JPH10180961A - Backing base material for floor material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a backing base material for a floor material of a 3-layer structure obtained by coating a front surface of 2-layer laminated glass fiber nonwoven fabric with coating liquid containing pigment and binder having satisfactory coating properties at the time of laminating the floor material without release at the time of practical use, sufficient durability at the time of practical use and dimensional stability of obtaining satisfactorily flat polyvinyl chloride coating processing surface in the backing base material to become the floor material formed by coating with polyvinyl chloride. SOLUTION: In the backing base material for a floor material of a 3-layer structure obtained by coating a surface of a second layer of 2-layer laminated glass fiber nonwoven fabric obtained by using oblique wire type papermaking machine and a Yankee dryer with coating liquid containing pigment and binder, the second layer contains glass fiber, pulp fiber and binder fiber, a central surface mean roughness SRa by a stylus type three-dimensional surface roughness meter is 5 to 12μm on a surface of an uppermost layer, 13 to 28μm on a surface of a lowermost layer and a lateral shrinkage factor of 0.2% or less.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method in which a coating liquid containing a pigment and a binder is smeared on the surface of a two-layer laminated glass fiber nonwoven fabric on a backing substrate of a flooring material made by coating and processing polyvinyl chloride on the surface. The present invention relates to a three-layer flooring backing substrate. More specifically, the uppermost smeared surface and the opposite lowermost surface of the three-layered flooring backing substrate are flat, so that the topmost smeared surface has little flatness and good flatness of polyvinyl chloride. A coated surface is obtained, and the lowermost layer surface on the opposite side has good workability when sticking to the base material with the adhesive applied to the base material, and there is no problem such as peeling during practical use after bonding Following the three-layer backing base material for flooring material that is practically usable and has no problem in dimensional stability, and the second layer papermaking by the inclined wire type paper machine,
The layers are combined, and the surface of the second layer is dried by applying a Yankee dryer to obtain a flat nonwoven glass fiber nonwoven fabric, and a coating liquid containing a pigment and a binder is applied to the surface of the second layer of the glass fiber nonwoven fabric. The present invention relates to a method for producing a three-layered flooring backing substrate.

[0002]

2. Description of the Related Art A general method of manufacturing a flooring material is as follows. The foamable PVC sol is applied to the surface of the backing substrate with a comma coater or the like, and the foamable PVC sol is once gelled by heating, and a wood grain pattern or the like is printed on the gelled foamable PVC sol surface. A transparent non-foaming PVC sol is applied on the printing surface, and the foaming PVC sol layer that has been gelled once by reheating is foamed about four times to increase the thickness. The floor material is made by gelling, and there is a disadvantage that if the coating thickness of the foamable PVC sol has uneven thickness, the unevenness in thickness is enlarged after foaming and the unevenness becomes conspicuous.

[0003] In the past, as flooring materials and the like, asbestos paper having excellent dimensional stability was used in which polyvinyl chloride or a foamed layer of polyvinyl chloride was provided, but asbestos paper was used. Glass fiber sheets were offered as an alternative to asbestos because floor materials are easily cracked and asbestos generates fine dust.However, glass fiber sheets have lower density than The vinyl chloride sol penetrates and escapes to the opposite surface of the sheet, so that a layer made of a predetermined amount of resin cannot be formed stably, and furthermore, there is a drawback that a transporter and the like cannot be soiled and smooth production cannot be performed. .

In order to make up for the drawbacks of this glass sheet, Japanese Utility Model Publication No. 60-10856 discloses a thermosetting resin, a self-crosslinking or reaction type resin using a curing agent, and a thermosetting resin as an essential component in a mixed paper made of glass fiber and pulp. A polyvinyl chloride layer is provided on a base sheet comprising one or more curable resins selected from polymer compounds such as polyvinyl alcohol, casein, and a water-soluble synthetic resin ammonium salt, which react with each other. Architectural laminates are described. However, this invention was made to solve the shortcomings of the substrate using glass fiber,
The idea is to increase the amount of pulp components mixed in the glass fiber and prevent the reduction in dimensional stability caused by the increase in the pulp component by blending the curable resin. If not, even if a curable resin is blended, there is a problem in dimensional stability in PVC processing, product construction, daily change after construction, deflection, etc. There was a drawback that it did not reach. In addition, when a glass sheet with a small structure is made by using a small amount of glass fiber and a large amount of curable resin, the penetration of polyvinyl chloride decreases during the processing of polyvinyl chloride, and the interlayer strength between the polyvinyl chloride and the glass sheet decreases. However, there is a disadvantage that the adhesive applied to the base material is less penetrated into the glass sheet when it is attached to the base material, and the adhesive strength between the glass sheet and the base material is weakened. When the sheet is used, there is a drawback in that the unevenness of the permeation of the polyvinyl chloride is increased during the processing of the polyvinyl chloride, so that the irregularities on the surface of the polyvinyl chloride become conspicuous. Furthermore, since the glass sheet is a single layer, when the building laminate is peeled off from the base material at the time of replacement after putting the building laminate to practical use, the glass sheet or the building laminate using this glass sheet Since a large amount of material is left on the ground surface in a non-uniform manner, unevenness occurs on the ground surface, and it is difficult to replace the new building laminate with the ground surface. There is a major drawback in that the glass sheet remaining on the glass sheet or the building laminate using the glass sheet must be removed.

