JP2005009290A - Flooring material and its manufacturing method - Google Patents
Flooring material and its manufacturing method Download PDFInfo
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- JP2005009290A JP2005009290A JP2003274427A JP2003274427A JP2005009290A JP 2005009290 A JP2005009290 A JP 2005009290A JP 2003274427 A JP2003274427 A JP 2003274427A JP 2003274427 A JP2003274427 A JP 2003274427A JP 2005009290 A JP2005009290 A JP 2005009290A
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- synthetic resin
- formaldehyde scavenger
- formaldehyde
- cushion material
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Abstract
Description
本発明は、床材、より詳細には、基材の下面にクッション材が貼着されている床材、およびその製造方法に関する。 The present invention relates to a flooring material, and more particularly, to a flooring material in which a cushion material is bonded to the lower surface of a base material, and a method for manufacturing the flooring material.
近年の住宅の高気密化に伴い、建材や家具から放散されるホルムアルデヒド等の揮発性有機化合物によって居住者の健康が損なわれる、いわゆるシックハウス症候群が問題となっている。そして、このような状況に対応するため、シックハウス対策を盛り込んだ改正建築基準法が施行されることになり、建材におけるホルムアルデヒド放散量の抑制に対する要求は、益々顕著なものとなってきた。 With the recent increase in airtightness of houses, so-called sick house syndrome, in which the health of residents is impaired by volatile organic compounds such as formaldehyde released from building materials and furniture, has become a problem. And in order to cope with such a situation, the revised Building Standard Law including measures against sick houses will be enforced, and the demand for the suppression of formaldehyde emission in building materials has become more and more remarkable.
ところで、床材としては、防音性を高めたり、あるいは不陸になじませたりするために、基材の下面に、合成樹脂発泡体や不織布等よりなるクッション材が貼着されたものが知られている。このような床材にあっては、基材として例えば合板が用いられる場合には、その製造過程で用いられた接着剤等からホルムアルデヒドが放散する。また、基材の上面には、通常、木質単板等よりなる化粧層が貼着されているが、この貼着時にも、ホルムアルデヒドを含有した接着剤が用いられている。 By the way, as a flooring material, a cushioning material made of a synthetic resin foam or a non-woven fabric is attached to the lower surface of the base material in order to enhance soundproofing or adapt to unevenness. ing. In such a flooring, when, for example, plywood is used as the base material, formaldehyde is diffused from the adhesive or the like used in the manufacturing process. In addition, a decorative layer made of a wood veneer or the like is usually attached to the upper surface of the substrate, and an adhesive containing formaldehyde is also used at the time of attachment.
このような床材のシックハウス対策としては、ホルムアルデヒドを含まない基材や接着剤を使用することが最も望ましいが、技術的に未確立であったり、コスト高になるといった問題がある。したがって、現状では、尿素等のホルムアルデヒド捕捉剤を使用して床材からのホルムアルデヒドの放散量を抑える方法が一般的に採用されている。 As a countermeasure against such a thick material for a flooring, it is most desirable to use a base material and an adhesive that do not contain formaldehyde, but there are problems such as technical unestablishment and high cost. Therefore, at present, a method is generally employed in which a formaldehyde scavenger such as urea is used to suppress the amount of formaldehyde emitted from the flooring.
ホルムアルデヒド捕捉剤を使用した床材としては、基材の下面に貼着されたクッション材の両面または片面に、ホルムアルデヒド捕捉剤の溶液が塗布されているものが知られている（例えば、下記特許文献１および２参照）。
上述した床材において、ホルムアルデヒド捕捉剤は、通常、水溶液の形態で塗布されるため、合成樹脂発泡体等によって形成されるクッション材に付着し難い。したがって、上記の床材の場合、製造工程中や輸送中に、ホルムアルデヒド捕捉剤がクッション材から脱落し易く、ホルムアルデヒドの放散量を抑制する効果が十分に得られない、という問題が生じる。 In the above-mentioned flooring material, the formaldehyde scavenger is usually applied in the form of an aqueous solution, so that it hardly adheres to a cushion material formed by a synthetic resin foam or the like. Therefore, in the case of the above flooring, the problem that the formaldehyde scavenger easily falls off from the cushioning material during the manufacturing process and during transportation, and the effect of suppressing the amount of formaldehyde emitted cannot be obtained sufficiently.
そのため、例えば、特許文献１記載の床材では、ホルムアルデヒド捕捉剤の溶液の塗布量を５０〜１００ｇ／ｍ２としているが、これだけ多くの量を塗布するには塗布回数を３回以上とする必要があり、作業性が極めて悪くなる。
Therefore, for example, in the flooring disclosed in
また、化粧層付き基材とクッション材とを貼着するためにこれらを交互に複数積み重ねた状態でコールドプレスする場合や、得られた床材を複数積み重ねた状態で保管・輸送する場合に、上側床材の下面のホルムアルデヒド捕捉剤が下側床材の上面に転写されて、床材としての外観が損なわれる、といった問題もある。 In addition, when sticking a base material with a decorative layer and a cushion material in a cold-pressed state in which these are alternately stacked, or when storing and transporting the obtained flooring material in a state of being stacked, There is also a problem that the formaldehyde scavenger on the lower surface of the upper floor material is transferred to the upper surface of the lower floor material, and the appearance as the floor material is impaired.
