JP2002339556A - Flooring and floor face using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide flooring and a floor face using the same, which are excellent in water resistance, which make a decorative sheet hard to peel off even in a case of application of an external force such as an impact during movement of casters, etc., which make it hard for socks, stockings, etc., to get runs because fibers of the socks, the stockings, etc., get snagged on the floor face, and which have groove parts with a sense of depth and excellent design properties. SOLUTION: The rectangular flooring, wherein the decorative sheet is stuck on a one-side surface of a wood base material, is characterized in that a slant face, which is covered with the decorative sheet, is formed at a peripheral edge on a side whereon the decorative sheet is stuck.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a decorative material having a groove with a sense of depth, in which a decorative sheet is hardly peeled off even when an impact or the like is applied when moving a caster or the like at a joint between flooring materials. The present invention relates to an excellent floor material and a floor surface using the same.

[0002]

2. Description of the Related Art Conventionally, floor materials obtained by attaching a decorative sheet to a wooden base material and performing actual processing have been used for detached houses and apartment houses. Such floor materials are chamfered at the corners of the decorative sheet which have been actually processed in consideration of designability. That is, the location where the actual processing is performed is a location where the floor materials are joined, and a groove is formed at the junction location between the floor materials, thereby improving the design.

[0003] The floor material having the above-described structure is formed in a groove formed by a joint between the floor materials.
The wood base material is exposed, and in order to improve the design by eliminating the discomfort caused by the difference in color tone between the decorative sheet and the wood base material, a color tone similar to the decorative sheet is usually formed in the groove. To eliminate the color difference between the decorative sheet and the wooden base material. Further, the above-described coating of the paint with the groove portion is also for preventing water from penetrating from the exposed portion of the wood-based base material and causing swelling. In particular, it becomes apparent when a medium-density fiberboard (MDF) is used as a wood base material.

[0004] Although the floor material thus constructed contributes to the improvement of design in the sense of eliminating the sense of discomfort of the groove, the groove has a poor depth feeling, and the groove part having a sense of depth must be removed. There has been a demand for floor materials having the same, and further improvement in performance in terms of water resistance has been demanded. Further, as another problem, since the adhesive interface between the decorative sheet and the wooden base material is exposed in the groove, an external force such as an impact is applied to the adhesive interface when the caster or the like is moved, and the decorative sheet may come off. Also, there has been a demand for floor materials that are hard to peel off decorative sheets.

[0005] Still another problem is that when plywood is used as a wooden base material, the fibers of the plywood are fuzzy in the grooves, so that fibers such as socks and stockings are caught and transmitted. Also, there is an inherent problem that when the cloth is wiped and cleaned, the fibers of the cloth remain in the grooves and are unsightly.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and has as its object to be excellent in water resistance and to be applied even when an external force such as an impact is applied when moving a caster or the like. Provided is a flooring material having a groove that is hard to peel off a decorative sheet, is hard to catch fibers such as socks and stockings, and does not easily generate electric lines, and has a deep feeling and excellent designability, and a floor surface using the same. It is in.

[0007]

Means for Solving the Problems In order to achieve the above object, the present inventors have set forth the invention according to claim 1 in the form of a rectangular base material having a decorative sheet adhered to one surface of a wooden base material. It is a flooring material, characterized in that a slope covered with the decorative sheet is formed at four peripheral edges on the side where the decorative sheet is stuck.

According to a second aspect of the present invention, there is provided a floor surface formed by laying a plurality of flooring materials using at least the flooring material according to the first aspect, wherein a joint between the flooring materials is provided. Comprises a groove covered with a decorative sheet.

With the above construction, a floor having a groove having excellent water resistance, a decorative sheet which is hard to peel off even when an external force such as an impact is applied when a caster or the like is moved, and which has a sense of depth and excellent design. Materials and floors.
In addition, even when plywood is used as the wooden base material, a floor material and a floor surface having a groove portion in which fibers such as socks and stockings are not easily caught and transmission lines are hardly generated can be obtained.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The above-mentioned present invention will be described below in detail with reference to the drawings. FIG. 1 is a perspective view showing an embodiment of a flooring material according to the present invention, FIG. 2 is an enlarged sectional view of a joint portion of the flooring material according to the present invention, and FIG. FIG. 4 is a schematic plan view showing a method for forming a slope at four peripheral edges of a flooring material according to the present invention, and FIG. 5 is a cross-sectional view taken along line XX of FIG. In the figure, 1 is a flooring material, 2 is a wooden base material, 3 is a decorative sheet, 4 is a slope, 5 is a female fruit, 6 is a male fruit, 7 is a groove, 8 is a corner floor material, 9 Denotes an end floor material, 10 denotes a floor surface, and α and β denote metal press rolls, respectively.

