CN1754692A - Decorative board for flooring with excellent impact resistance and scratch resistance - Google Patents

Abstract

The present invention provides a decorative board for flooring materials that exhibits excellent impact resistance and excellent scratch resistance even when an underlayment layer is not formed. Specifically, the present invention provides a decorative board for floor materials, in which a pattern layer, a transparent adhesive layer, a transparent polypropylene resin layer, and a transparent surface protection layer composed of ionizing radiation curable resin or two-component curable urethane resin, characterized in that: (1) the thickness of the transparent polypropylene resin layer is 150 μm or more; (2) the transparency The universal hardness of the polypropylene resin layer is 35N/mm2 ^or more; (3) the universal hardness of the transparent surface protection layer is 100N/mm2 ^or more.

Description

Decorative board for flooring with excellent impact resistance and scratch resistance

technical field

The present invention relates to a decorative board for flooring materials excellent in impact resistance and scratch resistance.

Background technique

Currently, polyvinyl chloride resin boards are often used as constituent materials of decorative boards for flooring materials made of resin. When using a polyvinyl chloride resin board, by adjusting the amount of plasticizer added, the hardness (hard to soft) of the board can be easily adjusted, and there is also an advantage that embossing and embossing can be easily performed.

However, polyvinyl chloride resin emits harmful graphite, chlorine gas, and the like when burned. Therefore, in recent years, polyolefin resins that do not emit chlorine gas have been gradually used instead of polyvinyl chloride resins.

As a floor decorative board using a polyolefin resin, for example, Japanese Patent Laid-Open No. 8-13740 and Japanese Patent Laid-Open No. 8-1883 disclose that a backing layer formed of a polyolefin resin On one side, the printed pattern layer and the bottom printing plate are sequentially laminated on one side, and then the transparent plate made of ionomer resin is laminated on the printed plate, and the backing layer/printing layer/transparent plate is laminated at the same time. Decorative panels for flooring made of 3 layers. The floor decorative material is formed by bonding the backing layer of the decorative board for floor materials to various materials to be bonded. In addition, the underlayment layer is a reinforcement layer provided in order to impart hardness, strength, etc. to the decorative board for flooring materials.

The decorative board for flooring materials having an underlayment layer tends to exhibit predetermined hardness, strength, etc., and exhibits excellent impact resistance.

However, a decorative board for flooring materials having an underlayment layer requires a process of adhering the underlayment layer part to other parts (for example, printed boards) during the production process, and product defects are likely to occur in this process. (product loss) problem.

Therefore, it is desired to develop a decorative board for flooring materials that has predetermined hardness, strength, etc., and exhibits excellent impact resistance without forming an underlayment layer.

In addition to excellent impact resistance, further improvement in scratch resistance (scratch resistance) is now required. This is because, in the existing plywood floor materials, scratches and dents caused by tenon processing, groove processing, etc. can be almost eliminated by sanding (sanding), and the bonding of the decorative board on the bonded board is formed. Sanding cannot be carried out on the floor material, therefore, the flaws generated on the surface (decorative surface) due to processing etc. will become the flaws of the final product.

Contents of the invention

A main object of the present invention is to provide a decorative board for flooring materials that exhibits excellent impact resistance and excellent scratch resistance without forming an underlayment layer.

The inventors of the present invention conducted intensive studies to achieve the above object, and as a result, found that the above object can be achieved by forming a specific polypropylene-based resin and a surface protective layer, thereby completing the present invention.

That is, the present invention relates to the following decorative board for flooring materials having excellent impact resistance and scratch resistance, and a decorative board for floors using the decorative board.

1. A decorative board for floor materials, wherein a pattern layer, a transparent adhesive layer, a transparent polypropylene resin layer, and a resin layer cured by ionizing radiation are sequentially formed on a substrate board made of polyolefin resin. A transparent surface protective layer composed of type resin or two-component curing type urethane resin, characterized in that:

(1) The thickness of the transparent polypropylene resin layer is 150 μm or more,

(2) The universal hardness of the transparent polypropylene resin layer is 35N/ ^mm2 or more,

(3) The universal hardness of the transparent surface protection layer is 100 N/mm ² or more.

2. A decorative board for floor materials, wherein a pattern layer, a transparent adhesive layer, a transparent polypropylene resin layer, and a resin layer cured by ionizing radiation are sequentially formed on a substrate board made of polyolefin resin. A transparent surface protective layer composed of type resin or two-component curing type urethane resin, characterized in that:

(1) The transparent polypropylene resin layer consists of two layers, the upper polypropylene resin layer and the lower polypropylene resin layer,

(2) The thickness of the upper polypropylene resin layer is 100 μm or more,

(3) The universal hardness of the upper polypropylene resin layer is above 35N/ ^mm2 ,

(4) The thickness of the lower polypropylene resin layer is 50 μm or more,

(5) The universal hardness of the lower polypropylene resin layer is above 20N/ ^mm2 ,

(6) The universal hardness of the transparent surface protection layer is 100 N/mm ² or more.

