JPH11335980A - Nonhalogen flooring - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a nonhalogen flooring hardly causing bending and swelling after construction, and excellent in dimensional stability by using a resin containing no halogen, and laminating and integrating a surface decorative layer, a fiber layer, a base material layer and a lining layer in order. SOLUTION: This nonhalogen flooring is obtained by laminating a fiber layer, a base material layer and a lining layer under a surface decorative layer in order. The surface decorative layer is obtained by using at least one resin containing no halogen, selected from the group consisting of an ethylene/vinyl acetate resin, an ethylene/ethyl acrylate resin, and an ethylene/methyl (meth) acrylate resin, and adding an assembly of a coarse granular material having 1-10 μm particle diameter and a fine granular material having <=0.5 μm average particle diameter, consisting of a filler such as calcium carbonate and talc. The fiber layer comprises a meshed material obtained by impregnating the resin containing no halogen therein, and the base material layer comprises the resin containing no halogen and having 10-30 melt flow rate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-halogen flooring material which is excellent in dimensional stability, has good workability, has a chip pattern on its surface, and does not use a halogen-based resin such as vinyl chloride resin (PVC).

[0002]

2. Description of the Related Art Floor materials using PVC have been known. However, when a halogen-based resin such as PVC is incinerated after being discarded, generation of hydrochloric acid gas, dioxin, and the like is concerned, and development of a non-halogen-based flooring material that does not use PVC has been desired.

[0003]

For this reason, a flooring material simply using a non-halogen resin instead of PVC has been proposed in, for example, Japanese Patent Application Laid-Open No. 7-195629, but has problems such as warpage and swelling after construction. Was. The object of the present invention is warpage, no swelling after construction, excellent dimensional stability, good workability,
An object of the present invention is to provide a non-halogen flooring material having a chip design on the surface and having a high designability.

[0004]

DISCLOSURE OF THE INVENTION The present invention provides a surface decorative layer comprising a particulate aggregate in which a halogen-free resin having a low melt flow rate (MFR) contains a filler having a coarse particle diameter and a fine filler. The present invention relates to a fiber layer impregnated with a halogen-free resin under a decorative layer, a halogen-free resin base material layer under the fiber layer, and a non-halogen floor material obtained by laminating a backing material under the base material layer.

[0005] Preferred embodiments of the present invention are as follows. (1) The resin constituting the surface decorative layer has an MFR of 0.5 to 5
2. The non-halogen flooring material according to claim 1, wherein (2) The resin constituting the surface decorative layer is EVA, EEA, E
The non-halogen floor material according to claim 1, which is at least one member selected from MA and EMMA. (3) The non-halogen floor material according to claim 1, wherein the resin constituting the base material layer has an MFR in the range of 10 to 30. (4) The resin constituting the base material layer is EVA, EEA, EMA
2. The non-halogen floor material according to claim 1, which is at least one member selected from the group consisting of EMMA and EMMA. (5) The non-halogen flooring material according to claim 1, wherein the average particle size of the fine filler compounded in the surface decorative layer is 0.5 µm or less. (6) The non-halogen floor material according to claim 1, wherein the fiber layer below the surface decorative layer is made of a mesh material. (7) The non-halogen floor material according to claim 1, wherein a wax or an ultraviolet curable resin is applied on the surface decorative layer. (8) The non-halogen floor material according to claim 1, wherein a resin coating is applied to an adhesive surface of the backing material.

In the present invention, the backing material is strongly adhered to a floor substrate such as a concrete slab with a general-purpose floor adhesive by a combination of a fiber layer impregnated with a halogen-free resin in the center of the layer and a nonwoven fabric on the back surface of the floor material. And the fiber layer prevents the elongation of the flooring due to moisture and ironing of the casters, so that there is no swelling after construction, which is a drawback of the conventional non-halogen flooring, and flooring with excellent dimensional stability is obtained. Can be

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The surface decorative layer of the present invention comprises a granular aggregate in which a halogen-free resin having a low melt flow rate (MFR) contains a resin having a coarse particle diameter and a fine filler. Examples of the halogen-free resin include olefin / acrylate resins such as ethylene / vinyl acetate resin (EVA), ethylene / ethyl acrylate resin (EEA), ethylene / methyl acrylate resin (EMA), and ethylene / methyl methacrylate resin (EMMA). Is mentioned. The MFR of these resins is preferably in the range of 0.5 to 5. When the amount of vinyl acetate or acrylate in these resins is in the range of 10 to 30% by weight, a non-halogen floor material having excellent performance can be obtained in combination with the above MFR.

As the filler, a filler having a coarse particle diameter and a fine filler are used in combination. A coarse filler has an average particle diameter of 1 to 10 μm, preferably 1 to 6 μm, and a fine filler has an average particle diameter of 0.5 μm or less, preferably 0.02.
の も の 0.2 μm is used. Examples of the filler include calcium carbonate, talc, clay, barium sulfate, magnesium hydroxide, and aluminum hydroxide. The ratio of the fine filler to the total filler is preferably in the range of 10/90 to 60/40 (fine filler / total filler). The amount of the filler is preferably in the range of 20/80 to 80/20 in the ratio of resin / filler.

