JPS60250150A - Long floor laying material and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a plastic elongated floor covering using a glass fiber nonwoven fabric as a reinforcing base material, and a method for manufacturing the same.

1. To Ren W” In recent years, various types of long floor coverings with plastic synthetic resin foam layers have been commercially available, but in order to stabilize their dimensions and shape, these long floor coverings have Its constituent members -
Therefore, it is common practice to use a reinforcing base material.

In order to satisfy the various conditions required for this reinforcing base material, inorganic material fibers are used as a reinforcing base material for long floor coverings that have a plasticsock, that is, a synthetic resin foam layer. Representative materials include asbestos paper and glass fiber nonwoven fabric.

However, these conventionally commonly used reinforcing base materials made of inorganic material fibers do not necessarily satisfy all required conditions, and many problems remain to be solved. The current situation is that

For example, the asbestos powder that separates and scatters during the processing of asbestos paper has a negative impact on the health of workers.
In addition, when it is applied to a floor surface after being processed as a long floor covering material, it has poor beer-up properties, and when removed from the floor surface, asbestos particles remain on the floor surface. There was a problem with that.

On the other hand, although glass fiber nonwoven fabric as a reinforcing base material can largely eliminate the above-mentioned problems with asbestos paper, it has one problem: it is bulky, which is a characteristic of lath a-fiber nonwoven fabric. Because it is porous, when manufacturing long floor coverings using it as a reinforcing base material,
When base trenone is applied to form a plastic foam layer on that surface, most of the base resin penetrates into the pores left between the fibers forming the reinforcing base material. However, it is difficult to form a base resin layer with a uniform thickness on the top surface of the glass fiber nonwoven fabric, and as the consumption of base resin increases, the product It also causes prices to soar.

Furthermore, glass fiber nonwoven fabrics are generally made by cutting glass fibers into predetermined lengths and mixing them with a suitable binder. , thermoplastic and thermosetting synthetic resins are used, but as a reinforcing base material for long floor coverings, in order to satisfy the required condition of f'4 gradient of dimensional and shape stability. In many cases, thermosetting synthetic resins are regularly used as binders, and synthetic resins such as urea-based, phenol-based, and melamine-based resins have been praised as thermosetting synthetic l'j5 resins. is the current situation. As a result, when using glass fiber nonwoven fabric with this type of thermosetting synthetic resin as a binder as a reinforcing base material for long floor coverings, when asbestos paper is used as a reinforcing base material, There are unique problems that do not occur during the manufacturing process of raw rice. That is, this type of glass fiber nonwoven fabric is used as a reinforcing base material, base trenone is applied on the surface thereof to form a synthetic resin foam layer, and in order to foam this applied layer,
When heat-treating the reinforcing base material and the coating layer together,
The thermal decomposition products of the binder contained in the glass fiber nonwoven fabric combine with the foaming agent in the base trenone, promoting the decomposition of the foaming agent, and causing the abnormal foaming phenomenon of the resin foam layer. This causes a problem in that it is difficult to produce a synthetic resin foam layer of uniform thickness.

For example, in the case of a urea resin binder, the formaldehyde remaining in the resin and the formaldehyde produced by thermal decomposition are easily oxidized, resulting in formic acid (Note:
1), and the foaming agent added to the foam layer (for example,
abnormally accelerates the decomposition (Note: 2) of azodicarbonamide) (
Note: 3) This is thought to be based on causing partial foaming or excessive foaming phenomena.

Note: 1) HCOH+02→2HCOOH2) H2N
C0N' NC0N++2→II, NC0NH7+C
O1N-23) (1□NC0N -NC0NI+, +
lIC0011→ll2NCOCOOI+±11. Nc
oll-+4-months → 2Nll++2CO+CO3 Togawa,
-Similarly, it is well known that 7-ether-based and melamine-based binders can promote abnormal foaming in the foam layer, just as in the case of urea-based binders. .