本発明の目的は、ホルムアルデヒド捕捉剤の脱落によるホルムアルデヒド捕捉性能の低下や、ホルムアルデヒド捕捉剤の転写による外観の低下を引き起こすことのない、床材を提供することにある。 An object of the present invention is to provide a flooring that does not cause a decrease in formaldehyde scavenging performance due to dropping off of the formaldehyde scavenger or a decrease in appearance due to transfer of the formaldehyde scavenger.
本発明による床材は、基材の下面に貼着されたクッション材の下面に、ホルムアルデヒド捕捉剤と合成樹脂の混合液が塗布されていることを特徴とするものである。 The flooring according to the present invention is characterized in that a mixed liquid of a formaldehyde scavenger and a synthetic resin is applied to the lower surface of the cushion material adhered to the lower surface of the base material.
上記の床材にあっては、クッション材の下面に形成される塗膜が、付着性に優れたホルムアルデヒド捕捉剤と合成樹脂との混合物によって構成されるため、クッション材の下面へのホルムアルデヒド捕捉剤の定着性が向上している。 In the above flooring material, the coating film formed on the lower surface of the cushion material is composed of a mixture of a formaldehyde scavenger and a synthetic resin with excellent adhesion, so the formaldehyde scavenger on the lower surface of the cushion material The fixing property is improved.
本発明による床材において、クッション材が、合成樹脂独立発泡体よりなる場合がある。 In the flooring according to the present invention, the cushion material may be made of a synthetic resin independent foam.
クッション材として用いられる合成樹脂発泡体には、気泡が連続している連続発泡体と、気泡が独立している独立発泡体とがあるが、コンクリートスラブ等の床基盤からの水分を遮断する点においては、独立発泡体の方が好ましい。その反面、独立発泡体にすると、ホルムアルデヒド捕捉剤の溶液の浸透性が良くないことから、ホルムアルデヒド捕捉剤の定着性が低下するおそれがあった。しかし、本発明の床材にあっては、合成樹脂の混入によりホルムアルデヒド捕捉剤の定着性が向上しているので、上記のようにクッション材として合成樹脂独立発泡体が用いられる場合であっても、ホルムアルデヒド捕捉剤が脱落し難く、ホルムアルデヒドの放散量を確実に抑制することができる。 Synthetic resin foams used as cushioning materials include continuous foams with continuous air bubbles and independent foams with independent air bubbles, but they block moisture from floor bases such as concrete slabs. In the case of, a closed foam is preferred. On the other hand, when a closed foam is used, since the permeability of the solution of the formaldehyde scavenger is not good, the fixability of the formaldehyde scavenger may be lowered. However, in the flooring of the present invention, since the fixability of the formaldehyde scavenger is improved by mixing the synthetic resin, even if the synthetic resin closed foam is used as the cushioning material as described above, Further, the formaldehyde scavenger is difficult to fall off, and the amount of formaldehyde emitted can be reliably suppressed.
また、本発明による床材において、クッション材が、合成樹脂連続発泡体と合成樹脂独立発泡体との複合品よりなり、合成樹脂連続発泡体が上側、合成樹脂独立発泡体が下側となるように、基材の下面に接合されている場合もある。 Further, in the flooring according to the present invention, the cushion material is composed of a composite product of a synthetic resin continuous foam and a synthetic resin closed foam so that the synthetic resin continuous foam is on the upper side and the synthetic resin closed foam is on the lower side. Further, it may be bonded to the lower surface of the substrate.
上記の場合、複合品の下側を構成する合成樹脂独立発泡体によって床基盤からの水分が遮断されるともに、該発泡体の下面には、ホルムアルデヒド捕捉剤と合成樹脂の混合液が塗布されるため、ホルムアルデヒド捕捉剤が脱落し難く、ホルムアルデヒドの放散を確実に抑制することができる。 In the above case, moisture from the floor base is blocked by the synthetic resin independent foam constituting the lower side of the composite product, and a mixed liquid of formaldehyde scavenger and synthetic resin is applied to the lower surface of the foam. Therefore, it is difficult for the formaldehyde scavenger to fall off, and the emission of formaldehyde can be reliably suppressed.
さらには、本発明による床材において、クッション材が、厚さ中間部に防湿層を有する不織布よりなる場合もある。 Furthermore, in the flooring according to the present invention, the cushion material may be made of a nonwoven fabric having a moisture-proof layer in the middle thickness portion.
上記の場合、不織布の厚さ中間部に介在された防湿層によって床基盤からの水分が遮断されるともに、該不織布には、ホルムアルデヒド捕捉剤と合成樹脂の混合液が塗布されるため、ホルムアルデヒド捕捉剤が脱落し難い。 In the above case, moisture from the floor base is blocked by the moisture-proof layer interposed in the middle part of the nonwoven fabric, and the mixed solution of formaldehyde scavenger and synthetic resin is applied to the nonwoven fabric. The agent is difficult to fall off.
本発明には、上記床材の製造方法も含まれる。この方法は、クッション材の下側となる面に、ホルムアルデヒド捕捉剤と合成樹脂の混合液を塗布した後、該クッション材を基材の下面に貼着することを特徴とするものである。 The present invention also includes a method for producing the flooring. This method is characterized in that after the mixed liquid of the formaldehyde scavenger and the synthetic resin is applied to the lower surface of the cushion material, the cushion material is adhered to the lower surface of the base material.
また、本発明には、上記床材の他の製造方法も含まれる。この方法は、基材の下面にクッション材を貼着した後、該クッション材の下面に、ホルムアルデヒド捕捉剤と合成樹脂の混合液を塗布することを特徴とするものである。 The present invention also includes other methods for manufacturing the flooring. This method is characterized in that after a cushion material is attached to the lower surface of the base material, a mixed solution of a formaldehyde scavenger and a synthetic resin is applied to the lower surface of the cushion material.
