HK1103770B - Decorative sheet for floor material and decorative material for floor using the same - Google Patents

Description

Decorative sheet for floor material and decorative material for floor using the same

Technical Field

The present invention relates to a decorative sheet for flooring material and a decorative material for flooring using the same.

The floor finishing material of the present invention is useful as a floor material in buildings such as houses, apartments, condominiums, leisure facilities, and stores built by each house.

Background

Conventionally, as a decorative material for flooring materials, a material obtained by bonding a wood decorative veneer to a wood plywood and coating the wood veneer, a material obtained by bonding a wood plywood and a Medium Density Fiberboard (MDF) and then bonding a wood decorative veneer to the MDF side and coating the wood decorative veneer, has been widely known.

However, wood decorative veneers are materials for thinning natural wood, and in consideration of the problem of exhaustion of wood resources and the rise of worldwide resource conservation movement, it is desired to control the use of natural wood. Therefore, in recent years, a decorative sheet artificially expressed by printing a wood pattern or the like has been used instead of a wood decorative veneer of natural wood.

The decorative material for a floor using the decorative sheet has a degree of freedom in design expression. Further, since the decorative sheet is a synthetic material, it is excellent in weather resistance and water resistance.

However, the floor finishing material using the decorative sheet has a disadvantage that the surface is far smoother and more uniform than the conventional floor finishing material using the wood veneer, and therefore, the floor finishing material is easy to attract attention with a scratch.

In addition, in recent years, with westernization and barrier-free indoor layout, there has been a problem that furniture, wheelchairs and the like with casters are increasingly used indoors and that the floor finishing material has insufficient caster resistance. This is a problem that a large load is applied to a small area and a pit remains on the surface of the floor finishing material along the track when the wheel rotates. Also, there is pointed out a problem that when hard matter falls down on the surface of the floor finishing material, impact resistance of the dents is insufficient.

For example, patent document 1 proposes a technique for improving the above-mentioned problems such as scratch resistance and caster resistance. Patent document 1 proposes a decorative material in which a decorative sheet is provided on a surface of a wood base material, wherein a hard sheet layer structure made of a high hardness material is provided between the wood base material and the decorative sheet. Here, the hard sheet layer is a so-called backing layer, and is a reinforcing layer for providing hardness, strength, and the like to the decorative sheet for flooring material.

The decorative material for floor using the decorative sheet for floor material having the backing layer has superior properties in strength, hardness and the like to those of conventional materials. However, in the production of a decorative sheet for flooring material having a cushion layer, a step of bonding the cushion portion and the other portion (for example, a printed board) is necessary, and product loss tends to occur in this step.

Patent document 1: japanese unexamined patent publication No. 2003-11277

Disclosure of Invention

Accordingly, an object of the present invention is to provide a decorative sheet for flooring material that exhibits good abrasion resistance, caster resistance, impact resistance, and the like without forming a backing layer.

It is another object of the present invention to provide a decorative material for floors, which has excellent abrasion resistance, caster resistance, impact resistance, and the like, using the decorative sheet for floors.

The present inventors have made extensive studies to achieve the above object, and as a result, have found that a decorative sheet for flooring material having at least a specific polyolefin resin layer can achieve the above object, thereby completing the present invention.

That is, the present invention relates to a decorative sheet for flooring material described below and a decorative material for flooring using the same.

1. A decorative sheet for flooring material, which is formed by laminating at least a decorative layer, a transparent polyolefin resin layer having a thickness of 150 to 500 [ mu ] m, and a transparent surface protective layer on a base sheet made of a polyolefin resin in this order.

2. The decorative sheet for flooring material according to claim 1, which is obtained by laminating at least a pattern layer, a transparent pressure-sensitive adhesive layer, a transparent polypropylene resin layer having a thickness of 150 to 500 μm, and a transparent surface protective layer made of an ionizing radiation curing resin on a base sheet made of a polyolefin resin in this order.

3. The decorative sheet for flooring according to the above item 2, wherein the transparent polypropylene resin layer contains homopolypropylene, and the resin layer alone has a tensile elastic modulus of 1000MPa or more.

4. The decorative sheet for flooring according to the above item 2, wherein a coloring concealing layer is further laminated between the base sheet and the design pattern layer.

5. The decorative sheet for flooring according to the above item 2, wherein the transparent surface protective layer has irregularities on a surface thereof.

6. The decorative sheet for flooring according to claim 1, which is obtained by laminating at least a decorative layer, a transparent polyolefin resin layer having a thickness of 300 to 500 μm, and a transparent surface protective layer having a thickness of 3 to 30 μm on a base sheet made of a polyolefin resin in this order.

7. The decorative sheet for flooring material according to item 6 above, wherein the polyolefin resin of the transparent polyolefin resin layer is homopolypropylene.

8. The decorative sheet for flooring according to item 6 above, wherein 70% by weight or more of the polyolefin resin of the transparent polyolefin resin layer is composed of homopolypropylene.

9. The above decorative sheet for flooring material according to claim 6, wherein the melting point of the homopolypropylene is 150 to 170 ℃.

10. The decorative sheet for flooring according to claim 6, wherein the base sheet made of a polyolefin resin is a polypropylene resin film or a polyethylene resin film.

11. A floor finishing material comprising the decorative sheet for floor material according to claim 2 or 6, wherein the base plate side is bonded to an adhesive material.

Drawings

Fig. 1 is a schematic sectional view of a decorative sheet for flooring produced in example 1.

Fig. 2 is a schematic cross-sectional view of the floor finishing material produced in example 1.

FIG. 3 is a schematic cross-sectional view of the floor finishing material of the present invention.

Fig. 4 is a schematic sectional view of a decorative sheet for flooring material (particularly embodiment 2) of the present invention.

Fig. 5 is a schematic configuration diagram of the caster resistance tester.

Description of the symbols

Embossing a concave-convex pattern, a transparent surface protection layer B, a transparent polyolefin resin layer C, a transparent adhesive layer D, a pattern layer E, a base material plate F made of polyolefin resin, a back bottom layer G, a groove shaped like H V, a decorative plate I for flooring material, an adhesive layer J, a wood base material K, a decorative plate 1 for flooring material, a wood base material 2, a polyolefin resin film 10, a transparent polyolefin resin layer 11, a decorative layer 12 (printed layer), a transparent surface protection layer 14, a base layer 15 (primer), a pattern layer 16, a color masking layer 17, a transparent adhesive layer 18, a decorative plate 100 for flooring material, a caster 1000 resistance test device 1001, a weight 1001, a load 1002, a handle 1003 adjustment 1012, a caster fixing base 1010, a caster 1011, a sample 1013, a sample fixing base

Detailed Description

The decorative sheet for flooring material of the present invention and the decorative sheet for flooring material using the same will be described below.

