JP2002038698A - Floor member and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor member capable of imparting high design property equivalent to a conventional wooden floor member composed of a natural lumber solid member and supplying products having stable design quality such as color and pattern inexpensively in a large quantity and having sufficient physical properties such as surface strength and durability as the floor member and a manufacturing method therefor. SOLUTION: This floor member is composed of a basic material 1, a base coat layer 2, a pattern layer 3, and a protective layer 4. The pattern layer 3 is formed by a transfer method using a transfer sheet on a base coat layer 2 face provided on a surface of the basic material 1 in advance. The protective layer 4 is provided by a coating method or a transfer method after transfer of the pattern layer 3 or is provided by the transfer method simultaneously with the pattern layer 3. The protective layer 4 has sufficient resistance against wear by adding hard inorganic particles.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring. More specifically, the present invention relates to a floor material particularly suitable for use as an indoor floor of a building such as a house.

[0002]

2. Description of the Related Art Conventional flooring materials for ordinary houses and the like include tatami mats,
Wood flooring (flooring), carpet (carpet), foam flooring (cushion floor), resin flooring (vinyl tile)
Etc. are typical. Traditionally, tatami mats have been a representative example of flooring for Japanese houses, but as the westernization of life progresses, the specific gravity of tatami mats declines relatively gradually. Being shunned from the problem,
In recent years, the value of clean and warm wood flooring has been reviewed and has become the most widely used.

Originally, solid wood such as oak wood or beech wood was used as such wood flooring, but it became expensive due to the depletion of high quality wood resources, and the color tone and wood grain design (shade of wood grain) were increased. Since it is difficult to supply a large amount of material having a constant density, density, shape, etc.), a veneer-attached plywood obtained by attaching a veneer with excellent wood grain design to the surface of a plywood made of less expensive wood, In place of veneer, decorative paper or decorative sheet with decorative paper such as wood grain or the like printed on paper or synthetic resin sheet or decorative sheet or plywood with decorative sheet,
In recent years, it has been widely used as a wooden flooring material that can be supplied in large quantities with more stable quality.

However, in the above-mentioned veneer-laminated plywood, the veneer affixed to the surface has a thickness of 1 mm or less, usually 0.3 to
Since it is an ultra-thin layer of about 0.5 mm, cracks are likely to occur due to the expansion and contraction of the wood with the passage of time, and even if it is a veneer, it uses the natural grain design of natural wood, so it is solid Although not as great as wood, it is still difficult to supply large quantities of products with consistent colors and wood grain designs.

[0005] In the case of decorative paper-laminated plywood or decorative sheet-laminated plywood, there is no problem as described above, and there is an advantage that products of stable design quality by printing can be easily supplied in large quantities. However, a decorative paper-laminated plywood using a paper-based decorative paper has a disadvantage that strength and water resistance are slightly inferior. Further, a decorative sheet pasted plywood using a decorative sheet having a synthetic resin sheet as a base material is covered with a thick synthetic resin layer having a thickness of about 100 μm to several hundred μm. The natural feel and warmth sensation that are possessed are reduced, resulting in an artificial feel similar to resin flooring, and because they are laminates of dissimilar materials, it is difficult to separate at the time of disposal and recyclability Disadvantages such as inferiority.

In addition, such a wooden flooring material may be required to have a parquet appearance in which rectangular blocks imitating a floor surface constructed using conventional solid wood are arranged vertically and horizontally on a plane. In many cases, specifically, in order to simplify the construction, it is required to supply a rectangular panel having dimensions and a design in the form of a panel in a number of rows and columns. In addition, it is generally required to form grooves along boundaries between blocks so as to give an appearance imitating a parquet construction surface made of solid wood not only on a plane but also three-dimensionally.

However, in the case of a decorative paper-laminated plywood or a decorative sheet-laminated plywood, a method of forming a groove on the surface includes a method of attaching a decorative paper or a decorative sheet to the surface of a plywood that has been previously grooved, and a method of forming a groove on the plywood. It is conceivable to apply a groove process after attaching a decorative paper or decorative sheet to the surface, but the former is technically extremely difficult to align the groove on the surface of the plywood with the pattern of the decorative paper or decorative sheet, On the other hand, the latter has problems such as the occurrence of burrs on the decorative paper or decorative sheet during the cutting of the groove to deteriorate the appearance quality or the peeling of the decorative paper or the decorative sheet from the end face of the cut portion. There is a point.

