JP2008063777A - Flooring material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for an inexpensive flooring material which is rich in various performances such as surface smoothness, water resistance and weatherability, and through which a unique pattern of pieces of crushed wood can be seen. <P>SOLUTION: This manufacturing method comprises: a step of applying and curing a UV-curable resin as a wood filling coat layer (13) with a thickness of about 70-90 μm throughout the surface of a bed plate (10) composed of an oriented strand board with a thickness of about 12-18 μm; a step of sequentially applying and curing the UV-curable resin as first and second undercoat layers (14a) and (14b) with the total thickness of about 50-70 μm throughout the surface of the wood filling coating layer (13), respectively; a step of continuously applying and curing the UV-curable resin as an intermediate coat layer (15) with a thickness of about 15-25 μm throughout the surface of the second undercoat layer (14b); and a step of applying and curing an epoxy-based UV-curable resin as an overcoat layer (16) with a thickness of about 10-15 μm throughout the surface of the intermediate coat layer (15) after the surface polishing of the intermediate coat layer (15). <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a flooring (flooring) used for building floor finishing and a production method useful in mass production.

  In general, plywood made of southern materials such as lauan is used as the base plate (substrate) for the flooring. However, the surface of the plywood gradually deteriorates with the depletion of the southern ocean materials. In order to maintain the properties, a method of repairing putty, a method of attaching a medium density fiberboard (MDF) as it is or slicing it to the surface, a method of using a coniferous plywood instead of a South Sea material, and the like are employed.

  On the other hand, oriented strand board (OSB) is used as a base plate for the above-mentioned flooring materials in European countries with earthen foot culture. According to this, thinned wood from artificial forests is used as the main raw material. Although it can meet social demands and has the advantage of being cheaper than the above-mentioned plywood such as lauan and conifers, in the case of Japan it is not a country of foot-striped culture, so oriented strand board imported from European countries ( OSB) is not yet used as a base plate for flooring, but is only used as a base material, a core material, and other invisible structural materials.

  In other words, the reason why the above-mentioned oriented strand board (OSB) is not used as a base plate for flooring is that it is a piece of wood (Strand) crushed to a length of about 10 to 12 cm and a thickness of several mm, It is mixed with adhesive, and the fiber direction is arranged in an orthogonal state for each layer (Oriented) and processed into a board shape (Board). It is considered. Moreover, the surface finish is inferior to the overall smoothness as rough polishing with sanding paper.

  Therefore, it is not suitable for barefoot walking in Japan, and there is a risk of tearing stockings. In addition to smoothness, it satisfies general requirements such as surface water resistance, stain resistance, weather resistance, abrasion resistance, scratch resistance, impact resistance, and designability as a flooring base plate. In addition, if it is exposed to water or high humidity, it will swell, resulting in restrictions on the place of use.

  In this regard, even if the surface of the oriented strand board (OSB) is painted with oil stain, wax, oil varnish, etc., the above performances are not achieved stably, especially the surface. A feeling of irregularities peculiar to is left behind.

  The present invention aims to improve such problems, and in order to achieve the object, in claim 1, an oriented strand board (OSB) is used as a base plate, and the entire surface thereof is made of a UV curable resin. A coating layer, an undercoat layer, an intermediate coat layer, and an overcoat layer are sequentially laminated and integrated.

  According to a second aspect of the present invention, a colored layer made of a color clear paint is interposed between the adjoining coating layer and the undercoat layer.

  Further, the present invention is characterized in that a moisture proof layer made of a UV curable resin is coated on the entire back surface of the base plate.

  On the other hand, in claim 4, as a method for producing a flooring material, a UV curable resin is used as a sealing coating layer on the entire surface of a base plate made of an oriented strand board (OSB) having a thickness of about 12 to 18 mm. Coating and curing to a thickness of ~ 90 μm;

  A step of applying and curing a UV curable resin as first and second undercoat layers sequentially on the entire surface of the sealing coating layer to a total thickness of about 50 to 70 μm;

  Coating the entire surface of the second undercoat layer with UV curable resin as an intermediate coat layer to a thickness of about 15 to 25 μm and curing;

  After the surface of the intermediate coating layer is polished, the entire surface thereof is coated with an epoxy UV curable resin as an overcoat layer to a thickness of about 10 to 15 μm and cured.

