JP2010065426A - Method of manufacturing floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a floor material having excellent waterproof and damp proof performance and restraining expansion, using a reusable particle board. <P>SOLUTION: According to this method of manufacturing the floor material, a facing sheet is stuck to the surface of a base plate formed of a particle board, a back-lining sheet having waterproof performance is stuck to the back thereof, subsequently an ionizing radiation curable resin with a viscosity of 2,500-50,000 mPa s is applied to the whole surface of a butt end of the base plate, and after that, the ionizing radiation is applied to the butt end to thereby forming a cured coat of the ionizing radiation curable resin. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a method for producing a flooring material, and more specifically, a flooring material using a base plate made of particle board, a decorative sheet on the base plate surface, and a waterproof backing sheet on the back surface. And it is related with the manufacturing method of the flooring in which the cured film formed by apply | coating an ionizing radiation curable resin to the mouthpiece of a baseplate and hardening | curing was formed.

Conventionally, plywood such as lauan plywood has been widely used as a base plate for flooring, but it is becoming difficult to obtain raw wood due to lack of wood resources, and it is difficult to use lauan plywood etc. for flooring Yes.
Particleboard, on the other hand, is a sheet material obtained by applying adhesives such as urea resin or melamine resin to a small piece of wood chip and hot-pressing it. Unused / waste wood including small diameter trees such as thinned wood and construction waste Since it can be used as a raw material, it is not only environmentally friendly, but also has an advantage that it can be obtained more stably than plywood. For this reason, recently, flooring using a base plate made of particle board has been manufactured and sold. However, particle board has the disadvantage that it is inferior in water resistance, and when particle board is used as a base plate for flooring, for example, even if waterproofing treatment is applied to the front and back surfaces, it absorbs water from the mouth and absorbs moisture. There is a problem that a duck occurs. In order to solve such problems, Patent Document 1 describes that a particle board having excellent water resistance can be provided by covering the particle board with a UV / EB curable water-resistant coating material so that the surface is not slippery. ing. However, with a viscosity of about 20 mPa · s to 1000 mPa · s actually used in Patent Document 1, the resin penetrates into the gaps between the wood chips, a sufficient film cannot be formed, water resistance is insufficient, and moisture from the mouth In addition, there was a problem that the amount of penetration of moisture was higher than expected.
Further, Patent Document 2 describes that at least a lip of a particle board is impregnated with a synthetic resin and cured to integrally form a synthetic resin layer on the lip to prevent moisture and moisture from entering. However, the method of Patent Document 2 is a method in which a synthetic resin layer is used instead of the band-shaped decorative material that has been pasted on the end of the mouth, and a mold is required because it is necessary to mold the thickness to about 4 mm. There was a problem.

JP 2003-313501 A JP-A-56-24104

The present invention has been made in view of the above problems, and its purpose is to change the dimensions greatly due to water absorption or moisture absorption, which becomes a problem when a particle board with poor water resistance is used as a base plate for flooring. It is another object of the present invention to provide a method for manufacturing a floor material that can prevent problems such as swelling and stagnation without involving a complicated method.

Therefore, even when the particle board is used as a base plate, the inventors apply an ionizing radiation curable resin having a specific viscosity to the mouth of the base plate and then cure it to form a cured coating made of an ionizing radiation curable resin. It has been found that the formation of a floor material in which dimensional change, swelling, and generation of duck due to water absorption and moisture absorption can be prevented can be provided, and the invention has been completed.
That is, the present invention attaches a decorative sheet to the surface of a base plate made of particle board and a waterproof backing sheet on the back surface, and then applies ionizing radiation curable resin having a viscosity of 2500 mPa · s to 50000 mPa · s to the table. The gist of the present invention is a method for producing a flooring material, which is characterized by forming a cured film made of an ionizing radiation curable resin on a mouth by irradiating with ionizing radiation after coating over the entire face of the wood. In addition, the gist of the method for producing a flooring material is characterized in that the base plate is subjected to sane processing. Furthermore, the gist of the method for producing a flooring material is characterized in that the coating amount of the ionizing radiation curable resin is 50 to 500 g / m ² . Further, the gist of the method for producing a flooring material is characterized in that the ionizing radiation curable resin is an acrylic ultraviolet curable resin. Furthermore, the gist is a method for producing a flooring material in which the acrylate resin is made of epoxy (meth) acrylate or urethane (meth) acrylate.

