Flooring

Abstract

To provide a floor material that has an excellent anti-static property and an anti-fouling property and has good processability.SOLUTION: A floor material 1 includes: a main body layer 2 having a resin layer containing a vinyl chloride resin; and a surface protection layer 3 provided on a surface of the main body layer 2 and containing an active energy ray-curable resin. The resin layer of the main body layer 2 contains a surfactant as an anti-static agent, and the surface protection layer 3 contains an ionic liquid as an anti-static agent.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] This invention relates to a flooring material with excellent antistatic and stain-resistant properties. [Background technology]

[0002] In flooring materials such as floor tiles and floor sheets, static electricity buildup on the surface due to friction is a problem. In particular, polyvinyl chloride resins, which are often used in resin-based flooring materials, are prone to generating static electricity because they contain relatively large amounts of fillers or bulking agents. Patent Document 1 discloses a flooring material having a flooring material body (body layer) and a surface layer (surface protective layer) provided on the flooring material body and containing an ionic liquid as an antistatic agent. The flooring material described in Patent Document 1 has excellent stain resistance because the antistatic agent is less likely to bleed onto the surface of the surface layer. Furthermore, since static electricity generated on the surface is released to the back side (the side where the flooring material is installed), flooring materials with low volume resistivity have excellent antistatic properties, and the flooring material described in Patent Document 1 has both low volume resistivity and excellent antistatic properties. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Patent No. 6175686 [Overview of the Initiative]

[0004] The demands on flooring materials are increasing year by year, requiring not only excellent antistatic and stain-resistant properties, but also good processability during the manufacturing process. Furthermore, since flooring materials are installed in various locations, it is desirable that they have excellent chemical resistance. [Problems that the invention aims to solve]

[0005] The first objective of the present invention is to provide a flooring material that is excellent in antistatic properties and stain resistance, and is easy to process. A second object of the present invention is to provide a flooring material that is excellent in antistatic properties and stain resistance, and also has excellent chemical resistance on the surface, and is easy to process. [Means for solving the problem]

[0006] The flooring material according to the first means of the present invention comprises a main body layer having a resin layer containing a vinyl chloride resin, and a surface protective layer provided on the surface of the main body layer and containing an active energy ray curable resin, The main body layer comprises, in this order, a front resin layer having a first front resin layer and a second front resin layer directly laminated on the back surface of the first front resin layer, a fiber reinforcement layer, and a back resin layer, wherein the first front resin layer, the second front resin layer, and the back resin layer all contain a surfactant as an antistatic agent, the first front resin layer and the second front resin layer contain the same type of surfactant, the surfactant contained in the first front resin layer and the second front resin layer is different from the surfactant contained in the back resin layer, and the amount of surfactant in the first front resin layer is less than the amount of surfactant in the second front resin layer. The aforementioned surface protective layer contains an ionic liquid as an antistatic agent.

[0007] The flooring material according to the second means of the present invention is, in the first means, Surfactants of the first and second surface resin layers However, the bleeding rate is slower than that of the surfactant in the aforementioned backside resin layer. The flooring material according to the third means of the present invention is characterized in that, in the first or second means, the ionic liquid contained in the surface protective layer contains a lithium salt. The flooring material according to the fourth means of the present invention is characterized in that, in the third means, the ionic liquid containing the lithium salt is contained in an amount of 0.5% by weight or more and 20% by weight or less based on 100% by weight of the total surface protective layer. The flooring material according to the fifth means of the present invention is characterized in that, in any of the first to fourth means, the surfactant is contained in an amount of 0.5% by weight or more and 20% by weight or less based on 100% by weight of the total resin layer of the main body layer. The flooring material according to the sixth means of the present invention is wherein, in any of the first to fifth means, the main body layer has a layer that does not contain an antistatic agent, and the volume resistivity of the flooring material in an environment with a temperature of 23°C and a humidity of 25%RH is 100 × 10 8 It is less than or equal to Ω. [Effects of the Invention]

[0008] The flooring material of the present invention is less prone to static electricity and less likely to attract dirt. Furthermore, the flooring material of the present invention is easy to process during its manufacturing process and boasts excellent productivity. The preferred flooring material of the present invention also exhibits excellent surface chemical resistance. [Brief explanation of the drawing]

[0009] [Figure 1] Plan view of the floor material of the first embodiment. [Figure 2] Plan view of the floor material of the second embodiment. [Figure 3] Cross-sectional view showing the first example of the layer structure of the floor material. [Figure 4] Cross-sectional view showing the second example of the same layer structure. [Figure 5] Cross-sectional view showing the third example of the same layer structure.

Mode for Carrying Out the Invention

[0010] Hereinafter, the present invention will be described with reference to the drawings as appropriate. In this specification, the "front surface" refers to the surface on the side far from the construction surface when the floor material is laid on the construction surface, and the "back surface" refers to the opposite surface (the surface on the side close to the construction surface). Plan view means viewing from a direction perpendicular to the front surface or the back surface. In this specification, "substantially" means the range acceptable in the technical field to which the present invention belongs. In this specification, a numerical range represented by "not less than the lower limit value and not more than the upper limit value" is assumed to be such that any lower limit value and any upper limit value can be selected and "not less than any lower limit value and not more than any upper limit value" can be set. Also, it should be noted that the dimensions such as thickness and size in each figure may be different from the actual ones.

[0011] [Basic Configuration of Floor Material] FIG. 1 is a plan view showing one embodiment of the floor material 1 of the present invention, and FIG. 2 is a plan view showing another embodiment.

[0012] Referring to Figure 1, the flooring material 1 is formed in a long strip shape in plan view. The flooring material 1 formed in a long strip shape is also called sheet flooring material. The long strip shape refers to a roughly rectangular shape in plan view in which the length in the longitudinal direction is sufficiently longer than the length in the short direction, for example, the length in the longitudinal direction is 3 times or more, preferably 5 times or more, the length in the short direction. Specific dimensions of the long strip shape include, for example, a case where the length in the short direction is 500 mm or more and 3000 mm or less, and the length in the longitudinal direction is 2 m or more and 500 m or less. The flooring material 1 formed in a long strip shape is usually stored and transported wound on a roll, and is cut to the desired shape at the construction site for use.

[0013] Referring to Figure 2, the flooring material 1 is formed in a sheet-like shape that is approximately square in plan view. However, the sheet-like flooring material 1 may also be formed in a roughly rectangular shape, a roughly hexagonal shape, or the like in plan view (not shown). The sheet-like flooring material 1 is also called tile flooring material. Specific dimensions of the roughly square or roughly rectangular flooring material 1 in plan view include, for example, a length × width of 200 mm to 1000 mm × 200 mm to 1000 mm. The sheet-like flooring material 1, as shown in the example, is stored and transported either in a stacked state or individually rolled up.

[0014] The flooring material 1 of the present invention may be flexible, or it may be relatively rigid without flexibility. Regarding the degree of flexibility of the flooring material 1, for example, it may be possible to roll it around a 10 cm diameter core with the back side of the flooring material 1 facing the core. The overall thickness of the flooring material 1 is not particularly limited, but for example, it is 0.5 mm or more and 10 mm or less, preferably 1 mm or more and 8 mm or less, and more preferably 1.5 mm or more and 5 mm or less.

[0015] [Layer structure of flooring materials] Figures 3 to 5 show the first to third examples of the layer configuration of flooring material 1. Figures 3 to 5 are cross-sectional views taken at the line III-III in Figures 1 and 2. The flooring material 1 of the present invention comprises a main body layer 2 having a resin layer containing a vinyl chloride resin, and a surface protection layer 3 provided on the surface side of the main body layer 2. If necessary, a primer layer (not shown) may be provided between the main body layer 2 and the surface protective layer 3 to firmly adhere the surface protective layer 3 to the main body layer 2. The surface protective layer 3 comprises an active energy ray curable resin and an antistatic agent, wherein at least an ionic liquid is used as the antistatic agent.