A halogen-free resin containing such a filler is kneaded with, for example, a Banbury mixer, rolled with a calender roll, and the obtained sheet is pulverized with a pulverizer, sieved and granulated for a surface layer. A body (chip) is obtained, and the granular body is sprayed on a fibrous layer on a base material and heated and rolled to obtain a surface decorative layer. The particle size of the granular material is preferably about 0.5 to 5 mm, and the thickness of the surface decorative layer is preferably about 0.5 to 5 mm. In this case, a surface layer excellent in design can be obtained by using 2 to 10 types, preferably 3 to 5 types of mixed chips. A sheet obtained by kneading a halogen-free resin containing a filler and rolling by a calender roll can also be used as it is, and in this case, a monochromatic (plain) plain surface layer is obtained. A wax may be applied on the surface layer, or an ultraviolet curable resin may be applied. Examples of the wax include acrylic wax, urethane wax, and carbana wax. Examples of the ultraviolet curable resin include polyester-based, ester-acrylate-based, urethane acrylate-based, and epoxy-based resins.

The surface layer of the present invention has a dense structure in which a fine filler used in combination with a filler having a coarse particle diameter is finely packed between granular materials such as a halogen-free resin and coarse calcium carbonate. The strength is high, the scratch resistance and the abrasion resistance are excellent, and since the MFR is relatively small, pattern design does not occur and excellent design properties can be obtained. In the present invention, a fiber layer impregnated with a halogen-free resin is provided below the surface decorative layer, and a halogen-free resin base material layer is laminated thereunder. Examples of the fiber layer include a nonwoven fabric, a woven fabric, and various mesh materials. The mesh material preferably has a mesh size of about 1 to 10 mm, and is particularly preferable because the decorative layer and the base material layer adhere to each other through the mesh.

Examples of the halogen-free resin for the base layer include olefin / acrylate resins such as EVA, EEA, EMA, and EMMA used for the surface layer, or polyethylene (PE), polypropylene (PP), and atactic polypropylene (APP). ), Olefin-based resins such as amorphous polyolefin (APAO). The MFR of these resins is preferably in the range of 10 to 15. When the amount of vinyl acetate or acrylic acid ester in these resins is in the range of 10 to 40% by weight, a non-halogen floor material having excellent adhesion to the substrate and the surface layer can be obtained in combination with the above MFR. Average particle size 1 to 10 as filler
It is preferable to mix normal-sized calcium carbonate, talc, clay, barium sulfate, magnesium hydroxide, aluminum hydroxide and the like having a size of μm, preferably 1 to 6 μm. The amount of filler is 20/80 to 50/5 in the ratio of resin / filler.
A range of 0 is preferred. From a halogen-free resin containing such a filler, a base layer having a preferable thickness of about 0.5 to 5 mm is obtained by an extruder. At the same time as forming the base material layer, a backing material is bonded to the lower surface and a fiber layer is bonded to the upper surface. Subsequently, the surface layer granules were evenly sprayed on the base material layer, heated to about 100 to 200 ° C. with a heater, and thermocompression-bonded to prepare a preferable non-halogen floor material having a total thickness of about 1 to 10 mm. .

In the base material layer of the present invention, the MFR is large, so that the adhesion between the decorative layer and the base material layer is large, and the lamination through the fiber layer impregnated with the halogen-free resin has dimensional stability,
This has a favorable effect on preventing warpage and swelling. As the backing material under the base material layer, a woven fabric or a nonwoven fabric can be used. As the woven or nonwoven fabric, for example, a woven or nonwoven fabric such as polyester and vinylon is preferable. MF of resin of base material layer
Since R is large, permeability to the backing material is large and excellent adhesive strength can be obtained. It is preferable to apply a coating of an acrylic resin, a urethane resin, an EVA resin, or the like to the floor base adhesive surface of the backing material because the adhesiveness is further improved.

[0013]

The present invention will be specifically described below with reference to examples and comparative examples. Example 1 40 parts of EVA (VA content 20%, MFR 2.5), 40 parts of heavy calcium carbonate (average particle size 1.65 microns), fine calcium carbonate (average particle size 0.08 microns) 20
Parts, 1 part of stearic acid and a predetermined amount of pigment were mixed, kneaded with a Banbury mixer, and rolled with a calender roll to obtain a 0.5 mm sheet. This sheet was pulverized with a pulverizer and sieved through 10 to 40 mesh to obtain surface layer chips. Similarly, several colors of surface layer chips having different colors were prepared. EVA (VA content 20%, MFR15) 40 parts, heavy calcium carbonate (average particle size 1.65 microns) 60
Parts, 1 part of stearic acid and a predetermined amount of pigment were blended, and a 1.0 mm substrate layer was formed by an extruder, and a polyester nonwoven fabric was bonded to the lower surface and a glass net was bonded to the upper surface. Next, a mixture of surface layer chips in four colors was sprayed on the glass net to a thickness of 3 mm, and then heated with a heater and rolled with a roll to make the total thickness 2 mm to prepare a halogen-free floor material.