In the present invention, the particle board is used as a base plate by forming a cured film made of an ionizing radiation curable resin having a viscosity in a specific range for waterproofing the mouth of the base plate of the particle board. Therefore, it has become possible to provide a flooring having sufficient water resistance.
That is, by applying an ionizing radiation curable resin having a specific viscosity, (1) there is no problem that a film having a sufficient thickness cannot be formed by being sucked into the mouth before the ionizing radiation curable resin is cured. Even after processing into a complicated shape such as sane processing, it became possible to apply without causing defects in the coating film or large thickness spots. In addition, since an ionizing radiation curable resin is used, it can be cured immediately after application, so that it has an effect of preventing thickness unevenness due to flow and dripping after application.
Furthermore, in the present invention, since a cured film of ionizing radiation curable resin is formed only on the mouth end surface, not only the amount of the resin used is reduced, but also a decorative sheet and a backing sheet adhered to the front and back surfaces of the base plate. There is no fear of soiling the surface. In addition, there is an advantage that there is no adhesion failure due to the presence of a cured coating when a decorative sheet or the like is pasted after dip coating.

Hereinafter, the flooring obtained by the production method of the present invention will be described with reference to FIG. 1 is a flooring, 2 is a base plate made of particle board, and 2a and 2b are male and female sane formed on the mouth of the base plate 2. A cured film 3 made of an ionizing radiation curable resin is formed on the entire end of the base plate 2. Further, a decorative sheet 4 is attached to the front surface of the base plate 2 and a waterproof backing sheet 5 is attached to the back surface thereof with an adhesive (not shown).

In the present invention, a particle board is used as the base plate 2 for the flooring. The particle board is preferably not particularly limited to density using particle board of ^{0.6g / cm 3 ~0.9g / cm 3} . When the density of the particle board 2 is less than 0.6 g / cm ³ , in addition to insufficient strength of the particle board, the gap of the lip becomes large, so that when ionizing radiation curable resin described later is applied to the lip, This is not preferable because the resin penetrates and it is difficult to form the cured film 3 made of an ionizing radiation curable resin. Further, if the density of the particle board exceeds 0.9 g / cm ³ , the obtained flooring 1 becomes heavy and workability is lowered, which is not preferable.

In the present invention, the decorative sheet 4 is a surface material of the flooring 1, and is attached to the surface of the base plate 2 so that the flooring 1 has an aesthetic appearance, design, durability, scratch resistance, and water resistance. And the like. For example, printed single-layer or multilayer synthetic resin sheets made of polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, etc., decorative paper coated with various waterproof paints, or a combination of these Although it is mentioned, what consists of a synthetic resin sheet is preferable since the object of the present invention is to impart water resistance. Moreover, although the thickness of the decorative sheet 4 is not specifically limited, It is preferable to set it as 10 micrometers-200 micrometers. If the thickness of the decorative sheet 4 is less than 10 μm, it is not preferable because it is easy to tear when pasted and the workability is poor, and if it exceeds 200 μm, the cost increases.

