JP2006328840A - Four-side catch up flooring - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a four-side rolling-in flooring having a design property equal to a conventional woody flooring, being capable of preventing the infiltration of a moisture from a joint between the mutual floorings and having an excellent water resistance. <P>SOLUTION: In the four-side catch-up flooring, a rectangular decorative base material section 2 is formed to the top face of a base material 4 for the flooring in which a shiplap, a rabbet joint, a shiplap rabbet joint or at least one kind of the tongue working of a fitting shape is carried out on end faces on four sides. In the flooring, tongues are fitted mutually by the four-side catch-up flooring in which the surface and each side face of the decorative base material section 2 are covered and bonded. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention is a wood-based substrate or wood powder-containing thermoplastic for use in building interior materials such as indoor floors, walls, and ceilings in buildings such as detached houses, apartments, condominiums, recreational facilities, and stores. The present invention relates to a four-way flooring material in which a thermoplastic resin decorative sheet is laminated on a resin base material.

  Currently, wood flooring materials are most widely used as flooring materials for indoor floors in buildings such as detached houses, apartments, condominiums, recreational facilities, and stores. The woody flooring material is generally made of a woody base material such as a solid plate of natural wood having a thickness of about 6 to 15 mm or a laminated plywood having a thickness of about 6 to 15 mm.

  In addition, a flooring material in which a veneer of a natural wood having a thickness of about several hundred μm to several mm is stuck on a wooden base material or a coated product is applied by pressing or the like is used and developed. .

  2. Description of the Related Art An architectural decorative floor material and a manufacturing method (see, for example, Patent Document 1) in which a veneer veneer is adhered on the wooden base material are known.

  As shown in FIG. 12, the decorative floor material 100 has a plurality of decorative veneers 102 adhered to a base material 101, and grooves 103 are formed along the side edges of the decorative veneers 102. In addition, the surface of each decorative veneer 102 has been painted, the side edge of the decorative veneer 101 around the groove 103 is pushed into the groove by a press mold, and the outer surface of the side edge is rolled into the groove radially. It is.

  Further, a floor material in which a decorative sheet is adhered to a wooden base material as shown in FIG. 13 and a floor surface using the floor material (see, for example, Patent Document 2) are also known.

  As shown in FIG. 13, the flooring 200 is a rectangular flooring in which a decorative sheet 105 is adhered to one surface of a wooden base material 104, and has four peripheral edges on the side to which the decorative sheet 105 is adhered. A slope 106 covered with the decorative sheet 105 is formed on the part.

  Since the wooden base material uses natural wood, there are problems that it is easily discolored by sunlight, is easily damaged by the surface, and has poor water resistance. However, the design of the surface is the grain of natural wood, and its greatest strength is that it is the most natural, friendly and beautiful design.

  For this reason, weak weather resistance is conspicuous due to natural products, and scratches on the surface are allowed by repairing by polishing and painting, and are widely accepted by consumers.

  In addition, the wood flooring material uses a natural wood veneer as a surface decorative material, and therefore is inherently weak in water resistance. For example, if it is used in a place where the floor surface is often wetted, such as in the bathroom dressing room, washroom, kitchen sink, etc., moisture tends to soak into the veneer layer and the wooden base material therebelow.

  And there existed a problem that the swelling of a veneer | plate board layer, peeling from a wooden base material, or the curvature of a flooring etc. was easy to generate | occur | produce.

In addition, the wood flooring material has a problem in that it is difficult to stably mass-produce products having a stable design quality such as color tone and grain pattern because the surface design depends on natural wood.

  Moreover, there is no problem at present if the oak is a relatively abundant resource. However, according to the consumer's diverse tastes, for example, products with a light tone (light color) design using birch material (wooden material), cherry material (sakura material), maple material (wooden material), etc. It is difficult to add to the product lineup due to the lack of wood resources worldwide.

  Furthermore, there is a problem that it is very difficult to supply a large quantity of natural wood with a stable design quality.

  In view of these problems, the flooring material has the same design as the wooden flooring material and has excellent water resistance not only on the surface of the flooring material but also at the joint portion between the flooring materials and the flooring material. A manufacturing method (see, for example, Patent Document 3) is also known.

  As shown in FIG. 14, the flooring 300 is continuously heated from the upper surface of the flat-plate-like flooring base material 107 to at least the upper side portions 111 and 112 of the side surfaces 109 and 110 on the entire outer periphery thereof. A decorative sheet 113 made of a plastic resin is laminated.

  And it is described that this flooring 300 has advantages such as excellent weather resistance and water resistance since the decorative sheet 113 is a thermoplastic resin as well as excellent flexibility and stability of the surface design. Yes.

  However, floors made by laying a large number of flooring materials made by sticking a decorative sheet made of thermoplastic resin on the surface of a wooden base material have a problem that moisture easily oozes from the joints between the flooring materials. . And the water | moisture content which permeated from the seam swells a wooden base material, and the swelling and peeling of a decorative sheet from the seam vicinity arise.

