JP2005193539A - Waterproof flooring material and its production method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To cheaply provide a waterproof flooring material which, in a flooring material required for waterproof performance used in a washroom, a chitin, etc., even in an inferior environment using the flooring material with moisture and water sprayed on the surface of the flooring material, in a channel processing part particularly vulnerable to water of the surface of the flooring material, can effectively prevent the penetration of water from the surface of the flooring material, can be produced easily, and has stable quality. <P>SOLUTION: In the flooring material, a decorative sheet of a synthetic resin is stuck on the surface of a woody substrate, and a decorative channel is formed on it. The surface layer in the decorative channel is formed from a composite of wood and a polymer obtained by being impregnated with an impregnation liquid mainly containing a vinyl monomer and polymerizing it. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a water-resistant flooring suitable for a floor in a place where water is relatively easily splashed in a building or a place with high humidity.

  Conventionally, floor materials used on floors inside buildings that are relatively wet and humid, such as washrooms and kitchens, have moisture from the floor surface even when used for a relatively short period of time after construction. It could not withstand long-term use due to permeation, swelling of the surface decorative material due to moisture absorption, or peeling of the surface decorative material.

  Compared to floor materials that use natural veneer veneer and veneer as surface decorative material, and surface finish coating on it, floor materials with synthetic resin sheets applied as surface decorative material are floor materials. Although relatively strong against moisture from the surface of the material, if the decorative groove is processed on the floor surface, the groove depth is usually deeper than the thickness of the synthetic resin sheet. The wood base material is exposed on the inner surface of the groove. When moisture permeates from the surface decorative groove, it causes the swelling of the surface of the flooring and the peeling of the surface decorative material as described above.

  Therefore, the conventional flooring material in which the synthetic resin sheet is adhered as a surface decorative material is obtained by adhering the synthetic resin sheet on the surface of the wooden base material and processing the surface decorative groove at a predetermined position from above. In areas where the wood substrate inside the groove is directly exposed to the outside due to groove processing, moisture penetration from outside tends to occur, so the finish paint is applied especially on the exposed portion of the wood substrate inside the groove. In many cases, the amount of water and the number of coatings were increased more than usual to improve the water resistance of the grooved portion.

  In addition to this, by using a base single plate layer on the surface of a wooden substrate produced by a resin impregnation method, that is, a WPC treatment method, by processing a surface groove having a groove depth within the range of the thickness of the WPC single plate. In addition, the water resistance inside the surface processing groove of the flooring has been improved.

In addition, as one method for improving the disadvantages of the WPC method, which requires high technology and is disadvantageous in terms of cost, 80% vinylon and 20% glass fiber are used between the base material and the surface decorative material. There is a flooring material having water resistance which is hot-pressure bonded through a resin sheet obtained by impregnating a sheet having a composition with resin. (For example, refer to Patent Document 1).
Japanese Patent Laid-Open No. 6-180057 (page 2-3, FIG. 1)

  In conventional floor coverings, water-resistant floor coverings where the amount of finish coating applied and the number of coatings are higher than usual are applied to the areas where the wood substrate inside the surface decorative groove is exposed. Even if the amount and the number of times of painting are increased, most of the paint is absorbed in the exposed wooden base material of the grooved part, even if it is much applied, and it does not remain as a film or remains It was quite thin and there was a limit to the water resistance of the grooved part.

  Even in floors such as washrooms and kitchens, it is relatively difficult to get moisture depending on the house, or in a house where there is a habit of wiping immediately even if it gets wet, this was still sufficient as water resistance, but the usage conditions and environment In houses where the conditions are inferior, as described above, swelling of the groove portions and peeling of the surface decorative material often occur in the groove processed portions.

  Also, in the method using a WPC veneer on the floor material surface, it is necessary to dry the veneer before impregnation with the resin, and the veneer is prone to cracking and flare in the veneer drying process, and the veneer yield is poor. It was quite difficult technically, took a lot of manufacturing steps, and was expensive. In addition, since the entire base single plate layer on the floor material surface is impregnated with resin, the amount of resin to be used is increased, which is disadvantageous in terms of cost.

  In addition, in the flooring described in JP-A-6-180057, a resin sheet obtained by impregnating a sheet composed of 80% vinylon and 20% glass fiber is used as a base material and a surface. Since it is hot-press bonded between the decorative material, the cost is considerably high.