In the present invention, the backing sheet 5 having waterproof properties is not particularly limited as long as it has waterproof properties, and is an olefin thermoplastic resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, or polyvinyl chloride. Can be used by appropriately selecting a sheet formed from a sheet, or a laminate of them with paper, nonwoven fabric, or the like. In particular, in consideration of waterproofness and adhesiveness to the base plate 2, it is preferable to use a laminate having a three-layer structure of paper / polyethylene / paper in which paper is laminated on both sides. Moreover, the thickness of the backing sheet 5 having waterproof properties is not particularly limited, but is preferably 10 to 100 μm. If the thickness is less than 10 μm, it is not preferable because it is easily broken at the time of sticking and the workability is poor, and if it exceeds 100 μm, the cost increases.

Now, in the present invention, in order to form the cured coating 3 on the mouth end of the base plate 2, the most characteristic feature is that an ionizing radiation curable resin having a viscosity of 2500 mPa · s to 50000 mPa · s is used. The ionizing radiation curable resin is crosslinked by irradiating visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), electron beam, ion beam, etc., as described in JP-A-2006-97321, for example. A resin that undergoes a polymerization reaction and changes to a three-dimensional polymer structure. For example, a monomer having a radically polymerizable unsaturated group such as (meth) acryloyl group or (meth) acryloyloxy group in the molecule, The polymer is mainly composed of a single polymer or a mixture of a plurality of types, but additionally contains a polymer, an extender pigment, a photopolymerization initiator and the like as appropriate.
Here, examples of the prepolymer having a radically polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, and triazine (meth) acrylate. This prepolymer usually has a molecular weight of about 1000 to 10,000. If the molecular weight exceeds 10,000, the viscosity becomes too high, which is not preferable. In addition, monomers having radically polymerizable unsaturated groups include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, methoxyethyl (meth) acrylate, methoxybutyl (meth) acrylate, butoxy Ethyl (meth) acrylate, 2 ethylhexyl (meth) acrylate, N, N-dimethylaminomethyl (meth) acrylate, N, N-dimethylaminoethyl (meth) acrylate, N, N-diethylaminoethyl (meth) acrylate, N, N-diethylaminopropyl (meth) acrylate, N, N-dibenzylaminoethyl (meth) acrylate, lauryl (meth) acrylate, isobornyl (meth) acrylate, ethyl carbitol (meth) acrylate, phenoxyethyl (meth) acrylate , Phenoxypolyethylene glycol (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, methoxypropylene glycol (meth) acrylate, 2- (meth) acryloyloxyethyl-2-hydroxypropyl phthalate, 2- (meth) acryloyloxypropyl Examples thereof include hydrogen terephthalate. In addition, as a polyfunctional monomer having a radical polymerizable unsaturated group, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, di Propylene glycol (meth) acrylate, neopentyl glycol di (meth) acrylate, 1,6 hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, tripropylene Glycol di (meth) acrylate, bisphenol-A-di (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate Pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, glycerin polyethylene oxide tri (meth) acrylate, tris (meth) acryloyloxyethyl A phosphate etc. are mentioned.

The above prepolymers and monomers having radically polymerizable unsaturated groups are sufficiently cured when irradiated with ionizing radiation, but when cured by irradiation with ultraviolet rays, a photopolymerization initiator is added as a sensitizer. To do. As photopolymerization initiators, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoylbenzoate, Michler ketone, diphenyl sulfide, dibenzyl disulfide, diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate or the like can be used alone or in combination.

The ionizing radiation curable resin used in the present invention has the above-mentioned prepolymer having a radical polymerizable unsaturated group, a monomer as a main component, and a compound containing a normal photopolymerization initiator as a basic component. However, in order to set the viscosity of the ionizing radiation curable resin to 2500 to 50000 mPa · s, it is preferable to add an extender shown below. If the ionizing radiation curable resin has a viscosity of less than 2500 mPa · s, the ionizing radiation curable resin is sucked into the base of the base plate 2 so that the cured coating 3 having a sufficient thickness cannot be formed. When it is applied to the surface, problems such as unevenness occur in the film thickness of the cured film 3 formed by dripping. On the other hand, if the viscosity exceeds 50000 mPa · s, not only the handleability at the time of application is deteriorated, but also the cured film 3 becomes too thick and it is difficult to fit the sane portion, which is not preferable.
Although it does not specifically limit as a kind of extender pigment, For example, a talc, a lomontite, a montmorillonite, an attapulgite, or these combination etc. can be illustrated. Of these, talc is particularly preferable.