  Furthermore, problems such as wrinkles and decay in the wet area near the seam, and warping of the flooring due to the action of exuded moisture may occur.

  In addition, it is said that it is very difficult to attach a decorative sheet made of a thermoplastic resin to various shapes of a real part of a wooden substrate, and is described (for example, see Non-Patent Document 1).

  Further, in order to prevent moisture from seeping out from the joints between the floor materials, a sealing process using a synthetic resin or the like is performed to solve the problem.

  However, in this method, there is a problem that a sealing process must be applied to all joints between the floor materials spread on the floor surface. Furthermore, there is also a problem that it takes much time to construct the flooring.

  In addition, after construction, there is a significant problem in terms of construction such that it is impossible to enter the construction site until the sealing agent is dried and hardened, and the next process work such as building work is hindered.

  Further, the joint between the floor materials blocked by the sealing treatment described above has a problem that the appearance is very poor compared to the conventional woody flooring material.

  Furthermore, there is a problem that it is very difficult to match the color and gloss of the flooring and the sealing agent. And there also exists a problem that it may become the result of reducing the designability of the constructed floor.

Prior art documents are shown below.
Japanese Patent No. 3497437 JP 2002-339556 A JP 2003-49530 A Edition of Shokokusha Co., Ltd., “Architecture Dictionary”, 2nd edition popular version, Shokokusha Co., Ltd., June 10, 2002 8, 9, 638

  The present invention has been made in view of the above-described conventional problems, and has the same designability as that of a conventional woody flooring material. Moreover, the surface of each flooring material as well as the joints between the flooring materials are provided. An object of the present invention is to provide a four-way wrapping floor material that has excellent water resistance and has a beautiful appearance even in the portion.

In order to solve the above problems, first, the invention according to claim 1 of the present invention is:
A rectangular decorative base is formed on the upper surface of the base material for flooring that has been subjected to at least one kind of actual processing such as mating, fruit, mating, or fitting shape on the four end faces. And a four-sided roll bed in which the surface of the decorative base portion and each side surface are coated and bonded with a thermoplastic resin decorative sheet formed in an appropriate shape for covering and bonding the surface of the decorative base portion and each end face Material,
A folding groove that is cut into a V-shape on each of the back sides in the vicinity of both ends in the short side direction of the decorative base part,
A four-way entrainment floor characterized in that the base material for a flooring material in which a decorative base material part formed by bending and folding the folded groove cut into the V shape inside is bonded to each other. It is a material.

  The four-side wrapping floor material of the present invention is a base material for flooring that has been subjected to at least one kind of actual processing of an end face in a four-way direction, an actual peel, an adjacent peel-off, or a fitting shape, and the floor material. A rectangular decorative substrate portion is provided on the upper surface of the substrate. The decorative base portion surface and each side surface are covered and adhered with a thermoplastic resin decorative sheet.

  For this reason, the flooring materials can be brought into close contact with each other without gaps when the fruits are fitted together. And the penetration of the water | moisture content from the joint line of a makeup | decoration base material part can be prevented, and it is excellent in water resistance.

  In addition, since the floor materials can be brought into close contact with each other without any gap, moisture can be prevented from seeping through the seam. And there is little deterioration such as expansion and contraction of the flooring, warpage and decay.

  Furthermore, since the floor materials are brought into close contact with each other with no gap, it is not necessary to perform a sealing process. For this reason, aesthetics are maintained. And when constructing, an unnecessary member becomes unnecessary and the work according to a schedule can be performed.

It can also be applied to places where there are many opportunities for moisture to adhere. And the designability of the surface can be maintained over a long period of time.

  Furthermore, the uneven | corrugated pattern imitating the external appearance of the wooden flooring which uses the conventional natural wood veneer board can be formed in a flooring base-material part surface. And sufficient water resistance is securable.

  The four-way wrapping flooring of the present invention will be described in detail below along the embodiments with reference to the drawings. 1 to 11 show an embodiment of the present invention.

  FIG. 1 is a schematic view showing an outline of an embodiment in which the four-side wrapping floor material of the present invention is produced. FIG. 2 is a schematic diagram showing an outline of an embodiment in which the decorative base portion surface of the four-side wrapping floor material of FIG. 1 and each side surface are coated and bonded with a thermoplastic resin decorative sheet. Further, FIG. 3 is a schematic plan view showing an outline of an embodiment of a thermoplastic resin decorative sheet for covering and adhering the decorative base portion.

  As shown in FIG. 1, the four-side wrapping flooring 1 of the present invention includes a flooring base 4 having a female real part 6 and a male real part 7, and a thermoplastic resin decorative sheet 10 on the flooring base 4. The upper surface and both long side surfaces 5 in the long side direction are composed of a decorative base portion 2 that is covered and adhered.

