JPH0952209A - Floor material prepared by laminating surface layer containing short fibers - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a floor material excellent in dimensional stability and warpage resistance and to improve the abrasion resistance and breakage resistance thereof by a method wherein a surface layer prepared by incorporating short fibers in thermoplastic resin is formed on a base and glass fibers are used for the short fibers in particular. SOLUTION: In a floor material 6, a fibrous backing material 1 is used for improvement of adhesion to a floor ground and other purposes. A synthetic resin base 2 is formed on the fibrous backing material 1, a decorative layer 3 is formed on the synthetic resin base 2 and a surface layer 4 prepared by incorporating short fibers 5 in thermoplastic resin is formed on the decorative layer 3. For the short fibers 5 incorporated, glass fibers, polyester, Vinylon, etc., can be used. As for the kind of the short fibers, the glass fibers cut to be short are the most effective and those called glass chopped strands are used preferably in general, in consideration of handling properties and others. The kind of the resin is no limited in particular and polyolefin or polyurethane resin or other thermoplastic resins are used.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor material, and more particularly to a floor material having improved dimensional stability.

[0002]

2. Description of the Related Art Conventionally, in order to achieve both improvement in physical strength such as abrasion resistance and tear resistance and reduction in manufacturing cost, only the surface layer which is directly abraded has a high resin compounding ratio, and a middle layer or a lower layer A flooring material containing a large amount of a filler is known. However, as a drawback of the above floor material, the molded product has a warp, the floor surface does not become smooth when this is applied, and the warp part is caught on the foot when walking, or the floor material peels from the edge when caught. Some trouble such as coming.

The cause of the warp is related to the shrinkage difference caused by the difference in the filler content of the upper layer and the lower layer. That is, the upper layer having a small amount of filler has a large shrinking force, and the lower layer having a large amount of filler has a small shrinking force. When these two layers are laminated, the upper layer having a large shrinking force is pulled to cause an upward warp. As a result, the amount of shrinkage of the whole also increased. To solve this, it is sufficient to fill the upper layer with the same amount of filler as the lower layer, but with this method,
It is not possible to improve the wear resistance and tear resistance of floor materials.

[0004]

Means for Solving the Problems The invention of the present application is to solve the above-mentioned problems, and "the floor material characterized by laminating a surface layer obtained by kneading a thermoplastic resin with short fibers on a substrate" To do. "FIG. 1" is a cross-sectional view of the flooring material, 1 is a fiber backing material, and the fiber backing material is used for improving the adhesion to the floor base. These lining materials are fiberglass,
Woven or non-woven fabric of polyester, nylon, vinylon, cotton, rayon and blended products with a basis weight of 30 to 150 g /
m ² is preferred.

A synthetic resin base material 2 is formed on the fiber backing material 1. The synthetic resin substrate 2 is PVC, polypropylene,
A relatively large amount of filler such as calcium carbonate, talc, clay, aluminum hydroxide, wood powder, cork powder was mixed with a binder such as ethylene-vinyl acetate copolymer, (EVA) amorphous poly α-olefin (APAO), and polyurethane. It is a composition. Further, the synthetic resin substrate may be a foam. When the synthetic resin substrate is PVC, it may be a composition of a conventionally known flooring substrate.

A decorative layer is formed on the synthetic resin substrate 2. Examples of the decorative layer include a plain colored layer, a random pattern layer such as a marble pattern, and a printed pattern layer. As the print pattern, for example, a print film layer is laminated, but as a further example, a PVC film having a pattern printed with gravure ink can be used. Further, as another print pattern layer, there are a method of directly printing on the surface of the lower layer and a patterning method using transfer print paper.

A thermoplastic resin surface layer containing short fibers is formed on the decorative layer. Short fibers are glass fibers,
Polyester, nylon, and vinylon can be used, and as the type of short fiber, the one obtained by cutting glass fiber into the shortest is most effective, and in view of handling property, the use of what is generally called glass chopped strand is preferable. The fiber length of the short fibers is 0.5 to 10 mm, and the addition amount is 1 to 50 parts by weight, more preferably 5 to 20 parts by weight, based on 100 parts by weight of the resin. If it is less than 1 part by weight, the effect of suppressing the dimensional shrinkage becomes small, and if it exceeds 50 parts by weight, the transparency is impaired and the abrasion property is rather deteriorated.

The type of resin is not particularly limited, and polyolefins such as PVC, PP, PE, EVA, APAO, polyurethane resins, and other thermoplastic resins are used. The upper layer may be transparent or opaque. When transparency is required, the glass fiber has a higher transparency than other fibers, so that when the base has a decorative layer, this can be seen through, which is preferable.

In the present invention, the transparent surface layer has a thickness of 0.
1 to 1.8 mm, and the total thickness is preferably 1 to 5 mm. It is preferable that the ratio of the thickness of the transparent surface layer to the thickness thereof is 1: 2 to 1: 7. The obtained laminate may be provided with mechanical embossing or chemical embossing as appropriate.