In Japanese Utility Model Publication No. 61-21240,
1. Mixing and adding an inorganic filler and an organic synthetic resin to the gap of a fiber base sheet in which glass fibers are 20 to 100% and pulp and / or other organic fibers are 80 to 0%. A description is given of the characteristic sheet material. However, this invention is based on the idea that even with a sheet in which a large amount of glass fibers and pulp and / or other organic fibers are mixed, even if the inorganic filler is used, the fineness of the particles makes it possible to even out the details of the gaps in the mixed paper. By adhering with an organic synthetic resin so that it does not enter and fall off, the sealing process can be achieved extremely effectively, and the idea is that the leaching of the polyvinyl chloride paste to the back can be stopped, Even if the filling process prevents the leaching of the polyvinyl chloride paste to the back side, if the flatness of the sheet surface is not ensured, the coating thickness unevenness will occur when applying the polyvinyl chloride paste. It has a disadvantage that the surface irregularities are noticeable after foaming. The purpose of blending glass fiber is to obtain dimensional stability, but if the fiber is not oriented in the horizontal direction, it can be used during PVC processing, product construction, daily change after construction, and deflection. However, there is a problem in that the dimensional stability in the above-mentioned methods and the like cannot be solved, and the pattern shift, curl and the like cannot be solved. Further, after the laminated material and the decorative surface material using this sheet material are put into practical use, the laminated material and the decorative surface material are peeled off from the base material at the time of replacement. It is impossible to leave the lower layer evenly like the product, and it is impossible to peel it off. This sheet material or the laminated material using this sheet material and the surface decorative material itself are left on the base surface unevenly and partially in large quantities. Therefore, it is difficult to replace a new laminated material and a surface decorative material under the condition as it is, and a sheet material or a sheet material that remains on the ground surface with much labor is used. There was a major drawback in that the laminate and the facing material had to be removed.

Regarding the method of applying the laminate material and the surface decorative material to the base material, unevenness and gaps of the base material are corrected by sanding or putty, and dust and paint stains are completely removed. Thoroughly dry the base, and then use a comb
Apply about 00 g / m ² of adhesive to the base material, and after a predetermined open time, put the laminated material and surface decorative material on it, and wrap it with a pressure roller or a cloth wrapped in a square material to remove air inside. From outside and paste it while collecting air pockets. As an adhesive for application, an emulsion type synthetic rubber latex is often used. 30
When an emulsion type adhesive of about 0 g / m ² is applied to the base material, the adhesive is applied in a streak shape, and the base material is not completely covered with the adhesive. When the backing substrate surface of the laminated material and the surface decorative material is attached to the base material coated with the adhesive in the form of a streak, if the unevenness of the backing substrate surface of the laminated material and the surface decorative material is up to a certain level, It is possible to stick while releasing air through these irregularities.However, if this irregularity is too large, air will remain due to the irregularity and sufficient adhesive strength will not be obtained. There is a problem that it is uneconomical if the amount of the adhesive applied is increased so as to sufficiently cover the irregularities on the base material surface.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to solve these drawbacks, and it is possible to obtain a surface coated with polyvinyl chloride having good flatness, and to attach a floor material to a base material. It has good workability at the time of application, has no problems such as peeling at the time of practical use, can withstand practical use, and has a coating containing a pigment and a binder on the surface of a two-layer laminated glass fiber nonwoven fabric for backing which has no problem with dimensional stability. It is an object of the present invention to provide a three-layer flooring backing substrate coated with a liquid.

[0008]

That is, the present invention provides a method for coating polyvinyl chloride on a three-layered flooring backing substrate in which a coating solution containing a pigment and a binder is applied to the surface of a two-layer laminated glass fiber nonwoven fabric. In the backing base material of the floor material formed by coating, the lowermost layer of the three-layered structure, which is bonded to the base surface, is the first layer, and the lowermost layer of the surface to which polyvinyl chloride is coated and processed is the first layer. The upper smear layer is a third layer, the second layer contains glass fiber, pulp fiber and fibrous binder, and the center plane average roughness SRa measured by a stylus type three-dimensional surface roughness meter is 5 μm on the surface of the third layer.
Not less than 12 μm and the surface of the first layer is not less than 13 μm and not more than 28 μm.
The shrinkage rate after leaving at 200 ° C. for 3 minutes is 0.2% or less, based on the size adjusted for 24 hours or more in an environment of 20 ° C. and 65%. It is a backing substrate for flooring (Claim 1). Preferably, the first layer comprises a pulp fiber, a sizing agent, and a fibrous binder, and the backing substrate has a three-layer structure according to claim 1 (claim 2). The backing substrate for floor materials having a three-layer structure according to claim 2, further comprising artificial fibers. The backing substrate for floor materials having a three-layer structure according to any one of claims 1 to 3, wherein the second layer contains a sizing agent (Claim 4). The backing substrate for floor materials having a three-layer structure according to any one of claims 1 to 4, wherein the fibrous binder is PVA fiber (Claim 5). Further, in the production method of the present invention, the second layer is formed by the inclined wire type fourdrinier, then the first layer is formed, and the surface of the second layer is dried by applying a Yankee dryer to a flat surface. The laminated glass fiber nonwoven fabric is obtained, and a coating solution containing a pigment and a binder is smeared on the surface of the second layer of the glass fiber nonwoven fabric, for a floor material having a three-layer structure according to any one of claims 1 to 5. A method for producing a backing substrate (claim 6).