  Folding grooves 8 that are cut in a V-shape are provided on the back surfaces in the vicinity of the inner sides of both end surfaces in the short side direction of the decorative base portion 2. And when both short side direction both end surfaces are bend | folded inside and adhesively bonded, the short side surface currently covered and bonded by the thermoplastic resin decorative sheet 10 is formed. In addition, when the surface 3 of the decorative base portion 2 is rectangular, if the thermoplastic resin decorative sheet 10 is first wrapped to the long side surface 5, the thermoplastic resin decorative sheet 10 will not be left after folding. It can be bent.

  Moreover, although the external shape of the four-way wrapping flooring 1 is rectangular in FIG. 1, it is not particularly limited. For example, a square shape, a regular triangle shape, a regular hexagonal shape, a complex polygonal shape, or the like may be used. Furthermore, the geometric shape which combined the 1 type (s) or 2 or more types of the said shape may be sufficient.

  Furthermore, the actual shape formed in the base material 4 for flooring is not specifically limited to the shape shown in FIG. For example, the shape may be a shape such as a peg 20 shown in FIG. 8, a real peg 30 shown in FIG. 9, a peg 40 shown in FIG. 10, or a snap fit 50 shown in FIG.

  And as shown in FIG. 2, the decorative base material part 2 formed in the upper part of the base material 4 for flooring is the thermoplastic resin decorative sheet 10, and the surface 3 of the decorative base material part 2, both long side surfaces 5, and A four-way wrapping floor material having both short side surfaces coated and bonded is formed.

  Both ends of the short side direction of the decorative base portion 2 are bent inward, and a decorative base is formed on a part of both long side surfaces 5 provided with short side surfaces coated and bonded with a thermoplastic resin decorative sheet 10. When the material part 2 is exposed, it is preferable to fill with a paint or a caulking agent.

  Moreover, in the four-way wrapping flooring 1 of the present invention, the material or configuration of the flooring base material 4 and the thermoplastic resin decorative sheet 10 is not particularly limited. And it can select suitably from the material similar to what is used for the conventional similar flooring based on required quality, and can use it.

An appropriate adhesive is used for covering adhesion of the thermoplastic resin decorative sheet 10, the surface 3 of the decorative base portion 2, the long side surfaces 5 in the long side direction, and the like, if necessary. Examples of the types of adhesives include, for example, ethylene-vinyl acetate copolymer resin-based aqueous emulsion adhesives, water-based or oil-based two-component curable urethane resin-based adhesives, and moisture-curable types such as urethane resins and polyether resins. Conventionally known materials such as hot melt adhesives can be used as appropriate, and are not particularly limited in the present invention.

  The thermoplastic resin decorative sheet 10 may be a base sheet made of thermoplastic resin or a single-layer thermoplastic resin decorative sheet in which a pattern layer is formed on the surface of the transparent resin layer.

  Moreover, even if it is the thermoplastic resin decorative sheet 10 which provided the surface protective layer 15 which consists of a transparent thermoplastic resin as shown in FIG. 4 or FIG. 5 on the pattern layer of the thermoplastic resin decorative sheet of the said single layer structure. good.

  Further, as shown in FIG. 6, the thermoplastic resin decorative sheet in which a pattern layer 12, an adhesive layer 13, a transparent resin layer 14, and a surface protective layer 15 are laminated in this order on the surface of a base sheet 11 made of a thermoplastic resin. It may be 10.

  Furthermore, in the thermoplastic resin decorative sheet 10 in which a hard base sheet 16, a base sheet 11, a pattern layer 12, an adhesive layer 13, a transparent resin layer 14, and a surface protective layer 15 are sequentially laminated as shown in FIG. There may be.

  The thermoplastic resin decorative sheet 10 having the configuration shown in FIG. 6 or 7 is excellent in design, adhesion, weather resistance, solvent resistance, abrasion resistance, and the like.

  In addition, the thermoplastic resin decorative sheet 10 is required to have concealability in order to conceal undesired colors, color unevenness, defects, and the like on the surface of the decorative base portion 2 and enhance design. For this reason, the base material sheet 11 made of the thermoplastic resin below the pattern layer 12 constituting the thermoplastic resin decorative sheet 10 is preferably an opaque base material sheet 11 in order to provide concealability.

  The opaque base sheet 11 is formed by adding an opaque pigment such as titanium oxide, zinc oxide, carbon black, iron oxide or the like to a thermoplastic resin. Moreover, a concealing layer can be formed with opaque printing ink etc., or these can also be used together.

  Examples of the thermoplastic resin of the opaque base sheet 11 or the transparent resin layer 14 include, for example, polyolefin resin, stretched, unstretched polyester resin, copolymerized polyester (commonly known as PET-G) resin, acrylic resin, polystyrene. Resin, polyamide resin, polyvinyl chloride resin and the like can be used.

  Among the thermoplastic resins, when covering and adhering the decorative base portion, considering the physical properties of the surface, workability, economy, disposal (including incineration), etc., polyolefin resins and / or polyester resins are used. It is desirable to use it.

