JP2004084285A - Floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor material which includes a woody substrate but excellent in water resistance, exhibits a three-dimensional feel in design by virtue of a groove portion formed in the surface thereof, does not cause defective cutting such as burrs, bleeding, and whitening at the time of groove finishing, and can be easily produced while ensuring the good quality thereof. <P>SOLUTION: The floor material is formed by laminating a thermoplastic resin decorative sheet 3 on the surface of the woody substrate 1 via a thermoplastic intermediate layer 2, and embossing the decorative sheet 3 from above the surface to form the groove portion 4 having a depth larger than the thickness of the decorative sheet 3. According to the floor material, it is desirable that the thermoplastic resin intermediate layer 2 is made of a thermoplastic resin with a heat distortion temperature of 60 to 130 °C. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a floor material used for an indoor floor surface, a stair tread surface, and the like in a building such as a house.
[0002]
[Prior art]
Currently, flooring materials used for indoor floors and the like in buildings such as houses include solid wood of a thickness of about 6 to 15 mm and a wooden base material such as a laminated plywood of a thickness of about 6 to 15 mm. Wood flooring materials, such as those to which a natural wood veneer of about 0.2 to 1 mm is adhered, are most widely used. However, since the wooden flooring material is made of natural wood, its surface is inherently weak in water resistance, and if it is used in places where the floor surface is often wet with water, such as in kitchens and washrooms, water seepage may occur. There is a problem that swelling and peeling of the veneer layer and warping and corrosion of the entire flooring material are liable to occur.
[0003]
Therefore, instead of a conventional natural wood veneer on a wood substrate such as laminated plywood, a thermoplastic resin sheet having excellent water resistance is provided with a design that artificially expresses a wood grain pattern or the like by printing or the like. Floor materials to which a decorative sheet is attached have also been proposed (utility model registration No. 3051530). However, in general, flooring materials are often provided with grooves on the surface to imitate the design of an old parquet floor, but the decorative sheet is a thin sheet at most about 300 μm or less. When a groove is formed with a typical depth (approximately 0.2 mm to 2 mm), the wood base material is exposed in the groove, and the moisture that has permeated there has caused swelling and peeling of the decorative sheet layer and warping of the entire flooring material. And corrosion may occur. On the other hand, a technique of embossing the surface of the decorative sheet in advance is also known, but the depth thereof is shallower than the thickness of the decorative sheet, and is limited to at most about 0.1 mm. The design is not enough.
[0004]
In order to solve this problem, a thermoplastic resin plate is interposed between a wood base material such as laminated plywood and a decorative sheet, and a groove is formed to a depth that does not penetrate the thermoplastic resin plate. There is also a proposal of a flooring material which prevents penetration of moisture into a wooden base material and has improved water resistance (Japanese Patent Application Laid-Open No. 2001-191454). However, since the thermoplastic resin plate is made of a thermoplastic resin, unlike a wooden base material, it is softened and stretched due to heat generated by friction with the cutting blade during grooving, causing burrs and whiskers, and cutting portions are generated. There has been a problem that the design of the surface of the flooring material is easily damaged by whitening. In addition, since the adhesive interface between the thermoplastic resin plate and the decorative sheet is exposed in the groove, moisture permeates from the exposed portion to the adhesive interface, deteriorating the adhesive, and may cause peeling of the decorative sheet. There were also problems.
[0005]
[Problems to be solved by the invention]
The present invention has been made in order to solve the above-described problems in the related art, and has excellent water resistance while using a wooden base material, and has a three-dimensional design by grooves formed on the surface. An object of the present invention is to provide a flooring material which has a feeling and has no cutting defects such as burrs, whiskers, and whitening at the time of grooving and can easily produce a good quality product.
[0006]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the present invention has a decorative sheet made of a thermoplastic resin laminated on a surface of a wooden substrate via a thermoplastic resin intermediate layer, and the decorative sheet is formed from the surface of the decorative sheet. A floor material characterized by having a groove formed by embossing to a depth exceeding the thickness.
[0007]
Further, the present invention provides the floor material, wherein the thermoplastic resin constituting the thermoplastic resin intermediate layer has a heat deformation temperature of 60 ° C. or more and 130 ° C. or less.
