KR100881006B1 - Methods for Manufacturing Sheets for Decorating Floor - Google Patents

Abstract

The present invention relates to a method for efficiently manufacturing a flooring decorative sheet having excellent properties such as cast resistance and impact resistance and not impairing other properties.

Specifically, the present invention has a patterned pattern layer, a transparent adhesive layer, a transparent resin layer, and a transparent surface protective layer on a base sheet in order, and a method for producing a cosmetic sheet for flooring having a backer layer made of synthetic resin on the back of the base sheet. Is about

(1) The transparency resin layer has a thickness of 60 to 250 µm,

(2) the flooring decorative sheet has a thickness of 300 to 580 µm,

(3) The decorative sheet for flooring material has a molten resin in the range of 80 to 250 µm with respect to the back side of the base sheet of the intermediate sheet on which the pattern pattern layer, the transparent adhesive layer, the transparent resin layer, and the transparent surface protective layer are formed. Provided is a method for producing a decorative sheet for flooring material obtained by forming a synthetic resin bucket layer by extrusion molding.

Flooring Sheets

Description

Manufacturing Method for Flooring Sheets {Methods for Manufacturing Sheets for Decorating Floor}

FIG. 1: is a schematic diagram (top view) which shows the shape of a sample, when measuring the tensile elasticity modulus of a sample according to JIS K6734. In the figure, R60 indicates the degree of curvature.

[Patent Document 1] Japanese Patent Laid-Open No. 2003-239517

[Patent Document 2] Japanese Patent Laid-Open No. 2005-290568

The present invention relates to a method for producing a decorative sheet for flooring.

The decorative sheet for flooring material is used for adhering to the substrate surface by adhering to a substrate (for example, a wooden substrate such as plywood) disposed on the bottom surface. Such a floor covering cosmetic sheet is required to have excellent characteristics such as cast resistance and impact resistance in addition to decorative performance. Cast resistance exhibits resistance to loads applied by casters (wheels), such as office chairs, to the surface of the floor covering sheet.

As the flooring decorative sheet, for example, a decorative layer is formed on a base sheet, and a backer layer made of synthetic resin is further provided on the back side of the base sheet, and the flooring decorative sheet expresses characteristics such as caster resistance and impact resistance as a whole. Sheets are known (Japanese Patent Laid-Open No. 2003-239517, etc.). In addition, a bucker layer is a comparatively large synthetic resin layer which not only moderates the influence of surface irregularities, such as a wooden base material, but becomes effective for expression of the said characteristic.

Conventionally, the cosmetic sheet for flooring material having a buckler layer is manufactured by adhering a buckler layer to the back surface of a base sheet by dry lamination or the like. However, in such a manufacturing method, defective products tend to occur at the time of adhesion, and take a long time at the time of adhesion. There is a problem that it is not suitable for mass production.

In view of the above problems, there has been an attempt to produce a floor covering makeup sheet by forming a relatively thick transparent resin layer on a base sheet without forming a buckler layer (Japanese Patent Laid-Open No. 2005-290568, etc.), but a large thickness. In order to laminate the resin layer, the production speed is also limited, and there is room for further improvement in terms of productivity.

In addition to the above, attempts have also been made to form the buker layer by extrusion of the molten resin as a method for producing the flooring decorative sheet for forming the buker layer. However, new problems arise in this manufacturing method. That is, since molten resin is high temperature, high temperature heat | fever is transmitted to the base material sheet side, and the problem that the embossed pattern on the surface of a makeup sheet | seat disappears by heat arises.

Therefore, there is a demand for the development of an efficient manufacturing method of a flooring cosmetic sheet having excellent characteristics such as cast resistance and impact resistance and not impairing other characteristics.

An object of the present invention is to provide an efficient manufacturing method of a flooring decorative sheet having excellent properties such as cast resistance and impact resistance.

MEANS TO SOLVE THE PROBLEM As a result of earnestly researching in order to achieve the said objective, when the inventors made the thickness of the floor covering sheet to a specific range, and laminated | stacked a bucker layer by a specific method, it discovered that the said objective could be achieved. The present invention has been completed.

That is, this invention relates to the manufacturing method of the following cosmetic floor sheets, and the floor cosmetics.

[1] A method for producing a decorative sheet for flooring, comprising a patterned pattern layer, a transparent adhesive layer, a transparent resin layer, and a transparent surface protective layer on the base sheet in order, and having a backer layer made of synthetic resin on the back of the base sheet;

(1) The transparency resin layer has a thickness of 60 to 250 µm,

(2) the flooring decorative sheet has a thickness of 300 to 580 µm,

(3) The decorative sheet for flooring material has a molten resin in the range of 80 to 250 µm with respect to the back side of the base sheet of the intermediate sheet on which the pattern pattern layer, the transparent adhesive layer, the transparent resin layer, and the transparent surface protective layer are formed. It is obtained by forming a synthetic resin bucket layer by extrusion molding.

