JP2000071364A - Production of floor material - Google Patents

Abstract

(57) [Problem] To provide a method of manufacturing a flooring material which is excellent in soundproofing performance and can provide a walking material with good walking feeling with high productivity. SOLUTION: After actual processing is performed on a hard plate-like body 15,
A method of manufacturing a floor material for laminating the hard plate-like body and the thermoplastic resin foam 1, wherein the thermoplastic resin foam includes a continuous foam layer 1 a made of a thermoplastic resin, and at least one surface of the continuous foam layer. A plurality of highly foamed portions 1d made of a thermoplastic resin, and a plate-shaped body made of a thermoplastic resin foam provided with a plurality of highly foamed portions 1d. A method for manufacturing a flooring material 17 in which an uneven surface is formed such that a surface is convex at a high foaming portion and concave between high foaming portions.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a flooring material which has soundproofing properties and can be obtained with a high productivity with a low level of sinking during walking.

[0002]

2. Description of the Related Art Conventionally, a sound-insulating flooring is known in which, for example, a buffer layer made of a resin foam for soundproofing is laminated and integrated on the back surface of a plywood. Specifically, 3-213
No. 95 discloses a wooden flooring material in which soundproofing performance is improved by laminating two types of foams having different magnifications as buffer layers on a wooden board. However, the method described in the publication has a problem that even when the soundproofing performance can be improved, when a person walks on the floor material, "fluffy" so-called "sickness phenomena" occurs, and walking feeling deteriorates.

[0003]

The problem is that the buffer layer is deformed when subjected to an impact to lower the natural frequency of the impact, thereby reducing the propagation of sound due to the impact and improving the soundproofing. It has been found that it is necessary to make the buffer layer thicker in order to exhibit soundproofing. In fact, the above publication discloses an example in which the total thickness of the two types of foams is 8 to 10 mm. Therefore, when a human load is applied, a “sickness phenomena” occurs and walking feeling is reduced. It gets worse.

[0004] Also, in consideration of the on-site work of actually laying the floor material on a floor slab, it is convenient to perform actual processing in advance, but a floor material having a high soundproofing property and a good walking feeling is specifically described. It is the fact that the literature which mentions the procedure for performing actual processing is not known at present. An object of the present invention is to solve the above-mentioned drawbacks of the prior art, and to provide a method of manufacturing a flooring material which is excellent in soundproofing performance and can obtain a flooring material having a good walking feeling with high productivity. .

[Means for Solving the Problems]

According to the first aspect of the present invention, the hard plate and the thermoplastic resin foam are laminated after at least one of the hard plate and the thermoplastic resin foam is actually processed. A method of manufacturing a flooring material, wherein the thermoplastic resin foam includes a continuous foam layer made of a thermoplastic resin, and a high foam portion made of a thermoplastic resin arranged on at least one surface of the continuous foam layer. In the plate-shaped body made of a thermoplastic resin foam, the surface of the plurality of high-foaming portions that is not covered with the continuous foam layer has a high-foaming portion convex and a concave portion between the high-foaming portions. A method of manufacturing a flooring material characterized in that the uneven surface is formed as described above.

[0006] The invention according to claim 2 is that the hard plate and the thermoplastic resin foam are subjected to actual processing on at least one of the hard plate and the thermoplastic resin foam. A method for producing a floor material to be laminated, wherein the thermoplastic resin foam is a continuous foam layer made of a thermoplastic resin, and a high foam portion made of a thermoplastic resin that is disposed on at least one surface of the continuous foam layer. A plate-shaped body made of a thermoplastic resin foam having: a surface of the plurality of high-foaming portions that is not covered with the continuous foam layer, the high-foaming portions are convex, and the space between the high-foaming portions is concave. A plurality of continuous foams having a concave-convex surface formed on the side covered with the continuous foam layer at least at a portion corresponding to a portion where each of the plurality of high foam portions is located. Characterized in that a layer side recess is formed It is a method of manufacturing a wood.

According to a third aspect of the present invention, there is provided the floor material manufacturing method according to the first or second aspect, wherein the highly foamed portions are arranged in a grid.

According to a fourth aspect of the present invention, there is provided the floor material manufacturing method according to the first or second aspect, wherein the highly foamed portions are arranged in a staggered manner.

According to a fifth aspect of the present invention, the height of the convex portion of the highly foamed portion is 1 mm with respect to the continuous surface.
The method for producing a flooring material according to any one of claims 1 to 4, characterized in that:

Further, the invention according to claim 6 is characterized in that the volume of the thermoplastic resin foam is 50 to 90% with respect to the minimum volume of the rectangular parallelepiped which can circumscribe the thermoplastic resin foam. A method for producing a flooring material according to any one of claims 1 to 5.

According to a seventh aspect of the present invention, in the method of manufacturing a floor material according to any one of the first to sixth aspects, the plurality of highly foamed portions are heat-sealed to each other. It is.

Hereinafter, the present invention will be described in more detail. (Hard plate) It is necessary that the surface of the flooring material is hard and does not easily break or be damaged even under load. For example, (1) veneer, (2) plywood, (3) Resin plate, (4)
A fiber reinforced synthetic resin plate (FRP plate) is exemplified. (1) In the case of a single veneer (usually a single veneer), simply applying varnish or oil will give a decorative surface with an excellent wooden texture. (2) In case of plywood, MDF (Medium Density Fiberboad
: Medium density fiberboard), HDF (High Density Fiberboad)
: High-density fiber board), a composite board such as a particle board, a hard board, and a parallel plywood are preferably used. (3) As the resin plate, a plate made of a so-called hard resin such as a polypropylene plate or a polyethylene plate, particularly an ultra-high molecular weight polyethylene plate or a vinyl chloride plate is preferably used. (4) As the FRP plate, a thermosetting polyester resin plate or an epoxy resin plate reinforced with glass fiber, a hard urethane resin plate foamed as necessary, or the like can be used.

If necessary, a surface decorative material such as a veneer, a synthetic resin or synthetic resin foam sheet, decorative paper, or a synthetic resin impregnated sheet may be adhered to and laminated on the hard plate. Further, printing, painting, coloring, coating, grooving and the like may be performed in order to impart designability, woody feel, scratch resistance and the like. Also, when gluing a “veneer” to the surface,
It is preferable to prevent a warp of the hard plate-like body by bonding a plate called "discarding" to the back surface.

The hard plate may be provided with a concave groove extending in an arbitrary direction on the lamination surface with the thermoplastic resin foam, thereby further reducing the bending rigidity of the hard plate and soundproofing. It is possible to further improve the performance. The shape of the concave groove is generally U-shaped, V-shaped, or U-shaped, and the groove width is about 1 to 5 mm.

The thickness of the hard plate is preferably 2 to 12 mm, more preferably 2 to 6 m.
m.

(Thermoplastic resin foam) The thermoplastic resin foam used in the present invention comprises a continuous foam layer made of a thermoplastic resin and a plurality of thermoplastic resins arranged on at least one surface of the continuous foam layer. With a high foaming part,
The surface of the plurality of high-foaming portions, which is not covered with the continuous foaming layer, has an uneven surface such that the high-foaming portions are convex and the spaces between the high-foaming portions are concave.

Thermoplastic used for thermoplastic resin foam
Resin The thermoplastic resin used for the continuous foam layer and the high foam body constituting the thermoplastic resin foam is not particularly limited. As such a thermoplastic resin, for example, low-density polyethylene, high-density polyethylene, linear low-density polyethylene (hereinafter, “polyethylene”
Low-density polyethylene, high-density polyethylene, linear low-density polyethylene, or a mixture thereof. Olefin resins such as random polypropylene, homopolypropylene, block polypropylene (hereinafter, “polypropylene” refers to random polypropylene, homopolypropylene, block polypropylene, or a mixture thereof) and copolymers thereof; Polyethylene vinyl acetate, polyvinyl chloride, chlorinated polyvinyl chloride, ABS resin, polystyrene, polycarbonate, polyamide, polyvinylidene fluoride, pophenylene sulfide, polysulfone, polyether ketone, and copolymers thereof, and the like. May be used alone or in combination.

Among the above-mentioned thermoplastic resins, olefin resins such as polyethylene and polypropylene, or a mixture thereof, in terms of good durability, easy cutting in actual processing, etc., and easy formation of the above-mentioned uneven surface. And high-density polyethylene, homopolypropylene or a mixture containing at least one of these, which can exhibit high compressive strength, are particularly preferable.

The thermoplastic resin used for the continuous foamed layer and the highly foamed portion does not need to be the same resin.
It is preferable to use the same type of resin, since the use of the same type of resin increases the fusion force of the thermoplastic resin foam and is less likely to break when a compressive load is applied.