  In claim 5, after applying and curing the sealing coating layer, before coating the first undercoating layer, a color clear paint is used as a colored layer on the entire surface of the sealing coating layer to a thickness of about 20 to 45 μm. It is characterized by being painted and cured.

  According to the sixth aspect of the present invention, the UV curable resin is used as a moisture-proof layer on the entire back surface of the base plate in the first step before coating the sealing coating layer or in the final step after coating and curing the top coating layer. It is characterized by being coated and cured to a thickness of ˜90 μm.

  According to the structure of claim 1, a low-grade timber oriented strand board (OSB) having unique irregularities on the surface is used as a base plate, and a walking-safe surface wearing barefoot or stockings. As a flooring that exhibits not only smoothness but also water resistance, contamination resistance, weather resistance, scratch resistance, impact resistance, etc. on the surface, it has the same commercial value as a wooden flooring made of conventional plywood plywood There is an effect that can be provided.

  If the structure of claim 2 is adopted, various colored colors can be selected for the wood chip pattern by the colored layer made of the color clear paint while allowing the pulverized wood chip pattern peculiar to the oriented strand board (OSB) to pass through. As a result, the interest and design of the flooring can be further improved.

  Furthermore, if the structure of Claim 3 is employ | adopted, since the whole back surface of the baseplate which consists of the oriented strand board (OSB) is coat | covered with the moisture-proof layer, even in the place exposed to the water and high humidity from under the floor Can be used without restrictions, and versatility is lost.

  On the other hand, according to the manufacturing method of Claim 4, the flooring material of the base plate which consists of an oriented strand board (OSB) is utilized as it is, using the manufacturing equipment currently used for the wooden flooring which consists of a conventional baseboard plywood. In addition, there is an effect that mass production is possible at a low cost.

  This can be achieved in the same manner even when the configurations of claims 5 and 6 are adopted, and the effect of being able to give added value as a flooring material by painting the colored layer or moisture-proof layer. There is.

  Hereinafter, the present invention will be described in detail with reference to the drawings. FIGS. 1 and 2 show a basic embodiment of the flooring according to the present invention, and (10) is composed of an oriented strand board (OSB). A base plate (substrate) having a constant thickness of about 12 mm, about 15 mm, or about 18 mm, which is substantially the same as a conventional base plate made of lauan plywood or other high-grade timber with high dimensional stability. Various processes necessary for flooring such as actual processing, chamfering, and surface polishing of the joining end faces are preliminarily applied. (11) (12) is a pair of male and female fruit.

  The entire surface of the base plate (10) that has been subjected to surface polishing processing has a constant coating layer (13) made of a UV curable resin of about 70 to 90 μm in order to eliminate the at random unevenness that still exists. It is in a state where it is laminated and integrated to a thickness to maintain smoothness. (14) is an undercoat layer laminated and integrated on the entire smooth surface of the sealing coating layer (13), which is also made of a UV curable resin and has a constant thickness of about 50 to 70 μm.

  In this case, the undercoat layer (14) is a relatively thick first undercoat of UV curable resin having the same amount of extender pigment as the previous coating layer (13), as is apparent from the manufacturing process of the flooring material to be described later. The layer (14a) and the relatively thin-walled second undercoat layer (14b) of the UV curable resin having a lower amount of extender pigment are divided into two portions, and the first, second, and second coating layers are sequentially coated and cured. The total thickness of the undercoat layers (14a) and (14b) is set to about 50 to 70 μm.

  For this reason, the first undercoat layer (14a) of the undercoat layer (14) and the above-mentioned sealing coating layer (13) are organically closely integrated and cannot be obtained by the conventional putty repair. It is possible to achieve a perfect sealing effect on the unevenness and the protective strength of the surface that cannot be obtained by the conventional painting such as oil stain, wax, oil varnish.