The decorative sheet for flooring material is formed by sequentially laminating at least a decorative layer, a transparent polyolefin resin layer having a thickness of 150 to 500 [ mu ] m, and a transparent surface protective layer on a base sheet made of polyolefin resin.

As the decorative sheet for flooring material and the decorative material for flooring using the same of the present invention, specific examples include the decorative sheet for flooring material and the decorative material for flooring shown in the following embodiments 1 and 2. Embodiments 1 and 2 are explained below.

1. Decorative sheet for floor material and decorative material for floor in embodiment 1

The decorative sheet for flooring material of embodiment 1 is formed by laminating at least a pattern layer, a transparent adhesive layer, a transparent polypropylene resin layer having a thickness of 150 to 500 μm, and a transparent surface protective layer made of ionizing radiation curing resin in this order on a base sheet made of polyolefin resin.

Substrate board

As the substrate sheet, a sheet composed of a polyolefin resin is used. In general, a film made of a polyolefin-based resin can be used.

The polyolefin-based resin is not particularly limited, and a resin generally used in the field of decorative sheets can be used. Examples thereof include polyethylene, polypropylene, polybutene, polymethylpentene, ethylene-propylene copolymers, ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-propylene-butene copolymers, polyolefin-based thermoplastic elastomers, and the like. Among them, polypropylene, polyolefin-based thermoplastic elastomers, and the like are particularly preferable.

Also preferred are those comprising polypropylene as a main component alone or in combination, and examples thereof include homopolypropylene resins, random polypropylene resins, block polypropylene resins, and α -olefins having 2 to 20 carbon atoms other than polypropylene and having a polypropylene crystal moiety. Other preferred are propylene- α -olefin copolymers containing a comonomer of ethylene, 1-butene, 4-methyl-1-pentene, 1-hexene or 1-octene in an amount of 15 mol% or more.

As the polyolefin-based thermoplastic elastomer, a block polymer is used which comprises an aromatic polyester having high crystallinity and a high melting point in the hard segment and an amorphous polyether having a glass transition temperature of-70 ℃ or lower in the soft segment. Particularly preferred is a mixture of a hard segment composed of isotactic polypropylene and a soft segment composed of atactic polypropylene at a weight ratio of 80: 20.

The polyolefin-based resin can be formed into a film form by, for example, a calendering method, an inflation method, a T-die extrusion method, or the like.

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

Additives may be added to the substrate sheet as required. Examples of the additives include fillers such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, and colorants (see below). The amount of the additive to be blended may be appropriately set according to the product characteristics.

The colorant is not particularly limited, and known colorants such as pigments and dyes can be used. Examples thereof include inorganic pigments such as titanium white, zinc white, red iron oxide, vermilion pigment, ultramarine blue, cobalt blue, titanium yellow, yellow lead, and carbon black; organic pigments (also including dyes) of isoindoline, hansa yellow a, quinacridone, permanent blue 4R, phthalocyanine blue, indanthrene blue-RS, aniline black, and the like; metallic pigments of aluminum, brass, and the like; pearl luster (pearl) pigments composed of foil powder of mica covered with titanium dioxide, basic lead carbonate, etc. The coloring forms of the substrate sheet include transparent coloring and opaque coloring (covert coloring), and these can be arbitrarily selected. For example, when the base color of the material to be bonded (the substrate to which the decorative sheet is bonded) is hidden by coloring, opaque coloring may be selected. On the other hand, when a pattern is formed on the bottom of the material to be bonded so that the material can be visually observed, transparent coloring is selected.

The substrate sheet may be subjected to surface treatment such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, or dichromic acid treatment, as necessary, on one surface or both surfaces thereof. For example, in the case of performing the corona discharge treatment, the surface tension of the surface of the base material plate may be 30dyne or more, preferably 40dyne or more. The surface treatment may be carried out according to a method generally used for each treatment.

If necessary, a base layer (for example, a back base layer for easily adhering an adhesive material and a base layer for easily forming a pattern layer) may be provided on one or both sides of the base sheet. By providing a primer layer, adhesion between the layer and an adjacent connecting layer (e.g., bonded material) may be improved.

The primer layer can be formed by applying a known primer to one or both surfaces of the substrate sheet. Examples of the primer include urethane resin-based primers composed of an acrylate-modified urethane resin or the like, and primers composed of a urethane resin-cellulose resin (for example, a resin obtained by adding 1, 6-hexamethylene diisocyanate to a mixture of urethane and nitrocellulose), and the like.

The amount of the primer is not particularly limited, but is usually 0.1 to 100g/m²Preferably 0.1 to 50g/m²Left and right.

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

Pattern layer (decorative layer)

A patterned layer is formed on the base sheet (the surface opposite to the surface to which the material to be bonded is bonded, and the same side in each layer below). The decorative pattern layer is one of layers that are decorated on a decorative sheet for a floor material.

The design pattern layer is a layer for imparting a desired design to the decorative sheet for flooring material, and the type of the design is not particularly limited. For example, there may be mentioned wood grain patterns, stone grain patterns, sand patterns, tile patterns, brick patterns, cloth grain patterns, leather grain patterns, geometric figures, characters, symbols, abstract patterns, and the like.

The method of forming the patterned layer is not particularly limited, and for example, the patterned layer can be formed by a printing method using a coloring ink or a coating material (coating) obtained by dissolving (or dispersing) a known colorant (dye or pigment) and a binder resin in a solvent (or dispersion medium) at the same time.

Examples of the colorant include inorganic pigments such as carbon black, titanium white, zinc white, red iron oxide, deep blue pigment, and cadmium red; organic pigments such as azo pigments, precipitated pigment pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindoline pigments, and dioxazine pigments; metal powder pigments such as aluminum powder and bronze powder; pearl pigments such as mica covered with titanium oxide and bismuth oxychloride; a fluorescent pigment; luminescent pigments, and the like. These colorants may be used alone or in combination of 2 or more. These colorants may also contain fillers such as silica, ground pigments (bulk pigment) such as organic glass beads, neutralizing agents, surfactants and the like.

Examples of the binder resin (vehicle) include acrylic resins, styrene resins, polyester resins, polyurethane resin resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl butyral resins, alcohol ester resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, cellulose derivatives, and gum resins. These resins may be used alone or in combination of two or more.

Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, 2-ethoxyethyl acetate, and the like; alcohol organic solvents such as methanol, ethanol, n-propanol, isopropanol, isobutanol, ethylene glycol, and propylene glycol; ketone organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as methylene chloride, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; inorganic solvents such as water, and the like. These solvents (or dispersion medium) may be used alone or in combination of 2 or more.

Examples of the printing method used for forming the pattern layer include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, an inkjet printing method, and the like. In the case of forming the pattern layer in the form of a full-surface coating (ベタ), various coating methods such as a roll coating method, a knife coating method (knife coat), an air knife coating method, a die coating method (die coat), a cut coating method (lip coat), a comma coat method (comma coat), a kiss coat method (kiss coat), a flow coat method (flow coat), and a dip coat method (dip coat) may be mentioned. Other methods may be used in combination with other forming methods, such as a manual drawing method, a flow ink method, a photographic method, a transfer method, a laser beam drawing method, an electron beam drawing method, a partial vapor deposition method using a metal or the like, an etching method, and the like.

The thickness of the patterned layer is not particularly limited, and may be appropriately set according to the product characteristics, and the layer thickness at the time of coating is about 1 to 15 μm, and the layer thickness after drying is about 0.1 to 10 μm.

Coloring hidden layer (decorative layer)

A coloring concealing layer may be laminated between the base plate and the pattern layer as required. The coloring concealing layer is provided, for example, when concealing the ground color of the material to be bonded from the outer surface of the decorative sheet. It is of course necessary when the substrate sheet is transparent, and it can be formed for stable concealment even when the substrate sheet has been concealingly colored. The color masking layer is a layer to which a color is applied to a decorative sheet for flooring material, and is one of decorative layers, like a design pattern layer.

The ink for forming the coloring concealing layer is an ink for forming a patterned layer, and an ink capable of concealing coloring can be used.

The coloring masking layer is preferably formed so as to cover the entire substrate sheet (in a full-surface coated state). For example, the above-mentioned roll coating method, blade coating method, air knife coating method, die coating method, cut coating method, comma coating method, kiss coating method, flow coating method, dip coating method, and the like can be cited as preferable methods.

The thickness of the color masking layer is not particularly limited, and may be appropriately set according to the product characteristics, and the layer thickness at the time of coating is about 0.2 to 10 μm, and the layer thickness after drying is about 0.1 to 5 μm.

Transparent adhesive layer

A transparent adhesive layer is formed on the pattern layer. The transparent pressure-sensitive adhesive layer is not particularly limited as long as it is a transparent layer, and includes any 1 kind of transparent, colorless transparent, colored transparent, translucent, and the like. The adhesive layer is formed to adhere the pattern layer and the transparent polyester resin layer.

The adhesive is not particularly limited, and an adhesive known in the field of decorative sheets can be used.

Examples of the adhesive known in the field of decorative sheets include thermoplastic resins such as polyamide resins, acrylate resins, and vinyl acetate resins, and curable resins such as thermosetting urethane resins. Further, a two-pack curable polyurethane resin or polyester resin containing isocyanate as a curing agent can also be used.

The pressure-sensitive adhesive layer is formed by, for example, applying a pressure-sensitive adhesive to the pattern layer, applying a transparent polypropylene resin constituting the transparent polypropylene resin layer, and then drying and curing the applied resin. Conditions such as drying temperature and drying time are not particularly limited, and may be appropriately set according to the type of the binder. The method of applying the adhesive is not particularly limited, and for example, a roll coating method, a curtain flow coating method (curve flow coat), a wire bar coating method (wire bar coat), a reverse coating method (reverse coat), a gravure coating method, a reverse gravure coating method (gravure reverse coat), an air knife coating method, a kiss coating method, a knife coating method (bladecoat), a transition coating method (smoothcoat) and the like can be used.

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

Transparent polyolefin resin layer

In embodiment 1, a transparent polypropylene resin layer having a thickness of 150 to 500 μm is used as the transparent polyolefin resin layer.

A transparent polypropylene resin layer having a thickness of 150 to 500 μm, preferably 300 to 500 μm, is formed on the transparent adhesive layer.

The transparent polypropylene resin layer is not particularly limited as long as it has the above thickness, but is preferably a resin layer containing homopolypropylene. The content ratio of the homopolypropylene is not particularly limited, but is preferably 75% by weight or more of the resin constituting the resin layer, and the resin layer is more preferably formed substantially of only the homopolypropylene.

A transparent homopolypropylene resin layer, wherein the tensile modulus of elasticity of the resin layer alone is 1000MPa or more, particularly 1500MPa or more. The upper limit of the tensile modulus is not particularly limited, and may be about 2000 MPa.

The tensile modulus can be measured by preparing a transparent polypropylene resin sheet having the same thickness and material as those of the resin layer. Among them, the tensile modulus of elasticity in the present specification is in accordance with JISK6734 "dimensions and characteristics of plastic hard polyvinyl chloride sheet — part 2: plates with a thickness of less than 1mm ".

The transparent polypropylene resin layer may be formed by laminating the transparent polypropylene resin on the transparent pressure-sensitive adhesive layer by, for example, a rolling method, an inflation method, a T-die extrusion method, or the like, or may be formed by using an existing film.

The surface of the transparent polypropylene resin layer on which a transparent surface protection layer described later is formed may be subjected to surface treatment such as corona discharge treatment, ozone treatment, plasma treatment, ionizing radiation treatment, or dichromic acid treatment, as necessary. The surface treatment may be carried out according to a usual method of various treatments.

Further, if necessary, a primer layer (primer layer for facilitating formation of a surface protective layer) may be provided on the surface.

The primer layer may be formed by applying a known primer to one or both surfaces of the substrate sheet. Examples of the primer include urethane resin primers composed of an acrylate-modified urethane resin and the like, and resin primers composed of a block copolymer of an acrylate and a urethane.

The amount of the primer is not particularly limited, but is usually 0.1 to 100g/m²Preferably 0.1 to 50g/m²Left and right.

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

Transparent surface protective layer

A transparent surface protective layer made of an ionizing radiation curing resin is formed on the transparent polypropylene resin layer. By forming the surface protective layer made of the ionizing radiation curable resin, the decorative sheet can be improved in abrasion resistance, impact resistance, stain resistance, scratch resistance, weather resistance, and the like.