The thermoplastic resin used for the above-mentioned thermoplastic resin foam may be cross-linked, if necessary. The use of the cross-linked resin is effective in reducing the expansion ratio of the thermoplastic resin foam. This is preferable because the number of the components increases and the cushioning property and the lightness are improved.

In the case where the thermoplastic resin used for the thermoplastic resin foam is a mixture of a highly crosslinked thermoplastic resin and a low crosslinked or non-crosslinked thermoplastic resin, which have almost no compatibility with each other as described later, the low thermoplastic resin is used during foaming. The crosslinked resin composition can flow,
The heat-sealing property between the high foams via the low foam film increases,
The resulting thermoplastic resin foam is suitable because it hardly breaks when a load is applied.

The thermoplastic resin used in the above-mentioned thermoplastic resin foam may be, if necessary, a reinforcing agent such as short glass fiber, short carbon fiber, short polyester fiber or the like in order to improve the compressive strength of the thermoplastic resin foam. Fillers such as calcium carbonate, aluminum hydroxide and glass powder may be added.

Shape of thermoplastic resin foam The shape of the thermoplastic resin foam will be described below by taking the thermoplastic resin foam of FIG. 1 as an example. The thermoplastic resin foam 1 has a continuous foam layer 1 made of a thermoplastic resin having a high expansion ratio on one surface of a continuous foam layer 1a made of a thermoplastic resin.
A plurality of high-foamed portions 1b whose surfaces not covered with a are formed in a convex shape are arranged, and adjacent high-foamed portions 1b are thermally fused to each other.

That is, the plurality of high-foaming portions 1b formed in a convex shape are joined to the adjacent high-foaming portions 1b on a part of the side surface, and the unjoined portions become voids to form a convex shape. The structure is a thermoplastic resin foam 1
A plate-like body is formed as a whole.

When the expansion ratio of the thermoplastic resin foam is low, the lightness is impaired, and when the expansion ratio is high, the compressive strength is reduced.
30 times is preferable, 3 to 20 times is more preferable, and 5 to
A factor of 10 is particularly preferred. The thickness of the thermoplastic resin foam is
It is preferably from 3 to 50 mm, more preferably from 3 to 30 mm, particularly preferably from 5 to 20 mm.

If the expansion ratio of the high expansion portion is low, it is difficult to reduce the weight, and if the expansion ratio is high, a thermoplastic resin foam having high compression strength cannot be obtained. 50 times is more preferable, and 10 to 35 times is particularly preferable.

When the size of the highly foamed portion is large, the compressive strength of the obtained thermoplastic resin foam decreases, and when the size is small, it becomes difficult to reduce the weight. Therefore, the size is preferably 3 to 50 mm, and 5 to 30 mm. Is particularly preferred. Note that the size of the highly foamed portion does not need to be uniform, and may be non-uniform. Here, the size of the highly foamed portion refers to the maximum value of the size in the cross-sectional direction.

If the expansion ratio of the continuous foam layer is low, it is difficult to reduce the weight. If the expansion ratio is high, the fusion force decreases, and a thermoplastic resin foam having high compressive strength cannot be obtained.
1 to 10 times is preferable, 2 to 8 times is more preferable,
2 to 7 times is particularly preferred.

If the thickness of the continuous foam layer is too large, the weight of the thermoplastic resin foam cannot be reduced, and if it is too thin, a thermoplastic resin foam having high compressive strength cannot be obtained.
m to 5 mm is preferred, 300 μm to 3 mm is more preferred, and 500 μm to 2 mm is particularly preferred. In addition,
The thickness of the continuous foam layer does not need to be uniform, and may be non-uniform. Here, the thickness of the continuous foam layer means the average thickness of the continuous foam layer in the longitudinal section direction of the thermoplastic resin foam.

If the height of the convex portion is too low, a high buffering property cannot be obtained, so that the height is preferably 1 mm or more, more preferably 2 mm or more, and most preferably 3 mm or more.

If the filling rate of the thermoplastic resin foam of the present invention is too small, high compressive strength cannot be exhibited, and if it is too large, the buffering property is reduced. ~ 90% is particularly preferred. The filling rate in the present invention is obtained by dividing the weight of the thermoplastic resin foam by the density in the volume (bulk volume) obtained from the maximum height when the thermoplastic resin foam is placed in a flat plate shape. Is the ratio of the volume (true volume).

As shown in FIG. 2, the thermoplastic resin foam used in the second aspect of the present invention is provided with a plurality of high foaming portions 1b, and the continuous foam layer 1b of the high foaming portion 1b is provided.
The surface on the side not covered with a is the same as the above-mentioned foam in that the uneven surface is formed such that the high foaming portion is convex and the space between the high foaming portions is concave. A portion corresponding to a portion where each high foaming portion 1b is located on the surface covered by the layer 1a is formed in a concave shape, and a plurality of continuous foam layer side concave portions 1c are formed.
Are formed. In addition, the thermoplastic resin foam shown in FIG. 2 exemplifies the foam used in the invention according to claim 7, since the high foamed portions are thermally fused to each other.

As described above, the uneven thermoplastic resin foam having one surface formed in a convex shape and the other surface formed in a concave shape has a high compressive strength and a further improvement in cushioning property. Particularly preferred. If the depth of the concave portion 1c of the uneven thermoplastic resin foam is too large, it is difficult to exhibit high compressive strength, and if it is too low, the effect of improving the buffering property cannot be obtained. 1-3mm
Is particularly preferred.

In order to improve the thickness accuracy and weight accuracy of the thermoplastic resin foam and to reduce the variation in compressive strength, a plurality of highly foamed portions should be arranged substantially uniformly in a plane in the cross-sectional direction of the foam. is necessary. However, the mode of arranging the plurality of high foams substantially uniformly in a plane is not particularly limited, and may be arranged in a grid as shown in FIG. 3 or as shown in FIG. May be arranged in a zigzag pattern.

When a plurality of high-foamed bodies are arranged in a grid, each high-foamed portion has the shape of a quadrangular prism, and the surface smoothness of the thermoplastic resin foam is good, and the compressive strength is also sufficient. Therefore, the expandable thermoplastic resin particles are preferably arranged in a lattice shape.

When a plurality of high foaming portions are arranged in a staggered manner, a plurality of hexagonal column-shaped high foaming portions 1b and a wall surface between adjacent high foaming portions has a low foaming wall 1c at the time of heat fusion. This structure is particularly preferable because a honeycomb-shaped thermoplastic resin foam can be obtained as a whole, and the surface smoothness is improved and the thermoplastic resin foam has particularly excellent compressive strength. In FIG. 1 and FIG. 2, only the continuous foam layer 1a and each high foam portion 1b are shown for convenience, but the surface of the high foam portion is usually an extremely thin low foam wall 1d, but the boundary is not always clear. Are formed. In claim 7,
The expression that the plurality of high foaming portions are thermally fused to each other includes the case where the plurality of high foaming portions are thermally fused to each other via the low foaming wall.

In order to improve the bending strength of the thermoplastic resin foam, if necessary, a woven or nonwoven fabric of inorganic fibers such as glass paper and chopped strand mat; a woven or nonwoven fabric of organic fibers such as polypropylene and polyester A sheet made of a thermoplastic resin or a thermosetting resin; a fiber-reinforced thermoplastic resin sheet; and a sheet made of a metal.

Method for Producing a Thermoplastic Resin Foam The method for producing a thermoplastic resin foam used in the present invention is not particularly limited. For example, foamable thermoplastic resin pellets containing a foaming agent may be foamed. After forming a plurality of high-foamed bodies made of thermoplastic resin and heat-sealing them together, a continuous foamed layer made of a thermoplastic resin formed in a separate process is heat-sealed and then formed by hot pressing or the like. The foaming thermoplastic resin granules described later are substantially uniformly arranged in a plane, and the foaming thermoplastic resin granules are integrally formed via a foaming thermoplastic resin thin film. After foaming the foamable thermoplastic resin sheet connected to the above, foaming by heating above the decomposition temperature of the foaming agent,
The method of cooling with a cooling device having a gap larger than the thickness of the thermoplastic resin foam obtained by foaming is most preferable.

When the foamable thermoplastic resin sheet is foamed, a portion of the foamable thermoplastic resin granule foams.
At this time, the wall surfaces of the adjacent foamable thermoplastic resin granules have a structure having low foaming walls due to the foaming pressure. As a result, the low-foamed wall is in a state where the high-foamed bodies having a high expansion ratio inside the granular body are heat-sealed to each other. The foamable thermoplastic resin thin film connecting the granules of the foamable thermoplastic resin sheet becomes a continuous foam layer, and a plurality of high foams are arranged on the continuous foam layer. Note that the continuous foam layer also has a small thickness, and it is difficult to hold air bubbles, so that low foaming occurs. Then, by setting the gap of the cooling device for cooling after foaming to be set to be equal to or more than the filling of the thermoplastic resin sheet body that expands and expands, the fusion proceeds only partially and cannot be completely filled. Is obtained.