  (15) is an intermediate coat layer that is continuously laminated and integrated over the entire surface of the second undercoat layer (14b), particularly the undercoat layer (14), and is the same extender as the second undercoat layer (14b) It consists of a UV curable resin with a small amount and has a constant thickness of about 15 to 25 μm.

  Further, (16) is an overcoat layer that is further laminated and integrated on the entire polished surface of the intermediate coating layer (15), and has a constant thickness of about 10 to 15 μm. The surface of the flooring is protected and strengthened by painting and curing from UV curable resin.

  Further, an oriented strand board (OSB) as shown in FIG. 2 is used as a base plate (10), and the entire surface thereof is made of a UV coating resin (13), an undercoat layer (14), and an intermediate coat layer. (15) According to the construction of the flooring in which the overcoat layer (16) is sequentially laminated and integrated, while using an inexpensive oriented strand board (OSB) of low-grade wood having irregularities on the surface, Not only the smoothness of the entire surface, which is safe for walking with barefoot and stockings, but also the water resistance, contamination resistance, weather resistance, abrasion resistance, scratch resistance, dent resistance, impact resistance, etc. of the entire surface Various performances can be satisfied, and even if it is not colored (clear coating), there is an effect that it can be seen through utilizing the pulverized wood chip pattern peculiar to the surface of the oriented strand board (OSB). Since the UV curable resin is a solvent-free paint that does not need to be diluted with an organic solvent, there is no possibility of causing symptoms such as sick house syndrome and chemical sensitivity.

  Next, FIG. 3 shows a first modified embodiment of the present invention corresponding to FIG. 2, and as will be apparent, after the coating layer (13) is applied and cured, an undercoat layer is formed. Before the first undercoat layer (14a) of (14) is applied, various color clear paints are applied to the entire surface of the sealing coat layer (13) and dried to obtain a constant thickness of the color clear paint. A colored layer (17) (about 20 to 45 μm) may be interposed between the first undercoat layer (14a) and the sealing coating layer (13) adjacent to each other.

  Then, while the natural crushed wood chip pattern of the oriented strand board (OSB) is permeated, it is possible to give it an artificial favorite coloring color. However, the compatibility with the place of use will be greatly expanded.

  Further, FIG. 4 shows a second modified embodiment of the present invention that also corresponds to FIG. 2, and in either the basic embodiment or the first modified embodiment, the oriented strand board (OSB) The entire back surface of the base plate (10) can be covered with a moisture-proof layer (18) having a constant thickness (about 70 to 90 μm), which is also made of UV curable resin.

  Such a moisture-proof layer (18) may be applied and cured in the first step before coating the sealing coating layer (13), or the final step after the top coating layer (16) is applied and cured. In this case, it can be painted and cured.

  In any case, if such a configuration of the second modified embodiment is adopted, there is no possibility that the oriented strand board (OSB) of the base plate (10) absorbs and swells, and the high humidity from the ground. Flooring that can be used without hindrance even in places exposed to water or water, has the effect of not being restricted by the place of use, and is highly versatile.

  Since the other configurations in the first and second modified embodiments are substantially the same as those in the previous basic embodiment, only the corresponding reference numerals to those in FIGS. Detailed description is omitted.

  The flooring material of the present invention is a conventional wood material in which a wood veneer veneer (attached board) is pasted on the entire surface of the baseboard plywood in any of the basic embodiment and the first and second modified embodiments. The same manufacturing equipment as the flooring (not shown) can be used as it is, and mass production can be efficiently performed under the necessary steps shorter than the conventional wooden flooring.

  In this regard, FIGS. 5 (a) and 5 (b) are general flowcharts showing the conventional wooden floor material manufacturing process and the floor material manufacturing process according to the basic embodiment of the present invention, in comparison with the conventional flowchart. As shown in FIG. 6 in which only the previous process (F) is extracted and shown as a previous process (F) until floor processing such as actual machining and V-grooving is performed, 1) Applying the first adhesive layer (2) to the Japanese paper (3), applying the second adhesive layer (4), applying the wood veneer veneer (5), hot pressure It was necessary to perform a series of actions leading to the press (6). FIG. 7 is a cross-sectional view of a semi-finished product that has undergone only such a previous step (F).