[0016] (Main layer) The main body layer 2 is the primary component that constitutes the strength, thickness, and weight of the flooring material 1. In the present invention, the main body layer 2 has at least one resin layer containing a vinyl chloride resin, and optionally further has a fiber reinforcement layer. The main body layer 2 preferably has two or more resin layers containing the vinyl chloride resin, and more preferably has two or more resin layers mainly composed of the vinyl chloride resin. In the layer configuration shown in Figures 3 to 5, the main body layer 2 has a resin layer comprising a front resin layer 21 containing vinyl chloride resin as the main component resin and a back resin layer 22 containing vinyl chloride resin as the main component resin. A fiber reinforcement layer 23 (hereinafter referred to as "intermediate fiber reinforcement layer 23") is interposed between the front resin layer 21 and the back resin layer 22. Furthermore, a fiber reinforcement layer 24 (hereinafter referred to as "back fiber reinforcement layer 24") is laminated on the back surface of the back resin layer 22. The resin layers, such as the surface resin layer 21, and the fiber reinforcement layers, such as the intermediate fiber reinforcement layer 23, that make up the main body layer 2 are strongly bonded to each other and laminated to such an extent that delamination between layers is difficult.

[0017] In the layer configuration shown in Figures 3 and 4, the front resin layer 21 consists of two or more resin layers, for example, a first front resin layer 211 containing vinyl chloride resin as the main component resin, and a second front resin layer 212 laminated on its back side and also containing vinyl chloride resin as the main component resin. Furthermore, in the layer configuration shown in Figure 4, the surface resin layer 21 comprises a first surface resin layer 211, a second surface resin layer 212, and a decorative layer 213 interposed between the first surface resin layer 211 and the second surface resin layer 212. When the surface resin layer 21 has a first surface resin layer 211 and a second surface resin layer 212, the first surface resin layer 211 is the outermost layer of the main body layer 2. In the layer configuration shown in Figure 5, the front resin layer 21 consists of a single resin layer. When the front resin layer 21 consists of a single resin layer, the front resin layer 21 is the outermost layer of the main body layer 2. In the layer configuration shown in Figures 3 to 5, the back side resin layer 22 consists of one resin layer, but it may also consist of two or more resin layers (not shown).

[0018] The resin layer of the main body layer 2 contains a surfactant as an antistatic agent. The amount of surfactant contained in the resin layer of the main body layer 2 is 0.5% by weight or more and 20% by weight or less, preferably 1% by weight or more and 8% by weight or less, based on 100% by weight of the entire resin layer of the main body layer 2.

[0019] Furthermore, if the main body layer 2 has multiple resin layers, the main body layer 2 only needs to have at least one resin layer containing a surfactant, and preferably has two or more resin layers containing a surfactant. For example, if the resin layer of the main body layer 2 has a front resin layer 21 and a back resin layer 22, it is preferable that the surfactant is contained in each of the front resin layer 21 and the back resin layer 22. Also, if the front resin layer 21 has a first front resin layer 211 and a second front resin layer 212, it is preferable that the surfactant is contained in each of the first front resin layer 211 and the second front resin layer 212. Furthermore, if the back resin layer 22 consists of two or more resin layers, it is preferable that the surfactant is contained in each of the resin layers. Furthermore, the main body layer 2 having a resin layer may also have a surfactant-free layer, such as a surfactant-free resin layer or a fiber-reinforced layer.

[0020] <Surface resin layer> The surface resin layer is interposed between the surface protective layer and the back resin layer, revealing the design of the flooring material. The surface resin layer has portions that are colored with one or more colors. Coloring with one or more colors means either colored transparent or colored opaque having one or more colors. In the case of the surface resin layer 21 shown in Figure 3, the first surface resin layer 211 is colored with one or more colors and the second surface resin layer 212 is colorless transparent or colored with one or more colors, or the first surface resin layer 211 is colorless transparent and the second surface resin layer 212 is colored with one or more colors. In the layer configuration shown in Figure 4, a decorative layer 213 is provided that is colored with one or more colors to reveal the design, so the first surface resin layer 211 is colorless transparent so that the design of the decorative layer can be seen, and the second surface resin layer 212 is colorless transparent or colored with one or more colors. The surface resin layer may be non-foamed or foamed. If the surface resin layer has a first surface resin layer and a second surface resin layer, the first surface resin layer and the second surface resin layer may each be independently non-foamed or foamed. When foamed as described above, the foaming ratio is not particularly limited, but is between 1.2 and 5 times. If the foaming ratio is above the lower limit, cushioning properties can be imparted to the flooring material, and the flooring material can be made lighter. If it is below the upper limit, deterioration of antistatic properties can be suppressed. It is preferable that the surface resin layers, including the first and second surface resin layers, are not foamed, as this improves the flow of electricity and enhances antistatic properties, and also improves the aesthetic appearance by making the surface of the flooring material smooth.

[0021] The surface resin layer, including the first and second surface resin layers, contains a vinyl chloride resin as its main component resin, and further contains a surfactant as an antistatic agent. The surface resin layer may contain other resins, or it may not contain other resins, provided that it contains a vinyl chloride-based resin as its main component. Herein, in this specification, the main component resin of a layer means a resin that accounts for 20% by weight or more, preferably 40% by weight or more, and more preferably 60% by weight or more, of the total resin components contained in the layer (when the total resin components are considered to be 100% by weight).

[0022] Vinyl chloride resins are polymers formed by polymerizing at least one monomer of vinyl chloride (chloroethylene). Vinyl chloride resins include not only homopolymers formed by the homopolymerization of chloroethylene, but also copolymers of chloroethylene and other monomers copolymerizable with chloroethylene, mixtures of homopolymers and copolymers, and mixtures of two or more copolymers. A mixture refers to a polymer in which homopolymers and copolymers, or copolymers, are kneaded together without substantially polymerization. Examples of vinyl chloride resins include vinyl chloride polymers (homopolymers); chlorinated vinyl chloride; partially crosslinked vinyl chloride; copolymers containing vinyl chloride, such as vinyl chloride-vinyl acetate copolymers, vinyl chloride-ethylene copolymers, vinyl chloride-propylene copolymers, vinyl chloride-styrene copolymers, vinyl chloride-isobutylene copolymers, vinyl chloride-vinylidene chloride copolymers, vinyl chloride-butadiene copolymers, vinyl chloride-isoprene copolymers, and vinyl chloride-chlorinated propylene copolymers; mixtures of homopolymers and one or more copolymers; and mixtures of two or more copolymers. Preferably, vinyl chloride polymers (homopolymers) are used. These vinyl chloride resins may be used individually or in combination of two or more types. The vinyl chloride polymer (homopolymer) can be one produced by emulsion polymerization, suspension polymerization, solution polymerization, bulk polymerization, etc., and it is preferable to use a paste vinyl chloride resin and / or a suspension vinyl chloride resin.

[0023] The paste vinyl chloride resin is, for example, a paste-like vinyl chloride resin obtained by emulsion polymerization, and its viscosity can be adjusted as appropriate with a plasticizer. The paste vinyl chloride resin is a fine powder consisting of aggregates of many fine particles with a particle size of 0.1 μm to 10 μm (preferably 1 μm to 3 μm), and preferably the surface of the fine powder is coated with a surfactant. The average degree of polymerization of the paste vinyl chloride resin is preferably about 1000 to 2000. The suspension vinyl chloride resin is, for example, a vinyl chloride resin obtained by suspension polymerization. The suspension vinyl chloride resin is a fine powder with a particle size of preferably 20 μm to 100 μm. The average degree of polymerization of the suspension vinyl chloride resin is preferably about 700 to 1500, more preferably about 700 to 1100, and even more preferably about 700 to 1000.

