JP2003041754A - Floor material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material having superior abrasion resistance and wearing resistance and having a groove part eliminating a run in socks and stockings and eliminating fiber of a wiping cloth from being left therein and to provide its manufacturing method. SOLUTION: This floor material is characterized in that, at least, a streak of the groove part 3 is formed in one surface of a wooden base material 2, a synthetic resin sheet 4 having a pattern thereon is stuck to the one surface provided with the single streak of the groove part in such a state as covering a corner part of the groove part so as to form a floor material base material, and a hardening type resin is applied to the whole surface of the floor material base material provided with the groove part so as to form a surface protecting layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material having grooves having excellent wear resistance and scratch resistance, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a veneer veneer is attached to a wooden base material,
For the purpose of improving the design, a groove portion such as a V groove is formed by matching with the joint portion of the veneer veneer by cutting or the like, and an uncomfortable feeling caused by a color tone difference between the veneer veneer and the wood-based substrate is formed in the groove. There is provided a flooring material coated with a colored paint for the purpose of improving the designability. Further, there is provided a flooring material in which a waterproof coloring paint is applied to the groove for the purpose of improving the water resistance of the groove as needed. However, in recent years, due to the shortage of high-quality raw wood used for veneer veneer, or the increase in resource protection and global environmental protection, flooring in which a decorative sheet is attached to a wood-based substrate is used instead of veneer veneer. It started to come.

Even in the case of a flooring material in which a decorative sheet is attached to a wood-based substrate as described above, the flooring material surface is subjected to V by, for example, cutting as in the flooring material using a single veneer plate. In general, a method of forming a grooved groove to provide a pseudo joint is provided, and a flooring material in which a colored coating material is applied to the grooved groove portion for the purpose of improving the design is provided. Also for this purpose, there is provided a flooring material in which the groove portion is coated with a water resistant coloring paint for the purpose of improving the water resistance of the groove portion if necessary.

However, the flooring material in which the above decorative sheet is attached to a wood-based substrate has a structure in which a coating material is applied to the groove, and the groove has abrasion resistance, scratch resistance, or water resistance. The problem is that it is inferior to the part where the plywood is attached, or when plywood is used for the wood-based substrate, the fibers of the plywood are fluffed in the groove, so fibers such as socks and stockings are caught and transmitted to this. There are problems such as lines, and when wiping, there are problems that the fibers of the cloth remain in the groove and are unsightly.
There has been a demand for a floor material that does not cause these problems.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object thereof is to provide excellent abrasion resistance and scratch resistance, and to conduct socks and stockings for wire transmission and wipe cleaning. The present invention provides a flooring material having a groove portion in which fibers of the cloth do not remain and a method for manufacturing the flooring material.

[0006]

In order to achieve the above object, the present inventors have found that the flooring material of the present invention according to claim 1 is provided with at least one groove on one surface of a wood base material. A synthetic resin sheet provided with a pattern to cover the corners of the groove is attached to the one surface provided with the one groove to form a flooring base material, and the flooring base. The surface protective layer is formed by applying a curable resin to the entire surface of the material on which the groove is provided. With this configuration, the fibers of the sock or stocking or the cloth for wiping can be prevented from being caught, so that the transmission lines of the sock or stocking can be prevented and the fiber of the cloth for wiping can be formed into the groove portion. Never remains.