  Examples of the polyolefin resin include polyolefin resins such as polyethylene, polypropylene, polybutene, and polymethylpentene, ethylene-propylene copolymer resin, ethylene-propylene-butene copolymer resin, and ethylene-vinyl acetate copolymer. Olefin-based copolymers such as coalescence resin, ethylene-vinyl alcohol copolymer resin, ethylene- (meth) acrylic acid copolymer resin, metal neutralized product (so-called ionomer resin), ethylene- (meth) acrylate copolymer resin, etc. Examples thereof include polymer resins and olefinic thermoplastic elastomer resins.

  Furthermore, examples of the polyester-based resin include crystalline polyester resins such as polyethylene terephthalate resin, polybutylene terephthalate resin, polytetramethylene terephthalate resin, polyethylene terephthalate-isophthalate copolymer resin, polyethylene naphthalate resin, and polycarbonate resin. Amorphous such as polyarylate resin, amorphous polyethylene terephthalate resin (so-called A-PET resin), copolymer polyester resin (eg, so-called PET-G resin which is 1,4-cyclohexanedimethanol copolymer polyethylene terephthalate resin), etc. Quality polyester resin and the like.

  Moreover, the thermoplastic resin decorative sheet 10 can also be configured by appropriately selecting a plurality of types from the various thermoplastic resins. And the thermoplastic resin decorative sheet 10 which is excellent in the surface scratch resistance etc. which are requested | required of a four-way roll-up flooring is produced suitably.

  Moreover, the covering adhesion | attachment of the thermoplastic resin decorative sheet 10 of the surface 3 of the decorative base part 2 and the both long side surfaces 5 can be performed by a vacuum forming method or a soft wrapping method.

  In the processing, the thermoplastic resin decorative sheet 10 is preferably soft.

  Moreover, as a thermoplastic resin decorative sheet having a two-layer structure preferable for processing suitability such as the vacuum forming method or the soft wrapping method, for example, the resin of the base sheet 11 is a soft polyolefin resin or olefin thermoplastic resin having excellent flexibility. An elastomer resin, an amorphous polyester resin, or the like is used, and the resin of the transparent resin layer 14 can be configured by combining a hard polypropylene resin, a crystalline polyester resin, or the like.

  Examples of the flexible polyolefin resin include ordinary polyolefin resins such as polypropylene resin, α-olefin polymers other than low density polyethylene, atactic polypropylene, ethylene and propylene, and ethylene-α-olefin copolymers. A resin having improved flexibility by adding or copolymerizing a soft component such as ethylene-propylene rubber, styrene-butadiene rubber or a hydrogenated product thereof can be used.

  Next, the pattern layer 12 represents a pattern of a desired design by printing or the like, and there are no restrictions on the type, constituent material, formation method, and the like of the pattern.

  In general, the pattern of the pattern layer includes a wood grain pattern, a stone pattern, a cloth pattern, an abstract pattern, a geometric pattern, a character or a symbol, or a combination thereof. Of course, a solid color (solid) may be used. Absent.

  Moreover, when the concealing property of the base material sheet 11 is insufficient, a concealing solid layer containing a large amount of an opaque pigment can be provided in combination with the design pattern or alone.

  The constituent material of the pattern layer 12 is generally a printing ink or paint in which a colorant such as a dye or pigment is dissolved or dispersed in a suitable solvent together with a color extender such as a synthetic resin.

  Examples of the coloring pigment include inorganic pigments such as titanium oxide, zinc oxide, iron oxide (petal, yellow iron oxide, iron black) cobalt blue, carbon black, and organic pigments such as azo pigments and imidazolone pigments. It can be illustrated.

  Furthermore, as the color developing agent, for example, urethane resins, acrylic resins, polyester resins, vinyl chloride-vinyl acetate copolymer resins, fiber derivatives, and the like can be used.

Moreover, as a formation method of the pattern layer 12, for example, a gravure printing method, an offset printing method,
Various printing methods such as gravure offset printing method, screen printing method, flexographic printing method, transfer printing method, electrostatic printing method and ink jet printing method can be exemplified.

  Further, when the pattern layer 12 is solid, for example, gravure coating method, knife coating method, air knife coating method, roll coating method, kiss coating method, rod coating method, die coating method, lip coating method, comma coating method, Various coating methods such as spray coating, flow coating, and dip coating are appropriately selected and used.

  Also. Prior to print formation of the pattern layer 12, the surface of the base sheet 11 is easily adhered, for example, corona discharge treatment, ozone treatment, plasma treatment, flame treatment, ionizing radiation treatment, acid treatment, alkali treatment, primer or anchor treatment, etc. By performing a surface treatment for making it easier, interlayer adhesion can be improved.

In addition, as a method for applying the design pattern of the thermoplastic resin decorative sheet 10, instead of using the printing or coating method as described above, a sheet in an insufficiently mixed state between an uncolored thermoplastic resin and a colored thermoplastic resin. To form. And the base material sheet 11 made to exhibit the coloring pattern similar to the grain can also be used.