[0008] Under the circumstances as described above, any of the veneer plywood and the decorative paper or the decorative sheet-laminated plywood can provide a flooring material having both design properties and physical properties comparable to conventional wooden flooring materials made of solid natural wood. At present, it cannot be realized, and there is an urgent need to develop flooring materials that have excellent design properties and various physical properties and that can be supplied in large quantities at low cost with stable quality.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems in the prior art, and it is an object of the present invention to provide a conventional wooden flooring made of natural wood. It is possible to supply high quality products with stable design quality such as color tone and pattern at low cost in large quantities, and has sufficient physical properties such as surface strength and durability as flooring material. And a method of manufacturing the same.

[0010]

In order to solve the above-mentioned problems, the present invention provides a flooring characterized by comprising at least a substrate, a base coat layer, a picture layer and a protective layer.

Further, the present invention provides the flooring material, wherein the base coat layer is formed of a two-part curable urethane resin obtained by blending an isocyanate compound and a polyol compound having a reactivity with the isocyanate compound. A flooring material characterized by being provided.

Further, the present invention further provides the floor material, wherein the protective layer comprises a hard particle-containing resin in which hard particles having a particle size of 0.5 to 100 μm are added in an amount of 5 to 30 parts by weight per 100 parts by weight of the main resin. The floor material characterized by being comprised with these.

[0013] The present invention further provides a flooring material characterized in that the surface of the flooring material is grooved.

[0014] The present invention also provides a transfer sheet comprising a base sheet on which a base coat layer is formed in advance and a transfer layer including at least a picture layer provided on a support sheet in a releasable manner.
The transfer sheet is placed so that the transfer layer surface of the transfer sheet is in contact with the base coat layer surface of the base material, and the base coat layer and the transfer layer are bonded to transfer the transfer layer to the base coat layer surface. And a method of manufacturing a floor material, wherein the support sheet is peeled off.

Further, the present invention further provides a method for manufacturing a flooring material according to the above-mentioned method, wherein a protective layer is provided on the surface of the transfer layer on the substrate after the support sheet is peeled off. I will provide a.

Further, the present invention further provides a method of manufacturing a flooring material according to the above-mentioned method of manufacturing a flooring material, wherein the protective layer is provided by a coating method.

Further, the present invention further provides the above floor material manufacturing method, wherein the protective layer is a transfer sheet having a protective sheet releasably provided on a support sheet. It is placed so as to be in contact with the transfer layer surface, the transfer layer and the protective layer are adhered to each other, the protective layer is transferred to the transfer layer surface, and then provided by peeling and removing the support sheet. The present invention provides a method for producing a flooring material.

Further, the present invention further provides the above floor material manufacturing method, wherein the transfer sheet includes a transfer layer including at least the pattern layer and a protective layer provided on the support sheet side of the pattern layer. Transferring the transfer layer to the base coat layer surface by using a transfer sheet to be formed, thereby simultaneously forming the picture layer and the protective layer on the base coat layer surface of the base material. I will provide a.

The present invention further provides a method of manufacturing a flooring material according to the above-described method of manufacturing a flooring material, wherein a base material having a surface subjected to groove processing is used as the base material.

Further, the present invention is further characterized in that in the above-mentioned method for manufacturing a flooring material, after the support sheet is peeled off, the surface of the base material including the transfer layer and the base coat layer is subjected to groove processing. Provided is a method for manufacturing a flooring material.

Further, the present invention further provides the above-mentioned method for producing a flooring material, wherein the base coat layer is formed of a two-part curable urethane resin obtained by blending an isocyanate compound and a polyol compound having reactivity with the isocyanate compound. The present invention provides a method for producing a flooring characterized by being formed.

The present invention further provides the method of manufacturing a flooring material according to the above, wherein the protective layer is formed by adding 5 to 30 parts by weight of hard particles having a particle size of 0.5 to 100 μm per 100 parts by weight of the main resin. Provided is a method for manufacturing a flooring material, which is formed of a particle-containing resin.

[0023]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a flooring material and a method for manufacturing the same according to the present invention will be described below in detail with reference to the drawings. 1 to 6 are side sectional views showing an embodiment of a flooring material of the present invention, respectively, and FIGS. 7 to 11 are side sectional views showing an embodiment of a method of manufacturing a flooring material of the present invention in the order of steps. It is.

As shown in FIG. 1, the flooring material of the present invention comprises at least a base material 1, a base coat layer 2 provided on the surface of the base material 1, and a full or partial coating on the base coat layer 2. And a protective layer 4 provided on the picture layer 3.

The material of the base material 1 used for the flooring material of the present invention is not particularly limited, and the same material and dimensions as those of various conventional flooring materials can be used. For example, in the case of a wooden flooring material, a wooden resin made of a resin composition containing a cellulosic powder such as a wooden board, a plywood, a laminated wood, a medium fiber board (MDF), a hard fiber board (HDF), a particle board, and wood flour. Wood-based base material such as a base material.