FIG. 1 is a perspective view showing an embodiment of a flooring material according to the present invention. The flooring material 1 is attached to one surface of a rectangular wooden base material 2 via an adhesive (not shown). The decorative sheet 3 having a wood grain pattern is adhered, and a round slope 4 is formed on the four peripheral edges on the side where the decorative sheet 3 is adhered.
When the floor materials 1 thus configured are joined together, the groove 7 covered with the decorative sheet 3 at the joint between the floor materials 1
(See FIG. 2). The wooden base material 2 is subjected to actual processing as necessary on the side of the floor material 1 to form female nuts 5 and male nuts 6, and the female nuts 5 and male nuts 6 are fitted. It is configured so that floor materials can be joined together.

FIG. 2 is an enlarged cross-sectional view of a joint portion of floor materials according to the present invention. The floor materials 1 are fitted with female dies 5 and male dies 6 provided on a wooden base material 2. At the same time, a groove 7 covered with the decorative sheet 3 is formed on the decorative sheet 3 side of the joint between the floor materials 1. Since the groove 7 has a configuration in which the entire surface is covered with the decorative sheet 3, the adhesive interface between the wooden base material 2 and the decorative sheet 3 is not exposed. The decorative sheet is difficult to peel off even when external force is applied. In addition, since the groove 7 is completely covered with the decorative sheet 3, water is
Swelling does not easily occur even when a medium density fiberboard (MDF) is used as the wooden base material 3. In addition, since the wooden base material 3 is structured not to be exposed in the groove 7, for example, even if the wooden base material 3 is made of a plywood having a sharply fuzzed fiber by cutting, fibers such as socks and stockings are not removed. There is no snagging, and as a result, it is difficult for a sock or a stocking or the like to have a conductive line. further,
By forming the groove portion 7 with the same decorative sheet 2 as the exposed surface, a groove portion having a sense of depth and excellent in design can be obtained.

FIG. 3 is a plan view of an essential part showing an embodiment of a floor surface on which the floor material according to the present invention is laid. A floor surface 10 has a plurality of floor materials laid in a corner of a room. is there. In FIG. 3, the portions indicated by the halftone dots are the joints between the floor materials and
As shown in FIG. 3, the flooring material 1 of the present invention is used at locations other than corners and ends of the floor surface as shown in FIG. That is, in FIG.
A total of five corner floor members 8 and end floor members 9 are used at the corners and ends. As a matter of course, the corner flooring material 8 and the end flooring material 9 have the slopes 4 covered with the decorative sheet 3 at two continuous and three peripheral edges.

Next, the material constituting the flooring 1 of the present invention will be described. First, the wooden base material 2 will be described.
The wood-based substrate 2 may be any of plywood (including LVL), medium-density fiberboard (MDF), high-density fiberboard (HDF), particle board, veneer, wood, laminated wood, and the like. Can be used as appropriate.

Next, the decorative sheet 3 constituting the flooring 1 of the present invention will be described. As a result, the decorative sheet 3 imparts a design as a floor material, and / or
It is provided in order to provide various physical properties required for the flooring material, particularly, surface physical properties. The sheet constituting the decorative sheet 3 is not particularly limited, and a single sheet of paper or various synthetic resin sheets, or a laminate thereof is suitable. Further, paper and various synthetic resin sheets are not limited to white or colorless and transparent sheets, and may be sheets colored with pigments or the like. Further, the sheet made of a synthetic resin may be in a non-stretched state or a sheet stretched in a uniaxial or biaxial direction. Note that one or both surfaces of paper or various synthetic resin sheets may be subjected to an easy-adhesion treatment such as a corona discharge treatment, a plasma treatment, or an ozone treatment, if necessary.

Further, the decorative sheet 3 is printed with, for example, a wood grain pattern as one means for giving a design as a floor material. As the ink used for this printing, a resin system may be appropriately selected depending on the material of the sheet to be printed. As the vehicle, chlorinated polyethylene,
Chlorinated polyolefins such as chlorinated polypropylene, polyesters, polyurethanes comprising isocyanates and polyols, polyacryls, polyvinyl acetates, polyvinyl chlorides, vinyl chloride-vinyl acetate copolymers, cellulose resins, polyamide resins and the like. Two or more types can be used as a mixture, and a pigment, a solvent, various auxiliaries and the like can be added to form an ink. In addition, the decorative sheet 3 can be provided with an uneven pattern by embossing or the like as necessary, and the design as a floor material can be improved. For example, a conduit groove or the like provided in a conduit portion such as a grain pattern.

