JP2011089362A - Floor panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To fit a decorating body to a panel base surely and neatly in a short time and finish the floor panel to have a beautiful appearance without a damage or deformation, in a floor panel having the decorating body fixed to an upper surface thereof. <P>SOLUTION: The panel base of the floor panel made of a synthetic resin is formed with a laser-beam transmitting resin material. The decorating body fixed to an upper surface of the panel base is formed to have a resin layer, which is formed by compounding a thermoplastic resin material and carbon black, on a lower surface thereof. The decorating body is placed on the upper surface of the panel base, and a laser beam is applied to the overlapping part of the resin layer and the upper surface of the panel base from a lower side of the panel base. The resin layer which is melted is welded to the upper surface of the panel base, so that the decorating body may be fixed. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a synthetic resin floor panel that is laid on an indoor / outdoor base floor slab such as a mortar floor, garden, balcony, or veranda to form a decorative floor surface.

As a synthetic resin floor panel that is laid on an underfloor slab such as a balcony to form a decorative floor surface, the decorative surface is made of an artificial grass mat on the panel surface in order to bring out the appearance and texture of a lawn on the floor. The floor panel which attached is used.
FIG. 6 shows an example, and this floor panel is a panel base made of a synthetic resin formed by supporting a panel surface 101 having a square shape in plan view with a plurality of legs 102 and projecting connecting pieces 103 on the periphery. The artificial turf mat 104 cut to a size to be superposed on the panel surface 101 is placed on the upper surface of the table 100, and the artificial turf mat 104 is attached to the panel surface 101 by using an adhesive or spot welding with an ultrasonic welder. Are integrally fixed to each other.
Then, a plurality of the floor panels are arranged side by side on the floor slab, and floor panels in which adjacent floor panels are arranged side by side by engaging the connecting pieces 103 of one floor panel with the legs 102 of the other floor panel are arranged. By connecting them together, a floor surface of an artificial turf with an appropriate area is configured (see, for example, Patent Documents 1 and 2).

Japanese Utility Model Publication No. 52-7924 Japanese Utility Model Publication No. 62-16102

As described above, in the conventional floor panel, the artificial turf mat 104 is fixed to the panel base 100 in an inseparable manner using an adhesive or an ultrasonic welder as a fixing means.
However, when an adhesive is used as a fixing means, after the artificial turf mat 104 is bonded to the panel surface 101, curing is required until the adhesive is completely cured, and the manufacturing cost is required due to the time and labor required for processing. In addition, when an ultrasonic welder is used, it is difficult to spot-weld only the superposed portion of the artificial turf mat 104 and the panel surface 101. The surface of the artificial turf mat 104 and the panel base 100 are difficult to weld. There is a problem that the exterior surface of the floor panel is easily melted to deteriorate the appearance of the floor panel.

  In view of such problems of the prior art, the present invention enables a decorative body to be attached to a panel base securely and neatly in a short time in a floor panel having a decorative body fixed on the upper surface. The problem is to finish the floor panel with a beautiful appearance without breakage or deformation.

In order to solve the above-described problems, the present invention provides a panel formed by fixing a decorative body to the upper surface of a synthetic resin panel base having a joint portion on a side, and a plurality of such panels on a floor slab. In the floor panel made of synthetic resin that is arranged side by side and integrated and constitutes the decorative floor surface,
The panel base is formed of a transparent resin material that transmits laser light, and the decorative body is formed by providing a resin layer mixed with carbon black on the lower surface thereof, and the decorative body is formed on the upper surface of the panel base. The resin layer is irradiated with laser light from the lower side of the panel base to the overlapping portion of the resin layer and the upper surface of the panel base, and the resin layer that melts with the heat generation of the carbon black due to absorption of the laser light is applied to the panel base. The decorative body is fixed by welding to the upper surface of the table.

In the floor panel having the above-described configuration, the transparent resin material that transmits laser light has thermoplasticity and does not exhibit sufficient absorption with respect to the laser light, that is, has a predetermined transmittance or more with respect to the laser light. The resin is not particularly limited as long as it is a resin that has a transmittance and does not melt when irradiated with a laser beam. For example, polypropylene, polyethylene, polyolefin-based composite materials, and the like can be used. A colorant may be blended.
If the panel base is formed of a resin material having a high transmittance of 95% or more with respect to the laser light, most of the laser light irradiated from the lower side of the panel base passes through the panel base, The energy of the laser beam is used to melt the resin layer on the lower surface of the decorative body and weld it to the panel surface of the panel base.

