Cigarette-resistant flooring

Abstract

To provide a cigarette resistant floor material capable of achieving improvement in production efficiency.SOLUTION: A cigarette resistant floor material 1 includes: a design layer 2 on which design is applied; a coat layer 4 arranged on one side of the design layer 2 in the thickness direction of the design layer 2, and for covering the design layer 2; and a heat radiation layer 5 arranged on the other side of the design layer 2 in the thickness direction, and coming into contact with the design layer 2. The coat layer 4 is a cured object of activated energy beam curable resin. The design layer 2 includes thermoplastic resin. The heat radiation layer 5 includes thermoplastic resin, and a heat radiation material having heat conductivity higher than the heat conductivity of the design layer 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a cigarette-resistant flooring material. [Background technology]

[0002] Conventionally, architectural decorative panels have been known that have a printed pattern layer and a core layer made of metal foil that is adhered to the pattern layer, and that can improve cigarette resistance (see, for example, Patent Document 1 below). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 10-37443 Summary of the Invention [Problem to be solved by the invention]

[0004] To manufacture the architectural decorative board described in Patent Document 1, a core layer (metal foil) and a pattern layer are joined together by hot pressing.

[0005] In this case, the core layer and the pattern layer must be joined together in a batch process, which makes it difficult to improve manufacturing efficiency.

[0006] The present invention provides a cigarette-resistant flooring material that can improve production efficiency. [Means for solving the problem]

[0007] The present invention [1] includes a cigarette-resistant flooring material comprising a design layer on which a design is applied, a coating layer arranged on one side of the design layer in the thickness direction and covering the design layer, and a heat dissipation layer arranged on the other side of the design layer in the thickness direction and in contact with the design layer, wherein the coating layer is a cured product of an active energy ray-curable resin, the design layer contains a thermoplastic resin, and the heat dissipation layer contains a thermoplastic resin and a heat dissipation material having a thermal conductivity higher than that of the design layer.

[0008] The present invention [2] includes the cigarette-resistant flooring material according to the above [1], wherein the heat-dissipating material is at least one selected from talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide.

[0009] The present invention [3] includes the cigarette-resistant flooring material according to the above [1] or [2], wherein the proportion of the heat-dissipating material in the heat-dissipating layer is 5 mass % or more.

[0010] The present invention [4] includes any one of the cigarette-resistant flooring materials [1] to [3] above, in which the heat dissipation layer further contains a filler, and the thermal conductivity of the heat dissipation material is higher than the thermal conductivity of the filler.

[0011] The present invention [5] includes the cigarette-resistant flooring material according to the above [4], in which the filler is calcium carbonate.

[0012] The present invention [6] includes the cigarette-resistant flooring material according to the above [4] or [5], wherein the mass ratio of the heat dissipation material to the filler is 10 / 90 or more and 90 / 10 or less. [Effects of the Invention]

[0013] According to the cigarette-resistant flooring material of the present invention, a heat dissipation layer is provided on the other side of the decorative layer in contact with the decorative layer. The decorative layer contains a thermoplastic resin, and the heat dissipation layer contains a thermoplastic resin and a heat dissipation material having a thermal conductivity higher than that of the decorative layer.

[0014] Therefore, the design layer and the heat dissipation layer can be laminated continuously by thermal lamination.

[0015] As a result, the manufacturing efficiency of the cigarette-resistant flooring material can be improved.

[0016] Furthermore, the cigarette-resistant flooring material of the present invention has a coating layer on one side of the decorative layer. The coating layer is a cured product of an active energy ray-curable resin and has excellent heat resistance.

[0017] Therefore, when the surface of the cigarette-resistant flooring material is heated, the coating layer prevents discoloration and deterioration of the decorative layer, and allows the heat transferred to the decorative layer to be dissipated to the heat dissipation layer.

[0018] As a result, discoloration and deterioration of the decorative layer can be suppressed, and the cigarette resistance of the cigarette-resistant flooring material can be improved. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 shows a cross-sectional view of one embodiment of the cigarette-resistant flooring material of the present invention. [Figure 2] FIG. 2 is a flowchart illustrating a method for manufacturing the cigarette-resistant flooring material shown in FIG. [Figure 3] FIG. 3 is an explanatory diagram for explaining a method for manufacturing the heat dissipation layer in the preparation step of FIG. [Figure 4] FIG. 4 is an explanatory diagram for explaining the laminating step, cutting step, coating step, and curing step in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0020] 1. Cigarette-resistant flooring The cigarette-resistant flooring material of the present invention will now be described.