[0024] The surface resin layer, including the first and second surface resin layers, may optionally contain plasticizers, fillers, and various additives. Examples of plasticizers include polyester-based plasticizers, glycerin-based plasticizers, polycarboxylic acid ester-based plasticizers, and polyalkylene glycol-based plasticizers. Examples of fillers include calcium carbonate, titanium dioxide, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica. Conventional known additives can be used, such as plasticizers, fillers, colorants, flame retardants, stabilizers, antioxidants, lubricants, antibacterial agents, antifungal agents, and antiviral agents.

[0025] {surfactants} Examples of surfactants contained in the surface resin layer include anionic, cationic, or amphoteric ionic surfactants, or nonionic surfactants. Examples of anionic surfactants include carboxylic acid types such as ether carboxylates; sulfonic acid types such as alkanesulfonates; sulfate ester types such as alkyl sulfates; and phosphate ester types such as alkyl phosphates. Examples of cationic surfactants include alkylamine salt types such as monoalkylamine salts; and quaternary ammonium salt types such as alkyltrimethylammonium chloride. Examples of amphoteric surfactants include alkylbetaine types such as alkyldimethylaminoacetic acid betaine; and alkylimidazolium betaine types such as 2-alkyl-N-carboxymethyl-N-hydroxyethylimidazolium betaine. Examples of nonionic surfactants include polyethylene glycol types such as higher alcohol ethylene oxide adducts and fatty acid ethylene oxide adducts; and polyhydric alcohol types such as fatty acid esters of polyethylene oxide or glycerin, fatty acid esters of sorbitol or sorbitan, and aliphatic amides of alkanolamines. These surfactants may be used individually or in combination of two or more.

[0026] From the standpoint of minimizing bleeding, it is preferable to use a cationic surfactant in the surface resin layer. In particular, since it is possible to obtain a flooring material with excellent antistatic properties and superior stain resistance, it is preferable to use a surfactant with a slower bleeding rate than the surfactant in the back resin layer. A surfactant with a slow bleeding rate can be determined as follows: Materials containing the same composition of resin, including a vinyl chloride resin, with equal amounts of two surfactants to be compared are molded into plates of the same shape and thickness. After standing them at 60°C, 1 atm, and 90% RH for 24 hours, the amount of surfactant seeping out onto the surface of both molded products is compared. This comparison can be made, for example, by touching the surface with a finger to check the degree of stickiness; the stickier the surface, the greater the amount of surfactant seeping out. The surfactant that seeps out in the smallest amount is the surfactant with a slow bleeding rate.

[0027] Furthermore, if the surface resin layer has a first surface resin layer and a second surface resin layer, the surfactants contained in the first surface resin layer and the second surface resin layer may be the same or different. It is preferable to use the same surfactant in the first surface resin layer and the second surface resin layer for ease of manufacturing.

[0028] The amounts of each component constituting the surface resin layer are as follows, with the entire surface resin layer being 100% by weight: for example, the resin component containing vinyl chloride resin is 20% to 85% by weight, the plasticizer is 10% to 40% by weight, the filler is 0% to 40% by weight, the additive is 0% to 20% by weight, and the surfactant, which is an antistatic agent, is 0.1% to 5% by weight. Note that if a component is 0% by weight, it means that the component is not present. In particular, the amount of surfactant in the surface resin layer is preferably 0.1% by weight or more and 3% by weight or less. The main layer may have a layer that does not contain surfactant, but when a layer without surfactant is interposed, the volume resistivity of the flooring material tends to increase. In this regard, by setting the amount of surfactant in the surface resin layer within the above-mentioned preferred range, a flooring material with low volume resistivity can be constructed. Hereinafter, a layer that does not contain surfactant may be referred to as a "surfactant-free layer". When the surface resin layer has a first surface resin layer and a second surface resin layer, the amounts of each component constituting the first surface resin layer and the second surface resin layer are appropriately set from the range of amounts of each component constituting the surface resin layer as described above. The thickness of the surface resin layer is not particularly limited, and is, for example, 0.1 mm or more and 1.5 mm or less. The thicknesses of the first surface resin layer and the second surface resin layer are not particularly limited, and are, independently of each other, for example, 0.01 mm or more and 0.7 mm or less.

[0029] <Cosmetic layer> The cosmetic layer is incorporated into the main layer as needed. Typically, decorative printed films are used as the decorative layer. These decorative printed films can be made by printing ink onto a resin film and allowing it to solidify, or by transferring a design foil (transfer foil) from a transfer sheet onto a resin film. As the resin film, for example, a colorless, transparent film made from a general-purpose resin such as polyethylene, polyethylene terephthalate, or polyvinyl chloride can be used. The cosmetic layer may or may not contain a surfactant. A main body layer having a cosmetic layer that does not contain a surfactant is a main body layer having a surfactant-free layer. The thickness of the cosmetic layer is not particularly limited, for example, it may be between 0.03 mm and 0.3 mm.

[0030] <Resin layer on the back> The back resin layer is located on the underside of the front resin layer and constitutes the thickness and weight of the flooring material. The backing resin layer may be colored or colorless and transparent. Furthermore, the backing resin layer may be non-foamed or foamed. If the backing resin layer is non-foamed, it can improve electrical conductivity and enhance antistatic properties. If the backing resin layer is foamed, it can provide cushioning to the flooring material and further reduce its weight. If foamed, the foaming ratio is not particularly limited, but is between 1.05 and 5 times. If the foaming ratio is above the lower limit, it can provide cushioning to the flooring material and further reduce its weight; if it is below the upper limit, it can suppress deterioration of antistatic properties. The back resin layer contains a vinyl chloride resin as its main component, and also contains a surfactant as an antistatic agent. The backing resin layer may contain other resins, or may not contain other resins, provided that it contains a vinyl chloride-based resin as its main component. Furthermore, the backing resin layer may contain plasticizers, fillers, and various additives as needed. As for the vinyl chloride resin, plasticizer, filler, and additives for the back side resin layer, those described in the section above under "Front side resin layer" can be used as appropriate.

[0031] Examples of surfactants contained in the back resin layer include anionic, cationic, or amphoteric ionic surfactants, or nonionic surfactants. Specific examples of these surfactants can be those described in the {surfactants} section of the <front resin layer> above. Due to its excellent conductive properties, it is preferable to use a cationic surfactant in the back resin layer, and among cationic surfactants, it is more preferable to use a quaternary ammonium salt type cationic surfactant such as quaternary ammonium chloride. In relation to the front resin layer, the surfactant used in the back resin layer may be the same surfactant as that used in the front resin layer, or a different surfactant may be used. For the reasons mentioned above, it is preferable to use a surfactant with a faster bleeding rate in the back resin layer than the surfactant used in the front resin layer.

[0032] The amounts of each component constituting the back resin layer are such that, with the entire back resin layer being 100% by weight, for example, the resin component containing vinyl chloride resin is 20% to 70% by weight, the plasticizer is 10% to 50% by weight, the filler is 10% to 60% by weight, the additive is 0.1% to 30% by weight, and the surfactant, which is an antistatic agent, is 0.1% to 20% by weight. In particular, the amount of surfactant in the back resin layer is preferably 1% to 7% by weight. If the amount of surfactant in the back resin layer is within the above range, the antistatic properties, antifouling properties, and processability are good. The thickness of the resin layer on the back is not particularly limited, but is, for example, 0.2 mm or more and 5 mm or less.