Method for producing a decorative sheet for flooring.

[2] The production method according to the above [1], wherein at least one of the transparent resin layer and the synthetic resin buker layer contains a thermoplastic resin as the resin component.

[3] The production method according to the above [1] or [2], wherein the transparent resin layer contains polypropylene as a resin component.

[4] The production method according to any one of [1] to [3], wherein the tensile modulus of the transparent resin layer measured in accordance with JIS K6734 is 600 MPa or more.

[5] The production method according to any one of [1] to [4], wherein the tensile modulus of the Bucker layer made of synthetic resin measured in accordance with JIS K6734 is 1000 MPa or more.

[6] The production method according to any one of [1] to [5], wherein the transparent surface protective layer contains an ionizing radiation curable resin as a resin component.

[7] The production method according to any one of [1] to [6], wherein the base sheet contains polyolefin resin as the resin component.

[8] A flooring decorative material formed by laminating a flooring decorative sheet and an adherend manufactured by the production method according to any one of [1] to [7].

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated in detail.

For flooring  How to make a makeup sheet

The present invention relates to a method for producing a decorative sheet for flooring having a pattern pattern layer, a transparent adhesive layer, a transparent resin layer, and a transparent surface protective layer on a base sheet in order, and having a backer layer made of synthetic resin on the back of the base sheet. ,

(1) The transparency resin layer has a thickness of 60 to 250 µm,

(2) the flooring decorative sheet has a thickness of 300 to 580 µm,

(3) The decorative sheet for flooring material has a molten resin in the range of 80 to 250 µm with respect to the back side of the base sheet of the intermediate sheet on which the pattern pattern layer, the transparent adhesive layer, the transparent resin layer, and the transparent surface protective layer are formed. It is obtained by forming the synthetic resin buckler layer by extrusion molding. It is characterized by the above-mentioned.

According to the manufacturing method of this invention which has the said characteristic, although the synthetic resin bucketer layer is formed by extrusion molding of molten resin, the cosmetic sheet for flooring materials can be manufactured, without losing the embossed pattern formed in the cosmetic sheet surface. . In addition, by adopting the conditions of the thickness specified in the above (1) to (3), the flooring decorative sheet has good characteristics such as cast resistance and impact resistance.

In the manufacturing method of this invention, the intermediate sheet | seat in which the pattern-pattern layer, the transparent adhesive bond layer, the transparent resin layer, and the transparent surface protection layer were initially formed on the base material sheet is prepared. Subsequently, a molten resin (molten synthetic resin) is extrusion molded into the range of 80-250 micrometers in thickness with respect to the back surface of the base sheet of an intermediate sheet, and a synthetic resin bucketer layer is formed.

The structure of the intermediate sheet is as follows.

(Base sheet)

Although it is not limited as a base material sheet, The base material sheet containing polyolefin resin as a resin component is preferable. Substantially, the sheet which consists of polyolefin resin is used.

It does not specifically limit as polyolefin resin, What is normally used in the field of a cosmetic sheet can be used. Examples thereof include polyethylene, polypropylene, polybutene, polymethylpentene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-propylene-butene copolymer, polyolefin thermoplastic elastomer, and the like. Can be. Among these, polypropylene, polyolefin thermoplastic elastomer, and the like are particularly preferable.

Homopolymers or copolymers containing polypropylene as a main component are also preferable, and have, for example, a homopolypropylene resin, a random polypropylene resin, a block polypropylene resin, and a polypropylene crystal moiety, wherein α- having 2 to 20 carbon atoms other than propylene. Olefins are mentioned. In addition, a propylene-α-olefin copolymer containing 15 mol% or more of a comonomer of ethylene, butene-1,4-methylpentene-1, hexene-1 or octene-1 is also preferable.

The polyolefin-based thermoplastic elastomer is preferably a mixture of isotactic polypropylene in hard segments and atactic polypropylene in soft segments in a weight ratio of 80:20.

The polyolefin resin can be formed into a film by, for example, a calender method, an inflation method, a T die extrusion method, or the like.

Although the thickness of a base material sheet is not specifically limited, Although it can set according to a product characteristic, it is 40-150 micrometers normally, Preferably it is about 50-100 micrometers.

An additive can also be mix | blended with a base material sheet as needed. Examples of the additive include fillers such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, and coloring agents (see below). The compounding quantity of an additive can be set suitably according to a product characteristic.