上述した２つの製造方法において、ホルムアルデヒド捕捉剤と合成樹脂の混合液のクッション材下面への塗布を、ロールコーターによって行うのが好ましい。 In the two manufacturing methods described above, it is preferable to apply the mixed liquid of the formaldehyde scavenger and the synthetic resin to the lower surface of the cushion material by a roll coater.
ロールコーターによれば、ホルムアルデヒド捕捉剤と合成樹脂の混合液を、クッション材の下面に均一にムラなく塗布できる上、塗布作業を効率良く行うことができる。 According to the roll coater, the mixed liquid of the formaldehyde scavenger and the synthetic resin can be uniformly and evenly applied to the lower surface of the cushion material, and the application work can be performed efficiently.
本発明の床材によれば、製造工程中や輸送中にホルムアルデヒド捕捉剤がクッション材から脱落し難く、ホルムアルデヒドの放散量を抑制する効果が確実に得られる。また、本発明の床材によれば、これらを製造時や保管・輸送時に複数積み重ねても、上側の床材の下面に形成された前記塗膜が下側の床材の上面に転写されず、床材としての外観が損なわれる心配がない。 According to the flooring of the present invention, the formaldehyde scavenger is unlikely to fall off from the cushioning material during the manufacturing process or during transportation, and the effect of suppressing the amount of formaldehyde emitted can be reliably obtained. Further, according to the flooring of the present invention, even when a plurality of these are stacked during manufacturing, storage and transportation, the coating film formed on the lower surface of the upper flooring is not transferred to the upper surface of the lower flooring. There is no worry that the appearance as a flooring material will be damaged.
本発明による床材の製造方法によれば、基材下面へのクッション材の貼着に先立って、クッション材の下側となる面にホルムアルデヒド捕捉剤と合成樹脂の混合液を塗布するため、塗布作業がやり易く、床材の製造効率を高めることができる。 According to the floor material manufacturing method of the present invention, prior to the attachment of the cushion material to the lower surface of the base material, the mixture of the formaldehyde scavenger and the synthetic resin is applied to the lower surface of the cushion material. The work is easy to do and the flooring production efficiency can be increased.
また、本発明による床材の他の製造方法によれば、まず、クッション材を基材の下面に貼着してから、クッション材の下面にホルムアルデヒド捕捉剤と合成樹脂の混合液を塗布するため、ホルムアルデヒド捕捉剤の脱落が少なくなり、ホルムアルデヒドの放散量を更に抑制できる床材が得られる。 Further, according to another method for producing a flooring material according to the present invention, first, the cushion material is attached to the lower surface of the base material, and then the mixed liquid of the formaldehyde scavenger and the synthetic resin is applied to the lower surface of the cushion material. As a result, the formaldehyde scavenger is less dropped, and a flooring that can further suppress the amount of formaldehyde emitted can be obtained.
次に、図１を参照して、本発明の好ましい実施の形態を以下に説明する。 Next, a preferred embodiment of the present invention will be described below with reference to FIG.
図１に示すように、本発明による床材(1)は、基材(2)と、基材(2)の下面に貼着されたクッション材(3)とを備えている。基材(2)の上面には、通常、化粧層(4)が形成されている。クッション材(3)の下面には、ホルムアルデヒド捕捉剤と合成樹脂の混合液が塗布されて、ホルムアルデヒド捕捉剤と合成樹脂の混合物よりなる塗膜(5)が形成される。 As shown in FIG. 1, a flooring (1) according to the present invention includes a base material (2) and a cushion material (3) adhered to the lower surface of the base material (2). A decorative layer (4) is usually formed on the upper surface of the substrate (2). On the lower surface of the cushion material (3), a mixed liquid of formaldehyde scavenger and synthetic resin is applied to form a coating film (5) made of a mixture of formaldehyde scavenger and synthetic resin.
床材(1)の形状は、特に限定されないが、例えば図１のような直方体状とする他、雁行形状としてもよい。 The shape of the flooring (1) is not particularly limited. For example, the flooring (1) may have a rectangular parallelepiped shape as shown in FIG.
基材(2)は、通常、木質板、無機質板、合成樹脂板、またはこれらの複合品によって形成される。木質板としては、例えば、合板、ＭＤＦやＨＤＦ等の木質繊維板、パーティクルボード、無垢材、集成材、木質板と木質繊維板との複合品を挙げることができる。無機質板としては、繊維混入珪酸カルシウム板、繊維混入スラグ石膏板、ガラス繊維混入無機質フェノール板、繊維混入水酸化アルミニウム成形板、火山性ガラス質複層板等が挙げられる。合成樹脂板としては、メラミン樹脂板、アクリル樹脂板等がある。 The substrate (2) is usually formed of a wood board, an inorganic board, a synthetic resin board, or a composite product thereof. Examples of the wood board include plywood, wood fiber boards such as MDF and HDF, particle boards, solid wood, laminated wood, and composite products of wood boards and wood fiber boards. As an inorganic board, a fiber mixed calcium silicate board, a fiber mixed slag gypsum board, a glass fiber mixed inorganic phenol board, a fiber mixed aluminum hydroxide molded board, a volcanic glassy multilayer board, etc. are mentioned. Examples of the synthetic resin plate include a melamine resin plate and an acrylic resin plate.