Used for a foamable thermoplastic resin sheet.
As the thermoplastic resin used for the expandable thermoplastic resin granules and the expandable thermoplastic resin thin film constituting the expandable thermoplastic resin sheet, the foamable thermoplastic resin is particularly preferable. It is not limited, and examples of such a thermoplastic resin include those exemplified above as the thermoplastic resin used for the thermoplastic resin foam.

Among them, olefin resins such as polyethylene and polypropylene or a mixture thereof are preferable in terms of good durability, easy cutting in actual processing, etc., and easy formation of the above-mentioned uneven surface. High-density polyethylene, homopolypropylene or a mixture containing at least one of these, which can exhibit high compressive strength when a plastic foam is obtained, is particularly preferred.

The thermoplastic resin used for the foamable thermoplastic resin granules and the thermoplastic resin used for the foamable thermoplastic resin thin film do not need to be the same resin. From the viewpoint of the above, it is preferable to use the same type of resin.

The thermoplastic resin used for the foamable thermoplastic resin sheet may be cross-linked if necessary. By using a crosslinked thermoplastic resin, it is possible to improve the expansion ratio and to reduce the weight of the obtained thermoplastic resin foam. Therefore, it is preferable to use a crosslinked thermoplastic resin. The crosslinking method is not particularly limited, and for example, 1)
After melt-kneading the silane-grafted polymer with the thermoplastic resin, water-treating and crosslinking are performed. 2) A peroxide is melt-kneaded with the thermoplastic resin at a temperature lower than the decomposition temperature of the peroxide.
Method of crosslinking by heating to a temperature higher than the decomposition temperature of peroxide 3)
A method of cross-linking by irradiating radiation may be used.

The foamable thermoplastic resin is not particularly limited as described above, but may be a mixture of a foaming agent, a highly crosslinked thermoplastic resin having little compatibility with each other, and a low crosslinked or non-crosslinked thermoplastic resin. In addition, since the low-crosslinking or non-crosslinking resin easily flows at the time of foaming, the unevenness of the obtained thermoplastic resin foam is easily formed, which is particularly preferable.

The high cross-linking resin composition and the high cross-linking and low cross-linking in the low cross-linking or non-cross-linking weight resin composition are relative expressions determined by the magnitude of both cross-linking degrees. The highly crosslinked resin composition is referred to as a highly crosslinked resin composition (A), and the other is referred to as a low crosslinked or noncrosslinked resin (B).

As the thermoplastic resin (before crosslinking) used for the two kinds of thermoplastic resins having little compatibility with each other, two kinds of the above-mentioned thermoplastic resins (hereinafter referred to as the crosslinking performance of the resin itself) are used. Regardless, the resin forming the highly crosslinked thermoplastic resin may be appropriately selected and used as “highly crosslinkable resin”, and the resin forming the low crosslinked or non-crosslinked thermoplastic resin as “low (non) crosslinked resin”). Although it is possible, in order to uniformly and finely disperse the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin without being compatible with each other, the thermoplastic resin of the highly crosslinked resin and the low (non) crosslinked resin is used. The difference in solubility parameter is preferably from 0.1 to 2.0, and more preferably from 0.2 to 1.5.

When the difference in the solubility parameter exceeds 2.0, the highly crosslinked thermoplastic resin obtained by crosslinking and the low crosslinked or non-crosslinked thermoplastic resin are very coarsely dispersed.
The expansion ratio of the obtained uneven thermoplastic resin foam decreases. On the other hand, if the difference in the solubility parameter is less than 0.1, the compatibility of the highly crosslinked thermoplastic resin obtained by crosslinking and the low crosslinked or non-crosslinked thermoplastic resin becomes high, and the obtained uneven thermoplastic resin foam is obtained. Has a reduced surface smoothness.

The solubility parameter is σ = ρΣFi
/ M. Here, ρ is the density of the resin component, M is the molecular weight of the monomer constituting the resin component, Fi
Is the number of moles of the monomer group.

When the difference in the melt index (MI) between the highly crosslinkable resin and the low (non) crosslinkable resin becomes large, the high crosslinkable thermoplastic resin obtained by crosslinking and the low crosslinkable or noncrosslinkable thermoplastic resin become Because it is very coarsely dispersed, the expansion ratio of the obtained uneven thermoplastic resin foam is reduced and becomes smaller, and the compatibility of the highly crosslinked thermoplastic resin obtained by crosslinking and the low crosslinked or non-crosslinked thermoplastic resin is high. Because it may be difficult to form the irregularities of the resulting irregular thermoplastic resin foam, the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin are finely divided without being compatible with each other. In order to obtain a thermoplastic resin foam having a high expansion ratio and a high expansion ratio, the MI difference is 5 to 13 g / 1.
0 minutes is preferable, and 7-11 g / 10 minutes is more preferable.

The MI in this specification is JIS.
It is a value measured according to K7210. In order to obtain a highly crosslinked thermoplastic resin obtained by crosslinking, a low crosslinked or non-crosslinked thermoplastic resin is uniformly and finely dispersed, and to obtain a thermoplastic resin foam having a high expansion ratio with excellent surface smoothness,
The mixing ratio between the highly crosslinkable resin and the low (non-) crosslinkable resin is desirably 2: 8 to 8: 2 by weight, and 4: 6.
~ 6: 4 is more preferable.

If the degree of cross-linking of the highly cross-linked thermoplastic resin is too high, cross-linking is excessively performed, and the expansion ratio of the obtained irregular thermoplastic resin foam decreases. Conversely, if it is too low, the cells break during foaming, Since a uniform cell may not be obtained,
The gel fraction serving as an index of the degree of crosslinking is preferably 5 to 40% by weight, more preferably 10 to 30% by weight.

If the degree of crosslinking of the low-crosslinking or non-crosslinking thermoplastic resin is high, crosslinking is excessive, and the fluidity of the resulting thermoplastic resin foam may be reduced, making it difficult to form irregularities. The gel fraction as an index of is preferably 5% by weight or less, more preferably 3% by weight or less.

The gel fraction in the present specification refers to the percentage by weight of the residue weight after immersing the crosslinked resin component in xylene at 120 ° C. for 24 hours with respect to the weight of the crosslinked resin component before immersion in xylene.

As a method of preparing a mixture of a highly crosslinked thermoplastic resin having little compatibility with each other and a low crosslinked or non-crosslinked thermoplastic resin, the above two kinds of thermoplastic resins are mixed, and only the highly crosslinked resin is mixed. Alternatively, this is achieved by preferentially crosslinking a highly crosslinkable resin over a low (non-) crosslinkable resin.

Examples of a method of preferentially crosslinking a highly crosslinkable resin only or a highly crosslinkable resin over a low (non) crosslinkable resin include, for example, (1) only a highly crosslinkable resin or a low (non) crosslinkable resin. (2) In the first step, a highly crosslinkable resin having a crosslinkable functional group and a crosslinkable resin of the same type are mixed and crosslinked. Then, after forming a highly crosslinked thermoplastic resin, a method of mixing the same with a non-crosslinkable resin in the second step is exemplified.

It should be noted that the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin can be uniformly and finely dispersed, that the highly crosslinked resin can be preferentially crosslinked, and that the thermoplastic resin can be easily prepared. From, the most cross-linkable resin having the same melt index, and having a cross-linkable functional group, the most cross-linkable resin and the same type of cross-linkable resin mixed with the high cross-linkable resin and low cross-linkable resin, the most cross-linking method preferable.

The same kind of crosslinkable resin as the highly crosslinkable resin having a crosslinkable functional group having almost the same melt index as the highly crosslinkable resin may be a thermoplastic resin having a reactive functional group and capable of being crosslinked. It is not particularly limited. Examples of such a functional group include the above-described thermoplastic resins having an unsaturated group such as a vinyl group, an allyl group, and a propenyl group, a hydroxyl group, a carboxyl group, an epoxy group, an amino group, a silanol group, and a silanate group. Can be

Specific examples of the crosslinkable resin include maleic acid-modified polyethylene, maleic acid-modified polypropylene, silane-modified polyethylene, and silane-modified polypropylene. Silane-modified polyethylene and silane-modified polypropylene are the most preferred because it is easy to crosslink highly crosslinkable resin only or only highly crosslinkable resin over low (no) crosslinkable resin, and easy to crosslink after mixing. preferable.

If the difference in melt index between the highly crosslinkable resin and the crosslinkable resin is large, it becomes difficult to crosslink only the highly crosslinkable resin or to preferentially crosslink the highly crosslinkable resin over the low (no) crosslinkable resin. Melt index difference is 2
g / 10 minutes or less, preferably 1 g / 10 minutes or less. As a method of crosslinking the crosslinking resin having the crosslinking functional group, a method of crosslinking with a peroxide, a method of crosslinking with an isocyanate, a method of crosslinking with an amine, and hydrolysis of a reactive functional group After that, a method such as water cross-linking, etc. are listed, since the cross-linking after mixing is easy,
Most preferred is a method of hydrolyzing a reactive functional group followed by water crosslinking.