A coloring agent is not specifically limited, Well-known coloring agents, such as a pigment and dye, can be used. For example, inorganic pigments, such as titanium white, zinc-ized, iron oxide, orange, ultramarine, cobalt blue, titanium sulfur, lead, carbon black; Organic pigments (including dyes) such as isoindolinone, Hanza yellow A, quinacridone, permanent red 4R, phthalocyanine blue, indanthrene blue RS, and aniline black; Metal pigments such as aluminum and brass; Pearlescent gloss (pearl) pigments composed of thin powder such as titanium dioxide coated mica and basic lead carbonate. In the coloring aspect of a base material sheet, there are transparent coloring and opaque coloring (hiding coloring), These can be selected arbitrarily. For example, when coloring and hiding the background color of a to-be-adhered material (substrate which adheres a cosmetic sheet, for example, a wooden substrate etc.), what is necessary is just to select opaque coloring. On the other hand, when making it possible to visually confirm the bottom pattern of the adherend, transparent coloring may be selected.

Surface treatments such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, and dichromic acid treatment may be applied to one side or both sides of the substrate sheet as necessary. For example, when performing a corona discharge process, the surface tension of the surface of a base material sheet may be 30 dyne or more, Preferably it is 40 dyne or more. What is necessary is just to perform surface treatment in accordance with the conventional method of each treatment.

On one side or both sides of the base sheet, a primer layer (for example, a primer layer for facilitating formation of a back surface primer layer for facilitating adhesion of the buker layer and a pattern pattern layer) may be provided.

The primer layer can be formed by applying a known primer to one side or both sides of the base sheet. Examples of the primer include a urethane resin primer composed of an acrylic modified urethane resin and the like, and a primer agent composed of a urethane-cellulose resin (for example, a resin obtained by adding hexamethylene diisocyanate to a mixture of urethane and vaginal screen). Etc. can be mentioned.

Although the application amount of a primer agent is not specifically limited, Usually, it is 0.1-100 g / m <2>, Preferably it is about 0.1-50 g / m <2>.

Although the thickness of a primer layer is not specifically limited, Usually, it is 0.01-10 micrometers, Preferably it is about 0.1-1 micrometer.

(Pattern pattern layer)

The pattern pattern layer is formed on the base material sheet (opposite the surface which forms a bucket layer).

The patterned pattern layer imparts designability by the desired pattern to the makeup sheet, and the type of the pattern is not particularly limited. For example, a wood grain pattern, a stone grain pattern, a sand grain pattern, a tile adhesive pattern, a brick laminated pattern, a cloth texture pattern, a skin pattern, a geometric figure, a character, a symbol, an abstract pattern etc. are mentioned.

The method for forming the patterned layer is not particularly limited, and for example, a coloring ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) in a solvent (or dispersion medium) together with a binder resin may be used. It can be formed by a printing method or the like.

As a coloring agent, For example, Inorganic pigments, such as carbon black, titanium white, zincation, iron red oxide, a blue tap, cadmium red; Organic pigments such as azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments and dioxazine pigments; Metal powder pigments such as aluminum powder and bronze powder: pearlescent pigments such as titanium oxide coated mica and bismuth oxide chloride; Fluorescent pigments; Luminous pigments and the like. These coloring agents can be used individually or in mixture of 2 or more types. In these coloring agents, fillers such as silica, extender pigments such as organic beads, neutralizing agents, surfactants and the like may be further added.

Examples of the binder resin include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl butyral resins, alkyd resins and petroleum resins. Resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fibrin derivatives, rubber resins and the like. These resin can be used individually or in mixture of 2 or more types.

As a solvent (or a dispersion medium), For example, petroleum organic solvents, such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, methylcyclohexane; Ester organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; Alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol and propylene glycol; Ketone organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone; Ether organic solvents such as diethyl ether, dioxane and tetrahydrofuran; Chlorine organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene and tetrachloroethylene; Inorganic solvents, such as water, etc. are mentioned. These solvents (or dispersion medium) can be used individually or in mixture of 2 or more types.

As a printing method used for formation of a design pattern layer, the gravure printing method, the offset printing method, the screen printing method, the flex printing method, the electrostatic printing method, the inkjet printing method, etc. are mentioned, for example. In addition, in the case of forming a pattern layer on the front solid, for example, a roll coating method, a knife coating method, an air knife coating method, a die coating method, a lip coating method, a commer coating method, a kiss coating method, a flow coating method, Various coating methods, such as the dip coating method, are mentioned. In addition, the method of drawing by hand, ink flow, photographing method, transfer method, laser beam drawing method, electron beam drawing method, partial vapor deposition method such as metal, etching method, etc. may be used, or may be used in combination with other forming methods. .

Although the thickness of a design pattern layer is not specifically limited, Although it can set suitably according to a product characteristic, the layer thickness at the time of coating is about 1-15 micrometers, and the layer thickness after drying is about 0.1-10 micrometers.

(Colored concealment layer)

Between a base material sheet and a patterned pattern layer, you may further form a coloring concealment layer as needed. The colored concealment layer is provided when the background color of the adherend is concealed from the front side of the makeup sheet. When the base sheet is transparent, of course, even when the base sheet is concealed colored, it may be formed to stabilize the concealment.