基材(2)における隣接床材との対向縁部には、通常、接合用加工部が形成されている。図１では、基材(2)における隣接床材との対向縁部に、接合用加工部として、雄実(21A)および雌実(21B)がそれぞれ形成されている。また、図示は省略したが、基材(2)の下面に複数の溝を形成し、それによって、床材(1)の防音効果を高めるようにしてもよい。 A joining processed portion is usually formed at the edge of the base material (2) facing the adjacent flooring. In FIG. 1, a male fruit (21A) and a female fruit (21B) are formed as bonding parts on the edge of the base material (2) facing the adjacent floor material. Although not shown, a plurality of grooves may be formed on the lower surface of the base material (2), thereby enhancing the soundproofing effect of the flooring (1).
クッション材(3)は、例えば、合成樹脂発泡体、不織布、ゴム系発泡体、またはこれらの複合品によって形成することができる。合成樹脂発泡体としては、ポリウレタン樹脂の連続発泡体、ポリエチレン樹脂、ポリプロピレン樹脂等の独立発泡体を挙げることができる。但し、合成樹脂連続発泡体よりなるクッション材(3)の場合、コンクリートスラブ等の床基盤からの水分が、クッション材(3)を通って、基材(2)とクッション材(3)との貼着に悪影響を与える上、基材(2)が木質板よりなるときには、該基材(2)を膨潤させて、床表面に凹凸を生じさせるおそれがある。したがって、クッション材(3)を構成する合成樹脂発泡体としては、床基盤からの水分の防止を考慮した場合、独立発泡体を用いるのが好ましい。また、クッション材(3)として、上記のような合成樹脂連続発泡体と合成樹脂独立発泡体との複合品を用いてもよい。この場合、合成樹脂連続発泡体が上側、合成樹脂独立発泡体が下側となるように、基材(2)の下面に貼着される。不織布の材料としては、ポリエステル、レーヨン等を挙げることができる。不織布よりなるクッション材(3)は、一般に、合成樹脂発泡体よりなるそれと比べて防音性能に優れているので、基材(2)が例えば合板と木質繊維板との複合品のような硬い材料よりなる場合に、特に好適に用いられる。但し、不織布の場合、床基盤からの水分を防ぐために、厚さ中間部に防湿層を有するものを用いるのが好ましい。防湿層としては、例えばポリエチレンフィルムが用いられる。ゴム系発泡体としては、天然ゴム、スチレンブタジエンゴム等の発泡体が挙げられる。 The cushion material (3) can be formed of, for example, a synthetic resin foam, a nonwoven fabric, a rubber foam, or a composite product thereof. Examples of the synthetic resin foam include closed foams such as polyurethane resin continuous foam, polyethylene resin, and polypropylene resin. However, in the case of the cushioning material (3) made of synthetic resin continuous foam, moisture from the floor base such as concrete slab passes through the cushioning material (3), and the base material (2) and the cushioning material (3). In addition to adversely affecting the sticking, when the base material (2) is made of a wood board, the base material (2) may swell and cause unevenness on the floor surface. Therefore, as the synthetic resin foam constituting the cushion material (3), it is preferable to use an independent foam in consideration of prevention of moisture from the floor base. Further, as the cushion material (3), a composite product of the above synthetic resin continuous foam and synthetic resin closed foam may be used. In this case, it is affixed on the lower surface of the base material (2) so that the synthetic resin continuous foam is on the upper side and the synthetic resin closed foam is on the lower side. Examples of the material for the nonwoven fabric include polyester and rayon. The cushion material (3) made of nonwoven fabric is generally superior in soundproofing performance compared to that made of synthetic resin foam, so the base material (2) is a hard material such as a composite product of plywood and wood fiberboard, for example. In particular, it is preferably used. However, in the case of a nonwoven fabric, in order to prevent moisture from the floor base, it is preferable to use one having a moisture-proof layer in the middle thickness portion. For example, a polyethylene film is used as the moisture-proof layer. Examples of the rubber foam include foams such as natural rubber and styrene butadiene rubber.
基材(2)下面へのクッション材(3)の貼着には、通常、水性ビニルウレタン系接着剤、ゴム系接着剤等のホルムアルデヒドを含まない接着剤が用いられる。 For the attachment of the cushion material (3) to the lower surface of the substrate (2), an adhesive not containing formaldehyde such as an aqueous vinyl urethane adhesive or a rubber adhesive is usually used.
化粧層(4)は、通常、天然突板や人工単板等の木質板、ポリエチレンやポリプロピレン等の合成樹脂シート、樹脂含浸紙、プリント紙、またはこれらの複合品によって形成される。また、化粧層(4)を形成する上記材料の表面に、ウレタン系樹脂等の塗料が塗布される場合もある。基材(2)上面への化粧層(4)の接合には、通常、ユリアメラミン系接着剤等のホルムアルデヒドを含む接着剤が用いられる。なお、床材は、例えばクッション材付き床暖房パネルのように、上から更に別の床仕上材が敷設されるものであってもよく、このような床材の場合、化粧層は無くてもよい。 The decorative layer (4) is usually formed of a wooden board such as a natural veneer or an artificial veneer, a synthetic resin sheet such as polyethylene or polypropylene, a resin-impregnated paper, a printed paper, or a composite product thereof. In addition, a paint such as urethane resin may be applied to the surface of the material forming the decorative layer (4). For bonding the decorative layer (4) to the upper surface of the substrate (2), an adhesive containing formaldehyde such as a urea melamine adhesive is usually used. In addition, the flooring material may be constructed by laying another floor finishing material from above, for example, a floor heating panel with a cushion material. In the case of such flooring material, there is no decorative layer. Good.