[0021] Cigarette-resistant flooring refers to a resin flooring that is resistant to cigarettes. Cigarette resistance refers to the ability to prevent discoloration and denaturation (deformation, etc.) of the flooring due to the heat of a lit cigarette when the lit cigarette is left on the flooring or when the lit cigarette is extinguished on the flooring. Cigarette resistance is evaluated by the method described in the examples below.

[0022] The resin flooring material of the present invention corresponds to, for example, the vinyl flooring material specified in JIS A5705, and includes floor tiles and floor sheets. Examples of floor tiles include multi-layer vinyl floor tiles, floor-laying vinyl floor tiles, and thin floor-laying vinyl floor tiles. Examples of floor sheets include multi-layer vinyl floor sheets.

[0023] When manufactured, floor tiles are formed into square, rectangular, hexagonal or other shapes, and are then transported to a construction site and laid on the floor.

[0024] The floor sheet is stored and transported in a roll, and is then laid on the floor at the construction site.

[0025] From the viewpoint of cigarette resistance, floor tiles are preferable to floor sheets. Floor tiles can be made harder than floor sheets, allowing for the addition of more heat dissipating material and filler, making them more heat-resistant, and they are often thicker, making them more likely to absorb and dissipate heat.

[0026] 1, the cigarette-resistant flooring material 1 includes a design layer 2, a clear layer 3, a coating layer 4, a heat dissipation layer 5, and a backing layer 6. Specifically, the cigarette-resistant flooring material 1 includes the backing layer 6, the heat dissipation layer 5, the design layer 2, the clear layer 3, and the coating layer 4, arranged in that order in one thickness direction.

[0027] (1) Design layer The design layer 2 is a layer for imparting a design to the cigarette-resistant flooring material 1. A predetermined design is applied to one side of the design layer 2. Specifically, the design layer 2 is a resin sheet with a predetermined design. Examples of the design layer 2 include printed film and colored resin. A printed film is a resin sheet on which a desired pattern is drawn by applying ink. A colored resin is a resin such as polyvinyl chloride to which a coloring agent such as a pigment or dye is added to form a desired color or pattern. The colored resin may be a single-color resin sheet, or may be a resin sheet containing resin chips of multiple colors.

[0028] The matrix resin of the design layer 2 is a thermoplastic resin. In other words, the design layer 2 contains a thermoplastic resin. The design layer 2 optionally contains a plasticizer, a pigment, and an additive.

[0029] Examples of thermoplastic resins include polyvinyl chloride, polyvinyl acetate, polyethylene, polypropylene, and polymethacrylate. The base resin of the design layer 2 is preferably polyvinyl chloride.

[0030] The plasticizer imparts plasticity to the design layer 2. Examples of the plasticizer include polyester-based plasticizers, glycerin-based plasticizers, polycarboxylic acid ester-based plasticizers, and polyalkylene glycol-based plasticizers. A preferred plasticizer is a polycarboxylic acid-based plasticizer, and a phthalate ester is preferably used. Examples of the phthalate ester include dioctyl phthalate, bis(2-ethylhexyl) phthalate, and diisononyl phthalate.

[0031] There are no limitations on the blending ratio of the plasticizer in the design layer 2. The blending ratio of the plasticizer in the design layer 2 is, for example, 3 parts by mass or more, preferably 5 parts by mass or more, and for example, 25 parts by mass or less, preferably 20 parts by mass or less, per 100 parts by mass of the base resin of the design layer 2.

[0032] The pigment imparts hiding properties and design properties to the design layer 2. Examples of pigments include rutile titanium oxide and zinc oxide.

[0033] Examples of the additives include flame retardants, stabilizers, antioxidants, lubricants, foaming agents, antibacterial agents, and antifungal agents.

[0034] The thickness of the design layer 2 is, for example, 0.03 mm or more, preferably 0.05 mm or more, and for example, 0.50 mm or less, preferably 0.20 mm or less.

[0035] (2) Clear layer The clear layer 3 is arranged on one side of the design layer 2 in the thickness direction of the design layer 2. The clear layer 3 is arranged between the design layer 2 and the coating layer 4 in the thickness direction of the design layer 2. The clear layer 3 covers the design layer 2. The clear layer 3 protects the surface (one side) on which the design of the design layer 2 is applied, and increases the durability as a flooring material. The cigarette-resistant flooring material 1 does not need to have the clear layer 3.

[0036] The clear layer 3 is made of a transparent or translucent thermoplastic resin, preferably a transparent one. Examples of the thermoplastic resin include the thermoplastic resins described above. The clear layer 3 is preferably made of polyvinyl chloride. The clear layer 3 contains the plasticizer and additives described above as necessary.

