Flooring materials and methods for manufacturing flooring materials

Abstract

To provide a flooring material and a method for manufacturing the flooring material, in which the adhesive strength does not decrease even when the adhesive layer is in direct contact with the backing layer, friction between the conveyor roll and the backing layer of the flooring material is reduced during molding, the amount of plasticizer used can be reduced, and the appearance has a matte finish. [Solution] A flooring material comprising a base material and a backing layer on the back side of the base material, wherein the backing layer comprises a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less, and diisononyl phthalate, wherein the blending ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the blending ratio of diisononyl phthalate is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material, and a method for manufacturing the flooring material.

Description

Technical Field

[0001] The present invention relates to a flooring material and a method for manufacturing the flooring material.

Background Art

[0002] Conventionally, as the back layer of a flooring material having a back layer on the back side of a base material, a vinyl chloride resin layer containing a vinyl chloride resin and a plasticizer is known. The plasticizer serves to impart flexibility to the inherently hard vinyl chloride resin. However, when the flooring material is a laminate with the vinyl chloride resin layer as the back layer on the outermost back side, if an adhesive layer is formed adjacent to the vinyl chloride resin layer, the plasticizer contained in the vinyl chloride resin layer migrates (bleeds out) into the adhesive layer, softening the adhesive and reducing the adhesive strength, making defects such as swelling and lifting in the installed flooring material more likely to occur.

[0003] As a method for solving this problem, a method of forming a barrier layer between the vinyl chloride resin layer and the adhesive layer is known. For example, Patent Document 1 describes "a flooring material provided with a back layer made of a vinyl chloride resin, characterized in that it comprises a primer layer made of an acrylic resin or urethane resin binder to which an adhesive is applied on the back side of the back layer." According to this flooring material, it is said that the type of adhesive is not restricted, the movement of the plasticizer is suppressed, and effects such as warping, peeling, and swelling do not occur during construction.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The flooring material described in Patent Document 1 can suppress the migration of plasticizers to the adhesive layer, but it has the drawback of requiring the formation of a primer layer, which increases the number of steps involved. On the other hand, while switching from dioctyl phthalate, commonly used in flooring materials, to diisononyl phthalate improved the migration of plasticizers to the adhesive layer, it was found that friction between the conveyor rolls and the back layer of the flooring material caused conveying problems such as wrinkle formation. The present invention has been made in view of the above problems, and aims to provide a flooring material and a method for manufacturing the said flooring material in which the migration of plasticizer to the adhesive layer is suppressed even without forming a barrier layer (primer layer) on the outermost surface, the adhesive does not soften and reduce the adhesive strength, there are no transportation problems after the flooring material is produced, and there are no problems such as blistering or lifting after installation. [Means for solving the problem]

[0006] In order to solve these problems, the present invention provides: A flooring material comprising a base material and a back layer on the back side of the base material, The aforementioned back layer is made of a vinyl chloride resin, comprising a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle size of 0.05 μm to 10 μm, and a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle size of 25 μm to 40 μm. It contains diisononyl phthalate as a plasticizer, The mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in terms of the mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material. The blending ratio of the diisononyl phthalate is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material. The present invention provides a flooring material characterized by the following features.

[0007] In the flooring material according to the present invention, it is preferable that the back layer further contains a liquid dispersant and / or a liquid defoaming agent.

[0008] Furthermore, the present invention, Preparation step (I) for preparing a vinyl chloride resin composition comprising a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less, and diisononyl phthalate as a plasticizer, wherein the blending ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the blending ratio of the diisononyl phthalate is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material, The process includes a back layer molding step (II) in which the vinyl chloride resin composition is applied to the back side of the substrate, and the resulting coating film is solidified and gelled to form a back layer. The present invention provides a method for manufacturing flooring materials characterized by the following features. [Effects of the Invention]

[0009] According to the flooring material of the present invention, even when an adhesive layer is formed adjacent to the vinyl chloride resin layer without forming a barrier layer (primer layer) on the outermost surface, the migration of plasticizer to the adhesive layer is suppressed, the adhesive does not soften and its adhesive strength does not decrease, and the occurrence of product problems such as blistering and lifting after installation is suppressed. According to the method for manufacturing flooring materials of the present invention, the flooring materials of the present invention can be manufactured efficiently and stably. [Brief explanation of the drawing]

[0010] [Figure 1] This is a cross-sectional view of the layer structure of one embodiment of the flooring material of the present invention. [Modes for carrying out the invention]

[0011] The present invention will be described in detail below, divided into two sections: 1) flooring material and 2) method for manufacturing the flooring material.