  The present invention is made in view of the above circumstances, and in flooring materials such as a washroom and a kitchen, even in a poor usage environment of moisture and moisture, in the groove processing portion of the flooring material surface, from the flooring material surface. It is an object of the present invention to provide a water-resistant flooring that can effectively prevent moisture penetration and that is inexpensive in terms of cost and a method for producing the same.

  The water-resistant flooring of the present invention according to claim 1, which has been made to solve the above-mentioned problems, is formed by attaching a decorative sheet made of a synthetic resin to the surface of a wooden base material, and providing a decorative groove thereon. In the flooring material, the surface layer in the decorative groove is formed of a composite of wood and a polymer that can be polymerized by impregnating an impregnation liquid mainly composed of a vinyl monomer.

  According to the present invention having such a configuration, since the surface layer in the decorative groove is formed of a composite of wood and polymer, the water resistance performance of the surface decorative groove processed portion on the floor material surface is improved. Even in a use environment that is inferior to moisture, there is no risk of swelling of the grooved portion of the floor material surface, peeling of the surface decorative sheet, or the like.

The method for producing a water-resistant flooring of the present invention according to claim 2 is the method for producing the water-resistant flooring according to claim 1.
1. An impregnating solution mainly composed of a vinyl monomer is applied to only the vicinity of the surface of the wood substrate corresponding to the position where the surface groove on the floor material surface is provided.
2. Next, the wooden base material coated with the impregnating liquid mainly composed of vinyl monomer is hot-pressed and impregnated on the surface of the wooden base material and cured.
3. A surface decorative sheet made of a synthetic resin is adhered thereon.
4). Performs actual machining and surface grooving as flooring.
5). Apply a surface finish to the floor surface.
It is manufactured by the above method.

  When the flooring is manufactured by such a method, since the surface layer inside the flooring surface decorative groove is formed by a composite made of wood and polymer, even in a poor usage environment against moisture, It is possible to produce a floor material that does not cause the swelling of the grooved portion of the floor material surface or the peeling of the surface decorative sheet, and the surface of the wooden substrate corresponding to the position where the surface groove is provided on the floor material surface Since the impregnating liquid mainly composed of the vinyl-based monomer is applied and impregnated only in the vicinity and polymerized, it is possible to form a composite made of wood and a polymer only at the planned groove processing portion, and therefore the impregnating liquid to be used is extremely Less is required, which is very advantageous in terms of cost.

  According to the present invention, since the surface layer in the decorative groove is formed of a composite made of wood and polymer, the water resistance of the floor groove surface, particularly the surface groove processed portion, is improved. Even when used for a long period of time, even in a use environment that is inferior to moisture, there is no risk of swelling of the grooved portion of the floor material surface, peeling of the surface decorative sheet, or the like. Further, according to the production method of the present invention, it is possible to produce a floor material having such water resistance performance at low cost and stably.

  Details of the present invention will be described with reference to the drawings. FIG. 1 is a plan view of a water-resistant flooring 1 according to the present invention, FIG. 2 is a cross-sectional view of FIG. 1, (A) is a cross-sectional view taken along line AA, and (B) is a cross-sectional view taken along line BB. . FIG. 3 is an enlarged view of a main part of FIG. 2, (A) is an enlarged sectional view of a C portion, and is an enlarged sectional view of a portion of the surface decorative groove 4. (B) is an enlarged cross-sectional view of the D part and the E part of the floor material end, and is an enlarged cross-sectional view of the half groove part M. When adjacent flooring materials are joined, the half groove portions M are joined together to form one groove. 4 (a) to 4 (e) are explanatory views showing the manufacturing process of the water-resistant flooring of the present invention.

  In FIG. 1, the place which looked at the water-resistant flooring 1 of this invention from the top is shown. In the water-resistant flooring 1 of the present invention, a surface decorative sheet 3 is adhered to the surface of a wooden substrate 2, and a decorative groove 4 is formed on the surface of the flooring material in the present example in the width direction of the flooring. Are formed into two equal parts. The surface decorative groove 4 may be only in the longitudinal direction of the flooring 1, or may be only in the short direction as shown in this example, and is formed vertically and horizontally in the longitudinal direction and the short direction. It may be done.

