JPH11158784A - Flooring material made of olefinic resin and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a flooring material made of an olefinic resin that has a variety of performances equal or superior to those of the flooring material made of a vinyl chloride resin. SOLUTION: This olefinic resin composition comprises, as the olefinic resin chips 11(A) and 11(B), a polyethylene (suitably low-density polyethylene and/or a linear low-density polyethylene), an ethylenic copolymer as ethylene-vinyl acetate copolymer and an inorganic filler (suitably calcium carbonate. In this case, a mixture of at least two kinds of olefinic resins having the melt indexes different from each other 11(A) and 11(B) is used and they are heated and pressed into sheets thereby producing the objective flooring material 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring made of an olefin resin and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as a synthetic resin flooring, a vinyl chloride resin flooring made of a vinyl chloride resin such as polyvinyl chloride has been mainly used. On the other hand, in recent years, the use of a floor material made of an olefin-based resin instead of the vinyl chloride-based resin floor material has been studied.

[0003]

As the above-mentioned olefin resin, use of an olefin resin mainly composed of polypropylene, an ethylene-vinyl acetate copolymer, or an olefin elastomer has been mainly studied. However, all of these were inferior to vinyl chloride-based resin flooring materials that have been widely used in the past in terms of the occurrence of curl and warpage, workability, workability on floor surfaces, and the like.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and has been developed in view of the occurrence of curl and warpage, workability, workability on floors, etc. An object of the present invention is to provide an olefin-based resin flooring material that is equal to or more excellent than a resin-based flooring material and a method for producing the same.

[0005]

Means for Solving the Problems The olefin resin flooring material of the present invention, which has been made to solve the above problems, comprises polyethylene, ethylene-
It is composed of an olefin resin composition containing at least one ethylene copolymer selected from a vinyl acetate copolymer and an ethylene- (meth) acrylate copolymer and an inorganic filler, at least in the olefin resin composition. It is characterized by being obtained by mixing and mixing two or more kinds of olefin-based resin chips having different melt indexes of polyethylene contained therein, and heating and pressing the chips to form a sheet.

As the above-mentioned polyethylene, low-density polyethylene, ultra-low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, high-density polyethylene and the like can be used. High density polyethylene or a mixture thereof. The low-density polyethylene has a density of about 0.900 to 0.935 g / cm ³ , and the linear low-density polyethylene has a density of 0.880 to 0.9.
Those having about 35 g / cm ³ can be suitably used.

The above-mentioned ethylene copolymers include ethylene-vinyl acetate copolymers, ethylene- (meth) acrylate copolymers, ethylene-based copolymers, and two or more ethylene copolymers selected from these. Mixtures of copolymers can be used.

The above-mentioned ethylene-vinyl acetate copolymer has an ethylene-vinyl acetate copolymer content of 10 to 70% by weight, particularly preferably 15 to 50% by weight, and more preferably 20 to 40% by weight. Coalescing can be suitably used. Of course, the ethylene-vinyl acetate copolymer may be a mixture of two or more ethylene-vinyl acetate copolymers having different vinyl acetate contents and the like.

As the above-mentioned ethylene- (meth) acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl methacrylate copolymer and the like can be used. The ethylene- (meth) acrylate copolymer has a (meth) acrylate content of 10 to 70% by weight, particularly preferably 15 to 50% by weight, and more preferably 20 to 40% by weight. An ethylene- (meth) acrylate copolymer can be suitably used.
Of course, the ethylene- (meth) acrylate copolymer is a mixture of two or more ethylene- (meth) acrylate copolymers having different types of (meth) acrylate and different contents thereof. You may.

If the ethylene copolymer used in the present invention has too low a content of components other than ethylene (vinyl acetate, acrylic ester, methacrylic ester), the obtained flooring material is inferior in flexibility and high. If too much is used, there is a concern that the chemical resistance, water resistance and antifouling properties of the resulting flooring material will be reduced.

In the present invention, the mixing ratio of the above-mentioned polyethylene and ethylene-based copolymer such as ethylene-vinyl acetate copolymer is 20: 80-80: 20 by weight, preferably 40: 60-80: It is desirable to set it to 20. If the mixing ratio of the polyethylene is too high, the workability deteriorates because the flexibility of the obtained flooring material is inferior, and if the mixing ratio of the polyethylene is too low, the obtained flooring material becomes inferior in dimensional stability, and warpage and curl occur. In addition, there is a concern that the generated warpage or curl becomes difficult to recover.