[0012] 1) Flooring The flooring material of the present invention comprises a base material and a back layer on the back side of the base material, The back layer is characterized in that it comprises a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less as a vinyl chloride resin, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less, and diisononyl phthalate (hereinafter sometimes abbreviated as "DINP") as a plasticizer, the mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the mixing ratio of DINP is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material.

[0013] (1) Base material The base material used in the flooring material of the present invention is not particularly limited and is appropriately determined according to the intended use of the flooring material. The material constituting the base material is not particularly limited and includes known materials used for decorative sheets, such as glass fibers, natural fibers such as pulp, organic fibers, synthetic resin fibers, metal fibers, and woven fabrics, nonwoven fabrics, and mixed paper composed of other fibers. Furthermore, the base material may be a composite material containing resin materials, etc., in addition to a fibrous material, or it may have a printed base layer, a printed layer, a surface layer, and a surface treatment layer on the surface side.

[0014] Examples of the resin material used as a composite material include those containing a thermoplastic resin and a thermosetting resin, with those containing a thermoplastic resin being preferred. Examples of the thermoplastic resin include polyvinyl resins such as polyvinyl chloride resin, polyvinyl acetate resin, and polyvinyl alcohol resin; polyolefin resins such as polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer resin (EVA), and ethylene-(meth)acrylic acid resin; polyester resins such as polyethylene terephthalate resin and polybutylene terephthalate resin; acrylic resin, polycarbonate resin, polyurethane resin, acrylonitrile-butadiene-styrene copolymer resin (ABS resin), acrylonitrile-styrene copolymer resin, diene rubbers such as styrene-butadiene rubber, isoprene rubber, and chloroprene rubber, non-diene rubbers such as butyl rubber and ethylene-propylene rubber, natural rubber, thermoplastic elastomer, or a mixed resin thereof. Among these, polyvinyl chloride resin, polyolefin resin, acrylonitrile-butadiene-styrene copolymer resin, etc. are preferable. These resins can be used alone or in combination of two or more kinds.

[0015] The thermoplastic resin and thermosetting resin may contain various additives such as a colorant (pigment or dye), a filler such as wood powder and calcium carbonate, a matting agent such as silica, a foaming agent, a flame retardant, a lubricant such as talc, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer, as necessary.

[0016] The base material may contain an inorganic compound. By containing an inorganic compound, the linear expansion coefficient of the base material can be reduced, and as a result, the water resistance of the flooring material can be improved. The base material may be composed of a single layer or a laminate composed of a plurality of materials.

[0017] The size of the base material is not particularly limited and can be appropriately determined according to the use of the flooring material. The thickness of the base material is not particularly limited. For example, 0.01 mm or more is preferable, and 0.1 mm or more and 50 mm or less is more preferable. Note that the base material includes substantially plate-like shapes other than flat plates and those having irregularities or curved surfaces.

[0018] (2) Back surface layer The flooring material of the present invention includes a backing layer on the back side of the base material. The back layer of the flooring material of the present invention is formed from a vinyl chloride resin composition containing a vinyl chloride resin and a plasticizer, as described later (hereinafter, the "back layer" is also referred to as the "vinyl chloride resin layer").

[0019] Vinyl chloride resins are polymers obtained by polymerizing monomer components that contain at least vinyl chloride. Examples include polyvinyl chloride resins, as well as copolymers of vinyl chloride with monomers such as ethylene, vinyl acetate, vinyl ether, maleic acid ester, acrylic acid, methacrylic acid, acrylic acid ester, and methacrylic acid ester. Blends of these with acrylic resins or urethane resins can also be used as vinyl chloride resins.

[0020] In the present invention, the vinyl chloride resin is preferably formed from a vinyl chloride resin composition comprising a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less, and DINP as a plasticizer. By using a combination of a first vinyl chloride resin raw material and a second vinyl chloride resin raw material as the vinyl chloride resin, a paste-like vinyl chloride resin composition with improved fluidity and viscosity stability can be easily obtained. Furthermore, the reduced stickiness after gelation reduces friction between the conveyor roll and the back layer of the flooring material during molding, thereby suppressing the occurrence of wrinkle defects. In addition, the amount of plasticizer used can be reduced, and flooring material with a matte appearance can be obtained.