In addition, for example, calcium silicate board, lightweight cellular concrete (ALC) board, glass fiber reinforced concrete (GRC) board, asbestos cement board, wood wool cement board,
Inorganic base materials such as gypsum slag plate, slate plate, cement plate, steel plate, brass plate, aluminum plate, stainless steel (SU
S) Metal base material such as plate, polystyrene, polyolefin, polycarbonate, polyurethane, polyester,
It is also possible to use synthetic resin base materials such as acryl and polyvinyl chloride, and composite base materials composed of two or more materials selected from these.

If necessary, the surface of the substrate 1 may be subjected to a surface treatment such as a surface polishing treatment or a sealer treatment in accordance with a conventional method. May be selected and designed as appropriate.

The base coat layer 2 prevents the components in the substrate 1 from seeping out to the surface, prevents moisture or contaminants from seeping into the substrate 1 from the outside, This is provided for the purpose of filling and densifying the fine voids to increase the surface strength, or for smoothing the surface of the base material 1 so that the picture layer 3 provided later is clearly formed.

The material of the base coat layer 2 is not particularly limited, and any paint which has been conventionally used for the base coat at the time of finishing the coating can be appropriately used according to the material of the base material 1 to be used. . Specifically, for example, acrylic, vinyl acetate, styrene, vinyl chloride,
Emulsion resins such as olefins and urethanes, latex resins such as styrene butadiene rubbers, acrylonitrile butadiene rubbers, and methyl methacrylate butadiene rubbers, urethanes, epoxies, melamines,
Urea, phenol, polyester, alkyd,
Thermosetting resins such as silicones, ionizing radiation-curable resins such as acrylates and unsaturated polyesters, and organic-inorganic composite polymer materials such as metal alkoxides can be used.

Among them, the most recommended is a two-pack curable polyurethane resin which is applied with a mixture of an isocyanate compound and a polyol compound and is cured by reaction. That strong adhesion can be obtained between them, and that large-area products can be easily produced with simple equipment without worrying about deterioration of the base material 1 because drying and curing do not require too high a temperature.
There are advantages such as faster drying and superior productivity as compared with emulsion resins and the like.

As the above-mentioned isocyanate compound, for example, hexamethylene diisocyanate, xylene diisocyanate, isophorone diisocyanate, diphenylmethane diisocyanate, etc., and as the above-mentioned polyol compound, for example, oligomer or prepolymer such as acrylic polyol and polyester polyol can be used.

Further, the base coat layer 2 can be made transparent, translucent, opaque or colored enamel according to a desired pattern. When the texture of the base material 1 is utilized, the base material 1 may be colorless and transparent or colored and transparent. Conversely, when the base material 1 needs to be concealed, the base material 1 may be set to an opaque enamel color. In short, the degree of concealing property and hue to be imparted to the base coat layer 2 may be appropriately adjusted based on the relationship between the color tone of the base material 1 and the desired design feeling for the picture.

The pattern layer 3 is provided to give a desired design pattern such as a wood grain design on the surface of the floor material as an object. The formation method is, for example, screen printing or gravure offset printing. Although a direct printing method such as an ink jet printing method or an ink jet printing method is also conceivable, painting by a transfer method is most preferable in terms of the sharpness of a pattern that can be formed and the compatibility of the surface of the substrate 1 with irregularities.

Specifically, as shown in FIG. 7, first, a base coat layer 2 is applied and formed on the surface of the base material 1, and thereafter,
On the support sheet 61 prepared separately, at least the picture layer 3
Transfer sheet 6 provided with a transfer layer including
Is placed on the base material 1 with the transfer layer (pattern layer 3) surface facing the base coat layer 2 application surface of the base material 1, and the pressure roll 81
The base coat layer 2 and the transfer layer (pattern layer 3) are brought into close contact with each other by applying pressure (and heating as necessary) to bond the transfer layer (pattern layer 3) to the base coat layer 2.
The transfer is performed by peeling off the support sheet 61 of the transfer sheet 6 from the transfer layer (picture layer 3) surface. Of course, instead of the roll press method using the above-mentioned pressure roll 81, for example, a flat pressure press method, a vacuum pressurized air press method (so-called vacuum transfer), a fluid pressure press method (so-called hydraulic transfer), a fluid jet pressure press method ( It is also possible to employ any conventionally known arbitrary pressure application method such as a so-called water jet transfer method and a solid particle impact pressure pressing method (so-called sand blast transfer).

The support sheet 61 of the transfer sheet 6 may be any sheet or film that can form a transfer layer such as the picture layer 3 on the surface so that the transfer layer can be peeled off. The material is not particularly limited. For example, a thermoplastic resin film of polyolefin, polyvinyl chloride, polyester, or the like, or a laminate of paper and a thermoplastic resin film such as a polypropylene laminated paper is used. The surface of the support sheet 61 may be subjected to a release treatment using, for example, a melamine-based resin, an ionizing radiation-curable resin, or a silicone-based compound, if necessary.

