JP5360027B2 - Floor material and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor material used for residences, commercial buildings, etc. in which coloring effect is applied on a groove section. <P>SOLUTION: The floor material is composed of a wooden material laminated on a floor material face sheet composed of a colored layer, a transparent resin layer, and a face layer on the colored layer side. A groove section is formed from the face layer side towards the transparent resin layer in a way that it does not reach the wooden material. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a flooring used in a house, a commercial building, or the like.

  As a flooring material, a decorative sheet having a design such as a wood grain pattern is bonded to a wood board (plywood, medium density fiber board (MDF), etc.) via a synthetic resin layer (Patent Document 1). . In these flooring materials, grooves are formed from the decorative sheet side toward the wooden board for the purpose of enhancing the design. In this case, the groove is often colored so that the formed groove is conspicuous. When coloring a groove part, 1) The method of coloring a groove part one by one, 2) After applying a coating material to the whole floor surface, the method of leaving a coating material in a groove part by performing a wiping process etc. is performed.

  However, since the method 1) requires a lot of time, it is difficult to say that the method is suitable for mass production. Even in the method 2), at least an application process and a wiping process are required.

JP 2003-239517 A

  Accordingly, a main object of the present invention is to provide a flooring in which a coloring effect is applied to the groove.

  As a result of intensive studies in view of the problems of the prior art, the present inventor has found that a flooring material having a specific configuration can achieve the above object, and finally has completed the present invention.

  That is, this invention relates to the following flooring and its manufacturing method.

1. A flooring material in which a wooden material is laminated on the colored layer side of the decorative sheet for flooring material comprising a colored layer, a transparent resin layer and a decorative layer,
Grooves are formed from the decorative layer side toward the transparent resin layer so as not to reach the wooden material.
A flooring characterized by that.

  2. Item 2. The flooring according to Item 1, wherein the thickness of the transparent resin layer is 200 µm or more.

  3. Item 3. The flooring according to Item 1 or 2, wherein the colored layer is a layer formed of a colored adhesive.

  4). Item 4. The flooring according to any one of Items 1 to 3, wherein the transparent resin layer and the decorative layer are laminated via a urethane adhesive layer and / or a urethane primer layer.

  5. For a flooring in which a colored layer, a transparent resin layer and a decorative layer are laminated in order on a wooden material, a groove is formed from the decorative layer side toward the transparent resin layer so as not to reach the wooden material. A method for producing a characteristic flooring.

  According to the flooring of the present invention, when the flooring is viewed from above, the colored layer can be visually recognized through the transparent resin layer. For this reason, the visual effect as if the groove part 5 is colored is produced.

  Moreover, since the groove portion does not reach the wood material (that is, the wood material is not processed into the groove portion), the wood material can be blocked from the outside air. Thereby, the quality of the woody material can be maintained without performing waterproofing treatment, water repellent treatment, etc. required for the groove portion.

It is sectional drawing which shows the basic composition of this invention flooring.

The flooring of the present invention is a flooring in which a wood material is laminated on the colored layer side of the decorative sheet for flooring composed of a colored layer, a transparent resin layer and a decorative layer,
Grooves are formed from the decorative layer side toward the transparent resin layer so as not to reach the wooden material.
It is characterized by that.

  An outline of the layer structure of the flooring of the present invention is shown in FIG. In the flooring of the present invention, a decorative layer 1, a transparent resin layer 2, a colored layer 3 and a wood material 4 are laminated in order from the upper layer. And the groove part 5 is formed in this flooring. The groove 5 is formed so as not to reach the wood material 4. By adopting such a configuration, the colored layer 3 can be visually recognized through the transparent resin layer 2 when the flooring is viewed from above, so that a visual effect as if the groove 5 is colored is obtained. Moreover, since this groove part 5 is stopped in front of the wood material, the wood material is placed in a state of being blocked from the outside air. For this reason, the quality of the woody material can be maintained without performing waterproofing treatment, water repellent treatment, etc. that have been conventionally required.

(1) Groove part The groove part 5 has a V-shaped cross section in FIG. 1, but is not limited thereto. For example, the cross-sectional shape may be a quadrangular shape (concave shape), a semicircular shape, or a U shape. Moreover, the formation part of a groove part is not limited, It can determine suitably according to a desired design etc.

  The groove 5 penetrates the decorative layer 1 in FIG. 1 and reaches the transparent resin layer. In addition, the decorative layer and the transparent resin layer may be penetrated. That is, the case where the deepest portion of the groove is in the colored layer is also included in the present invention. Further, as long as the groove does not reach the woody material, the groove may penetrate the decorative layer, the transparent resin layer, and the colored layer.

  What is necessary is just to implement the formation method of a groove part in accordance with a well-known method. For example, what is necessary is just to process with well-known apparatuses, such as tenoner.