[0021] (First vinyl chloride resin raw material) The first vinyl chloride resin raw material is a first vinyl chloride resin obtained by emulsion polymerization, having a volume-average particle size of 0.05 μm or more and 10 μm or less. In this specification, the volume-average particle diameter of the first vinyl chloride resin raw material and the second vinyl chloride resin raw material described later are values ​​measured by a dynamic light scattering particle size distribution analyzer.

[0022] The first vinyl chloride resin raw material can be obtained, for example, by using water as a medium, dissolving an emulsifier or surfactant in it, adding a monomer component containing vinyl chloride that is insoluble or has low solubility in water, and carrying out polymerization using a polymerization initiator that is soluble in water, such as potassium persulfate or hydrogen peroxide.

[0023] (Second vinyl chloride resin raw material) The second vinyl chloride resin raw material is a commonly used vinyl chloride resin raw material, specifically a suspension vinyl chloride resin, manufactured by suspension polymerization, with a volume-average particle size of 25 μm or more and 40 μm or less.

[0024] The second vinyl chloride resin raw material can be manufactured, for example, as follows: Specifically, the monomer component containing liquefied vinyl chloride raw material is added to a reactor containing water and a suspension agent, and the entire mixture is stirred at high speed to break down the monomer component into extremely fine droplets. Next, a polymerization initiator is added to the reactor, and the reaction is carried out under several atmospheres and a temperature between 40°C and 60°C to synthesize the desired vinyl chloride resin. The vinyl chloride resin obtained by the suspension polymerization method is usually in the form of particles with a diameter of 80 μm to 200 μm, suspended in water (slurry state). Therefore, after being removed from the reactor, it is dehydrated and dried, and the particle size is further adjusted using a screen to obtain a white powder product with a volume-average particle size of 25 μm to 40 μm.

[0025] The mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less by mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, preferably 55 / 45 or more and 70 / 30 or less. By using the first vinyl chloride resin raw material and the second vinyl chloride resin raw material in this blending ratio, a paste-like vinyl chloride resin composition with improved fluidity and viscosity stability can be easily obtained. Furthermore, the reduced stickiness after gelation reduces friction between the conveyor roll and the back layer of the flooring material during molding, thereby suppressing the occurrence of wrinkle defects. In addition, the amount of plasticizer used can be reduced, and the excellent effects of the present invention, such as a matte finish, can be obtained.

[0026] (Plasticizer) In this invention, DINP is used as a plasticizer. By using DINP as a plasticizer, the migration of the plasticizer from the vinyl chloride resin layer to the adjacent adhesive layer is suppressed. As a result, the adhesive layer does not soften, and the adhesive strength does not decrease. This makes it possible to obtain flooring materials that do not have problems such as blistering or lifting after installation.

[0027] The blending ratio of DINP is 35 parts by mass or more and 45 parts by mass or less, preferably 35 parts by mass or more and 40 parts by mass or less, based on 100 parts by mass of the total of the first vinyl chloride resin raw material and the second vinyl chloride resin raw material. By using DINP as a plasticizer in this proportion, the excellent effects of the present invention can be obtained.

[0028] In the present invention, by using DINP as a plasticizer and using the first vinyl chloride resin raw material and the second vinyl chloride resin raw material in such a blending ratio, a paste-like vinyl chloride resin composition with improved fluidity and improved viscosity stability can be easily obtained. Furthermore, the excellent effects of the present invention can be obtained, such as reducing the amount of plasticizer used and easily forming a back layer with a matte appearance.

[0029] (Back layer) The back layer of the flooring material of the present invention is formed from a vinyl chloride resin composition comprising, as a vinyl chloride resin, a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm to 10 μm, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm to 40 μm, and DINP as a plasticizer, wherein the mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 to 80 / 20 in terms of the mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the mixing ratio of DINP is 35 parts by mass to 45 parts by mass per 100 parts by mass of the total of the first vinyl chloride resin raw material and the second vinyl chloride resin raw material. The amount of vinyl chloride resin composition to be applied is 500 g / m². 2 The above is preferable, 800g / m 2 More than 1500g / m 2 The following are preferable.