[0033] <Intermediate fiber reinforcement layer and back fiber reinforcement layer> The intermediate fiber reinforcement layer is a layer that suppresses dimensional changes in the flooring material due to shrinkage and expansion over time, and also increases its mechanical strength. The intermediate fiber reinforcement layer is provided as needed. The intermediate fiber reinforcement layer may be one layer or two or more layers. Nonwoven fabrics or woven fabrics can be used as the intermediate fiber reinforcement layer. The material of the fibers constituting the nonwoven fabrics and woven fabrics is not particularly limited, and examples include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; and natural fibers. It is preferable to use glass fiber nonwoven fabrics or glass fiber woven fabrics as the intermediate fiber reinforcement layer because they can improve the dimensional stability of the flooring material, have significantly less dimensional variation compared to organic fibers, and have good compatibility with vinyl chloride resins. The intermediate fiber reinforcement layer does not contain surfactants; therefore, the main layer having the intermediate fiber reinforcement layer is a main layer having a non-containing layer. The thickness of the intermediate fiber reinforcement layer is not particularly limited, but is, for example, 0.001 mm or more and 0.5 mm or less, preferably 0.02 mm or more and 0.06 mm or less. The basis weight of the intermediate fiber reinforcement layer is not particularly limited, but is preferably 30 g / m². 2 More than 90g / m 2 The following applies:

[0034] The underside fiber reinforcement layer is the layer located on the innermost surface of the main layer (flooring material) and is designed to prevent warping of the flooring material. The underside fiber reinforcement layer is provided as needed. The back fiber reinforcement layer may be one layer or two or more layers. As the back fiber reinforcement layer, nonwoven fabrics (including felt), woven fabrics, and paper can be used. When laying the flooring material on the installation surface using adhesives, etc., it is preferable to use nonwoven fabric as the back fiber reinforcement layer because it improves the adhesion and bonding between the flooring material and the installation surface. By improving the adhesion and bonding of the flooring material to the installation surface, the lifting of the flooring material over time after installation is prevented, and electricity can be continuously discharged from the flooring material to the subfloor, allowing it to exhibit antistatic properties for a long period of time. Examples of the nonwoven fabric include spunbond nonwoven fabric, thermal bond nonwoven fabric, chemical bond nonwoven fabric, needle punch nonwoven fabric, and spunlace nonwoven fabric, and among these, it is preferable to use spunbond nonwoven fabric. The material of the fibers constituting the nonwoven fabric is not particularly limited, and examples include synthetic resin fibers such as polyester (e.g., polyethylene terephthalate), polyolefins such as polypropylene, and natural fibers. The back fiber reinforcement layer does not contain surfactants; therefore, the main layer having the back fiber reinforcement layer is a main layer having a non-containing layer. The thickness of the back fiber reinforcement layer is not particularly limited, but is, for example, 0.001 mm to 1.5 mm, preferably 0.02 mm to 0.06 mm. The basis weight of the back fiber reinforcement layer is not particularly limited, but is preferably 30 g / m². 2 More than 90g / m 2 The following applies:

[0035] (Surface protective layer) The surface protection layer is the outermost layer of the flooring material and protects the surface of the main layer. The surface protective layer is colorless and transparent or colored and transparent, preferably colorless and transparent, in order to allow the design exposed on the main layer to be visible. The surface protection layer is provided on the surface of the main body layer. For example, if the main body layer has a front resin layer and a back resin layer, the surface protection layer is provided on the surface of the front resin layer. Also, if the front resin layer has a first front resin layer and a second front resin layer, the surface protection layer is provided on the surface of the first front resin layer. The surface protective layer comprises an active energy ray curable resin and an ionic liquid as an antistatic agent, and may optionally contain various additives. Examples of additives for the surface protective layer include solvents, leveling agents, fine particles, fillers, dispersants, plasticizers, UV absorbers, surfactants, antioxidants, thixotropizing agents, flame retardants, stabilizers, antibacterial agents, antifungal agents, and antiviral agents.

[0036] The surface protective layer is formed by applying an active energy ray-curable resin composition containing an ionic liquid to the surface of the main body layer to form a coating film, and then curing the coating film by irradiating it with active energy rays. The active energy ray curable resin composition comprises an active energy ray curable monomer and / or oligomer as the main component, and optionally includes other components such as a radical polymerization initiator, an active energy ray absorber, and an active energy ray stabilizer.

[0037] The aforementioned active energy ray-curable resin refers to a resin that has energy quanta capable of crosslinking and polymerizing monomers, etc., in charged particle beams or electromagnetic waves, that is, a resin that has been crosslinked and cured by irradiation with electron beams or ultraviolet rays, etc. An active energy ray-curable resin is, for example, a resin in which a curable monomer or oligomer has been cured by active energy rays. The curable monomer or oligomer is not particularly limited as long as it can be cured by active energy rays. The curable monomer can be a single or combined type of conventionally known monofunctional monomer, difunctional monomer, or polyfunctional monomer with three or more functions that has properties such as hardness, gloss, and stain resistance required for a surface protective layer and is suitable for coating. The curable oligomer can be a single or combined type of oligomer such as bisphenol A type, novolac type, polybutadiene type epoxy (meth)acrylate or polyether type urethane (meth)acrylate that has properties such as hardness, gloss, and stain resistance required for a surface protective layer and is suitable for coating. It is preferable to use a curable monomer or oligomer that hardens when exposed to ultraviolet light, as it can form a relatively strong surface protective layer and is versatile. Examples of curable monomers or oligomers include monomers or oligomers having polymerizable unsaturated bonding groups such as (meth)acrylate groups or (meth)acryloyloxy groups, or epoxy groups in the molecule.

[0038] Specific examples of the curable monomer include styrene monomers such as α-methylstyrene, methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol penta(meth)acrylate, urethane (meth)acrylate, and polyol compounds having two or more thiol groups in the molecule. Specific examples of the curable oligomer include urethane (meth)acrylate, polyester (meth)acrylate, epoxy (meth)acrylate, monofunctional (meth)acrylate or polyfunctional (meth)acrylate having polymerizable unsaturated bonds, such as organic-inorganic hybrid (meth)acrylate obtained by condensing colloidal silica and (meth)acryloylalkoxysilane, unsaturated polyester, and epoxy. Among these, urethane (meth)acrylate is preferred because it has moderate flexibility, can form a flooring material with excellent heat resistance, chemical resistance, and durability, and furthermore, has excellent adhesion to the main layer. The molecular weight of the curable monomer or oligomer is not particularly limited, but examples include a range of 200 to 10,000.

[0039] A radical polymerization initiator is usually added to the curable monomer or oligomer. The radical polymerization initiator is a compound that generates radicals upon irradiation with active energy rays, and conventionally known types such as hydrogen abstraction type or photocleavage type can be used alone or in combination of two or more. A photosensitizer may also be used in combination with such a radical polymerization initiator. Examples of the radical polymerization initiators include 2,2-dimethoxy-2-phenylacetophenone, acetophenone, benzophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4'-dimethoxybenzophenone, benzoinpropyl ether, benzyldimethyl ketal, N,N,N',N'-tetramethyl-4,4'-diaminobenzophenone, 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one, and other thioxant compounds.