  In contrast, the flooring material of the present invention employs the oriented strand board (OSB) as the base plate (10) as described above, and can be seen through utilizing the unique crushed wood chip pattern on the surface. The series of the previous steps (F) in the conventional wooden flooring is no longer necessary, and instead of this, in the subsequent step (R) after performing the flooring processing such as the actual processing or chamfering processing, By applying and curing a UV curable resin on the entire surface of the plate (10), it is sufficient to form a constant thickness of the sealing coating layer (13). As is apparent from FIGS. The number of series of processes from undercoating to completion does not increase from the number of conventional processes. FIG. 8 shows a semi-finished product of the present invention corresponding to FIG.

  That is, a method for manufacturing a flooring according to the basic embodiment of the present invention will be described. An oriented strand board (OSB) having a thickness of about 12 mm, about 15 mm or about 18 mm is selected as a base plate (10) for the flooring. Then, the surface is polished in advance.

  Then, as is clear from the details of the post-process (R) extracted in FIG. 9, the UV curable resin heated to a constant temperature on the entire surface of the base plate (10) is converted into a rubber roll coater ( 19) and a metal roll coater (20), and then cured by UV irradiation from a UV irradiation device (mercury lamp) (21) to obtain a constant thickness of about 70 to 90 μm (13) Is formed.

  In that case, as the UV curable resin which becomes the sealing coating layer (13), that whose extender pigment content is increased to about 50 to 60% is used. If the body pigment content of the UV curable resin is less than about 50%, it is difficult to surely eliminate the unevenness present on the surface of the base plate (10), and if it exceeds about 60%, the viscosity becomes high. This is because the suitability for coating deteriorates. Such extender pigments can be appropriately set by adjusting the composition of the oligomer and monomer constituting the UV curable resin and the blending ratio thereof.

  Moreover, the above-mentioned rubber roll coater (19) is used as a reverse roll coater, and the metal roll coater (20) that feeds the base plate (10) is rotated in the reverse direction, thereby increasing the amount of the above-mentioned extender pigment. The cured resin is elastically pressed against the surface of the base plate (10) to give up the effect of sealing the unevenness, and on the smooth surface coating layer (13) having a constant thickness of about 70 to 90 μm. Finish.

  Thereafter, the step of coating and curing the undercoat layer (14) over the entire surface of the sealing coating layer (13) can be confirmed with that in the conventional wooden flooring (FIG. 5 (A)). However, as the UV curable resin therefor, in the present invention, a UV curable resin having an extender content of about 50 to 60% which is the same as that of the sealing coating layer (13) is employed. First, the first undercoat layer (14a) for the first time is applied, and also by UV irradiation, the first undercoat layer (14a) is closely adhered and integrated with the previous sealing coat layer (13), They are kept at a high strength that never causes delamination.

  Then, the entire surface of the first undercoat layer (14a) is coated with about 10 to 25% of a UV curable resin having a relatively small amount of extender pigment as the second undercoat layer (14b) for the second time, and UV. By irradiating, the first and second undercoat layers (14a) and (14b) are finished into an undercoat layer (14) having a total thickness of about 50 to 70 μm.

  In addition, the total thickness of the undercoat layer (14) is the same as that of the above-mentioned sealing coating layer (13) in the flooring of the present invention, compared to the conventional thickness of about 15 to 35 μm in the conventional wooden flooring. Only a certain thickness of the first undercoat layer (14a) made of UV-curing resin (40 μm in the examples described later) is set to be thicker than the overall thickness of the undercoat layer in the conventional wooden flooring, thereby The sealing effect of the base plate (10) is improved, and complete smoothness of the surface can be obtained.

  The entire surface of the second undercoat layer (14b) in such an undercoat layer (14) is subsequently coated with a UV curable resin having about 10 to 20% of the same amount of extender pigment as the second undercoat layer (14b). The intermediate coating layer (15) having a constant thickness of about 15 to 25 μm is finished by UV irradiation.