  Further, the number of the surface decorative grooves 4 may be two as shown in this example, and of course, it may be other than two. On the side surfaces of the four circumferences of the flooring 1, fitting engagement portions 5 are provided. In this example, the fitting convex part 5a and the fitting concave part 5b are formed so that it can mutually fit between adjacent floor materials at the time of construction in the side surface which opposes, and this actual process is made | formed.

  FIG. 2 shows a cross-sectional view of the flooring 1 of the present invention. The surface decorative groove 4 shown in this example has a V-shaped groove having a substantially V-shaped cross-sectional view as shown in (b), and the joining structure between the flooring materials is also (a) and (b). In this example, the actual processing such as the fitting convex portion 5a and the fitting concave portion 5b is shown. However, the surface decorative groove 4 is not limited to the V groove, and may be a U groove, a square groove, or the like.

  Further, a half groove portion M is formed at the end portion of the flooring 1. The half-groove portion M is formed by combining the half-groove portion M and the half-groove portion M when adjacent floor materials are joined together to form one surface decorative groove. Further, as shown in the present example, the joining structure between the floor materials may be a hiring actual process other than the actual process, a laminating process, or any other joining structure. A decorative sheet 3 is attached to the surface of the wooden substrate 2.

  As the wood base material 2, for example, plywood, medium specific gravity fiber board, particle board, OSB, LVL, laminated material and the like can be suitably used. In addition, the decorative sheet 3 has, for example, a synthetic resin sheet such as a polyolefin resin sheet, a vinyl chloride resin sheet, a polyester resin sheet, a polyurethane resin sheet, or the like, and has a grain or an abstract pattern on a thin paper. Printed decorative paper and natural veneer veneer can be used. Among these, synthetic resin sheets such as polyolefin resin sheets, vinyl chloride resin sheets, polyester resin sheets, polyurethane resin sheets, etc. -It can use suitably from a viewpoint of water resistance performance.

  In FIG. 3, the principal part expanded sectional view of the water-resistant flooring 1 of this invention is shown. (A) shows an enlarged cross-sectional view of the C part including the surface decorative groove 4, and (B) shows an enlarged cross-sectional view of the D part and E part which are the end parts of the flooring 1. As can be seen from the cross-sectional view, a composite of wood and polymer that can be polymerized by impregnating an impregnating liquid R mainly composed of a vinyl monomer in the vicinity of the surface of the surface decorative groove 4 and the half groove portion M. G is formed.

  At this time, as the impregnation liquid R mainly composed of a vinyl monomer, for example, styrene and methyl methacrylate (MMA), as well as a crosslinked monomer addition system impregnation liquid R, BDMA, EDMA, or polar monomer addition As the system impregnation liquid R, HEMA, GHA and the like can be exemplified as suitable ones. Moreover, as a reaction initiator, peroxides, such as BPO, and azo compounds, such as AIBN, can be illustrated as a suitable thing, for example.

In (a) of FIG. 3, the structure of the surface decoration groove part of the flooring 1 of this invention is expanded and shown. In this portion, a substantially V-shaped cross-sectional view is shown in this example. The method for producing the surface decorative groove includes:
An impregnation liquid mainly composed of a vinyl-based monomer is applied only to the vicinity of the surface of the wooden base material corresponding to the position where the surface groove is provided on the floor material surface, and then the wooden base material coated with the impregnation liquid is heated. The impregnating liquid applied by pressure is impregnated and cured on the surface of the wooden base material, and a surface decorative sheet made of synthetic resin is adhered thereon, and actual processing and surface groove processing as a flooring material are performed. As the grooving machine, for example, a V gluer, an NC router, a handle turter, a tenor, and other processing machines are suitable. Of course, even other processing machines may be used. Finally, the surface finish is applied to the groove or the entire surface of the flooring.

  In (b) of FIG. 3, the structure of the edge part of the flooring 1 of this invention is expanded and shown. As described above, the half-groove portion M is formed in this portion at the end portion of the flooring 1. The half groove portion M is configured such that when adjacent floor materials are joined, the half groove portion M and the half groove portion M are combined to form one surface decorative groove.