The present invention according to claim 2 provides the invention according to claim 1.
The floor material described above is characterized in that a coating layer is formed below the surface protective layer of the groove. With this structure, the design property can be improved, and the entire surface having the groove in which the coating layer is formed is covered with the surface protective layer, so that the groove has excellent wear resistance and scratch resistance. You can

Further, in the flooring production method of the present invention according to claim 3, a step of providing at least one groove on one surface of the wood-based substrate, and a pattern pattern on the one surface with an adhesive agent. A step of sticking a synthetic resin sheet provided with, and a step of cutting the synthetic resin sheet provided with the picture pattern of the groove along the longitudinal direction of the groove at substantially the center in the width direction of the groove. , A step of folding a synthetic resin sheet provided with the picture pattern cut in the groove portion into the groove portion and adhering so as to cover a corner portion of the groove portion, and applying a paint to the groove portion as necessary. To form a coating layer, and a step of forming a surface protective layer by coating a curable resin on the entire surface on which the groove is provided.
By adopting such a manufacturing method, it is possible to easily manufacture a flooring material having a groove portion that is excellent in abrasion resistance and scratch resistance and does not leave fibers of a conductive wire such as socks or stockings or a cloth for wipe cleaning. .

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention described above will be described in detail below with reference to the drawings. FIG. 1 is a perspective view showing an embodiment of a flooring base material used for a flooring material according to the present invention, FIG. 2 is a sectional view of an essential part showing an embodiment of the flooring material according to the present invention, and FIG. 4 is a cross-sectional view of an essential part for explaining the manufacturing method of the floor material of FIG. 4, and FIG. 4 is a cross-sectional view of the main part for explaining the conventional manufacturing method of the floor material. In FIG. , 3'is a groove portion, 4 is a synthetic resin sheet, 4'is a decorative sheet, 5 is a coating layer, 6 is a surface protective layer, 7 is a female seed, 8 is a male seed, and 10 is a flooring base material, respectively. .

FIG. 1 is a perspective view showing an embodiment of a flooring base material used for a flooring material according to the present invention.
Is provided with a single groove 3 on one surface of the wood-based substrate 2, and an adhesive (not shown) is provided to cover the corner of the one surface of the groove 3 on the one surface provided with the groove 3. Through)
For example, a synthetic resin sheet 4 having a wood grain pattern is attached, and the wood-based base material 2 of the groove 3 is attached.
The coating layer 5 is formed on the exposed portion. In addition, if necessary, the wooden base material 2 is subjected to actual processing to form female seeds 7 and male seeds 8 on the side portions of the flooring base material 10 to form the female seeds 7 and male seeds 8. Are configured so that they can be fitted and joined.

FIG. 2 is a cross-sectional view of an essential part showing an embodiment of the flooring material according to the present invention. The flooring material 1 is provided with the groove portion 3 of the base material 10 for flooring material shown in FIG. Surface protection layer 6 on the entire surface
Is formed. By covering the entire surface on one side where the groove 3 is provided with the surface protective layer 6 as described above, the abrasion resistance and the scratch resistance are excellent, and the fibers of the transmission line such as socks and stockings and the cloth for wipe cleaning do not remain. A floor material having a groove can be used.

As the wood base material 2 constituting the floor material 1, plywood (including LVL), medium density fiberboard (MD
F), high density fiberboard (HDF), particle board,
Any of veneer, wood, laminated wood or the like, or a laminated material in which these are appropriately laminated is suitable.

Next, the wood-patterned synthetic resin sheet 4 constituting the floor material 1 is provided for giving a design as a floor material. The sheet forming the synthetic resin sheet 4 having the wood pattern is not particularly limited, and various synthetic resin sheets alone or a laminate of these sheets is suitable. Further, the various synthetic resin sheets are not limited to white or colorless and transparent sheets, and may be sheets colored with a pigment or the like, in a non-stretched state or stretched uniaxially or biaxially. The sheet may be in any state, such as a folded state. In addition, various synthetic resin sheets may be subjected to easy adhesion treatment such as corona discharge treatment, plasma treatment, or ozone treatment on one surface or both surfaces thereof, if necessary.