[0008]
Still further, in the flooring material, the thermoplastic resin constituting the thermoplastic resin intermediate layer is selected from a polybutylene terephthalate resin, an amorphous crystalline polyethylene terephthalate resin, an amorphous copolymerized polyester resin, and a polyethylene resin. Or a mixture or a laminate of two or more of these.
[0009]
Further, in the flooring material, the groove is formed at a depth not exceeding a distance from a front surface of the decorative sheet to a back surface of the thermoplastic resin intermediate layer.
[0010]
Further, in the flooring material, the groove is formed at a depth exceeding a distance from a front surface of the decorative sheet to a back surface of the thermoplastic resin intermediate layer.
[0011]
Further, in the flooring material, a thermoplastic resin foam layer is sandwiched between the wooden base material and the thermoplastic resin intermediate layer.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
As shown in FIG. 1, the flooring material of the present invention has a thermoplastic resin excellent in water resistance on a surface of a wooden base material 1 made of laminated plywood or the like via a thermoplastic resin intermediate layer 2 excellent in embossing workability. A decorative sheet 3 made of a resin sheet for imparting design is laminated, and a floor formed by embossing the surface of the decorative sheet 3 to a depth exceeding the thickness of the decorative sheet 3 to form a groove 4. Material.
[0013]
As described above, the floor material of the present invention has the grooves 4 formed by embossing from the surface of the thermoplastic resin decorative sheet 3 laminated on the thermoplastic resin intermediate layer 2. Utilizing thermoplasticity, the groove 4 having a sufficient depth exceeding the thickness of the decorative sheet 3 can be easily formed by embossing. In addition, unlike the case where the groove 4 is formed by cutting, the interface between the thermoplastic resin intermediate layer 2 and the decorative sheet 3 is not exposed in the groove 4, and therefore, moisture permeates between the layers from the exposed interface. And has excellent water resistance without deteriorating the adhesive.
[0014]
Furthermore, since the inner surface of the groove 4 is also covered with the same decorative sheet 3 as the general surface of the flooring material, it is not always necessary to apply the paint to the groove 4 in a later step from various physical properties and design (color). Therefore, there is an advantage that the productivity is excellent. Of course, it is possible to apply a colored coating to the groove portion 4 by a wiping method or a roll coating method or the like as required according to a design requirement. It is not as strict as in the case of coating on grooves formed by cutting, and even if minor coating defects such as slight displacement and fine pinholes may occur, water resistance etc. Since there is no serious influence on the physical properties of the coating material, there are also advantages that the choice of the coating material and the coating method is wide, the yield is improved, and the production can be performed with high productivity.
[0015]
In the flooring material of the present invention, as the woody base material 1, various conventionally known woody boards such as a laminated plywood, a veneer laminate, an oriented board, a particle board, and a high-density fiberboard are optionally used. can do. Among them, the most typical is a laminated plywood, which is obtained by laminating and bonding a plurality of (usually an odd number) of veneers with their fiber directions alternately orthogonal to each other. The seed may be any of hardwood such as rawan and softwood such as pine or a mixture thereof. As the outermost timber veneer, for example, using a hard and durable Nanyo-based material containing silica, such as Klein, Kapoor, and Menclane, a flooring material with more excellent surface strength can be obtained. be able to.
[0016]
The thickness of the wooden base material 1 is not particularly limited, but the total thickness of the flooring material is generally selected from a range of about 6 to 15 mm. Therefore, the thickness of the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are subtracted from this. The thickness is set and usually designed within a range of about 2.5 to 12 mm.
[0017]
The thermoplastic resin intermediate layer 2 secures the embossing suitability of forming the groove 4 on the surface of the flooring material of the present invention by the embossing method. There is no particular limitation as long as it has embossable thermoplasticity. However, if the thermal deformation temperature of the thermoplastic resin is too low, the thermoplastic resin easily deforms at a high temperature during use, and the groove portion 4 becomes shallow due to an emboss return phenomenon, or the surface becomes uneven due to thermal deformation, resulting in a design. On the other hand, if the temperature is too high, embossing becomes difficult. Therefore, it is desirable to use a thermoplastic resin having a heat deformation temperature (JIS K 7191, load 0.45 MPa) of 60 ° C. or more and 130 ° C. or less. .