  As a lamination method for producing the thermoplastic resin decorative sheet 10, for example, a dry lamination method with an appropriate adhesive, a wet lamination method, a thermal lamination method with or without an adhesive layer, a high-frequency lamination method, a heat There is an extrusion lamination method in which a plastic resin is extruded in a molten state and laminated at the same time. And it selects and uses suitably.

  In the extrusion lamination method, if necessary, an adhesive resin such as an acid-modified olefin resin or an olefin- (meth) acrylate copolymer resin as an adhesive layer is simultaneously laminated by coextrusion. Also good.

  Moreover, when comprising from the transparent resin layer 14, when these are formed by a coextrusion method, the thing excellent in interlayer adhesiveness is obtained easily, and it is suitable.

  Moreover, the thermoplastic resin decorative sheet 10 can form the surface protective layer 15 on the surface of the transparent resin layer 14, or can emboss (uneven | corrugated pattern) etc. normally like the case of a similar decorative sheet. Furthermore, although not shown in the figure on the back surface of the base material sheet 11, an easy-adhesion coat layer can be formed.

  The easy-adhesion coat layer is for ensuring adhesion to general-purpose adhesives such as vinyl acetate and urethane used when the decorative base portion 2 is coated and adhered with the thermoplastic resin decorative sheet 10. . For example, those mainly composed of an easily adhesive resin composition such as a two-component curable urethane resin, an acrylic resin, or an ethylene-vinyl acetate copolymer resin are used.

  And by adding inorganic powders such as silica having a particle size of about 0.5 to 5 μm to these resins, the adhesive strength is improved by the anchoring effect, and at the time of winding and storing the thermoplastic resin decorative sheets 10 and 20. It is also possible to prevent blocking.

  Next, the surface protective layer 15 is desirably made of a curable resin that is harder and tougher than the thermoplastic resin that forms the base sheet 11 and the transparent resin layer 14. Specifically, for example, urethane-based resins, melamine-based resins, epoxy-based resins, urea-based resins, unsaturated polyester-based resins, silicone-based resins and other thermosetting resins, unsaturated polyester-based resins, and (meth) acrylate-based resins Examples include ionizing radiation curable resins such as resins.

  Among the curable resins, it is most preferable to use an ionizing radiation curable resin that has a high crosslink density and is hard and can provide a cured film having excellent wear resistance and scratch resistance.

  The ionizing radiation curable resin is appropriately blended with a prepolymer, oligomer and / or monomer having at least one radical polymerizable double bond in the molecule capable of undergoing a polymerization crosslinking reaction by irradiation with ionizing radiation such as ultraviolet rays or electron beams. It is made. Such prepolymers and oligomers include (meth) acrylates such as polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, polyether (meth) acrylate, and polyol (meth) acrylate. Examples of monomers such as prepolymers or oligomers such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, cyclohexyl (meth) acrylate, ethylhexyl (meth) acrylate, and hydroxyethyl (meth) acrylate Monofunctional (meth) acrylates, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, Polyfunctional (meth) acrylates such as bifunctional (meth) acrylates such as lenglycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, and dipentaerythritol hexa (meth) acrylate And the like. Here, “(meth) acrylate” means acrylate or methacrylate.

  In the case where the coating film of the ionizing radiation curable resin is cured by irradiation with ultraviolet rays, for example, the radical photopolymerization of benzoin, acetophenone, thioxanthone, benzophenone, azo compound is initiated on the ionizing radiation curable resin. Agent is added. If necessary, a photosensitizer such as a tertiary amine such as triethanolamine or a benzoic acid derivative such as ethyl 2-dimethylaminobenzoate is used in combination.

  In addition, as subcomponents, colorants, fillers, matting agents, antifoaming agents, mold release agents, antiwear agents, flame retardants, lubricants, antistatic agents, UV absorbers, light stabilizers, heat stabilizers, oxidation An inhibitor, an antibacterial agent, an antifungal agent, a diluent solvent and other additives may be appropriately added as necessary.

  Moreover, there is no restriction | limiting in particular in the thickness and the formation method of the surface protective layer 15, What is necessary is just to design suitably according to the physical property requested | required of the surface of the four-way entrainment flooring 1. FIG.

  In general, the thickness of the surface protective layer 15 is about 1 to 100 μm, more preferably about 5 to 50 μm.

  Examples of the method for forming the surface protective layer 15 include a roll coating method, a knife coating method, an air knife coating method, a die coating method, a lip coating method, a comma coating method, a kiss coating method, a flow coating method, a dip coating method, and a gravure. What is necessary is just to select arbitrarily from various coating methods, such as a coating method, a gravure reverse coating method, and a micro gravure coating method.