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.
The two-layer laminated glass fiber nonwoven fabric of the present invention is coated with a coating solution containing a pigment and a binder on the surface thereof. Regarding the flooring material, if the flatness is poor even if sealing is performed sufficiently for the purpose of preventing uneven and excessive penetration of the PVC sol on the surface of the uppermost layer, this flooring backing When the foamable PVC sol is applied to the surface of the uppermost layer of the material, the applied thickness is not uniform and has uneven thickness. The foamable PVC sol with uneven thickness is foamed and foams when it becomes about 4 times thicker The surface of the uppermost layer is required to be flat because the unevenness of the surface of the PVC later is conspicuous. Therefore, the second layer surface is applied to the surface of the Yankee dryer during the papermaking of the two-layer assembling glass fiber nonwoven fabric and dried to obtain a flat surface. , The surface of the second layer has a non-uniform PVC sol It is not providing the third layer of the purpose of preventing over - Do penetration. If the center plane average roughness SRa measured using a stylus type three-dimensional surface roughness meter as an index of flatness is not 12 μm or less on the surface of the third layer, the unevenness of the PVC surface after foaming is conspicuous, and the surface of the third layer The flatness is preferable because the unevenness of the PVC surface after foaming becomes less noticeable as it is flat, but if it is less than 5 μm, it cannot be achieved unless the blending amount of glass fiber is reduced, and in this case, the dimensional stability is lacking. There is. The center plane average roughness SRa of the third layer surface is 5 μm or more and 1
2 μm or less. When two layers are combined and the surface of the second layer is made flat by applying it to the surface of the Yankee dryer, the uneven formation leads to the unevenness of the surface of the first layer on the opposite side, and the flooring material is attached with the adhesive applied to the base material. If the surface irregularities of the first layer are too large at the time of attachment, insufficient bonding strength will be caused, and it is necessary to reduce formation unevenness. Therefore, the blending amount of the glass fiber, which is blended mainly for ensuring the dimensional stability of the second layer, is small, and by using a thin and short glass fiber, the fiber length is long, there is no flexibility, and the dispersibility is low. This eliminates the adverse effect of formation of formation that is not good, and obtains a flat surface with less irregularities on the surface of the first layer. If the center surface average roughness SRa measured using a stylus type three-dimensional surface roughness meter as an index of flatness is not 28 μm or less on the surface of the first layer, the floor material is stuck with an adhesive applied to the base material. In some cases, it is preferable that the surface of the first layer is flat, but it is not preferable to reduce the glass fiber content to less than 13 μm. In this case, dimensional stability is lacking. There is a problem, and the center plane average roughness SRa of the surface of the first layer is 13 μm or more and 28 μm or less. As a countermeasure against the deterioration of the dimensional stability in the horizontal direction by using a small amount of the glass fiber of the second layer and using a thin and short glass fiber, the fiber is formed in the horizontal direction by making a slant wire type fourdrinier paper machine. Is also oriented so that the dimensional stability can be ensured even when a small amount of glass fiber is used and the length is small and short. The shrinkage ratio is desirably within 0.1% according to the conventional empirical rule, and at worst is required within 0.2%. As described above, the uppermost layer on which the foaming PVC sol is applied is flat, the lowermost layer adhered to the base material is flat, and the dimensional stability in the lateral direction is good.
Thus, a backing substrate for a floor material having a layer structure is obtained.

