JP2018087443A - Flooring material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a flooring material which can be properly bonded to an application surface by using an adhesive, which hardly causes set-off on a front side after execution of work, and which is excellent in dynamic load resistance.SOLUTION: A flooring material includes a flooring material body 2, and a plurality of protrusions 3 that are provided in a scattered manner on the backside of the flooring material body 2. The protrusion 3 assumes an approximately rectangular shape in a plan view, which is 2-3 millimeters in length and 2-3 millimeters in width, or an approximately rhombic shape in a plan view, which is 2-3 millimeters long on each side. The width of a recess 4 formed between the adjacent protrusions 3 is set to be more than 0.5 mm and less than 2 mm.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a flooring material that can be satisfactorily bonded to a construction surface using an adhesive, has excellent dynamic load resistance, and has a good construction appearance.

As a method for laying a floor material, an adhesive is used to adhere and fix the floor material to a construction surface.
In such a laying method using an adhesive, blistering may occur in a part of the flooring due to a gas generated from a construction surface or an adhesive. In order to prevent such blisters, Patent Documents 1 to 3 disclose floor materials in which a concave portion for venting gas is formed by projecting a convex portion on the back surface.

In the flooring, after bonding to the construction surface, when viewed from the front side of the flooring, the contour of the convex portion protruding from the back surface may appear. Hereinafter, the appearance of the contour of the convex portion on the surface of the flooring is referred to as “covering”.
Furthermore, dynamic load resistance is not taken into consideration for the flooring, and damage may occur if a predetermined or higher dynamic load is applied. The “dynamic load resistance” refers to a property that hardly causes swelling or dents when a relatively heavy object is moved on the floor surface.

Japanese Utility Model Publication No. 6-083835 Japanese Patent Laid-Open No. 7-305488 JP-A-8-232446

  An object of the present invention is to provide a flooring material that can be satisfactorily bonded to a construction surface by using an adhesive, is less likely to be exposed after construction, and has excellent dynamic load resistance.

  The flooring of the present invention has a flooring main body and a plurality of protrusions provided on the back surface of the flooring main body, and the protrusions are 2 mm to 3 mm x 2 mm in length x width. 3 mm in plan view generally rectangular shape or one side length of 2 mm to 3 mm in plan view substantially rhombus, and the width of the recess formed between the adjacent projections exceeds 0.5 mm and less than 2 mm Has been.

In a preferred flooring material of the present invention, the height of each convex portion is 0.08 mm to 0.5 mm.
In a preferred floor material of the present invention, the floor material body has a substantially square shape in plan view, and at least one side of the convex part in the plan view shape forms an acute angle with respect to one edge of the floor material body. The plurality of convex portions are provided on the back surface of the flooring main body.
The preferable flooring material of this invention contains the convex part in which the said several convex part has the small dent in which the convex top surface was dented in the substantially dish shape.

  According to the flooring of the present invention, it is possible to satisfactorily adhere to a construction surface using an adhesive, and it is possible to construct a floor structure that is less likely to be exposed after construction and has excellent dynamic load resistance.

The top view which looked at the long strip-like flooring of this invention from the surface side. The top view which looked at the same strip-like flooring from the back side. The top view which looked at the sheet-like flooring of this invention from the surface side. The top view which looked at the same sheet-like flooring from the back side. The end view cut | disconnected by the VV line | wire of FIG. The enlarged plan view which expanded a part of Drawing 4 (the enlarged plan view which looked at the flooring from the back side). Sectional drawing cut | disconnected by the VII-VII line of FIG. Sectional drawing cut | disconnected by the VIII-VIII line of FIG. Sectional drawing cut | disconnected by the IX-IX line of FIG. The enlarged plan view which looked at the flooring which concerns on a 1st modification from the back surface side. The enlarged plan view which looked at the flooring which concerns on a 2nd modification from the back surface side. The enlarged plan view which looked at the flooring which concerns on a 3rd modification from the back surface side.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In this specification, “plan view” refers to viewing a flooring material in the vertical direction from the back side, and “plan view shape” refers to a shape when viewed in the vertical direction from the back side. The “substantially rectangular shape” means a substantially square shape or a substantially rectangular shape.
In the present specification, “substantially parallel” includes an error range allowed in the technical field to which the present invention belongs, for example, in a case where objects to be parallel are strictly 0 degrees, Within the range of 0 ± 5 degrees, preferably within the range of 0 ± 3 degrees.
In the present specification, a numerical range represented by “to” means a numerical range including numerical values before and after “to” as a lower limit value and an upper limit value. When a plurality of lower limit values and a plurality of upper limit values are separately described, an arbitrary lower limit value and an arbitrary upper limit value can be selected and set to a range connected by “˜”.