Furthermore, Japanese Patent Publication No. 57-53189 discloses an invention of ``Method for manufacturing a core material for decorative sheets'', in which a large number of pores are formed at predetermined intervals in a thermoplastic resin film, and then the thermoplastic film is was superimposed on both sides of a glass fiber nonwoven fabric, and air was removed from the pores of the glass fiber nonwoven fabric by applying roll pressure while heating. # A core material for a decorative sheet is disclosed, which is characterized in that it is welded to a nonwoven fabric in such a way that a portion of thermoplastic synthetic resin fills on both sides are melted into the pores of the nonwoven fabric, and this core material is Like the invention, it is said to be suitable as a core material for architectural riverbed flooring materials, but 1. In this core material, the thermoplastic synthetic resin film has a large number of pores at predetermined intervals, and the silent plastic synthetic resin is thermally welded to both sides of the glass fiber nonwoven fabric by roll pressure. In contrast, in the present invention, the thermoplastic synthetic 01 resin film is non-porous, and
7α, which is formed by melt-coating a thermoplastic synthetic resin film on both sides of a glass fiber nonwoven fabric by a calendaring method, is fundamentally different in structure and other points. Because, as mentioned above,
During the production of long floor coverings, a chemical reaction takes place with the blowing agent contained in the glass fiber nonwoven fabric.
This is because in this prior art, it is impossible to prevent IF due to the presence of many pores in the thermoplastic synthetic resin film. This is because there is no knowledge whatsoever regarding the existence of such problems that occur during the manufacturing process of materials.

The present invention is a new method that solves the above-mentioned problems in long floor coverings using glass fiber woven fabric as a reinforcing base material. The object of the present invention is to obtain a long bedding material and a method for producing the same. To achieve this objective, basically, a film layer of thermoplastic synthetic resin, for example, soft polyvinyl chloride, is integrally formed on both sides of a glass fiber nonwoven fabric, which is a reinforcing base material, and the -・A foamed layer of synthetic resin, e.g., vinyl chloride, is integrally formed to the desired thickness on the second surface, and a thermoplastic synthetic resin, e.g., a soft polyvinyl chloride film, having the desired thickness is formed on the surface of the second surface. On the other hand, on the other side of the lath i-fiber nonwoven fabric, a fill 11 or sheet of thermoplastic synthetic resin, for example, soft polyvinyl chloride, is bonded as a backing layer. It is characterized by this.

The long floor covering according to the present invention having such a basic structure can be modified by forming various patterns and printed layers such as foaming inhibitors on the back side of the surface layer, or by forming a printed layer of glass fiber non-woven fabric on the back side of the surface layer. If on the other side, a synthetic resin foam layer may be additionally provided between the resin film and the backing layer, or in this variation, a thermoplastic synthetic resin on the second side of the glass fiber nonwoven fabric. There is a film in which the synthetic resin foam layer formed on the upper surface of the film is omitted.

In addition, according to the method of the present invention, the long floor covering material having such a basic structure is manufactured by applying non-foaming heat on both sides of the glass Nll fiber nonwoven fabric as the reinforcing base material in the first step. A film layer of a plastic synthetic resin, for example, soft polyvinyl chloride, is formed by melt coating by a calendaring method, and as a second step, a film layer of a non-foaming thermoplastic synthetic resin is coated on one surface of the non-foaming thermoplastic synthetic resin skin layer. A synthetic resin, for example, a foamable polyvinyl chloride foam layer is formed, and as a third step, packaging and a foaming inhibitor are printed on the top surface of the foamable thermoplastic synthetic resin layer, and as a fourth step, a thermoplastic The surface layer of the synthetic resin film is bonded, and as a fifth step,
On the thermoplastic synthetic resin film layer formed on the other side of the glass fiber nonwoven fabric, a thermoplastic synthetic resin, for example, a soft polyvinyl chloride film or sheet is bonded as a backing layer, and finally, as a sixth step. It can be manufactured by heating such a laminate to foam the foamable thermoplastic synthetic resin layer.