[0018]
Specific examples of the thermoplastic resin constituting the thermoplastic resin intermediate layer 2 include, for example, polybutylene terephthalate resin, amorphous crystalline polyethylene terephthalate resin (commonly known as A-PET), and 1,4-cyclohexanedimethanol copolymer. Examples thereof include non-crystalline copolymerized polyester resins represented by polyethylene terephthalate resin (commonly known as PET-G), polyethylene resins, and the like. As the polyethylene resin, any of a high-density polyethylene resin (HDPE), a low-density polyethylene resin (LDPE), a linear low-density polyethylene resin (LLDPE), an ultrahigh-molecular-weight polyethylene resin (UHMWPE), and the like can be used. Some of the low-density polyethylene resin and the linear low-density polyethylene resin have a heat deformation temperature of less than 60 ° C. Therefore, it is desirable to select and use a resin having a heat deformation temperature of 60 ° C. or more.
[0019]
An appropriate filler may be added to the thermoplastic resin intermediate layer 2 as long as the suitability for embossing is not impaired. Specific examples of the filler include inorganic fillers such as calcium carbonate, talc, clay, glass powder, glass fiber, glass beads, mica powder, and metal powder, wood powder, paper powder, chaff, wood pulp, and the like. Organic fillers such as synthetic resin beads can be used, and any one of them can be used alone or in combination of two or more. Further, if necessary, it is also optional to add a coloring pigment such as titanium oxide, zinc oxide, iron oxide, carbon black, cobalt blue, and phthalocyanine for coloring. When it is provided, there is an advantage that the color tone variation, unevenness, defects, and the like of the wooden base material 1 are concealed, and a floor material having a stable design quality can be obtained.
[0020]
If the thickness of the thermoplastic resin intermediate layer 2 is too small, it is not possible to secure embossing aptitude for forming the groove 4 having a sufficient depth. Although the upper limit depends on the design of the thickness of the entire flooring material, it is generally preferably about 5 mm or less, more preferably 3 mm or less in consideration of the balance with the thickness of the wooden base material 1 and economic efficiency. .
[0021]
The decorative sheet 3 is provided to impart desired design and surface physical properties such as abrasion resistance, scratch resistance, solvent resistance, weather resistance and oil resistance to the surface of the floor material. In some cases, a paper-based decorative sheet or the like in which a pattern is printed and a surface protective coat layer is applied to the surface of paper such as thin paper, etc., but in the flooring material of the present invention, the above-described various surface physical properties In addition, since excellent embossing suitability is required, it is necessary to use a decorative sheet 3 made of a thermoplastic resin.
[0022]
The decorative sheet 3 made of the thermoplastic resin is, specifically, an opaque base sheet made of a thermoplastic resin provided with a pattern layer on the surface, or a transparent base sheet made of a thermoplastic resin, The decorative sheet may be a single-layer decorative sheet such as a sheet provided with a pattern layer on its surface, or a sheet provided with a surface protective layer on its surface. However, in consideration of various required qualities such as design properties, adhesive suitability, weather resistance, solvent resistance and abrasion resistance, on a base sheet made of a transparent or opaque thermoplastic resin, a transparent It is most preferable to use a decorative sheet having a multilayer structure in which a transparent resin layer made of a thermoplastic resin is provided. The picture layer may be provided between the base sheet and the transparent resin layer, or may be provided on the front surface of the transparent resin layer or on the back surface of the base sheet when the base sheet is transparent.
[0023]
As the thermoplastic resin constituting the base sheet, the transparent resin layer, and the like, which is the main component of the decorative sheet 3, for example, a polyolefin resin, a polyester resin, an acrylic resin, a polystyrene resin, a polyamide resin, or the like is used. Can be. In particular, in consideration of the surface physical properties as a floor material, workability, economy, disposability (including incineration), and the like, it is desirable to use a polyolefin resin and / or a polyester resin as the material of the decorative sheet 3. . Further, in consideration of the treatment of waste materials generated after the use of the floor material or during processing, if the same resin as that contained in the thermoplastic resin intermediate layer 2 is used, the thermoplastic resin intermediate layer 2 and the decorative sheet 3 can be used. Can be reused as a raw material of the thermoplastic resin intermediate layer 2 without separation.