In order to provide the decorative sheet 3 with physical properties required as a flooring material, in particular, surface properties such as scratch resistance, abrasion resistance, and stain resistance, the decorative sheet 3 is usually used.
Is provided with a surface protective layer on the outermost surface. Examples of the resin forming the surface protective layer include an epoxy resin, an acrylic resin, a urethane resin, an amide resin, an ester resin, polyethylene, polypropylene, and the like.
Copolymers of one or more polyolefins such as polybutene, polybutadiene and polyisoprene or two or more of olefins such as ethylene, propylene, butene, butadiene and isoprene, or copolymers of α-olefins having 4 or more carbon atoms (wires) Low-density polyethylene), an ethylene-vinyl acetate copolymer, an ethylene-vinyl alcohol copolymer, or a mixed resin of one or more of these. As a method of forming the surface protective layer, for example, the above-mentioned resin is converted into a solution or heated and melted, and a known coating method such as a gravure printing method, a roll coating method, or an extrusion coating method is used. It can be formed by appropriately applying and coating, or can be formed by forming the above resin into a film and laminating it by a known lamination method such as a dry lamination method.

However, more preferably, the surface protective layer is formed of an ionizing radiation curable resin. This is because the surface hardness is high and the productivity is excellent. The ionizing radiation-curable resin is a resin that undergoes a cross-linking polymerization reaction upon irradiation with ionizing radiation and changes into a three-dimensional polymer structure. Ionizing radiation refers to electromagnetic waves or charged particle beams having energy quanta that can polymerize and crosslink molecules, and include visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-rays, electron beams, ion beams, and the like. is there. Normally, ultraviolet rays or electron beams are used. As the ultraviolet rays, light sources of an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, and a metal halide lamp can be used. The wavelength of the ultraviolet light is usually 19
The wavelength range of 00 to 3800 is mainly used. Further, as the electron beam, various electron beam accelerators such as Cockloft-Walton type, Van degraft type, resonance transformer type, insulating core transformer type, or linear type, dynamitron type and high frequency type are used, and 100 to 1000 KeV, Preferably, one that irradiates electrons having an energy of 100 to 300 KeV can be used.

As the ionizing radiation-curable resin, a monomer having a radical polymerizable unsaturated group such as a (meth) acryloyl group or a (meth) acryloyloxy group, or a cationic polymerizable functional group such as an epoxy group in a molecule. Body, prepolymer or polymer (hereinafter, these are collectively referred to as compounds). These monomers, prepolymers, and polymers may be used alone or as a mixture of two or more. In this specification, (meth) acrylate is used to mean acrylate or methacrylate.

Examples of the prepolymer having a radical polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, triazine (meth) acrylate, and polyvinylpyrrolidone. No. This prepolymer usually has a molecular weight of 1000
Those having about 0 or less are used. If the molecular weight exceeds 10,000, the cured resin layer has insufficient surface properties such as scratch resistance, abrasion resistance, chemical resistance, and heat resistance. Although the above acrylate and methacrylate can be used in common, acrylate is faster in terms of the rate of crosslinking and curing by ionizing radiation. Therefore, acrylate is more advantageous for the purpose of efficiently curing at high speed and in a short time.

Examples of the prepolymer having a cationically polymerizable functional group include epoxy resins such as bisphenol type epoxy resin, novolak type epoxy resin and alicyclic type epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, and urethane type. Examples thereof include vinyl ether resins such as vinyl ether and ester vinyl ether, and prepolymers such as cyclic ether compounds and spiro compounds.

The ionizing radiation-curable resin cures sufficiently when irradiated with an electron beam, but when it is cured by irradiating ultraviolet rays, a photopolymerization initiator can be added as a sensitizer. As a photopolymerization initiator in the case of a resin system having a radical polymerizable unsaturated group, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoin benzoate, Michler ketone, diphenyl sulfide, dibenzyl disulfide, Diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used alone or in combination. In the case of a resin having a cationically polymerizable functional group, an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, a freeloxysulfoxonium diallyliodosyl salt, or the like is used alone or as a mixture. be able to. The amount of these photopolymerization initiators generally depends on the amount of the ionizing radiation curable resin 1.
It is about 0.1 to 10 parts by weight with respect to 00 parts by weight.
Further, as a method of forming the protective layer with an ionizing radiation-curable resin, for example, a solution of the ionizing radiation-curable resin,
It can be formed by coating by a known coating method such as a gravure coating method or a roll coating method. The coating amount is suitably about 5 to 30 g / m ² as a solid content, and more preferably 15 to 25 g / m ² .