The ionizing radiation-curable resin is not particularly limited, and a transparent resin containing, as a main component, a prepolymer (including an oligomer) and/or a monomer containing, in the molecule, a radical polymerizable double bond capable of undergoing a polymerization crosslinking reaction upon irradiation with an ionizing radiation such as ultraviolet rays or electron beams can be used. These prepolymers or monomers may be used singly or in combination of two or more. The curing reaction is typically a cross-linking curing reaction.

Specifically, the prepolymer or monomer may be a mixture having a (meth) acryloyl group, a radical polymerizable unsaturated group such as a (meth) acryloyloxy group, a cation polymerizable functional group such as an epoxy group, or the like in the molecule. Also preferred are polyolefin/thiol prepolymers produced from a combination of a polyolefin and a polythiol. Here, the (meth) acryloyl group means an acryloyl group or a methacryloyl group.

Examples of the prepolymer having a radical polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, triazine (meth) acrylate, and silicone (meth) acrylate. The molecular weight of these is preferably about 250 to 100000 in general.

Examples of the monomer having a radical polymerizable unsaturated group include monofunctional monomers such as methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, and phenoxyethyl (meth) acrylate. Examples of the polyfunctional monomer include diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, trimethylpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and the like.

Examples of the prepolymer having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol epoxy resins and novolak epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Examples of the thiol include polythiols such as trimethylolpropane trimercaptoacetate and pentaerythritol tetramercaptoacetate. Examples of the polyalkene include polyalkenes obtained by adding allyl alcohol to both ends of polyurethane produced from diol and diisocyanate.

As the ionizing radiation used for curing the ionizing radiation curable resin, electromagnetic waves or charged particles having energy capable of causing a curing reaction of molecules in the ionizing radiation curable resin (composition) can be used. Generally, ultraviolet rays or electron beams can be used, but visible rays, X-rays, ion rays, and the like can also be used.

As the ultraviolet source, for example, a light source such as an ultra-high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, an invisible light, a metal halide lamp, or the like can be used. The wavelength of the ultraviolet light is preferably 190 to 380 nm.

As the electron beam source, various electron beam Accelerators such as a Cockcroft-Walton accelerator (Cockcroft-Walton Accelerators), Van degraf (Van de Graaff) type, a resonance transformer type, an insulating core transformer type, a linear type, a high frequency high voltage accelerator (Dynamitron) type, and a high frequency type can be used. Among them, an accelerator capable of irradiating electrons having an energy of 100 to 1000keV, particularly 100 to 300keV, is preferable.

The surface protective layer can be formed by coating an ionizing radiation-curable resin on the transparent polypropylene resin layer by a known coating method such as gravure coating or roll coating, and then curing the resin by irradiation with ionizing radiation.

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

The surface protective layer may have irregularities on its outer surface (surface exposed to the atmosphere). The embossing is generally performed by an embossing process. The embossing method is not particularly limited, and a preferable method includes, for example, a method of heating and softening the surface of the transparent acrylic resin layer, pressing the surface with an embossing plate, shaping the surface, and cooling the shaped surface. In the embossing, a known paddle type or rotary type embosser may be used. Examples of the uneven shape include a wood grain board duct groove, an uneven stone board surface (granite cleavage surface, etc.), a cloth surface texture, a pearskin texture, a sand texture, a fine line (hairline), and a dense hemp groove.

Weather-resistant agent

In at least 1 of the layers constituting the decorative sheet for flooring material of the present invention, a weather resistant agent may be blended as necessary. As the weather resistant agent, ultraviolet absorbers, hindered amine light stabilizers, and the like are preferable. These binders may be used alone or in combination of 2 or more.

(ultraviolet absorber)

As the ultraviolet absorber, an absorber having a basic component (particularly, a hydroxyl group) is particularly preferable. For example, 2- (2 ' -hydroxy-3 ', 5 ' -di-tert-butylphenyl) -5-chlorobenzotriazole, 2- (2 ' -hydroxy-3 ' -tert-butyl-5 ' -methylphenyl) -5-chlorobenzotriazole, 2- (2 ' -hydroxy-3 ' -tert-amyl-5 ' -isobutylphenyl) -5-chlorobenzotriazole, 2 ' -hydroxyphenyl-5-chlorobenzotriazole ultraviolet absorbers such as 2- (2 ' -hydroxy-3 ' -isobutyl-5 ' -methylphenyl) -5-chlorobenzotriazole and 2- (2 ' -hydroxy-3 ' -isobutyl-5 ' -propylphenyl) -5-chlorobenzotriazole; benzotriazole ultraviolet absorbers such as 2 '-hydroxyphenylbenzotriazole ultraviolet absorbers such as 2- (2' -hydroxy-3 ', 5' -di-tert-butylphenyl) benzotriazole and 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole; 2, 2 '-dihydroxybenzophenone ultraviolet absorbers such as 2, 2' -dihydroxy-4-methoxybenzophenone, 2 '-dihydroxy-4, 4' -dimethoxybenzophenone and 2, 2 ', 4, 4' -tetrahydroxybenzophenone; benzophenone-based ultraviolet absorbers such as dihydroxybenzophenone-based ultraviolet absorbers including 2-hydroxy-4-methoxybenzophenone and 2, 4-dihydroxybenzophenone; salicylate ultraviolet absorbers such as phenyl salicylate and 4-tert-butyl-phenyl salicylate. In addition, a reactive ultraviolet absorber or the like in which an acryloyl group or a methacryloyl group is introduced into the benzotriazole skeleton may also be used. Among the above, benzotriazole-based ultraviolet absorbers are particularly preferable. The amount of the ultraviolet absorber added is usually about 0.1 to 5% by mass relative to the resin component.

The content of the ultraviolet absorber is not particularly limited, but is about 100 to 10000 ppm by weight, preferably about 500 to 7500 ppm by weight in each layer. The layer to be added is not particularly limited, and may be appropriately set according to the product characteristics.

(hindered amine light stabilizer)

In order to prevent deterioration of each layer by ultraviolet rays and improve weather resistance, it is preferable to add a hindered amine light stabilizer as another weather resistant agent. Examples of the bis- (2, 2, 6, 6-tetramethyl-4-piperidyl) sebacate and bis- (N-methyl-2, 2, 6, 6-tetramethyl-4-piperidyl) sebacate include those disclosed in, for example, Japanese examined patent publication (JP-B) No. 4-82625. The amount of these light stabilizers to be added is not particularly limited, but is usually about 0.1 to 5% by weight based on the resin component.