  In the method for producing the half groove portion M, it is preferable to adjust the shape of the cutter blade so that the actual processing fitting convex portion 5a and the half groove portion M can be simultaneously formed when the wood substrate 2 is actually processed. . The same applies to the fitting recess 5b and the half groove M. The processing machine in the case of processing may be the same as that of the surface decorative groove 4. If the surface decorative groove 4 has a substantially V-shaped cross-sectional view as in this example, half-V processing may be performed.

  In FIG. 4, the method for producing the water-resistant flooring 1 of the present invention will be described in detail. Although FIG. 4 shows the case of two V-grooves in the middle of the flooring 1, the same applies to the case of the half-groove M at the end of the flooring 1.

  In FIG. 4A, the impregnating liquid R is applied to a position where the surface decorative groove 4 on the surface of the wooden substrate 2 is processed and its vicinity. As a method of applying only to the position of the surface decorative groove 4 and the vicinity thereof, for example, the template T is placed on the surface of the wooden base material 2 of the flooring, and from there, for example, the roll coater C, It is good to apply using spray coating machine S, application means, such as brush painting. As the template T, for example, a synthetic resin film such as a PET film which has solvent resistance and heat resistance and can be used repeatedly is suitable. In the case of the roll coater C, for example, a soft roll SR made of a soft synthetic resin foam is used as an application roll, and the impregnating liquid R is introduced between the doctor roll D and the roll. The wood substrate 2 on which the template T is placed is placed between the lower feed roll Q and coating is performed.

Next, as shown in (b), the surface of the wood substrate 2 is polymerized by heating the surface of the wood base material 2 coated with the impregnation liquid R at a predetermined position with a hot press H to polymerize the impregnation liquid R. To form a composite G of wood and polymer. At this time, although the impregnation hot pressure condition is slightly different depending on the type of the impregnation liquid R, the application amount of the impregnation liquid R is about 160 to 300 g / m ² , and the hot pressure condition is that the pressure is about 10.0 to 12.0 kg / The temperature of the hot plate HP at cm ² is about 140 to 160 ° C., and the hot pressing time is preferably about 5 to 10 minutes. Cured at room temperature for at least 24 hours after hot pressing.

  Next, as shown in (c), for example, a polyolefin resin-based decorative sheet or a vinyl chloride resin-based decorative sheet is formed on the surface of the wooden substrate 2 on which the composite G is formed on the surface layer portion at a predetermined position by the impregnating liquid R. A synthetic resin-based surface decorative sheet 3 such as a glue is attached. At this time, the adhesive may be appropriately selected from acrylic resin adhesive, urethane resin adhesive, and the like that are suitable for the synthetic resin surface decorative sheet 3 to be used.

  Next, as shown in (d), the surface decorative groove 4 is processed at the position where the composite G of the wooden substrate 2 is formed. At this time, it is important that the surface decorative groove 4 has such a size and shape as to fit in the formation part of the composite G. Thus, it is important to perform the surface groove processing so that the composite G remains on the inner surface layer of the surface decorative groove 4, that is, the groove inner surface and the vicinity thereof. The machine device used for grooving can be performed using an NC router, a handle turter, a rubber, a tenor, or other grooving machines used for woodworking.

  Finally, as shown in (e), the surface finish paint F is applied to the entire surface of the flooring 1 thus produced or to the grooved portion of the surface decorative groove 4 of the flooring 1. -Use the coating machine S to apply the surface finish. As the surface finish paint F at this time, for example, a urethane resin paint, an acrylic-modified urethane resin paint, an amino alkyd resin paint, a polyester resin paint, and the like can be mentioned as suitable ones. Of course, it may be other than these. As the coating method, roll coating, spray coating, curtain coating using a flow coater, or the like can be suitably used. Of course, it may be other than these. In this way, the coating film P is formed on the surface decorative groove portion of the flooring 1 or the entire surface of the flooring.

[Example 1]
A 5-ply lauan plywood having a width of 920 mm, a length of 1830 mm, and a thickness of 12 mm was used as a base material. Next, two slits having a width of 4.0 mm larger than the surface groove width were formed on the PET film so as to match the planned position of the surface groove processing. The slits were made for horizontal grooves in the lateral direction of the flooring at a pitch of 2 left and right (606 mm).

