JPH04293854A - Floor member made of thermo plastic resin having sandgrain-like pattern - Google Patents

Abstract

PURPOSE:To let chips appear clearly while coming up to the surface as well as to enhance solid feeling and artistic design by dispersing, synthetic resin made of a specified grain size in the inside of a sheet made of thermo plastic resin. CONSTITUTION:The sheet 1 made of thermo plastic resin is formed, the transmitting rate of which is equal to or more than 80% for visual light of 55Onm in wave length. And there are provided within the aforesaid sheet a transparent surface layer (a) wherein chips of more than two colors 2-1 through 2-3 which pass through the 16 mesh in grading of a sieve but do not pass the 32 mesh in grading, are dispersed by the rate of 1 to 10%, by weight to the sheet compound, an intermediate color layer (b) and a backing base material layer (c). In addition, 0.1 to 1.0 parts of anti-static agent is blended with 100 parts of resin by weight in the transparent surface layer (a) An abrasion resistant resin layer 3 whose transmitting rate of visual light at 550nm in wave length is equal to or more than 80%, is provided over the transparent surface layer (a).

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a thermoplastic resin flooring material having a sand grain pattern, and more specifically, the present invention relates to a thermoplastic resin flooring material having a sand grain pattern, and more specifically, a three-dimensional and colorful flooring material in which colored chips are dispersed and mixed inside a surface sheet with excellent transparency. The present invention relates to a thermoplastic resin flooring material having a grain pattern.

0002

BACKGROUND OF THE INVENTION Conventionally, flooring materials with a sand grain pattern or a stone grain pattern using chips or flakes as a surface layer have been widely used. However, in recent years, the design of plastic flooring materials has become important, and conventional patterns have already become obsolete.Therefore, there is a method of designing various patterns by back printing on the back of a transparent film. It is being done. Flooring materials that simulate natural materials, such as sand grain patterns and stone grain patterns, are very popular.
Even if this sand grain pattern was printed using the back printing method, it would only be possible to create a two-dimensional pattern, and it would not be possible to express the stone or sand three-dimensionally.

[0003] Conventional thermoplastic resin flooring materials with a sand grain pattern are made by softening and melting thermoplastic resin chips and pressing them to form a surface layer, or by applying vinyl chloride paste to the inside of the flooring material. What has been used is a surface sheet made by dispersing thermoplastic resin chips, coating the base material, heating it, and gelling it.

0004

[Problem to be solved by the invention] These conventional thermoplastic resin flooring materials, which form a surface layer by pressing thermoplastic resin chips and flakes while softening and melting, have a pattern of crushed chips. However, if the surface layer is formed by dispersing chips in vinyl chloride paste, the vinyl chloride paste may be colored or transparent, but the vinyl chloride paste may not be applied. The sheet formed by heating and gelling has poor transparency, so it has poor permeability to the chip, and this is because the finer the chip particles, the blurrier the chip design becomes. It was only possible to express the pattern of the sand by using it as a layer.

[0005] The present invention provides a sand-grain pattern that is more three-dimensional and rich in design than the conventional sand-grain pattern, in which the sand-grain pattern made of fine colored chips can be clearly transmitted through, and also appears to be floating. The purpose is to provide flooring materials with

[0006]

[Means for Solving the Problems] The present invention solves the above-mentioned object, and provides a thermoplastic resin sheet in which the transparency in the thickness direction of the transparent portion is 80% or more in terms of visible light transmittance at a wavelength of 550 nm. , synthetic resin chips colored in any color have a melting temperature higher than the processing temperature of the thermoplastic resin sheet, have a particle size that passes through a 16-mesh sieve, and remain on a 32-mesh sieve. 2
Sand consisting of a transparent surface sheet layer dotted with colors or more, an intermediate colored sheet layer colored in a color corresponding to the color of the colored synthetic resin chip, and a backing base sheet layer provided as the bottom layer. A thermoplastic resin flooring material having a grain pattern is provided.