What is important in the present invention is to weld and form a film layer of non-foaming thermoplastic synthetic resin on both sides of the glass fiber nonwoven fabric as a reinforcing base material by a calendaring method. When a synthetic resin foam layer is formed on one side or both sides of the foam layer, components remaining in the binder in the lath WL fiber nonwoven fabric or components generated by thermal decomposition are added to the foam layer. The objective is to effectively prevent abnormal acceleration of the decomposition of the agent and excessive foaming by using a non-foaming thermoplastic synthetic resin film layer on the glass fiber nonwoven fabric.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, the present invention will be explained based on the accompanying drawings showing embodiments of a long floor covering according to the present invention.

First, FIG. 1 is a sectional view showing the structure of a reinforcing base material 1 for a long floor covering according to the present invention. In the figure, 2 is a glass fiber nonwoven fabric that is the main body of the base material 1. , the thickness is 2
5g/I11? ~50 g/m2 is preferred.

Further, 3 and 4 indicate coatings which are film layers of thermoplastic synthetic resin such as soft polyvinyl chloride melt-coated on both sides of the glass fiber nonwoven fabric 2 by a calendering method.

That is, the coatings 3 and 4 are formed by melt-coating molten resin from both sides of the glass fiber non-woven fabric 2, so that the resins are welded to each other in the IJI haze of the glass fiber non-woven fabric 2,
These lath wtlIt nonwoven fabrics 2 and thermoplastic synthetic resin coatings 3 and 4 are integrated to form a strong reinforcing base material 1. In this case, the thermoplastic synthetic resin coatings 3 and 4 contain vinyl chloride, an appropriate amount of plasticizer (for example, 40 to 804"HR), and an appropriate amount of filler,
The thickness is preferably about 0.08 to 0.2, but by appropriately changing the amount of each additive added, a reinforcing base material 1 suitable for the purpose of use can be obtained.

Next, FIGS. 2, 3, and 4 are cross-sectional views showing examples of the structure of the elongated floor covering 10 according to the present invention, which is constructed using the reinforcing base material 1 shown in FIG. It is something.

That is, in these drawings, 5 indicates a synthetic resin foam layer, for example, a vinyl chloride foam is melt coated on one or both sides of the reinforcing base material 1, and has a density of, for example, 0.3 to 1. It is foamed to a diameter of 0.5. Also,
6 is a surface layer bonded to the negative side of the synthetic resin foam layer 5 by thermal lamination, and is made of a transparent thermoplastic synthetic resin, such as soft polyvinyl chloride, for example, 0. The film has a thickness of 15 to 0.3 mm.

Note that, on the upper surface of the foam layer 5, a printing layer 7 such as packaging and foam layer 11 is applied in advance. This printing 7
[7] Conventional long floor covering materials were often applied by transfer printing, but reinforcing base material 1 according to the present invention
By using this method, it can be easily applied by direct printing, and therefore, the manufacturing process can be rationalized and the manufacturing cost can be reduced. Also, 8
indicates a backing layer consisting of a film of thermoplastic synthetic resin, e.g. flexible polyvinyl chloride, in which the flexible polyvinyl chloride is enriched with a filler such as calcium carbonate (e.g. ]oo~2°0PIIR). In addition, the purpose is to heat-laminate the reinforcing base material 1 or the synthetic resin foam layer 5 to improve adhesion to the floor surface, etc., and to facilitate construction work.

In addition, although several examples of the structure of the long floor covering 1o according to the present invention and the manufacturing method thereof have been explained above, the manufacturing method itself is different from the structure of the reinforcing base material and the manufacturing method thereof. These can basically be manufactured by conventionally known methods.

The long bedding material 10 according to the present invention has the above-described structure and is manufactured by the method described above. The effects of the shakubed bedding material and its manufacturing method are as follows.