The method of forming the picture layer 3 on the support sheet 61 is not particularly limited, and may be, for example, a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a letterpress printing method, an ink jet printing method. Conventionally known printing methods can be used, and among them, a gravure printing method capable of printing a clear picture with high designability at a high speed on a long printing medium is most recommended.

Examples of the binder of the printing ink used for printing the picture layer 3 include nitrocellulose, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, styrene, alkyd, fluorine, polyurethane, acrylic, and polyester. Or a modified resin, a copolymer, a mixture, or the like of a synthetic resin such as an organic-inorganic composite polymer such as a metal alkoxide.

In addition to these binders, coloring agents such as pigments and dyes, solvents and various additives contained in ordinary inks are added. Particularly frequently used pigments such as condensed azo, insoluble azo, quinacridone, isoindolinone, anthraquinone, phthalocyanine, diketopyrrolopyrrole, carbon black, iron oxide,
There is a titanium oxide type or the like.

The transfer layer of the transfer sheet 6 may be provided with a peeling layer, a protective layer (details will be described later), an adhesive layer, and the like, if necessary, in addition to the picture layer 3. There is no particular limitation, and the same materials as those in the conventional transfer sheet can be adopted.

The type of the pattern of the pattern layer 3 is most naturally a wood pattern in consideration of the alternative to the conventional natural wood flooring material. However, other than the wood pattern, for example, a stone pattern, a cloth pattern, Any desired pattern such as an abstract pattern, a geometric figure, a character or a symbol, or a combination of a plurality of them can be provided as desired. For example, when an inorganic base material such as a cement board is used as the base material 1, a pattern of a stone pattern or a ceramic tile pattern is provided as the pattern layer 3 so that the texture and the design are natural stone-like. And ceramic tiled flooring.

Although the material of the protective layer 4 is not particularly limited, a material having excellent surface hardness, abrasion resistance, scratch resistance, stain resistance and the like is used as the material constituting the outermost surface of the flooring material. Since it is necessary to adopt such a method, and there is a chance that the floor surface near a window or a door is exposed to direct sunlight, some consideration must be given to weather resistance (light resistance).

Specific examples of the material of the protective layer 4 include thermosetting resins such as urethane, epoxy, melamine, urea, phenol, polyester, alkyd, and silicone, acrylate, and unsaturated polyester. And organic / inorganic composite polymer materials such as metal alkoxides. Among them, the most recommended are two-component curable polyurethane resins,
Fluorinated resin, silicone-modified resin and the like.

For the protective layer 4, for example, an ultraviolet absorber, a light stabilizer, a heat stabilizer, a gloss regulator, a lubricant, an antistatic agent, an antibacterial agent, an antifungal agent, a flame retardant, a coloring agent, etc. , Fillers, lubricants and the like can also be added. In particular, floor materials have particularly severe requirements for wear resistance and abrasion resistance.
It is desirable to add hard particles such as alumina or silicon carbide as a lubricant to the protective layer 4. The particle size of the hard particles is 0.5 to 100 μm, more preferably 5 to 50 μm.
m, the amount of addition is 5 per 100 parts by weight of the base resin of the protective layer 4.
The most effective amount is up to 30 parts by weight.

As a method for forming the protective layer 4, after forming the base coat layer 2 and the pattern layer 3 on the surface of the base material 1, the material for forming the protective layer 4 is layered on the surface of the pattern layer 3 by an appropriate coating device 82. (FIG. 7), after forming the base coat layer 2 and the picture layer 3 on the surface of the substrate 1, the protective layer 4 is detachably formed on a support sheet 71 prepared separately. A method of transferring and forming the protective layer 4 on the surface of the picture layer 3 of the substrate 1 using the provided transfer sheet 7 for forming the protective layer 4 (FIG. 8), and the base coat layer 2 formed on the surface of the substrate 1 When the pattern layer 3 is transferred and formed on the surface, the protective layer 4 and the transfer sheet 6 provided with the pattern layer 3 are provided on a support sheet 61 so that the protective layer 4 and the pattern layer 3 can be peeled off. (See FIG. 9).

In the case where the protective layer 4 is formed by a coating method (FIG. 7), examples of the coating method include a roll coating method, a knife coating method, an air knife coating method, and the like.
Any conventionally known coating method such as a spray coating method, a kiss coating method, a die coating method, a rod coating method, a flow coating method, and a dip coating method can be appropriately employed.