[0007]

[Example] To explain examples of the present invention based on the drawings, the thermoplastic resin flooring of the present invention is a thermoplastic resin flooring material made of a transparent surface layer a, an intermediate colored layer b, and a backing base layer c. It is something.

The surface transparent layer a can be made of thermoplastic resins commonly used in this type of technical field, including polyvinyl chloride resins, and various compounding agents are added to these resins to form a calender molding method, extrusion method, etc. 0.1-1.0m by molding
The transparent thermoplastic resin sheet 1 is formed into a transparent thermoplastic resin sheet 1 in which synthetic resin colored chips 2 of two or more colors are dispersed and mixed, and its transparency is 550 nm in visible light in the thickness direction of the transparent part of the layer a. As long as it is transparent and has a transmittance of 80% or more at the wavelength, it is not necessarily colorless and may be colored. Examples of the transparent thermoplastic resin sheet include polyvinyl chloride resin, ethylene-vinyl acetate copolymer (EVA), ethylene-acrylate copolymer (EEA), ethylene-methacrylate copolymer (EMA), Other transparent resins such as thermoplastic elastomer (TPE) are not limited to these as long as they are transparent as a sheet, and other resins may also be used. Furthermore, a compounding agent may be added to these as appropriate.

[0009] When the transparent surface layer a is formed into a sheet by calendering, the resins that can be used are limited due to the characteristics of calendering, and moreover, resins with good transparency are limited. Usually, polyvinyl chloride resin alone or a blend of other thermoplastic resins, EVA, E as described above, etc.
EA, EMA, urethane-based TPE, etc. are suitable. Among these, vinyl chloride resins are particularly preferred from the viewpoint of processability and transparency.

[0010] When molding a sheet by extrusion processing, various resins can be used, but the above-mentioned resins are suitable as long as they are transparent and can be extruded at a temperature that does not melt the colored chips.

Furthermore, when the colored chips 2 are mixed with the compound of the transparent surface layer a, kneaded, and rolled, the colored chips become fine particles, and the chips come into contact with each other and become charged with static electricity due to friction, making them easy to aggregate or disperse. Since defects are likely to occur, it is preferable to add an antistatic agent to the colored chip 2. However, since the processing temperature of this colored chip is high, it is difficult to impart antistatic properties, and adding antistatic properties may cause the chip to deteriorate. It becomes expensive. Therefore, 0.1 to 1.0 of an antistatic agent is added to the compound of the soft synthetic resin sheet 1.
By adding 0.3 to 0.6 parts by weight, preferably 0.3 to 0.6 parts by weight, static electricity is not generated from the finely divided colored chips.
Dispersion during mixing and kneading is sufficient, and a transparent layer in which colored chip particles are uniformly dispersed can be obtained.

The colored chips 2 made of synthetic resin are made of a synthetic resin that does not soften or melt the chips during sheet molding of the transparent surface layer a (if it softens or melts, the color may flow to the transparent layer or the chips may be crushed). It is completely compatible with the transparent layer, making it impossible to obtain the desired pattern).
For example, when calendering is performed using polyvinyl chloride resin, the transparent sheet 1 is rolled at 150 to 195°C, so synthetic resins that do not melt or soften at this temperature, such as polyester resins such as PET and PBT, Thermoplastic synthetic resins such as polycarbonate resins and polyamide resins, or crosslinked thermoplastic resins made by chemically crosslinking polyvinyl chloride, can be used, and thermosetting resins can also be used. I don't like things that are brittle and easily chipped. Among these, the above-mentioned thermoplastic resin has a melting temperature 30° higher than the resin processing temperature of the transparent layer.
It is preferable to use a resin that has a temperature of ~80°C and is relatively compatible with the resin of the transparent layer, such as polyvinyl chloride resin, such as the polyester resin, nylon 66, nylon 6, crosslinked polyvinyl chloride, etc. It is more desirable because it softens.