[0037] There are no limitations on the blending ratio of the plasticizer in the clear layer 3. The blending ratio of the plasticizer in the clear layer 3 is, for example, 10 parts by mass or more, preferably 25 parts by mass or more, and for example, 50 parts by mass or less, preferably 35 parts by mass or less, relative to 100 parts by mass of the base resin of the clear layer 3.

[0038] When the cigarette-resistant flooring material 1 has the clear layer 3, the durability of the flooring material can be improved by making the clear layer 3 thicker than the decorative layer 2. The thickness of the clear layer 3 is, for example, 0.05 mm or more, preferably 0.15 mm or more, and for example, 1.00 mm or less, preferably 0.50 mm or less, more preferably 0.25 mm or less.

[0039] (3) Coating layer The coating layer 4 is the outermost layer of the cigarette-resistant flooring material 1. One side of the coating layer 4 is exposed. The coating layer 4 is disposed on one side of the clear layer 3 in the thickness direction of the design layer 2. In other words, the coating layer 4 is disposed on one side of the design layer 2 in the thickness direction of the design layer 2. The coating layer 4 covers the clear layer 3 and the design layer 2.

[0040] The coating layer 4 is a cured product of an active energy ray-curable resin. When the coating layer 4 is a cured product of an active energy ray-curable resin, as described below, the coating layer 4 can be formed by laminating and cutting each layer, followed by coating, drying, and curing in succession. This significantly improves the productivity of the cigarette-resistant flooring material 1. The coating layer 4 also has a crosslinked structure. This allows the coating layer 4 to have higher heat resistance than the clear layer 3 and the design layer 2.

[0041] The active energy ray-curable resin refers to a resin having an energy quantum capable of crosslinking or polymerizing monomers or the like in a charged particle beam or electromagnetic wave, i.e., a resin that is crosslinked and cured by irradiation with an electron beam, ultraviolet light, etc. Among active energy ray-curable resins, ultraviolet light-curable resins are preferred from the viewpoints of excellent transparency and ease of forming the coating layer 4.

[0042] The ultraviolet curable resin is not limited, and examples of the ultraviolet curable resin include urethane acrylate resin, polyester acrylate resin, epoxy resin, epoxy acrylate resin, and silicone acrylate resin.

[0043] As the ultraviolet-curable resin, urethane acrylate resins, polyester acrylate resins, and silicone acrylate resins are preferred, and urethane acrylate resins are particularly preferred, as they have excellent adhesion to the clear layer 3 containing polyvinyl chloride, as well as excellent durability, light resistance, flexibility, and flexibility.

[0044] The ultraviolet curable resin may contain at least one resin selected from a silicon-modified urethane (meth)acrylate resin and a fluorine-modified urethane (meth)acrylate resin.

[0045] When the ultraviolet-curable resin contains at least one type selected from silicone-modified urethane (meth)acrylate resin and fluorine-modified urethane (meth)acrylate resin, the sliding properties and water- and oil-repellent properties of silicone and fluorine can prevent dirt from adhering to the surface of coating layer 4, and dirt that has adhered to the surface of coating layer 4 can be easily removed.

[0046] The coating layer 4 may contain a filler to improve its physical properties. Examples of the filler contained in the coating layer 4 include inorganic particles and organic particles. Examples of inorganic particles include alumina, silica, and glass beads. Examples of organic particles include cellulose.

[0047] The coating layer 4 preferably contains inorganic particles, as these can impart heat resistance to the heat of tobacco and durability to the coating layer 4.

[0048] The content ratio of the inorganic particles is, for example, 5 parts by mass or more, preferably 20 parts by mass or more, more preferably 30 parts by mass or more, and for example, 50 parts by mass or less, preferably 40 parts by mass or less, more preferably 35 parts by mass or less, relative to 100 parts by mass of the base resin of the coating layer 4 (i.e., the cured product of the active energy ray-curable resin).

[0049] When the cigarette-resistant flooring material 1 has the clear layer 3, the coating layer 4 is, for example, thinner than the clear layer 3. The thickness of the coating layer 4 is, for example, 0.01 mm or more, preferably 0.02 mm or more, and for example, 0.05 mm or less, preferably 0.04 mm or less.

[0050] (4) Heat dissipation layer The heat dissipation layer 5 is arranged on the other side of the design layer 2 in the thickness direction of the design layer 2. In other words, the heat dissipation layer 5 is arranged on the other side of the design layer 2 in the thickness direction of the design layer 2. The heat dissipation layer 5 is arranged on the opposite side of the coating layer 2 from the design layer 2 in the thickness direction of the design layer 2. The heat dissipation layer 5 is arranged between the design layer 2 and the backing layer 6 in the thickness direction of the design layer 2. The heat dissipation layer 5 is in contact with the design layer 2. When the temperature of the design layer 2 rises, the heat dissipation layer 5 removes heat from the design layer 2. In other words, the heat of the design layer 2 is dissipated to the heat dissipation layer 5. As a result, the heat dissipation layer 5 suppresses an increase in the temperature of the design layer 2.