By subjecting the floor material of the present invention to groove processing on the surface, it is possible to obtain a design feeling having a three-dimensional effect closer to the construction floor surface of, for example, a conventional solid wood of natural wood. Of course, this is not limited to the wood type. For example, a stone-paved pattern layer 3 and groove processing are combined to give a cobblestone-like design feeling, or a ceramic tile-tone pattern layer 3 and groove processing are combined. Various applications are possible, such as a tiled design with joints.

The surface groove is formed by using a base material 1 on which a desired groove portion 5 has been formed by previously performing a groove process by an appropriate method such as embossing or cutting, and a base coat layer 2 and a picture layer 3 and a protective layer 4 may be provided (FIG. 10).
Then, after the base coat layer 2 and the picture layer 3 are provided on the surface of the planar base material 1, a groove 5 is formed by performing a groove processing with a cutting tool 83 such as a router (FIG. 11).

According to the former manufacturing method, as shown in FIG. 10, the pattern layer 3 is not formed on the groove 5 on the surface of the substrate 1, and the pattern layer 3 is formed only on a portion other than the groove 5. Therefore, if it is not necessary to facilitate the pattern including the color pattern of the groove 5 corresponding to the arrangement of the groove 5 on the base material 1 as the design layer 3, the base material may be formed when the design layer 3 is formed on the base material 1. There is no need to align the groove 5 on the upper surface 1 with the pattern on the pattern layer 3, and a high-design floor material that matches the color pattern on the pattern layer 3 and the concavo-convex pattern on the groove 5 can be obtained simply and easily. be able to.

In the flooring material of the present invention manufactured by this method, as shown in FIG. 2, only the groove 5 has the color of the base coat layer 2 and the other portions have the design of the pattern by the pattern layer 3. become. Therefore, if a desired color is used as the paint used for the base coat layer 2 in the groove 5 of the floor material, which is the object, only the groove 5 has an appropriate color as the groove 5 different from the pattern of the other parts. A colored flooring material excellent in design can be easily obtained.

In the above method, when a light-colored pattern is provided in a portion other than the groove portion 5 and the groove portion 5 is to be colored dark, if the pattern layer 3 does not have a sufficient concealing property, When the dark base coat layer 2 underlying the picture layer 3 is seen through, the color tone of the portion where the picture layer 3 is provided becomes dark, and good design properties may not be obtained. It is necessary to provide concealment.

In order to give the pattern layer 3 a sufficient concealing property, it is necessary to increase the application amount of the printing ink for forming the pattern layer 3 or
And / or it is necessary to add a large amount of pigment to the printing ink for forming the picture layer 3. However, in particular, when the picture layer 3 is formed on the base coat layer 2 by a transfer method using the transfer sheet 6, an increase in the application amount of the picture layer 3 on the support sheet 61 of the transfer sheet 6 causes the picture layer 3 to increase. The transfer layer to be peeled and removed together with the support sheet 61 without being transferred on the groove 5 of the substrate 1 is formed on the groove 5 by deteriorating the strippability of the transfer layer including the transfer layer. Phenomena that remain in the shape of a sheet) tend to cause transfer failure. On the other hand, if the amount of the pigment is increased without increasing the application amount of the pattern layer 3 to improve the concealing property, the pattern layer 3 becomes brittle, so that only a part of the pattern layer 3 is transferred at the time of transfer. During the handling of the transfer sheet 6, a part of the picture layer 3 may peel off, which may cause a powder dropping phenomenon.

When it is difficult to impart sufficient concealing properties to the picture layer 3 due to such circumstances, the base coat layer 2 is formed as the base coat layer 2 with a base color base coat layer 21 of a desired dark color in the groove 5 and the groove 5. 5 or a method of providing two layers of a white to light-colored convex base coat layer 22 provided in a portion other than 5 (FIG. 3), or after forming the white to light-colored base coat layer 2, before or after forming the picture layer 3. According to the method of attaching the colorant 51 of the color for the groove 5 only to the groove 5 by an appropriate method such as the wiping method (FIG. 4), even if the concealability of the picture layer 3 is poor, the above-described problem is solved. Can be solved enough.

As described above, the color of the groove 5 is often darker (darker) than the color of the portion other than the groove 5 in order to emphasize the three-dimensional effect of the groove 5. The invention is not limited to this. For example, depending on the color tone of the pattern layer 3 and the type of the pattern, if the color tone difference from the groove portion 5 is conspicuous, a sense of discomfort may be given as if the material of the surface other than the groove portion 5 and the material of the groove portion 5 are different. In such a case, by making the color of the groove 5 the same color as the color tone of the pattern layer 3, even if the pattern layer 3 is not formed inside the groove 5,
By unifying the color tone as a whole, it is possible to provide a design with a sense of continuity of the material without generating the above-mentioned uncomfortable feeling.