The amount of the colored chips 2 added is 1 to 10% by weight, preferably 3 to 5% by weight, based on the resin compound of the transparent layer a, and if it is less than 1%, the amount of particles distributed in the transparent layer is low. If it is less than 10%, a design that expresses a sand grain pattern cannot be obtained, but if it exceeds 10%, the number of chips increases and a sand grain pattern can be expressed, but the proportion of the transparent part of the transparent layer decreases, and the middle part under the transparent layer a. This is not preferable because the color pattern of the colored layer b becomes invisible, and it becomes impossible to express the colored chip three-dimensionally and improve the design quality by the desired coloring effect with the intermediate colored layer b. In addition, if 10% or more is added, colored chip particles will contact each other and be sheared during calender rolling.
The chip may be damaged and become even finer particles, resulting in a chip of the same color only in that area, or lack of transparency in that area, which is undesirable.

[0014] The colored chip 2 is molded by crushing a colored sheet, and a predetermined coloring agent is mixed with the above synthetic resin by extrusion molding, casting, calendering, or injection molding. For example, thickness 0.1
A sheet of about 0.1 mm in size is molded in multiple colors, and these are crushed using a pulverizer, etc., large chips are removed using a 16 mesh sieve, and small chips are removed using a 32 mesh sieve. Colored chips in the range of .0 mm, 2
Colored chips 2 of a color or higher are mixed and dispersed at an appropriate ratio.

The particle size of the colored chips 2 is thus 1
The particle size that passes through a 6-mesh sieve and remains on a 32-mesh sieve is preferable; 16 mesh is about 1 mm, and 32 mesh is about 0.5 mm, but the diameter of the particles is not necessarily smaller than this 0.5 mm.
It does not mean that it is in the range of mm to 1.0 mm, but also includes elongated type tips that pass through this mesh. In the case of elongated chips, the chips must be dispersed within the transparent layer and must not protrude from the surface of the transparent layer. If the chip is relatively elongated and longer than the thickness of the transparent surface layer, the chip is mixed in in a lying state and does not substantially protrude from the surface of the transparent layer. If the diameter of the chip is larger than the thickness of the transparent surface layer at any part, the chip will be exposed from the surface layer, and the colored chips that are the object of the present invention will be suspended in the transparent surface layer. In addition, during processing, for example, when molding is performed by calendering, the chips are crushed in the gaps between the calender rolls, and chips of the same color become crowded in that area, which is undesirable.

[0016] Therefore, the shape of the chip may be spherical, rod-like, angular or piece-like, but the short axis must be smaller than the thickness of the transparent layer. stomach. Maximum 0 in calender rolling
．． Since a sheet with a thickness of 7 mm can be formed, the short axis of the chip is required to be 0.7 mm or less. When molded by extrusion, it is possible to mold a sheet with a thickness of 0.7 mm or more, but due to problems with the transparency of the sheet in the thickness direction and the grain size of natural sand being 1.5 mm or less, a sand-grain design is required. To express this, the maximum particle size of the chip is 1.5 mm.
Hereinafter, it is preferably 1.0 mm or less. Further, it is preferable that the minimum particle size of the chips is 32 mesh or more, since the shape of the particles can be identified, which is preferable in terms of design, and allows the desired grain pattern to be expressed.

Furthermore, for the coloring of the chips, it is best to mix organic pigments or inorganic pigments into the resin as a coloring agent, and to color them with dyes, or to color them by impregnation after making the chips, which may cause discoloration during calendering or to prevent plasticizers from fading during calendering. This is not preferable because the dye may migrate and impair the transparency of the transparent layer.

Since the surface of the colored chip particles dotted and mixed inside the transparent surface layer a is coated with a resin matrix, the chips do not fall off. If the tip is used, the surface may become abraded and the tip may fall off.
Furthermore, a transparent protective wear-resistant layer 3 may be provided.