3. The decorative board for flooring materials according to the above 2, wherein the thickness of the upper polypropylene resin layer is 100 to 300 μm.

4. The decorative sheet for flooring according to any one of 1 to 3 above, wherein a colored concealing layer is further formed between the base sheet and the design pattern layer.

5. The decorative board for flooring according to any one of 1 to 4 above, wherein irregularities are formed on the main surface of the transparent surface protection layer.

6. A decorative material for flooring, wherein the base plate side of the decorative sheet for flooring material according to any one of 1 to 5 above is bonded to an adherend.

Description of drawings

FIG. 1 is a schematic diagram of a decorative material for floors produced in Example 1. FIG.

FIG. 2 is a schematic diagram of a decorative material for floors produced in Example 3. FIG.

Symbol Description

1 transparent surface protection layer; 2 transparent polypropylene resin layer (the upper polypropylene layer in Figure 2); 3 pattern pattern layer and transparent adhesive layer; 4 substrate plate; 5 adhesive layer; 6 lauan plywood; 7 lower polypropylene layer.

Detailed ways

Hereinafter, the decorative board for floor materials and the decorative material for floors of this invention are demonstrated in detail.

Decorative boards for flooring

In the decorative sheet for flooring materials of the present invention, a pattern layer, a transparent adhesive layer, a transparent polypropylene resin layer, and a resin layer cured by ionizing radiation are sequentially formed on a substrate sheet made of polyolefin resin. A decorative board for flooring materials composed of a transparent surface protection layer composed of type resin or two-component curing type urethane resin, characterized in that:

(1) The thickness of the transparent polypropylene resin layer is 150 μm or more,

(2) The universal hardness of the transparent polypropylene resin layer is 35N/ ^mm2 or more,

(3) The universal hardness of the transparent surface protection layer is 100 N/mm ² or more.

(substrate board)

A plate made of polypropylene resin was used as the base plate. Usually, a film made of polypropylene resin may be used.

The polypropylene-based resin is not particularly limited, and those generally used in the field of decorative boards can be used. For example, polyethylene, polypropylene, polybutene, polymethylpentene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-propylene-butene copolymer , polyolefin thermoplastic elastomers, etc. Among them, polypropylene, polyolefin-based thermoplastic elastomer, and the like are particularly preferable.

Homopolymers or copolymers mainly composed of polypropylene are also preferable, for example, homopolypropylene resins, random polypropylene resins, block polypropylene resins, and polypropylene crystals containing carbon atoms other than propylene. α-alkenes with numbers 2-20. In addition, propylene-α-olefin copolymers containing 15 mol% or more of comonomers of ethylene, 1-butene, 4-methyl-1-pentene, 1-hexene, or 1-octene are also preferred. .

Polyolefin-based thermoplastic elastomers are blocks that use highly crystalline and high-melting aromatic polyester for the hard segment and amorphous polyether with a glass transition temperature of -70°C or lower for the soft segment. polymer. Particularly preferably, a hard segment composed of isotactic polypropylene and a soft segment composed of atactic polypropylene are mixed at a weight ratio of 80:20.

The polyolefin-based resin may be formed into a film by a calendering method, an expansion method, or a T-die extrusion method.

The thickness of the base plate is not particularly limited, and can be set according to product characteristics, and is usually 40-150 μm, preferably about 50-100 μm.

Additives may be blended in the base plate as needed. Examples of additives include fillers such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, slip agents, foaming agents, colorants (see below), and the like. The mixing amount of additives can be appropriately set according to product characteristics.

The coloring agent is not particularly limited, and known coloring agents such as pigments and dyes can be used. For example, titanium white, zinc white, ferric oxide, cinnabar (vermilion), ultramarine blue, cobalt blue (cobalt blue), titanium yellow, chrome yellow, carbon black and other inorganic pigments; isoindolinone (isoindolinone), Hansa yellow-A, quinacridone, permanent red 4R, phthalocyanine blue, Indanthrene blue RS, aniline black, etc. Organic pigments (including dyes); aluminum, brass and other metal pigments: titanium dioxide covered mica, basic lead carbonate and other pearl luster (pearl) pigments composed of foil powder, etc. There are transparent coloring and opaque coloring (covert coloring) as the coloring method of the base plate, and it can be selected arbitrarily. For example, when hiding the base color of the material to be adhered (the substrate to which the decorative material is bonded), opaque coloring may be selected. On the other hand, if you want to see the bottom pattern of the bonded material with the naked eye, you can choose transparent coloring.