When the surface protective layer formed of the ionizing radiation-curable resin is to be further provided with abrasion resistance and abrasion resistance, powdery aluminum oxide, silicon carbide, silicon dioxide, calcium titanate, etc. , Barium titanate, magnesium pyroborate, zinc oxide, silicon nitride, zirconium oxide, chromium oxide, iron oxide, boron nitride, diamond, gold sand, glass fiber, and other abrasives. An appropriate ratio of the abrasive to 100 parts by weight of the ionizing radiation-curable resin is 1 to 80 parts by weight.

The adhesive used for attaching the decorative sheet 3 to the wood-based substrate 2 needs to be appropriately selected depending on the material constituting the surface of the decorative sheet 3 which is in contact with the adhesive. A known adhesive such as a vinyl acetate resin, a urea resin, or a urethane resin may be used.

The slope 4 covered with the decorative sheet 3 formed on the four peripheral edges of the flooring 1 on the decorative sheet 3 side can be formed by various methods. After sticking the decorative sheet on the wooden base material,
As shown in FIGS. 4 and 5, a metal press roll α having a concave shape in the circumferential direction, and having a surface shape in which inclined surfaces having a rounded cross section are formed in both ends in the axial direction of the concave portion in the circumferential direction, and a flat surface. Metal press roll β with various surface shapes
Between the decorative sheet side and the metal press roll α side to form a slope at the end of the decorative sheet side (the metal press rolls α and β are both drive rolls) A method of forming a slope at the end of the decorative sheet side by pressing from the decorative sheet side with a press plate having a shape, or after attaching the decorative sheet to a wooden base material, Cutting the vicinity of the interface into a slope shape, applying an adhesive to the cut surface as necessary, applying a decorative sheet to the cut surface, and forming a slope at the end of the decorative sheet side, or wood After cutting the end of one surface of the base material into a slope shape with a tenoner, a router, etc., a decorative sheet is attached to the one surface consisting of a flat surface and a slope, and a slope is formed at the end on the decorative sheet side. A forming method and the like can be given. The above-mentioned forming methods may be used in combination, and the slopes in the long direction and the short direction of the floor material may be formed by different forming methods. In addition, as a method of attaching a decorative sheet to a wooden base material, a soft roll laminating method,
A vacuum press method, a bead shot (BS) method, a lapping method, and the like can be given. In the description so far, the slopes formed on the four peripheral edges of the flooring material 1 on the decorative sheet 3 side are rounded, but the shape of the slopes is not limited to this, and for example, the flooring materials are joined together. The groove may be a V-shaped or U-shaped slope.

[0026]

Next, the present invention will be described in more detail with reference to the following examples. [Manufacture of decorative sheet] 60 with corona discharge treatment on both sides
acrylic on one side of a μm olefin resin sheet
Urethane resin (resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol)
The solution is applied by a gravure coating method so that the solid content becomes 2 g / m ² to form a printing primer layer, and an acrylic-urethane resin (100 parts by weight of acrylic polyol and hexamethylene diisocyanate is added to the printing primer layer) 5
A solid pattern printing layer and a pattern printing layer are sequentially printed by a gravure printing method using a printing ink consisting of a resin to which parts by weight are added) to form a wood-grained printing layer. A urethane-based adhesive is applied to 10 g / m ² to form an adhesive layer, and a propylene-based resin is heated and melt-extruded on the adhesive layer by a T-die extruder to a thickness of 80 μm. A transparent resin layer was formed. Thereafter, the surface of the transparent resin layer is subjected to a corona discharge treatment, and an acryl-urethane resin (resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of an acrylic polyol) is applied to the surface of the corona discharge treated surface by a gravure coating method. Is applied so as to be 1 g / m ² to form a primer layer for a surface protective layer, and a urethane acrylate-based electron beam-curable resin is coated on the primer layer for a surface protective layer with a solid content of 15 g by a roll coating method. / m ² and by coating and drying so as to form an electron beam-curable resin layer of uncured, oxygen concentration 200ppm following environment under electron beam to the electron beam curing resin layer of uncured (accelerating voltage (125 KeV, 5 Mrad) to cure to form a surface protective layer made of an electron beam-curable resin, and a 50 μm deep wood grain from the surface protective layer side. Carried out embossed with Jo embossing plate, to prepare a decorative sheet obtained by forming an uneven pattern of the wood grain conduit.