The synthetic resin sheet 4 having the wood pattern
The wood grain pattern provided in is provided for giving a design as a floor material, and is provided by using a known printing method such as a gravure printing method, an offset printing method, and a silk screen printing method. As the ink used for this, a resin system may be appropriately selected depending on the material of the sheet to be printed, but as the vehicle, chlorinated polyethylene, chlorinated polyolefin such as chlorinated polypropylene, polyester, polyurethane composed of isocyanate and polyol, and poly. Acrylic, polyvinyl acetate, polyvinyl chloride,
Vinyl chloride-vinyl acetate copolymer, cellulosic resin,
It is possible to use one or a mixture of two or more kinds of polyamide and the like, which is used as an ink by adding a pigment, a solvent, various auxiliary agents and the like. Further, the synthetic resin sheet 4 having the wood grain pattern may be provided with an uneven pattern by embossing or the like, if necessary. In the description, the synthetic resin sheet having a picture pattern has been described as the synthetic resin sheet 4 having a wood pattern. However, the picture pattern is not limited to the wood pattern, and for example, a stone pattern, a geometric pattern, or
It is possible to provide an appropriate pattern such as various abstract patterns.

The paint applied to form the coating layer 5 is appropriately selected from vinyl acetate, vinyl chloride, vinyl chloride-vinyl acetate copolymer, urethane, acryl, ester resins and the like. And use it,
It may be a transparent paint, or may be a paint colored with a pigment or the like. As a method of forming the coating layer 5, a method of coating the inside of the groove portion 3 of the flooring base material 10 using a groove coating machine or the like, or the flooring base material 1
0 groove portion 3 is applied to the entire surface of one side, and then groove portion 3 is formed.
Other methods such as a method of scraping the paint on the surface (so-called wiping method) can be adopted. In addition, the coating layer 5
As another method for forming, the synthetic resin sheet 4 having a pattern, for example, a wood grain pattern, may be applied to the groove 3 before being adhered.

Further, the surface protection layer 6 constituting the floor material 1
Is provided in order to impart surface physical properties such as abrasion resistance, scratch resistance, stain resistance, and water resistance required as a floor material, and particularly excellent in abrasion resistance, scratch resistance, and water resistance, It is provided in order to form the groove 3 in which the fibers of socks, stockings and the like and the fibers of the cloth for wiping and cleaning do not remain. As the resin forming the surface protective layer 6, a curable resin such as an epoxy resin, a urethane resin, an acrylic resin, an ester resin, or a mixed resin composed of one or more of these is used. For example, a solution of the resin can be formed by appropriately using a well-known coating method such as a roll coating method. However, the surface hardness is hard to be formed by an ionizing radiation curable resin in order to improve productivity. It is particularly preferable because it is excellent.

The ionizing radiation curable resin is a resin which undergoes a cross-linking polymerization reaction upon irradiation with ionizing radiation to change into a three-dimensional polymer structure. Ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing and cross-linking molecules, and includes visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-ray, electron beam, ion beam, etc. is there. Normally, ultraviolet rays or electron beams are used, and as the ultraviolet rays, light sources such as an ultrahigh 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 lamp can be used. The wavelength of ultraviolet rays is usually 19
The wavelength range of 00 to 3800Å is mainly used. As the electron beam, various electron beam accelerators such as Cockloft-Walton type, Van de Graft type, resonance transformer type, insulating core transformer type, linear type, dynamitron type, and high frequency type are used, and 100 to 1000 KeV, It is preferable to use one that radiates electrons having an energy of 100 to 300 KeV.

The ionizing radiation curable resin is a monomer having a radically polymerizable unsaturated group such as a (meth) acryloyl group or a (meth) acryloyloxy group, or a cationically polymerizable functional group such as an epoxy group in the molecule. It is composed of a body, a prepolymer or a polymer (hereinafter collectively referred to as a compound). These monomers, prepolymers and polymers may be used alone or in combination of two or more. In addition, in this specification, (meth) acrylate is used to mean acrylate or methacrylate.