Example 2 EVA (VA amount 15%, MFR 0.5) was applied to a surface layer chip.
EVA (VA amount 28%, MFR15)
30 parts, 70 parts of heavy calcium carbonate (average particle size: 1.65 microns), non-halogen-based in the same manner as in Example 1 except that a polyester woven fabric was used as a backing material, and an acrylic wax was applied to the surface and dried. Created flooring.

Example 3 EVA (VA amount 20%, MFR 2.5) was applied to a surface layer chip.
20 parts, 65 parts of heavy calcium carbonate (average particle diameter 1.65 microns), 15 parts of fine calcium carbonate (average particle diameter 0.08 microns), EVA (VA amount 20%, MF
R15) 25 parts and low density polyethylene (LDPE) 15
A non-halogen floor material was prepared in the same manner as in Example 2 except that vinylon nonwoven fabric was used for the part and the backing material.

Example 4 EVA (VA amount 20%, MFR 2.5) was applied to a surface layer chip.
60 parts, 20 parts of heavy calcium carbonate (average particle diameter 1.65 microns), 20 parts of fine calcium carbonate (average particle diameter 0.08 microns), EVA (VA amount 20%, MF
R15) 20 parts, atactic polypropylene (AP
P) A non-halogen flooring material was prepared in the same manner as in Example 2 except that 10 parts, 70 parts of heavy calcium carbonate (average particle size: 1.65 microns) and vinylon nonwoven fabric were used as a backing material.

Example 5 EEA (EA content 19%, MFR5) 35 was used for the surface layer chip.
Part, heavy calcium carbonate (average particle size 1.65 microns)
35 parts, 30 parts of fine calcium carbonate (average particle size 0.08 micron), EEA (EA amount 35%, MFR2
5) A non-halogen flooring material was prepared in the same manner as in Example 2, except that 50 parts, 50 parts of heavy calcium carbonate (average particle size: 1.65 microns), and a glass mat impregnated with EVA in the intermediate layer were used. .

Comparative Example 1 A non-halogen floor material was prepared in the same manner as in Example 1 except that fine calcium carbonate was not used for the surface chip. Since fine calcium carbonate was not used, the adhesion between the surface layer and the intermediate layer was low, and swelled immediately.

Comparative Example 2 A non-halogen floor material was prepared in the same manner as in Example 1 except that EVA having an MFR of 2.5 and an MFR of 2.5 was used for the base material layer. Since the MFR of the substrate layer was low, the adhesion to the intermediate layer was poor, and the substrate layer peeled off during use.

Comparative Example 3 A non-halogen floor material was prepared in the same manner as in Example 1 except that the intermediate layer was not used. There was no intermediate layer (fiber layer), the adhesion between the surface layer and the substrate was poor, and the layer swelled during use.

Comparative Example 4 A non-halogen floor material was prepared in the same manner as in Example 1 except that no backing material was used on the back surface of the base material. Since there was no backing material on the back surface of the base material, the adhesion to the base material was poor and the base material immediately peeled off.

The performance was evaluated by the following method. Adhesion between layers: The peel strength between the surface layer and the base material layer of the prepared flooring material was measured by an autograph, and the strength was 1.0 kg / 50 mm.
The above is regarded as non-defective. Adhesion to substrate: After the sample was bonded and fixed to a slate plate with a rubber latex adhesive for flooring, a 90 degree peel strength was determined. A product having a strength of 1.0 kg / 25 mm or more is defined as a good product. Caster test: DIN 54325 Chair Caster
Performed according to Test. Ferrule (iron caster diameter 75m
After applying a load of 60 kg to three wheels (m, 20 mm in width) and conducting a test for 2 hours (about 1000 rotations), the occurrence of swelling was visually confirmed, and the time until the occurrence of swelling was recorded. When no swelling occurred, "no problem" was determined.

[0023]

[Table 1]

[0024]

[Table 2]

[0025]

[Table 3] Evaluation of hydrogen chloride generation during combustion: JIS K72
17 Generation of hydrogen chloride was confirmed based on "Plastic combustion gas analysis method".

[0026]

According to the present invention, it is possible to obtain a non-halogen flooring material which is free from warping and swelling after construction, has excellent dimensional stability, has good workability, and has a chip design on the surface and has a high design property.

 ──────────────────────────────────────────────────続 き Continuation of front page (72) Inventor Toru Funayama 5-125 Higashi-Arioka, Itami-shi, Hyogo Tori Corporation

Claims (1)

[Claims] 1. A surface decorative layer comprising a granular aggregate in which a halogen-free resin having a low melt flow rate (MFR) contains a filler having a coarse particle diameter and a fine filler, and a halogen-free layer beneath the surface decorative layer. A non-halogen floor material comprising a fiber layer impregnated with a resin, a halogen-free resin base material layer under the fiber layer, and a backing material laminated under the base material layer.