Blowing Agent In the present invention, a pyrolytic blowing agent is used as the blowing agent contained in the expandable thermoplastic resin granules and the expandable thermoplastic resin thin film.

The pyrolytic foaming agent is not particularly limited as long as it has a decomposition temperature higher than the melting temperature of the thermoplastic resin used. Examples thereof include sodium bicarbonate, ammonium carbonate, ammonium bicarbonate and azide. Compounds, inorganic pyrolytic foaming agents such as sodium borohydride; azodicarbonamide, azobisformamide, azobisisobutyronitrile, barium azodicarboxylate, diazoaminobenzene, N, N'-dinitrosopentamethylenetetramine , P-toluenesulfonyl hydrazide, P, P'-oxybisbenzenesulfonyl hydrazide, trihydrazinotriazine, etc., which are easy to adjust the decomposition temperature and decomposition rate, generate a large amount of gas, and are excellent in hygiene. Amides are preferred.

If the amount of the above-mentioned thermal decomposition type foaming agent is too large, foam breaks and a uniform cell is not formed. On the other hand, if the amount is too small, foaming may not be sufficiently performed. It is preferable that the content be contained in a proportion of 1 to 25 parts by weight based on 100 parts by weight of the thermoplastic resin.

In order to increase the strength of the component foam which can be added , the above-mentioned thermoplastic resin used for the above-mentioned foamable thermoplastic resin granules and the foamable thermoplastic resin thin film may, if necessary, be a glass short fiber. And reinforcing materials such as short carbon fibers and short polyester fibers; fillers such as calcium carbonate, aluminum hydroxide, and glass powder may be added.

When the above-mentioned filler is added, if the amount is large, the cells are broken at the time of foaming, and a foam having a high expansion ratio cannot be obtained. If the amount is small, the obtained foam is reinforced. Effect may not be obtained sufficiently. Therefore, the addition amount of the filler is preferably 10 to 100 parts by weight, particularly preferably 30 to 50 parts by weight, based on 100 parts by weight of the thermoplastic resin.

The shape of the expandable thermoplastic resin sheet is shown below by taking the expandable thermoplastic resin sheet of FIG. 5 as an example. Foamable thermoplastic resin sheet The foamable thermoplastic resin sheet suitable for producing the thermoplastic resin foam used in the present invention will be described with reference to the drawings as appropriate.

5A and 5B, the expandable thermoplastic resin particles 3 are integrally connected by an expandable thermoplastic resin thin film 4 to form an expandable thermoplastic resin sheet 2. I have. In other words, in the foamable thermoplastic resin sheet 2, the columnar protrusions formed of the foamable thermoplastic resin granules 3 project from one surface of the foamable thermoplastic resin thin film 4. It has the shape that is formed. In the example shown in FIG. 5, the expandable thermoplastic resin granules 3 are connected at one end, that is, at the lower end side, by the expandable thermoplastic resin thin film 7. It may be connected by the foamable thermoplastic resin thin film 4 at a substantially central portion in the vertical direction.

In the foamable thermoplastic resin sheet 2, the foamable thermoplastic resin granules 3 are substantially uniformly arranged in a lattice as shown in a plan view in FIG.
The shape of the expandable thermoplastic resin particles is not particularly limited, and includes, for example, a hexagonal shape, a columnar shape, a spherical shape, and the like.When the expandable thermoplastic resin particles expand, the foaming is uniform. 5 and 6, a columnar shape is most preferable.

When the expandable thermoplastic resin particles are cylindrical, the diameter thereof is not particularly limited since it varies depending on the expansion ratio, thickness, etc. of the target thermoplastic resin foam, but is too large. If the foaming speed is too low, the column will melt and deform due to heating during foaming, and will easily deform.
The secondary foaming property cannot be exhibited, and variations in thickness accuracy and weight accuracy increase. Therefore, when the expandable thermoplastic resin particles are cylindrical, the diameter thereof is preferably 1 mm to 30 mm, and particularly preferably 2 mm to 20 mm.

When the expandable thermoplastic resin particles are columnar, the height thereof is not particularly limited because it varies depending on the expansion ratio, thickness, etc. of the target thermoplastic resin foam. If it is too high, the foaming speed will decrease, and if it is too low, it will foam simultaneously with the foamable thermoplastic resin thin film, so that it will expand greatly in the width direction and the longitudinal direction. Therefore, the height of the columnar foamable thermoplastic resin particles is 1 m as a numerical value not including the thickness of the foamable thermoplastic resin thin film.
m to 30 mm is preferable, and 2 to 20 mm is particularly preferable.

The distance between the expandable thermoplastic resin granules is not particularly limited since it varies depending on the expansion ratio, thickness, and the like of the target thermoplastic resin foam, but is not particularly limited. When the expandable thermoplastic resin granules foam, there is a possibility that a large amount of insufficient filling occurs. If the amount is too short, complete filling occurs. Therefore, the center-to-center distance between the expandable thermoplastic resin particles is preferably 2 mm to 50 mm,
Particularly preferred is 3 mm to 30 mm.

In order to improve the thickness accuracy and weight accuracy of the finally obtained thermoplastic resin foam and to make the shape and the expansion ratio uniform, the foamable thermoplastic resin granules are formed from a foamable thermoplastic resin sheet. It is necessary that they be arranged substantially uniformly in a plane in the shape. The mode in which the thermoplastic resin particles are arranged substantially uniformly in a plane is not particularly limited, and the thermoplastic resin particles may be arranged in a grid as shown in FIG. Such a staggered arrangement may be used.

When the foamable thermoplastic resin granules are arranged in a lattice, the highly foamed portions obtained by foaming the individual foamable thermoplastic resin granules have the shape of a quadrangular prism. Since the cushioning property of the plastic resin foam becomes uniform and the compressive strength becomes a sufficient value, it is preferable that the foamable thermoplastic resin granules are arranged in a lattice shape.

When the expandable thermoplastic resin granules are arranged in a staggered manner, the highly foamed portions obtained by foaming the individual expandable thermoplastic resin granules have a hexagonal column shape. Thus, a pseudo honeycomb structure is formed.
Therefore, the cushioning property of the obtained irregular thermoplastic resin foam becomes uniform, and the compressive strength becomes sufficient. Therefore,
More preferably, the foamable thermoplastic resin particles are arranged in a staggered manner.

The thickness of the foamable thermoplastic resin thin film is not particularly limited because it varies depending on the expansion ratio, thickness, etc. of the target thermoplastic resin foam. The mutual positions of the thermoplastic resin particles are unexpectedly changed, and the expansion in the width direction and the longitudinal direction increases. When the thickness is too small, the expandable thermoplastic resin particles cannot be held. Therefore, the thickness of the foamable thermoplastic resin thin film is preferably 0.05 to 3 mm, and 0.1 to 2 m.
m is particularly preferred.

Method for Producing a Foamable Thermoplastic Resin Sheet The method for producing the above foamable thermoplastic resin sheet is not particularly limited. For example, the thermoplastic resin constituting the foamable thermoplastic resin sheet After supplying the resin and the foaming agent to the injection molding machine, melt-kneading at a temperature lower than the decomposition temperature of the pyrolytic foaming agent, and injecting the mixture into a mold having a concave portion corresponding to the shape of the foamable thermoplastic resin granule. Of course, a cooling method is also possible. However, after supplying the thermoplastic resin and the foaming agent constituting the foamable thermoplastic resin sheet to the extruder, and melt-kneading at a temperature lower than the decomposition temperature of the pyrolytic foaming agent, the sheet-like foam in the softened state is formed. The thermoplastic thermoplastic resin has a clearance smaller than the thickness of the sheet-shaped foamable thermoplastic resin, and a pair of shaping rolls rotating in different directions in which a large number of concave portions are uniformly arranged on at least one outer peripheral surface. The method of introducing and pressing a part of the sheet-like foamable thermoplastic resin in a softened state into the concave portion, and then cooling and releasing the mold is most preferable from a comprehensive viewpoint such as mold cost and productivity.

The latter method will be described in more detail. First, in order to obtain a sheet-shaped foamable thermoplastic resin in a softened state, a method of melt-kneading and extruding the foamable thermoplastic resin with an extruder or a method of melting using a calender roll is usually used. The melting used is most preferable from the viewpoint of continuous weight accuracy and quantitativeness.

The form of the foamable thermoplastic resin in the softened state is as follows:
The form is not particularly limited as long as it can be continuously formed, and includes a sheet form, a large number of strand forms, and the like. The sheet form is most preferable from the viewpoint of quantitativeness in the direction perpendicular to the flow (width direction).