Examples of the prepolymer having a radically polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, triazine (meth) acrylate and polyvinylpyrrolidone. Can be mentioned. This prepolymer usually has a molecular weight of 1000.
Those of about 0 or less are used. When the molecular weight exceeds 10,000, surface properties such as scratch resistance, abrasion resistance, chemical resistance, and heat resistance of the cured resin layer are insufficient. Although the above-mentioned acrylate and methacrylate can be used in common, the acrylate is faster in terms of the cross-linking curing speed with ionizing radiation, and therefore the acrylate is more advantageous for the purpose of curing efficiently at a high speed in a short time.

As the prepolymer having a cationically polymerizable functional group, epoxy resins such as bisphenol type epoxy resin, novolac type epoxy resin and alicyclic epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, 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 is sufficiently cured by irradiation with an electron beam, but when it is cured by irradiation with ultraviolet rays, a photopolymerization initiator can be added as a sensitizer. As a photopolymerization initiator in the case of a resin system having a radically 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. Further, in the case of a resin system having a cationically polymerizable functional group, it is used as an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, a fryloxysulfoxonium diallyl iodosyl salt or the like alone or as a mixture. be able to. In addition, the addition amount of these photopolymerization initiators is generally 1
It is about 0.1 to 10 parts by weight with respect to 00 parts by weight.
As a method of forming the surface protective layer 6 with an ionizing radiation curable resin, for example, a solution of an ionizing radiation curable resin is prepared, and a gravure offset coating method, a roll coating method,
It can be formed by applying a well-known coating method such as a flow coating method. As a coating amount, a solid content of about 5 to 30 g / m ² is suitable, and more preferably,
It is 15 to 25 g / m ² .

[0022]

EXAMPLES Next, the method for producing a flooring material of the present invention will be described in more detail with reference to the following examples. First, a method for manufacturing a synthetic resin sheet having a wood pattern will be described.
An acrylic-urethane resin (a resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol) solution on one surface of a 60 μm olefin resin sheet subjected to double-sided corona discharge treatment, and the solid content was 2 g. / M ² to form a printing primer layer by coating, and an acrylic-urethane resin (a resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol) on the printing primer layer. A solid pattern printing layer and a pattern printing layer are sequentially printed by a gravure printing method using a printing ink to form a wood grain pattern printing layer, and the solid content is 10 g / m 2 on the printing layer.
^A urethane-based adhesive is applied so as to have a thickness of 2 to form an adhesive layer, and a propylene-based resin is heated and melt-extruded by a T-die extruder to a thickness of 80 μm on the adhesive layer to form a transparent resin layer. Was formed. Thereafter, the transparent resin layer surface is subjected to corona discharge treatment, and an acrylic-urethane resin (resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol) solution is applied to the surface of the corona discharge treated surface by a gravure coating method. Of 1 g / m ² to form a primer layer for the surface protective layer, and then a plate depth of 50 μ from the primer layer side for the surface protective layer.
The synthetic resin sheet 4 having a wood grain pattern in which the unevenness pattern of the wood grain conduit was formed was produced by embossing with a m-grained conduit embossing plate.

