JPH11117514A - Cushioning flooring and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a cushioning flooring, in which a restorable property to indents is improved largely, by forming a fibrous base material layer, a cushion layer, in which a foam particle layer is bonded with the fibrous base material layer by a foamed layer, and a surface protective layer. SOLUTION: The upper section of a fibrous base material layer 1 consisting of a glass-fiber nonwoven fabric, etc., is coated with foamable paste 2 composed of a polyvinyl chloride resin composition, etc., and foamable particles 3 made up of the polyvinyl chloride resin composition, etc., are scattered onto the whole surface. The upper section of the particles 3 are coated with a transparent protective layer 4 consisting of the polyvinyl chloride resin composition, etc., and the whole is heated and foamed together with the foamable paste and the formable particles 3. Accordingly, the cushioning flooring having a residual indentation rate of 3.5% or less is obtained. The cushioning flooring has an extremely excellent restorable property to indents, and has superior cushioning properties and soundproofness.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel cushioning flooring material which is more excellent in dent resilience than a conventional cushioning flooring material, and a method for producing the same.

[0002]

2. Description of the Related Art A conventional cushioning flooring material is provided with a foam layer 2 on a fibrous base material layer 1 as shown in FIG.
Further, the surface protection layer 4 is provided thereon.

[0003] Cushioning flooring materials having such a structure, when heavy furniture such as a closet is placed thereon,
Even after this was removed, the place was indented and did not restore, and after the remodeling of the room, there was a face that had to be uncomfortable in this regard.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a novel cushioning flooring material which has greatly improved the resilience to dents which is a drawback of the conventional cushioning flooring material, and a method of manufacturing the same. .

[0005]

SUMMARY OF THE INVENTION A first aspect of the present invention is to provide a fibrous base material layer, a cushion layer formed by bonding a foam particle layer to the fibrous base material layer with a foamed layer, and a surface protective layer. The present invention relates to a cushioning floor material characterized by the following.

A second aspect of the present invention is that the residual dent ratio is 3.5%.
The present invention relates to a cushioning floor material according to claim 1, which is as follows.

The residual dent ratio of the cushioning flooring material is as follows:
It is at most 3.5%, preferably at most 3.0%. This residual dent ratio was measured according to JIS A5705.

The expandable particles used in the present invention are generally referred to as expandable chips or beads, and are formed by mixing a vinyl chloride resin composition with a blowing agent such as azodicarbonamide (ADCA). Sex chips,
Examples thereof include polystyrene foam beads, polyolefin foam beads, and acrylic resin foam beads. The particle size of the expandable particles is 0.2 to 3.0 mm, preferably 0.5 to 1.0 mm.

The foam particles or expanded particles in the present invention are the above-mentioned expandable particles, that is, particles obtained by expanding expandable chips or beads. The particle diameter of the expanded particles is 1.0 mm or more, preferably 1.5 to 2.0 m
m, and as the particle size increases, the thickness of the flooring material inevitably increases. In terms of the expansion ratio of the expandable particles, the expansion ratio is preferably about 1.5 to 3.0 times. The specific gravity of the foamed particles is 0.9 to 1.8, preferably 1.0 to 1.5, though it depends on the type of the resin. Since these particles are in a state where each particle wraps the foam layer with a surface film, that is, a skin layer, the internal gas is compressed even when a heavy object is placed on the top. Since the gas in the bubbles does not escape as in the case of an open-celled body, the property that the restoring force is immediately exerted when a heavy object placed on the top, such as a closet, is removed. Have. The formation of the skin layer can be remarkably observed in a portion where the chips are in contact with each other and a portion where the chip and the foam layer are in contact with each other. Furthermore, it is desirable to form the skin layer more aggressively, and one example of a method for this is to coat a foamable chip with a non-foamable composition. This coating means includes a spray method and a dipping method.

However, if the expanded particle layer is adhered to the fibrous layer with an adhesive (non-expandable), the above-mentioned individual compression and restoration movements of the expanded particles are suppressed. Therefore, the foamed layer plays the role of adhering these foamed particles onto the fibrous layer without restricting the movement of compression and restoration of the foamed individual particles. And as the layer made of expanded particles constitutes the main body of the layer that is expanded,
In other words, the smaller the proportion of the foamed layer compared to the layer of foamed particles, the smaller the residual dent ratio and the better the dent recovery. Therefore, the thickness of the foamed layer is preferably set to 0.5 mm or less at most from a thickness as close to 0 as possible. The specific gravity of the foam layer depends on the type of resin, but is 0.1 to
0.8, preferably 0.2 to 0.5.