In addition, when the hindered amine-based light stabilizer is added, it is preferable not to use a resin containing a chlorine atom in the layer constituting the decorative sheet from the substrate sheet in order to improve weather resistance. For example, when a resin containing a chlorine atom in a molecule such as a vinyl chloride-vinyl acetate copolymer or a chlorinated polyolefin is used as the binder resin, and hydrogen chloride is generated from the chlorine-containing resin by a dechlorination reaction with ultraviolet light or heat, the hydrogen chloride reacts with the hindered amine-based light stabilizer to inactivate and inhibit the action of the hindered amine-based light stabilizer, and therefore the effect of improving the weather resistance by the scavenger may not be sufficiently exhibited.

The content of the hindered amine-based light stabilizer is not particularly limited, and is about 100 to 10000 ppm by weight, preferably about 500 to 7500 ppm by weight in each layer. The layer to be added is not particularly limited, and may be appropriately set according to the product characteristics.

Decorative material for floor

The decorative sheet for floor material can be bonded to various materials to be bonded to form a decorative material for floor. The material of the material to be bonded is not particularly limited, and examples thereof include inorganic nonmetal-based materials, metal-based materials, wood-based materials, and plastic-based materials.

Specifically, examples of the inorganic nonmetal include non-ceramic firing materials such as papermaking cement, extrusion cement, slag cement, ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), slurry cement, wood chip cement, asbestos cement, calcium silicate, gypsum, and gypsum slag, and ceramic materials such as earthenware, pottery, porcelain, stoneware, glass, and enamel.

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

Examples of the woody material include veneers, plywood, particle board, fiberboard and integrated materials made of japanese cedar (cryptomeria), cypress, oak, willow, teak and the like.

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

The shape of the adherend is not particularly limited, and may be a flat plate, considering the installation of flooring materials (flooring) and the like.

After being bonded to the material to be bonded, for example, depending on the characteristics of the final product, cutting, processing using a tenoner, grooves provided with a V-shape, four-side chamfering, and the like may be applied.

2. Decorative sheet for floor material of embodiment 2 and decorative material for floor using same

The decorative sheet for flooring material of embodiment 2 is formed by laminating at least a decorative layer, a transparent polyolefin resin layer having a thickness of 300 to 500 μm, and a transparent surface protective layer having a thickness of 3 to 30 μm in this order on a base sheet made of polypropylene resin.

Fig. 4 is a schematic sectional view (one example) showing a decorative sheet for flooring according to embodiment 2.

A decorative sheet 100 for flooring material is a decorative sheet in which a base sheet 10 (polyolefin thermoplastic resin film) made of polyolefin resin is provided with a base layer 15 on one side, a decorative layer 12 (printed layer) composed of a coloring concealing layer 17 (entire surface coating printed layer) and a design pattern layer 16 is formed on the base layer 15 by printing in this order, a transparent polyolefin resin layer 11 is laminated on the decorative layer 12 through a transparent adhesive layer 18, and a transparent surface protective layer 14 is formed on the surface of the transparent polyolefin resin layer 11.

Substrate plate 10

The substrate sheet 10 is an olefin-based thermoplastic resin film. Examples of the olefinic thermoplastic resin include a polypropylene resin, a polyethylene resin, an ethylene-propylene copolymer, a polyolefin-based resin such as a polyolefin-based thermoplastic elastomer resin, a polyethylene terephthalate resin, a polyethylene naphthalate resin, a copolymerized polyester resin (for example, a polyethylene terephthalate resin copolymerized with 1, 4-cyclohexanedimethanol, which is generally called a PET-G resin), a polyester-based resin such as an amorphous polyester resin, a polyacrylonitrile resin, an acrylate resin such as polymethyl methacrylate, and a polyvinyl chloride resin.

The polyolefin-based resin film is preferable from the viewpoints of adhesion to the transparent polyolefin-based resin layer 11, prevention of curling of the laminated sheet (which tends to curl depending on the material to be laminated), actual performance in building material use (durability such as weather resistance, and processability such as embossing), and the like.

The film 10 may be colored or not colored by adding a known colorant. The thickness of the film 10 is 50 μm or more, preferably about 50 to 150 μm, and more preferably 50 to 80 μm. When the film thickness is too small, concealment becomes insufficient when concealment is required. The upper limit of the thickness is not particularly limited, but if it is 50 μm or more, it is preferable that the thickness is smaller in this range. On the other hand, the use of a thicker material increases the cost, and the thickness is as thick as about 150 μm from the viewpoint of easy handling.

Bottom layer (primer)

The primer layer 15 is provided to improve the adhesion between the polyolefin resin layer 11 and decorative layers such as the design pattern layer 16 and the color masking layer 17, and in the present invention, the primer layer may be provided arbitrarily.

Examples of the resin for forming the primer layer include ester resins, urethane resins, acrylate resins, polycarbonate resins, vinyl chloride-vinyl acetate copolymers, polyvinyl butyral resins, and nitrocellulose (nitro cellulose) resins. These resins are used alone or in combination to prepare a coating composition or an ink composition. In the formation, the film can be formed to a thickness of about 1 to 6 μm by a known coating method such as a roll coating method or a gravure printing method.

Decorative layer 12

In fig. 4, a design pattern layer 16 and a color masking layer 17 are shown as the decorative layer 12. The design pattern layer 16 and the color masking layer 17 can be formed on the film 10 by a known printing method such as gravure printing, offset printing, screen printing (silk screen coat), or the like, using an ink. In fig. 4, two design pattern layers 16 and two coloring masking layers 17 are shown, but only 1 of them may be used.

Examples of the patterned layer 16 include wood grain patterns, stone grain patterns, cloth grain patterns, leather grain patterns, geometric patterns, characters, symbols, line drawings, and various abstract patterns. The thickness of the pattern portion is usually about 1 to 15 μm. The coloring concealing layer 17 is a layer printed by applying a concealing coloring ink over the entire surface, and its thickness is usually about 1 to 10 μm.

As the ink composition used for the design pattern layer 16 and the coloring concealing layer 17, 1 kind or 2 or more kinds of chlorinated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, polyesters, polyurethanes composed of isocyanate and polyhydric alcohol, polyacrylates, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymers, cellulose resins, polyamide resins, and the like are used as a vehicle, and an ink composition in which a pigment, a solvent, and various auxiliary agents are added can be used. In view of environmental problems, adhesion to a surface to be printed, and the like, ink compositions in which 1 or more types of polyester, polyurethane composed of isocyanate and polyol, polyacrylate, polyamide resin, and the like are mixed are preferable.