Example 1 A plywood sheet having a thickness of 12 mm was cut into a predetermined size, and then a groove 3 having a V-shaped cross section was formed on one surface by a V-grooving machine, and a side portion of the plywood was formed by an actual machine. A wood-based substrate 2 [see FIG. 3 (a)] provided with female fruits (not shown) and male fruits (not shown) was produced. Synthetic resin sheet 4 with wood grain pattern produced above
On the other surface of the above olefin resin sheet, a urethane type two liquid curing adhesive is applied in a wet state at 120 g / m ² (not shown), and this sheet is applied to the groove portion 3 of the wood base material 2. Lapping is performed on the formed surface by using a lapping machine [see FIG. 3 (b)], and thereafter, a substantially central portion of the groove portion 3 of the wood-patterned synthetic resin sheet 4 is cut along the groove portion 3 [FIG. b)) along with the cutting edge of the synthetic resin sheet 4 having the wood pattern so as to cover the corners of the groove 3 with a roller, and the inside of the groove 3 is formed. Then, a sepia-color urethane paint is applied to the surface of the groove 3 where the wood-based material 2 is exposed [see FIG. 3 (c)] to prepare a base material for flooring in which a coating layer 5 is formed. , Urethane acrylate-based electron beam curing on the entire surface of the base material for flooring on which the groove 3 is formed The solid content of the resin in the roll coating method 1
An uncured electron beam curable resin layer is formed by coating and drying so as to have a concentration of 5 g / m ^2, and the uncured electron beam curable resin layer is irradiated with an electron beam (acceleration) under an environment of oxygen concentration of 200 ppm or less. A floor material 1 (see FIG. 2) of the present invention in which a surface protective layer 6 made of an electron beam curable resin was formed by curing by irradiating with a voltage of 125 KeV, 5 Mrad) was obtained.

Comparative Example 1 An acrylic-urethane resin (resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol) was gravure coated on one surface of an olefin resin sheet of 60 μm subjected to double-sided corona discharge treatment. A printing primer layer is formed by coating so that the solid content is 2 g / m ^2, and an acrylic-urethane resin (100 parts by weight of acrylic polyol and 5 parts by weight of hexamethylene diisocyanate is applied to the printing primer layer). The solid pattern printing layer and the pattern printing layer are sequentially printed by a gravure printing method using a printing ink composed of the added resin) to form a wood grain pattern printing layer, and the solid content is 10 g / m 2 on the printing layer.
^A urethane-based adhesive is applied so as to have a thickness of 2 to form an adhesive layer, and a propylene-based resin is heated and melt-extruded by a T-die extruder to a thickness of 80 μm on the adhesive layer to form a transparent resin layer. Was formed. Thereafter, the transparent resin layer surface is subjected to corona discharge treatment, and an acrylic-urethane resin (resin obtained by adding 5 parts by weight of hexamethylene diisocyanate to 100 parts by weight of acrylic polyol) solution is applied to the surface of the corona discharge treated surface by a gravure coating method. Of 1 g / m ² to form a primer layer for a surface protective layer, and a urethane acrylate electron beam curable resin on the primer layer for a surface protective layer having a solid content of 1 by roll coating.
An uncured electron beam curable resin layer is formed by coating and drying so as to have a concentration of 5 g / m ^2, and the uncured electron beam curable resin layer is irradiated with an electron beam (acceleration) under an environment of oxygen concentration of 200 ppm or less. A voltage of 125 KeV, 5 Mrad) is applied for curing to form a surface protective layer made of an electron beam curable resin.
Embossing was performed from the surface protective layer side with a wood grain conduit-shaped embossing plate having a plate depth of 50 μm to produce a decorative sheet 4 ′ having an uneven pattern of the wood grain conduit.

Next, a urethane-based two-component curable adhesive was applied to one surface of the wood-based substrate 2 made of plywood having a thickness of 12 mm in a wet state at 120 g / m ² (not shown). The produced decorative sheet 4'is attached so that the surface protective layer is exposed [see FIG. 4 (a)], and then the V-groove machine from the side of the decorative sheet 4'to the groove portion of the decorative sheet 4 '. To form a groove portion 3'having a V-shaped cross section, and then applying a sepia-colored urethane paint to the entire surface of the groove portion 3 '[see FIG. 3 (c)] to form a coating layer 5 and further cut to a predetermined size. Also, a floor material was obtained as a comparative example in which female and male fruits were provided by subjecting the side portions of the plywood to actual processing.

With respect to the flooring materials of Example 1 and Comparative Example 1 produced above, the groove portion was subjected to an abrasion resistance test, an abrasion resistance test, and a fiber hooking test, and the evaluation results are shown in Table 1.
It is summarized and shown in.