The combination of the first layer may be a combination of pulp fiber, sizing agent and fibrous binder, or a combination of pulp fiber, sizing agent, fibrous binder and artificial fiber.
The composition of the second layer is a combination of glass fiber, pulp fiber and fibrous binder, or a combination of glass fiber, pulp fiber, fibrous binder and sizing agent. Each raw material is used mainly as a sizing agent in the first layer for adjusting sizing properties, pulp fibers for adhering materials and moisture absorption, fibrous binders as adhesives, and artificial fibers for adjusting air permeability and flooring. Depending on the intended use of the material, the sizing agent in the second layer is used for adjusting the size, the glass fiber is used for dimensional stability, the pulp fiber is used for absorbing moisture and the permeation of PVC sol, and the fibrous binder is bonded. Used as an agent. The pigment of the third layer is used as a filler for preventing uneven and excessive penetration of the PVC sol, and the binder is used for bonding the pigment. By including these, the above characteristics can be realized. Incidentally, the first layer preferably has a basis weight of 16 g / m ² or less so that a thin layer with little unevenness can be left on the base adhesive at the time of replacement of the floor material so as not to hinder the replacement.
The second layer preferably has a basis weight of 50 g / m ² or more and 150 g / m ² or less, with the basis weight adjusted according to required properties such as the thickness and strength of the flooring material.
The amount of smear of the third layer is adjusted according to the method of smearing and the permeation of the polyvinyl sol, and is preferably from 5 g / m ^{2 to} 60 g / m ² .

The glass fiber used in the present invention may be any glass fiber as long as it is hard to be broken, has an ability to form a fiber sheet, and has no significant adverse effect on formation. Fiber diameter is 5
It is generally from μ to 13μ, and thin glass fibers of less than 6μ can provide excellent texture etc., but their strength is weak. Thick glass fibers of more than 13μ improve dimensional stability, but become too thick, resulting in gaps. And its workability is inferior, and it is difficult to use because it is irritating to the skin. The fiber length is generally from 3 mm to 25 mm, but if it is less than 6 mm, the strength is weak, and if it exceeds 25 mm, the formation deteriorates, which is not preferable. From the above, the more preferable glass fiber has a fiber diameter of 6 μm or more and 13 μm or less, and a fiber length of 6 μm.
mm or more and 25 mm or less.

The second layer contains a glass fiber and a fibrous binder. Since the polyvinyl chloride is applied to the surface of the third layer and is used as a flooring and is made of a nonwoven fabric for backing, it is uniform. When the total weight of glass fiber, pulp fiber, and fibrous binder is 100%, the preferable addition rate of glass fiber is 45%. More than 6
5% or less.

The pulp fibers used in the present invention are conifers,
An aggregate of plant fibers extracted from hardwood or other plant bodies by a mechanical method, a chemical method, or a method in which the above two methods are appropriately combined in the middle, and either pulp is used alone or in combination. Beat it moderately.

The fibrous binder used in the present invention includes PVA fiber, viscose fiber, polyester fiber,
Examples include vinylon fibers and various types of core-sheath fibers, and any fibrous binder may be used as long as the desired effects of the present invention are not impaired. In particular, the PVA fiber used in the examples is preferable. More specifically, the PVA fiber is a fiber produced under appropriate conditions using a suitable raw material PVA for the purpose, and is almost soluble in water at room temperature. Although it keeps the fiber form, it is easily melted when heated on the dryer surface after paper making, and at that moment it is pressurized with equipment such as a touch roll, and it becomes a fibrous binder across the main fibers. Then, it is re-coagulated by dehydration and drying, and becomes a strong paper layer constituting fiber which is not easily separated unless it is in high-temperature water. Although there are various effects on the adhesive strength of the fiber, it can be roughly classified into three points: softening point in water, fineness, and fiber length. The softening point in water is actually
This roughly indicates the temperature at which the wet paper web is heated by the dryer and the binder fibers begin to melt and exhibit an adhesive function. As the PVA fiber having a lower softening point in water is used, the dissolution of the binder fiber, which is a prerequisite for bonding, is facilitated and the bonding effect is increased, but the lower the softening point in water is better from the viewpoint of the bonding effect, but the dryer is better. Adhesion is likely to occur. In order for the PVA fibers to dissolve, the temperature of the wet paper must be higher than its softening point in water. Therefore, the higher the drying temperature, the greater the adhesive effect and the higher the strength. If the water temperature in the wet paper is lower than the softening point of the PVA fiber in water, the dissolution of the binder fiber does not occur, so that the binder effect is completely lost. In case of Yankee dryer, dryer steam temperature is 130
About 160 ° C., and the temperature of the wet paper web
Since it is considered to be 0 to 90 ° C., if the softening point of the PVA fiber in water is 65 to 85 ° C., a sufficient adhesive strength can be obtained. As for the fineness, the strength increases as the fineness decreases. This is because, when added at the same weight ratio, the use of thin fibers increases the number of added fibers and increases the number of bonding points, thereby increasing the adhesive force.
A fiber is typically 1 denier. The shorter the fiber length, the more uniform the distribution in the slurry at the time of papermaking, resulting in a higher strength. From this point, 3 to 4 mm is appropriate.