As ink which forms a colored concealment layer, what can conceal coloring can be used as ink which forms a pattern pattern layer.

As for the formation method of a colored concealment layer, the method which can be formed so that the whole base material sheet may be coat | covered (front solid state) is preferable. For example, the above-mentioned roll coating method, knife coating method, air knife coating method, die coating method, lip coating method, commer coating method, kiss coating method, flow coating method, dip coating method, etc. are mentioned as a preferable thing.

Although the thickness of a colored hiding layer is not specifically limited, Although it can set suitably according to a product characteristic, the layer thickness at the time of coating is about 0.2-10 micrometers, and the layer thickness after drying is about 0.1-5 micrometers.

(Transparent adhesive layer)

The transparent adhesive bond layer is formed on the design pattern layer. The transparent adhesive layer is not particularly limited as long as it is transparent, and includes colorless transparent, colored transparent, translucent and the like. A transparent adhesive bond layer is formed in order to adhere | attach a design pattern layer and a transparent resin layer.

The adhesive is not particularly limited, and an adhesive known in the field of the cosmetic sheet can be used.

As an adhesive known in the field of a cosmetic sheet, thermoplastic resins, such as a polyamide resin, an acrylic resin, and a vinyl acetate resin, a curable resin, such as a thermosetting urethane resin, etc. are mentioned, for example. In addition, a two-component curable polyurethane resin or a polyester resin containing isocyanate as a curing agent can also be applied.

An adhesive bond layer can be formed by apply | coating an adhesive agent on a design pattern layer, for example, after coating the coating agent (adhesive agent) which comprises a transparency resin layer, and drying and hardening. Conditions, such as drying temperature and drying time, are not specifically limited, It can set suitably according to the kind of adhesive agent. The method of applying the adhesive is not particularly limited, and for example, roll coating, curtain flow coating, wire bar coating, reverse coating, gravure coating, gravure reverse coating, air knife coating, kiss coating, blade coating, smooth coating, commer coating, etc. The method of can be adopted.

Although the thickness of an adhesive bond layer is not specifically limited, The thickness after drying is 0.1-30 micrometers, Preferably it is about 1-20 micrometers.

(Transparent resin layer)

The transparent resin layer with a thickness of 60-250 micrometers is formed on the transparent adhesive bond layer. If it is the range of the thickness (preferably 100-250 micrometers, More preferably, it is 150-250 micrometers), the makeup sheet for flooring materials will be easy to ensure the outstanding flaw resistance. As long as transparency resin layer is transparent, colorless transparent, colored transparent, translucent, etc. are all contained.

Although the resin component contained in a transparency resin layer is not limited, It is preferable if it is a thermoplastic resin, Polypropylene is more preferable, Homopolypropylene is still more preferable. It is preferable that the transparency resin layer is substantially formed of the said polypropylene resin.

It is preferable that the tensile elasticity modulus is 600 Mpa or more, and, as for the transparency resin layer, it is more preferable that it is 1000 Mpa or more. The upper limit of the tensile modulus is not particularly limited, but may be about 2000 MPa. In addition, the tensile modulus in this specification refers to the tensile modulus of the sample (for example, the transparent resin layer) in accordance with JIS K6734 "Plastic-Rigid Polyvinyl Chloride Sheet-Dimensions and Properties-Part 2: Sheets Less Than 1mm Thick". Measured value in accordance with The Japanese Industrial Standards (JIS) refer to Japanese Industrial Standards. In detail, when both ends (A and B of FIG. 1) of the sample punched to the shape shown in FIG. 1 were tension | pulled at the speed | rate of 50 mm / min using the tension tester (Tensilon universal testing machine RTC-1250A), Is a value which reads the tensile elasticity modulus (MPa) at the time of breaking at the center part.

The transparent resin layer forms the polypropylene resin by, for example, a calender method, an inflation method, a T die extrusion method, or the like. In addition, a ready-made film can also be used.

The transparency resin layer may contain a weathering agent as needed. As a weathering agent, a ultraviolet absorber, a hindered amine light stabilizer, etc. are preferable, for example. These weathering agents can be used individually or in mixture of 2 or more types. It is preferable to contain a weathering agent especially when a transparency resin layer contains polypropylene.

As a ultraviolet absorber, a benzophenone series ultraviolet absorber, a benzotriazole type ultraviolet absorber, a triazine type ultraviolet absorber, etc. are mentioned, for example. As the light stabilizer, for example, a hindered amine light stabilizer is preferable. Although content of these weathering agents is not limited, Both a ultraviolet absorber and a light stabilizer can be about 1000-10000 weight ppm in a transparency resin layer.

The surface which is the surface of a transparent resin layer and forms the transparent surface protection layer mentioned later can also surface-treat, such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, and dichromic acid treatment as needed. What is necessary is just to perform surface treatment in accordance with the conventional method of each treatment.