[0030] (Flooring) Figure 1 shows a cross-sectional view of the layer structure of one embodiment of the flooring material of the present invention. In Figure 1, the flooring material 100 consists of a base layer 10, a back layer 11, a printing base layer 12, a printing layer 13, a surface layer 14, a surface treatment layer 15, and an adhesive layer 16. The back layer 11 of the flooring material 100 shown in Figure 1 is formed using the vinyl chloride resin composition described above. By reducing stickiness after gelling, friction between the conveyor roll and the back layer of the flooring material is reduced during molding, thereby suppressing the occurrence of wrinkle defects.

[0031] The flooring material of the present invention is not limited to the one shown in Figure 1, as long as it can achieve the effects of the present invention, and may have an appropriate layer configuration depending on the application and other factors.

[0032] 2) Method of manufacturing flooring The method for manufacturing the flooring material of the present invention is: The present invention provides a vinyl chloride resin composition comprising: a preparation step (I) for preparing a vinyl chloride resin composition containing a first vinyl chloride resin raw material with a volume average particle diameter of 0.05 μm or more and 10 μm or less obtained by emulsion polymerization, a second vinyl chloride resin raw material with a volume average particle diameter of 25 μm or more and 40 μm or less obtained by suspension polymerization, and DINP as a plasticizer, wherein the mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the mixing ratio of the DINP is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material; and a back layer molding step (II) for coating the vinyl chloride resin composition onto the back side of the substrate and solidifying and gelling the resulting coating film to form a back layer. The manufacturing method of the present invention is suitable as a method for manufacturing the flooring material of the present invention.

[0033] Preparation process (I) First, a vinyl chloride resin composition is prepared. That is, a first vinyl chloride resin raw material, a second vinyl chloride resin raw material, a plasticizer, and optionally other additives are mixed in appropriate proportions to obtain a vinyl chloride resin composition.

[0034] The first vinyl chloride resin raw material is added in an amount of 40 to 80 parts by mass, preferably 55 to 70 parts by mass, relative to 100 parts by mass of the vinyl chloride resin composition. The second vinyl chloride resin raw material is added in an amount of 20 to 60 parts by mass, preferably 30 to 45 parts by mass, relative to 100 parts by mass of the vinyl chloride resin composition. By blending the first vinyl chloride resin raw material and the second vinyl chloride resin raw material within this range, a paste-like vinyl chloride resin composition can be easily obtained that has an appropriate fluidity (viscosity after mixing) and can be uniformly applied to a substrate layer.

[0035] (Other additives) In addition to the first vinyl chloride resin raw material, the second vinyl chloride resin raw material, and the plasticizer, other additives may be optionally added to the vinyl chloride resin composition used to form the back layer, as long as they do not impair the effects of the present invention. Other additives include liquid dispersants, liquid defoamers, fillers, and liquid stabilizers. From the viewpoint of obtaining better effects of the present invention, it is preferable to include a liquid dispersant and / or a liquid defoamer as other additives.

[0036] (1) Liquid dispersant Liquid dispersants are dispersants that are liquid at room temperature (10°C to 40°C). Examples include one or more combinations of saturated fatty acids such as caprylic acid, capric acid, lauric acid, palmitic acid, myristic acid, stearic acid, and arachidic acid; unsaturated fatty acids such as myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, linoleic acid, and arachidonic acid; hydrocarbon oligomers; surfactants; and nonionic polymer compounds such as polyvinyl alcohol, polyethylene oxide, and cellulose derivatives. The amount of liquid dispersant added is preferably 0.005% by mass or more and 5% by mass or less, and more preferably 0.01% by mass or more and 1% by mass or less, relative to the total mass of the vinyl chloride resin composition.

[0037] (2) Liquid defoaming agent Liquid defoaming agents are defoaming agents that are liquid at room temperature. Examples include one or more compounds selected from polysiloxanes, polyoxyethylene polyoxypropylene, polypropylene oxides and their derivatives (polyoxypropylene, polyoxypropylene glyceryl ether, etc.), acetylene glycols and their derivatives (acetylene glycol, alkylene oxide adducts of acetylene glycol, etc.), polyoxyalkylene fatty acid esters, polyoxyalkylene alkyl ethers, polyoxyalkylene alkylamides, trialkyl phosphates, alkylamines, and alcohols. The amount of liquid defoaming agent added is preferably 0.005% by mass or more and 5% by mass or less, and more preferably 0.01% by mass or more and 1% by mass or less, relative to the total mass of the vinyl chloride resin composition.