Next, the PET film was temporarily fixed on the Lauan substrate while confirming the position. The impregnating solution was applied on the wood base material thus prepared with a roll coater. As the impregnation liquid, styrene and methyl methacrylate (MMA) were used. BPO was used as a reaction initiator. The coating amount of the impregnation solution R was set to 200 g / ^{m 2,} hot pressing conditions the pressure 12 kg / cm ^2, temperature of 160 ° C., hot pressing time was 8 minutes. Thereafter, the PET film of the template was peeled off and cured at room temperature for 24 hours.

  Next, a polyolefin resin sheet having a thickness of 0.2 mm on which the wood grain pattern was printed was pressure-bonded at room temperature with a two-component urethane resin adhesive. Next, a surface decorative groove having a substantially V-shaped sectional view was processed at the impregnated position. The groove width was 1.5 mm and the groove depth was 0.75 mm. The angle of the V-shaped groove bottom was approximately 90 degrees. Finally, actual processing was carried out on the four sides of the flooring, and the entire surface of the flooring was finished with a urethane resin paint. Thus, the flooring of Example 1 was produced.

Next, a comparative example will be described.
[Comparative Example 1]
A flooring material of Comparative Example 1 was produced in the same manner as in Example 1 except that the impregnation process was not performed at a predetermined position of the wooden substrate.

Next, a water resistance test was performed on the flooring material of Example 1 and Comparative Example 1 in the following manner, particularly in the surface decorative groove portion.
[Water resistance test method]
Three test samples each having a side of 100 mm are cut out from the flooring material of Example 1 and Comparative Example 1. At this time, the surface decorative groove portion must be included. Next, 4 cc of water is dropped on the surface decorative groove, covered with a watch glass and allowed to stand at room temperature for 2 hours. The surface adhering water is thoroughly wiped off with a waste cloth, and the water absorption is measured with an electronic balance. The presence or absence of fine swelling due to water on the surface of the material is visually observed.
Water resistance performance evaluation criteria (floor surface wrinkle generation condition)
Occurrence of fine swelling: No evaluation at all ○
Same as above: 1 to 3
Same as above: 4 to 10 or less Evaluation ×
Same as above: In case of 11 or more Evaluation XX
[Water resistance performance test results]
The test results of Example 1 and Comparative Example 1 are shown below.

[Discussion]
The floor material of Example 1 in which the surface layer part inside the floor material surface decorative groove is impregnated and cured with an impregnating liquid to form a composite has extremely good water resistance even in the groove part.

The top view of the water-resistant flooring of this invention. Sectional drawing of FIG.

        (A) AA line sectional view.

(B) BB line sectional view.
The principal part enlarged view of FIG.

        (A) The C section expanded sectional view of FIG.

(B) Enlarged sectional view of the D and E parts in FIG.
Explanatory drawing which shows the manufacturing process of the water-resistant flooring of this invention. (A) Application process of impregnating liquid. (B) Hot-pressure curing process (c) Surface decorative sheet application process (d) Surface decorative groove processing process (e) Surface finish painting process

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Water-resistant flooring of this invention 2 Woody base material 3 Surface decorative sheet 4 Surface decorative groove 5 Fitting latching part 5a Fitting convex part 5b Fitting concave part M Half groove part R Impregnating liquid G Complex P Coating film T Template C Roll Coater
SR Soft roll D Doctor roll Q Feed roll H Hot press HP Hot plate S Spray coating machine F Surface finish paint

Claims (2)

In a flooring material in which a decorative sheet made of a synthetic resin is adhered to the surface of a wooden substrate and a decorative groove is provided thereon, an impregnating liquid mainly composed of a vinyl monomer is used for the surface layer in the decorative groove. A water-resistant flooring material comprising a composite of wood and polymer obtained by impregnation and polymerization. In producing the water-resistant flooring according to claim 1,
1. An impregnating solution mainly composed of a vinyl monomer is applied to only the vicinity of the surface of the wood substrate corresponding to the position where the surface groove on the floor material surface is provided.
2. Next, the wooden base material coated with the impregnating liquid mainly composed of vinyl monomer is hot-pressed and impregnated on the surface of the wooden base material and cured.
3. A surface decorative sheet made of a synthetic resin is adhered thereon.
4). Performs actual machining and surface grooving as flooring.
5). Apply a surface finish to the floor surface.
A method for producing a water-resistant flooring, characterized by being produced by the above method.

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