[0040] {Ionic liquids} Ionic liquids are composed of ions and are in liquid form. In the present invention, the ionic liquid includes room-temperature molten salts that are liquid at room temperature (e.g., 30°C), and alkali metal salts that are solid at room temperature (e.g., 30°C) but become liquid at room temperature when dissolved in a suitable solvent. The room-temperature molten salt can be one in which at least one of the cations and anions constituting it is an organic ion. Examples of the cations include ions such as monosubstituted, disubstituted, and trisubstituted ions of ammonium, imidazolium, pyridinium, pyrrolidinium, phosphonium, guanidinium, and isouronium. Examples of the anions include halides, sulfuric acid, sulfonic acid, amide, imide, methane, boric acid, phosphoric acid, antimonylic acid, cobalt tetracarbonyl, trifluoroacetic acid, and decanoic acid. These may be used individually or in combination of two or more. As the room-temperature molten salt, it is preferable to use at least one selected from the group consisting of organic compound salts such as ammonium salts, imidazolium salts, pyrazolium salts, thiazolium salts, oxazolium salts, pyrrolidinium salts, pyridinium salts, pyrimidinium salts, pyrazinium salts, phosphonium salts, tetraalkylammonium salts, and tetraalkylphosphonium salts. The ammonium salt is more preferable because it is relatively inexpensive and has excellent antistatic effects. Specific examples of room-temperature molten salts are those described in paragraphs

[0032] to

[0038] of Patent Document 1 (Japanese Patent Publication No. 6175686). Due to space limitations, those descriptions are omitted here, but the contents described in paragraphs

[0032] to

[0038] above may be incorporated directly into the description of room-temperature molten salts in this specification.

[0041] Examples of the alkali metal salt include salts of organic acids or inorganic acids. Examples of alkali metals include lithium, sodium, potassium, cesium, and rubidium. Examples of organic acids include aliphatic monocarboxylic acids with 1 to 18 carbon atoms, such as formic acid, acetic acid, propionic acid, butyric acid, and lactic acid; aliphatic dicarboxylic acids with 1 to 12 carbon atoms, such as oxalic acid, malonic acid, succinic acid, fumaric acid, maleic acid, and adipic acid; aromatic carboxylic acids with benzoic acid, phthalic acid, isophthalic acid, terephthalic acid, and salicylic acid; and sulfonic acids with 1 to 20 carbon atoms, such as methanesulfonic acid, p-toluenesulfonic acid, dodecylbenzenesulfonic acid, and trifluoromethanesulfonic acid. Examples of inorganic acids include hydrochloric acid, hydrobromic acid, sulfonic acid, sulfurous acid, phosphoric acid, phosphorous acid, polyphosphate, nitric acid, and perchloric acid.

[0042] Specifically, examples of alkali metal salts include lithium salts such as lithium acetate, lithium chloride, lithium phosphate, lithium perchlorate, lithium sulfonates such as lithium trifluoromethanesulfonate and lithium dodecylbenzenesulfonate; sodium salts such as sodium acetate, sodium phosphate, sodium perchlorate and sodium toluenesulfonate; and potassium salts such as potassium acetate, potassium chloride, potassium phosphate, potassium perchlorate and potassium toluenesulfonate. These may be used individually or in combination of two or more. In particular, it is preferable to use an ionic liquid containing lithium salt (a solution in which lithium salt is dissolved in a solvent) because it can create a flooring material with excellent chemical resistance.

[0043] Furthermore, the solvent used to dissolve the alkali metal salt is one that dissolves the alkali metal salt and exhibits excellent dispersibility with the active energy ray-curable resin that forms the surface protective layer. Examples of solvents for dissolving the alkali metal salt include alcohols such as methanol, ethanol, isopropyl alcohol, butanol, and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, and methyl isobutyl; esters such as methyl acetate, ethyl acetate, and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, octane, and cyclopentanone; and aromatic hydrocarbons such as benzene, toluene, and xylene. These solvents can be used individually or in combination of two or more. As described above, alkali metal salts dissolved in a solvent become liquid at room temperature. The concentration of the alkali metal salt is set as appropriate, but for example, if the total is 100% by weight, it is between 10% and 30% by weight.

[0044] The amount of the ionic liquid is preferably 0.5% to 20% by weight, more preferably 1% to 15% by weight, even more preferably 2% to 13% by weight, and particularly preferably 3% to 10% by weight, based on 100% by weight of the entire surface protective layer. If the amount of the ionic liquid is too small, the antistatic and chemical resistance properties may not be sufficiently exhibited, and if the amount of the ionic liquid is too large, the chemical resistance may decrease and the mechanical strength of the surface protective layer may decrease. When the ionic liquid is an alkali metal salt dissolved in a solvent, the range of the amount of ionic liquid in the surface protective layer is a value based on the total weight of the solvent and the alkali metal salt. The thickness of the surface protective layer is not particularly limited, but is, for example, 1 μm to 100 μm, preferably 5 μm to 70 μm, and more preferably 10 μm to 50 μm. If the thickness of the surface protective layer is below the upper limit, deterioration of antistatic properties can be suppressed, and if it is above the lower limit, the surfactant contained in the resin layer of the main body layer can be effectively prevented from bleeding onto the floor material surface.

[0045] [Advantages of the flooring material of the present invention] The flooring material of the present invention has a resin layer in the main body that contains a surfactant as an antistatic agent, and a surface protective layer that contains an ionic liquid as an antistatic agent. The surfactant has good dispersibility with vinyl chloride resins, and the ionic liquid has good dispersibility with active energy ray curable resins. For this reason, the flooring material of the present invention has excellent processability during manufacturing. Furthermore, since the flooring material of the present invention contains an antistatic agent in both the resin layer of the main body layer and the surface protective layer, the volume resistivity is relatively low, resulting in excellent antistatic properties. In particular, flooring materials having a non-containing layer tend to have higher volume resistivity because the electrical resistance in that layer is higher. In this respect, the flooring material of the present invention has excellent antistatic properties due to the above-described structure, even though it has a non-containing layer.

[0046] For example, the volume resistivity of the flooring material of the present invention is 100 × 10⁻¹⁰ in an environment with a temperature of 23°C and a humidity of 25%RH. 8 It is less than or equal to Ω, preferably 60 × 10 8 It is less than or equal to Ω, and more preferably 4.0 × 10 8 It is less than or equal to Ω. However, the volume resistivity is a value measured in accordance with JIS A1454 ("Test Methods for Polymer-Based Flooring Materials"), specifically section 23, Electrical Properties Test, and is the average value measured at any multiple locations on the surface of the flooring material.

[0047] Furthermore, since the surface protective layer of the flooring material of the present invention contains an ionic liquid as an antistatic agent, the ionic liquid is less likely to bleed onto the surface of the surface protective layer. Therefore, according to the present invention, it is possible to provide a flooring material that is less prone to dirt adhering to its surface and has excellent stain resistance.

[0048] Furthermore, if the surface protective layer contains an ionic liquid of lithium salt, a flooring material with excellent chemical resistance can be provided. The flooring material of the present invention may be either a sheet flooring material or a tile flooring material, but the form of a sheet flooring material is particularly preferred. When tile flooring material is laid on a construction surface, numerous joints are formed between adjacent tile flooring materials. On the other hand, because sheet flooring material is long, when laid on a construction surface, the number of places where joints occur between adjacent sheets is extremely small. These joints are generally joined with welding rods or the like, and adjacent sheets are integrated. Because there are fewer joints, even if chemicals adhere to the surface of the sheet flooring material after installation, the risk of chemicals penetrating into the joints is reduced, and discoloration of the surface can be suppressed by the chemical resistance of the surface protective layer.

[0049] [Method for manufacturing the flooring material of the present invention] The flooring material of the present invention can be manufactured, for example, as follows. Typically, the flooring material of the present invention is obtained by forming a main body layer and then forming a surface protection layer on the surface of the main body layer. For example, in the case of the main body layer 2 with the layer configuration shown in Figure 3, the layers are laminated in the following order from the back side: a back fiber reinforcement layer 24 such as spunbond nonwoven fabric, a back resin layer 22 containing vinyl chloride resin and surfactant, an intermediate fiber reinforcement layer 23 such as glass woven fabric, a second surface resin layer 212 containing vinyl chloride resin and surfactant, and a first surface resin layer 211 containing vinyl chloride resin and surfactant. Furthermore, in the case of the main body layer 2 with the layer configuration shown in Figure 4, the following layers are laminated in order from the back side: a back fiber reinforcement layer 24 such as spunbond nonwoven fabric, a back resin layer 22 containing vinyl chloride resin and surfactant, an intermediate fiber reinforcement layer 23 such as glass woven fabric, a second surface resin layer 212 containing vinyl chloride resin and surfactant, a decorative layer 213 such as design printing film, and a first surface resin layer 211 containing vinyl chloride resin and surfactant. The aforementioned back resin layer, second front resin layer, and first front resin layer can be formed by gelling a paste sol, calendering, or extrusion molding, etc. The forming material used is one containing a vinyl chloride resin and a surfactant, as described in the (main body layer) section above. When forming the resin layer by gelling a paste sol, the forming material is applied to a development surface such as a development film to form a coating.