The concave portions on the outer peripheral surface of the shaping roll are preferably arranged substantially uniformly in order to improve the weight accuracy and thickness accuracy of the foamable thermoplastic resin sheet obtained.
The arrangement of the concave portions on the outer peripheral surface of the shaping roll is not particularly limited as long as it is uniform over the entire outer peripheral surface of the shaping roll, but since it is more uniform, it is most preferably arranged in a lattice or staggered manner. .

The shape of the concave portion on the outer peripheral surface of the shaping roll is not particularly limited, and examples thereof include a hexagonal shape, a columnar shape, a spherical shape, and the like. Cylinders are most preferred because they can be easily molded uniformly and can be easily released after cooling.

When the shape of the concave portion on the outer peripheral surface of the forming roll is cylindrical, the diameter of the cylindrical column is not particularly limited because it varies depending on the shape of the target foamable thermoplastic resin sheet, but is too large. And the mold release after cooling is difficult to perform, the foamable thermoplastic resin thin film is broken, and if it is too small, the foamable thermoplastic resin granules are broken at the time of mold release after cooling.
30 mm is preferable, and 2 mm to 20 mm is particularly preferable.

When the shape of the concave portion on the outer peripheral surface of the shaping roll is cylindrical, the height of the column is not particularly limited since it varies depending on the shape of the target foamable thermoplastic resin sheet. If the temperature is too high, mold release after cooling is difficult to perform, and the foamable thermoplastic resin thin film is broken. If the temperature is too low, a foamable thermoplastic resin sheet that can perform one-dimensional foaming cannot be formed. Is particularly preferred.

The clearance of the shaping roll needs to be smaller than the thickness of the softened sheet-like foamable thermoplastic resin. Therefore, within this range, there is no particular limitation because the shape changes according to the shape of the target foamable thermoplastic resin sheet, but if it is too thick, a foamable thermoplastic resin sheet capable of performing one-dimensional foaming is formed. No longer,
If the thickness is too small, the foamable thermoplastic resin thin film is easily broken at the time of release after cooling.
1 mm to 2 mm is particularly preferred.

A method of press-fitting a part of the softened sheet-like foamable thermoplastic resin into the concave portion is to apply the softened sheet-like foamable thermoplastic resin to the softened sheet-like foamable thermoplastic resin by not changing the clearance between the pair of forming rolls. This is achieved by applying pressure from a form roll.

That is, for example, in FIG. 7, a foamable thermoplastic resin composition extruded in a sheet shape from a T-die 6 connected to an extruder 5 is cooled by a pair of cooling members arranged to face each other with a predetermined clearance. It is supplied between the shaping rolls 7. The roll 7 comprises a surface smooth shaping roll 7a and a roll 7b having a large number of recesses 8 corresponding to the shape of the foamable thermoplastic resin granules 3 provided on the outer peripheral surface.
A part of the sheet-like foamable thermoplastic resin composition supplied into the concave portion 8 of the roll 7 is press-fitted, and the foamable thermoplastic resin granules 3 integrally connected by the foamable thermoplastic resin thin film 4. Is formed, and the foamable thermoplastic resin sheet 2 is obtained.

Here, in order to press-fit a part of the softened sheet-like foamable thermoplastic resin into the concave portion, the clearance of the pair of shaping rolls is not changed so that the softened sheet-like foamable thermoplastic resin is not changed. This is achieved by applying pressure from a shaping roll to the resin. The cooling method of the sheet-shaped foamable thermoplastic resin in a softened state in which a part is press-fitted is not particularly limited as long as it can be lowered to the melting point of the foamable thermoplastic resin or lower, for example, inside the shaping roll. There are methods such as flowing cooling water.

Method for Producing Irregular Thermoplastic Foam The foamable thermoplastic resin sheet is heated to a temperature not lower than the decomposition temperature of the foaming agent and foamed, and then the foamed thermoplastic resin sheet is completely expanded. Cooling is performed by a cooling device having a gap larger than the space to be filled. The uneven thermoplastic resin foam used in claim 1 or 2 is obtained by cooling the expanded foam while maintaining the “gap more than completely filled with the thermoplastic resin sheet” in this manner. Will be done.

In this case, for the step of foaming by heating, an appropriate method capable of heating the foamable thermoplastic resin sheet to a temperature not lower than the decomposition temperature of the pyrolytic foaming agent contained in the foamable thermoplastic resin granules is used. Examples thereof include a method of heating using an electric heater, a far-infrared heater, a heating device that circulates a heating medium such as heated oil or air, or the like.

The cooling device for the thermoplastic resin foam is not particularly limited as long as it has a gap larger than the space where the thermoplastic resin sheet which expands and expands is completely filled, and the resin constituting the foam is softened. An appropriate method capable of cooling to a temperature equal to or lower than the point can be adopted. .

The gap beyond which the expandable thermoplastic resin sheet is completely filled is a size calculated from the expansion ratio, weight, etc. of the expandable thermoplastic resin sheet, but the gap is too large. And the entire thermoplastic resin foam is greatly wavy, so that it is 10 mm from the completely filled gap calculated from the expansion ratio, weight, etc. of the foamable thermoplastic resin sheet.
Or less, more preferably 5 mm or less, and most preferably 3 mm or less.

(Floor Material) The method for producing a floor material according to the present invention comprises laminating the above-mentioned thermoplastic resin foam and a hard plate.

The laminated material of the floor material obtained by the method of the present invention has the laminated structure of the hard plate and the thermoplastic resin foam described above. The ratio to the thickness of the body is preferably 1 to 10 when the thickness of the hard plate-like body is 1.
Times, more preferably 1 to 5 times, and most preferably 1 to 3 times. If the ratio of the thickness of the rigid plate to the thickness of the thermoplastic resin foam is 1 or less, the bending rigidity of the flooring material increases,
If the soundproofing property is reduced, and if it is 10 times or more, the sinking during walking increases.

The thickness of the flooring material is not particularly limited, but if it is too thick, the ceiling of the room becomes low and the sinking during walking becomes large, so that it is preferably 65 mm or less.

In the method for manufacturing a flooring material of the present invention, in addition to the above-mentioned hard plate-like body and thermoplastic resin foam, a cushioning property,
In order to improve vibration damping properties, sound insulation properties, and terrain improvement properties, a soft foam may be further laminated between the hard plate and the thermoplastic foam, or on the back surface of the thermoplastic foam. Many. The laminating order may be previously bonded and integrated to the hard plate or the thermoplastic resin foam, or may be simultaneously performed at the time of laminating the hard plate and the thermoplastic resin foam.

(Soft foam) cushioning, vibration damping, sound insulation,
Examples of the flexible foam to be laminated for improving the non-landing property include resins such as polyethylene, polypropylene, polyethylene vinyl acetate, polyvinyl chloride, unsaturated polyester, and urethane, and foamed sheets of these copolymers. Can be

The flexible foam used in the present invention is not particularly limited as long as it has a relatively low compression modulus relative to the thermoplastic resin foam. For example, a polyethylene foam having an expansion ratio of 20 to 50 times, Soft polyurethane foams and the like can be mentioned. When an open-cell foam is used, the adhesive may be impregnated into the cells at the time of application, and thus it is preferable to laminate a film, a fine nonwoven fabric, or the like.

When the soft foam is too thick, the sink of the flooring material becomes large, and when the soft foam is too thin, the effects of cushioning, vibration damping, sound insulation and unevenness improvement cannot be exhibited.
10 mm to 10 mm, more preferably 500 μm to 5 mm, and most preferably 1 mm to 3 mm.

Further, in order to improve the cushioning property, vibration damping property, sound insulation property, and unevenness improvement property, a resin sheet, a woven or nonwoven fabric, and a foam sheet may be further laminated alone or in addition to the soft foam. May be.

Examples of the resin sheet laminated for improving the buffering property, vibration damping property, sound insulation property, unevenness improving property, etc. include thermoplastic resins such as polyethylene, polypropylene, polyethylene vinyl acetate, polyvinyl chloride and the like. Resin sheet of copolymer: Resin sheet of thermosetting resin such as unsaturated polyester, urethane, epoxy, etc., vulcanization, non-vulcanization of isoprene rubber, butadiene rubber, styrene butadiene rubber, butyl rubber, nitrile rubber, ethylene-propylene rubber, etc. Examples include a resin sheet of vulcanized rubber. Also,
The resin sheet also includes a composite resin sheet in which the resin is filled with an inorganic, organic or metal material.

If the resin sheet is too thick, the sink of the floor material becomes large, and if the resin sheet is too thin, the effects of cushioning, vibration damping, sound insulation and unevenness improvement cannot be exhibited.
10 mm is preferable, 50 μm to 5 mm is more preferable, and 100 μm to 3 mm is most preferable.