[0024]
In consideration of the embossing suitability required for the decorative sheet 3, it is desirable to select a thermoplastic resin that is excellent in flexibility that is less likely to break or whiten due to elongation during embossing, in consideration of the suitability for embossing required for the decorative sheet 3. . For example, if it is a polyolefin resin, an ordinary polyolefin resin such as polyethylene or polypropylene, low-density polyethylene, atactic polypropylene, ethylene-propylene rubber, styrene-butadiene copolymer or an olefin-based soft component such as a hydrogenated product thereof. Or a resin composition to which a rubber component is added, or, for example, an ethylene-propylene random copolymer, an ethylene-propylene-butene random copolymer, an ethylene-propylene-α-olefin random copolymer, a polyolefin-based thermoplastic elastomer resin It is desirable to use a soft polyolefin resin such as
[0025]
In the case of a polyester resin, for example, an amorphous crystalline polyethylene terephthalate resin (A-PET), a polyethylene terephthalate-isophthalate copolymer, a 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate (PET-G) It is desirable to use a flexible polyester-based resin such as a copolymerized polyester-based resin such as a) or a polyester-based thermoplastic elastomer resin. In addition, a decorative sheet 3 is prepared by adding a suitable amount of a crystalline polyester resin such as a polybutylene terephthalate resin to the flexible polyester resin and forming the crystalline polyester resin into a sheet without crystallization. And a method of partially crystallizing the crystalline polyester resin by heat at the time of embossing after lamination on the thermoplastic resin intermediate layer 2 is employed. It is excellent in embossing suitability and has excellent surface properties such as surface hardness and solvent resistance due to crystallization after embossing. Therefore, it is excellent in both design properties and various surface properties by a sufficiently deep groove 4. There is also an advantage that the floor material can be easily obtained.
[0026]
There are no particular restrictions on the type of pattern in the pattern layer applied to the decorative sheet 3, and any type of pattern, such as a wood pattern, a stone pattern, or an abstract pattern, may be used as desired. Further, the decorative sheet 3 is required to have a concealing property in order to conceal undesired colors, color unevenness, defects and the like on the surface of the wooden base material 1 and / or the thermoplastic resin intermediate layer 2 to enhance the design. Often. In order to provide the decorative sheet 3 with hiding properties, titanium oxide, zinc oxide, carbon black, iron oxide, or the like is applied to the thermoplastic resin layer on the back side from the picture layer, that is, the base sheet in the multi-layer decorative sheet described above. It is most effective to add an opaque pigment of the formula (1) and color the film in a concealing property. In addition, a concealing layer can be formed on the back side of the picture layer with an opaque printing ink containing an opaque pigment, or these can be used in combination.
[0027]
In addition to the above, if necessary, the decorative sheet 3 may be embossed on its surface, filled with a coloring agent by a wiping method in the recesses of the embossed surface, or may have a top coat layer which also has gloss control and surface protection on the surface. Or by providing a resin layer having a different gloss state as the top coat layer to express a visual three-dimensional effect by gloss difference, or adding a lubricant to the top coat layer to improve abrasion resistance and scratch resistance. Alternatively, a primer layer may be provided on the back surface to improve the adhesiveness with the thermoplastic resin intermediate layer 2. Further, it is possible to arbitrarily improve the weather resistance by adding an ultraviolet absorber, a light stabilizer, or the like to the transparent resin layer and / or the top coat layer in the decorative sheet 3.
[0028]
The embossed groove 4 needs to be formed at a depth exceeding the thickness of the decorative sheet 3 at least according to design requirements. The depth is such that the bottom of the groove 4 remains within the thermoplastic resin intermediate layer 2, that is, the depth does not exceed the distance from the surface of the decorative sheet 3 to the rear surface of the thermoplastic resin intermediate layer 2. By utilizing the embossing suitability of the thermoplastic resin intermediate layer 2, it is possible to form the film satisfactorily without causing embossing defects.
