive (synthetic rubber latex type, vinyl acetate resin solvent type). , epoxy resin, acrylic emulsion, EVA emuldigon, etc.), or by adhering to the floor surface of a raised floor using a conductive adhesive, it can also be used as a floor surface material for a raised floor.

[Effect]

The cushioned heavy walking flooring material of the present invention has a thermoplastic synthetic resin layer laminated on at least the surface of the base layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming on the back side of the base layer. This makes it a cushion-cast walking flooring material that has excellent strength and excellent walkability.

〔Example] Examples of the present invention will be described in detail below.

Example 1 The cushion cast walking flooring material of Example 1 had a thickness of 0.25
On glass fiber paper with a dense fiber structure of mm+, the vinyl chloride resin paste of Formulation Example 2 in Table 1 was applied to a thickness of 0.50 cm using a doctor knife coater, and the paste was coated in a heating furnace to
After gelling by heating at 80°C for 1 minute, a predetermined pattern was printed on the surface using a gravure printing machine, and then the vinyl chloride resin paste of Formulation Example 3 in Table 1 was coated with a doctor knife coater to a thickness of 0.1 mm. Apply to a thickness of 180 ml in a heating oven.
After gelling by heating at °C for 1 minute, compressed air was blown into the vinyl chloride resin paste of Formulation Example 1 in Table 1 on the side opposite to the applied side of the vinyl chloride resin paste, and the mixture was stirred with a mixer. Once the air bubbles have dispersed throughout, the liquid foam is applied to a thickness of 0.5 (1+W) using a doctor knife coater, and heated to gel in a heating oven at 180°C for 2 minutes to form a thermoplastic synthetic resin foam layer. After cooling, it was rolled up to obtain a cushion-cast walking flooring material with a total thickness of 1.35+*m.

Next, we tested the abrasion resistance of this cushion-cast walking flooring material using a Taber abrasion test using 5-42 sandpaper, and it was found to be preferable with almost no abrasion even after 10,000 cycles. Ta.

In addition, a strength test was conducted for 100 days in which a load of 8 kg/25 cmd (a load equivalent to a person weighing 80 kg) was applied continuously at 10 second intervals for 12 hours, and no load was applied for 12 hours. No corrosion occurred at all, indicating good cushioning properties.

(Left below) Table 1 Comparative Example 1 The cushion cast walking flooring material of Comparative Example 1 has a thickness of 0.25
The vinyl chloride resin paste of Formulation Example 2 in Table 1 was applied to a thickness of 0.50-I using a doctor knife coater on glass fiber paper with a dense fiber structure of
After gelling by heating at 0°C for 1 minute, a predetermined pattern was printed on the surface using a gravure printing machine, and then the vinyl chloride resin paste of Formulation Example 3 in Table 1 was coated with a doctor knife coater to a thickness of 0.1 mm. Apply it in a thick layer and heat it at 180° in a heating furnace.
After gelling by heating for 1 minute at C, apply the vinyl chloride resin paste of Formulation Example 4 in Table 1 to the surface opposite to the applied surface of the vinyl chloride resin paste using a doctor knife coater.
．． Coated in a thickness of 25+m and heated in a heating oven at 200°C for 2 hours.
The mixture was heated and foamed for a minute to obtain a cushion-cast walking flooring material with a total thickness of 1.35 mm.

The abrasion resistance of this cushion-cast walking floor material was the same as in Example 1, but the results of the same strength test as in Example 1 showed that there was no sagging in the parts under continuous load. It did not show good cushioning properties.

[Brief explanation of the drawing]

FIG. 1 is an enlarged sectional view of the cushion-cast walkable flooring material of the present invention. 10; Base material layer 20; Thermoplastic synthetic resin layer 30; Thermoplastic synthetic resin foam layer

Claims (1)

[Claims] (1) A cushioned heavy walking floor comprising a thermoplastic synthetic resin layer laminated on at least the surface of the base layer, and a thermoplastic synthetic resin foam layer formed by mechanical foaming on the back side of the base layer. Material.