The woven fabric or nonwoven fabric laminated for the purpose of improving the cushioning property, vibration damping property, sound insulation property, and non-woven fabric improvement property is exemplified by a woven fabric or a nonwoven fabric of inorganic fibers such as glass fiber and carbon fiber. A woven or non-woven fabric of organic fibers such as polypropylene, polyester, nylon, and aramid can be used.

When the resin sheet is too thick, the sink of the composite flooring material increases when the resin sheet is too thick, and when the resin sheet is too thin, the effects of cushioning, vibration damping, sound insulation, and unevenness are exhibited. 30 g / m2-1000 g /
m2 is preferable, 50 g / m2 to 800 g / m2 is more preferable, and 80 g / m2 to 500 g / m2 is most preferable.

(Actually) In the present invention, before laminating the hard plate and the thermoplastic resin foam, at least one of them is actually worked. This is because the actual processing after lamination of the two has low productivity.

The method of actual processing is not particularly limited, but the actual processing may be performed only on the hard plate-like body using a tenoner or the like, or may be performed only on the thermoplastic resin foam. Alternatively, actual processing may be performed on a part of the hard plate-like body and a part of the thermoplastic resin foam, and the fruit may be formed only when both are laminated.

Although the kind and shape of the fruit are not particularly limited, it is preferable that the fruit is real, hired, or missing (15c in FIG. 9). In the case of chipping, if only one of the hard plate and the thermoplastic resin foam is processed, the actual fruit is formed by lamination with the other as shown in FIG. This is convenient. The actual size is preferably 2 to 6 mm because the workability is poor if the length of the male is too long, and the engagement of the male and female is insufficient if the length is too short. In addition, the height of the male fruit depends on the thickness of the flooring material. However, if the height is too high, the strength of the portion constituting the female fruit is weakened. About 3 mm is preferable.

In the present invention, in order to improve the soundproofing performance, the hard plate is thinned, and it is difficult to form a fruit with only the hard plate, but the hard plate and the thermoplastic resin foam are combined. Since actual processing is performed on at least one of the layers before lamination, it is possible to form the fruits only by laminating the hard plate and the thermoplastic resin foam. In addition, since the blade for processing the fruit can use a hard plate-shaped body and a blade dedicated to the thermoplastic resin foam, the fruit can be accurately processed.

(Method of manufacturing flooring material, etc.) As a method of laminating a hard plate-like body having at least one of which has been actually processed in advance and a thermoplastic resin foam, a laminating method using an adhesive or a pressure-sensitive adhesive is preferable. Can be Examples of the adhesive used include a vinyl acetate-based adhesive, a vinyl ester-based adhesive, and a chloroprene-based adhesive, and examples of the adhesive include an acrylic adhesive. Further, in order to improve the adhesiveness and tackiness, it is preferable that at least one surface of the thermoplastic resin foam is subjected to corona treatment or primer treatment.

The method of applying the adhesive or the pressure-sensitive adhesive is not particularly limited, and a method in which a fixed amount of the adhesive or the pressure-sensitive adhesive is uniformly applied to the hard plate by a roll coater may be used. After applying the adhesive or adhesive, the rigid plate and the thermoplastic resin foam are overlapped and pressed for a certain time,
Cure.

The flooring material produced by the method of the present invention may be directly adhered to a stencil such as concrete, or may be adhered to an upper surface of a plywood or a particle board laid on a joist or a pillar, in addition to a method of applying an adhesive. Or you may construct with an adhesive material.

[0109]

EXAMPLES The effects of the present invention will be clarified by giving non-limiting examples and comparative examples of the present invention.

[Production of foamable thermoplastic resin sheet] Examples 1 to 10 and Comparative Example 3 The proportions (parts by weight) of thermoplastic resin shown in Table 1 and dibutyltin dilaurate 0.1 as a silane crosslinking catalyst were used. Parts by weight,
And azodicarbonamide as a pyrolytic foaming agent (manufactured by Otsuka Chemical Co., Ltd., trade name: SO-20, decomposition temperature 210 ° C.)
A composition containing 4 parts by weight was applied to a composition having a diameter of 44 mm shown in FIG.
Was melt-kneaded at 180 ° C., and a softened sheet-like foamable thermoplastic resin was extruded with a T-die 6 having a surface length of 500 mm.

Further, the shaping rolls 7a and 7 having the concave portions arranged as shown in Table 1 and having a diameter of 250 mm and a surface length of 500 mm.
b) cooling while shaping the sheet-like foamable thermoplastic resin, further immersing the foamable thermoplastic sheet-like body in water at 98 ° C. for 2 hours, and then drying, thereby obtaining the form shown in Table 1. An expandable thermoplastic resin sheet 2 was obtained.

[0112] The foamable heat of Examples 1 to 10 and Comparative Example 3
In the foamable thermoplastic resin sheet 2 of Examples 1 to 10 and Comparative Example 3 obtained as described above, such as the shape of the plastic resin sheet , the shaping roll 7 was used.
The foamable thermoplastic resin granules 3 are formed in a portion corresponding to the concave portion 8 of b, and the foamable thermoplastic resin granules are connected by the foamable thermoplastic resin thin film 4 to form the foamable thermoplastic resin as a whole. A resin sheet was formed.

The shape of the foamable thermoplastic resin particles in the foamable thermoplastic resin sheet obtained as described above,
The arrangement, height, diameter, center-to-center spacing between granules, and thickness of the foamable thermoplastic resin thin film are shown in Table 1 below. In addition,
The height of the foamable thermoplastic resin granules is, when the foamable thermoplastic resin thin film is connected to one end in the height direction of the foamable thermoplastic resin granules, the thickness of the foamable thermoplastic resin thin film It refers to the dimension in the height direction of the expandable thermoplastic resin granules not containing.

Comparative Example 1 0.1 parts by weight of a thermoplastic resin having a ratio (parts by weight) shown in Table 2 and dibutyltin dilaurate as a silane crosslinking catalyst were used.
And the same azodicarbonamide 4 used in each Example
The composition containing parts by weight was extruded into a sheet in the same manner as in each example.

Next, the sheet extruded from the T-die 6 is subjected to a process with a diameter of 250 mm and a surface length of 500 mm having no concave portions on the surface.
mm between the rolls, and the cooled sheet is cooled to 9 mm.
After immersing in water of 8 ° C. for 2 hours, it is dried and has a thickness of 0.9 mm.
A flat foamable thermoplastic resin sheet was obtained.

Comparative Example 2 The thermoplastic resin in the ratio (parts by weight) shown in Table 2 and 0.1 part by weight of dibutyltin dilaurate as a silane crosslinking catalyst were used.
And the same azodicarbonamide 4 used in each Example
The composition containing parts by weight was extruded into a sheet in the same manner as in each example. Further, the extruded sheet was formed to have a diameter of 250 mm and a surface length of 500 mm without a concave portion on the surface.
After cooling between the rolls, the pellets were pelletized, immersed in water at 98 ° C. for 2 hours, and dried. In this way, foamable thermoplastic resin pellets of 5 × 5 mm × 1.5 mm thickness were obtained.

[Production of Thermoplastic Resin Foam] Examples 1 to 10 In Examples 1 to 10, as shown in FIG. 8, the foamable thermoplastic resin sheet 2 obtained as described above was On the fluorinated ethylene resin sheet 9 so as to have the weight shown in Table 1, and further above the fluorinated ethylene resin sheet 1
0, and heated and foamed for 10 minutes using the hand presses 11 and 12 at a temperature of 210 ° C., transferred to a cooling press at 30 ° C. having a gap shown in Table 1, and cooled for 10 minutes to form a thermoplastic resin foam. I got

The thickness, thickness variation and expansion ratio of the obtained thermoplastic resin foam were measured as follows, and the results are shown in Table 1.

(Thickness of foam) Using a caliper, the thickness of the obtained thermoplastic resin foam was measured. (Thickness Variation) The thickness of the foam was measured using a caliper with n = 20, and the difference between the maximum value and the minimum value was determined. (Expansion ratio) The expansion ratio of the thermoplastic resin foam was measured by an underwater substitution method.

Comparative Example 1 In Comparative Example 1, the foamable thermoplastic resin sheet was
It was arranged on the fluorinated ethylene resin sheet 9 at the weight (weight per unit area) shown in Table 1, and the others were the same as in the respective examples.
A thermoplastic resin foam was obtained, and the thickness, expansion ratio, and the like of the obtained thermoplastic resin foam were measured. The results are shown in Table 2.

Comparative Example 2 On the other hand, in Comparative Example 2, instead of the foamable thermoplastic resin sheet, the foamable thermoplastic resin pellets were applied onto a sheet 9 made of a fluoroethylene resin at a rate of 900 g / m 2. A thermoplastic resin foam was obtained in the same manner as in each example, and the thickness, thickness variation, expansion ratio, and the like of the obtained thermoplastic resin foam were measured. The results are shown in Table 2. In the same manner as above, a thermoplastic resin foam was obtained.