[0050] By heating the entire unsolidified laminate, which is laminated in the order of the back fiber reinforcement layer 24, back resin layer 22, intermediate fiber reinforcement layer 23, second surface resin layer 212, and first surface resin layer 211, the vinyl chloride resin is solidified to obtain the main body layer 2 with the layer configuration shown in Figure 3. Similarly, by heating the entire unsolidified laminate, which is laminated in the order of the back fiber reinforcement layer 24, back resin layer 22, intermediate fiber reinforcement layer 23, second surface resin layer 212, decorative layer 213, and first surface resin layer 211, the vinyl chloride resin is solidified to obtain the main body layer 2 with the layer configuration shown in Figure 4. In the above, all layers are laminated to create a laminate and the entire laminate is heated, but the lamination and heating may be repeated sequentially. For example, the main body layer shown in Figures 3 and 4 may be produced by sequentially repeating the stacking of each layer and heating of the stacks, such as heating a first stack made by stacking several layers, and then heating a second stack made by stacking other layers on top of the first stack. The heating means is not particularly limited, but examples include electric heaters. The heating temperature is, for example, 130°C to 200°C, preferably 135°C to 210°C, and the heating time is, for example, 10 seconds to 300 seconds.

[0051] A coating film is formed by applying a surface protection layer forming material to the surface of the main body layer. If necessary, a primer layer may be formed on the surface of the main body layer, and then the surface protection layer forming material may be applied to the surface of the primer layer to form the coating film. Alternatively, an embossed surface may be formed on the surface of the main body layer, and then the surface protection layer forming material may be applied to the surface with the formed irregularities to form the coating film. The material used to form the surface protective layer can be an active energy ray curable resin composition containing an ionic liquid, as described in the (Surface Protective Layer) section above. As the active energy ray-curable resin composition, a commercially available paint may be used. Representative examples of the commercially available paint include ultraviolet-curable resin compositions. Specifically, for example, Oracryl (manufactured by Nippon Paint Co., Ltd.), Adeka Optomer (manufactured by Asahi Denka Kogyo Co., Ltd.), Co-A Hard (manufactured by Koei Chemical Industry Co., Ltd.), Seika Beam (manufactured by Dainichi Seika Kogyo Co., Ltd.), EBECRYL (manufactured by Daicel Cytec Co., Ltd.), Unidic (manufactured by DIC Corporation), Sunrad (manufactured by Sanyo Chemical Industries, Ltd.), and the like.

[0052] By irradiating the uncured coating film of the forming material of the surface protective layer with active energy rays, the curable monomer or oligomer polymerizes and becomes a polymer. By such polymerization, the uncured coating film cures and the surface protective layer is formed. Examples of the apparatus for irradiating active energy rays include low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, halogen lamps, carbon arc lamps, metal halide lamps, xenon lamps, nitrogen lasers, electron beam accelerators, radiation sources of radioactive elements, and the like. The irradiation amount of the active energy rays is appropriately set according to the curable monomer and the like. For example, in terms of the integrated light amount at an ultraviolet wavelength of 365 nm, it is about 50 to 5,000 mJ / cm 2 degree. In the above manner, the floor material of the present invention in which the surface layer is firmly adhered to the surface of the main body layer can be obtained.

Examples

[0053] Hereinafter, examples and comparative examples will be shown to describe the present invention in more detail. However, the present invention is not limited to the following examples.

[0054] [Materials Used] · Forming material for the surface protective layer As the active energy ray curable resin composition, a urethane acrylate-based ultraviolet curable paint (manufactured by Chugoku Marine Paints Ltd., product name "Aurex UV146B") was used. This paint is a liquid that can be applied on its own, and contains trace amounts of polymerization initiators and additives (however, no antistatic agents are included) in a urethane acrylate monomer or oligomer.

[0055] • Ionic liquid (Li): As the ionic liquid (Li), a mixture of lithium perchlorate and lithium trifluoromethanesulfonate (product name "PEL25" manufactured by Nippon Carlit Co., Ltd.) was used. The mixture itself is solid at 30°C, but the product named "PEL25" is a liquid obtained by dissolving the mixture in a solvent (polyalkylene glycol), and it is liquid at 30°C. The weight ratio of this liquid was lithium perchlorate:lithium trifluoromethanesulfonate:polyalkylene glycol = 10:5:85. • Ionic liquid (M): As the ionic liquid (M), a tetraalkylammonium salt (product name "IL-A2" manufactured by Koei Chemical Co., Ltd.) was used. This product "ILA-2" was liquid at 30°C.

[0056] • Surfactant (A) A cationic surfactant (product name "C500" manufactured by Shin-Nippon Rika Co., Ltd.) was used as surfactant (A). This product, with the product name "ILA-2," was liquid at 30°C. • Surfactants (B) As surfactant (B), a cationic surfactant, quaternary ammonium chloride (product name "ST55" manufactured by Katsuta Chemical Co., Ltd.), was used. This product "ST55" was liquid at 30°C.

[0057] • Material for forming the resin layer (Table 1) A vinyl chloride resin composition was used as the material for forming the first surface resin layer. This vinyl chloride resin composition contains 60 parts by weight of paste vinyl chloride, 20 parts by weight of plasticizer (DOP), 1 part by weight of pigment (colorant), and 5 parts by weight of stabilizer. • Material for forming the resin layer (Table 2) A vinyl chloride-based resin composition was used as the material for forming the second surface resin layer. This vinyl chloride-based resin composition contains 50 parts by weight of paste vinyl chloride, 20 parts by weight of plasticizer (DOP), 20 parts by weight of filler (calcium carbonate), and 5 parts by weight of stabilizer.

[0058] • Intermediate fiber reinforcement layer Glass woven fabric was used as the intermediate fiber reinforcement layer. The glass woven fabric does not contain any antistatic agents. • Material for forming the resin layer on the back A vinyl chloride-based resin composition was used as the material for forming the back resin layer. This vinyl chloride-based resin composition contains 50 parts by weight of suspension vinyl chloride, 20 parts by weight of plasticizer (DOP), 20 parts by weight of filler (calcium carbonate), and 5 parts by weight of stabilizer. • Reinforced fiber layer A spunbond nonwoven fabric made of polyethylene terephthalate was used as the back fiber reinforcement layer. The spunbond nonwoven fabric does not contain any antistatic agents.

[0059] [Example 1] <Preparation of the main layer> The backing resin layer forming material was mixed thoroughly with surfactant (B) to form a paste. The mixing ratio of the backing resin layer forming material to surfactant (B) was 55:2 by weight. Therefore, surfactant (B) is present in approximately 3.5% by weight of the backing resin layer, assuming the total weight is 100%. The material forming the first surface resin layer was mixed thoroughly with surfactant (A) to form a paste. The mixing ratio of the material forming the first surface resin layer to surfactant (A) was 49:1 by weight. Therefore, surfactant (A) is present in approximately 2% by weight of the entire first surface resin layer, assuming a total weight of 100%. The material forming the second surface resin layer was mixed thoroughly with surfactant (A) to form a paste. The mixing ratio of the material forming the second surface resin layer to surfactant (A) was 97:3 by weight. Therefore, surfactant (A) is present in approximately 3% by weight of the entire second surface resin layer, assuming a total weight of 100%.

