JPH0529740B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to durable, non-slip plastic flooring having a substantially smooth surface and stain resistance. Conventional flooring materials with smooth surfaces have been slippery when wet with water or oil, making it dangerous to walk on. Therefore, research has been conducted into flooring materials that have anti-slip properties, but these include, for example, mechanically embossing the surface, embedding small sand or granules only in the surface layer, etc.
Alternatively, flexible or compressible elastic rubber particles were randomly arranged in a matrix. However, a flooring material having an uneven pattern formed by embossing has the drawback that it is easily soiled due to sand, dirt, dust, etc. being buried in the recessed portions. For example, U.S. Pat. No. 3,227,604, U.S. Pat. No. 4,239,797, and U.S. Pat. No. 4,336,293 disclose flooring materials in which small sand and granules are buried or arranged in the surface layer, but these lose their non-slip function when the surface layer is worn away by walking. It has the disadvantage that it disappears and has a short lifespan in areas with heavy walking speed. Further, when using small sand, there is a problem that it damages the calender roll. Additionally, U.S. Pat. No. 3,030,251 describes a sheet-like article in which a large number of discontinuous, non-adhesive, elastic particles are randomly arranged in an essentially continuous, easily deformable, rubbery matrix. However, the granules are not exposed, and the granules have lower abrasion resistance than the matrix layer and are non-adhesive, so they are easily peeled off. Further, U.S. Pat. No. 3,267,187 describes a method for producing a sheet with a woven surface effect by forming a dry blend of thermoplastic resin granules and compressible thermosetting rubber granules into a sheet. The average particle size of rubber particles is as large as 1/16 to 1/4 inch (1.6 to 6.4 mm), and thin, flat chips destroy the weaving effect, so it is said that large clumps are best for rubbery granules. There is. Therefore, this sheet-like material has a very large proportion of rubber granules, and does not exhibit non-slip properties even if the surface is abraded, providing a floor tile material that simply has the effect of being covered with various woven fabrics or pebbles. It is something to do. The present invention solves the above-mentioned drawbacks of conventional flooring materials, and provides a highly durable plastic flooring material with a substantially smooth surface that is resistant to dirt and retains its non-slip function even when the surface is abraded. The purpose is to provide. That is, the present invention uses a polyvinyl chloride resin matrix chip with a particle size of 100 μm to 5 mm, and a synthetic resin chip that has a higher softening temperature than the matrix chip and has better abrasion resistance. It is characterized in that the synthetic resin chips are dispersed throughout the entire layer of the matrix chip layer and a portion is exposed on the surface. The focus is on non-slip flooring. In the present invention, the polyvinyl chloride (abbreviated as PVC) used for the matrix chip is PVC.
Examples include homopolymers and copolymers of vinyl chloride and other monomers such as vinyl acetate, ethylene, propylene, acrylic acid, methacrylic acid, or esters thereof. In this invention, these PVC
Well-known additives such as plasticizers, fillers, heat stabilizers, etc. are appropriately blended into the mixture, and the mixture is processed by known methods such as calendering and extrusion processing at about 150 to 250°C, usually to a size of 0.1 to 5 mm, preferably 0.3 to 3 mm. It is formed into a sheet and passed through a crusher to make chips. In the present invention, PVC matrix chips and synthetic resin chips are mixed and integrated under heat and pressure to obtain the desired non-slip flooring material. The synthetic resin chips of the present invention are also manufactured into chips of approximately the same size by the same method as the PVC matrix chips. The synthetic resin chips are not uniformly compatible with the PVC matrix chip layer, with only the surface of the chips softening slightly during processing.
The chips remain in their original shape and are dispersed throughout the entire thickness of the matrix chip layer, and some of them are exposed on the surface of the matrix chip layer. As such chips, chips made of acrylic resins such as polymethyl methacrylate, polyurethane, nylon resins such as nylon 6 and nylon 66, linear polyesters such as polyethylene terephthalate, and synthetic resins such as ABS resins are preferably used. be done. Furthermore, these chips can be used not only for new materials, but also for example, by crushing plastic waste. These synthetic resin chips must have a softening point higher than the processing temperature of the PVC matrix chip, and the wear resistance of the chips is also greater than that of the matrix chip layer. For example, using a Taber type abrasion tester, a load of 500 g was applied to each wheel axle with S-33 abrasive paper adhered to the surface, and the sample was rotated 1000 times. The amount of wear of each sheet is measured, and the difference is preferably 50 mg or more, and the difference in thickness of wear is preferably 0.01 mm or more. The particle size of the chips is in the range of 100μ to 5mm, particularly preferably in the range of 140μ to 1mm. Chips smaller than 100 μm are too fine to provide non-slip properties to the flooring material when walking on them, and are therefore undesirable. The synthetic resin chips are added in an amount of 3% or more of the total weight of the matrix chips. Although there is no particular upper limit to the amount added, for example, even if it is added in an amount of 30% by weight or more, there is almost no difference in the effect. A backing material such as a foamed or non-foamed plastic sheet, or a woven or nonwoven fabric made of organic or inorganic fibers may be separately laminated on the back side of the obtained flooring material of the present invention. The thickness of the finished floor covering, including the backing material, is usually in the range of about 1 to 10 mm, preferably about 2 to 5 mm. FIG. 1 shows a process diagram for manufacturing the non-slip flooring material of the present invention. The hopper 2 is filled with a mixture of PVC matrix chips and synthetic resin chips in advance.
Chips 3 mixed from a hopper 2 are sprinkled onto the backing material 1 guided through the guide roll 4.