[0051] The thickness of the heat dissipation layer 5 is not limited. For example, the heat dissipation layer 5 is thicker than the design layer 2. For example, the heat dissipation layer 5 is thicker than the sum of the thicknesses of the design layer 2, the clear layer 3, and the coating layer 4. When the heat dissipation layer 5 is thicker than the other layers, it has a superior heat dissipation effect. Therefore, discoloration and deterioration of the design layer 2 can be further suppressed.

[0052] The heat dissipation layer 5 has a thickness of, for example, 0.1 mm or more, preferably 0.5 mm or more, and for example, 2.0 mm or less, preferably 1.5 mm or less.

[0053] The heat-dissipating layer 5 contains a thermoplastic resin, a heat-dissipating material, and, if necessary, a filler, the above-mentioned plasticizer, and the above-mentioned additives.

[0054] The blending ratio of the plasticizer in the heat dissipation layer 5 is, for example, 5 parts by mass or more, preferably 10 parts by mass or more, and for example, 100 parts by mass or less, preferably 60 parts by mass or less, per 100 parts by mass of the base resin of the heat dissipation layer 5.

[0055] (4-1) Thermoplastic resin The thermoplastic resin is the base resin of the heat dissipation layer 5. Examples of the thermoplastic resin include the thermoplastic resins described above. The base resin of the heat dissipation layer 5 is preferably polyvinyl chloride.

[0056] The proportion of the thermoplastic resin in the heat dissipation layer 5 is, for example, 10 mass % or more, preferably 15 mass % or more, and for example, 40 mass % or less, preferably 30 mass % or less.

[0057] (4-2) Heat dissipation material The heat dissipation material improves the thermal conductivity of the heat dissipation layer 5. The heat dissipation material is dispersed in the matrix resin of the heat dissipation layer 5.

[0058] The thermal conductivity of the heat dissipation material is higher than that of the decorative layer 2. Therefore, when the temperature of the decorative layer 2 rises, the heat of the decorative layer 2 is dissipated to the heat dissipation layer 5. As a result, discoloration and denaturation of the decorative layer 2 due to heating can be suppressed, improving the cigarette resistance of the cigarette-resistant flooring material 1. In addition, the thermal conductivity of the heat dissipation material is higher than that of the filler in the heat dissipation layer 5.

[0059] The thermal conductivity of the heat dissipation material is, for example, 1 W / m·K or more, preferably 2 W / m·K or more, and for example, 200 W / m·K or less.

[0060] Specifically, the heat dissipation material is at least one selected from talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide. The heat dissipation material is preferably at least one selected from talc and aluminum hydroxide, more preferably talc. When the heat dissipation material is talc, it is easy to process and can improve cigarette resistance while suppressing cost increases. Furthermore, when the heat dissipation material is talc, the heat dissipation layer 5 can be easily formed by calendar molding.

[0061] The form of the heat dissipation material is not limited as long as it can be dispersed in the matrix resin of the heat dissipation layer 5. Specifically, the heat dissipation material is a powder or granular material. The shape of the particles of the heat dissipation material is also not limited. Examples of the shape of the particles of the heat dissipation material include spherical, elliptical, and flaky.

[0062] When metal foil is used to provide cigarette resistance, as in the architectural decorative board described in Patent Document 1, it is difficult to recycle the scraps from manufacturing and the used products, and they are often discarded as industrial waste. This is because recycling scraps from manufacturing and used products requires separating the metal foil from the base material and cutting it into small pieces, which makes disposal time-consuming.

[0063] In this regard, in the cigarette-resistant flooring material 1 of this embodiment, the heat-dissipating material in the heat-dissipating layer 5 is powder or granular, so the heat-dissipating layer 5 can be recycled as is without being separated from the other layers.

[0064] Therefore, it is possible to prevent scraps from being produced during manufacturing and used products from being discarded as industrial waste, thereby reducing the environmental burden.

[0065] The particle size of the heat dissipation material is, for example, 5 μm or more, preferably 10 μm or more, more preferably 15 μm or more, and for example, 100 μm or less, preferably 50 μm or less, more preferably 20 μm or less. In this specification, "particle size" means the volume mean diameter (MV).

[0066] When the particle size of the heat dissipation material is equal to or greater than the above lower limit, it is possible to improve the processability and handleability when manufacturing the heat dissipation layer 5. When the particle size of the heat dissipation material is equal to or less than the above upper limit, it is possible to ensure the dispersibility of the heat dissipation material in the matrix resin, and it is possible to prevent the heat dissipation material from damaging the manufacturing equipment when manufacturing the heat dissipation layer 5.