[Lamination of wood base material and decorative sheet] 12
Adhesive (manufactured by Chuo Rika Kogyo:
(Licabond BA-10A / BA-10B = 100/5)
Is applied in a wet state so as to have a weight of 6 g / scale ^2, and the decorative sheet prepared above is laminated and pressed with a cold press machine (press pressure: 2 kg / cm ² , press time: 1 hour). To make a decorative board.

Example 1 The decorative plate prepared above was cut into a desired rectangular shape, and the four sides were actually processed using a tenoner.
Using a slope forming apparatus as shown in FIG.
The veneer subjected to actual processing at / min was processed in the order of a long direction and a short direction to form a slope of 0.5 mm, thereby obtaining a flooring material of the present invention.

Comparative Example 1 The decorative panel produced above was cut into a desired rectangular shape, and the four side surfaces were actually processed using a tenoner to obtain a flooring material as Comparative Example 1.

Comparative Example 2 The decorative board prepared above was cut into a desired rectangular shape, and the four side faces were actually processed using a tenoner, and a chamfering process of 0.5 mm round was performed on the four peripheral edges of the decorative sheet side. A urethane-based water-based paint was applied to the chamfered surface, dried and solidified to obtain a floor material of Comparative Example 2.

Example 1 produced above and Comparative Example 1
Were joined so that a step difference of 0.2 to 0.3 mm was generated, and a peeling test of a decorative sheet described below was performed on the joined portion. The evaluation results are shown in Table 1.

[0032]

[Table 1] * Facial sheet peeling test A rectangular stainless steel jig with a cross section of 2 cm square and a length of 4 cm is placed so that one long side is in contact with the floor material surface, and crosses the joint of the floor material by its own weight. The decorative sheet was reciprocated as described above, and the number of reciprocations until the decorative sheet was peeled off from the wooden base material was evaluated.

The floor materials of Example 1 and Comparative Example 2 produced as described above were joined together, and the joints were subjected to the following fiber hooking test. The evaluation results are shown in Table 2.

[0034]

[Table 2] * Fiber hooking test Using a residential wiper (Quickle Wiper manufactured by Kao Corporation), the surface of the floor material was rubbed along the floor material joint, and the number of times the wiper fiber adhered to the joint was evaluated. .

As is clear from the above evaluation results, the present invention is a flooring material in which the decorative sheet is hardly peeled off and the fibers are hardly caught.

[0036]

As has been described so far, according to the present invention, the floor material having the structure in which the decorative sheet is adhered to the wooden base material is provided on the four sides on the side where the decorative sheet is adhered. By forming the slope so that a groove covered with a decorative sheet is formed at the joint between the materials, the decorative sheet is difficult to peel off even when an external force such as an impact is applied to the groove when the caster or the like is moved, It is difficult for water to penetrate the wood-based base material and cause swelling, and so that fibers such as socks and stockings are caught and wire is not easily generated in socks and stockings.
Furthermore, it is possible to provide a flooring material having a groove with a sense of depth and excellent in design.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a flooring material according to the present invention.

FIG. 2 is an enlarged cross-sectional view of a joint of floor materials according to the present invention.

FIG. 3 is a plan view of an essential part showing one embodiment of a floor surface on which floor materials according to the present invention are laid.

FIG. 4 is a schematic view illustrating a method for forming a slope at four peripheral edges of a decorative sheet side of a flooring material according to the present invention.

FIG. 5 is a sectional view taken along line XX of FIG. 4;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Floor material 2 Wooden base material 3 Decorative sheet 4 Slope 5 Female fruit 6 Male fruit 7 Groove 8 Corner floor material 9 End floor material 10 Floor surface α, β Metal press roll

Claims (2)

[Claims] 1. A rectangular flooring material in which a decorative sheet is attached to one surface of a wooden base material, and four peripheral edges on the side where the decorative sheet is attached are covered with the decorative sheet. A flooring material characterized by a sloped slope. 2. Use of at least the flooring material according to claim 1,
A floor surface formed by laying a plurality of floor materials, wherein a joint between the floor materials comprises a groove covered with a decorative sheet.