Moreover, in order to color the panel base in a desired color, the panel base can be formed using a material in which a colorant that transmits laser light is blended with the transparent resin material.
The colorant that transmits the laser beam is not particularly limited as long as it is non-absorbable with respect to the laser beam, that is, has a high laser beam transmittance. For example, perylene-based or perinone-based organic colorants can be used, depending on the absorbent resin material in which the colorant is blended and the color to be colored.

The decorative body is formed in a plate shape or a sheet shape so that the upper surface can be appropriately decorated and can be superimposed on the upper surface of the panel base using a synthetic resin material or the like. The decorative body can be made of any material as long as it can be fixed on the upper surface of the panel base.
The decoration process applied to the upper surface of the decorative body is a process applied to improve the appearance of the surface of the floor panel and the texture of the sole when a person gets on the floor panel. Examples thereof include a pattern, other colored patterns, or uneven arrangement of streaks and grooves, and uneven portions. When the floor surface is configured to have a lawn-like appearance and texture, an artificial turf mat in which turf yarn is planted on a base fabric made of a thermoplastic resin such as polypropylene is used as a decorative body.

  As the resin layer provided on the lower surface of the decorative body, a thermoplastic resin, that is, a resin material that melts with the heat generation of carbo black that has absorbed laser light, such as polypropylene, polyethylene, or a polyolefin-based composite material, is used. The resin layer is formed by blending an appropriate amount of carbon black in the resin material and applying it to the lower surface of the decorative body to an appropriate thickness. In the case of an artificial turf mat joined to the upper surface of the main body panel, the resin layer is formed by applying the resin mixed with carbon black on the back surface of the base fabric or kneading the base fabric.

  Note that laser light such as a YAG laser, a helium neon laser, or a semiconductor laser can be used as the laser light used for fixing the decorative body to the main body panel, and the wavelength of the laser light is preferably 1060 nm or less.

The floor panel of the present invention has a lower surface on a panel base formed of a transparent resin material, or on a panel base formed of a material in which a transparent resin material is mixed with a colorant that transmits laser light. If a decorative body formed by providing a resin layer mixed with carbon black is superposed, and a laser beam is irradiated from the lower side of the panel base toward the overlapping portion, the laser light will be transmitted through the panel base. To the resin layer of the decorative body polymerized on the upper surface of the panel base, carbon black that absorbs laser light generates heat due to the energy of the laser light, and the resin layer around the carbon black is heated accordingly, The decorative body is firmly fixed to the upper surface of the main body panel by melting and simultaneously heating and melting the upper surface of the panel base that is in contact therewith and welding the overlapping portions of both members.
The panel base is formed to transmit laser light, and only the resin layer on the lower surface of the decorative body and the overlapping portion thereof are heated and melted by receiving the laser beam. The surface of the base and the decorative body is not deformed or damaged by receiving the laser beam, and no curing is required when fixing with an adhesive, and the decorative body is attached to the panel base. Can be performed reliably and neatly in a short time. In addition, depending on the adhesive, a decorative body made of polyolefin, polyamide, fluorine resin, or the like that is not easily bonded to the panel base can be securely fixed to the panel base.

It is the top view (A) and bottom view (B) of the floor panel of one Embodiment of this invention. It is a principal part expanded sectional view of the artificial turf mat which is a decoration. It is the side view of the floor panel which showed the state which fixes the artificial turf mat to a main body panel with a laser beam. It is the figure which showed the irradiation position of the laser beam in the case of welding at several points. It is the figure which showed the irradiation position of the laser beam in the case of welding in linear form. It is sectional drawing of the floor panel decorated with the conventional artificial grass mat.

Preferred embodiments of the present invention will be described with reference to the drawings.
As shown in FIG. 1, the floor panel 1 of the present embodiment is configured by integrally attaching an artificial turf mat 3 as a decorative body to the upper surface of a polyethylene panel base 2 that is a permeable resin material. .

The panel base 2 is integrally formed as a square block panel by joining square unit panels 21 arranged in three rows vertically and horizontally and joining adjacent panels with a joint portion 22.
Specifically, each unit panel 21 has a plurality of through holes 23 in the panel surface 21a, a side wall 24 is suspended around the unit panel 21, and a columnar leg having an appropriate height at the bottom of the panel surface 21a. The body 25 is provided in a shape in which a plurality of protrusions are provided with a predetermined interval.
Further, a lower connecting piece that has an engagement slit 26a on the side wall 24 of each unit panel 21 along two adjacent sides sandwiching one corner of the panel base 2 and protrudes outward from the bottom of the side wall. On the other hand, on the side wall 24 of each unit panel 21 along two adjacent sides facing the two sides, an upper connecting piece 27 that is an engaging projection protruding downward from the side wall bottom is provided. These are formed into corresponding shapes that engage with each other by press-fitting the upper connecting piece 27 into the engagement slit 26a of the lower connecting piece 26, and adjacent panel bases when the panel bases 2 are juxtaposed. The panel bases 2 and 2 can be connected together by engaging the lower connecting piece 26 and the upper connecting piece 27 corresponding to each other between the bases 2.