[0067] The proportion of the heat dissipation material in the heat dissipation layer 5 is, for example, 5% by mass or more, preferably 10% by mass or more, and preferably 15% by mass or more. When the proportion of the heat dissipation material in the heat dissipation layer 5 is 5% by mass or more, it is possible to improve the cigarette resistance of the cigarette-resistant flooring material 1. When the proportion of the heat dissipation material in the heat dissipation layer 5 is 10% by mass or more, it is possible to impart sufficient cigarette resistance to the cigarette-resistant flooring material 1.

[0068] The proportion of the heat dissipating material in the heat dissipating layer 5 is, for example, 20 mass % or less. When the proportion of the heat dissipating material in the heat dissipating layer 5 is 20 mass % or less, an increase in the material cost of the cigarette-resistant flooring material 1 can be suppressed.

[0069] (4-3) Filling material The filler, together with the heat dissipation material, is dispersed in the matrix resin of the heat dissipation layer 5. The filler ensures the heat dissipation properties of the heat dissipation material, while improving the processability of the heat dissipation layer 5 and increasing the dimensional stability.

[0070] The thermal conductivity of the filler is lower than the thermal conductivity of the heat dissipation material in the heat dissipation layer 5. The thermal conductivity of the filler is preferably higher than the thermal conductivity of the design layer 2.

[0071] The thermal conductivity of the filler is, for example, 0.1 W / m·K or more, preferably 0.5 W / m·K or more, and for example, 100 W / m·K or less.

[0072] Examples of fillers include inorganic particles other than the above-mentioned heat dissipation materials. Examples of inorganic particles include calcium carbonate, magnesium carbonate, magnesium hydroxide, kaolin, silica, perlite, alumina, mica, boron nitride, aluminum nitride, and silicon nitride. Volcanic ash, which is primarily composed of silica and alumina, can also be used as inorganic particles. The filler is preferably calcium carbonate. When the filler is calcium carbonate, dimensional changes in the cigarette-resistant flooring material 1 can be suppressed, and increases in material costs can be suppressed.

[0073] The particle size of the filler is, for example, 5 μm or more, preferably 10 μm or more, and for example, 400 μm or less, preferably 100 μm or less, more preferably 30 μm or less.

[0074] The difference between the particle size of the filler and the particle size of the heat dissipation material is, for example, 200 μm or less, preferably 100 μm or less, more preferably 30 μm or less. The difference between the particle size of the filler and the particle size of the heat dissipation material may be 0.

[0075] If the difference between the particle size of the filler and the particle size of the heat dissipation material is less than the above upper limit value, the dispersibility of the filler and the heat dissipation material in the base resin can be improved during the production of the heat dissipation layer 5, and the cigarette resistance of the cigarette-resistant flooring material 1 can be improved.

[0076] The proportion of the filler in the heat-dissipating layer 5 is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 30% by mass or more, and more preferably 50% by mass or more. When the heat-dissipating material is talc, a proportion of the filler in the heat-dissipating layer 5 of 5% by mass or more can improve processability. When the heat-dissipating material is aluminum hydroxide, a proportion of the filler in the heat-dissipating layer 5 of 10% by mass or more can improve processability. When the heat-dissipating material is magnesium oxide or zinc oxide, a proportion of the filler in the heat-dissipating layer 5 of 30% by mass or more can improve processability. When the heat-dissipating material is carbon, a proportion of the filler in the heat-dissipating layer 5 of 50% by mass or more can improve processability. Furthermore, a proportion of the filler in the heat-dissipating layer 5 of 30% by mass or more can suppress dimensional changes in the cigarette-resistant flooring material 1 and suppress increases in material costs.

[0077] The upper limit of the filler proportion in the heat-dissipating layer 5 is not limited as long as the heat-dissipating layer 5 can contain the heat-dissipating material. The filler proportion in the heat-dissipating layer 5 is, for example, 80% by mass or less, preferably 60% by mass or less, and more preferably 55% by mass or less. When the filler proportion in the heat-dissipating layer 5 is 80% by mass or less, the blending proportion of the heat-dissipating material can be ensured, and the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. When the filler proportion in the heat-dissipating layer 5 is 60% by mass or less, the blending proportion of the heat-dissipating material can be more ensured, and the cigarette resistance of the cigarette-resistant flooring material 1 can be more improved. When the filler proportion in the heat-dissipating layer 5 is 55% by mass or less, the blending proportion of the heat-dissipating material can be sufficiently ensured, and the cigarette resistance of the cigarette-resistant flooring material 1 can be imparted with sufficient cigarette resistance.