This protective wear-resistant layer 3 is made of a curable polyurethane resin, an ultraviolet curable monomer, an oligomer (urethane acrylate, epoxy acrylate, polyester acrylate, etc.) in a thickness of 3 to 50 μm, preferably 5 to 20 μm.
Coat it to a coating thickness of μm. It is usually coated with crosslinked urethane, epoxy, urethane, or acrylic resin cured by ultraviolet light. In any case, it must be transparent.

The intermediate colored layer b is a synthetic resin layer made of thermoplastic resins commonly used in this type of technical field, including vinyl chloride resin, and is made of organic and inorganic pigments such as masterbatches and powders. colored. The colored layer is for highlighting the colored chips 2 scattered on the transparent surface layer a, and the color tone is a color corresponding to or contrasting with the color of the colored chips, or a pale color, for example, blue. If there are many colored chips, the intermediate colored layer will also have a blue color or
Any color may be used as long as it is a base color that accentuates the color of the chip 2, such as a light brown color, and further, printing may be performed on the surface of the colored layer b.

The backing base material layer c is a backing layer commonly used in this type of technical field, and for example, a synthetic resin backing sheet 4 made of a resin such as polyvinyl chloride resin, and a synthetic resin backing sheet 4 made of hemp, polyester fiber, etc. A backing material 5 such as base cloth or paper is laminated, and the synthetic resin backing sheet 4 may be a foam layer or a non-foam layer.

These transparent surface layer a and intermediate colored layer b,
Lamination with the backing base material layer c is performed by first forming the backing base material layer c by calendering, then calender rolling the colored intermediate layer b, and heat-sealing it with the backing base material layer c at the same time as sheeting. Laminate. Next, colored chip 2
The transparent surface layer a mixed with is formed by calendering or extrusion processing, and then laminated onto the surface of the intermediate layer on which the backing base material layer c is laminated to form a laminated structure.

Next, examples according to specific embodiments of the present invention will be described in detail.

(Example 1) (Preparation of colored chips) Polybutylene terephthalate (PBT) with a thickness of 0.1 mm containing each coloring agent.
A resin sheet was created by extrusion molding. These sheets of several colors are crushed by a crusher, passed through a 16-mesh sieve to remove large particles, and then sieved through a 16-mesh sieve to remove large particles.
Remove fine chips with a mesh sieve until the particle size is approximately 0.
Colored chips ranging in size from 1 to 1.0 mm were obtained.

(Sheet Forming) Among these colored chips, three types of chips, white, black, and blue, were blended in a ratio of 1:1:1, and the mixed colored chips were added to the PVC compound shown in Formulation 1. 5% by weight was added, and this compound was heated and melted and mixed using a Banbury mixer, etc., and 19% by weight was added.
Calender rolling was performed at 0 to 195°C to obtain a transparent polyvinyl chloride resin sheet in which colored chips were dispersed and mixed inside the sheet with a thickness of 0.4 mm. The visible light transmittance at a wavelength of 550 nm in the thickness direction of the transparent portion of this sheet was 87%.

Next, the polyvinyl chloride resin containing the blue pigment shown in Formulation 2 was heated and melted using a Banbury mixer, etc., mixed, and calender rolled to a thickness of 0.3 m.
A blue-colored sheet of m was molded and laminated by heating and pressing with a backing base sheet to which a base fabric made of polyester fiber was adhered.

The transparent polyvinyl chloride resin sheet is laminated by heating and pressing on the colored sheet surface of this laminated sheet, and a curable urethane resin treatment liquid is applied onto the transparent layer.
A sand-grained polyvinyl chloride resin flooring material was obtained which was cured to form an abrasion resistant layer and had a transparent layer in which colored chips were dispersed.

(Example 2) (Preparation of colored chips) Vinyl chloride pastes having a degree of polymerization of 1300 and colored in respective colors according to Formulation 3 were prepared. These were applied to release paper to form a PVC crosslinkable sheet with a thickness of 0.1 mm. These were crosslinked at 220° C., pulverized using a pulverizer, passed through a 16 mesh sieve, and the remaining material after passing through a 32 mesh sieve was used as colored chips.