As shown in FIG. 2, the artificial turf mat 3 has turf threads 32 planted on the upper surface of a sheet-like base cloth 31 as a base, and the base of the turf threads 32 protruding from the lower surface of the base cloth 31 and the lower surface. The portion is covered with a back material 33.
Specifically, the base fabric 31 is formed of a plain woven fabric made of a thermoplastic resin such as polypropylene or polyester. The turf yarn 32 is formed by bundling a plurality of fibers made of a thermoplastic resin such as polyethylene or polypropylene, and a root portion bundled at a predetermined interval is sewn to the base fabric 2. The backing material 32 is formed by blending an appropriate amount of carbon black into a resin emulsion made of a thermoplastic resin such as polyethylene or polypropylene, and coats the lower surface of the base fabric 31 and the root portion of the turf yarn 32. In this way, a resin layer is formed by coating with an appropriate thickness, and the turf yarn 32 is fixed to the base fabric 31 by the resin layer.

The artificial turf mat 3 is attached to the panel base 2 as shown in FIG. 3, with the artificial turf mat 3 cut to a size that overlaps the upper surface of the panel base 2 placed on the panel surface 2a. The laser beam is irradiated from the lower side of the panel base 2 toward the overlapping portion of the panel base 2 and the artificial turf mat 3 from the condenser lens of the laser light generator 4.
Then, the irradiated laser light passes through the panel base 2 and reaches the back material 33 of the artificial turf mat 3, and carbon black showing absorbability with respect to the laser light generates heat due to the energy of the laser light. When the resin layer around the black is heated and melted, and the upper surface of the panel base 2 in contact with it is heated and melted at the same time, the overlapping portions of both members are welded, so that the artificial turf mat 3 is It is firmly fixed to.

  In addition, welding by laser light irradiation may be performed by providing welding points 41 by laser light in a plurality of points at every unit panel 21 of the panel base 2 as shown in FIG. As shown in FIG. 5, the laser beam 41 may be continuously irradiated over the entire panel base 2 to provide a linear shape. In order to firmly fix the artificial turf mat 3 on the panel base 2, it is preferable to secure a large welding area.

  In addition, the form shown in figure is an example and the structure of the floor panel 1 of this invention is not limited to this. Although the panel base 2 is formed in a square shape in plan view, it may be formed in a rectangular shape or other polygonal shape, and a connecting piece for connecting the panels may be provided in other appropriate forms. Moreover, it may replace with the artificial grass mat | matte 3, and the floor panel 1 may be comprised by adhering the decoration body in which other decoration processings, such as a tile shape, were given.

1 floor panel, 2 panel base, 2a panel surface, 21 unit panel, 21a panel surface, 22 joint part, 23 through hole, 24 side wall, 25 leg, 26 lower joint piece, 26a engagement slit, 27 upper connection Pieces, 3 Artificial grass mat, 31 Base fabric, 32 Grass yarn, 33 Back material, 4 Laser light generator

Claims (4)

A decorative floor formed by adhering a decorative body to the upper surface of a synthetic resin panel base having a joint on the side, and connecting and integrating a plurality of such panels on the floor slab In the floor panel made of synthetic resin that constitutes the surface,
The panel base is formed of a transparent resin material that transmits laser light, and the decorative body is formed by providing a resin layer mixed with carbon black on the lower surface thereof, and the decorative body is formed on the upper surface of the panel base. The resin layer is irradiated with laser light from the lower side of the panel base to the overlapping portion of the resin layer and the upper surface of the panel base, and the resin layer that melts with the heat generation of the carbon black due to absorption of the laser light is applied to the panel base. A floor panel, wherein a decorative body is fixed by welding to the upper surface of a table.   The floor panel according to claim 1, wherein the panel base is formed of a material in which a colorant that transmits laser light is blended with a transparent resin material that transmits laser light.   The floor panel according to claim 2, wherein a perylene-based colorant is used as a colorant that transmits laser light. The floor panel according to any one of claims 1 to 3, wherein an artificial turf mat obtained by planting turf yarn on a base fabric coated with a resin emulsion in which carbon black is blended on the back is used as a decorative body.

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