[0078] Furthermore, the mass ratio of the heat dissipating material to the filler (mass of the heat dissipating material in the heat dissipating layer 5 / mass of the filler in the heat dissipating layer 5) is, for example, 10 / 90 or more, preferably 20 / 80 or more. When the mass ratio of the heat dissipating material to the filler is 10 / 90 or more, the cigarette resistance of the cigarette-resistant flooring material 1 can be improved. When the mass ratio of the heat dissipating material to the filler is 20 / 80 or more, sufficient cigarette resistance can be imparted to the cigarette-resistant flooring material 1.

[0079] The mass ratio of the heat dissipation material to the filler (mass of the heat dissipation material in the heat dissipation layer 5 / mass of the filler in the heat dissipation layer 5) is, for example, 90 / 10 or less, preferably 80 / 20 or less, more preferably 50 / 50 or less, and more preferably less than 30 / 70. When the mass ratio of the heat dissipation material to the filler is 90 / 10 or less, the heat dissipation layer 5 can be formed by calendar molding. When the mass ratio of the heat dissipation material to the filler is 80 / 20 or less, the heat dissipation layer 5 can be easily formed by calendar molding.

[0080] When the mass ratio of the heat dissipation material to the filler is equal to or greater than the above lower limit and equal to or less than the above upper limit, both heat dissipation properties and processability can be achieved.

[0081] (5) Backing layer The backing layer 6 supports the heat dissipation layer 5, the design layer 2, the clear layer 3, and the coating layer 4. The backing layer 6 is arranged on the other side of the heat dissipation layer 5 in the thickness direction of the design layer 2. The backing layer 6 is arranged on the opposite side of the design layer 2 from the heat dissipation layer 5 in the thickness direction of the design layer 2. Note that the cigarette-resistant flooring material 1 does not necessarily have to include the backing layer 6.

[0082] The backing layer 6 contains the above-mentioned thermoplastic resin as a base resin, and optionally the above-mentioned filler and plasticizer. The base resin of the backing layer 6 is preferably polyvinyl chloride. The filler in the backing layer 6 is preferably calcium carbonate.

[0083] Although FIG. 1 shows an example in which the backing layer 6 is a single layer, the present invention is not limited to this and the backing layer 6 may be made up of multiple layers. Furthermore, when the backing layer 6 is made up of multiple layers, the backing layer 6 may include a fiber reinforcement layer. For example, the fiber reinforcement layer is located in the center of the backing layer 6 in the thickness direction. The fiber reinforcement layer may be a nonwoven fabric or a woven fabric. Due to its excellent heat resistance and high effect of suppressing dimensional change, the fiber reinforcement layer is preferably a nonwoven fabric containing glass fibers, and more preferably a nonwoven fabric whose fibers are made only of glass fibers.

[0084] The backing layer 6 has a thickness of, for example, 1.0 mm or more, preferably 2.0 mm or more, and for example, 7.0 mm or less, preferably 5.0 mm or less.

[0085] 2. Manufacturing method of cigarette-resistant flooring Next, a method for producing the cigarette-resistant flooring material will be described.

[0086] As shown in FIG. 2, the method for producing the cigarette-resistant flooring material includes, for example, a preparation step (S1), a lamination step (S2), a cutting step (S3), a coating step (S4), and a curing step (S5).

[0087] (1) Preparation process In the preparation step, the design layer 2, the heat dissipation layer 5, and the backing layer 6 are prepared.

[0088] To prepare the design layer 2, for example, a commercially available resin sheet with a predetermined design can be purchased. The purchased design layer 2 may be provided with a clear layer 3. If the purchased design layer 2 does not have a clear layer 3, the above-mentioned clear layer 3 may be laminated onto the design layer 2. To prepare the design layer 2, the design layer 2 may be molded from the above-mentioned design layer 2 material by calendar molding, as described below, and a predetermined design may be applied.

[0089] To prepare the heat-dissipating layer 5, the heat-dissipating layer 5 is formed by calendar molding as shown in Fig. 3. Specifically, the materials for the heat-dissipating layer 5 described above are mixed in a Banbury mixer 11 while being heated to, for example, 140°C to 170°C.

[0090] Next, the resulting mixture is kneaded with the mill roll 12 while being heated to, for example, 140°C to 190°C.

[0091] Next, the obtained kneaded product is formed into a sheet while being heated, for example, to 140° C. to 170° C. by a calender roll 13, to obtain a resin sheet containing a heat dissipation material as the heat dissipation layer 5.