In addition, a primer layer (a primer layer for facilitating formation of a surface protective layer) can also be provided on the surface as needed.

The primer layer can be formed by applying a known primer to one side or both sides of the base sheet. Examples of the primer include a urethane resin primer composed of an acrylic modified urethane resin and the like, a resin primer composed of a block copolymer of acryl and urethane, and the like.

Although the application amount of a primer agent is not specifically limited, Usually, it is 0.1-100 g / m <2>, Preferably it is about 0.1-50 g / m <2>.

Although the thickness of a primer layer is not specifically limited, Usually, it is 0.01-10 micrometers, Preferably it is about 0.1-1 micrometer.

(Transparent surface protective layer)

The transparent surface protection layer is formed on the transparency resin layer. The transparent surface protective layer is not limited, but preferably contains an ionizing radiation curable resin or a two-liquid curable urethane resin as the resin component. It is preferable that it is formed from these resin substantially. When forming a transparent surface protection layer by ionizing radiation hardening type resin or two-component hardening type urethane type resin, it is easy to raise abrasion resistance, impact resistance, stain resistance, scratch resistance, weather resistance, etc. of a makeup sheet.

The ionizing radiation curable resin is not particularly limited, and a prepolymer (including oligomer) and / or monomer containing a radically polymerizable double bond capable of polymerizing crosslinking reaction by irradiation of ionizing radiation such as ultraviolet rays or electron beams in a molecule thereof as a main component Transparency resin to make can be used. These prepolymers or monomers may be used alone or in combination. The curing reaction is usually a crosslinking curing reaction.

Specifically, as said prepolymer or monomer, the compound which has radical polymerizable unsaturated groups, such as a (meth) acryloyl group and a (meth) acryloyloxy group, cationically polymerizable functional groups, such as an epoxy group, etc. in a molecule | numerator is mentioned. . Also preferred are polyene / thiol based prepolymers in combination with polyenes and polythiols. Here, a (meth) acryloyl group means acryloyl group or methacryloyl group.

As the prepolymer having a radical polymerizable unsaturated group, for example, polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, triazine (meth) acrylate And silicone (meth) acrylates. As these molecular weights, about 250-100000 are normally preferable.

As a monomer which has a radically polymerizable unsaturated group, methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, phenoxyethyl (meth) acrylate, etc. are mentioned as a monofunctional monomer, for example. As the polyfunctional monomer, for example, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate and trimethylolpropane ethylene oxide tri (meth) Acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate and the like.

As a prepolymer which has a cationically polymerizable functional group, the prepolymer of vinyl-based resin, such as epoxy resin, such as bisphenol-type epoxy resin and a novolak-type epoxy compound, fatty acid-type vinyl ether, and aromatic vinyl ether, is mentioned, for example. Can be. Moreover, as a thiol, polythiol, such as a trimethylol propane trithioglycolate and a pentaerythritol tetrathioglycolate, is mentioned, for example. As polyene, what added allyl alcohol to the both ends of the polyurethane by diol and diisocyanate is mentioned, for example.

As ionizing radiation used for curing the ionizing radiation curable resin, electromagnetic waves or charged particles having energy capable of curing reaction of molecules in the ionizing radiation curable resin (composition) are used. Usually, ultraviolet rays or electron beams can be used, but visible rays, X-rays, ion beams and the like can also be used.

As the ultraviolet light source, for example, a light source such as an ultra high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light, a metal halide lamp, or the like can be used. As wavelength of an ultraviolet-ray, 190-380 nm is preferable normally.

As an electron beam source, various electron beam accelerators, such as a cocroft Walton type, a band graph type | mold, a resonant transformer type | mold, an insulation core transformer type | mold, or a linear type | mold dynatron type | mold and a high frequency type, can be used, for example. Especially, it is especially preferable to be able to irradiate the electron which has an energy of 100-1000 keV, Preferably it is 100-300 keV.

The two-component curable urethane resins are not particularly limited, but among them, polyol components (acryl polyols, polyester polyols, polyether polyols, epoxy polyols, etc.) having OH groups as main agents, and isocyanate components (tolylene diisocyanate, hexa) as hardener components Methylene diisocyanate, metha xylene diisocyanate, etc.) can be used.

If necessary, the surface protective layer may include a colorant such as a weathering agent, a plasticizer, a stabilizer, a filler, a dispersant, a dye, a pigment, a solvent, and the like. The kind and content in the case of containing a weatherproof agent are the same as that of description in a transparency resin layer.

The surface protective layer can be formed by, for example, applying ionizing radiation curable resin or two-component curable urethane resin on a transparent polypropylene resin layer by a known coating method such as gravure coating or roll coating, and then curing the resin. have. In the case of ionizing radiation curable resins, the resin is cured by electron beam irradiation.