Next, the manufacturing method of the flooring 1 of this invention is demonstrated, referring FIG. 2, FIG.
First, a particle board having a predetermined size is prepared as the base plate 2. A decorative sheet 4 is attached to the surface of the base plate 2 using an adhesive (not shown).
Next, a waterproof backing sheet 5 is attached to the back surface of the base plate 2 using an adhesive (not shown). Examples of the adhesive used to attach the decorative sheet 4 or the waterproof backing sheet 5 include adhesives such as vinyl acetate resin, ethylene / vinyl acetate resin, urea resin, and urethane resin. Is mentioned.
Next, on the front end of the base plate 2 with the decorative sheet 4 and the waterproof backing sheet 5 attached to the front and back surfaces, male sash 2a and female sash 2b are formed by machining, for example.

The floor material using a conventional plywood or the like as a base plate is completely manufactured at this point, but the floor material 1 of the present invention is particularly characterized by the subsequent manufacturing method.
That is, in the present invention, the above-mentioned ionizing radiation curable resin is applied over the entire end of the base plate 2. Although there is no restriction | limiting in particular as an application method, For example, a brush coating or the spray system by a machine, a die head system, the application system by a sponge roll etc. can be illustrated. Further, the coating amount of the ionizing radiation curable resin is 50 to 500 g / m ² , particularly 100 to 500 g / m ² , more preferably 160 to 500 g / m ² . If the coating amount is less than 50 g / m ² , it is difficult to form the cured coating 3 having a sufficient thickness to suppress the dimensional change, ducking, and swelling of the base plate 2, and the coating amount is 500 g / m ^2. Exceeding this is not preferable because it causes dripping after application, or the fitting between the two pieces (2a and 2b) becomes poor.

Next, the ionizing radiation curable resin applied by irradiating with ionizing radiation is cured to form a cured coating 3, whereby the flooring 1 of the present invention is manufactured. In the present invention, since an ionizing radiation curable resin is used for the cured coating formed on the end of the mouth, it is cured in an extremely short time by irradiating with ionizing radiation. Therefore, the cured film 3 can be formed immediately after application without taking any time, so that it has the effect of preventing suction into the mouth and dripping.
The film thickness of the cured film 3 formed in this manner is basically determined by the coating amount and suction into the mouth, but it is preferable that the average film thickness is 50 to 300 μm. If the film thickness of the cured coating 3 is less than 50 μm, it is not preferable because sufficient moisture resistance and waterproofness cannot be imparted. On the contrary, if the average film thickness of the cured coating 3 exceeds 300 μm, it may be difficult to fit the flooring materials 2 together in the sunk portion. As ionizing radiation, ultraviolet rays or electron beams are usually used. As the ultraviolet light source, for example, a light source such as an ultrahigh pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, or a metal halide lamp can be used. As a wavelength of ultraviolet rays, a wavelength range of 1900 to 3800 mm is usually used. As an electron beam source, 100 to 1000 KeV using various electron beam accelerators such as a cockroft Walton type, a bandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type lamp. Those that irradiate with electrons having the following energy can be used.

EXAMPLES The present invention will be specifically described below based on examples, but the present invention is not limited to the following examples.

The following materials were used in the examples and comparative examples of the present invention.
<Particle board>
The thickness made by Okura Kogyo Co., Ltd. was 12 mm, the density was 0.75 g / cm ³ , and the P18 type (JIS A5908) was used.
<Coating sheet>
A decorative sheet for flooring having a thickness of 160 μm in which a polypropylene film was laminated on the printed surface of a printed polypropylene film was used.
<Waterproof backing sheet>
A waterproof sheet having a three-layer structure of paper / polyethylene film (thickness: 20 μm) / paper and having a total thickness of 75 μm was used.