Transparent polyolefin resin layer 11

The same polyolefin-based resin as that used for the polyolefin-based resin film 10 can be used for the transparent polyolefin-based resin layer 11. Among them, a resin composed of homopolypropylene having excellent surface strength and abrasion resistance, preferably a resin composed of homopolypropylene in an amount of 70 wt% or more is desired as a flooring material from the viewpoint of imparting surface properties, processability, economy, disposal (including incineration), and the like, particularly caster resistance. In the present invention, homopolypropylene having a melting point of 150 to 170 ℃ is preferably used. It is more preferable to use homopolypropylene having a bending modulus of elasticity of 1000MPa or more, a tensile yield strength of 30MPa or more, and a Rockwell hardness of 75 or more.

Further, by homopolypropylene is meant a separate polymer of propylene monomers. Further, the resin which may be contained in addition to the homopolypropylene is not particularly limited as long as it does not cause a problem in production up to the step of producing the flooring material.

The melting point is expressed by a value measured according to JIS K7121, the bending modulus is expressed by a value measured according to JIS K7171, the tensile yield strength is expressed by a value measured according to JIS K7161, and the rockwell hardness is expressed by a value measured according to JIS K7202.

The polypropylene used in the present invention can be produced by a known polymerization method, and as a commercially available product, a polypropylene having a trade name of F-704 NP: bright petrochemical company, etc.

In the present invention, the transparent polyolefin resin layer 11 is formed to have a thickness of 300 μm or more. A thickness of less than 300 μm does not provide sufficient caster resistance. The upper limit of the thickness is not particularly limited, but is set to a thickness of 500 μm or less from the viewpoint of productivity and cost. Since the polyolefin resin is a transparent resin, the present invention has an effect of giving a high-grade feel to the flooring material because the polyolefin resin layer 11 is thick and the transparency is extremely noticeable.

Transparent adhesive layer 18

The transparent adhesive layer 18 bonds the film 10 forming the decorative layer 12 and the transparent polyolefin resin layer 11. Examples of the method for laminating the transparent polyolefin resin layer 11 include a dry lamination method or a wet lamination method using the adhesive layer 18, a hot lamination method or a high-frequency lamination method using the adhesive layer 18 or without using the adhesive layer 18, and a simultaneous lamination and extrusion lamination method in which a transparent thermoplastic resin is extruded in a molten state. In the extrusion lamination method, an adhesive resin layer such as an acid-modified olefin resin or a (meth) acrylic acid olefin ester copolymer resin may be used as the adhesive layer 18, and the adhesive resin layer and the resin layer 11 may be simultaneously laminated by extrusion. Before the lamination, a surface treatment for facilitating adhesion, such as corona treatment, ozone treatment, plasma treatment, ionizing radiation treatment, acid treatment, alkali treatment, reinforcement treatment (anchor), or the like, may be applied to the surface to be adhered to the resin layer 11.

Transparent surface protective layer

The transparent surface protection layer 14 provided on the surface of the decorative sheet 100 for flooring material will be described. The transparent surface protection layer 14 is provided to impart surface physical properties required for floor finishing materials, such as abrasion resistance, water resistance, and stain resistance. The resin forming the surface protection layer 14 may be a known curable resin such as a thermosetting resin or an ionizing radiation curable resin. The thickness of the transparent surface protection layer is 1 to 100 μm, preferably 3 to 30 μm. More specifically, the technical matters related to the surface protection layer described in paragraphs [0031] to [0044] of the specification of patent document 1 can be applied as they are to the present application, and therefore, the description is incorporated herein as a part of the specification of the present application. In the present invention, an ionizing radiation curing resin having high surface hardness and excellent productivity is preferable.

Recoating the resin layer

When the surface protective layer 14 made of the ionizing radiation curable resin is provided on the surface of the decorative sheet 100 for flooring material, it is necessary to secure sufficient adhesion between the surface of the resin layer 11 and the surface protective layer 14 made of the ionizing radiation curable resin on the surface on which the surface protective layer 14 is formed, that is, in the example shown in fig. 4. Therefore, it is preferable to apply a surface activation treatment such as a corona discharge treatment or an ozone treatment to the surface of the resin layer 11, or to provide a recoating resin layer made of a resin composition having excellent adhesion to both the thermoplastic resin constituting the resin layer 11 and the ionizing radiation curable resin constituting the surface protective layer 14 on the surface of the resin layer 11.

As the recoating resin layer, for example, thermosetting resins such as urethane resin-based resin, epoxy resin, phenol resin, urea resin, alkyd resin, polyester resin and the like are preferable, and among them, two-liquid curing type urethane resin-based resin in which a polyol compound and an isocyanate compound are blended is most preferable. As the polyol compound, for example, an acrylate polyol compound, a polyether polyol compound, a polyester polyol compound and the like can be used, and among them, the polyester polyol compound is most preferably used in view of the balance between the adhesion and the internal cohesive force of the thermoplastic resin and the ionizing radiation curable resin.

The coating amount of the recoating resin layer is preferably about 0.1 to 2.0 μm after drying. As a method for forming the recoatable resin layer, various coating methods known in the art, such as a gravure coating method, a microgravure coating method, a roll coating method, a blade coating method, an air knife coating method, a cutting coating method, and a die coating method, can be arbitrarily used.

Bonded material (Wood base 2)

The wood base material 2 (see fig. 3) is not particularly limited, and examples thereof include a veneer, a lumber plywood, a particle board, and a Medium Density Fiberboard (MDF) manufactured from a material such as a fir, a cypress, a law (japanese tree name), a pine, a willow, a teak, and a meranti (メラピ —, lauan). In addition, from the viewpoint of imparting a moisture-proof effect, for example, a moisture-proof layer may be formed on one surface of the wood base material.

The wood base material 2 and the decorative sheet 1 for floor material are bonded to form a decorative material for floor. The method of attaching the decorative sheet for flooring material to the wooden base material or the method of laminating the decorative sheet for flooring material is not limited, and for example, a method of attaching the decorative sheet to the base material with an adhesive can be used.

The binder may be appropriately selected from known binders according to the kind of the substrate. For example, in addition to polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ionomer and the like, butadiene-acrylonitrile rubber, chloroprene rubber, natural rubber and the like can be cited.

From the viewpoint of improving the adhesion between the wood base material 2 and the decorative sheet 1 for flooring material, a primer layer may be provided on the other surface (back surface) of the decorative sheet of the present invention opposite to the surface-protecting layer side. The description of the base layer (15) can be applied to the base layer on the back surface in the same manner. In this case, a base pigment such as silica or barium sulfate may be added for the purpose of blocking prevention.