  Further, a lubricant may be added to the surface protective layer 15 to improve wear resistance. As the lubricant, for example, alumina, diamond, silicon carbide, silica, glass, zirconia, zeolite, shirasu balloon, diatomaceous earth and the like, an average particle made of a material having a hardness higher than that of the resin that is at least the main component of the surface protective layer 15 is used. A granular material having a diameter of about 5 to 50 μm is used.

In addition, by appropriately designing the relationship between the particle size of the lubricant and the film thickness of the surface protective layer 15, the lubricant protrudes from the average surface of the surface protective layer 15 and is finely projected on the surface of the surface protective layer 15. If formed so as to form a shape portion, the surface hardness, abrasion resistance, scratch resistance and the like of the surface 3 of the resulting decorative base portion 2 are further improved, and the surface 3 of the decorative base portion 2 is slip resistant. (Anti-slip property) can also be imparted.

  However, if the lubricant is exposed in a state of protruding from the surface of the surface protective layer 15, the back of the sock of a person walking on the flooring is worn, or the knee kid is scraped when the child falls. May cause problems.

  Therefore, the surface protective layer 15 is composed of a plurality of layers, and the lubricant is a layer other than the uppermost layer (for example, a subbing layer, a subbing layer, an intermediate coating layer in a two-layer configuration of a subbing layer and a top coating layer) In addition, an anti-friction agent is added so as to cover the surface of the anti-friction agent protruding from the average surface of the layer. It is desirable to provide an uppermost layer (overcoat layer) that is not present.

  In this case, the sharp surface irregularities formed by the fine protrusions due to the protrusion of the lubricant from the average surface of the surface protective layer 15 are blunted by the uppermost surface protective layer 15 (the top coat layer), and as a result, the contact described above. Reduce wear of objects. In addition, it is possible to reduce roughness when touching the surface, visual excessive matte feeling (powder), and the like.

  In the production of the four-side wrapping flooring 1 of the present invention, the surface protective layer 15 may be formed before or after the thermoplastic resin decorative sheet 10 covers and adheres the decorative base portion 2. Also good. Also, a plurality of layers can be formed before and after coating adhesion, such that a part (for example, the undercoat layer) is before coating adhesion and the remaining part (for example, the top coating layer) is after coating adhesion.

  Moreover, according to the method of forming a part or all of the surface protective layer 15 after the covering adhesion of the thermoplastic resin decorative sheet 10 to the decorative base portion 2, the surface having a large coating amount that is not suitable for handling in a wound form Since it can respond easily also when providing the protective layer 15, there exists an advantage which can manufacture easily the flooring which was excellent in surface physical properties, such as damage resistance.

  Furthermore, when providing the surface protective layer 15 on the surface of the thermoplastic resin decorative sheet 10, sufficient adhesion is provided between the surface of the surface protective layer 15, that is, the surface of the transparent resin layer 14 and the surface protective layer 15. It is necessary to secure. For this purpose, the surface of the transparent resin layer 14 is subjected to surface activation treatment such as corona discharge treatment or ozone treatment.

  Alternatively, a recoatable resin layer made of a resin composition not shown in the figure but having excellent adhesion to both the thermoplastic resin constituting the transparent resin layer 14 and the resin constituting the surface protective layer 15. Can also be provided on the surface of the transparent resin layer 14.

  As the recoatable resin layer, for example, it is desirable to use a thermosetting resin such as a urethane resin, an epoxy resin, a phenol resin, a urea resin, an alkyd resin, or a polyester resin. Of the above, it is most desirable to use a two-component curable urethane resin by blending a polyol compound and an isocyanate compound.

  As said polyol compound, an acrylic polyol compound, a polyether polyol compound, a polyester polyol compound etc. can be used, for example.

  Of the above, it is most desirable to use a polyester polyol compound from the viewpoint of the balance between adhesion to a curable resin such as a thermoplastic resin and an ionizing radiation curable resin and the internal cohesive force.

Further, when the recoatable resin layer is provided between the transparent resin layer 14 and the surface protective layer 15, the surface protective layer 15 is formed after the decorative base material portion 2 is covered and adhered with the thermoplastic resin decorative sheet 10. can do. And, for convenience of the process, after covering and adhering the decorative base material part 2 with the thermoplastic resin decorative sheet 10 on which the surface protective layer 15 is not formed, even if the surface protective layer 15 is formed after a long period of time, it is transparent. There is an advantage that sufficient adhesion between the resin layer 14 and the surface protective layer 15 can be easily obtained.

  In addition, the four-way entrained flooring 1 of the present invention is provided with a four-way entraining floor in order to prevent the floor material from expanding and contracting and warping due to the influence of moisture under the floor and the effect of moisture movement due to environmental temperature and humidity changes. A moisture-proof sheet or the like is laminated on the back surface of the material 1.

  Furthermore, instead of the moisture-proof sheet, a foam layer is laminated on the back surface of the four-side wrapping flooring 1 for the purpose of absorbing unevenness of the floor surface and preventing rattling, heat insulation, soundproofing, vibration proofing, etc. Also good.