Surface treatments such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, and dichromic acid treatment may be performed on one or both surfaces of the base plate as required. For example, when corona discharge treatment is performed, the surface tension of the base plate surface may be 30 dyne or more, preferably 40 dyne or more. The surface treatment may be carried out in accordance with conventional methods for various treatments.

On one side or both sides of the base plate, a bottom layer (for example, an inner bottom layer to facilitate the bonding of the adhered materials; a bottom layer to easily form a pattern layer) can also be provided as required. By providing an underlayer, the interlayer adhesive force with an adjacent layer (for example, to-be-adhered material) can be improved.

The underlayer can be formed by applying a known primer to one or both surfaces of the substrate sheet. As the primer, for example, a urethane-based primer composed of an acrylic-modified urethane resin, a urethane-cellulose resin (for example, in urethane and nitrocellulose) A primer composed of a resin composed of hexamethylene diisocyanate) is added to the mixture.

The coating amount of the primer is not particularly limited, but is usually about 0.1 to 100 g/m ² , preferably about 0.1 to 50 g/m ² .

The thickness of the undercoat layer is not particularly limited, but is usually about 0.01 to 10 μm, preferably about 0.1 to 1 μm.

(pattern pattern layer)

A patterned layer is formed on the base plate (the surface opposite to the bonding surface of the material to be bonded, which is referred to as the same side in the following layers).

The design pattern layer is provided with a decorative property by imparting a desired design to the decorative sheet, and the type of the design is not particularly limited. For example, wood grain patterns, stone grain patterns, sand grain patterns, tiling patterns, brick patterns, cloth grain patterns, leather patterns, geometric figures, characters, symbols, abstract patterns, etc. are mentioned.

The method for forming the pattern pattern layer is not particularly limited, for example, using a known coloring agent (dye or pigment) and a binder resin dissolved (or dispersed) in a solvent (or dispersion medium) to obtain colored ink, coating agent, It may be formed by a printing method.

Examples of colorants include inorganic pigments such as carbon black, titanium white, zinc white, ferric oxide, prussian blue, and cadmium red; azo pigments, lake dyes, anthraquinone ( Organic pigments such as anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments; metal powder pigments such as aluminum powder and bronze powder ; Titanium oxide covered mica, bismuth oxychloride and other pearl luster pigments; fluorescent pigments; luminous pigments, etc. These colorants may be used alone or in combination of two or more. Fillers such as silica, extender pigments such as plexiglass beads (organic beads), neutralizers, surfactants, and the like may be added to these colorants.

Examples of binder resins include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl alcohol Butyral resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluororesins, silicone resins, cellulose derivatives, rubber resins, etc. These resins may be used alone or in combination of two or more.

As the solvent (or dispersant), for example, petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, Butyl acetate, 2-methoxyethyl acetate, 2-ethoxyethyl acetate and other ester organic solvents; Methanol, ethanol, n-propanol, isopropanol, isobutanol, ethylene glycol, propylene glycol Alcohol organic solvents; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and other ketone organic solvents; diethyl ether, dioxane, tetrahydrofuran and other ether organic solvents; dichloromethane, carbon tetrachloride, three Chlorine organic solvents such as vinyl chloride and tetrachloroethylene; inorganic solvents such as water, etc. These solvents (or dispersants) may be used alone or in combination of two or more.

The printing method for forming the pattern layer includes, for example, gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, inkjet printing and the like. In addition, the method of forming a pattern layer on the entire surface includes, for example, a roll coating method, a knife coating method, an air knife coating method, a filter coating method (tie coat), a knife coating method, and a spot coating method ( commacoat method), kiss coat method, flow coat, tip coat and other coating methods. In addition, hand drawing, flowing ink, photocopying, laser beam drawing, electron beam drawing, partial vapor deposition of metal, etc., etching, etc., or in combination with other forming methods may be used.

The thickness of the design pattern layer is not particularly limited, and can be appropriately set according to product characteristics. The thickness of the layer during coating is about 1-15 μm, and the thickness of the layer after drying is about 0.1-10 μm.

(shading hidden layer)

Between the base plate and the design pattern layer, a coloring concealment layer may be further formed if necessary. When it is desired to hide the base color of the layer to be bonded from the main surface of the decorative board, a colored concealing layer is provided. Regardless of whether the substrate sheet is transparent or the substrate sheet is concealed and colored, a colored concealing layer may be formed in order to stabilize concealment.