[0038] (3) Fillers Examples of fillers include calcium carbonate, titanium dioxide, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica. The amount of filler added (total amount if two or more types are used) is preferably 10% to 50% by mass, and more preferably 25% to 40% by mass, relative to the total mass of the vinyl chloride resin composition.

[0039] (4) Liquid stabilizer Liquid stabilizers are stabilizers that are liquid at room temperature. For example, metal salts of the Ba-Zn, Ca-Zn, Pb, Sn, and Cd-Ba systems, organophosphite stabilizers such as diphenyldecyl phosphite, triphenyl phosphite, trixylenyl phosphite, tris(nonylphenyl) phosphite, tridecyl phosphite, tris(2-ethylhexyl) phosphite, tristearyl phosphite, and octyldiphenyl phosphite, and tin-based stabilizers such as dibutyltin laurate, dibutyltin malate, organotin mercaptides, and organotin sulfonamides can be used. The amount of liquid stabilizer added is preferably 0.001% by mass or more and 1% by mass or less, and more preferably 0.001% by mass or more and 0.5% by mass or less, relative to the total mass of the vinyl chloride resin composition.

[0040] A vinyl chloride resin composition can be obtained by uniformly mixing a first vinyl chloride resin raw material, a second vinyl chloride resin raw material, a plasticizer, and optionally other additives. The mixing method is not particularly limited as long as a uniform mixture can be obtained. Examples of mixing methods include a fixed container type using mechanical stirring force with a Henschel mixer, etc., and a rotating container type using a container blender, etc.

[0041] The resulting vinyl chloride resin composition is preferably in the form of a paste.

[0042] Back layer formation process (II) Next, a vinyl chloride resin composition is applied to the back surface of the substrate layer using a known coating method, and then pressed with a pressure-drawing roll to form a coating film of the vinyl chloride resin composition on the back surface of the substrate layer. The coating method is not particularly limited, and conventional coating methods such as knife coaters, roll coaters (natural or reverse), rotary screens, silk screens, dipping, die coaters, lip coaters, and sprays can be applied. The coating amount of the vinyl chloride resin composition is preferably 500 g / m² relative to the substrate layer. 2 More preferably, 800 g / m² 2 More than 1500g / m 2 The following applies:

[0043] Next, the vinyl chloride resin composition coating can be heated using a heating device such as a heater or oven to solidify and gel it, thereby forming a back layer.

[0044] Subsequently, by laminating a printing base layer, a printing layer, a surface layer, and a surface treatment layer onto the surface of the substrate layer using known methods, a flooring material having the layer structure shown in Figure 1 can be obtained. Furthermore, the flooring material can be manufactured in a continuous sheet form or in predetermined lengths.

[0045] The flooring material obtained in the manner described above is laid on a subfloor, which is then coated with an adhesive layer, and pressed down to secure it in place. The adhesive layer serves to firmly fix the underside of the flooring material to the floor surface. Examples of adhesives to be used include known flooring adhesives such as one-component adhesives and two-component adhesives. Specifically, examples include one or more mixtures selected from urethane resins, vinyl acetate resins, styrene-butadiene copolymers, acrylic resins, vinyl chloride resins, and epoxy resins. Alternatively, an adhesive layer may be provided on the back surface of the flooring material, and a release layer may be laminated on the surface of the adhesive layer to protect the surface. The release layer is peeled off before use.

[0046] In the flooring material of the present invention, even when an adhesive layer is formed adjacent to the back layer, the plasticizer contained in the back layer does not migrate to the adhesive layer. Therefore, it is possible to suppress problems such as swelling and lifting of the flooring material after installation, which can occur due to the softening of the adhesive caused by the migration of the plasticizer to the adhesive layer. [Examples]

[0047] The present invention will be specifically described below with reference to examples, but the present invention is not limited to the following examples.