The artificial fibers used for the first layer in the present invention are synthetic fibers, semi-synthetic fibers, recycled artificial fibers, inorganic fibers, and the like.
Synthetic fibers include polyamide, polyester, polyurethane, polyethylene, polyvinyl chloride, polyvinylidene chloride, polyfluoroethylene, polyacryl, and polyvinyl alcohol fibers. Recycled artificial fibers include cellulose-based viscose rayon, cuprammonium rayon, nitrocellulose, saponified acetate, protein-based casein, and soybeans. Proteins, peanut proteins, corn proteins, regenerated silk fibers, etc., and inorganic fibers include metal fibers, glass fibers, rock fibers and the like.
Any material that does not affect formation and is not easily affected by heat during processing or that has excellent dimensional stability can be used at a ratio according to the purpose within a range that does not impair the desired effect of the present invention. It is.

The sizing agent used in the present invention is a reinforced rosin sizing agent, a rosin emulsion sizing agent, a petroleum resin sizing agent, a synthetic sizing agent, a neutral rosin sizing agent, etc., as long as the desired effect of the present invention is not impaired. Any of the known sizing agents can be used.

The pigment used in the coating liquid of the present invention may be an inorganic pigment or an organic pigment, as long as it has an affinity for a binder and does not fall off after smearing and drying. For example, barium sulfate, calcium carbonate, kaolin, satin White, synthetic silica, talc, titanium dioxide, zinc oxide, aluminum hydroxide, plastic pigment and the like are used alone or in combination. Further, the binder used in the coating liquid of the present invention may have any affinity as long as it has an affinity for the pigment and the coating layer does not fall off after smearing and drying.For example, a styrene-butadiene copolymer, a styrene-acrylic copolymer may be used. Coalescing,
Methacrylic acid / butadiene copolymer, acrylonitrile / butadiene copolymer, chloroprene copolymer, acrylate ester polymer, ethylene / vinyl acetate copolymer, vinyl chloride / vinyl acetate copolymer, vinylidene chloride polymer , Polyvinyl alcohol, oxidized starch, phosphated starch, enzyme-modified starch, carboxymethylcellulose, casein, etc. may be used alone or in combination. Good binders are more preferred.

In addition, various anionic, nonionic, cationic or amphoteric retention improvers, drainage agents, dispersing agents, etc. which are conventionally used within the range not impairing the desired effects of the present invention are also added during the compounding. Agents, paper-strength improvers and tackifiers are appropriately selected and used as needed. In addition, for the purpose of papermaking internal additives such as pH adjusters, defoamers, pitch control agents, slime control agents, etc. It can also be added as appropriate.

The production method in the present invention can be carried out, for example, as follows. The second layer is prepared by adding a nonionic dispersant to water, adding glass fibers, stirring for about 15 minutes, and then adding a polymer polyacrylamide aqueous solution and storing the mixture as a glass fiber slurry while stirring with a reciprocating stirrer. After mixing and dispersing the beaten pulp fiber, fibrous binder, sizing agent, and sodium hexametaphosphate in water, the mixture is sent to another storage tank as a pulp slurry, and the former slurry and the latter slurry are used for the second layer. Is sent to an inclined wire-type fourdrinier paper machine by a fixed amount, and the second layer is first formed so as to have a target basis weight. Next, the first layer is prepared by mixing and dispersing pulp fiber, fibrous binder, sizing agent, and sodium hexametaphosphate after beating in water, sending the slurry to a storage tank, and using this slurry for the first layer in a circular net. The paper is sent to a paper machine and mixed with the previously formed second layer so as to have a target basis weight. Furthermore, after this assembling, the second layer surface is dried so that the surface of the second layer hits the surface of the Yankee dryer to obtain a flat glass fiber nonwoven fabric. A coating liquid further containing a pigment and a binder is smeared on the surface of the second layer of the glass fiber nonwoven fabric.

Regarding the paper machine used in the present invention, there are roughly three types of non-woven paper machines: a horizontal fourdrinier paper machine, an inclined wire fourdrinier paper machine, and a round net paper machine. When the horizontal Fourdrinier machine makes paper using wood pulp, the stock inlet concentration is 1%
Basically, the speed of the wire is tuned to or slightly higher than the speed of ejection from the stock inlet, and the fiber is easily oriented in the machine direction, that is, in the longitudinal direction. On the other hand, glass fiber has a much longer fiber length than wood pulp, is not hydrophilic and has poor water dispersibility, is not fibrillated and has high drainage like wood pulp, and therefore contains glass fiber When making non-woven paper, the stock inlet concentration must be less than 0.1% and the speed of the wire must be higher than the ejection speed from the stock inlet so that the formation is not damaged by the jet flow. In other words, it is not a preferable paper machine for easily orienting fibers in the longitudinal direction more easily. Circular web machine is a cylindrical system in which a backing wire and a surface wire are stretched on a perforated frame or honeycomb roll, the suction forming box is placed inside the cylinder, and the paper layer is generally formed by a cylinder. 1 / of the surface
In step 4, there is no means for promoting the entanglement of the fibers, and the stock having one end of the fibers attached to the wire is fixed to the wire surface while being sucked with the rotation of the cylinder. Accordingly, the fiber arrangement of the wet paper web is deviated in the vertical direction, which is not a preferable paper machine for orienting a large number of fibers in the horizontal direction as in the case of the horizontal fourdrinier paper machine. Finally, the second
As the name implies, the inclined wire type fourdrinier used to make layers has a 10-degree to 25-degree slope of the forming zone wire with respect to the papermaking direction. There is a manifold to be adjusted, a head box to regulate the flow of the stock, and a stock deflector inside the head box that converts the upward kinetic energy of the stock to the forming section. There is a pound regulator to drain on the box. After the breast roll, there are an apron board for uniformly flowing out the stock supplied from the head box and a forming box for sucking the stock to form a paper layer. After the hinge roll, there is a suction box for adjusting the moisture content of the wet paper web, and the wet paper web whose moisture has been adjusted is conveyed to the first-layer netting machine, which is formed together with the felt by the pick-up suction sucking through the wet felt. . During the formation of the paper layer, the stock material flows while being dehydrated while being sandwiched between the inclined wire on the forming box and the pound regulator, and the fibers are also sucked in a direction perpendicular to the wire to form a paper layer. For this reason, it is a preferable paper machine for trying to orient a large amount of fibers in the lateral direction.