  Further, the formation of the groove may be at any stage. For example, a method of forming a groove after all the layers of the flooring of the present invention are formed, a method of forming a groove after laminating a decorative layer and a transparent resin layer, and laminating a colored layer and a woody material thereon, a decorative layer Any method such as a method of forming a groove after laminating a transparent resin layer and a colored layer and laminating a wood material thereon may be used.

(2) Layers constituting the flooring The laminating method of each layer in the flooring of the present invention is not limited, and various methods such as adhesion using an adhesive, lamination, and the like can be employed. In particular, it is desirable that the transparent resin layer and the decorative layer are laminated via a urethane adhesive layer and / or a urethane primer layer.

  Moreover, the thickness of each layer is not limited, and can be appropriately set within a range employed in a known flooring material.

The decorative layer decorative layer is not particularly limited, and a known or commercially available decorative sheet can be used. For example, a decorative sheet in which at least a base material layer, a pattern layer, an adhesive layer, a synthetic resin layer, and a surface protective layer are sequentially laminated can be suitably used.
The lamination of each layer may be performed by a normal procedure. For example, a picture layer is printed on one side of a colored base material layer, and further, a synthetic resin via an adhesive layer formed with a known dry lamination adhesive such as a two-component curable urethane resin on the picture layer. The layers may be laminated by a known dry lamination method, T-die extrusion method or the like, a primer layer may be provided on the entire surface of the transparent resin layer as necessary, and a surface protective layer may be formed thereon. And the transparent resin layer 2 is laminated | stacked on the back surface of the said base material layer.

Transparent resin layer The material of the transparent resin layer is not particularly limited as long as it has transparency. For example, polyethylene (high density polyethylene, medium density polyethylene, low density polyethylene), vinyl chloride resin, polystyrene, polypropylene, methacrylic resin, acrylonitrile styrene resin, polyamide resin, acrylonitrile butadiene styrene resin, polyimide resin, polyamideimide resin, fluorine resin, Examples include urethane resin, polysulfone, polycarbonate, polyacetal, polyphenylene ether, polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), and polyarylate. Amorphous polyethylene terephthalate, so-called A-PET [Mitsubishi Chemical Corporation: Nova Clear (trade name)], PETG and the like can also be suitably used. PETG is a polyethylene terephthalate copolymer in which a part of ethylene glycol is substituted with 1,4-cyclohexanedimethanol or diethylene glycol. For example, a commercially available product “PETG6763” (manufactured by Eastman Chemical) can be used.

  The thickness of the transparent resin layer (the total thickness when the transparent resin layer is composed of two or more layers) is not limited, but considering caster resistance, scratch resistance, etc. It is preferable to do.

Colored layer The colored layer may be the same as the solid ink layer or the like in a known decorative sheet. In general, the ink can be formed by a known printing method such as gravure printing, offset printing, silk screen printing, or the like, using an ink in which a coloring material is dispersed or dissolved in a vehicle.

  A well-known thing or a commercial item can be used for ink, and it can select suitably according to desired coloring etc.

  Examples of the colorant include inorganic pigments such as titanium white, zinc white, petal, vermilion, ultramarine blue, cobalt blue, titanium yellow, and carbon black, isoindolinone, Hansa Yellow A, quinacridone, permanent red 4R, phthalocyanine blue, and indus. Examples include organic pigments (including dyes) such as Ren Blue RS and Anine Phosphorus Black, metal pigments such as aluminum and brass, pearlescent pigments made of foil powder such as titanium dioxide-coated mica and basic lead carbonate, etc. It is done. These can be used alone or in combination of two or more. Examples of the vehicle include chlorinated polyolefin such as chlorinated polyethylene and chlorinated polypropylene, polyester, polyurethane composed of isocyanate and polyol, polyacryl, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, cellulose. It is possible to use a mixture of one type or two or more types of resin, polyamide resin, or the like, which is made into an ink by adding a pigment, a solvent, various auxiliary agents, and the like.

  In particular, in the present invention, it is desirable that the colored layer also has a function as an adhesive layer. For this reason, it is preferable to form a colored layer with the adhesive agent containing a coloring material.

  The adhesive is not particularly limited as long as it can be applied to the wood material, and may be appropriately selected from known adhesives according to the kind of the wood material. Examples thereof include polyvinyl acetate, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ionomer, butadiene / acrylonitrile rubber, neoprene rubber, natural rubber and the like.

  The thickness of the colored layer varies depending on the desired degree of coloring, the type of adhesive to be used, etc., but is usually about 0.1 to 50 μm.