Although the thickness of a surface protection layer is not specifically limited, Although it can set suitably according to the characteristic of a final product, it is usually 0.1-50 micrometers, Preferably it is about 1-20 micrometers.

Unevenness may be formed in the front surface (surface exposed to air) of the surface protective layer. Usually, an uneven pattern is formed by embossing. The embossing processing method is not particularly limited, and for example, a method of cooling after heating and softening the front surface of the transparent acrylic resin layer by pressing and shaping with an embossing plate may be mentioned as a preferable method. In the embossing process, a well-known single leaf type or a rotary type embossing machine is used. As the concave-convex shape, for example, wood-coated conduit grooves, slab surface concave-convex (granite cleaved surfaces, etc.), cloth surface textures, checkered patterns, sand grains, hairlines, and bare strips.

In the manufacturing method of this invention, a synthetic resin buckler layer is formed by extrusion molding molten resin in the range of 80-250 micrometers with respect to the back surface of the base sheet of the intermediate sheet mentioned above. By extruding the molten resin within such a range, it is possible to form a synthetic resin backer layer on the back of the base sheet without losing the embossed pattern formed on the intermediate sheet surface.

When forming the said synthetic resin bucket layer by extrusion molding of molten resin, extrusion molding using a T die can be used preferably, for example. In the case where the synthetic resin bucket layer is a multilayer, for example, a multilayer co-extrusion may be performed by using a T die of a multi-manifold type or a feed block type. When making a synthetic resin bucket layer into a multilayer, for example, it is preferable to make the layer closest to the back surface of a base material sheet into a reverse adhesion resin layer. Such improvement can be achieved, for example, by blending a known thermoplastic elastomer into a layer made of an antiadhesive resin layer. The kind of thermoplastic elastomer is not specifically limited, It can select widely from what is high in compatibility with resin which comprises a buckler layer, and can contribute to the adhesive improvement with a base material sheet.

In addition, when the synthetic resin bucketer layer formed by extrusion molding is hard to be in close contact with the back surface of the base sheet only by heat fusion, the adhesive layer may be interposed in order to increase the adhesiveness as necessary. Although the kind of adhesive agent is not limited, The thing described in the column of the said transparent adhesive bond layer can be used. Although the thickness of an adhesive bond layer is not limited, it is about 0.1-30 micrometers. When forming an adhesive bond layer, the thickness of this adhesive bond layer is also included in the thickness of the floor covering decorative sheet.

The synthetic resin forming the buker layer is not limited, but a thermoplastic resin is preferable, and for example, polypropylene, ethylene-vinyl alcohol copolymer, polymethylene, polymethylpentene, polyethylene terephthalate, polybutylene terephthalate, polycar Carbonate, polyarylate, polyethylene naphthalate-isophthalate copolymer, polyimide, polystyrene, polyamide, ABS and the like.

Although the thickness of the synthetic resin bucket layer should just be 80-250 micrometers, about 100-250 micrometers is preferable and 150-250 micrometers is more preferable. Thus, within the range of 80-250 micrometers, it is preferable that it is thick as long as conditions are allowable. In addition, the synthetic resin bucketer layer may be a single layer or a multilayer formed by extrusion molding. Synthetic resin may be single or a mixture.

It is preferable that the tensile elasticity modulus is 1000 Mpa or more, and, as for the Bucker layer made of synthetic resin, it is more preferable that it is 1500 Mpa or more. The upper limit of the tensile modulus is not particularly limited, but may be about 2500 MPa.

The makeup sheet for floor coverings of this invention obtained by forming the synthetic resin buckler layer by the said method requires that thickness is 300-580 micrometers. In addition, the range of this thickness also includes the thickness of arbitrary layers, such as a primer layer.

Floor Cosmetic

By joining the floor covering material sheet of this invention with various to-be-adhered materials, it can be called a floor covering material. The material of the adherend is not particularly limited, and examples thereof include inorganic nonmetals, metals, woods, and plastics.

Specifically, in the inorganic nonmetal type, for example, paper cement, extruded cement, slug cement, ALC (light foamed concrete), GRC (glass fiber reinforced concrete), pulp cement, wood cement, asbestos cement, calcium silicate, gypsum, Non-ceramic ceramic industry materials, such as gypsum slug, ceramic materials, such as earthenware, pottery, porcelain, stoneware, glass, and enamel, etc. are mentioned.

In a metal system, metal materials (metal steel plate), such as iron, aluminum, copper, are mentioned, for example.

In the wood-based system, for example, a single board, plywood, particle board, fiber board, aggregate material, etc., which are made of cedar, fir, oak, larch, teak and the like, may be mentioned.

In plastics, resin materials, such as a polypropylene, ABS resin, and a phenol resin, are mentioned, for example.

The shape of such a to-be-adhered body is not specifically limited, Usually, it can be set as a flat plate in consideration of installation in a flooring etc ..