(1) Since a soft polyvinyl chloride film layer is melt-coated on both sides of the glass fiber non-woven fabric as a reinforcing base material for the long floor covering by a calendaring method, it is not included in the glass fiber non-woven fabric. Completely prevents the chemical reaction between the bonding agent and the synthetic resin foaming agent laminated on the layer.
Ensuring uniform foaming of the foam layer (2) The thermoplastic synthetic resin is welded in the sludge of the base material, the dark blue nonwoven fabric, and remains within the dark blue nonwoven fabric. By filling the gaps, it is effective to prevent bubbles left in the glass fiber nonwoven fabric itself from thermally expanding and causing intralayer delamination. (3) The thermoplastic synthetic resin is made of glass fibers. By covering the non-woven fabric so that it is not exposed, it is possible to prevent glass fiber fragments from scattering, adhering to products or semi-finished products, or causing damage to the mold, ensuring high quality and stability. (4) It has excellent dimensional stability, which is an absolute requirement for long floor coverings. By melt-coating a thermoplastic synthetic resin and using a reinforcing base material in which the lath m-fiber woven fabric and the thermoplastic synthetic resin are integrated, the second scrap part and the lower layer of the reinforcing base material This is due to the fact that the difference in expansion and contraction between the parts is eliminated, and therefore, obstacles such as warping and sagging can be prevented after construction.

(5) Since the layers of the various constituent members that make up the long floor covering material are welded using melt coating or thermal lamination, the interlayer adhesion is strong and does not change over time! (6) The layers of the various constituent members that make up the long floor covering can be opened by melt coating and thermal lamination. Since it is laminated, it can completely block moisture from the floor surface, and since it is made of foam, it has great cushioning and insulation effects, making it a comfortable long floor covering. Ability (7) The manufacturing process is stable and manufacturing costs can be kept low.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of a reinforcing base material used in a long floor covering according to the present invention, and FIGS. 2 to 4 are cross-sectional views showing several embodiments of the long floor covering according to the present invention. It is a diagram. 1. Reinforcing base material, 2. Glass fiber nonwoven fabric, 3.4.
・Thermoplastic synthetic resin coating, 5.・Synthetic resin foam layer, 6
...Surface layer, 7. Printing layer, 8. Backing layer. Patent applicant Nippon Wavelock Co., Ltd. 0 ＼

Claims (1)

[Claims] 1. Both sides of the reinforcing base material are coated with a synthetic resin film,
A synthetic resin foam layer is integrally laminated on one or both surfaces, and a synthetic resin surface layer is integrally formed on the outer surface of the synthetic resin foam layer or on one surface of the synthetic resin coating of the reinforcing base material. A long floor covering material characterized by: 2.4 A synthetic resin backing layer is integrally bonded to the other surface of the synthetic resin coating of the strong base material or one surface of the synthetic resin foam layer according to claim 1. Long floor covering. 3. The elongated floor covering according to claim 1 or 2, wherein the strength base material is a glass fiber nonwoven fabric and the synthetic resin coating is soft polyvinyl chloride. 4. The elongated floor covering according to claim 1, 2 or 3, wherein the synthetic resin foam layer is a vinyl chloride foam layer. 5. The long floor covering according to claim 2, 3 or 4, wherein the surface layer and the backing layer are made of soft polyvinyl chloride. 6. Form a synthetic resin coating layer by melt-coating a thermoplastic synthetic resin on both sides of the reinforcing base material by a calendar method, and integrally laminate a synthetic resin foam layer on one side of this coating layer or on the art dealer, 1. A method for producing a long floor covering, comprising bonding a synthetic resin surface layer or backing layer to the other surface of the synthetic resin foam layer or the other surface of a reinforcing base material by a thermal lamination method. 7. The manufacturing method according to claim 6, wherein the reinforcing base material is a glass fiber nonwoven fabric containing a binder. 8. The manufacturing method according to claim 6 or 7, wherein the synthetic resin coating layer is formed of soft polyvinyl chloride. 9. Claim 6.7 or 8, wherein the synthetic resin foam layer is formed of a foaming agent that chemically reacts with the binder.
Manufacturing method described in section. 10. The manufacturing method according to claim 7, 8 or 9, wherein the surface layer and the backing layer are made of soft polyvinyl chloride.