As for the Yankee dryer used in the present invention, the dryer has a large-diameter dryer cell in which steam is dried at 130 to 160 ° C., and the surface of the dryer is highly polished and wet. The sheet is brought into close contact with the surface of the Yankee dryer by a pressing roll called a touch roll, so that the sheet surface is provided with flatness and gloss.

[0022]

EXAMPLES The present invention will be described below in detail with reference to Examples and Comparative Examples, but is not limited thereto. Table 1
Shows the compounding ratio of the example and the comparative example.

Preparation of Cushion Flooring Material A sample of a three-layered flooring backing substrate was cut into a width of 25 cm and a length of 30 cm, preheated in a constant-temperature hot-air dryer at 110 ° C. for 30 seconds, and then placed on a glass plate. The surface of the layer is placed on the bottom, and foamable PVC sol for cushion flooring is applied to the surface of the third layer with an applicator bar having a gap of 0.4 mm, and heated with a 200 ° C. constant temperature hot air drier for 20 seconds to form a gel. It was made. A non-foaming transparent PVC sol is further applied to the cooled gelled sheet with an applicator bar having a gap of 0.6 mm (application cap is 0.2 mm), and heated at 200 ° C. for 15 seconds in a constant temperature hot air drier to produce a foaming PVC sol. Was foamed, and the non-foaming transparent PVC salt was gelled to prepare a cushion flooring material.

The measurement of data in the examples and comparative examples is performed by the following method. Center plane average roughness SRa: Center plane average roughness S measured using a stylus type three-dimensional surface roughness meter as an indicator of flatness
Ra is defined by Equation 1.

[0025]

(Equation 1)

In Equation 1, Wx represents the length of the sample surface area in the X-axis direction (papermaking direction), Wy represents the length of the sample surface area in the Y-axis direction (direction perpendicular to the papermaking direction), and Sa Represents the area of the sample surface area. Specifically, as a stylus type three-dimensional surface roughness meter and a three-dimensional surface roughness analyzer, Kosaka Laboratory Co., Ltd.
Using the SE-3AK and SPA-11 manufactured by
x = 50 mm, Wy = 23.976 mm, and therefore Sa =
It can be determined under the following conditions: 1198.8 mm ² , low-frequency cutoff = R + W, high-frequency cutoff = R + W, and X feed speed of 2 mm / sec. In the data processing in the X-axis direction, sampling is performed at 500 points, and scanning in the Y-axis direction is performed in 25 lines. Peel strength: Adhesive for synthetic rubber latex flooring agent (Bond FL101 Konishi Co., Ltd.), width 40 mm, length 2
Coating on plywood having a thickness of 5.5 mm and a thickness of 5.5 mm using a comb-shaped spatula so that the coating amount becomes 250 g / m ² ,
After 0 minutes, the bonding area of the cushion flooring material is 40 mm x 150
mm, and reciprocated two times with a roller weighing 8 kg, and after 168 hours, a peeling width of 32 mm
A value was obtained by multiplying a value obtained by measuring a 90 ° peel strength at a pulling speed of 200 mm / min by 25/32 and cutting the cushion floor material with a cutter so as to obtain a peel strength. According to the conventional empirical rule, if the peel strength is 2 kgf / 25 mm or more, there is no problem such as peeling at the time of practical use, and it can sufficiently withstand practical use. Dimensional stability: glass fiber nonwoven fabric sample at temperature 20
Humidity is controlled for 24 hours or more in an environment of a humidity of 65 ° C. and the length of the sample is accurately measured. This sample is kept at 200 ° C
Was left in a constant temperature hot air for 3 minutes, the length of the sample was measured, and the shrinkage ratio to the original size was obtained. The closer to 0, the better the dimensional stability. According to conventional empirical rules, the shrinkage ratio is desirably within 0.1%, and at worst, within 0.2%. Flatness of the PVC surface: The unevenness of the PVC surface of the cushion flooring material created by the above method was visually observed, and the one with small unevenness was ranked as 1 and the one with large unevenness was set as rank 10.
It was rated on a 0 scale. Rank 1 is the best, and ranks 1 to 5 are good according to the conventional rules of thumb, and rank 6 at worst.
Is desirable. Pulp freeness: The pulp freeness was measured according to JIS P8121.