[0027]

[Table 1] * Attach a gauze impregnated with methyl ethyl ketone to the hemispherical tip of a jig that has a hemispherical tip with a 0.5 inch radius for abrasion resistance test.
Apply a 500g load to the surface of the flooring so that it crosses the V groove.
The colored state of the gauze was visually evaluated by reciprocating 0 times. * Scratch resistance test V The nails were raised on the surface of the floor material so as to cross the groove portion, and the blade was reciprocated 20 times to visually evaluate the scratches and gloss change on the surface of the groove portion. * Fiber hooking test Using a residential wiper (Kioco's Quickle wiper), the floor material surface was rubbed along the groove of the floor material, and the number of times when the fiber of the wiper adhered to the groove was evaluated. .

As is clear from the above-mentioned evaluation results, the flooring material of the present invention is a flooring material having a groove portion in which fibers are not easily caught while having excellent abrasion resistance and scratch resistance.

[0029]

As described above, according to the present invention, the corners of the groove of the floor are covered with the synthetic resin sheet provided with the pattern, and the entire surface of the floor is covered with the surface protective layer. By coating, wear resistance, scratch resistance, stain resistance,
A flooring material that has excellent surface properties such as water resistance, particularly excellent abrasion resistance, scratch resistance, and water resistance, and has groove portions that do not leave fibers of socks, stockings, etc. can do.

The flooring material of the present invention comprises a step of providing at least one groove on one surface of a wood-based substrate, and a synthetic resin sheet having a pattern on one surface thereof with an adhesive. A step of adhering, a step of cutting a synthetic resin sheet provided with the pattern of the groove along the longitudinal direction of the groove at a substantially central portion in the width direction of the groove, and the cut pattern of the groove A step of folding a synthetic resin sheet provided with a pattern into the groove part and adhering it so as to cover the corner part of the groove part; and a step of applying a paint in the groove part to form a coating layer, if necessary. By adopting a manufacturing method comprising a step of forming a surface protective layer by applying a curable resin on the entire surface provided with the groove portion, it is particularly excellent in abrasion resistance, scratch resistance, water resistance, socks, stockings, etc. The fibers of the wire and the cloth for wiping remain The flooring having no grooves can be efficiently produced.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a flooring base material used for a flooring material according to the present invention.

FIG. 2 is a sectional view of an essential part showing an embodiment of a flooring material according to the present invention.

FIG. 3 is a cross-sectional view of an essential part for explaining the method for manufacturing a flooring material of the present invention.

FIG. 4 is a sectional view of an essential part for explaining a conventional method for manufacturing a floor material.

[Explanation of symbols]

1 floor material 2 Wood-based materials 3,3 'groove 4 synthetic resin sheet 4'decorative sheet 5 coating layers 6 Surface protection layer 7 female 8 male facts 10 Base material for flooring

Claims (3)

[Claims] 1. A synthetic resin in which at least one groove portion is provided on one surface of a wood-based substrate, and a pattern is provided on the one surface provided with the one groove portion so as to cover a corner portion of the groove portion. A flooring material comprising a sheet-made sheet adhered to form a flooring base material, and a curable resin is applied to the entire surface of the flooring base material provided with the groove to form a surface protective layer. . 2. The flooring material according to claim 1, wherein a coating layer is formed below the surface protective layer of the groove. 3. A step of providing at least one groove on one surface of a wood-based substrate, and a step of attaching a synthetic resin sheet having a picture pattern provided on the one surface via an adhesive.
A step of cutting a synthetic resin sheet provided with the picture pattern of the groove along the longitudinal direction of the groove at a substantially central portion in the width direction of the groove, and a synthetic resin provided with the picture pattern cut in the groove A step of folding the sheet-making sheet into the groove part and adhering it so as to cover the corner part of the groove part; and a step of applying a paint in the groove part to form a coating layer, if necessary,
And a step of forming a surface protective layer by applying a curable resin on the entire surface on which the groove is provided.