According to the latter manufacturing method, that is, a method of forming a groove after forming the base coat layer 2 and the pattern layer 3 on the base material 1, unlike the case of a decorative sheet-attached plywood, etc., Since the thermoplastic resin film layer does not exist on the upper surface, burrs are generated at the end of the groove portion 5 which is a cutting portion, or the cut surface of the end portion of the groove portion 5 triggers the pattern layer 3.
It is possible to easily obtain a high-quality and highly durable floor material while having a three-dimensional design feeling by the groove 5 without peeling off from the base material 1.

As shown in FIG. 5, the flooring material of the present invention manufactured by this method has a pattern of the base material 1 exposed in the groove 5 and a design of the design layer 3 in other portions. become. Therefore, if a desired color is used for the groove portion 5 of the floor material as the base material 1, only the groove portion 5 has an appropriate color as the groove portion 5 different from the pattern of the other portion, and the design is improved. Excellent flooring can be easily obtained.

On the other hand, if the color of the base material 1 is inappropriate as the color of the groove 5 of the floor material as the object, as shown in FIG. By a method suitable for applying the colorant 51 having a desired color to the groove 5 only to the groove 5 by the appropriate method described above, it is also possible to obtain a high-design flooring material in which the groove 5 is colored in a desired color.

When a groove is formed after the base coat layer 2 and the pattern layer 3 are formed on the base material 1 as described above, the protective layer is formed on the pattern layer 3 and the groove 5 after the groove processing. 4
Is desirably provided. The method of forming the protective layer 4 is not particularly limited, and may be any of a coating method, a transfer method, and the like. However, the surface physical properties such as scratch resistance, water resistance, and stain resistance of the groove 5 of the floor material to be manufactured are determined. Considering this, the protective layer 4 is continuously formed on the inner surface of the groove 5 while maintaining the uneven shape of the groove 5.
It is preferable to use a method capable of forming This point is common to the manufacturing method in which the base coat layer 2, the picture layer 3 and the protective layer 4 are formed on the base material 1 which has been subjected to groove processing in advance.

Specifically, for example, a spray coating method, a flow coating method, a dip coating method, an air knife coating method or the like is suitable as the coating method. However, depending on various conditions such as the shape of the groove 5, the groove 5 may be used. Roll coating method using a flexible elastic roll that can be deformed following the shape of
It is also possible to apply a brush coating method or a flow coating method performed along the direction of the groove 5.

In the case of the transfer method, the support sheet 61 or 71 of the transfer sheet 6 or 7 is made of a material that can be deformed following the shape of the groove 5, for example, a flexible thermoplastic resin film or rubber having a low softening temperature. Using an elastic sheet or the like, as a pressing method, for example, a flat pressure press method or a roll press method performed through a flexible elastic plate or an elastic roll,
The support sheet 61 or 71 is pressed along the inner surface of the groove 5 of the base material 1 by a method such as a vacuum pressurized air press method, a fluid pressure press method, a fluid jet pressure press method, or a solid particle impact pressure press method. It is better to use a method of transferring the image.

In the above-described method, the protection layer 4 on the transfer sheet 6 or 7 is naturally covered with the groove 5 on the substrate 1.
Formability that can be deformed to follow the shape of is required. However, since such formability and surface properties as the protective layer 4 on the outermost surface of the flooring material essentially require contradictory performances, it is difficult to satisfy both performances simultaneously. In many cases.

In such a case, as the transfer sheet 6 or 7, the protective layer 4 made of a thermosetting resin exhibiting a thermoplastic solid state in an uncured or semi-cured state or a curable resin such as an ionizing radiation-curable resin. To the support sheet 61 or 7
Using the transfer sheet 6 or 7 provided on the
When the method of transferring the protective layer 4 thereon and completely curing the protective layer 4 simultaneously with or after the transfer is adopted, the inner surface of the groove 5 can sufficiently follow the shape of the groove 5 on the base material 1. While the protective layer 4 is continuously formed, it is easy to satisfy sufficient surface physical properties as the outermost protective layer 4 of the flooring material.

[0062]

The present invention will now be described in more detail with reference to specific examples of the flooring material of the present invention and a method for producing the same.

Example 1 Iron oxide coloring was applied to the surface of a 12 mm thick hard fiberboard (HDF) having vertical grooves of about 1 mm in width and about 1 mm in depth provided at intervals of about 60 mm on the surface. Spray isocyanate-containing two-component curable polyurethane resin paint containing isocyanate blended in a brownish color with high opacity by a pigment (however, the blending ratio of isocyanate curing agent is 10 parts by weight per 100 parts by weight of main resin). The coating was applied at a coating amount of 20 g / m ² after drying by a coating method to form a base coat layer, and the coating was dried to the extent that finger touch was eliminated.