As the inorganic filler, calcium carbonate, aluminum hydroxide, talc and the like can be used, and calcium carbonate is preferred. The amount of the inorganic filler is preferably 50 to 300 parts by weight per 100 parts by weight of the olefin resin (total of polyethylene and ethylene copolymer). If the amount of the inorganic filler is too small, the resulting flooring material has poor dimensional stability,
If the amount is too large, the obtained floor material becomes brittle.

The olefin-based resin composition constituting the olefin-based resin chip may contain, if necessary, an antistatic agent, an antioxidant, a lubricant, a flame retardant, an ultraviolet absorber, a light stabilizer such as a hindered amine compound, an antibacterial agent.・ A fungicide, a deodorant,
Various additives such as a conductive material such as carbon black and metal fiber, and a coloring agent may be added.

The olefin resin composition having the above composition is formed into pellets having a desired size by an extruder or the like, and then molded by a known method such as a method of pulverizing, a calendering method, or an extrusion method. Then, the olefin resin sheet having a desired thickness is formed, and then the olefin resin chip is formed into a desired size by a method such as pulverizing the sheet. The size of the olefin-based resin chip is not particularly limited, but is usually a size such that it passes through a mesh of 30 mmφ but does not pass through a mesh of 0.5 mmφ.

In the present invention, as the above-mentioned olefin resin chip, at least two kinds of olefin resin chips composed of olefin resin compositions having different melt indexes (MI) of polyethylene are used. I do.

In the present invention, the melt index is particularly 0.3 or more and less than 10, particularly preferably 0.5 to 10.
And at least one olefin-based resin chip comprising an olefin-based resin composition containing a polyethylene, an ethylene-based copolymer and an inorganic filler in the range of 5, and a melt index of 10 or more and 50 or less, particularly preferably 15 to 30.
It is desirable to use a mixture of one or more olefin-based resin chips composed of an olefin-based resin composition containing polyethylene, an ethylene-based copolymer, and an inorganic filler in the range described above. At this time, the mixing ratio of the olefin-based resin chip containing polyethylene whose melt index is in the range of 0.3 or more and less than 10 and the olefin-based resin chip containing polyethylene whose melt index is in the range of 10 or more and 50 or less is: Optional, but usually 2
The range is about 0:80 to 80:20. in this way,
By mixing and using two or more types of olefin resin chips containing polyethylene having different melt indices, it is possible to obtain an olefin resin floor material having a smooth surface.

The olefin resin chips mixed in the present invention may be colored in the same color, or may be colored in different colors. Of course, it is not necessary that all the olefin resin chips having the same resin composition have the same color.

A preferred method of producing the olefin resin flooring material of the present invention is a method in which the above-mentioned olefin resin chip is sprayed on a fibrous base material and heated and pressed to form a sheet. . At this time, the fibrous base material may be coated and impregnated with an appropriate adhesive as necessary.

As the fibrous base material used when the olefin resin flooring material of the present invention is produced by the above-mentioned method, those conventionally used as the base material of the flooring material can be used. If a material having almost no elasticity, such as glass fiber nonwoven fabric (glass paper), is used, there is a concern that the resulting floor material may be warped. It is desirable to use a material having properties and elasticity, specifically, a woven fabric (including cold water and the like) or a nonwoven fabric made of organic fibers. Further, the fibrous base material, on one or both surfaces, formed a layer made of a synthetic resin other than the vinyl chloride resin, specifically, an olefin resin, an acrylic resin, a synthetic resin such as a urethane resin. It may be something.

The above organic fibers include cotton, hemp, wool,
Fibers such as natural organic fibers such as silk; synthetic fibers such as polyamide, polyester, polyolefin, and acrylic; regenerated fibers such as rayon; and blended fibers thereof can be used.

The flooring material obtained by the above method has a fibrous base material on the back surface, and is made of an olefin-based resin to be used depending on the adhesiveness at the time of construction and the workability during the manufacturing process. The composition of the chip and the like are not restricted as described below.

On the other hand, the olefin-based resin flooring material of the present invention is formed into a sheet by means other than the above, specifically, by spraying olefin-based resin chips on a releasable carrier and applying heat and pressure. Thereafter, it can also be produced by peeling the release carrier. However, when such a production method is adopted, the mixing ratio of the above polyethylene and ethylene-vinyl acetate copolymer is 50:50 to 80: 2 by weight ratio.
If it is not set to about 0, there is a problem that it is difficult to peel off the release carrier.