As the ink for forming the colored concealing layer, an ink that forms a patterned pattern layer and can conceal coloring can be used.

The method of forming the colored concealing layer is preferably a method of forming the entire substrate sheet (over the entire surface). For example, preferably, the above-mentioned roll coating method, knife coating method, air knife coating method, die coating method, knife coating method, spot coating method (comma coat method), kiss coating method (kiss coating method) can be mentioned. coat method), flow coating method (flow coat), oblique coating method (tip coat), etc.

The thickness of the colored masking layer is not particularly limited, and can be appropriately set according to product characteristics. The thickness of the layer when applied is about 0.2 to 10 μm, and the thickness of the layer after drying is about 0.1 to 5 μm.

(transparent adhesive layer)

A transparent adhesive layer is formed on the design pattern layer. The transparent adhesive layer is not particularly limited as long as it has transparency, and may be any of colorless and transparent, colored and transparent, and translucent. The adhesive layer is formed to bond the design pattern layer and the transparent polypropylene resin layer.

The adhesive layer is not particularly limited, and a well-known adhesive in the field of decorative panels can be used.

Examples of the adhesive known in the field of decorative panels include thermoplastic resins such as polyamide resins, acrylic resins, and vinyl acetate resins, cured resins such as thermosetting urethane resins, and the like. In addition, a two-component curing type polyurethane resin or polyester resin using isocyanate as a curing agent can also be applied.

The adhesive layer is, for example, coated with a transparent polypropylene resin layer (upper polypropylene layer or lower polypropylene layer described later) by applying an adhesive agent on the design pattern layer. After the resin is dried and cured, it is formed. Conditions such as drying temperature and drying time are not particularly limited, and can be appropriately set according to the type of adhesive. The coating method of the adhesive is not particularly limited, for example, roll coating, curtain flow coating (curtain flow coater), bar coating (wire bar coater), spin coating, gravure coating can be used. , gravure spin coating, air knife coating, kiss coater, blade coater, smooth coater, comma coat method and other methods.

The thickness of the adhesive layer is not particularly limited, but the thickness after drying is about 0.1 to 30 μm, preferably about 1 to 20 μm.

(transparent polypropylene resin layer)

A transparent polypropylene-based resin layer (individual layer) is formed on the transparent adhesive layer. The thickness of the transparent polypropylene resin layer is 150 μm or more, and the general hardness is 35 N/mm ² or more. By forming such a transparent polypropylene-based resin layer, it is possible to impart scratch resistance performance in a high-load area to the decorative board for flooring materials.

Here, the so-called "high scratch resistance performance in the high-load area" means that when the surface of the decorative board is scratched with a high load (referring to a large load per unit area), it is difficult to form scratches, indentations, etc. . The degree of scratch resistance performance in the high-load area can be evaluated by, for example, the pencil hardness test (JIS K 5600-5-4), the Kremen test, and the like.

The general-purpose hardness in this specification is the hardness measured with FISCHERSCOPE H100V (manufactured by FISCHER INSTRUMENT Co., Ltd.), which is useful for hardness measurement of film coating, elastic materials, etc. The hardness measurement performed by this FISCHERSCOPE H100V is a so-called Ultra-micro Vickers Hardness (Ultra-micro Vickers Hardness) test method. Specifically, the indenter is pressed into the surface of the sample (for example, a transparent polypropylene-based resin layer), and the depth of the depression is directly read in a state where a load is applied to measure the hardness of the sample. The measured value (universal hardness) is specified as follows (refer to ISO Technical Report). The indenter uses a diamond indenter (Φ0.4mm ball indenter), and measures the indentation depth under the test load. The universal hardness is represented by a ratio obtained by dividing the test load by the surface area of the indentation formed under the test load.

General hardness (N/mm ² )＝F/S

F: test load (N)

S: surface area of ball indenter (Φ0.4mm) under test load (mm ² )

The thickness of the transparent polypropylene resin layer is required to be 150 μm or more, preferably 300 μm or more, more preferably 400 μm or more.

The universal hardness of the transparent polypropylene resin layer is required to be 35 N/mm ² or higher, preferably 40 N/mm ² or higher.

For the transparent polypropylene resin layer, a transparent polypropylene resin layer can be laminated on the transparent adhesive layer by, for example, a calendering method, an expansion method, or a T-die extrusion method, or an already formed film can be used.

The transparent polypropylene-based resin layer is a single layer (one layer) as described above, but may be multilayered (two or more layers) as necessary. For example, by forming a transparent polypropylene-based resin layer with a two-layer structure of an upper polypropylene layer and a lower polypropylene layer as described below, it is possible to impart scratch resistance in a high-load area to a decorative board for flooring materials and scratch resistance in the low-load area described below.