As the ionizing radiation curable resin composition, the following commercially available ultraviolet curable paints were used.
<Ionizing radiation curable resin>
(1) Resin A: Epoxy acrylate UV curable paint (viscosity: 710 mPa · s, manufactured by DIC Corporation, trade name: S816KC1)
(2) Resin B: Epoxy acrylate UV curable paint (viscosity: 2650 mPa · s, manufactured by DIC Corporation, trade name: SKS-M061)
(3) Resin C: Epoxy acrylate UV curable paint (viscosity: 4600 mPa · s, extender pigment: 40 wt% (talc), manufactured by DIC Corporation, trade name: SK-S-08-5)
(4) Resin D: Epoxy acrylate UV curable paint (viscosity: 11800 mPa · s, manufactured by Nitta Gelatin Co., Ltd., trade name: AUV-8300X12)
(5) Resin E: Urethane acrylate UV curable paint (viscosity: 45500 mPa · s, manufactured by Nitta Gelatin Co., Ltd., trade name: AUV-8300)
(6) Resin F: Urethane acrylate UV curable paint (viscosity: 80000 mPa · s, manufactured by Sunrise MSI Co., Ltd., trade name: F-2)
The viscosity of the ionizing radiation curable resin was measured at 23 ° C. using a B-type viscometer.

  In this example, a decorative sheet is applied to the surface of a particle board having dimensions of 945 mm × 1840 mm × 12 mm, and a waterproof backing sheet is applied to the back surface using an ethylene-vinyl acetate adhesive at an application amount of 87 g / m 2. Each was affixed. Next, by machining, a 145 mm × 145 mm × 12 mm sap having a sap as shown in FIG. 2 (male sap: length 5.5 mm, thickness 4.0 mm, female sap: length 6.5 mm, thickness 4.0 mm) Dimensions were used for each subsequent test. (In FIG. 2, W corresponds to a length of 145 mm in the width direction of the test piece.) For the purpose of reference, the test was carried out with a size of 100 mm × 100 mm × 12 mm without any sash.

The performance of the flooring material in this example was evaluated by testing by the following method.
(1) Moisture absorption test specimens are allowed to stand for 7 days at 40 ° C. and 90% humidity, and the moisture absorption rate (%), thickness direction (T), length direction (L) and width direction (W ) Expansion rate (%).
(2) The water absorption test specimen is immersed in water at 23 ° C. for 24 hours, and the water absorption (%), thickness direction (T), length direction (L) and width direction (W ) Expansion rate (%).
(3) Application amount of ionizing radiation curable resin The application amount of the ultraviolet curable resin is calculated by subtracting the weight of the test piece before application from the weight of the test piece after application to calculate the application amount (g). It was calculated by dividing by the total area (m2).

[Reference example]
A predetermined amount of the ionizing radiation curable resin shown in Table 1 is applied over the entire surface of the end of the sampleless test piece having a size of 100 mm × 100 mm × 12 mm, and irradiated with ultraviolet rays (irradiation conditions: line speed 10 m / min, integrated light quantity 700 mJ / cm ² ) to form a cured coating. Table 1 also shows the evaluation results of the test pieces of the obtained experiment numbers 1 to 10. Moreover, the same evaluation was performed also about the test piece of the experiment number 11 which stuck only the decorative sheet and the waterproof backing sheet on the front and back for comparison. The results are also shown in Table 1.

As is clear from Table 1, the test pieces of Experiment Nos. 1 to 10 to which ionizing radiation curable resin was applied had no viscosity and the top of the lip was flat regardless of the amount of application and the amount of application. Excellent water resistance was exhibited as compared with the test piece of Experiment No. 11 in which no mold resin was applied.