  Then, after polishing the surface of the intermediate coating layer (15), the intermediate coating layer is finally coated with less UV curable resin having an extender pigment content of about 5 to 10%, particularly preferably an epoxy UV curable resin. The entire surface of (15) is applied and cured by UV irradiation to form an overcoat layer (16) having a constant thickness of about 10 to 15 μm. If it does so, the flooring material excellent in surface protection strength can be obtained. The finished flooring product according to the present invention is as shown in FIGS.

  When the floor material of the first modified embodiment shown in FIG. 3 is manufactured, various color clear paints are applied to the entire surface after forming the sealing coating layer (13) of the base plate (10). By drying, a colored layer (17) having a constant thickness (about 20 to 45 μm) is formed. After that, it goes without saying that a series of steps from the first undercoat layer (14a) to the overcoat layer (16) may be performed.

  In the case of manufacturing the flooring according to the second modified embodiment of FIG. 4, in the first step before coating the sealing coating layer (13) on the entire surface of the base plate (10), or the top coating layer. In the final step after coating and curing (16), a UV curable resin having the same amount of extender pigment as the previous sealing coating layer (13) is applied to the entire back surface of the base plate (10) exposed. A moisture-proof layer (18) having a certain thickness (about 70 to 90 μm) necessary for moisture prevention may be formed by coating and UV irradiation.

〔Example〕
Further, the embodiment of the present invention will be specifically described. In the floor material manufacturing method, an oriented strand board (OSB) having a thickness of about 12 mm is used as a base plate (10), and this is actually processed. After chamfering, surface polishing was performed using a sanding paper of particle size # 240, and coating was performed in the following order.

1. Formation of Sealing Coating Layer (13) First, as a UV curable resin coating for sealing to eliminate the unevenness of the base plate (10), a trade name “Polymedic SKS-OSB-001” manufactured by Dainippon Ink and Chemicals, Inc. ”(100% by weight) and the same product name“ Polymedic SKS-098S ”(10% by weight) are heated to 40 ° C. and sequentially passed through a sponge roll coater and a rubber reverse roll coater. After coating by 80 g / m ² (80 μm thickness), UV irradiation was performed.

2. Formation of first undercoat layer (14a) As a UV curable resin coating for sealing, the above-mentioned product name “Polymedic SKS-OSB-001” manufactured by Dainippon Ink & Chemicals, Inc. is heated to 40 ° C. After coating only 40 g / m ² (40 μm thickness) with a sponge roll coater and a rubber reverse roll coater, UV irradiation was performed.

3. Formation of second undercoat layer (14b) Next, as a UV curable resin paint for undercoat, trade name “Polymedic SKS-025” (100% by weight) manufactured by Dainippon Ink Chemical Co., Ltd. and Kylite abrasive stock A mixture of company-made white fused alumina, abrasive, and trade name “WA # 500” (30% by weight) is also heated to 40 ° C., and is coated only by 24 g / m ² (24 μm thickness) with a natural roll coater. Then, UV irradiation was performed.

4). Formation of intermediate coating layer (15) As a UV curable resin coating for intermediate coating, the same product name “Polymedic SKS-025” manufactured by Dainippon Ink & Chemicals, Inc. is heated to 40 ° C., and again by a natural roll coater. After coating only 16 g / m ² (16 μm thickness), UV irradiation was performed.

5. Surface Polishing The entire surface of the intermediate coating layer (15) was then polished with a sanding paper having a particle size of # 320.

6). Formation of Topcoat Layer (16) Finally, as an epoxy-based UV curable resin paint for topcoat, the product name “Polymedic SK-208-matte” (100% by weight) manufactured by Dainippon Ink & Chemicals, Inc. After heating a mixture with the trade name “Polymedic SK-208-Woen Gloss” (30% by weight) to 40 ° C. and applying only 11 g / m ² (11 μm thickness) with two natural roll coaters, UV Irradiated.