[0060] A back-side resin layer forming material paste mixed with surfactant (B) was applied to the intermediate fiber reinforcement layer, and the back fiber reinforcement layer was placed on top of it. The assembly was heated in a 160°C oven for 2 minutes to obtain a laminate of back fiber reinforcement layer / back-side resin layer / intermediate fiber reinforcement layer. A second surface resin layer forming material paste mixed with surfactant (A) was applied to the intermediate fiber reinforcement layer of this laminate, and the assembly was heated in a 160°C oven for 2 minutes to obtain a laminate of back fiber reinforcement layer / back-side resin layer / intermediate fiber reinforcement layer / second surface resin layer. A first surface resin layer forming material paste mixed with surfactant (A) was applied to the second surface resin layer of this laminate, and the assembly was heated in a 200°C oven for 2 minutes to produce a main body layer consisting of a back fiber reinforcement layer with a thickness of approximately 0.05 mm, a back-side resin layer with a thickness of approximately 1 mm, an intermediate fiber reinforcement layer with a thickness of approximately 0.05 mm, a second surface resin layer with a thickness of approximately 0.5 mm, and a first surface resin layer with a thickness of approximately 0.5 mm. Two identical main layers were manufactured. One of the two main layers was used for a stain resistance test, and the other main layer was used to create flooring material by forming a surface protective layer on top of it.

[0061] <Formation of surface protective layer> The surface protective layer forming material was thoroughly mixed with an ionic liquid (Li). The mixing ratio of the surface protective layer forming material to the ionic liquid (Li) was 19:1 by weight. Therefore, the ionic liquid (Li) makes up approximately 5% by weight of the entire surface protective layer, assuming a total weight of 100%. The forming material containing this ionic liquid (Li) was applied to the surface of one of the two prepared main layers to a uniform thickness using a roll coater. Immediately thereafter, under standard conditions, ultraviolet light was irradiated with an electrode ultraviolet lamp to polymerize the curable monomer or oligomer, forming a surface protective layer with a thickness of approximately 20 μm. In this way, the flooring material of Example 1 was prepared.

[0062] [Example 2] Except for changing the antistatic agent added to the back resin layer formation material to a surfactant (A), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0063] [Example 3] Except for changing the antistatic agent added to the forming materials of the first and second surface resin layers to surfactant (B), two main body layers were prepared in the same manner as in Example 1, and a surface protection layer was formed on one of the main body layers to produce a flooring material.

[0064] [Example 4] Except for changing the antistatic agent added to the forming material of the back side resin layer to surfactant (A), and changing the antistatic agent added to the forming materials of the first surface resin layer and the second surface resin layer, respectively, to surfactant (B), two main body layers were prepared in the same manner as in Example 1, and a surface protection layer was formed on one of the main body layers to produce a flooring material.

[0065] [Example 5] Except for changing the antistatic agent added to the surface protective layer forming material to an ionic liquid (M), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0066] [Example 6] Except for changing the amount of surfactant (A) added to the resin layer forming material in the first surface layer to twice the original amount (4% by weight), two main layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main layers to produce a flooring material.

[0067] [Example 7] Except for not incorporating an antistatic agent into the resin layer forming material of the second surface layer, two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0068] [Example 8] Except for changing the amount of surfactant (A) added to the resin layer forming material in the second table to twice the amount (6% by weight), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0069] [Example 9] Except for changing the amount of surfactant (B) added to the back resin layer forming material to twice the amount (7% by weight), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0070] [Comparative Example 1] Except for changing the antistatic agent added to the forming materials of the first surface resin layer, the second surface resin layer, and the back surface resin layer to an ionic liquid (Li), two main body layers were prepared in the same manner as in Example 1, and a surface protection layer was formed on one of the main body layers to produce a flooring material.

[0071] [Comparative Example 2] Except for changing the antistatic agent added to the forming materials of the surface protective layer, the first surface resin layer, the second surface resin layer, and the back side resin layer to an ionic liquid (M), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0072] [Comparative Example 3] Except for changing the antistatic agent added to the material forming the surface protective layer to a surfactant (B), two main body layers were prepared in the same manner as in Example 1, and a surface protective layer was formed on one of the main body layers to produce a flooring material.

[0073] [Measurement of volume resistivity] The volume resistivity was measured for each of the flooring materials in Examples 1 to 9 and Comparative Examples 1 to 3. Volume resistivity was measured according to JIS A1454 ("Test Methods for Polymer-Based Flooring Materials"), Section 23, Electrical Characteristics Test, which evaluates the electrical performance of conductive and antistatic flooring. Electrodes were placed on a sample (flooring material) on a metal plate, and a voltage of 500V was applied for 30 seconds using an insulation resistance meter (Chauvin Arnoux, product name "Megohmmeter CA6541") to measure the resistance. Volume resistivity was measured at multiple locations on the surface of the flooring material at 150mm intervals under conditions of 23°C and 25%RH, and the average value was adopted. The results are shown in Tables 1 to 3. A "○" in the Electrical Resistance Evaluation column indicates a volume resistance of 13.0 × 10⁻⁶. 8 The symbol "△" represents a value less than Ω, and is 13.0 × 10 8 Ω or more 150.0×10 8 The "×" symbol represents a value less than Ω, and is equivalent to 150.0 × 10 8 Represents Ω or greater. In Tables 1 to 3, the "%" attached to the numerical values ​​representing the antistatic agent content of each layer, such as the surface protective layer, means "weight percent".

[0074] [Stain-resistant] In Examples 1 to 9 and Comparative Examples 1 to 3, the antifouling properties were evaluated using one of the two main body layers that did not have a surface protective layer applied. To evaluate the stain resistance, the main body layer without the aforementioned surface protective layer was left standing for 24 hours at 60°C and 90% RH, and the presence or absence of liquid seeping onto the surface of the main body layer (the surface of the first surface resin layer) was checked by touch with a finger. The results are shown in Tables 1 to 3. In each table, "○" in the stain resistance column indicates no bleeding, "△" indicates slight bleeding, and "×" indicates clear bleeding. It should be noted that since flooring materials have a protective surface layer formed on the surface of the main layer, checking for liquid seepage on the surface of the main layer does not strictly constitute an evaluation of the stain resistance of the flooring material. However, flooring materials with a main layer that shows a lot of liquid seepage can be evaluated as being prone to staining because liquid easily seeps through the protective surface layer and onto the surface of the protective surface layer.

[0075] [Workability] The processability of the flooring material during manufacturing was evaluated for each of Examples 1 to 9 and Comparative Examples 1 to 3. Processability was evaluated according to the following criteria. The results are shown in Tables 1 through 3. (Evaluation Criteria) The evaluation criterion was whether or not the antistatic agent could be easily dispersed when it was mixed into the forming material that makes up each layer: the surface protective layer, the first surface resin layer, the second surface resin layer, and the back side resin layer. ○: In all layers, the mixed antistatic agents dispersed easily, resulting in excellent processability. △: In all layers, the mixed antistatic agent was dispersed, resulting in relatively good processability. ×: The antistatic agent had high viscosity and poor dispersibility, resulting in separation over time after mixing.

[0076] [Table 1]

[0077] [Table 2]

[0078] [Table 3]

[0079] [Examples 10 to 16] Except for changing the amount of ionic liquid (Li) added to the surface protective layer forming material as shown in Table 4, the flooring materials were prepared in the same manner as in Example 1. In other words, the flooring materials of Examples 10 to 16 had the same layer structure as the flooring material of Example 1, except that the ionic liquid (Li) in the surface protective layer was different.