A resin layer 5 of 0.5 to 10 mm is formed, and the thickness is made uniform by a diaphragm 7 equipped with a vibrator 6 under the backing material if necessary.The matrix chips are heated and softened by a heater 8, and rolled into rolling rolls 9, 9'. The lining material and the surface resin layer are integrated by rolling, and a finished product is obtained and wound onto a roll 10. FIGS. 2 and 3 are cross-sectional views of the non-slip flooring material, and 1 is the backing material. In FIG. 2, the synthetic resin chip 12 has a softening point higher than the processing temperature of the matrix chip even if it is heated after being mixed with the matrix chip 11 at the processing temperature of the PVC matrix chip, so only the surface of the synthetic resin chip is processed during processing. The chips soften slightly and do not mix uniformly, and the chip retains its original shape.
Distributed throughout the PVC matrix chip layer,
In addition, a portion of the chip surface is exposed. Further, as mentioned above, since the surface of the chip is slightly softened and then comes into close contact with the PVC matrix chip layer, it is compatible with the matrix chip layer. FIG. 3 shows the state of the flooring shown in FIG. 2 after it has been used for a certain period of time. When the flooring material of the present invention is installed on a subfloor and people actually walk on it, their shoes step on the synthetic resin chips exposed on the surface of the PVC matrix chip layer, which greatly increases the coefficient of friction and prevents continuous slipping. Excellent non-slip properties are exhibited. That is, in the flooring material of the present invention, if the synthetic resin chips 12' have greater wear resistance than the PVC matrix chips 11', the exposed chips 12' will not disappear faster than the matrix 11', and the chips 12' will not disappear faster than the matrix 11'. Since the chips are distributed over the entire thickness of the matrix chip layer, even if the matrix chips 11' gradually wear out, the chips 12' inside the matrix chip layer are exposed one after another, and the non-slip property ensures long-term use of the flooring material. However, nothing changes. In addition, the synthetic resin chips are compatible with the matrix chip layer during processing, and the exposed portions do not peel off when walking. In addition, the surface is virtually smooth, so sand, dirt, dust, etc. do not accumulate.
Not only does it maintain its beautiful appearance for a long time, it also exhibits outstanding non-slip properties even when the flooring gets wet. Furthermore, by appropriately preparing PVC matrix chips and synthetic resin chips in two colors or even more colors, a beautiful mosaic pattern sheet with non-slip properties can be obtained. Note that a sheet with an inlaid pattern can be obtained by feeding the mixture of PVC matrix chips and synthetic resin chips of the present invention to a rotary screen machine provided with openings in a pattern. The present invention will be described below with reference to Examples. Parts indicate parts by weight. Example 1 200 parts of PVC matrix resin with the following formulation was made into chips with a particle size of 0.2 to 0.5 mm, mixed with 10 parts of thermoplastic polyurethane (softening point 200°C) chips (Note 1) of approximately the same size, and made into a hopper. filled with glass fiber, sprinkled on the glass fiber-containing backing material, and then applied to the vibration plate.
It was placed at a thickness of 2.0 mm. PVC (=1000) 100 parts CaCO ₃ 50 parts Stabilizer 2 parts DOP 50 parts Pigment Trace amount (Note 1) The difference in the amount of wear between the PVC matrix chip layer and the sample where the chips were made into sheets was approximately 500 mg, and the difference in the amount of wear due to the wear thickness The difference was 0.12mm. Next, the polyurethane chips were heated with a heater to a surface temperature of 180°C and then rolled with rolling rolls to disperse the polyurethane chips over the entire thickness of the matrix chip layer and to form a non-slip chip with a part of it exposed on the surface. I got the flooring. Example 2 PVC (=1050) 50 parts PVC (=840) 50 parts CaCO ₃ 50 parts Stabilizer 2.5 parts DOP 45 parts Pigment Trace amount Example on 200 parts of PVC matrix chips with a particle size of 0.1 to 0.5 mm having the above composition. Mix 20 parts of the same thermoplastic polyurethane chips (Note 2) as in Example 1 and spread it on a release paper (approximately 0.1 mm) as in Example 1 instead of the backing material.
After forming the sheet, the release paper was removed and two sheets were stacked to form a floor material surface layer, and a polypropylene nonwoven fabric was laminated thereon. A flooring material was obtained in which the urethane chips were dispersed throughout the entire thickness of the matrix chip layer and a portion of the urethane chips were exposed on the surface. (Note 2) The difference in the amount of wear between the polyurethane chip sheet and the PVC matrix chip layer is approximately 500 mg.
The difference in wear thickness was 0.12 mm. Example 3 PVC/vinyl acetate copolymer (Note 3) 100 parts Asbestos 5 parts CaCO ₃ 200 parts Stabilizer 2 parts DOP 40 parts Pigment Trace amount (Note 3) = 800, vinyl acetate content 5% Consisting of the above formulation 350 parts of PVC matrix chips with a particle size of 0.1 to 0.5 mm were mixed with 20 parts of polymethyl methacrylate (PMMA, softening point: 190°C) chips (Note 4) with approximately the same particle size, and heated to 150°C in the same manner as in Example 2.
Heat and press to form a 1.0mm thick sheet.
Laminated with PVC backing material. (Note 4) The difference in wear amount between the PMMA sheet and the PVC matrix resin sheet was approximately 890 mg, and the difference in wear thickness was 0.11 mm. The obtained sheet was punched into a square with a side of approximately 30 cm to obtain a non-slip floor tile in which the PMMA chips were dispersed over the entire thickness of the PVC matrix chip layer and a portion of it was exposed on the surface. . Example 4 PVC (=760) 100 parts CaCO ₃ 40 parts Stabilizer 1.5 parts DOP 50 parts Pigment Trace amount 12 parts of nylon 12 chips (softening point 210℃, Note 5) were added to 200 parts of PVC matrix chips with the above composition. The mixture was heated at 170°C and then rolled to produce a 0.5 mm sheet in the same manner as in Example 2. Four of the sheets were laminated and lined with a 0.02 mm vinylon fabric to form a nylon sheet.
A non-slip flooring material was obtained in which the 12 chips were dispersed over the entire thickness of the matrix chip layer and a portion of the chips were exposed on the surface. (Note 5) The difference in wear amount between the nylon 12 sheet and the PVC matrix chip layer was approximately 430 mg, and the difference in wear thickness was 0.10 mm. Table 1 summarizes the Taber wear amount and wear thickness of the synthetic resin chip sheets of the matrix chip layers of Examples 1 to 4.