[Examples 1-5, Comparative Examples 1-3]
A predetermined amount of the ionizing radiation curable resin shown in Table 2 was applied over the entire surface of the tip of a test piece with a size of 145 mm × 145 mm × 12 mm, and irradiated with ultraviolet rays (irradiation conditions: line speed 10 m / min, integrated light quantity 700 mJ / cm ² ) to form a cured coating. The evaluation results of the obtained test pieces are also shown in Table 2. Moreover, the same evaluation was performed also about the test piece which stuck only the decorative sheet and the waterproof backing sheet on the front and back for the comparison. The results are also shown in Table 2.

As is clear from Table 2, the flooring materials of Examples 1 to 5 according to the present invention showed excellent water resistance, whereas the comparative example in which an ionizing radiation curable resin having a viscosity of 710 mPa · s was applied. The flooring material according to No. 1 was less effective in improving water resistance. This is thought to be due to the fact that a hard coating with sufficient thickness cannot be formed due to suction or the like when the floor has a complex shape with a lip and has a lower lip than in the case of Experiment Nos. 1 to 3 where the lip is flat. It is done. Conversely, the flooring material according to Comparative Example 2 coated with an ionizing radiation curable resin having a viscosity of 80000 mPa · s was also less effective in improving water resistance. This is because the viscosity of the ionizing radiation curable resin is too high, and it is difficult to apply a uniform film thickness. ing.

[Reference experiment]
Resin C used in Examples 2 and 3 was used as the ionizing radiation curable resin at the mouth end of the flooring treated with sane processing, applied at a coating amount of 259 g / m ² , and then irradiated with ultraviolet rays. Table 3 shows the results of actual measurement of the film thickness.

The film thickness was cut at intervals of 10 mm as shown in FIG. 4, and the film thickness at each measurement point was measured at 10 points with a microscope, and the average film thickness, maximum film thickness, and minimum film thickness at each position were measured. Asked.
As is apparent from Table 3, when the film has a thickness, the minimum value of the average value at each measurement point was 72 μm and the maximum was 105 μm. Moreover, the minimum film thickness in all the measurement points was 51 micrometers, and the maximum film thickness was 127 micrometers. In particular, the film thickness of the concave part of the female rape tends to be thick, and conversely, the film thickness of the joint processing portion on the surface tends to be thin.

According to the method of the present invention, even when a particle board having poor water resistance is used as a base plate, a floor material having excellent water resistance can be obtained. Therefore, it can be suitably used as a flooring material for general houses, rental houses, condominiums, and the like.

It is a perspective view which shows the flooring of this invention. It is sectional drawing of the flooring of this invention. FIG. 3 is a partially enlarged view of FIG. 2. It is a figure which shows the measurement location of the film thickness of the film which hardened | cured the ionizing-radiation-hardening-type resin formed in the mouthpiece of the flooring material of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Flooring material 2 Base plate 2a Male sap 2b Female sane 3 Cured film 4 Decorative sheet 5 Waterproof backing sheet

Claims (5)

A decorative sheet is attached to the surface of the base plate made of particle board, and a waterproof backing sheet is attached to the back surface, and then an ionizing radiation curable resin having a viscosity of 2500 mPa · s to 50000 mPa · s is applied to the entire top of the base plate. A method for producing a flooring material comprising: forming a cured film made of an ionizing radiation curable resin on a mouth by irradiating with ionizing radiation after coating. 2. The method for manufacturing a flooring according to claim 1, wherein the base plate is subjected to sane processing. Method for producing a flooring material according to claim 1 or 2 coating amount of ionizing radiation-curable resin is characterized by a 50 to 500 g / m ^2. 4. The method for producing a flooring according to claim 1, wherein the ionizing radiation curable resin is an acrylic ultraviolet curable resin. The method for producing a flooring material according to claim 4, wherein the acrylic ultraviolet curable resin comprises epoxy (meth) acrylate or urethane (meth) acrylate.

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