In the case where the above steps are taken, the ethylene copolymer contained in at least one of the olefin resin chips to be mixed may contain components other than ethylene (vinyl acetate, acrylate, methacrylate). ) Even when the content is high (specifically, the content of vinyl acetate exceeds 30% by weight) alone, there is a problem that it is difficult to peel off the release carrier. .
However, those having a high content of components other than ethylene have a low content of components other than ethylene (specifically, 30%).
Wt% or less) ethylene-vinyl acetate copolymer,
The above problem can be solved by mixing about 10 parts by weight or more per 100 parts by weight of the ethylene-vinyl acetate copolymer having a high vinyl acetate content.

On the other hand, in the case of the flooring material of the present invention which is manufactured by the above-described manufacturing method and does not have a backing material as described later, the ethylene-based copolymer contained in the olefin-based resin chip is mixed with In all the olefin-based resin chips to be used, if the content of components other than ethylene is only low, the resulting floor material will have inferior adhesiveness, and at least a part of the olefin-based resin It is desirable that the ethylene-based copolymer contained in the resin chip contains a high content of components other than ethylene.

The melt index of polyethylene, the proportion of each component of the ethylene copolymer, the mixing proportion of the polyethylene and the ethylene copolymer, and the inorganic The amount of filler added depends on the properties of the resulting floor material, such as surface smoothness, dimensional stability, adhesiveness during construction, chemical resistance, water resistance, and stain resistance, and workability in the manufacturing process. It is determined not only in consideration of satisfying, but also in consideration of the design of the obtained flooring material (whether it is to be a block pattern or a marble pattern, etc.). In addition, the mixing ratio of each olefin resin chip, the size of the olefin resin chip, etc., have a large effect on the design of the resulting flooring,
If the olefin resin chips with a low melt index of polyethylene contained in the olefin resin chips are mixed at such a ratio that the amount of the olefin resin chips becomes extremely large, the floor material having a smooth surface cannot be obtained. Should also be determined with due consideration.

The flooring material of the present invention obtained as described above may be laminated with a backing material on the back side, if necessary. As a backing material, a foamed or non-foamed synthetic resin sheet made of an olefin resin, a urethane resin, or the like;
Fabrics such as woven fabrics, knitted fabrics, nonwoven fabrics, etc. made of cotton, hemp, polyester, polyamide, polyacrylonitrile, polyolefin, polyvinyl alcohol, rayon, suf, acetate or the like alone or blended fibers thereof; or laminates thereof Can be used.

The flooring material of the present invention obtained as described above can be embossed on its surface, if necessary, and can be used for adjusting gloss, improving surface strength, imparting antifouling properties, etc. Surface treatment (including the formation of a coating film with an ultraviolet-curable paint or the like, the lamination of a transparent film, and the like).

[0028]

EXAMPLES Examples of the present invention will be described below, but the present invention is not limited to the following examples.

[Examples 1 to 6 and Comparative Examples 1 and 2] The olefin resin chip A and the olefin resin chip B having the composition shown in Table 1 were mixed at a ratio of 1: 1. Sprayed on a fibrous substrate (Korean sand). Then, after heating and softening and melting the olefin resin chip,
The floor material was obtained by pressing and pressing with a pair of rolls. The obtained flooring materials were evaluated for surface smoothness and the occurrence of warpage (including curl) according to the following criteria. The results are shown in Table 1.

(1) Surface smoothness ○: Good surface smoothness Δ: Slightly poor surface smoothness ×: Poor surface smoothness (unsuitable as a product) (2) Presence or absence of warpage ○: Warpage occurring Hardly observed △: Slightly warped, but workable area ×: Significant warpage, not possible

Further, Example 1 obtained as described above was used.
FIG. 1 shows a partially enlarged cross-sectional view of the flooring of FIG. 1, and FIG. The reference numeral 1 in FIG.
(A) and (B) are olefin resin chips A, B, 1
2 shows a fibrous base material. Reference numeral 91 in FIG. 2 denotes a doctor knife type tip spraying device, 92 denotes an oven, 9 denotes an oven.
3 indicates a ceramic heater, 94 indicates a roll, and 95 indicates a cooling roll.