[0029]
However, if the wood substrate 1 itself has some flexibility to withstand embossing, as shown in FIG. 2, the thermoplastic resin intermediate layer 2 goes over the back surface before embossing, It is also possible to form the groove 4 having a depth reaching the wooden substrate 1. Also in this case, most of the deformation for forming the groove 4 by embossing is borne by the thermoplastic resin intermediate layer 2, and a deformation corresponding to a part of the depth of the groove 4 is applied to the wood substrate 1. Therefore, compared with the case where the decorative sheet 3 is directly laminated on the surface of the wooden substrate 1, there is an advantage that the groove 4 which is much deeper can be easily formed.
[0030]
Further, the thermoplastic resin intermediate layer 2 may be a foam layer as a whole, or may include a foam layer in a part thereof. For example, as shown in FIG. 3, the thermoplastic resin intermediate layer 2 may be constituted by a laminate of the non-foamed layer 21 on the decorative sheet 3 side and the foamed layer 22 on the wooden base material 1 side. And a configuration in which the thermoplastic resin foam layer 5 is sandwiched between them. With this configuration, even if the groove 4 having a depth exceeding the back surface of the non-foamed layer 21 in the thermoplastic resin intermediate layer 2 from the surface of the decorative sheet 3 is formed, the deformation of the portion exceeding the back surface of the non-foamed layer 21 is prevented. Since all or most of the burden can be borne by the foam layer 22, the wooden substrate 1 is not affected at all, or the effect on the wooden substrate 1 can be reduced. That is, even when the wooden base material 1 having no or very poor embossability is used, the deeper groove portion 4 can be formed.
[0031]
The embossing suitability improvement effect of the foam layer 22 similar to the above is obtained when the thermoplastic resin intermediate layer 2 is composed of only the foam layer 22 or when the vertical relationship between the non-foam layer 21 and the foam layer 22 is opposite to the above. In the case of a three-layer structure of the non-foamed layer 21 / the foamed layer 22 / the non-foamed layer 21, in the case of the three-layered structure of the foamed layer 22 / the non-foamed layer 21 / the foamed layer 22, in the case of a multi-layered structure of four or more layers, In short, as long as the thermoplastic resin intermediate layer 2 includes at least the foamed layer 22, it can be effectively expressed. In addition, the provision of the foam layer 22 has an advantage that cushioning, walking, impact resistance, sound insulation, heat insulation, and the like are improved.
[0032]
In the production of the flooring material of the present invention, the laminating method of the wood substrate 1 and the thermoplastic resin intermediate layer 2 and the laminating method of the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are not limited at all. Without, for example, a wet lamination method or a dry lamination method via an appropriate adhesive, a heat lamination method with or without an adhesive, a sand lamination method through an extruded layer of a molten thermoplastic resin, an ultrasonic fusion method, The method can be arbitrarily selected from any conventionally known lamination methods such as a high-frequency fusion method.
[0033]
In addition, the order of lamination of these three layers is not particularly limited, and after the wooden base material 1 and the thermoplastic resin intermediate layer 2 are laminated in advance, the decorative sheet 3 is placed on the surface of the thermoplastic resin intermediate layer 2 side. Alternatively, the wooden substrate 1 may be laminated on the surface of the thermoplastic resin intermediate layer 2 side after the thermoplastic resin intermediate layer 2 and the decorative sheet 3 are laminated in advance. Of course, three layers of the wood substrate 1, the thermoplastic resin intermediate layer 2, and the decorative sheet 3 may be simultaneously laminated.
[0034]
Also, instead of laminating the thermoplastic resin intermediate layer 2 formed in a plate shape in advance with the wooden base material 1 and the decorative sheet 3, simultaneously with the molding of the thermoplastic resin intermediate layer 2 by an extrusion molding method or an injection molding method, It is also possible to laminate with the wooden substrate 1 and / or the decorative sheet 3 by utilizing the adhesive force in the molten state. For example, in the case of an extrusion molding method, when the thermoplastic resin composition is extruded in a molten state on the surface of the wooden substrate 1 or on the back surface of the decorative sheet 3 or between the layers of the wooden substrate 1 and the decorative sheet 3. At the same time, a method of laminating and cooling and solidifying to form the thermoplastic resin intermediate layer 2 may be adopted.