  The moisture-proof sheet is mainly composed of a moisture-proof resin layer having a thickness of about 10 to 100 μm, and a paper layer such as thin paper, resin-impregnated paper, and inter-paper reinforcing paper is laminated on the front and / or back as necessary. Such as a sheet.

  As the moisture-proof resin layer, for example, a polyolefin resin such as polyethylene (high density polyethylene, medium density polyethylene, low density polyethylene), or a hydrophobic material having low moisture permeability such as polyvinyl chloride resin, polyester resin, or polyvinylidene fluoride resin. A suitable thermoplastic resin can be used.

The moisture permeability of the moisture-proof sheet is generally preferably about 3 to 30 g / m ² · 24 h. Moreover, the formaldehyde scavenger such as a nitrogen-containing compound can be added to the paper layer to provide a function of capturing and removing formaldehyde emitted from a wooden substrate such as laminated plywood.

  Examples of the foamed layer include polyolefin resins such as polyethylene (high density polyethylene, medium density polyethylene, low density polyethylene), polyvinyl chloride resin, polystyrene resin foamed with a known foaming agent, A polyurethane foam etc. can be illustrated.

  Further, a sheet-like material having an expansion ratio of about 2 to 20 times and a thickness of about 2 to 12 mm can be used. In addition, you may laminate | stack a foaming layer on the back surface of the moisture-proof sheet laminated | stacked on the back surface of the base material 4 for flooring. Moreover, you may laminate | stack directly on the back surface of the base material 4 for floor materials, without providing a moisture-proof sheet | seat.

  Next, the most typical material for the flooring base 4 or the decorative base 2 is a woody base such as laminated plywood. The laminated plywood is laminated and bonded with a plurality of (usually odd number) wood veneers with their fiber directions alternately orthogonal.

  The wood type of the wood veneer may be either hardwood material such as lauan material, softwood material such as pine material (pine material), or a mixture thereof. As the outermost wood veneer, for example, a cruin material, a Kapool material, a menclan material, or the like can be used.

  Further, if the outermost wood veneer is made of a hard and durable South Sea wood type material that contains silica, the floor base material 4 or the decorative material that is further excellent in surface strength, caster resistance, etc. The base material part 2 is obtained.

In addition to the laminated plywood, various conventionally known wooden boards such as a single-plate laminated material, an orientation board, a particle board, and a high-density fiber board can be arbitrarily used.

  Furthermore, in addition to the wood base material, for example, an inorganic base material such as ceramic or concrete plate, a metal base material such as iron, aluminum, brass or stainless steel, or a thermoplastic resin such as polypropylene resin is added. It is also possible to use a modified resin base material such as a profile extrusion molded body obtained by adding wood powder and a foaming agent to a thermoplastic resin or a polypropylene resin and foaming the inside thereof, fiber reinforced plastic (FRP), or the like.

  In general, the metal-based substrate and the synthetic resin-based substrate are free from problems such as swelling and warping due to moisture penetration.

  Of the various materials mentioned above, it is most desirable in terms of workability such as actual processing and cutting / nailing at the construction site, warm touch feeling when touching the skin, walking feeling due to moderate elasticity, economy, etc. The thing is a woody base material such as laminated plywood.

  However, in recent years, it has been pointed out that flooring materials using wooden base materials are likely to remain indented along the track of the caster as the use of furniture with casters, wheelchairs, etc. increases in a room such as a house. In order to avoid this problem, a thermoplastic resin decorative sheet 10 having a structure as shown in FIG. 7 in which a hard sheet layer 16 made of a high hardness material is provided on the thermoplastic resin decorative sheet 10 as shown in FIG. A four-way wrapping floor material coated and bonded to the upper surface of the decorative base part 2 is preferable.

  The hard sheet layer 16 is made of a material having a high hardness, preferably a surface hardness of 60 or more according to durometer hardness test type D (JIS K 6253), more preferably 65 or more, and a thickness of 0.5 to 3 mm. It may be in the form of a sheet of the order, and the specific material is not particularly limited.

  In addition, specific examples of materials used for the hard sheet layer 16 include wood materials having particularly high hardness, such as compressed wood, resin-impregnated wood, inorganic-impregnated wood, high-density fiberboard, and medium-density fiberboard. For high-density surface layer parts, for wood-based materials, inorganic materials such as ceramic non-combustible plates, thermosetting resin-impregnated paper (diaryl phthalate for paper such as wood pulp fiber paper, kenaf fiber paper, synthetic or semi-synthetic fiber paper) Resin, a resin impregnated with a thermosetting resin such as a phenol resin, a melamine resin), a thermosetting resin, or a thermoplastic resin sheet. Among these, it is most desirable to use thermoplastic resin sheets in consideration of processability and recyclability.

  Since the thermoplastic resin sheet 10 is generally insufficient in hardness as a simple substance, it is desirable to use a material in which an appropriate filler is added to enhance the surface strength.