The method for laminating the surface layer on the substrate is not particularly limited, and for example, a flat plate pressing method, a continuous pressing method, or a laminating method using a laminating machine can be carried out.
In this way, the floor material 6 of the present invention is obtained. In addition to the floor material shown in FIG. 1, a thermoplastic resin surface layer in which short fibers are directly kneaded may be laminated on the base material, and the surface layer or the base material may be colored at this time. The floor material of the present invention can be implemented in a tile shape or a sheet shape.

[0011]

INDUSTRIAL APPLICABILITY According to the present invention, by laminating a layer in which short fibers are kneaded on the surface, and particularly by using short fibers as glass fibers, dimensional shrinkage is suppressed, warpage does not occur, and abrasion resistance is improved. The makeup layer can be seen through.

[0012]

【The invention's effect】

-Since glass short fibers are kneaded into the surface layer, it has excellent dimensional stability and warpage resistance. -Improved wear resistance and tear resistance. -Because it is transparent, the print pattern below can be seen and the design is improved.

[0013]

[Examples] Examples and comparative examples will be described in detail below.
The invention is not limited by these examples. The parts described in the examples and comparative examples mean parts by weight.

[Embodiment 1] Number of implants 6 / cm × 6 / cm, 50
Gravure printing of a 1.3 mm thick sheet of formulation A from "Table 1" on the backing material of a cotton / rayon woven fabric of g / m ² and then a 0.2 mm thick sheet of formulation B on top. The above-mentioned printed sheet decorative layer and the surface layer sheet having a thickness of 0.5 mm of Formulation C were simultaneously heat-laminated at 170 ° C. in a laminating machine to obtain a sheet floor material.

[0014]

[Table 1] (Unit: part)Formulation A Formulation B Formulation C Formulation D Formulation E PVC (P = 1000) 100 100 100 100 100 Plasticizer (DOP) 65 20 30 30 50 Stabilizer (barium-zinc composite) 3 3 3 3 3 Filler (calcium carbonate) 300 5 --200 Pigment 1 1--1 Glass fiber − − 15 − −  Glass fiber: Glass chopped strand (fiber length 1 mm) made by Nippon Glass Fiber Co., Ltd., trade name RESI5BM42 was used.

[0015]

[Comparative Example 1] A flooring material having the same constitution as that of the example except that the sheet of the formulation D was used as the surface layer in place of the formulation C of "Table 1" of the example 1 was obtained.

[0016]

Comparative Example 2 A sheet of formulation E was used in place of the formulation C of Example 1. Other than that, a flooring material having the same structure as the example was obtained.

"Table 2" shows the results of testing the quality of the molded articles prepared in Example 1 and Comparative Examples 1 and 2 by the following method. As shown in the table, Example 1 showed stable quality as compared with Comparative Examples 1 and 2.

Each test method in the table was as follows. Heating dimensional stability: According to JIS A5705. Heating warp: The sample whose heating dimensional stability had been measured was placed on a smooth horizontal plate, and the four-sided warp of the sample was measured as the distance from the plate surface. Warp at room temperature: A sample of 30 × 30 cm is placed on a smooth plate with the surface facing up, and left in a 60 ° C. atmosphere at 20 ° C. for 7 days. Was measured as. Abrasion resistance: According to JIS A1453.

[0019]

[Table 2] Example 1 Comparative example 1 Comparative example 2 Heating dimensional stability 0.5% 2.2% 1.0% Warpage 1.2 mm 5.5 mm 2.5 mm Warp left at room temperature 0 mm 3.7 mm 2. 0mm Abrasion resistance 1000rpm 0.08mm 0.07mm 0.14mm Designability ○ ○ ×

In Example 1, the dimensional stability was good, the warpage resistance was excellent in that it did not warp at room temperature, and the wear resistance was also good. The design was also excellent. On the other hand, in the flooring material of Comparative Example 1, there was no glass fiber layer and no filler was added, so the dimensional stability was low and the warpage was large. Comparative Example 2
The flooring material of No. 2 was not so good in dimensional stability and warpage resistance as the performance of the intermediate level between Example 1 and Comparative Example 1. The abrasion resistance was extremely low. Further, the lower decorative layer could not be seen through, and the designability was poor. Thus, only the flooring material of Example 1 was excellent in all performances.

[Brief description of drawings]

FIG. 1 is a sectional view of a floor material of the present invention

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Fiber lining material 2 ... Synthetic resin base material 3 ... Decorative layer 4 ... Thermoplastic resin surface layer 5 ... Short fiber 6 ... Floor material of this invention

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Seiji Endo 5-125 Higashiarioka, Itami City, Hyogo Prefecture Tori Co., Ltd.

Claims (4)

[Claims] 1. A flooring material comprising a base material and a surface layer obtained by laminating a thermoplastic resin and short fibers on the base material. 2. A flooring comprising a base material, a decorative layer formed on the base material, and a surface layer having short fibers kneaded thereon. 3. The flooring material according to claim 1, wherein the short fibers are glass short fibers. 4. The flooring material according to claim 1, wherein 1 to 50 parts by weight of short fibers are added to 100 parts by weight of the thermoplastic resin of the surface layer.