(Formation of sheet) Among these colored chips, three types of chips, white, black, and green, were blended in a ratio of 1:1:2, and methyl acrylate as shown in Formulation 4 was 25%.
Containing ethylene-methacrylic acid ester copolymer (E
MA) Add 3.0% by weight of this mixed colored chip to the resin, blend, and feed L/L from a hopper with a feeder.
The mixture was supplied to a D=25 single screw extruder, and a 0.5 mm thick sheet was formed using a coat hanger die with a shaft of 1200 mm. The temperature of the barrel during molding was 130 to 170°C, and the temperature of the die was 165°C.

550 nm in the thickness direction of this sheet
The visible light transmittance was 83% in terms of wavelength.

The obtained sheet had excellent transparency, and the colored chips in the form of fine particles were uniformly dispersed inside the sheet, and each chip was clearly visible.

An EVA resin having a vinyl acetate content of 15% as shown in Formulation 5 was calender rolled to form a green colored sheet having a thickness of 0.4 mm.

[0033] The EVA resin shown in Formulation 6 was similarly calender rolled to form a sheet, a glass fiber base fabric was pasted on it, the intermediate colored sheet colored green was pasted thereon, and the colored chips mentioned above were further applied on top of this. A thermoplastic resin flooring material with colored chips dispersed therein was formed by pasting together transparent sheets in which colored chips were dispersed.

[0034]

[Table 1]

[0035]

[Table 2]

[0036]

Effects of the Invention According to the present invention, the transparency in the thickness direction of the transparent portion is 80 in terms of visible light transmittance at a wavelength of 550 nm.
% or more of the thermoplastic resin sheet, the melting temperature is higher than the processing temperature of the thermoplastic resin sheet, the particle size is a size that passes through a 16 mesh sieve, and remains on a 32 mesh sieve. a transparent top sheet layer dotted with synthetic resin chips colored in two or more colors, an intermediate colored sheet layer colored in a color corresponding to the color of the colored synthetic resin chips, and a bottom layer provided with By consisting of a backing base sheet layer, there are
Even though the colored chips that are scattered and dispersed have a fine particle size, the outline and color of each chip can be clearly seen, and the color of the intermediate layer underneath can also be clearly seen. As a result, the colored chips appear to be floating and dotted, and it is possible to obtain a flooring material with a sand grain pattern that has a very three-dimensional effect and is excellent in design.

[Brief explanation of drawings]

FIG. 1 is a partially cutaway plan view of the flooring material of the present invention.

[Figure 2] Enlarged sectional view

[Explanation of symbols]

a is a transparent surface layer, b is an intermediate colored layer, and c is a backing base layer 1
is a thermoplastic resin sheet, 2 is a synthetic resin colored chip 2-
1, 2-2, 2-3 are chips with different colors, 3 is a protective wear-resistant layer

Claims (3)

[Claims] Claim 1: Inside a thermoplastic resin sheet molded by calender processing or extrusion processing, the transparency in the thickness direction of the transparent portion is 80% or more in visible light transmittance at a wavelength of 550 nm. The thermoplastic resin has two or more colored synthetic resin chips having a melting temperature higher than the temperature, a particle size that passes through a 16-mesh sieve, and remains on a 32-mesh sieve, and is colored in any color. 1-10% by weight based on sheet compound
A transparent surface sheet layer dotted with a transparent surface sheet layer at a ratio of A thermoplastic resin flooring material with a grain pattern. Claim 2: The transparent surface sheet layer contains 100% of the resin.
The thermoplastic resin flooring material according to claim 1, characterized in that 0.1 to 1.0 parts by weight of an antistatic agent is blended with respect to parts by weight. 3. The thermoplastic resin flooring material according to claim 1, which has an abrasion-resistant resin layer having a visible light transmittance of 80% or more at a wavelength of 550 nm on the transparent surface sheet layer.