Example 1 Following the production of 50 g / m ² of the second layer on an inclined wire type fourdrinier under the mixing ratio shown in Table 1 and the papermaking conditions shown in Table 2,
8 g / m ² of the first layer was combined with a circular paper machine, and after pressing, the surface of the second layer was dried with a Yankee dryer to make it flat, and the combined glass fiber non-woven fabric having a basis weight of 58 g / m ² was obtained. Was obtained, and the surface of the second layer of this glass fiber nonwoven fabric was added to Table 1
Was coated with a solid content of 35 g / m ² to prepare a coated sheet of a combined glass fiber nonwoven fabric having a total basis weight of 93 g / m ² . Tables 3 and 5 show the measurement results.

Example 2 Papermaking of the second layer of 150 g / m ² was carried out on an inclined wire type Fourdrinier paper machine under the mixing ratio shown in Table 1 and the papermaking conditions shown in Table 2, followed by a round paper machine. 16 g / m ^{2 of} one layer is combined,
After pressing, the surface of the second layer was dried by applying a Yankee dryer to a flat surface to obtain a combined glass fiber nonwoven fabric having a basis weight of 166 g / m ^2. Further, the surface of the second layer of the glass fiber nonwoven fabric is shown in Table 1. 35 g / m ² solid content of the coating solution and total basis weight 2
A smeared sheet of a combined glass fiber nonwoven fabric of 01 g / m ² was prepared. Tables 4 and 6 show the measurement results.

COMPARATIVE EXAMPLE 1 Following the production of 50 g / m ² of the second layer on an inclined wire type fourdrinier under the mixing ratios shown in Table 1 and the papermaking conditions shown in Table 2,
8 g / m ² of the first layer was combined with a circular paper machine, and after pressing, the surface of the second layer was dried with a Yankee dryer to make it flat, and the combined glass fiber non-woven fabric having a basis weight of 58 g / m ² was obtained. Was obtained, and the surface of the second layer of this glass fiber nonwoven fabric was added to Table 1
Was coated with a solid content of 35 g / m ² to prepare a coated sheet of a combined glass fiber nonwoven fabric having a total basis weight of 93 g / m ² . Table 3 shows the measurement results.

Comparative Example 2 The second layer was formed at 150 g / m ^{2 on} an inclined wire-type fourdrinier paper machine under the mixing ratios shown in Table 1 and the papermaking conditions shown in Table 2, followed by a round paper machine. 16 g / m ^{2 of} one layer is combined,
After pressing, the surface of the second layer was dried by applying a Yankee dryer to a flat surface to obtain a combined glass fiber nonwoven fabric having a basis weight of 166 g / m ^2. Further, the surface of the second layer of the glass fiber nonwoven fabric is shown in Table 1. 35 g / m ² solid content of the coating solution and total basis weight 2
A smeared sheet of a combined glass fiber nonwoven fabric of 01 g / m ² was prepared. Table 4 shows the measurement results.

Comparative Example 3 A 50 g / m ² second layer was formed on a round paper machine under the mixing ratios shown in Table 1 and the paper making conditions shown in Table 2, followed by 8 g of the first layer on a round paper machine. / m ² to Extract alignment and pressed, dried and the flat surface against a surface of the second layer to the Yankee dryer, a basis weight of 58 g / m was obtained ² Extract laminated glass fiber nonwoven fabric, further second glass fiber non-woven fabric The coating liquid shown in Table 1 was applied to the surface of the layer at a solid content of 35 g / m ² to prepare a coated sheet of a combined glass fiber nonwoven fabric having a total basis weight of 93 g / m ² . Table 5 shows the measurement results.

Comparative Example 4 The second layer was formed at 150 g / m ^{2 on} an inclined wire-type fourdrinier paper machine under the mixing ratios shown in Table 1 and the papermaking conditions shown in Table 2, followed by a round paper machine. 16 g / m ^{2 of} one layer is combined,
After pressing, dried with an air dryer, basis weight 166 g / m ²
Was obtained. Further, the coating liquid shown in Table 1 was applied to the surface of the second layer of the glass fiber nonwoven fabric with a solid content of 35%.
Extract alignment g / m ² smeared total basis weight of 201g / m ² was prepared smear sheet of glass fiber nonwoven fabric. Table 6 shows the measurement results.