ホルムアルデヒド捕捉剤は、ホルムアルデヒドの除去効果を発揮しうるものであればよく、これには、一般にホルマリンキャッチャー剤（略してＦＣ剤）と称されるものも含まれる。具体的には、ホルムアルデヒド捕捉剤として、尿素類、ヒドラジド類、アゾール類、アジン類といった公知のものを採用することができる。 Any formaldehyde scavenger may be used as long as it can exhibit the effect of removing formaldehyde, and this includes what is generally called a formalin catcher agent (FC agent for short). Specifically, known formaldehyde scavengers such as ureas, hydrazides, azoles and azines can be employed.
また、ホルムアルデヒド捕捉剤として、ヒドラジド類、アゾール類、アジン類等よりなる主剤に、塩化カルシウム、水酸化ナトリウム、硫酸ナトリウム、硫酸マグネシウム、亜硫酸ナトリウム等の添加剤を加えたものを用いてもよい。この場合、塩化カルシウム等の添加剤により、溶媒へのヒドラジド類等の主剤の溶解度が向上する。
主剤と添加剤の配合比（重量比）は、１：０．２〜０．５となされるのが好ましい。添加剤の比率が０．５を越えると、床材(1)が複数積み重ねられた状態で湿気を帯びた際に、クッション材(3)下面のホルムアルデヒド捕捉剤がこれと接する他の床材(1)の表面に対してブロッキングを起こすおそれがある。一方、添加剤の比率が０．２未満であると、湿気を帯びることによってヒドラジド類等の主剤が再結晶化して白くなり易い。したがって、床材(1)が複数積み重ねられた際、クッション材(3)下面のホルムアルデヒド捕捉剤がこれと接する他の床材(1)の表面に付着して目立ち易くなる上、ホルムアルデヒド放散量の抑制効果が低減するおそれがある。なお、上記配合比は、後述するように、ホルムアルデヒド捕捉剤と混合すべき合成樹脂の形態をエマルジョンとする場合に、特に適合しうる。
In addition, as a formaldehyde scavenger, a main agent composed of hydrazides, azoles, azines, etc., and additives such as calcium chloride, sodium hydroxide, sodium sulfate, magnesium sulfate, sodium sulfite may be used. In this case, the solubility of the main agent such as hydrazides in the solvent is improved by an additive such as calcium chloride.
The mixing ratio (weight ratio) of the main agent and the additive is preferably 1: 0.2 to 0.5. When the ratio of the additive exceeds 0.5, when the floor material (1) is dampened in a state where a plurality of the floor materials (1) are stacked, the floor material (3) other floor materials ( There is a risk of blocking the surface of 1). On the other hand, when the ratio of the additive is less than 0.2, the main agent such as hydrazides is likely to be recrystallized and become white due to moisture. Therefore, when a plurality of flooring materials (1) are stacked, the formaldehyde scavenger on the lower surface of the cushioning material (3) is easily attached to the surface of the other flooring material (1) in contact with the flooring material (1), and the formaldehyde emission amount is increased. There is a risk that the suppression effect is reduced. In addition, the said compounding ratio can be adapted especially when making the form of the synthetic resin which should be mixed with a formaldehyde scavenger into an emulsion so that it may mention later.
ホルムアルデヒド捕捉剤と混合する合成樹脂は、ホルムアルデヒド捕捉剤の定着性を向上させることができるものであればよいが、それ自体ホルムアルデヒドを含有するものは、当然のことながら使用すべきでない。上記の合成樹脂を構成しうる熱可塑性樹脂としては、ポリ塩化ビニル、ポリオレフィン（ポリエチレン、ポリプロピレン等）、アクリル、ポリビニルアルコール、アセトアセチル化ポリビニルアルコール、ＡＢＳ、塩化ビニリデン、酢酸ビニル、ポリアミド、ポリアセタール、ポリカーボネート、変性ポリフェニレンエ−テルポリスルホン、ポリフェニレンスルフィド等が挙げられる。熱硬化性樹脂としては、ポリウレタン、ポリエステル、エポキシ、キシレン、ジアリルフタレート、ビニルエステル、フラン、ポリイミド、マレイン等を例示することができる。また、ゴム系樹脂としては、ＳＢＲ、ＮＢＲ、ＮＲ、ＳＲ、ＣＲ、メタクリル酸ブチル等が挙げられる。これらの合成樹脂の中でも、クッション材(3)との相性が良くて付着性に優れたもの、換言すれば、クッション材(3)と同質のものを使用するのがより好ましい。具体的には、例えば、ポリエチレン、ポリプロピレン、ポリウレタン、ポリエステル、アクリル等が好適に用いられる。 The synthetic resin to be mixed with the formaldehyde scavenger is not limited as long as it can improve the fixability of the formaldehyde scavenger, but it should naturally not be used if it contains formaldehyde. The thermoplastic resins that can constitute the above synthetic resins include polyvinyl chloride, polyolefin (polyethylene, polypropylene, etc.), acrylic, polyvinyl alcohol, acetoacetylated polyvinyl alcohol, ABS, vinylidene chloride, vinyl acetate, polyamide, polyacetal, polycarbonate. , Modified polyphenylene ether polysulfone, polyphenylene sulfide and the like. Examples of the thermosetting resin include polyurethane, polyester, epoxy, xylene, diallyl phthalate, vinyl ester, furan, polyimide, malein and the like. Examples of the rubber-based resin include SBR, NBR, NR, SR, CR, butyl methacrylate and the like. Among these synthetic resins, it is more preferable to use those having good compatibility with the cushion material (3) and excellent adhesion, in other words, the same quality as the cushion material (3). Specifically, for example, polyethylene, polypropylene, polyurethane, polyester, acrylic and the like are preferably used.