Next, the case where the transparent polypropylene resin layer has a two-layer structure will be described.

A. Upper polypropylene layer

The upper polypropylene layer is formed for scratch resistance, especially in high load areas.

The thickness of the upper polypropylene layer is required to be at least 100 μm, preferably about 100 to 300 μm, particularly preferably about 250 μm.

The universal hardness of the upper polypropylene layer is required to be above 35N/ ^mm2 , preferably above 40N/ ^mm2 .

B. Lower polypropylene layer

The lower polypropylene layer is formed for scratch resistance, especially in the low load area. Here, "high scratch resistance in a low-load area" means that when the surface of the decorative board is scratched with a low load (meaning a small load per unit area), it is difficult to form scratches, indentations, and the like. The degree of scratch resistance in the low-load area can be evaluated by, for example, Hoffman's scratch test.

The method for forming the lower polypropylene layer may be the same as the method for forming the transparent polypropylene-based resin layer described above. The upper layer and the lower layer may also be formed by simultaneous extrusion as required.

The thickness of the lower polypropylene layer is required to be 50 μm or more, preferably 100 μm or more. The upper limit of the lower polypropylene layer is not limited, but is usually around 200 μm.

The universal hardness of the lower polypropylene layer is required to be below 20N/mm ² , preferably below 15N/mm ² .

By forming such a lower polypropylene layer in addition to the upper polypropylene layer, it is possible to impart scratch resistance performance in a low-load area to the decorative sheet for flooring materials.

When a transparent surface protective layer described below is formed on the surface of the upper polypropylene layer, surface treatments such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, and dichromic acid treatment may be performed as necessary. The surface treatment may be carried out in accordance with common methods for each treatment.

In addition, if necessary, a primer (a primer to facilitate the formation of a surface protective layer) may be provided on the surface.

The primer layer can be formed by applying a known primer to one or both sides of the substrate sheet. Examples of the primer include urethane-based primers composed of acrylic-modified urethane resins, primers composed of copolymers of acrylic acid and urethane, and the like.

The coating amount of the primer is not particularly limited, but is usually about 0.1 to 100 g/m ² , preferably about 0.1 to 50 g/m ² .

The thickness of the undercoat layer is not particularly limited, but is usually about 0.01 to 10 μm, preferably about 0.1 to 1 μm.

(transparency surface protection layer)

A transparent surface protection layer made of ionizing radiation curable resin or two-component curable urethane is formed on the transparent polypropylene resin layer. By forming a transparent surface protection layer made of ionizing radiation curable resin or two-component curable urethane, the abrasion resistance, impact resistance, stain resistance, scratch resistance, and weather resistance of the decorative board can be improved wait.

The ionizing radiation-curable resin is not particularly limited, and prepolymers (including oligomers) and/or A transparent resin whose main component is a monomer. These prepolymers or monomers may be used alone or in combination of multiple types. The curing reaction generally refers to a crosslinking curing reaction.

Specifically, examples of the above-mentioned prepolymers or monomers include radically polymerizable unsaturated groups such as (meth)acryloyl groups and (meth)acryloyloxy groups in the molecule, cationic polymerizable groups such as epoxy groups, etc. Compounds with functional groups. In addition, a polyene/polythiol-based prepolymer that is a combination of a polyene and a polythiol is also preferred. Here, (meth)acryloyl means acryloyl or methacryloyl.

Examples of the prepolymer containing a radically polymerizable unsaturated group include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, base) acrylate, triazine (meth)acrylate, silicon (meth)acrylate, etc. These molecular weights are usually preferably about 250 to 100,000.

As a monomer containing a radically polymerizable unsaturated group, for example, as a monofunctional monomer, meth (meth)acrylate, 2-ethylhexyl (meth)acrylate, phenoxyethyl ( Meth)acrylate, etc. In addition, examples of polyfunctional monomers include diethylene glycol di(meth)acrylate, propylene glycol (meth)acrylate, trimethylolpropane tri(meth)acrylate, trimethylolpropane Ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and the like.

Examples of prepolymers containing cationic polymerizable functional groups include epoxy resins such as bisphenol epoxy resins and novolac epoxy compounds, and prepolymers of vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Polymer. In addition, examples of polythiols include polythiols such as trimethylol propane tri-thioglycolate and pentaerythritol tetrathioglycolate. As a polyene, the thing produced|generated from diol and diisocyanate, and allyl alcohol was added to both ends of polyurethane is mentioned, for example.