[0048] (material) Using the following materials, we manufactured a flooring material having a base layer and a backing layer on the back side of the base layer (the side that will be the back of the flooring material). <Base material layer> A glass fiber nonwoven fabric was prepared as the fibrous base layer (manufactured by Olivest, product name: MSA). <Vinyl chloride resin (A)> (1) First vinyl chloride resin raw material (A1): (Manufactured by Shin-Daiichi Vinyl Chloride Co., Ltd., product name: PQ137, volume average particle size 1 μm) (2) Second vinyl chloride resin raw material (A21): (Product name: TK1001(SL), volume average particle size 100 μm) (3) Second vinyl chloride resin raw material (A22): (Manufactured by Kaneka Corporation, product name: Kane Vinyl Paste PBM-B5F, composition details: polyvinyl chloride 97% or more, polymerization additive (residue) 3% or less, volume average particle size 40 μm) (4) Second vinyl chloride resin raw material (A23): (Manufactured by Kaneka Corporation, product name: PS-300K, volume average particle size 26 μm, composition details: K value; 69, volatile content 0.4% or less, apparent density; 0.36 (g / ml), polyvinyl chloride 97% or more, polymerization additive (residue) 3% or less)

[0049] <Plasticizer (B)> (1) Plasticizer (B1): Diisononyl phthalate (abbreviation: DINP) (2) Plasticizer (B2): Dioctyl phthalate (Abbreviation: DOP (Alternative abbreviations: DNOP, DEHP))

[0050] <Liquid stabilizer (C)> Liquid stabilizer (C1): (Product name: KKL-800)

[0051] <Filler (D)> Filler (D1): Calcium carbonate (manufactured by Nitto Funka Kogyo Co., Ltd., light calcium carbonate, untreated surface, product name: NN#500, composition details: average particle size; 4.4 μm) Filler (D2): Titanium dioxide (manufactured by Teika Co., Ltd., product name: JR-401)

[0052] <Liquid viscosity reducer (E)> Liquid viscosity reducer (E1): Aliphatic hydrocarbon containing a neutral wetting and dispersing component (manufactured by BYK, product name: BYK-4041)

[0053] <Liquid dispersant (F)> Liquid dispersant (F1): Mixture of hydrocarbon oligomer and wetting agent (manufactured by BYK, product name: BYK-1165)

[0054] <Liquid defoaming agent (G)> (1) Liquid defoaming agent (G1): Polyoxyalkylene derivative mixture (manufactured by BYK, trade name: BYK-3155)

[0055] (Example 1) First, the vinyl chloride resin composition that forms the back layer was prepared in the proportions shown in Table 1. Next, the obtained vinyl chloride resin composition is applied to the back side (the side that will become the back of the flooring material) of the glass fiber-containing substrate (substrate layer) at a coating rate of 800 g / m². 2 The material was applied as is, and the resulting coating film was heated and gelled to form a vinyl chloride resin layer, thereby obtaining the flooring material of Example 1.

[0056] (Examples 2-10, Comparative Examples 1-7) Vinyl chloride resin compositions were prepared in the proportions shown in Tables 1 and 2, and the back layers of Examples 2-10 and Comparative Examples 1-7 were formed in the same manner as in Example 1 to obtain flooring materials for Examples 2-10 and Comparative Examples 1-7. In Tables 1 and 2, the values ​​represent parts by mass.

[0057] [Table 1]

[0058] [Table 2]

[0059] <Evaluation test of vinyl chloride resin composition and flooring material> The physical properties of the vinyl chloride resin composition and flooring material were measured and evaluated using the following methods. Processability evaluation: viscosity (fluidity) after mixing (Test method) The measurement was taken using a Type B viscometer (ATAGO VISCO, settings: rotation speed 10 RPM, temperature 25°C). (Evaluation method) The fluidity of the vinyl chloride resin composition was evaluated as follows. Excellent (◎): 12000 to less than 16000 CP Good (〇): 9000 to less than 12000 CP / 16000 to less than 30000 CP △: 5000 CP or more but less than 9000 CP / 30000 CP or more but less than 40000 CP ×: Less than 5000 CP / 40000 CP or more

[0060] Flooring evaluation: Presence or absence of wrinkles due to stickiness. (Test method) A vinyl chloride resin composition was coated onto the substrate to form the back layer, and the roll slipperiness and winding properties were evaluated at temperatures of 25°C or 35°C. (Evaluation method) The evaluation was as follows: ○: Wrinkles do not occur even at 35℃ △: No wrinkles occur at 25℃ ×: Wrinkles can form even at 25℃.

[0061] <Evaluation of flooring materials> Plasticizer bleed evaluation (Test method) Oil-absorbing paper was placed on the back layer of the flooring materials in Examples 1-10 and Comparative Examples 1-7. Both sides were sandwiched between glass plates, and a 2kg load was applied for heating at 70°C for 72 hours to accelerate the process. After that, the oil absorption status of the oil-absorbing paper was visually confirmed. (Evaluation method) If no plasticizer bleeding is observed, mark it with ○. A slight bleed of plasticizer was observed, but the bedding material was still usable (△). When plasticizer bleeding is observed, causing the adhesive to soften and leading to construction problems, it is marked with an asterisk (×). It was evaluated as such.