ホルムアルデヒド捕捉剤および合成樹脂の混合液は、通常、溶液または分散液の形態に調製される。使用される溶剤としては、例えば、水、メタノール、エタノール、イソプロピルアルコール、ｎ−プロパノール等のアルコール類、アセトン、メチルエチルケトン、シクロヘキサノン等のケトン類、Ｎ，Ｎ−ジメチルホルムアミド、Ｎ，Ｎ−ジメチルアセトアミド等のアミド類、テトラヒドロフラン、ジオキサン、メチルセロソルブ等のエーテル類、酢酸メチル、酢酸エチル、酢酸ブチル等のエステル類、ジメチルスルホキシド、スルホラン等のスルホキシドおよびスルホン類が、単独で、または２種以上混合して用いられる。合成樹脂の形態は、溶液、エマルジョン、および粉状や粒状等の固体のうちいずれであってもよいが、溶媒として水を用いる場合には、水に溶けやすいエマルジョンとするのが好ましい。 The liquid mixture of formaldehyde scavenger and synthetic resin is usually prepared in the form of a solution or dispersion. Examples of the solvent used include water, methanol, ethanol, isopropyl alcohol, alcohols such as n-propanol, ketones such as acetone, methyl ethyl ketone, cyclohexanone, N, N-dimethylformamide, N, N-dimethylacetamide, and the like. Amides, ethers such as tetrahydrofuran, dioxane and methyl cellosolve, esters such as methyl acetate, ethyl acetate and butyl acetate, sulfoxides and sulfones such as dimethyl sulfoxide and sulfolane, alone or in combination of two or more Used. The form of the synthetic resin may be any of a solution, an emulsion, and a solid such as powder or granules, but when water is used as a solvent, it is preferably an emulsion that is easily soluble in water.
ホルムアルデヒド捕捉剤、合成樹脂および溶剤の配合比は、特に限定されないが、好ましくはホルムアルデヒド捕捉剤が薬剤成分量で１ｇ／ｍ２以上（より好ましくは１．５ｇ／ｍ２以上）塗布されるように設定される。塗布量が薬剤成分量で１ｇ／ｍ２未満になると、ホルムアルデヒドの放散量を抑える効果が十分に得られない。配合比は、通常、ホルムアルデヒド捕捉剤１０重量部、合成樹脂２〜２０重量部、および溶剤２０〜３００重量部となされる。塗布量は、好ましくは２０〜５０ｇ／ｍ２、より好ましくは２５〜３５ｇ／ｍ２となされる。 The mixing ratio of the formaldehyde scavenger, the synthetic resin and the solvent is not particularly limited, but preferably the formaldehyde scavenger is applied in an amount of 1 g / m 2 or more (more preferably 1.5 g / m 2 or more) in terms of the amount of the drug component. Is set. When the coating amount is less than 1 g / m 2 in terms of the amount of drug component, the effect of suppressing the amount of formaldehyde emitted cannot be sufficiently obtained. The blending ratio is usually 10 parts by weight of formaldehyde scavenger, 2 to 20 parts by weight of synthetic resin, and 20 to 300 parts by weight of solvent. The coating amount is preferably 20 to 50 g / m 2 , more preferably 25 to 35 g / m 2 .
本発明において、ホルムアルデヒド捕捉剤と合成樹脂の混合液を、クッション材(3)の下面に塗布するのは、以下の理由による。即ち、例えば、前述した特許文献１には、ホルムアルデヒド捕捉剤の溶液にクッション材を浸漬する方法も記載されているが、浸漬による場合、浴槽等の大がかりな設備が必要となる上、生産性にも劣る。また、特許文献２に記載されているように、クッション材の上面にホルムアルデヒド捕捉剤の溶液を塗布した場合、基材の下面にクッション材を貼着した後は、基材の下面側以外から放散されるホルムアルデヒドを捕捉することができず、ホルムアルデヒド放散量の抑制効果が低減してしまう。これに対して、ホルムアルデヒド捕捉剤と合成樹脂の混合液を、クッション材(3)の下面に塗布すれば、大がかりな設備を必要とせず、生産性に優れている上、施工されるまでは、形成された塗膜(5)が露出しているため、ホルムアルデヒド放散量の抑制効果が十分に得られる。
In the present invention, the liquid mixture of the formaldehyde scavenger and the synthetic resin is applied to the lower surface of the cushion material (3) for the following reason. That is, for example,
次に、上記床材の製造方法の一例を説明する。
まず、クッション材(3)の下側となる面に、ホルムアルデヒド捕捉剤と合成樹脂の混合液を塗布した後、これを乾燥させ、ホルムアルデヒド捕捉剤と合成樹脂の混合物よりなる塗膜(5)を形成する。上記混合液の塗布は、ロールコーター、フローコーター等の公知の手段によって行うことができるが、作業性を考慮した場合、微量から多量まで塗布量を調整できるロールコーターによるのが好ましい。ロールコーターの中でも、ロール表面に複数の凹部が網点状または螺旋格子状に形成されたもの（例えば、グラビアコーター）を用いると、前記凹部に入り込んだ混合液が確実にクッション材(3)の下面に転写されるので、安定的な塗布が可能である。
Next, an example of a method for manufacturing the flooring will be described.