On the other hand, on one side of a support sheet made of a rigid polyvinyl chloride resin film having a thickness of 80 μm, a wood grain pattern layer was formed by printing using a polyvinyl butyral resin printing ink by a gravure printing method. A transfer sheet was prepared.

The pattern layer surface of the transfer sheet was placed with the pattern layer surface of the transfer sheet facing the base coat layer surface of the substrate, and a silicone rubber roll heated to a surface temperature of 150 ° C. and having a rubber hardness of 60 ° was used. Thermocompression bonding under conditions that do not contact the inner surface of the vertical groove of the material, the base coat layer and the pattern layer in a portion other than the vertical groove portion are adhered, and then the support sheet of the transfer sheet is peeled off to remove the pattern. The layer was transferred onto the basecoat layer.

Thereafter, a transparent isocyanate-containing two-component curable polyurethane resin paint containing 20 parts by weight of alumina particles having an average particle diameter of 50 μm per 100 parts by weight of the main resin (provided that the compounding ratio of the isocyanate curing agent is (10 parts by weight per 100 parts by weight of the main material resin) was applied by a spray coating method to a coating amount of 20 g / m ² after drying to form a protective layer, which was cured by drying and curing to prepare a flooring material of the present invention.

The obtained flooring material has a wood grain pattern on the surface other than the vertical groove portion, and the vertical groove portion is colored in a brownish color, which is extremely rich in design. There was no particular problem with the adhesion of the layers, and the physical properties such as abrasion resistance, scratch resistance, solvent resistance, and stain resistance of the surface were sufficient as flooring materials.

Example 2 Hard fiber board (H) having a dark brown color and a thickness of 12 mm
A two-component isocyanate-containing acrylic polyol-based curable polyurethane resin colored in a creamy color with high concealment properties using a titanium oxide-based white pigment and an iron oxide-based coloring pigment over the entire surface of a substrate made of DF) Paint (however,
The isocyanate curing agent is mixed in an amount of 10 parts by weight per 100 parts by weight of the main resin) to a coating amount of 20 g / m ² after drying by a spray coating method to form a base coat layer. Dried.

On the other hand, on one side of a support sheet made of a rigid polyvinyl chloride resin film having a thickness of 80 μm, a light-colored wood-grain pattern layer was printed by a gravure printing method using a polyvinyl butyral resin-based printing ink. Then, a transfer sheet was prepared.

The pattern layer surface of the transfer sheet was placed on the base coat layer surface of the base material, and thermocompression-bonded with a silicone rubber roll having a rubber hardness of 60 degrees heated to a surface temperature of 150 ° C. After that, the support sheet of the transfer sheet was peeled off and the pattern layer was transferred onto the base coat layer.

After the transfer was completed, vertical grooves having a width of about 1 mm and a depth of about 1 mm were cut at intervals of about 60 mm on the surface of the picture layer using a router. At the time of the cutting, no remarkable burrs were generated. By this groove processing, the color of the dark brown base material was exposed in the vertical groove portion.

Thereafter, a transparent isocyanate-containing acrylic polyol-based two-part curable polyurethane resin paint containing 20 parts by weight of alumina particles having an average particle diameter of 50 μm per 100 parts by weight of the main resin (provided that the compounding ratio of the isocyanate curing agent is (10 parts by weight per 100 parts by weight of the main material resin) was applied by a spray coating method to a coating amount of 20 g / m ² after drying to form a protective layer, which was cured by drying and curing to prepare a flooring material of the present invention.

The obtained flooring material has a light wood grain pattern on the surface other than the vertical grooves, and the vertical grooves have a deep brown color, and are extremely rich in design. There were no burrs around, and physical properties such as abrasion resistance, scratch resistance, solvent resistance, and stain resistance of the surface were sufficient as flooring materials.

[0074]

As described above in detail, according to the flooring material and the method of manufacturing the same according to the present invention, the design of the surface of the flooring material is a pattern by printing or the like which does not use a natural material such as solid wood or veneer. Therefore, it is not only possible to supply a large amount of products with stable design quality such as color tone and grain shape at low cost, but also the base coat layer, picture layer, and protective layer adhere sufficiently to the base material, and more than the decorative sheet. Since it can be formed sufficiently thin, problems such as lack of water resistance and surface strength, such as in decorative paper-laminated plywood, as well as loss of material texture of the base material, such as decorative paper-laminated plywood, and difficulty in recycling, etc. No problem, and
Without accompanying the problem of pattern alignment and processing defects such as burrs and peeling, it is easy to form grooves on the surface of the base material and to give a three-dimensional design feeling by the color of the grooves.
This is an extremely remarkable effect that a floor material excellent in all aspects such as designability, physical properties, productivity, economy, environmental protection and the like can be easily realized.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a flooring material of the present invention.