[0062] Surface appearance (Test method) The glossiness of the back surface of the flooring materials in Examples 1-10 and Comparative Examples 1-7 was measured using a gloss checker (handheld gloss meter, Horiba, Ltd., IG-320 (reference: measured at 60° incident and reflected angles)) to evaluate the presence or absence of gloss. (Evaluation method) The evaluation was as follows: 15 or less: Matte finish 15 to 25: Slightly glossy 25+: Glossy The above measurement and evaluation results are summarized in Tables 3 and 4.

[0063] [Table 3]

[0064] [Table 4]

[0065] The results shown in Tables 3 and 4 indicate the following: The back layers of Examples 1 to 10 that satisfy the requirements of Claim 1 of this application are characterized by the excellent fluidity of the vinyl chloride resin composition used to form the back layer, resulting in no wrinkling defects due to stickiness, no migration of plasticizer to the surface of the back layer, and even when an adhesive layer is formed on the back layer, the plasticizer does not migrate to the adhesive layer, softening the adhesive and reducing the adhesive strength, thus preventing problems such as swelling or lifting of the flooring material during product use. Furthermore, the appearance of the back surface was relatively low in gloss.

[0066] On the other hand, the back layer of Comparative Example 1 contained a large amount of plasticizer, resulting in the formation of wrinkles due to stickiness and plasticizer bleeding. Comparative Example 2 was a vinyl chloride resin composition with a low plasticizer content, which resulted in poor fluidity and poor processability. Comparative Example 3 was a vinyl chloride resin composition containing a large amount of the second vinyl chloride resin raw material, and it had poor fluidity and poor processability. In Comparative Example 4, the back layer of the second vinyl chloride resin raw material had a volume-average particle size of 100 μm, and furthermore, DOP was used as a plasticizer, resulting in migration of the plasticizer to the surface of the back layer. In addition, the occurrence of wrinkles due to stickiness was also observed. Comparative Example 5 was a vinyl chloride-based resin composition in which the plasticizer of Comparative Example 4 was replaced with DINP, and it exhibited poor fluidity and poor processability. The back layer of Comparative Example 6 had improved fluidity because the amount of filler was reduced compared to Comparative Example 5, but wrinkles due to stickiness were observed. The back layer of Comparative Example 7 contained a large amount of the first vinyl chloride resin raw material, and wrinkles due to stickiness were observed, and the surface of the back layer was glossy.

[0067] The present invention is not limited to the above embodiments, and the composition of the vinyl chloride resin composition, the layer structure of the flooring material, etc., can be appropriately adjusted without departing from the spirit of the present invention. [Explanation of symbols]

[0068] 10: Base material layer 11: Back layer 12: Print base layer 13: Printing layer 14: Surface layer 15: Surface treatment layer 16: Adhesive layer 100: Flooring

Claims

1. A flooring material comprising a base material and a back layer on the back side of the base material, The aforementioned back layer is made of a vinyl chloride resin, comprising a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less, and a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less. It contains diisononyl phthalate as a plasticizer, The mixing ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in terms of the mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material. A flooring material in which diisononyl phthalate is added in a proportion of 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material.

2. Preparation step (I) for preparing a vinyl chloride resin composition comprising a first vinyl chloride resin raw material obtained by emulsion polymerization with a volume average particle diameter of 0.05 μm or more and 10 μm or less, a second vinyl chloride resin raw material obtained by suspension polymerization with a volume average particle diameter of 25 μm or more and 40 μm or less, and diisononyl phthalate as a plasticizer, wherein the blending ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material is 40 / 60 or more and 80 / 20 or less in mass ratio of the first vinyl chloride resin raw material to the second vinyl chloride resin raw material, and the blending ratio of the diisononyl phthalate is 35 parts by mass or more and 45 parts by mass or less per 100 parts by mass of the vinyl chloride resin raw material, The process includes a back layer molding step (II) in which the vinyl chloride resin composition is applied to the back side of a substrate, and the resulting coating film is solidified and gelled to form a back layer. A method for manufacturing flooring materials.

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