First, after applying a mixed solution of a formaldehyde scavenger and a synthetic resin on the lower surface of the cushion material (3), this is dried, and a coating film (5) made of the mixture of the formaldehyde scavenger and the synthetic resin is applied. Form. The application of the mixed liquid can be performed by a known means such as a roll coater or a flow coater. However, in consideration of workability, it is preferable to use a roll coater that can adjust the coating amount from a very small amount to a large amount. Among roll coaters, when a roll surface with a plurality of recesses formed in a dot pattern or a spiral lattice pattern (for example, a gravure coater) is used, the mixed liquid that has entered the recesses is reliably transferred to the cushion material (3). Since it is transferred to the lower surface, stable application is possible.
一方、基材(2)の上面に予め化粧層(4)を貼着しておき、また、基材(2)における隣接床材との対向縁部に接合用加工部(21A)(21B)を形成しておく。そして、基材(2)の下面に、クッション材(3)を貼着する。クッション材(3)の貼着は、例えば、水性ビニルウレタン系等の接着剤を用いて、コールドプレスにより両者(2)(3)を軽く圧締しながら行われる。コールドプレスによる圧締は、通常、複数組の基材(2)およびクッション材(3)を交互に重ねて行う。こうして、図１に示す床材(1)が得られる。 On the other hand, the decorative layer (4) has been previously pasted on the upper surface of the base material (2), and the joining processed portion (21A) (21B) on the opposite edge of the base material (2) with the adjacent flooring Is formed. Then, the cushion material (3) is adhered to the lower surface of the substrate (2). The cushion material (3) is attached, for example, by using a water-based vinyl urethane adhesive or the like and lightly pressing both (2) and (3) by cold pressing. The cold pressing is usually performed by alternately stacking a plurality of sets of base materials (2) and cushion materials (3). In this way, the flooring (1) shown in FIG. 1 is obtained.
また、上記床材は、次のような方法によっても製造することができる。
即ち、まず、上面に化粧層(4)が形成されかつ隣接床材との対向縁部に接合用加工部(21A)(21B)が形成された基材(2)の下面に、クッション材(3)を貼着する。接合方法は、前述した製造方法の場合と同じである。
The flooring can also be produced by the following method.
That is, first, the cushion material (4) is formed on the lower surface of the base material (2) in which the decorative layer (4) is formed on the upper surface and the bonding processing portions (21A) and (21B) are formed on the opposite edge portion with the adjacent flooring material. Stick 3). The joining method is the same as that of the manufacturing method described above.
次に、クッション材(3)の下面に、ホルムアルデヒド捕捉剤と合成樹脂との混合液を塗布した後、これを乾燥させ、ホルムアルデヒド捕捉剤と合成樹脂との混合物よりなる塗膜(5)を形成する。塗布方法は、前述した製造方法の場合と同じである。こうして、図１に示す床材(1)が得られる。 Next, after applying a mixed liquid of formaldehyde scavenger and synthetic resin to the lower surface of cushion material (3), this is dried to form a coating film (5) made of a mixture of formaldehyde scavenger and synthetic resin To do. The coating method is the same as that in the manufacturing method described above. In this way, the flooring (1) shown in FIG. 1 is obtained.
まず、クッション材(3)としてポリウレタンの５０倍連続発泡体とポリエチレンの２５倍独立発泡体との複合品を用意し、このクッション材(3)の下側となる面（独立発泡体側の面）に、ホルムアルデヒド捕捉剤（ヒドラジド類：商標「ケムキャッチ」、大塚化学株式会社製）とポリウレタン樹脂の混合液を、ロール表面に複数の凹部が網点状に形成されたグラビアコーターによって塗布した後、これを乾燥させて、ホルムアルデヒド捕捉剤とポリウレタン樹脂の混合物よりなる塗膜(5)を形成した。
なお、上記混合液の調製は、次のようにして行った。即ち、溶剤としてイソプロピルアルコールと酢酸エチルの混合液を用意し、これにホルムアルデヒド捕捉剤（「ケムキャッチ」）を混合した後、さらにポリウレタン樹脂の固形物を混合して、溶液としたものである。配合比は、ホルムアルデヒド捕捉剤１０重量％、ポリウレタン樹脂６重量％、溶剤８４重量％とした。
First, as a cushioning material (3), a composite product of 50 times continuous foam of polyurethane and 25 times independent foam of polyethylene is prepared, and the lower surface of this cushioning material (3) (surface of the independent foam side) In addition, after applying a liquid mixture of formaldehyde scavenger (hydrazides: trademark “Chemcatch”, manufactured by Otsuka Chemical Co., Ltd.) and polyurethane resin with a gravure coater in which a plurality of recesses are formed in a dot pattern on the roll surface, This was dried to form a coating film (5) comprising a mixture of a formaldehyde scavenger and a polyurethane resin.
The above mixed solution was prepared as follows. That is, a liquid mixture of isopropyl alcohol and ethyl acetate is prepared as a solvent, a formaldehyde scavenger (“chem catch”) is mixed with this, and then a polyurethane resin solid is further mixed to form a solution. The blending ratio was 10% by weight of formaldehyde scavenger, 6% by weight of polyurethane resin, and 84% by weight of solvent.