The decorative sheet for flooring material of the present invention can be a flooring material having excellent surface scratch resistance and caster resistance without forming a conventionally provided backing layer on the back surface of the resin film 10.

The decorative sheet for flooring material of the present invention exhibits excellent abrasion resistance, caster resistance, impact resistance and the like even without a backing layer. Such a decorative sheet for flooring material is a highly useful decorative material for flooring by being bonded to an adhesive material.

The decorative sheet for flooring material of the present invention can eliminate the production loss caused in the conventional spacer layer forming process while simplifying the production process because the spacer layer is not required to be formed.

The present invention will be described more specifically below with reference to examples and comparative examples. However, the present invention is not limited to the examples.

Example 1

(production of decorative plate for flooring Material)

A60 μm-thick colored polypropylene sheet was prepared as a substrate sheet F, which was corona-discharge-treated on both sides. On one side of the substrate sheet F, the solid content was 2g/m by gravure printing²The back primer G was formed by applying a urethane-cellulose resin (a resin obtained by adding 5 parts by weight of 1, 6-hexamethylene diisocyanate to 100 parts by weight of a mixture of urethane and nitrocellulose).

On the opposite side of the formation surface of the back surface under layer G, the solid content was formed to be 2G/m by gravure printing²Of acrylate-urethanesA resin (a resin obtained by adding 5 parts by weight of 1, 6-hexamethylene diisocyanate to 100 parts by weight of an acrylic polyol) was used to form a base layer for printing (not shown).

On the back sheet (not shown) for printing, a coloring concealing layer (not shown) having a thickness of 2 μm and a wood grain pattern layer E having a thickness of 4 μm were formed by gravure printing using a solution of an acrylate urethane resin (a resin obtained by adding 5 parts by weight of 1, 6-hexamethylene diisocyanate to 100 parts by weight of an acrylic polyol) as a printing ink.

On the pattern layer E, the solid component is formed as 10g/m²The method (2) was followed by applying a urethane resin adhesive and then heating and melt-extruding a polypropylene resin from a T-die extruder to form a transparent adhesive layer D having a thickness of 10 μm and a transparent polypropylene resin layer C having a thickness of 200 μm. The resin layer C alone had a tensile modulus of 1500MPa, and the resin layer C was substantially composed of homopolypropylene alone.

After the surface of the transparent polypropylene resin layer C was subjected to corona discharge treatment, the surface of the resin layer C was subjected to gravure printing to form a solid content of 1g/m²The primer layer (not shown) for forming a transparent surface protective layer was formed by applying an acrylate-urethane resin (a resin obtained by adding 5 parts by weight of 1, 6-hexamethylene diisocyanate to 100 parts by weight of an acrylic polyol).

On the transparent surface protective layer-forming primer layer (not shown), the solid content was 15g/m by a roll coating method²The urethane acrylate-based electron beam-curable resin is applied and dried to form an uncured electron beam-curable resin layer. Thereafter, the uncured resin layer was irradiated with an electron beam under conditions of an accelerating voltage of 125KeV and 5Mrad to cure the resin, thereby forming an electron beam-curable resin layer B (transparent surface protective layer B) having a thickness of 15 μm.

Subsequently, a grainy tubular indentation pattern A having a depth of 50 μm was formed from the transparent surface protective layer B by embossing.

The decorative sheet for flooring is produced through the above process.

(production of decorative Material for floor)

A laminated board was prepared by laminating the back surface base layer of the decorative sheet I for flooring obtained above to a 12mm thick Liuan wood board K through a water-soluble urethane-modified ethylene-vinyl acetate emulsion adhesive layer J having a thickness of about 4 μm.

After the laminated board was cut to a predetermined size (1 x 6), four sides were actually processed using a tenoner, and V-shaped grooves H from the transparent surface protective layer to the depth of the willow plywood were formed in the longitudinal direction and the width direction. Further, the longitudinal side portions of the laminated plate are chamfered.

After applying a water-based two-pack curable urethane-based coloring paint to the groove portion and the chamfered portion of the V-shape, rubbing treatment was performed.

The decorative material for floor is manufactured through the above processes.

Examples 2 to 3 and comparative example 1

A floor finishing material was produced in the same manner as in example 1 except that the thickness of the transparent polypropylene resin layer was changed as shown in Table 1 below

TABLE 1

	Thickness (μm) of transparent polypropylene resin layer
		Example 2	300
Example 3	400
		Comparative example 1	80

Test example 1

The floor finishing materials prepared in examples 1 to 4 and comparative example 1 were subjected to an impact resistance test. Specifically, 2 kinds of impact resistance tests of DuPont type and falling ball type (according to JIS K5600-5-3) were conducted. The impact resistance test was conducted at a portion other than the groove portion, while avoiding the groove having a V-shape already formed in the floor finishing material. The results are shown in table 2 below.

TABLE 2

In the case of a floor finish material, depending on the specific use of the finish material, the impact resistance can be sufficiently exhibited when the dent amount is 400 μm or less in both of the DuPont-type and falling ball-type impact resistance tests.

Reference test example 1

The conventional floor finishing material having a cushion layer was subjected to 2 kinds of impact resistance tests of a dupont type and a falling ball type in the same manner as in test example 1.

A400 μm thick backing layer of amorphous polyethylene terephthalate (A-PET) was laminated on the back side of the decorative sheet of comparative example 1 with a polyester urethane adhesive, and the A-PET side of the laminate and a 12mm thick Liuan wood board were laminated with a water-soluble urethane-modified ethylene-vinyl acetate emulsion adhesive to prepare a conventional floor material decorative material.

The test results are shown in table 3 below.

TABLE 3

Example A

A two-pack curing type urethane base layer having a thickness of 2 μm was provided on one side of a 60 μm-thick colored polypropylene film having both sides subjected to corona discharge treatment, and a wood grain pattern printed layer was formed on the other side with the two-pack curing type urethane base layer and an acrylic urethane printing ink.

Then, on the printed layer, a transparent homopolypropylene resin (melting point 170 ℃ C.) having a bending modulus of 1500MPa, a tensile yield strength of 38MPa and a Rockwell hardness of 80 was extruded through a urethane adhesive by a T-die extruder so that the thickness of the polypropylene thermoplastic resin layer became 300. mu.m, to prepare a laminate.