[0092] To prepare the backing layer 6, the backing layer 6 is formed from the material for the backing layer 6 by the above-mentioned calender molding.

[0093] (2) Lamination process In the laminating step, the design layer 2, the heat dissipation layer 5, and the backing layer 6 obtained in the preparation step are laminated together by thermal lamination.

[0094] More specifically, as shown in FIG. 4, the heat dissipation layer 5 is laminated on the backing layer 6, and then the design layer 2 is laminated on the heat dissipation layer 5.

[0095] After the design layer 2 is laminated on the heat dissipation layer 5, the clear layer 3 may be laminated on the design layer 2 as needed.

[0096] Because the heat dissipation layer 5 contains a thermoplastic resin, it can be bonded to the design layer 2 and the backing layer 6 by heating and pressing. In particular, when the thermoplastic resin of the backing layer 6, heat dissipation layer 5, design layer 2, and clear layer 3 is polyvinyl chloride, the layers can be easily bonded by heating and pressing, and peel strength can be improved.

[0097] In the lamination process, each layer is laminated roll-to-roll, allowing the laminate of the backing layer 6, heat dissipation layer 5, design layer 2, and clear layer 3 to be produced continuously.

[0098] (3) Cutting process The cutting step is carried out as necessary after the laminating step and before the coating step. In the cutting step, the obtained laminate is cut into a predetermined shape and a predetermined size. To cut the laminate, for example, the laminate is cut using a cutting machine 20. Examples of cutting methods include circle cutting and guillotine cutting.

[0099] The cutting process before the application process is necessary when the flooring material is floor tiles, but not when the flooring material is a floor sheet. When the flooring material is a floor sheet, after the lamination process, it goes through the application process and curing process without being cut, and is then stored in a rolled up state. When the flooring material is a floor sheet, after the curing process, either before or after it is rolled up, both ends of the floor sheet in the width direction are cut to adjust the width dimension.

[0100] (4) Coating process In the coating step, a coating device 21 is used to apply a precursor of the coat layer 4 (a coating liquid containing an active energy ray-curable resin) to the clear layer 3 of the obtained laminate.

[0101] There is no limitation on the coating device 21. Examples of the coating device 21 include a bar coater, a slit die coater, and a roll coater.

[0102] (5)Curing process In the curing step, the coating liquid applied to the laminate in the coating step is dried and cured using an ultraviolet irradiation device 22. As a result, a coating layer 4 is formed on the clear layer 3.

[0103] The above steps complete the production of the cigarette-resistant flooring material.

[0104] 3. Effects 1, the cigarette-resistant flooring material 1 has a heat dissipation layer 5 on the other side of the decorative layer 2, which is in contact with the decorative layer 2. The decorative layer 2 contains a thermoplastic resin, and the heat dissipation layer 5 contains a thermoplastic resin and a heat dissipation material having a thermal conductivity higher than that of the decorative layer 2.

[0105] Therefore, as shown in FIG. 4, the design layer 2 and the heat dissipation layer 5 can be laminated continuously by thermal lamination.

[0106] As a result, the manufacturing efficiency of the cigarette-resistant flooring material 1 can be improved.

[0107] Furthermore, as shown in Fig. 1, the cigarette-resistant flooring material 1 has a coating layer 4 on one side of the design layer 2. The coating layer 4 is a cured product of an active energy ray-curable resin, and has excellent heat resistance.

[0108] Therefore, when the surface of the cigarette-resistant flooring material 1 is heated, the coating layer 4 can dissipate the heat transferred to the decorative layer 2 to the heat dissipation layer 5 while preventing discoloration and deterioration of the decorative layer.

[0109] As a result, discoloration and deterioration of the decorative layer 2 can be suppressed, and the cigarette-resistant flooring material 1 can have improved cigarette resistance. [Example]

[0110] The present invention will be described in more detail below with reference to examples, but is not limited thereto. The specific numerical values ​​of the blending ratios (content ratios), physical property values, parameters, etc. used in the following description can be replaced with the upper limit values ​​(numeric values ​​defined as "not more than" or "less than") or lower limit values ​​(numeric values ​​defined as "not less than" or "exceeding") of the corresponding blending ratios (content ratios), physical property values, parameters, etc. described in the above "Form for Carrying Out the Invention." Note that "parts" and "%" are based on mass unless otherwise specified.

[0111] 1. Polyvinyl chloride sheet manufacturing (preparation process) (1) Comparative Example As a comparative example, a normal polyvinyl chloride sheet (i.e., not a heat-dissipating layer) was produced.

[0112] Polyvinyl chloride (thermoplastic resin), calcium carbonate (filler) with a particle size of approximately 13 μm, dioctyl phthalate (plasticizer), and additives (coloring pigment, processing aid, heat stabilizer) were mixed in the amounts shown in Table 1 at 140°C to 170°C using a Banbury mixer.