[Outline of flooring]
1 and 2 are plan views of a flooring according to one embodiment of the present invention, and FIGS. 3 and 4 are plan views of a flooring according to another embodiment of the present invention.
The flooring 1 shown in FIG.1 and FIG.2 is formed in planar view elongate strip shape. In FIGS. 1 and 2, the intermediate portion of the flooring 1 and the left side of the sheet are omitted.
The long strip shape refers to a substantially rectangular shape in a plan view in which the length in the first direction is sufficiently longer than that in the second direction. For example, the length in the second direction is 1000 mm to 4000 mm, the length in the first direction is 5 m or more, and preferably the length in the first direction is 10 m or more. In the present specification, the first direction is a direction orthogonal to the second direction. For example, the first direction is the horizontal direction of the drawing, and the second direction is the vertical direction.

The flooring 1 shown in FIG.3 and FIG.4 is formed in sheet shape, such as planar view substantially rectangular shape, for example. However, the planar view shape of the sheet-like flooring 1 is not limited to a substantially rectangular shape, and is formed in, for example, a substantially polygonal shape such as a substantially circular shape, a substantially elliptical shape, a substantially triangular shape, or a substantially hexagonal shape. However, since it is easy to lay and the manufacturing efficiency is good, the flooring material 1 having a substantially rectangular shape in plan view is preferable.
In this specification, “substantially” when expressing a shape means a shape allowed in the technical field to which the present invention belongs. A substantially polygonal “substantially” shape such as a substantially rectangular shape in plan view (substantially square shape or substantially rectangular shape in plan view) or a substantially triangular shape is, for example, a shape whose corners are chamfered, and a part of the side slightly swells Alternatively, a recessed shape, a shape with slightly curved sides, and the like are included. In addition, the “substantially” of the substantially circular shape and the substantially elliptical shape in a plan view includes, for example, a shape in which a part of the circumference is slightly inflated or depressed, and a shape in which a part of the circumference is slightly straight or oblique. .
Although the dimension of the flooring material 1 having a substantially rectangular shape in plan view is not particularly limited, for example, the length in the first direction × the length in the second direction is 100 mm to 1000 mm × 100 mm to 1000 mm.
3 and 4 exemplify the flooring material 1 having a substantially square shape in plan view.

The flooring 1 of the present invention has flexibility. The degree of flexibility of the flooring 1 is, for example, so flexible that the flooring 1 can be wound around a core having a diameter of 10 cm in a roll shape.
The thickness of the flooring 1 of the present invention is not particularly limited, and is, for example, 1 mm to 8 mm, preferably 1.5 mm to 6 mm.

[Layer composition of flooring]
As shown in FIG. 5, the flooring 1 of the present invention includes a flooring main body 2 and a plurality of convex portions 3 provided on the back surface of the flooring main body 2.
FIG. 5 is an end view that appears when the sheet-like flooring 1 shown in FIGS. 3 and 4 is cut along a line parallel to the first direction. The end face (cross section) that appears when the flooring 1 is cut along a line parallel to the second direction and a line inclined with respect to the first direction has the same structure as that shown in FIG. ing. Also, the end surface (cross-section) that appears when the strip-like flooring 1 shown in FIGS. 1 and 2 is cut along a line parallel to the first direction and the second direction and a line inclined with respect to the first direction. ) Also has the same structure as that in FIG.

The floor material body 2 is a main member constituting the sheet-like floor material 1 and has the same flexibility as the floor material 1.
The layer structure of the flooring main body 2 is not particularly limited. Usually, the flooring main body 2 includes a front surface layer 21 and a back surface layer 22, and includes a reinforcing layer 23 and / or an intermediate layer 24 as necessary.
The surface layer 21 constitutes the outermost surface of the flooring body 2. For example, the surface layer 21 may be a pile ground on which a desired design is expressed. The pile fabric is a fabric in which pile yarn is tufted. The flooring 1 having the surface layer 21 made of a pile fabric is generally called a carpet. However, in the case where the surface layer 21 made of a pile fabric is provided on the front surface, the phenomenon of “appearance” in which the contour of the convex portion protruding on the back surface appears is rarely a problem. For this reason, the present invention can be most effectively applied to floor materials that do not have piles on the surface, and in particular, floor materials having a surface layer 211 including a resin layer made of a relatively soft resin.