[Table] Comparative Examples 1 to 4 Using the compositions of Examples 1 to 4 above except for the synthetic resin chips, flooring materials consisting only of matrix chip layers were prepared in the same manner as in the respective examples and compared. I got the flooring. The flooring materials of Examples 1 to 4 and Comparative Examples 1 to 4 obtained above were examined for non-slip properties when dry and when wet using a stainless steel pendulum according to the method of JIS A1407. The results are shown in Table 2. A three-level evaluation was performed based on the floor slip resistance coefficient (U). A: Hard to slip (U>0.4) B: Slightly hard to slip (U=0.25~0.4) C: Easy to slip (U<0.25)

[Table] The flooring materials obtained in Examples 1 to 4 were definitely improved in non-slip properties as compared to the flooring materials in Comparative Examples 1 to 4, and the abrasion resistance was also improved. Especially Example 1
The floor slip resistance coefficient was U=0.65 or higher. The same non-slip property was observed until the thickness completely disappeared due to wear. In addition, since the surface does not have as obvious an uneven pattern as conventional flooring materials, sand, dirt, and dust do not accumulate on the surface, making it easy to maintain.
Furthermore, a flooring material with non-slip properties and a multicolored mosaic pattern was obtained, doubling the appeal of the product. Comparative Example 5 A mixture of a powder matrix composition of the same composition as the PVC matrix chips of Example 1 and the same polyurethane chips as of Example 1 was mixed with the above blended composition in a Banbury mixer at about 180°C and a mixing roll at 150°C. Knead appropriately with
A non-slip flooring material formed into a sheet and laminated with a pre-made 1.5mm PVC backing sheet, the above granules are dispersed over the entire thickness of the matrix layer, and a part of it is exposed on the surface. I got it. The floor material obtained had a floor slip resistance coefficient of U=0.50, which was lower in non-slip properties than in the example.

[Brief explanation of the drawing]

FIG. 1 is a manufacturing process diagram of the non-slip flooring material of the present invention, FIG. 2 is a cross-sectional view thereof, and FIG. 3 is a cross-sectional view of the state shown in FIG. 2 after it has been used for a certain period of time. 11, 11' are PVC matrix chips, 1
2 and 12' are synthetic resin chips.

Claims (1)

[Claims] 1. Polyvinyl chloride resin matrix chips each having a particle size of 100 μm to 5 mm, and synthetic resin chips having a higher softening temperature and better wear resistance than the matrix chips, with the synthetic resin chips weighing 3 to 30% of the total weight of the matrix chips. A non-slip floor obtained by mixing and integrating the synthetic resin chips so as to have a concentration of 30%, and characterized in that the synthetic resin chips are dispersed throughout the entire layer of the matrix chip layer, and a part of the matrix chip layer is exposed on the surface. Material.