  The floor material of the present invention thus produced was evaluated for its surface smoothness, water resistance, stain resistance, weather resistance, impact resistance, wear resistance and scratch resistance. The results of comparison with the unpainted base plate (OSB) (10) itself are as shown in Table 1.

  As is apparent from the comparison results in Table 1, the flooring material of the present invention employs an oriented strand board (OSB) made of low-grade wood with unique irregularities on the surface as the base plate (10), but barefoot and stockings. In addition to smoothness that is safe for walking on the surface, water resistance, contamination resistance, weather resistance, impact resistance, wear resistance and scratch resistance of the surface necessary and sufficient for flooring were also obtained.

  As a result, as with conventional Lauan plywood and other high-grade timber flooring, even if the surface is exposed to cleaning water or beverages, it can be used without any problems, and durability and mass productivity There is an effect that can be widely spread as a rich flooring.

It is a slope view which shows the flooring of this invention. FIG. 2 is an enlarged cross-sectional view taken along line 2-2 of FIG. 1 and shows a basic embodiment of the present invention. It is sectional drawing which shows the 1st modification embodiment of this invention corresponding to FIG. It is sectional drawing which shows the 2nd modified embodiment of this invention corresponding to FIG. 2 similarly. It is a flowchart which compares and shows the manufacturing process of the conventional wood flooring and the flooring which concerns on this invention. It is detail drawing which extracts and shows the front process (F) of FIG. It is sectional drawing which shows the conventional wooden flooring as a semi-finished product. It is sectional drawing which shows the flooring of this invention as a semi-finished product corresponding to FIG. FIG. 6 is a detailed view showing a post-process (R) extracted from FIG.

Explanation of symbols

(10)-Base plate (11)-Male (12)-Female (13)-Seal coating layer (14)-Undercoat layer (14a)-First undercoat layer (14b)-Second undercoat layer (15 ) ・ Intercoat layer (16) ・ Top coat layer (17) ・ Colored layer (18) ・ Dampproof layer (19) ・ Rubber reverse roll coater (20) ・ Metal roll coater (21) ・ Mercury lamp (F) ・Pre-process (R) / Post-process

Claims (6)

  An oriented strand board (OSB) is used as a base plate (10), and the entire surface of the base coat layer (13), the undercoat layer (14), the intermediate coat layer (15), and the top coat layer (16) each made of a UV curable resin. ) Are laminated and integrated sequentially.   2. The flooring material according to claim 1, wherein a colored layer (17) made of a color clear paint is interposed between the adjoining layers of the sealing coating layer (13) and the undercoat layer (14).   The flooring according to claim 1 or 2, wherein a moisture-proof layer (18) made of a UV curable resin is applied to the entire back surface of the base plate (10). The entire surface of the base plate (10) made of an oriented strand board (OSB) having a thickness of about 12 to 18 mm is coated with a UV curable resin as a sealing coating layer (13) to a thickness of about 70 to 90 μm. Curing, and
A step of applying and curing a UV curable resin as a first and a second undercoat layer (14a) (14b) to the entire surface of the sealing coating layer (13) to a total thickness of about 50 to 70 μm;
Coating the entire surface of the second undercoat layer (14b) with a UV curable resin as an intermediate coat layer (15) to a thickness of about 15 to 25 μm and curing;
And a step of coating the entire surface of the intermediate coating layer (15) with an epoxy-based UV curable resin as a top coating layer (16) and curing it to a thickness of about 10 to 15 μm. Method of manufacturing the material.   After coating and curing the sealing coating layer (13), before applying the first undercoating layer (14a), a colored clear coating is applied to the entire surface of the sealing coating layer (13) as a colored layer (17). 5. The method for producing a flooring material according to claim 4, wherein the floor material is coated and cured to a thickness of about 20 to 45 μm.   In the first step before applying the sealing coating layer (13), or in the final step after applying and curing the top coating layer (16), a UV curable resin is applied to the entire back surface of the base plate (10). The method for producing a flooring material according to claim 4, wherein 18) is coated and cured to a thickness of about 70 to 90 µm.

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