Comparative Example 3 In Comparative Example 3, the foamable thermoplastic resin sheet 2 obtained as described above was placed on a fluorinated ethylene resin sheet 9 as shown in Table 1 in the same manner as in Example. After laying the fluorinated ethylene resin sheet 10 further thereon and heating and foaming it for 10 minutes using the hand presses 11 and 12 at 210 ° C., the sheet having the gap shown in Table 1 is obtained.
C., and cooled for 10 minutes to obtain a thermoplastic resin foam having no irregularities.

This is because the space of the cooling device was narrower than the basis weight of the sheet 2, so that the space was completely filled with the foam, and the plate was flat without irregularities. The thickness, thickness variation, and expansion ratio of the obtained thermoplastic resin foam were measured in the same manner as in each example. The results are shown in Table 2.

[Production of Thermoplastic Resin Foam Evaluation Sample] As described below, a predetermined sample was subjected to pretreatment such as cutting if necessary. Examples 1, 3, 5, 7, 9 The concave surface of the obtained thermoplastic resin foam was cut with a planar so as to have the thickness shown in Table 1.

Examples 2, 4, 6, 8, and 10 The obtained thermoplastic resin foam was used for evaluation as it was. The thickness, expansion ratio, presence or absence of concave portions, height of convex portions, and filling rate of the obtained thermoplastic resin foam were measured as follows. The results are shown in Table 1.

(Thickness of foam) Using a caliper, the thickness of the obtained thermoplastic resin foam was measured. (Presence or absence of concave portion) The presence or absence of a concave portion having a depth of 1 mm or more was visually evaluated. (Protrusion height) The thickness of the non-fused part of the high-foamed material whose outer surface is covered with a low-foaming thin film that has been cut in the vertical section direction of the thermoplastic resin foam and has not been fused. The maximum value in the vertical direction was measured with a caliper.

(Filling rate) The volume (bulk volume) obtained from the maximum height when the thermoplastic resin foam is placed on a flat plate, and the volume (the volume) obtained by dividing the weight of the thermoplastic resin foam by the density ( (True volume).

Comparative Examples 1 and 2 The obtained thermoplastic resin foam was coated on one surface with a depth of 3 mm.
80 mm in a closed mold of 200 x 200 x 5 mm with a diameter of 10 mm, a center-to-center distance of 10.1 mm, and a large number of staggered holes
It was filled with 0 g / m 2, heated under a condition of a temperature of 170 ° C. and a pressure of 0.5 kgf / cm 2 to form evaluation samples shown in Table 2.

The thickness, expansion ratio, presence or absence of concave portions, convex portion height, filling rate, etc. of the obtained thermoplastic resin foam were measured in the same manner as in the Examples. The results are shown in Table 2.

Comparative Example 3 The obtained thermoplastic resin foam was used for evaluation as it was. The thickness, expansion ratio, presence or absence of concave portions, height of convex portions, and filling rate of the obtained thermoplastic resin foam were measured in the same manner as in the examples. The results are shown in Table 2.

The thickness variation, the compression deformation variation, and the maximum impact force of the obtained thermoplastic resin foam were measured as follows. The results are shown in Table 2 below.

(Compression deformation amount) By cutting, 200 mm
A 200 mm × 200 mm foam was cut out, a plywood having a thickness of 3 mm was adhered to the surface opposite to the convex surface of the foam, and a compression test was performed with a φ50 mm cylindrical indenter and a pressing speed of 2 m / min.
The amount of compressive deformation under a gf load was defined as the amount of depression. (Variation in amount of compressive deformation) The amount of compressive deformation of the foam having n = 20 was measured, and the difference between the maximum value and the minimum value was determined.

(Maximum impact force) By cutting, 200 mm
After cutting out a foam of 200 mm and attaching a 3 mm thick plywood to the opposite side of the convex surface of the foam, the maximum impact force when a hammer defined by JIS A1418 is dropped from a height of 40 mm is measured. It was measured with an acceleration sensor.

[Production of Floor Material Evaluation Samples] Examples 1 to 10 and Comparative Examples 1 to 3 As shown in FIG.
m, a veneer plate 15b (manufactured by Kitasan Co., trade name: White Oak) is bonded with an aqueous vinyl urethane resin (manufactured by Koyo Sangyo Co., Ltd., trade name: KR120), dried, and then actually processed 15c (2 mm in height) with a tenoner. , 5 mm deep) to obtain a hard plate 15 having a thickness of 3.0 mm.

Then, both surfaces of the thermoplastic resin foam 1 were subjected to corona treatment, and a polyvinyl acetate emulsion adhesive (trade name: Esdine # 5, manufactured by Sekisui Chemical Co., Ltd.)
660), the hard plate 15 and the thermoplastic resin foam 1, and the thermoplastic resin foam 1 and the soft foam 16
(Bridgestone soft urethane foam, expansion ratio: 3
(× 0, thickness: 2.5 mm) was adhered and laminated to obtain a flooring material 17 (thickness: 12 mm) shown in FIG. 9.

Comparative Example 4 A veneer plate 15b having a thickness of 0.2 mm was adhered to a rawan plywood 15a with an aqueous vinyl urethane resin, dried and then subjected to actual processing 15c with a tenoner to obtain a hard plate having a thickness of 9.5 mm. 15 was obtained. Further, the hard plate 15 and the soft foam 1 obtained by using the polyvinyl acetate emulsion-based adhesive are used.
6 was bonded and laminated to obtain a floor material 17 in the same manner as in Example 1 except that a floor material 17 (thickness: 12 mm) was obtained.

Comparative Example 5 In the production of the evaluation sample for floor material of Example 1, the veneer 1
A floor material was once prepared in the same manner except that no actual processing was performed on the rawan plywood 15a to which 5b was bonded. Thereafter, actual processing (height: 2 mm, depth: 5 mm) was performed on the Lauan plywood 15a with a tenoner to obtain a final flooring evaluation sample.

The overall thickness, sinking amount, soundproofing performance and the like of the obtained flooring material were measured as follows. The results of Examples are shown in Table 1 below, and the results of Comparative Examples are shown in Table 2 below.

(Overall thickness of flooring material) The thickness of the obtained composite flooring material was measured using calipers. (Sinking amount) By cutting, 200mm x 200mm
Of the floor material of the composite floor material, φ50m
A compression test was performed with an m-column indenter and a holding speed of 2 m / min, and the amount of compressive deformation under a load of 80 kgf was defined as the sinking amount.

(Soundproofing performance) The floor impact sound level was measured according to JIS A1418. (Productivity) Evaluated in terms of appearance, dimensional accuracy, non-defective product yield, etc. of flooring materials, and indicated by ○, ×

[0141]

[Table 1]

[0142]

[Table 2]

In Tables 1 and 2, PP was polypropylene (manufactured by Nippon Polychem Co., Ltd., trade name: MA3, melt index (MI) = 11 g / 10 minutes), and silane-modified PP.
Is a crosslinkable silane modified polypropylene (manufactured by Nippon Polychem Co., Ltd., trade name: XPM800H, MI = 11 g / 10 min,
The gel fraction after cross-linking was 80% by weight, and HDPE was high-density polyethylene (manufactured by Nippon Polychem, trade name: HY34).
0, MI = 1.5 g / 10 min).

As is clear from Table 2, the expansion ratio of the thermoplastic resin foam obtained in Comparative Example 1 was 8 times, but the thermoplastic resin foam was wavy and the thickness variation was very poor. In addition, since the thermoplastic resin foam is homogeneous, the compressive strength is low, and the sinking amount is a very large value of 3.60 mm.

In Comparative Example 2, since the thickness of the foam depends on the accuracy of dispersing the expandable thermoplastic resin pellets, the thickness varies greatly, the amount of compressive deformation is 1.75 mm, and the amount of sink of the floor material is reduced. Is 3.20 mm, and the variation in the amount of compressive deformation is a very large value of 0.35 mm.

In Comparative Example 3, a three-dimensionally uniform thermoplastic resin foam having an expansion ratio of 8 was obtained using a foamable thermoplastic resin sheet. Thermoplastic foam 3
Since it is dimensionally uniform, the amount of compressive deformation is as small as 1.10 mm and the dispersion is small. However, since the filling rate is 100% and a flat thermoplastic resin foam, the maximum impact force is large and sufficient cushioning is provided. The soundproofing performance is L
L-47 and low soundproof performance.