Preferably, the surface layer 21 has a sheet shape. In the example of illustration, the flooring main body 2 which has the sheet-like surface layer 21 is represented. The sheet-like surface layer 21 includes a surface layer 211 constituting the outermost surface of the flooring body 2, and preferably includes a decorative layer 212 provided on the back surface side of the surface layer 211.
The surface layer 211 is a layer provided to protect the decorative layer 212 when it is provided and to easily remove dirt adhered to the flooring 1. The surface layer 211 may be transparent or opaque, but is preferably transparent so that the design of the decorative layer 212 and the like provided on the lower side of the surface layer 211 can be visually recognized.
The surface layer 211 is usually composed of a resin layer formed from a resin material. In particular, the surface layer 211 is preferably formed from a non-foamed resin layer having a relatively high density.

  The surface layer 211 may have a single-layer structure or may be composed of two or more layers. For example, the surface layer 211 includes a first resin layer laminated on the surface of the decorative layer 212, and a second resin layer (surface protection) laminated on the surface of the first resin layer and constituting the outermost surface of the flooring body 2. Layer), (not shown).

The resin material for forming the surface layer 211 is not particularly limited, and may be a relatively soft resin or a relatively hard resin.
When the surface layer 211 has a single-layer structure, it is preferably formed from a relatively soft resin.
When the surface layer 211 is formed of a laminate of two or more layers, for example, it is preferable that the first resin layer is formed of a relatively soft resin and the second resin layer is formed of a relatively hard resin.

Examples of the relatively soft resin include a soft thermoplastic resin as will be described later. Since the resin is firmly bonded to the decorative layer 212, it is preferable to use a vinyl chloride resin such as a paste vinyl chloride resin. .
Examples of the relatively hard resin include a resin material containing a hard synthetic resin as a main component resin. Although it does not specifically limit as said hard synthetic resin, It is preferable to use curable resin from the favorable workability, and since it is general purpose, it is more preferable to use ionizing radiation curable resins, such as an ultraviolet curable resin. Examples of the curable resin include thermosetting resins and resins that are cured by non-ionizing radiation, in addition to ionizing radiation curable resins such as ultraviolet curable resins.
Although the thickness of the surface layer 211 formed from the said resin material is not specifically limited, For example, they are 30 micrometers-1 mm. When the surface layer 211 is composed of a laminate of two or more layers, for example, the thickness of the first resin layer is about 20 μm to 1 mm, and the thickness of the second resin layer is about 1 μm to 500 μm.

Examples of the decorative layer 212 include a transfer layer, a design printing sheet, and a thermoplastic resin layer to which design properties are imparted. However, the decorative layer 212 is not limited to these exemplary layers, and any layer can be used as long as it can express the design.
The transfer layer is composed of a transfer film formed by printing and solidifying a printing ink on a base material such as release paper and then peeling the solidified printing ink. The said design printing sheet consists of a sheet | seat which gave design printing previously. Examples of the material of the design printing sheet include a thermoplastic resin sheet such as a vinyl chloride resin sheet. The thermoplastic resin layer to which the design property is imparted is a layer that itself can be a design. The thermoplastic resin layer has (1) a design property imparted by the color of the resin itself, (2) a colorant is mixed, and the design property is imparted by the color of the colorant and how it is mixed. (3) When resin chips are mixed and design properties are given by the color, shape, dispersion method, etc. of the resin chips, (4) Colorants having different colors and resin chips are mixed, When designability is imparted depending on the color or mixing method, etc.
Although the thickness of the said decorative layer 212 is not specifically limited, For example, they are 0.5 micrometer-1 mm, Preferably they are 0.01 mm-0.8 mm. In particular, the thickness of the decorative layer 212 made of a design printing sheet is 20 μm to 500 μm.

The back layer 22 includes a back layer that constitutes the outermost back surface of the flooring body 2.
The back layer 22 may be composed of only the back layer, or may be a laminated structure of the back layer and other layers. That is, the back surface layer 22 may have a single layer structure, or may have a laminated structure of two or more layers. In the illustrated example, a back layer 22 having a single layer structure is shown.
The back surface layer 22 including the back layer is preferably a resin layer formed of a resin material. When the back layer 22 has a laminated structure, it is preferable that both the back layer and the intermediate layer are resin layers formed of a resin material.
The resin material for forming the back layer 22 is not particularly limited, but it is preferable to use a resin material containing a soft synthetic resin as a main component resin in order to constitute the flooring 1 having excellent flexibility.
In this specification, the soft synthetic resin and the hard synthetic resin mean the soft plastic and the hard plastic described in the plastic terminology of JIS K6900 (1994).