[0113] The resulting mixture was kneaded while being heated to 140°C to 190°C using a mill roll.

[0114] The obtained kneaded product was formed into a sheet using a calendar roll (temperature: 140°C to 170°C) to obtain a polyvinyl chloride sheet with a thickness of 0.7 mm.

[0115] (2) Examples 1 to 50 A polyvinyl chloride sheet was produced as a heat-dissipating layer in the same manner as in the comparative example, except that part of the calcium carbonate was replaced with the heat-dissipating materials shown in Tables 1 to 5 (all with a particle size of approximately 16 μm).

[0116] The ease of manufacturing (processability) of the heat dissipation layer was evaluated in comparison with the comparative example according to the following evaluation criteria.

[0117] <Evaluation criteria> ◯: Can be produced as a sheet in the same manner as in the comparative example.

[0118] Δ: Compared with the comparative example, although it can be formed into a sheet, the processability of the obtained sheet is inferior in terms of surface smoothness.

[0119] ×: Unable to be molded into a sheet due to holes or other reasons, and therefore not suitable for manufacturing.

[0120] 2. Flooring manufacturing The polyvinyl chloride sheet of the comparative example and each example, the design layer (polyvinyl chloride, thickness: 0.07 mm), and the clear layer (polyvinyl chloride, thickness: 0.2 mm) were laminated in that order on top of the backing layer (polyvinyl chloride, thickness: 4 mm) to obtain a laminate of the backing layer, the polyvinyl chloride sheet of the comparative example and each example, the design layer, and the clear layer (lamination process).

[0121] Next, a coating liquid containing an ultraviolet curable resin (Polymedic SK-0910-2, manufactured by DIC Corporation) was applied to the clear layer of the obtained laminate (coating step).

[0122] Next, the coating liquid was dried, and the resulting coating film was irradiated with ultraviolet light to be cured (curing step), thereby forming a coating layer on the clear layer and obtaining a flooring material.

[0123] 3. Evaluation of cigarette resistance The flooring materials of the comparative example and each example were evaluated for cigarette resistance by the following method.

[0124] A test piece (9.5 mm x 9.5 mm) was cut from the obtained flooring material and a lit cigarette was left on it for 3 minutes (Test A).

[0125] A test piece (9.5 mm x 9.5 mm) cut from the obtained flooring material was used to extinguish a lit cigarette for 5 seconds (Test B).

[0126] The condition of the test piece after the test was evaluated according to the following evaluation criteria. In the following evaluation criteria, changes on the surface mean discoloration and denaturation. The results are shown in Tables 1 to 5.

[0127] <Evaluation criteria> ○: In both Test A and Test B, there was almost no change in the surface.

[0128] △: There was a slight change in the surface in either test A or test B.

[0129] ×: In either Test A or Test B, there was a significant change in the surface.

[0130] [Table 1]

[0131] [Table 2]

[0132] [Table 3]

[0133] [Table 4]

[0134] [Table 5] [Explanation of symbols]

[0135] 1. Cigarette-resistant flooring 2 Design layer 4 Coating Layer 5 Heat dissipation layer

Claims

1. a design layer on which a design is applied; A coating layer is disposed on one side of the design layer in the thickness direction of the design layer and covers the design layer. a heat dissipation layer disposed on the other side of the design layer in the thickness direction and in contact with the design layer; the coating layer is a cured product of an active energy ray-curable resin, The design layer contains a thermoplastic resin, The heat dissipation layer is A thermoplastic resin as a base resin, a heat dissipation material having a thermal conductivity higher than that of the design layer and dispersed in the matrix resin; A cigarette-resistant flooring material containing

2. 2. The cigarette-resistant flooring material according to claim 1, wherein the heat-dissipating material is at least one selected from the group consisting of talc, aluminum hydroxide, carbon, magnesium oxide, and zinc oxide.

3. The cigarette-resistant flooring material according to claim 1 or 2, wherein the heat-dissipating material has a proportion of 5% by mass or more in the heat-dissipating layer.

4. The heat dissipation layer further contains a filler, The filler is calcium carbonate, The cigarette-resistant flooring material according to claim 1 , wherein the heat dissipation material has a thermal conductivity higher than that of the filler material.

5. A cigarette-resistant flooring material as described in claim 1, wherein the thickness of the heat dissipation layer is greater than 0.1 mm and less than 2.0 mm.

6. The cigarette-resistant flooring material according to claim 4, wherein a mass ratio of the heat dissipation material to the filler is 10 / 90 or more and 90 / 10 or less.

Images