After joining with the adherend, for example, cutting or sane processing using tenon, provision of a V-shaped roughness, removal of four edges, etc. may be performed depending on the characteristics of the final product.

According to the manufacturing method of this invention, although the synthetic resin buckler layer is formed by extrusion molding of molten resin, the cosmetic sheet for flooring materials can be manufactured, without losing the embossed pattern formed in the cosmetic sheet surface. Moreover, the flooring decorative sheet obtained by employ | adopting the conditions of the thickness prescribed | regulated to said (1)-(3) has favorable characteristics, such as cast resistance and impact resistance.

Best Mode for Carrying Out the Invention

An experimental example is shown below and this invention is demonstrated more concretely.

Reference Example  One, Example  1 to 3 and Comparative example  1 to 4

(Production of the makeup sheet for the flooring material)

The patterned pattern layer (2 micrometers) was printed and formed on the coloring polypropylene (base sheet) of 0.06 mm thickness. Subsequently, a 0.08 mm thick transparent polypropylene resin film (transparent resin layer) was bonded onto the patterned pattern layer using an urethane-based dry laminate adhesive. In addition, the thickness of the transparent adhesive bond layer was 3 micrometers. Subsequently, an electron beam curing type transparent surface protective layer (15 µm) was formed on the transparent resin layer. Subsequently, embossing was performed from the transparent surface protective layer side to prepare an intermediate sheet. In embossing, the wood grain conduit pattern of about 30 micrometers in depth was provided. Finally, a urethane adhesive was applied to the back surface of the intermediate sheet, and the transparent polypropylene resin layer (the synthetic resin bucker layer) of the thickness shown in Table 1 was laminated at the same time as extrusion to prepare a flooring decorative sheet. The resin temperature at the time of melt extrusion was 240 degreeC.

(Production of cosmetics for the floor)

12 mm round plywood was affixed on the back surface (synthetic resin bucker layer side) of the manufactured flooring decorative sheet, and the flooring decorative material was manufactured. The urethane modified ethylene-vinyl acetate emulsion adhesive (9 g per 1 square chuck in wet state) was used for this adhesion | attachment.

(Embossed state)

It was confirmed by visual observation whether the embossed pattern of the manufactured flooring cosmetics disappeared by the heat at the time of lamination of the synthetic resin buckler layer.

It was evaluated that the embossed pattern remained clearly. Most of the embossed pattern remaining was evaluated as ○ to Δ. It was evaluated as Δ-x that the embossed pattern almost disappeared. The embossed pattern completely lost was evaluated as x. The evaluation results are written together in Table 1.

(Dupont impact test)

The impact resistance of the manufactured floor covering material was evaluated using the DuPont impact tester (based on JIS K5600-5-3). Specifically, the weight of the prescribed weight was dropped on the surface of the cosmetic material from the height of 30 cm, and the amount of depression was evaluated by measuring. The test results are listed in Table 1.

(My caster examination)

The caster resistance of the produced flooring decorative material was evaluated using the caster test apparatus L6-04 (manufactured by Asano Kikai Seisaku Co., Ltd.). Specifically, the caster was moved on the flooring decorative material, and then visually observed to measure the depth of the recessed portion formed in the flooring decorative material with a depth meter. The test results are listed in Table 1.

<< specification of my caster test apparatus >>

Sample holder: 80 mm diameter, 8 mm thick acrylic

Three casters: 420SA-N75 (φ 75mm * 25mm, wheel nylon product) made by Hanma caster

Rotational speed of caster stand: 0 to 60 rpm (variable motor drive)

Load part: adjustable from 40 to 210 kg

Adjustment handle: The caster moves up and down by turning the weight handle

Rotation direction reversal interval: 1 to 12 minutes (settable by timer)

Presetting counter: displays the setting of the rotational speed and the cumulative rotational speed

Digital tachometer: displays the caster rotation speed

Sample size: 30 cm x 30 cm

<< my caster test condition >>

The flooring decorative material to be tested in the caster test apparatus was fixed to the sample holder. After the caster holder was raised by the adjustment handle so that the three casters did not contact the surface of the flooring decorative material, a load was loaded on the load table so as to weigh 70 kg. The speed of rotation was set at a speed of 20 rpm, half a revolution every 5 minutes, and 1000 revolutions, and the caster was turned down on the surface of the flooring decorative material to be tested by turning the adjusting handle. The start switch of the rotary drive of the caster holder was turned on and the test was started. After completion of the test, the adjustment handle was turned to raise the caster holder to take out and evaluate the flooring decorative material to be tested.

(Pencil hardness test)

The pencil hardness of the produced flooring decorative material was performed using the pencil hardness tester. The test was conducted in accordance with JIS K5600-5-4, except that the tester was set to apply a load of 1000 g to the tip of the pencil when the tester was in the horizontal position. The test results are listed in Table 1.