As ionizing radiation for curing the ionizing radiation-curable resin, electromagnetic waves or charged particles having energy capable of causing a curing reaction of molecules in the ionizing radiation-curable resin (composition) are used. Ultraviolet rays or electron beams are usually used, but visible light, X-rays, ion rays, 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 lamp, a black light, or a metal halide lamp can be used. The ultraviolet wavelength is usually preferably 190 to 380 nm.

As the electron beam source, for example, Cockcroft-Walton type, Van de Graaff type, resonant transformer type, insulating core transformer type, or linear type, Dina Various electron beam accelerators such as Dynamitron type and high frequency type. Among them, an accelerator capable of irradiating an electron beam having an energy of 100 to 1000 keV, preferably 100 to 300 keV, is particularly preferable.

The two-component curable urethane resin is not particularly limited, and among them, polyol components (acrylic polyol, polyester polyol, polyether polyol, epoxy polyol) containing OH groups as main components can be used. Polyol compounds, etc.), substances containing isocyanate components (toluene diisocyanate, hexamethylene diisocyanate, metaxylene diisocyanate, etc.) as curing agent components.

These surface protective layers may contain plasticizers, stabilizers, fillers, dispersants, coloring agents such as dyes and pigments, solvents, and the like as necessary.

The surface protective layer can be coated with an ionizing radiation curable resin or a two-component curable urethane resin on the transparent polypropylene resin layer by a known coating method such as gravure printing or roll coating. After the cloth, the cured resin is formed. Ionizing radiation-curable resins are cured by irradiating electron beams.

The thickness of the surface protective layer is not particularly limited, and can be appropriately set according to the characteristics of the final product, but is usually 0.1 to 50 μm, preferably about 1 to 20 μm.

The hardness of the surface protective layer is 100 N/mm ² or more, preferably 150 N/mm ² or more in the aforementioned general hardness. When the general hardness of the surface protection layer is less than 100 N/mm ² , there is a problem that the scratch resistance performance cannot be sufficiently exhibited. In addition, the overall general hardness of the decorative board including the surface protection layer is preferably 45 N/mm ² or more, more preferably 50 N/mm ² or more.

Concavity and convexity may be formed on the main surface (surface exposed to the atmosphere) of the surface protection layer. The concave and convex pattern is usually formed by embossing. The method of embossing is not particularly limited. For example, a preferred method includes heating and softening the main surface of the transparent acrylic resin layer, pressing and shaping it with a relief plate, and then cooling it. Known blade type or rotary wheel type embossing machines are used in relief processing. Concave-convex shapes include, for example, wood-grained board conduit grooves, stone slab surface irregularities (granite fault planes, etc.), cloth surface textures, pear skin grains, sand grains, hairlines, and million-line grooves.

Decorative materials for floors

The decorative board for floor materials of this invention becomes a decorative material for floors by joining with various to-be-adhered materials. The material of the material to be bonded is not particularly limited, and examples thereof include materials such as inorganic nonmetals, metals, wood, and plastics.

Concretely, inorganic non-metallics include, for example, manufactured cement, extruded cement, slag cement, ALC (light air cell concrete), GRC (glass fiber reinforced concrete), slurry cement, wood chip cement, asbestos cement, Calcium silicate, gypsum, gypsum slag and other non-ceramic firing materials, earthenware, pottery, porcelain, stoneware, glass, enamel and other ceramic materials, etc.

Examples of metals include metal materials (metal steel sheets) such as iron, aluminum, and copper.

Examples of wooden materials include veneers, plywood, particle boards, fiberboards, and laminates made of cryptomeria, hinoki, oak, lauan, teak, and the like.

Examples of plastics include resin materials such as polypropylene, ABS resin, and phenol resin.

The shape of these to-be-adhered bodies is not particularly limited, and it is generally sufficient to make flat plates in consideration of placement on floor materials.

After bonding with the material to be bonded, for example, according to the characteristics of the final product, it is also possible to use a cutting and tenoner to process the tongue, give a V-shaped groove, and perform chamfering on the four sides.

The decorative board for flooring materials of the present invention exhibits excellent impact resistance and also excellent scratch resistance without forming an underlayment layer.

In addition, since there is no need to form an underlayment layer, the manufacturing process of the decorative panel for flooring materials is facilitated, and manufacturing defects that have occurred in the conventional underlayment layer formation process can be eliminated.

Examples are given below to illustrate the present invention in more detail.

Example 1

(Manufacture of decorative panels for floor materials)

Printing was performed on a colored polypropylene film (substrate plate) with a thickness of 0.06 mm to form a pattern layer.

Next, a transparent polypropylene resin film having a thickness of 0.3 mm (300 μm) divided into two parts with a hardness was bonded with a urethane dry lamination adhesive to form a transparent polypropylene resin layer.