[0032]

[Table 1]

[Examples 7 to 12] After mixing the olefin resin chip A and the olefin resin chip B having the composition shown in Table 2 at a ratio of 1: 1, the mixture was placed on a release carrier. Sprayed. Then, after heating to soften and melt the olefin-based resin chip, the chip was pressed and pressed with a pair of rolls, and then the release carrier was peeled off to obtain a floor material. The obtained flooring material is evaluated for surface smoothness and the presence or absence of warpage in the same manner as described above, and the workability during the flooring manufacturing process (easiness of peeling of the releasable carrier) and the floor surface are evaluated. The adhesion was evaluated according to the following criteria. The results are shown in Table 2.

(3) Workability during floor material production process ○: Easy release of release carrier △: Difficult release of release carrier ×: Cannot release release carrier (4) Floor surface Adhesion ○: Good adhesion △: Slightly poor adhesion, difficult to work ×: Poor adhesion, not workable

[0035]

[Table 2]

In Example 9 described above, it was evaluated that peeling of the release carrier was difficult. However, as in Examples 1 to 6, the fibrous base material was used without using the release carrier. In the case where the floor material of the present invention is obtained by directly spraying an olefin-based resin chip thereon and applying heat and pressure thereto, it goes without saying that the olefin-based resin chip of Example 9 has no particular problem. In addition, the above Example 8 is evaluated to be slightly inferior in the adhesiveness. However, if it is manufactured by the manufacturing method as in Examples 1 to 6, or if the backing material is laminated on the back surface, no particular trouble occurs. Absent.

[0037]

As described above, the olefin resin flooring material of the present invention is excellent in surface smoothness because two or more kinds of olefin resin chips containing polyethylene having different melt indices are mixed and used. , And less occurrence of curl and warpage, and good adhesion to the floor surface,
It is also excellent in workability.

[Brief description of the drawings]

FIG. 1 is a partially enlarged cross-sectional view of a floor material according to a first embodiment.

FIG. 2 is a manufacturing process diagram of the flooring material shown in Example 1.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Olefin resin flooring material 11 (A), (B) ... Olefin resin chip 2 ... Fibrous base material

Claims (7)

[Claims] 1. Polyethylene; at least one ethylene-based copolymer selected from ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer and ethylene-methacrylate copolymer; and an inorganic filler. An olefin resin floor material obtained by heating and pressing an olefin resin chip made of an olefin resin composition to form a sheet, wherein the olefin resin chip is at least in the olefin resin composition. An olefin-based resin floor material obtained by mixing two or more types of olefin-based resin chips having different melt indexes of polyethylene contained in the olefin resin. 2. An olefin-based resin chip is a polyethylene having a melt index in a range of 0.3 or more and less than 10; ethylene-vinyl acetate copolymer, ethylene-
An olefin resin chip comprising an olefin resin composition containing at least one ethylene copolymer selected from an acrylate copolymer and an ethylene-methacrylate copolymer; an inorganic filler; and a melt index. Polyethylene in the range of 10 or more and 50 or less; one or more ethylene-based copolymers selected from ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer and ethylene-methacrylate copolymer; inorganic filler The olefin resin flooring according to claim 1, which is mixed with an olefin resin chip made of an olefin resin composition containing an agent. 3. An olefin resin composition constituting an olefin resin chip, comprising 20 to 80% by weight of polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer and ethylene-methacrylate copolymer. Olefin resin 100 comprising 80 to 20% by weight of at least one ethylene copolymer selected from polymers
The olefin-based resin flooring material according to claim 1 or 2, comprising 50 to 300 parts by weight of an inorganic filler per part by weight. 4. The olefin resin flooring according to claim 1, which is obtained by spraying an olefin resin chip on a fibrous base material, and heating and pressing to form a sheet. . 5. Polyethylene; at least one ethylene-based copolymer selected from ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer and ethylene-methacrylate copolymer; and inorganic filler. An olefin-based resin flooring material is formed by spraying an olefin-based resin chip made of an olefin-based resin composition on a fibrous base material and heating and pressing the olefin-based resin chip to form a sheet. The olefin resin chip sprayed on the fibrous base material
A method for producing an olefin-based resin flooring material comprising a mixture of two or more olefin-based resin chips having different melt indices of polyethylene contained in at least the olefin-based resin composition. 6. The method for producing an olefin resin flooring according to claim 5, wherein the fibrous base material is a woven or nonwoven fabric made of organic fibers. 7. The method for producing an olefin resin flooring material according to claim 5, wherein a synthetic resin layer other than a vinyl chloride resin is formed on one or both surfaces of the fibrous base material.