FIG. 2 is a side sectional view showing an embodiment of the flooring material of the present invention.

FIG. 3 is a side sectional view showing an embodiment of the flooring material of the present invention.

FIG. 4 is a side sectional view showing an embodiment of the flooring material of the present invention.

FIG. 5 is a side sectional view showing an embodiment of the flooring material of the present invention.

FIG. 6 is a side sectional view showing an embodiment of the flooring material of the present invention.

FIG. 7 is a side sectional view showing an embodiment of the floor material manufacturing method of the present invention in the order of steps.

FIG. 8 is a side sectional view showing an embodiment of the method for manufacturing a flooring material of the present invention in the order of steps.

FIG. 9 is a side sectional view showing an embodiment of the floor material manufacturing method of the present invention in the order of steps.

FIG. 10 is a side sectional view showing an embodiment of the method for manufacturing a flooring material of the present invention in the order of steps.

FIG. 11 is a side sectional view showing an embodiment of a floor material manufacturing method of the present invention in the order of steps.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Base material 2 ... Base coat layer 21 ... Base coat whole surface base coat layer 22 ... Convex part base coat layer 3 ... Picture layer 4 ... Protective layer 5 ... Groove part 51 ... Colorant 6 ... Transfer sheet 61 ... Support sheet 7 ... Transfer sheet 71 ... Support sheet 81 ... Pressing roll 82 ... Coating device 83 ... Cutting tool

Continued on front page F-term (reference) 3B005 EA01 EB01 EC01 EC14 FA08 FB03 FB14 FB38 FC09X 4F100 AA19 AK01D AK15 AK23 AK51B AK54B AP03 AT00A BA04 BA10A BA10D BA13 CA13 CB02 CC00B DD05D DE01D EC042E86 EBH E112H ECB2H HB31 JB07 JK09 JK12D JK14 JL00 JL06 YY00D

Claims (13)

[Claims] 1. A flooring material comprising at least a base material, a base coat layer, a picture layer and a protective layer. 2. The composition according to claim 1, wherein the base coat layer is composed of a two-part curable urethane resin obtained by blending an isocyanate compound and a polyol compound having a reactivity with the isocyanate compound. Flooring. 3. The protective layer comprises a hard particle-containing resin in which hard particles having a particle size of 0.5 to 100 μm are added in an amount of 5 to 30 parts by weight per 100 parts by weight of the main resin. The flooring according to claim 1 or 2, wherein 4. The flooring according to claim 1, wherein a groove is formed on the surface. 5. A transfer sheet in which a transfer layer including at least a picture layer is provided on a support sheet in a releasable manner on a base material on which a base coat layer has been previously formed, and the transfer sheet is transferred to the base coat layer surface of the base material The transfer layer surface of the sheet is placed so that the transfer layer surface is in contact, the base coat layer and the transfer layer are adhered, the transfer layer is transferred to the base coat layer surface, and then the support sheet is peeled off. A flooring manufacturing method characterized by the above-mentioned. 6. The method according to claim 5, wherein a protective layer is provided on the surface of the transfer layer on the substrate after the support sheet is peeled off. 7. The method according to claim 6, wherein the protective layer is provided by a coating method. 8. A transfer sheet comprising a support sheet and a protective layer provided releasably on a support sheet so that the protective layer surface is in contact with the transfer layer surface of the base material. The floor material according to claim 6, wherein the transfer layer and the protective layer are adhered to each other, and the protective layer is transferred to the transfer layer surface, and then provided by peeling and removing the support sheet. Manufacturing method. 9. A transfer sheet comprising a transfer layer including at least the picture layer and a protective layer provided on the support sheet side of the picture layer, wherein the transfer layer is formed of the transfer layer. The method for manufacturing a flooring material according to claim 5, wherein the pattern layer and the protective layer are simultaneously formed on the base coat layer surface of the base material by transferring the pattern layer to the base coat layer surface. 10. The method for manufacturing a flooring material according to claim 5, wherein a base material having a groove processed in advance is used as the base material. 11. The method according to claim 5, wherein a groove is formed on the surface of the base material including the transfer layer and the base coat layer after the support sheet is peeled off. Method of manufacturing flooring. 12. The two-part curable urethane resin comprising the base coat layer and an isocyanate compound and a polyol compound reactive with the isocyanate compound.
The method for producing a flooring material according to any one of the above items. 13. The protective layer according to claim 1, wherein the particle size is 0.5 to 100 μm.
The method for producing a floor material according to any one of claims 5 to 12, wherein the hard particles are formed of a hard particle-containing resin added in an amount of 5 to 30 parts by weight per 100 parts by weight of the main material resin. .