Next, an electron beam-curable transparent surface protection layer (15 μm) having a universal hardness of 170 N/mm ² was formed on the transparent polypropylene resin layer.

Next, embossing was performed from the side of the transparent surface protection layer to produce a decorative board for flooring materials.

(Manufacturing of decorative materials for floors)

A 12 mm Lauanplywood (Lauanplywood) was bonded to the base plate side of the decorative board for floor materials to produce a decorative material for floors. As the adhesive, a urethane-modified ethylene-vinyl acetate emulsion adhesive (100 g/m ² wet) was used.

(Scratch resistance performance of floor decoration materials)

The scratch resistance performance of the prepared floor decoration material was evaluated. The following pencil hardness test and Clemen test are used to evaluate the scratch resistance performance in the high load area. In addition, Hoffman's scratch test is used to evaluate the scratch resistance performance in the low load area. Each test method is as follows.

1. Pencil hardness test (high load evaluation)

Test with a pencil hardness tester. When the testing machine is in a horizontal position, it is set so that the pen point of the pencil applies a load of 1000 g to the decorative board. In addition, tests are performed in accordance with JIS K 5600-5-4.

2. Hoffman scratch test (low load evaluation)

The test was carried out with a Hoffman scratch tester manufactured by BYK-GARDNER, USA. Specifically, a scratching blade (a cylindrical blade of Φ7 mm) was set so as to contact the surface of the decorative material at an angle of 45°, and the testing machine was moved on the decorative material. Gradually increase the load (hammer), and repeat the test until scratches, indentations, etc. occur on the surface of the decorative material.

3. Klemen test (high load evaluation)

Tested in accordance with JIS K 5600-5-5. As the needles for scratching the surface of the decorative material, diamond needles were used.

Their test results are shown in Table 1 below.

Table 1 HU of PP layer 15 20 25 30 35 40 45 HU for decorative panels 25 30 35 40 45 50 55 Pencil hardness ^*1 6B 4B 3B 2B HB HB HB Hoffman Scratch ^*2 400 400 400 400 400 400 400 Clementine ^*3 70 80 80 80 90 90 90

HU: Universal Hardness (N/mm ² ) PP: Polypropylene

^* 1: Hardness that does not cause whitening or dents

^* 2: Maximum load without whitening (g)

^* 3: These units are also the same for the maximum load (g) that does not cause whitening.

Example 2

The general hardness of the transparent polypropylene resin layer was fixed at 40N/mm ² , and the thickness was divided into two parts. Others were the same as in Example 1 to produce a floor decoration material.

The scratch resistance of the prepared floor decoration materials was evaluated. The evaluation results are shown in Table 2 below.

Table 2 PP layer thickness (μm) 60 80 100 150 300 400 500 pencil hardness 3B 3B 2B HB HB HB HB

Example 3

(Manufacture of decorative panels for floor materials)

Printing was performed on a colored polypropylene film (substrate plate) with a thickness of 0.06 mm to form a pattern layer.

Next, a co-extruded film (2-layer structure: film thickness 0.3 mm) of an upper layer polypropylene layer with a universal hardness of 40 N/ ^mm2 and a lower layer polypropylene layer with a hardness of 0.15 mm in two parts was coated with urethane Adhesive bonding for dry lamination.

Next, an electron beam-curable transparent surface protection layer (15 μm) having a universal hardness of 170 N/mm ² was formed on the upper polypropylene layer.

Next, embossing was performed from the side of the transparent surface protection layer to produce a decorative board for flooring materials.

(Manufacturing of decorative materials for floors)

A 12 mm Lauanplywood (Lauanplywood) was bonded to the base plate side of the decorative board for floor materials to produce a decorative material for floors. As the adhesive, a urethane-modified ethylene-vinyl acetate emulsion adhesive (100 g/m ² wet) was used.

(Scratch resistance performance of floor decoration materials)

The scratch resistance performance (pencil hardness, Hoffmann scratch, Klemen's scratch) of the prepared floor decoration material was evaluated. The evaluation results are shown in Table 3 below.

table 3 HU in the upper PP layer 40 HU of the lower PP layer 15 20 30 35 40 Hoffman Scratch 600 600 400 400 400 pencil hardness HB HB HB HB HB Clementine 90 90 90 90 90

Example 4

The HU of the upper polypropylene layer is fixed at 40N/ ^mm2 , and the HU of the lower polypropylene layer is fixed at 15N/ ^mm2 , and co-extrusion is carried out so that the total film thickness of the upper layer/lower layer is 0.3mm. , Others are identical with embodiment 3, make floor decoration material.

(Scratch resistance performance of floor decoration materials)

The scratch resistance performance (pencil hardness, Hoffmann scratch, Klemen's scratch) of the prepared floor decoration material was evaluated. The evaluation results are shown in Table 4 below.