In Comparative Example 4, a hard plate (thickness: 9.5 m) was used.
m) and a soft foam (thickness: 2.5 mm), so that the soundproofing performance is LL-65, which is low. In Comparative Example 5, since the actual processing was performed after lauan plywood and the foam were laminated, compared with the case of actually processing the Lauan plywood alone, the foam was pressed down and the entire floor had to be positioned. In addition, the ratio of poor appearance due to scratching was high. Further, since the plywood and the foam are processed with the same blade for the actual processing after the lamination, the processing accuracy, the finish appearance, and the productivity are poor.

On the other hand, in the thermoplastic resin foams used in Examples 1 to 7, since a low foaming wall is formed, the amount of compressive deformation is as small as 1.4 mm or less, and the variation is small. It can also be seen that the thermoplastic resin foam has high strength. In addition, the soundproof performance is also comparative example 1 having a small compressive strength.
It can be said that it is a flooring material that has both compression resistance and soundproofing because it shows performance equal to or higher than.

Further, from the comparison between Examples 1, 2, or 3, 4, or 5, and 6, it is found that the thermoplastic resin foam in which the concave portion is formed has a reduced maximum impact force and excellent cushioning properties. Therefore, it can be seen that high soundproofing performance can be obtained.

The comparison between Examples 1, 3, and 5 and the comparison between Examples 2, 4, and 6 show that the grids are larger than the case where the foamable thermoplastic resin particles are arranged almost uniformly at random. It can be seen that a floor material having better compressive strength and soundproofing performance can be obtained when arranged in a zigzag manner, and a floor material having the most excellent compressive strength can be obtained when arranged in a staggered manner.

From comparison with Examples 5 to 10, it was found that a particularly high soundproofing performance can be obtained when the height of the convex portion is 3 mm or more. It can also be seen that soundproofing can be achieved at the same time.

[0152]

According to the first aspect of the present invention, the hard plate and the thermoplastic resin foam are subjected to actual processing to at least one of the hard plate and the thermoplastic resin foam. A method for producing a floor material to be laminated, wherein the thermoplastic resin foam is a continuous foam layer made of a thermoplastic resin, and a high foam portion made of a thermoplastic resin that is disposed on at least one surface of the continuous foam layer. A plate-shaped body made of a thermoplastic resin foam having: a surface of the plurality of high-foaming portions that is not covered with the continuous foam layer, the high-foaming portions are convex, and the space between the high-foaming portions is concave. Since the uneven surface is formed so that the bending elastic modulus is small and high compressive strength can be expressed, it has a laminated structure with a hard plate-like body, is excellent in soundproofing performance, and when walking. Subduction is small, that is, “sickness phenomena” does not occur. Walking feeling good flooring, it is possible to produce with good productivity.

According to the second aspect of the present invention, the hard plate and the thermoplastic resin foam are laminated after at least one of the hard plate and the thermoplastic resin foam is subjected to actual processing. A method for manufacturing a flooring material, wherein the thermoplastic resin foam includes a continuous foamed layer made of a thermoplastic resin, and a high foamed part made of a thermoplastic resin arranged on at least one surface of the continuous foamed layer. In a plate-shaped body made of a thermoplastic resin foam, the surface of the plurality of high foaming portions that is not covered with the continuous foam layer is such that the high foaming portions are convex and the spaces between the high foaming portions are concave. A plurality of concave portions on the side covered with the continuous foam layer, at least in a portion corresponding to a portion where each of the plurality of high foam portions is located. Is formed,
A floor material with improved soundproofing performance and walking sensation as a result of further improving the compressive strength of the thermoplastic resin foam due to the continuous foam layer-side recesses further formed as compared with the invention of claim 1 It can be manufactured with good performance.

According to the third aspect of the present invention, in the first or second aspect of the present invention, since the high-foamed portions are arranged in a lattice, each high-foamed portion has the shape of a quadrangular prism. It is possible to manufacture a flooring material having little variation and excellent compression strength and soundproofing performance.

According to the fourth aspect of the present invention, in the first or second aspect of the present invention, since the high foaming portions are arranged in a staggered manner, each of the high foaming portions has a hexagonal column shape and a honeycomb structure. Therefore, it is possible to manufacture a floor material having particularly excellent compressive strength.

According to the fifth aspect of the present invention, the first to fourth aspects are described.
In the invention described in the above, since the height of the convexly formed portion of the high foaming portion is 1 mm or more with respect to the continuous surface, the deformation amount of the high foaming portion increases, so that a floor material having excellent soundproofing performance can be obtained. Can be manufactured.

According to the sixth aspect of the present invention, the first to fifth aspects are described.
In the invention described in the above, the volume of the thermoplastic resin foam,
Since the volume is 50 to 90% of the minimum volume of the rectangular parallelepiped that can circumscribe the thermoplastic resin foam, it has excellent compressive strength,
In addition, it is possible to manufacture a flooring material having high soundproofing performance.

According to the invention described in claim 7, claims 1 to 5
In the invention described in (1), since the plurality of high-foamed portions are heat-sealed to each other, there is no separation or breakage at the fusion interface between the low-foamed walls when a compressive load is applied.

[0159]

[Brief description of the drawings]

FIG. 1 is a partially cutaway sectional view for explaining an example of a thermoplastic resin foam of the present invention.

FIG. 2 is a partially cutaway sectional view for explaining a state in which a concave portion is provided in the thermoplastic resin foam of the present invention.

FIG. 3 is a cross-sectional plan view illustrating a state in which high foams in the thermoplastic resin foam of the present invention are arranged in a lattice.

FIG. 4 is a cross-sectional plan view for explaining a form in which high foams are arranged in a staggered manner in the thermoplastic resin foam of the present invention.

FIG. 5 is a view for explaining an example of an expandable thermoplastic resin sheet according to the present invention. FIG. 5 (a) is a view for explaining a state in which expandable thermoplastic resin granules are arranged in a lattice. The top view, (b) is the side view.

FIG. 6 is a plan view for explaining a state in which foamable thermoplastic resin particles are arranged in a staggered manner in the foamable thermoplastic resin sheet of the present invention.

FIG. 7 is a schematic side view for explaining a step of producing the foamable thermoplastic resin sheet according to the present invention.

FIG. 8 is a schematic side view for explaining a step of foaming the foamable thermoplastic resin sheet of the present invention to obtain a foam.

FIG. 9 is a perspective view illustrating an example of the flooring material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Thermoplastic resin foam 1a ... Continuous foaming layer 1b ... High foaming part 1c ... Continuous foaming layer side recessed part 1d ... Low foaming wall 2 ... Foamable thermoplastic resin sheet 3 ... Foamable thermoplastic resin granule 4 ... Foamable thermoplastic resin thin film 5 ... twin screw extruder 6 ... T die 7 ... shaping roll 9 ... sheet 10 ... sheet 15 ... hard plate 15a ... lauan plywood 15b ... veneer 15c ... female fruit 16 ... soft foam 17… flooring

Claims (7)

[Claims] 1. A method for producing a flooring material, wherein actual processing is performed on at least one of a hard plate and a thermoplastic resin foam, and then the hard plate and the thermoplastic resin foam are laminated. The thermoplastic resin foam, from a thermoplastic resin foam comprising a continuous foam layer made of a thermoplastic resin, and a high foam portion made of a thermoplastic resin that is arranged on at least one surface of the continuous foam layer. In the plate-like body, the surface of the plurality of high foaming portions that is not covered with the continuous foaming layer is formed with an uneven surface so that the high foaming portions are convex and the space between the high foaming portions is concave. A method of manufacturing a flooring material. 2. A method of manufacturing a flooring material, comprising: subjecting at least one of a hard plate and a thermoplastic resin foam to actual processing, and then laminating the hard plate and the thermoplastic resin foam. The thermoplastic resin foam, from a thermoplastic resin foam comprising a continuous foam layer made of a thermoplastic resin, and a high foam portion made of a thermoplastic resin that is arranged on at least one surface of the continuous foam layer. In the plate-like body, the surface of the plurality of high foaming portions that is not covered with the continuous foaming layer is formed with an uneven surface so that the high foaming portions are convex and the space between the high foaming portions is concave. A plurality of continuous foam layer-side recesses are formed on the surface covered with the continuous foam layer at least in a portion corresponding to a portion where each of the plurality of high foam portions is located. A method for producing a flooring, characterized by the following. 3. The method according to claim 1, wherein the highly foamed portions are arranged in a grid. 4. The method according to claim 1, wherein the highly foamed portions are arranged in a staggered manner. 5. The production of a flooring material according to claim 1, wherein the height of the convex portion of the highly foamed portion is 1 mm or more with respect to the continuous surface. Method. 6. The volume of the thermoplastic resin foam is 5 to the minimum volume of the rectangular parallelepiped that can circumscribe the thermoplastic resin foam.
The method for producing a flooring material according to any one of claims 1 to 5, wherein the content is 0 to 90%. 7. The method for manufacturing a flooring material according to claim 1, wherein the plurality of highly foamed portions are heat-sealed to each other.