一方、合板よりなる基材(2)の上面に、天然突板よりなる化粧層(4)を、ホルムアルデヒドを含有するユリアメラミン系接着剤を用いて、ホットプレスにより接合し、さらに化粧層(4)の上面に、ホルムアルデヒドを含有しないウレタン樹脂系塗料を塗布後、乾燥させた。基材(2)を構成する合板は、ＪＡＳガラスデシケーター法によるホルムアルデヒド放散量（Ｆ）が、１．５ｍｇ／Ｌであった。また、基材(2)における隣接床材との対向縁部に雄実(21A)および雌実(21B)を形成した。 On the other hand, on the upper surface of the base material (2) made of plywood, the decorative layer (4) made of natural veneer is joined by hot pressing using a urea melamine adhesive containing formaldehyde, and further the decorative layer (4) A urethane resin-based paint containing no formaldehyde was applied to the upper surface of the substrate, and then dried. The plywood constituting the substrate (2) had a formaldehyde emission amount (F) by the JAS glass desiccator method of 1.5 mg / L. In addition, a male fruit (21A) and a female fruit (21B) were formed at the edge of the base material (2) facing the adjacent flooring.
そして、基材(2)の下面に、クッション材(3)を、ホルムアルデヒドを含有しない水性ビニルウレタン系接着剤を用いて、コールドプレスにより貼着し、床材(1)を得た。 Then, the cushioning material (3) was attached to the lower surface of the base material (2) by a cold press using an aqueous vinyl urethane adhesive not containing formaldehyde to obtain a flooring (1).
実施例１と同じ材料よりなるクッション材(3)を用意し、このクッション材(3)の下側となる面に、アジピン酸ジヒドラジド（主剤）に塩化カルシウム（添加剤）を加えてなるホルムアルデヒド捕捉剤とアクリル樹脂（エマルジョン）との混合液を、グラビアコーターによって塗布した後、これを乾燥させ、ホルムアルデヒド捕捉剤とアクリル樹脂の混合物よりなる塗膜(5)を形成した。
なお、上記混合液の調製は、次のようにして行った。即ち、溶剤としてメタノールと水の混合液を用意し、これにホルムアルデヒド捕捉剤（アジピン酸ジヒドラジド粉末および塩化カルシウム粉末）を混合した後、さらにアクリル樹脂のエマルジョンを混合して、分散液としたものである。配合比は、アジピン酸ジヒドラジド７重量％、塩化カルシウム２重量％、アクリル樹脂１５重量％、メタノール２０重量％、水５６重量％とした。
Cushion material (3) made of the same material as in Example 1 is prepared, and formaldehyde trapping is obtained by adding calcium chloride (additive) to adipic acid dihydrazide (main agent) on the lower surface of this cushion material (3). A liquid mixture of an agent and an acrylic resin (emulsion) was applied by a gravure coater and then dried to form a coating film (5) comprising a mixture of a formaldehyde scavenger and an acrylic resin.
The above mixed solution was prepared as follows. That is, a mixture of methanol and water was prepared as a solvent, and after mixing a formaldehyde scavenger (adipic acid dihydrazide powder and calcium chloride powder), an acrylic resin emulsion was further mixed to form a dispersion. is there. The blending ratio was 7 wt% adipic acid dihydrazide, 2 wt% calcium chloride, 15 wt% acrylic resin, 20 wt% methanol, and 56 wt% water.
そして、これ以降は、実施例１と同じ要領により、床材(1)を作製した。 Thereafter, the floor material (1) was produced in the same manner as in Example 1.
実施例１および２の床材(1)の下面、即ち、クッション材(3)の下面を観察したところ、いずれもホルムアルデヒド捕捉剤の脱落は見られなかった。また、各床材(1)の上面には、貼着時の積み重ねに伴うホルムアルデヒド捕捉剤の転写も見られなかった。さらに、実施例２の床材(1)の上面には、貼着時の積み重ねに伴うホルムアルデヒド捕捉剤のブロッキングの発生も見られなかった。 When the lower surface of the flooring material (1) of Examples 1 and 2, that is, the lower surface of the cushion material (3) was observed, none of the formaldehyde scavenger was removed. In addition, on the upper surface of each flooring material (1), no transfer of formaldehyde scavenger accompanying the stacking at the time of sticking was observed. Furthermore, no blocking of the formaldehyde scavenger was observed on the upper surface of the flooring material (1) of Example 2 due to the stacking at the time of sticking.
次に、実施例１および２の床材(1)について、ＪＡＳガラスデシケーター法により、ホルムアルデヒド放散量を測定したところ、いずれもＦ＝０．１５ｍｇ／Ｌであった。これは、ＪＡＳのホルムアルデヒド放散量の改正基準における最上級レベル「Ｆ☆☆☆☆」（Ｆ≦０．３ｍｇ／Ｌ）を満たすものである。 Next, for the flooring materials (1) of Examples 1 and 2, when the formaldehyde emission was measured by the JAS glass desiccator method, both were F = 0.15 mg / L. This satisfies the highest level “F ☆☆☆☆” (F ≦ 0.3 mg / L) in the revised standard of formaldehyde emission of JAS.
(1)：床材
(2)：基材
(3)：クッション材
(4)：化粧層
(5)：ホルムアルデヒド捕捉剤と合成樹脂との混合物よりなる塗膜
(1): Flooring
(2): Base material
(3): Cushion material
(4): Makeup layer
(5): Coating film consisting of a mixture of formaldehyde scavenger and synthetic resin
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| JP2015145616A (en) * | 2008-07-22 | 2015-08-13 | 大日本印刷株式会社 | Decorative material for floor |
| JP2020204180A (en) * | 2019-06-17 | 2020-12-24 | 朝日ウッドテック株式会社 | Floor material |
| JP7295715B2 (en) | 2019-06-17 | 2023-06-21 | 朝日ウッドテック株式会社 | flooring |
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