Wood material Wood material is not particularly limited, for example, veneer, wood veneer, wood plywood, particle board, medium density fiber made from various materials such as cedar, firewood, firewood, pine, lawan, teak, merapie A board (MDF) etc. are mentioned. When the wood material is laminated on the colored layer, the wood material may be laminated together with the formation of the colored layer when the colored layer is formed by an adhesive. Moreover, when the colored layer is not formed of the adhesive, the adhesive may be applied to the colored layer and / or the woody material and then laminated together.

  Next, the present invention will be described in more detail with reference to the following examples. However, the scope of the present invention is not limited to the examples.

Example 1
A flooring having a structure as shown in FIG. 1 was produced.

(1) Production of decorative sheet Urethane cellulose resin (5 parts by weight of hexamethylene diisocyanate was added to 100 parts by weight of a mixture of urethane and nitrified cotton on one side of a colored polypropylene film having a thickness of 60 μm subjected to double-sided corona discharge treatment. Were coated by a gravure coating method so as to have a solid content of 2 g / m ² to form a back primer layer. On the other side, an acrylic urethane-based resin (100 parts by weight of acrylic polyol added with 5 parts by weight of hexamethylene diisocyanate) is applied by a gravure coating method so as to have a solid content of 2 g / m ^2, and a primer layer for printing Formed.

  Next, a solid ink layer and a pattern ink layer are sequentially formed by gravure printing using a printing ink containing an acrylic urethane resin (100 parts by weight of acrylic polyol and 5 parts by weight of hexamethylene diisocyanate) as a binder. A patterned picture layer was formed.

  Next, after applying a urethane-based adhesive on the pattern layer, a transparent resin layer was formed by heating and extruding a propylene-based resin with a T-die extruder so as to have a thickness of 80 μm.

  The transparent resin layer is subjected to corona discharge treatment, and a surface protective layer is applied to the treated surface by an acrylic urethane-based resin (100 parts by weight of acrylic polyol added with 5 parts by weight of hexamethylene diisocyanate) by a gravure coating method. A primer layer was formed.

A urethane acrylate electron beam curable resin is applied onto the primer layer for the surface protective layer by a roll coating method so as to have a solid content of 15 g / m ² , dried, and then oxygen is applied to the uncured electron radiation curable resin layer. A surface protective layer made of an electron radiation curable resin was formed by irradiating and curing an electron beam (acceleration voltage 175 KeV, irradiation amount 5 Mrad) in an environment having a concentration of 200 ppm or less.

  Subsequently, embossing was carried out from the surface protective layer side with a wood grain conduit embossed plate or a wood surface / abstract tone embossed plate having a plate depth of 50 μm to obtain a makeup layer having a wood grain conduit shape or a wood surface / abstract surface uneven pattern.

(2) Lamination of a transparent resin layer and a decorative layer A non-crystalline polyethylene terephthalate (A-PET) as a transparent resin layer by further interposing a urethane adhesive layer on the back primer layer of the decorative layer by a dry lamination method By laminating, a decorative sheet for flooring was produced.

(3) Production of floor material Lauan plywood (thickness 12 mm) is laminated on the surface of the synthetic resin layer of the decorative sheet for floor material of (2) above with a water-soluble emulsion adhesive colored black with a pigment, and has a predetermined dimension. After cutting into (313mm x 1840mm), actual processing of the four sides is performed using a tenoner, and a V-shaped groove (strip groove) having a depth reaching the transparent resin layer from the decorative layer side is formed, and a predetermined floor The material was obtained.

  When the flooring obtained is viewed from above, the groove portion exhibits the color of the colored layer, giving the impression that the groove portion is directly colored, and it is confirmed that it exhibits good design properties. It was.

Claims (4)

Decorative layer from the upper layer in this order, the decorative layer is at least colored base layer of the transparent resin layer and the colored layer decorative sheet flooring stacked, picture layer, an adhesive layer, the synthetic resin layer and a surface protective layer laminated in this order are those that are, the transparent resin layer is Ri Na is laminated on the colored base material layer side of the decorative layer, flooring wooden materials are laminated on the colored layer side of the decorative sheet for the flooring there is,
The so as not to reach the coloring layer on the woody material, the groove having a depth reaching the transparent resin layer through at least the decorative layer is formed,
A flooring characterized by that. The flooring according to claim 1, wherein the thickness of the transparent resin layer is 200 to 500 µm. The flooring according to claim 1 or 2, wherein the colored layer is a layer formed of a colored adhesive. Decorative layer from the upper layer in this order, the transparent resin layer, a method for producing a colored layer and flooring wooden materials are laminated, the decorative layer is at least colored base layer, picture layer, an adhesive layer, the synthetic resin layer and are those surface protective layer are layered in this order, said transparent resin layer is laminated on the colored base material layer side of the decorative layer, the flooring hand, so as not to reach the coloring layer on the woody material a method for producing a flooring, which comprises forming at least the decorative layer through a depth reaching to the transparent resin layer groove part.

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