[0080] [Comparative Example 4] The flooring material was prepared in the same manner as in Example 1, except that an ionic liquid (Li), which is an antistatic agent, was not added to the surface protective layer. In other words, the flooring material of Comparative Example 4 had the same layer structure as the flooring material of Example 1, except that the surface protective layer did not contain an ionic liquid (Li).

[0081] [Examples 17 to 23] Except for changing the amount of ionic liquid (M) added to the surface protective layer forming material as shown in Table 5, the flooring material was prepared in the same manner as in Example 5. In other words, the flooring materials of Examples 17 to 23 had the same layer structure as the flooring material of Example 5, except that the ionic liquid (M) in the surface protective layer was different.

[0082] [Comparative Example 5] The flooring material was prepared in the same manner as in Example 5, except that an ionic liquid (M), which is an antistatic agent, was not added to the surface protective layer. The flooring material of Comparative Example 5 had the same layer structure as the flooring material of Example 5, except that the surface protective layer did not contain the ionic liquid (M). However, since the flooring material of Comparative Example 5 has the exact same configuration as the flooring material of Comparative Example 4, we did not actually manufacture the flooring material of Comparative Example 5, and instead used the measurement results of the flooring material of Comparative Example 4.

[0083] [Table 4]

[0084] [Table 5]

[0085] [Measurement of volume resistivity] The volume resistivity of the flooring materials of Examples 10 to 23 and Comparative Example 4 was measured using the same method as described in the [Measurement of Volume Resistivity] section above. The results are shown in Tables 4 and 5. Tables 4 and 5 also include the volume resistivity values ​​and evaluation results for the flooring materials in Examples 1 and 5. Furthermore, as mentioned above, the measurement results for Comparative Example 5 are based on those of Comparative Example 4.

[0086] [Chemical resistance] The flooring materials of Examples 1, 5, 10 to 23 and Comparative Example 4 were each tested for chemical resistance. The test involved placing a 2cm thick layer of absorbent cotton on each flooring material, dropping 1mL of povidone-iodine onto the cotton, covering it with a watch glass, and then leaving it undisturbed for 24 hours at 23°C and 50% RH. Afterward, the flooring material was washed with water, and the degree of discoloration (ΔE) on its surface was measured. The degree of discoloration (ΔE) was measured using a color difference meter (product name "Color Meter ZE2000" manufactured by Nippon Denshoku Industries Ltd.) and is the color difference according to the L*a*b* color system (L*: lightness, a*b*: chromaticity) in accordance with JIS Z8729. Note that ΔE = {(L-L0)² + (a-a0)² + (b-b0)} 2 It can be calculated as 1 / 2. ΔE is an indicator that the smaller its value, the less discoloration there is. The results are shown in Tables 4 and 5. Note that, as mentioned above, the measurement results for Comparative Example 5 are the same as those for Comparative Example 4. In each table, "○" in the chemical resistance column indicates that ΔE is less than 8 and there was little to no visible discoloration; "△" indicates that ΔE is 8 or more but less than 20 and there was slight visible discoloration; and "×" indicates that ΔE is 20 or more and there was visible discoloration.

[0087] Furthermore, when the processability of the flooring material manufacturing process for Examples 10 to 23 and Comparative Examples 4 and 5 was evaluated in the same way using the evaluation criteria described in the [Processability] section above, it was found that in all cases, the mixed antistatic agent dispersed easily in all layers, and the processability was extremely good.

[0088] [Examples 24 to 27] The flooring material was prepared in the same manner as in Example 1, except that the amount of surfactant added to the forming materials of the first surface resin layer, the second surface resin layer, and the back surface resin layer was changed as shown in Table 6.

[0089] For Examples 24 to 27, volume resistivity was measured, antifouling properties were evaluated, and processability was evaluated in the same manner as in Example 1. The results are shown in Table 6. In Table 6, the "%" attached to the numerical values ​​representing the antistatic agent content of each layer, such as the surface protective layer, means "weight percent".

[0090] [Table 6]

[0091] [Example 28] Except for laminating a decorative layer between the second surface resin layer and the first surface resin layer, two main body layers were prepared in the same manner as in Example 1, and a surface protection layer was formed on one of the main body layers to produce a flooring material. Specifically, a vinyl chloride film approximately 0.15 mm thick with a printed design was prepared as the decorative layer. This film does not contain any antistatic agents. A laminate consisting of a back fiber reinforcement layer, a back resin layer, an intermediate fiber reinforcement layer, and a second surface resin layer was prepared in the same manner as in Example 1. The decorative layer was laminated on the second surface resin layer of this laminate, and a paste for forming the first surface resin layer, mixed with surfactant (A), was applied on top of the decorative layer. The laminate was heated in a 200°C oven for 2 minutes to produce a main body layer consisting of a back fiber reinforcement layer with a thickness of approximately 0.05 mm, a back resin layer with a thickness of approximately 1 mm, an intermediate fiber reinforcement layer with a thickness of approximately 0.05 mm, a second surface resin layer with a thickness of approximately 0.35 mm, a decorative layer with a thickness of approximately 0.15 mm, and a first surface resin layer with a thickness of approximately 0.5 mm. In Example 28, a surface protective layer forming material containing 5% by weight of an ionic liquid (Li) was applied to the surface of one of the two main layers in the same manner as in Example 1, and then cured to form a surface protective layer with a thickness of approximately 20 μm, thereby producing the flooring material of Example 28.

[0092] [Example 29] The flooring material of Example 29 was prepared in the same manner as in Example 28, except that the antistatic agent added to the back resin layer forming material was changed to a surfactant (A).

[0093] For Examples 28 and 29, volume resistivity was measured, antifouling properties were evaluated, and processability was evaluated in the same manner as in Example 1. The results are shown in Table 7. In Table 7, the "%" attached to the numerical values ​​representing the antistatic agent content of each layer, such as the surface protective layer, means "weight percent".

[0094] [Table 7] [Explanation of Symbols]

[0095] 1. Flooring 2. Main Layer 21 Front resin layer 211 1st surface resin layer 212 2nd surface resin layer 22. Backside resin layer 3 Surface protective layer

Claims

1. It comprises a main body layer having a resin layer containing a vinyl chloride resin, and a surface protective layer provided on the surface of the main body layer and containing an active energy ray curable resin, The main body layer comprises, in this order, a front resin layer having a first front resin layer and a second front resin layer directly laminated on the back surface of the first front resin layer, a fiber reinforcement layer, and a back resin layer. The first surface resin layer, the second surface resin layer, and the back surface resin layer all contain a surfactant as an antistatic agent. The first surface resin layer and the second surface resin layer contain the same type of surfactant, The surfactant contained in the first surface resin layer and the second surface resin layer is different from the surfactant contained in the back surface resin layer. The amount of surfactant in the first surface resin layer is less than the amount of surfactant in the second surface resin layer. A flooring material wherein the surface protective layer contains an ionic liquid as an antistatic agent.

2. The flooring material according to claim 1, wherein the surfactants of the first surface resin layer and the second surface resin layer have a slower bleeding rate than the surfactant of the back surface resin layer.

3. The flooring material according to claim 1, wherein the ionic liquid contained in the surface protective layer contains a lithium salt.

4. The ionic liquid containing the lithium salt is present in an amount of 0.5% to 20% by weight relative to 100% by weight of the entire surface protective layer. The flooring material according to claim 3, wherein the surfactant is contained in an amount of 0.5% by weight or more and 20% by weight or less based on 100% by weight of the resin layer of the main body layer.

5. The main body layer has a layer that does not contain an antistatic agent, The volume resistivity of the flooring material under conditions of 23°C and 25% RH is 100 × 10⁻¹⁰ ８ A flooring material according to any one of claims 1 to 4, wherein the ohm value is less than or equal to Ω.

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