[0035]
The embossing of the groove 4 needs to be performed at least after the lamination of the thermoplastic resin intermediate layer 2 and the decorative sheet 3, and the groove 4 having a depth exceeding the back surface of the thermoplastic resin intermediate layer 2 is formed. In the case of forming the groove 4 having a depth that remains within the layer of the thermoplastic resin intermediate layer 2, it is necessary to perform the lamination with the wood substrate 1. It may be after or before lamination. Further, when the decorative sheet 3 is laminated at the same time as the molding of the thermoplastic resin intermediate layer 2, the groove 4 can be formed by embossing at the same time as the lamination.
[0036]
When the thermoplastic resin intermediate layer 2 has a multilayer structure including the non-foamed layer 21 and the foamed layer 22, the thermoplastic resin intermediate layer 2 may be laminated after molding each layer separately, The whole or a part of the plurality of layers may be simultaneously formed by a coextrusion method or the like. Furthermore, after partially laminating the constituent layers of the thermoplastic resin intermediate layer 2 with the decorative sheet 3 or the wooden base material 1 in advance, the entire thermoplastic resin intermediate layer 2 may be integrally laminated.
[0037]
In the flooring material of the present invention, similarly to the case of the conventional wooden flooring material, a groove is formed on the back surface of the wooden base material 1 and / or a foam layer and / or fiber is formed on the back surface of the wooden base material 1. It is also possible to add a layer of material to the floor to give the floor base an absorptive property, a soundproofing / soundproofing property, a cushioning property, a heat insulating property, an impact resistance and the like.
[0038]
【Example】
Example 1
A 70 μm-thick colored non-crystalline copolymerized polyester resin sheet (“Rivester” manufactured by Riken Technos Co., Ltd.) was used as a base sheet, and the surface of the base layer was coated with a urethane resin-based printing ink by a gravure printing method using a concealing layer and a cherry material ( (Cherry wood material) A pattern layer of wood grain is sequentially formed by printing, and a two-component curable urethane resin-based adhesive for dry lamination is applied at a coating amount of 6 g / m ² after drying. Extruding a transparent crystalline polyethylene terephthalate resin (PET) to which 0.2% by weight of a stabilizer and 0.3% by weight of an ultraviolet absorber are added using an extruder while corona-treating both sides so as not to be crystallized, and having a thickness of 100 μm. Dry lamination was performed while forming into a shape. Further, a two-component curable urethane resin is applied to the surface at a coating amount of 6 g / m ² after drying to provide a surface protective layer, and a urethane resin-based primer compounded with silica powder is coated on the back surface by a gravure coating method. The primer layer was formed by coating at a coating amount of 1 g / m ² after drying to prepare a decorative sheet.
[0039]
A transparent amorphous 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin having a heat distortion temperature (JIS K 7191, load 0.45 MPa) of about 68 ° C. is formed into a plate having a thickness of 2 mm by an extrusion molding method. Was subjected to a corona treatment to produce a thermoplastic resin intermediate layer.
[0040]
A modified vinyl acetate resin-based emulsion adhesive (a mixture of 100 parts by weight of “Licabond BA-10L” and 2.5 parts by weight of “BA-11B” manufactured by Chuo Rika Kogyo Co., Ltd.) was applied on the upper surface of the laminated plywood having a thickness of 12 mm at 80 g / m ² (wet) application, the above-mentioned thermoplastic resin intermediate layer was stuck, and the same adhesive as above was applied in the same application amount, and the above-mentioned decorative sheet was stuck. Thereafter, the surface of the decorative sheet is heated to a surface temperature of 120 ° C. by a far-infrared heater. The floor material of the present invention was produced by forming a groove having a shape.
[0041]
The flooring material of the present invention obtained in this way, the inner surface of the groove is also covered with the same decorative sheet as the general surface, and even if the surface is wet with water, water does not seep into the lower layer from the groove, and The inner surface of the groove is also given the same color wood grain design as the general surface, and it has a design feeling like solid wood, and it can be sufficiently satisfactory in design without separately painting the groove. there were.