  Examples of the filler include inorganic fillers such as calcium carbonate, talc, clay, glass powder, glass fiber, and metal powder, and organic fillers such as wood powder and paper powder. The amount is usually about 5 to 400 parts by weight per 100 parts by weight of the thermoplastic resin. Further, for the enhancement of the surface hardness, it is necessary to increase the filling, and it is preferable to add about 150 to 400 parts by weight of a filler per 100 parts by weight of the thermoplastic resin.

  The type of the thermoplastic resin is not particularly limited. For example, polyolefin resin (polypropylene, polyethylene, olefin rubber, etc.), stretched, unstretched polyethylene terephthalate resin, copolymerized polyester resin, polyethylene naphthalate resin, polybutylene terephthalate. Resins, acrylonitrile-styrene-butadiene resins, acrylic resins, and mixtures and multilayer products thereof can be suitably used.

Single sheet of the resin, or wood powder on the resin (average particle size of about 0.005 to 0.3 mm)
A sheet or the like obtained by adding and adding can be suitably used as the hard sheet layer 16. In addition, as long as the water resistance and surface strength of the hard sheet layer 16 are not affected, foaming may be performed by a known chemical and / or physical method.

  The thermoplastic resin decorative sheet 10 imparts surface properties such as a desired design, abrasion resistance, scratch resistance, solvent resistance, weather resistance, and oil resistance to the surface of the four-sided floor material of the present invention. Furthermore, the exposed surface of the base material 4 for flooring is covered and water resistance is also provided.

  The present invention is a wood-based substrate or wood powder-containing thermoplastic for use in building interior materials such as indoor floors, walls, and ceilings in buildings such as detached houses, apartments, condominiums, recreational facilities, and stores. In addition to being excellent as a flooring material in which a thermoplastic resin decorative sheet is coated and bonded to a resin base material, it can be used in a wide range of fields, such as a decorative wooden box or an industrial return box.

It is the schematic for demonstrating the outline with which the four-way entrainment flooring of this invention is produced. It is the schematic which shows the outline of one Example with which the four-way entrainment flooring of this invention was produced. It is a schematic plan view which shows the shape of one Example of the thermoplastic resin decorative sheet used for the four-way entrainment flooring of this invention. It is a schematic sectional drawing which shows the cross-sectional structure of one Example of the thermoplastic resin decorative sheet used for the four-way entrainment flooring of this invention. It is a schematic sectional drawing which shows the cross-sectional structure of other one Example of the thermoplastic resin decorative sheet used for the four-way entrainment flooring of this invention. It is a schematic sectional drawing which shows the cross-sectional structure of other one Example of the thermoplastic resin decorative sheet used for the four-way entrainment flooring of this invention. It is a schematic sectional drawing which shows the cross-sectional structure of other one Example of the thermoplastic resin decorative sheet used for the four-way entrainment flooring of this invention. It is the schematic which shows the form of one Example of the edge joint shape formed in the base material for floors of the four-way wrapping floor material of this invention. It is the schematic which shows the form of another Example of the edge joint shape formed in the base material for floors of the four-way wrapping floor material of this invention. It is the schematic which shows the form of another Example of the edge joint shape formed in the base material for floors of the four-way wrapping floor material of this invention. It is the schematic which shows the form of another Example of the edge joint shape formed in the base material for floors of the four-way wrapping floor material of this invention. This is a conventionally used decorative flooring material for buildings. It is a flooring to which a conventionally used decorative sheet is adhered. It is a floor material having water resistance that has been conventionally used.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Four-way enveloping floor material 2 ... Makeup base material part 3 ... Surface of makeup base material part 4 ... Base material for flooring material 5 ... Long side surface 6 ... Female real part 7 ... Male real part 8 ... Folding groove 9 ... Long side Direction 10 ... thermoplastic resin decorative sheet 11 ... base sheet 12 ... pattern layer 13 ... adhesive layer 14 ... transparent resin layer 15 ... surface protective layer 16 ... hard sheet 17 ... short side direction 18 ... short side surface 19 ... adhesive joint 20 ... Matching shape 30 ... Actual peel shape 40 ... Matching shape 50 ... Snap fit shape

Claims (1)

A rectangular decorative base is formed on the upper surface of the base material for flooring that has been subjected to at least one kind of actual processing such as mating, fruit, mating, or fitting shape on the four end faces. And a four-sided roll bed in which the surface of the decorative base portion and each side surface are coated and bonded with a thermoplastic resin decorative sheet formed in an appropriate shape for covering and bonding the surface of the decorative base portion and each end face Material,
A folding groove that is cut into a V-shape on each of the back sides in the vicinity of both ends in the short side direction of the decorative base part,
A four-way entrainment floor characterized in that the base material for a flooring material in which a decorative base material part formed by bending and folding the folded groove cut into the V shape inside is bonded to each other. Wood.

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