Clemens Scratch Test

The Clemens scratch test was done about the produced flooring decorative material. Specifically, the test was conducted in accordance with JIS K5600-5-5. As a scratch needle, a diamond thing was used for the surface of the cosmetic material. Test results (maximum load without whitening: g) are listed in Table 1.

(Review)

From Table 1, it can be seen that the loss of the embossed pattern occurs remarkably when the thickness of the synthetic resin buker layer is 300 µm or more.

Comparative example  5 to 9

A flooring decorative material was produced in the same manner as in Comparative Example 3 except that the thickness of the buker layer was fixed to 300 µm and the thickness of the transparent resin layer was set to the thickness shown in Table 2 below.

It was confirmed by visual observation whether the embossed pattern of the manufactured floor covering material disappeared by the heat at the time of lamination of the synthetic resin buckler layer. Evaluation method and evaluation criteria are as above. Test results are listed in Table 2.

(Review)

From Table 2, when the thickness of the synthetic resin bucketer layer is 300 micrometers or more, it turns out that disappearance of an embossed pattern arises irrespective of the thickness of a transparent resin layer.

Example  4 to 6 and Comparative example  10 to 11

A flooring decorative material was produced in the same manner as in Comparative Example 1 except that the thickness of the buker layer was fixed to 80 µm and the thickness of the transparent resin layer was set to the thickness shown in Table 3 below. In addition, the embossed state, DuPont impact characteristic, caster resistance, pencil hardness, and Clemens scratch characteristic were evaluated by the same method as the above. Table 3 shows the test results.

(Review)

From Table 3, when the thickness of the synthetic resin bucketer layer is constant, it turns out that scratch resistance improves, so that the thickness of a transparent resin layer increases. In addition, the impact test characteristic is considered to be a factor of the total thickness of a makeup sheet, and it turns out that a required characteristic is met when the total thickness is 300 micrometers or more.

Example  7 to 11 and Comparative example  12

A flooring decorative material was produced in the same manner as in Example 4 except that the thickness of the transparent resin layer was fixed at 150 µm and the thickness of the synthetic resin bucketer layer was set to the thickness shown in Table 4 below. In addition, the embossed state, the DuPont impact characteristic, the caster resistance, the pencil hardness, and the Clemens scratch characteristic were evaluated by the same method as the above. Test results are listed in Table 4.

(Review)

It is understood from Table 4 that the impact characteristics and the caster resistance characteristics are insufficient when the thickness of the synthetic resin bucketer layer is 60 µm.

According to the manufacturing method of this invention which has the said characteristic, although the synthetic resin bucketer layer is formed by extrusion molding of molten resin, the cosmetic sheet for flooring materials can be manufactured, without losing the embossed pattern formed in the cosmetic sheet surface. . Moreover, by employ | adopting the conditions of the thickness prescribed | regulated to (1)-(3) described in this specification, the flooring decorative sheet has favorable characteristics, such as cast resistance and impact resistance.

Claims (8)

It is a manufacturing method of the flooring decorative sheet which has a pattern pattern layer, a transparent adhesive bond layer, a transparent resin layer, and a transparent surface protection layer in order on a base material sheet, and has a backer layer made of synthetic resin on the back of a base material sheet, (1) The transparency resin layer has a thickness of 60 to 250 µm, (2) the flooring decorative sheet has a thickness of 300 to 580 µm, (3) The decorative sheet for flooring material has a molten resin in the range of 80 to 250 µm with respect to the back side of the base sheet of the intermediate sheet on which the pattern pattern layer, the transparent adhesive layer, the transparent resin layer, and the transparent surface protective layer are formed. It is obtained by forming a synthetic resin bucket layer by extrusion molding. Method for producing a decorative sheet for flooring. The method for producing a makeup sheet for flooring according to claim 1, wherein at least one of the transparent resin layer and the synthetic resin buker layer contains a thermoplastic resin as the resin component. The manufacturing method of the cosmetic sheet for floor coverings of Claim 1 or 2 characterized by the transparent resin layer containing polypropylene as a resin component. The manufacturing method of the decorative sheet for floors of Claim 1 or 2 whose tensile elasticity modulus of the transparent resin layer measured according to JIS K6734 is 600 Mpa or more. The manufacturing method of the cosmetic sheet | seat for flooring materials of Claim 1 or 2 whose tensile elasticity modulus of the synthetic resin buckler layer measured according to JIS K6734 is 1000 Mpa or more. The manufacturing method of the floor covering cosmetic sheet of Claim 1 or 2 characterized by the transparent surface protection layer containing an ionizing radiation curable resin as a resin component. The manufacturing method of the floor covering cosmetic sheet of Claim 1 or 2 characterized by the base sheet containing polyolefin resin as a resin component. The flooring decorative material formed by laminating | stacking the flooring decorative sheet manufactured by the manufacturing method of Claim 1 or 2, and a to-be-adhered material.

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