[0042]
Example 2
In Example 1 described above, the thickness of the thermoplastic resin intermediate layer was changed to 1 mm, the depth of the groove was changed to 1.5 mm, and the other materials were prepared in the same manner as in Example 1 above. The embossed groove reached the laminated plywood, but embossing could be performed without any particular problem. The decorative sheet made of the copolyester resin had been previously embossed with a conduit having a maximum depth of about 50 μm. However, due to the excellent flexibility of the resin, the sheet was cracked even in the groove portion and the opening of the conduit embossment. No flooring occurred, and a flooring material free from defects in both physical properties and design could be obtained.
[0043]
Example 3
In the above Example 2, the thermoplastic resin intermediate layer is composed of a non-foamed layer which is the same as the thermoplastic resin intermediate layer used in the above Example 2, and a foamed polyethylene sheet having a thickness of 1 mm (expansion ratio 5 times). With a two-layer structure including a foam layer, a decorative sheet is laminated on the non-foam layer side, and a laminated plywood is laminated on the foam layer side, and the depth of the groove is changed to 2 mm. When the floor material was prepared in the same manner, a good floor material could be manufactured without any particular problem. In this example, even when a hardwood plywood having a thickness of 2 mm is used as the outermost veneer layer instead of a normal product (coniferous or hardwood) as the laminated plywood, Despite the depth of the groove being as deep as 2 mm, a good floor material could be produced without any particular problem.
[0044]
【The invention's effect】
As described above in detail, the flooring material of the present invention is obtained by laminating a decorative sheet made of a thermoplastic resin on a wooden base material via a thermoplastic resin intermediate layer, and a depth exceeding the thickness of the decorative sheet from the surface thereof. The inner surface of the groove is also covered with the same decorative sheet as that of the general surface by forming the groove by embossing the surface, and the lower wooden base material and the thermoplastic resin intermediate layer are not exposed in the groove. Therefore, even if the surface of the flooring material may get wet with water, moisture may seep into the wood base material from the groove and cause warpage or corrosion, or the interface between the decorative sheet and the thermoplastic resin interlayer from the groove may It is excellent in water resistance without causing infiltration of water and deterioration of the adhesive to cause swelling or peeling of the decorative sheet. In addition, since the grooves are provided with the same color and pattern design by the same decorative sheet as the general surface portion, various excellent effects are exhibited, such as a sense of incompatibility in the design without separately painting the grooves. Things.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view showing an embodiment of a flooring material of the present invention.
FIG. 2 is a schematic sectional view showing an embodiment of the flooring material of the present invention.
FIG. 3 is a schematic sectional view showing an embodiment of the flooring material of the present invention.
[Description of Signs] 1 Wooden base material 2 Thermoplastic resin intermediate layer 21 Non-foamed layer 22 Foamed layer 3 Decorative sheet 4 Groove 5 Thermoplastic foamed layer

Claims (6)

A decorative sheet made of a thermoplastic resin is laminated on the surface of the wooden base material through a thermoplastic resin intermediate layer, and a groove is formed from the surface of the decorative sheet by embossing to a depth exceeding the thickness of the decorative sheet. Floor material characterized by having. The floor material according to claim 1, wherein the thermoplastic resin constituting the thermoplastic resin intermediate layer has a heat deformation temperature of 60C or more and 130C or less. The thermoplastic resin constituting the thermoplastic resin intermediate layer is a polybutylene terephthalate resin, an amorphous crystalline polyethylene terephthalate resin, an amorphous copolymerized polyester resin, and one or more kinds selected from polyethylene resins. The flooring according to claim 1, comprising a mixture or a laminate. The floor material according to any one of claims 1 to 3, wherein the groove is formed at a depth not exceeding a distance from a front surface of the decorative sheet to a back surface of the thermoplastic resin intermediate layer. The flooring according to any one of claims 1 to 3, wherein the groove is formed at a depth exceeding a distance from a front surface of the decorative sheet to a back surface of the thermoplastic resin intermediate layer. The floor material according to any one of claims 1 to 5, wherein the thermoplastic resin intermediate layer includes a foam layer on the whole or a part thereof.

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