Table 4 The thickness of the upper PP layer 300 280 250 200 150 100 100 The thickness of the lower PP layer 0 20 50 100 150 200 50 Hoffman Scratch 400 400 600 600 600 800 700 pencil hardness HB HB HB HB HB B B Clementine 90 90 90 90 90 80 80

At the end of Table 4, the evaluation results when the thickness of the upper PP layer is 100 μm and the thickness of the lower PP layer is 50 μm are collectively shown. The evaluation results showed that even when the thickness of the upper PP layer was 100 μm and the thickness of the lower PP layer was 50 μm, it was highly useful as a decorative material for floors.

Example 5

The lower polypropylene layer is fixed at HU: 15N/mm ² , thickness 50μm; the thickness of the upper polypropylene layer (HU: 40N/mm ² ) is divided into two parts for co-extrusion, except for sheeting, the others are the same as those in the examples 3 is the same, making floor decoration materials.

(Scratch resistance performance of floor decoration materials)

The scratch resistance performance (pencil hardness, Hoffmann scratch, Klemen's scratch) of the prepared floor decoration material was evaluated. The evaluation results are shown in Table 5 below.

table 5 The thickness of the upper PP layer 250 350 450 The thickness of the lower PP layer 50 50 50 Hoffman Scratch 600 500 500 pencil hardness HB HB HB Clementine 90 90 90

(Shock resistance of floor decoration materials)

The impact resistance of the decorative materials (three types) described in Table 5 was evaluated with a DuPont impact tester (in accordance with JIS K 5600-5-3). Specifically, the evaluation was performed by dropping a hammer of a predetermined weight onto the surface of the decorative material from a height of 30 cm to measure dents. The evaluation results are shown in Table 6 below.

Table 6 The thickness of the upper PP layer 250 350 450 The thickness of the lower PP layer 50 50 50 DuPont dent amount: μm 350 300 250

In addition, the conventional floor material with a backer has a dent amount of about 250 μm measured by the same impact test, and it can be seen that it has almost the same impact resistance as the floor decorative material of the present invention. The existing plywood floor material has a hard surface and is difficult to cushion impacts, so the coating film is easily cracked, and the amount of dents is about 400 μm.

Example 6

Examples 1 to 5 were carried out by replacing the electron beam-curable transparent surface protective layer with a transparent surface protective layer composed of a two-component curable urethane resin.

Each evaluation result was at the same level as the results shown in Tables 1 to 6. It can be seen that the same effect is obtained regardless of whether the surface protective layer is composed of an electron beam curable resin or a two-component curable urethane resin.

Claims (6)

1. floor material decorative board; on the backing material plate that constitutes by the polyalkenes hydrocarbon resins; be formed with design pattern layer, transparent bond layer, transparent polypropylene-based resin layer successively, reach the transparent sealer that constitutes by ionizing radiation gel-type resin or two solution curing type carbamate resinoids, wherein:

(1) thickness of transparent polypropylene-based resin layer is more than 150 μ m;

(2) universal hardness of transparent polypropylene-based resin layer is at 35N/mm ²More than;

(3) universal hardness of transparent sealer is at 100N/mm ²More than.

2. floor material decorative board; on the backing material plate that constitutes by the polyalkenes hydrocarbon resins; be formed with design pattern layer, transparent bond layer, transparent polypropylene-based resin layer successively, reach the transparent sealer that constitutes by ionizing radiation gel-type resin or two solution curing type carbamate resinoids, wherein:

(1) transparent polypropylene-based resin layer is made of for 2 layers upper strata acrylic resin layer and lower floor's acrylic resin layer;

(2) thickness of upper strata acrylic resin layer is more than the 100 μ m;

(3) universal hardness of upper strata acrylic resin layer is 35N/mm ²More than;

(4) thickness of lower floor's acrylic resin layer is more than the 50 μ m;

(5) universal hardness of lower floor's acrylic resin layer is 20N/mm ²More than;

(6) universal hardness of transparent sealer is 100N/mm ²More than.

3. floor material decorative board as claimed in claim 2 is characterized in that, the thickness of upper strata acrylic resin layer is 100～300 μ m.

4. as each described floor material decorative board in claim 1 or 2, it is characterized in that, between backing material plate and design pattern layer, also be formed with painted hidden layer.

5. as each described floor material decorative board in claim 1 or 2, it is characterized in that, on the interarea of transparent sealer, be formed with concavo-convex.

6. a decorating material for flooring is characterized in that, with backing material plate one side bonds of each described floor material decorative board in described 1 or 2 on by adhesives.

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