[0033]

[Table 1]

[0034]

[Table 2]

[0035]

[Table 3]

In comparison between Example 1 and Comparative Example 1, the second
When the total weight of the glass fiber, pulp fiber, and fibrous binder in the layer is 100%, the glass mixing ratio of the second layer is 45% in order to improve the flatness of the first layer surface, that is, the center plane average roughness SRa. When the average surface roughness SRa is reduced from 13.0 μm to 12.7 μm, the shrinkage ratio is reduced from 0.10% to 0.21%. The lower limit of the center plane average roughness SRa of 13.
It can be seen that it is 0 μm. Similarly, when the total weight of the glass fiber, the pulp fiber, and the fibrous binder of the second layer is set to 100%, in order to improve the flatness of the third layer surface, that is, the center plane average roughness SRa. When the glass mixture ratio of the second layer is reduced from 45% to 40%, the center plane average roughness SRa is improved from 5.0 μm to 4.7 μm, but the shrinkage ratio is reduced from 0.10% to 0.21%. , The lower limit of the center plane average roughness SRa of the third layer surface is 5.0.
μm.

[0037]

[Table 4]

In comparison between Example 2 and Comparative Example 2, the second
When the total weight of the glass fiber, pulp fiber, and fibrous binder of the layer is 100%, the glass blending ratio of the second layer is 6%.
When it is increased from 5% to 70%, the flatness of the first layer surface, that is, the center plane average roughness SRa is deteriorated from 28.0 μm to 29.5 μm, and accordingly, the peel strength is reduced from 2.0 kgf / 25 mm to 1. Since it is weakened to 8 kgf / 25 mm, it can be understood that the upper limit of the center plane average roughness SRa of the first layer surface is 28.0 μm.
Similarly, when the total weight of the glass fiber, pulp fiber, and fibrous binder in the second layer is 100%, the flatness of the third layer surface, that is, the center plane average roughness SRa
Is deteriorated from 12.0 μm to 13.1 μm, and the flatness of the PVC surface is deteriorated from 6 to 7 with this.
It can be seen that the upper limit of the center plane average roughness SRa of the layer surface is 12.0 μm.

[0039]

[Table 5]

In the comparison of Example 1 using the inclined wire type paper machine in the second layer paper making and Comparative Example 3 using the circular net paper machine, Comparative Example 3 has a poor shrinkage and requires the use of the inclined wire type paper machine. It is understood that.

[0041]

[Table 6]

In the drying of the second layer surface, a comparison between Example 2 using a Yankee dryer and Comparative Example 4 using an air dryer shows that Comparative Example 4 has poor flatness on the third layer surface and poor flatness on the PVC surface. It turns out that it is necessary to use a dryer.

[0043]

As described above, according to the present invention,
The center surface average roughness SRa measured using a stylus type three-dimensional surface roughness meter as an indicator of flatness is 5 μm or more and 12 μm or less, and the lowermost layer on the opposite side is coated with polyvinyl chloride. The center surface average roughness SRa of the surface is 13 μm
Since it is a backing base material for floor materials having a three-layer structure of 28 μm or less and a shrinkage ratio of 0.2% or less in the horizontal direction, a polyvinyl chloride-coated surface with good flatness can be obtained, and the floor material can be adhered. The workability at the time of attachment is good, there is no problem such as peeling at the time of practical use, the effect can be sufficiently endured to practical use, and the effect of no problem in dimensional stability can be obtained.

Claims (6)

[Claims] 1. A floor material obtained by applying polyvinyl chloride to a three-layer flooring backing substrate in which a coating solution containing a pigment and a binder is applied to the surface of a two-layer laminated glass fiber nonwoven fabric. In the backing substrate, of the three-layer structure, the lowermost layer on the side to be bonded to the base surface is the first layer, and the uppermost layer on the side on which polyvinyl chloride is applied and processed is the third layer. , Second
The layer contains a glass fiber, a pulp fiber and a fibrous binder, and has a center plane average roughness SR measured by a stylus type three-dimensional surface roughness meter.
a: Shrinkage after standing at 200 ° C. for 3 minutes based on the dimensions of the third layer surface of 5 μm or more and 12 μm or less, the first layer surface of 13 μm or more and 28 μm or less, and humidity of 24 hours or more in an environment of 20 ° C. and 65%. Is not more than 0.2%. 2. The backing substrate for floor materials having a three-layer structure according to claim 1, wherein the first layer contains pulp fibers, a sizing agent, and a fibrous binder. 3. The method according to claim 2, wherein the fibers contain artificial fibers.
The backing substrate for floor materials having a three-layer structure according to the above. 4. The backing substrate for floor materials having a three-layer structure according to claim 1, wherein the second layer contains a sizing agent. 5. The backing substrate for a flooring material having a three-layer structure according to claim 1, wherein the fibrous binder is PVA fiber. 6. A laminated glass fiber which has been flattened by drying the second layer with a Yankee dryer and then drying the second layer after the second layer is formed by the inclined wire type fourdrinier paper machine. 6. A backing substrate for flooring having a three-layer structure according to claim 1, wherein a nonwoven fabric is obtained, and a coating liquid containing a pigment and a binder is applied to the surface of the second layer of the glass fiber nonwoven fabric. Manufacturing method.