The foamed layer is formed by foaming the foamable composition. Examples of the foamable composition include a foamable polyvinyl chloride resin composition, a foamable polyolefin resin composition, and a foamable polyamide resin composition. Products, foamable polyamide-imide resin composition, foamable polyimide resin composition, foamable polyurethane composition, foamable synthetic rubber composition, and the like.

A typical foamable polyvinyl chloride resin composition is in the form of a sol. As the foamable polyolefin-based resin composition, there are two types of a crosslinked type and a non-crosslinked type, and a crosslinked type is preferable. The foamable polyurethane-based resin composition can be used in various combinations of a polyol component and an isocyanate component. Any known technique can be used for the foamable composition of the present invention itself.

The protective layer in the present invention is a layer for protecting the lower layer of the foam particles and the foam layer, and usually a resin layer capable of forming a relatively tough coating can be used.
Examples of resins used for these include vinyl chloride resins, polyamide resins, polyester resins, polycarbonate resins, polyamide imide resins, polyester imide resins, and polyimide resins. This layer is colorless and transparent, and may be colored and transparent. In addition, printing can be performed on the front and back surfaces of the protective layer, or a pattern layer and a print layer can be separately provided below the protective layer. Further, a backing layer such as a synthetic resin may be provided on the back surface of the fibrous base material.

Examples of the fibrous base material in the present invention include a woven fabric, a nonwoven fabric and a mat made of various materials. As the material, inorganic fibers such as glass fibers, synthetic fibers such as polyester or polyamide, natural fibers, semi-synthetic fibers, and the like can be used.

In carrying out the method of the present invention, a fibrous base material is disposed, a paste-like foamable resin composition is coated thereon, and then foamable particles are sprayed thereon. After providing a surface protective layer thereon, foam molding into a predetermined shape is performed, or after foaming particles are sprayed after coating with the foamable resin composition, heating is performed first to foam. Then, a protective layer is formed by coating the surface of the expanded particle layer.

[0016]

The present invention will be described below with reference to examples, but the present invention is not limited thereto.

Example 1 A glass fiber nonwoven fabric having a thickness of 0.2 mm was used as a fibrous base material, a foamable paste made of a polyvinyl chloride resin composition was applied thereon, and a foamed paste made of a polyvinyl chloride resin composition was further applied. Foamable particles (particle diameter: 0.5 mm) are spread over the entire surface, and a transparent surface protective layer (thickness after curing: 0.15 mm) made of a polyvinyl chloride resin composition is applied thereon, and then the whole is heated. Then, the foaming paste and the foaming particles were foamed together. The total thickness of the expanded particle layer and the expanded layer was 1.95 mm, and the total thickness was 2.3 m.
m. The residual dent ratio of this product is JIS A570
As a result of measurement with No. 5, it was 2.97%.

Comparative Example 1 A glass fiber nonwoven fabric layer of 0.2 mm and a foam layer of 1.95 m were prepared according to the method of Example 1, except that no foamable particles were used.
m, floor material with a surface protection layer of 0.15 mm (total thickness of 2.3
mm). The residual dent ratio of this product was 4.3%.

[0019]

[Effect] The cushioning flooring material of the present invention is extremely excellent in restoring property against dents as compared with the conventional cushioning flooring material, and is also a flooring material excellent in cushioning property and soundproofing property.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a specific example of the present invention.

FIG. 2 is a cross-sectional view showing a conventional cushioning floor material.

[Explanation of symbols]

 Reference Signs List 1 fibrous base material layer 2 foam layer 3 foam particle layer 4 protective layer

Claims (4)

[Claims] 1. A cushioning flooring material comprising a cushion layer and a surface protection layer formed by bonding a fibrous base material layer and a foam particle layer to the fibrous base material layer with a foamed layer. 2. The cushioning flooring material according to claim 1, wherein the residual dent ratio is 3.5% or less. 3. A method for applying a foamable composition on a fibrous base material layer, spraying foamable particles on the foamable composition, further forming a surface protective layer thereon, and heating the resultant. By
Expanding the expandable particles and the expandable composition and bonding the expandable particle layer to the fibrous base material layer with the expandable layer or forming the expandable particles and the expandable particles before forming the surface protective layer. A method for producing a cushioning flooring material, comprising heating a foamed composition and then providing a surface protective layer thereon. 4. The method according to claim 4, wherein the expandable particles have a non-expandable coating.