A urethane primer layer having a thickness of 2 μm was formed on the transparent homopolypropylene resin surface of the laminate. An ionizing radiation-curable resin was coated and dried on the urethane base layer by a reverse gravure coating method so as to have a thickness of 15 μm after drying, thereby forming an uncured ionizing radiation-curable resin layer. The uncured ionizing radiation curable resin layer is cured by irradiating an electron beam (acceleration voltage 175keV, irradiation dose 5Mrad) in an atmosphere of oxygen concentration 200PPM or less to form a surface protective layer made of an ionizing radiation curable resin, and an embossing plate having a wood grain conduit shape with a plate depth of 50 μm is embossed from the surface protective layer side to form a wood grain conduit-shaped uneven pattern. The decorative sheet was produced as described above.

Example B

A decorative sheet of the present invention was produced in the same manner as in example A except that a laminate was produced by extruding a transparent homopolypropylene resin (melting point 170 ℃ C.) having a bending modulus of 1500MPa, a tensile yield strength of 38MPa and a Rockwell hardness of 80 into a thickness of 400 μm on the printed layer of the wood grain pattern with a urethane adhesive by a T-die extruder.

Comparative example A

A decorative sheet as a comparative example was produced in the same manner as in example a except that a transparent atactic polypropylene resin (melting point 145 ℃) having a flexural modulus of elasticity of 600MPa, a tensile yield strength of 26MPa and a rockwell hardness of 72 was extruded onto the printed layer of the wood grain pattern through a urethane adhesive by a T-die extruder to form a laminate so that the thickness thereof was 300 μm.

The random polypropylene resin used in this comparative example was a random copolymer of ethylene and propylene.

Comparative example B

A decorative sheet as a comparative example was produced in the same manner as in example A except that a transparent homopolypropylene resin having a bending modulus of 1500MPa, a tensile yield strength of 38MPa and a Rockwell hardness of 80 (melting point 170 ℃ C.) was extruded onto the printed layer of the wood grain pattern in a T-die extruder by using a urethane adhesive so as to have a thickness of 200 μm, thereby producing a laminate.

Comparative example C

A decorative sheet as a comparative example was produced in the same manner as in example A except that a resin layer containing 50 wt% of a transparent homopolypropylene resin (melting point 170 ℃ C.) having a bending elastic modulus of 1500MPa, a tensile yield strength of 38MPa and a Rockwell hardness of 80, and 50 wt% of a transparent random propylene resin (melting point 145 ℃ C.) having a bending elastic modulus of 600MPa, a tensile yield strength of 26MPa and a Rockwell hardness of 72 was extruded to a thickness of 400 μm on the printed layer of the wood grain pattern by means of a urethane adhesive by a T-die extruder to produce a laminate.

Method for manufacturing floor material

The decorative sheet for flooring obtained in example A, B and comparative examples A to C was bonded to a wood base material with a water-soluble urethane emulsion adhesive using a 12 mm-thick Liuan plywood as the wood base material, thereby producing a decorative material for flooring.

Evaluation (Caster resistance)

The floor materials obtained using the decorative sheets obtained in example A, B and comparative examples A to C were evaluated for caster resistance using a caster resistance test apparatus L6-O4 (manufactured by Hill-Rou Co., Ltd.).

FIG. 5 is a schematic view of the caster-resistance test apparatus L6-O4. The caster resistance test apparatus 1000 is an apparatus comprising a weight 1002 whose weight can be changed by a weight 1001, an adjustment handle 1003, a rotatable caster mount 1010 (mount: diameter 320mm, diameter of the portion to which the caster is attached: 260mm), 3 casters 1011 mounted on the caster mount at equal intervals (apex positions when an equilateral triangle is drawn in the circular mount), and a sample mount 1013 (diameter 80cm, thickness 80cm) (made of acrylic). The casters used were 420SA-N (wheels: made of nylon) available from HANMMER CASTER (average diameter 75mm, thickness 25 mm).

A floor material (sample) (30 cm. times.30 cm) to be tested was fixed to a sample fixing base 1013, a weight 1001 of 30kg was loaded on a weight portion 1002, 3 casters 1011 were brought into contact with the surface of the floor material on the decorative layer side (total load 70kg/m) by adjusting a handle 1003, and the caster fixing base 1010 was moved and rotated 1000 times at a speed of 20rpm repeatedly every 5 minutes.

The caster resistance was evaluated as to the presence or absence of cracks in the surface of the flooring material, and the floor was rated as follows.

O: the depth of the recess is less than 70 μm

And (delta): the depth of the recess is 70 μm or more and less than 100 μm

X: the depth of the recess is greater than or equal to 100 μm

TABLE 4

	Example A	Example B	Comparative example A	Comparative example B	Comparative example C
						Endurance Caster test, indentation depth (μm)	90	60	130	160	100
Judgment of	△	○	×	×	×

Further, the caster resistance can be evaluated by a different testing machine if it is equivalent to that of L6-O4 (manufactured by Hill-Johnson & Co., Ltd.).

Claims (9)

1. A decorative sheet for floor materials, characterized by being formed by laminating at least a decorative layer, a transparent homopolypropylene resin layer having a thickness of 200 to 500 [ mu ] m, and a transparent surface protective layer in this order on a base sheet made of a polyolefin resin.

2. The decorative sheet for flooring according to claim 1, wherein the decorative sheet is formed by laminating at least a design pattern layer, a transparent adhesive layer, a transparent homopolypropylene resin layer having a thickness of 200 to 500 μm, and a transparent surface protective layer made of ionizing radiation curing resin on a base sheet made of polyolefin resin in this order.

3. The decorative sheet for flooring according to claim 2, wherein the transparent homopolypropylene resin layer alone has a tensile modulus of elasticity of 1000MPa or more.

4. The decorative sheet for flooring material according to claim 2, further comprising a color masking layer laminated between the base sheet and the design pattern layer.

5. The decorative sheet for flooring according to claim 2, wherein the transparent surface protective layer has irregularities formed on a surface thereof.

6. The decorative sheet for flooring according to claim 1, wherein the decorative sheet is formed by laminating at least a decorative layer, a transparent homopolypropylene resin layer having a thickness of 300 to 500 μm, and a transparent surface protective layer having a thickness of 3 to 30 μm on a base sheet made of a polyolefin resin in this order.

7. The decorative sheet for flooring according to claim 6, wherein the homopolypropylene has a melting point of 150 to 170 ℃.

8. The decorative sheet for flooring according to claim 6, wherein the substrate sheet made of polyolefin resin is a polypropylene resin film or a polyethylene resin film.

9. A floor finishing material characterized by comprising the base material sheet of the floor finishing material decorative sheet according to claim 2 or 6 bonded to an adhesive material.