The main component resin of the back layer 22 is not particularly limited, and a conventionally known resin can be used. Generally, a thermoplastic resin is used, and a soft thermoplastic resin is preferably used.
Examples of the soft thermoplastic resin include vinyl chloride resins such as vinyl chloride and vinyl chloride-vinyl acetate copolymers; polyolefin resins; urethane resins; vinyl acetate resins such as ethylene-vinyl acetate copolymers; -Acrylic resins such as methacrylate resins; polyamide resins; ester resins; various elastomers such as olefin elastomers and styrene elastomers; and rubbers. These can be used alone or in combination of two or more. The back layer 22 is a resin layer containing a vinyl chloride resin as a main component resin because it is inexpensive and has excellent flexibility, is easy to emboss, has strength, and has excellent dynamic load resistance. It is preferable. The characteristic that the embossing is easy leads to that the back surface structure of the flooring material of the present invention can be produced as designed.
In the present specification, the main component resin refers to the largest component (weight ratio) among the resin components (excluding additives) constituting the layer. The amount of the main component resin is more than 50% by weight, preferably 70% by weight or more, more preferably 80% by weight or more when the total resin component constituting the layer is 100% by weight. The upper limit of the amount of the main component resin is 100% by weight. When the amount of the main component resin is less than 100% by weight, the resin other than the main component resin contained in the layer is not particularly limited, and a known resin component can be used.

As the vinyl chloride resin, those produced by an emulsion polymerization method, a suspension polymerization method, a solution polymerization method, a bulk polymerization method, or the like can be used. A vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferred because it is easy to process and handle. These vinyl chloride resins may be used alone or in combination of two or more.
When the back layer 22 is mainly composed of a vinyl chloride resin, it may be a paste vinyl chloride resin or a suspension vinyl chloride resin. Preferably, the back layer 22 is made of a paste vinyl chloride resin as a main component resin. Including. By forming the back layer 22 with a paste vinyl chloride resin, it is possible to configure the back layer 22 that is easy to emboss while securing the strength of the flooring 1.

The paste vinyl chloride resin is, for example, a paste-like vinyl chloride resin obtained by an emulsion polymerization method, and the viscosity can be appropriately adjusted with a plasticizer. The paste vinyl chloride resin is a fine powder having a particle diameter of 0.1 to 10 μm (preferably 1 to 3 μm) composed of a large number of fine particle aggregates. Preferably, the surface of the fine powder is coated with a surfactant. ing. The average degree of polymerization of the paste vinyl chloride resin is preferably about 1000 to 2000.
The suspension vinyl chloride resin is, for example, a vinyl chloride resin obtained by a suspension polymerization method. The suspension vinyl chloride resin is a fine powder having a particle size of preferably 20 μm to 100 μm. The average degree of polymerization of the suspension vinyl chloride resin is preferably about 700 to 1500, more preferably about 700 to 1100, and still more preferably about 700 to 1000.
However, the particle diameter is the median diameter (D50) in the volume-based particle size distribution. Each vinyl chloride resin preferably has a K value of about 60 to 95, and more preferably has a K value of about 65 to 80.
The back layer 22 usually contains various additives in addition to the resin component. As the additive, conventionally known additives can be used, and examples thereof include a filler, a plasticizer, a flame retardant, a stabilizer, a hygroscopic agent, an antioxidant, a lubricant, a colorant, a foaming agent, and an antifungal agent.

The thickness of the back surface layer 22 is not particularly limited and can be appropriately set. For example, the thickness is 0.5 mm to 5 mm, and preferably 0.7 mm to 2 mm. In addition, the thickness of the said back surface layer 22 is corresponded to the total thickness, when the back surface layer 22 is a laminated structure of two or more layers.
The back layer 22 may be a foam or a non-foam. When the back surface layer 22 is a foam, it is excellent in flexibility and can constitute a relatively light flooring 1. When the back layer 22 is a non-foamed material, the embossability is excellent and the strength is increased, so that the flooring 1 having high dynamic load resistance can be configured. When the back layer 22 is made of a foam, the foaming ratio of the foamed resin is not particularly limited, but if it is too small, cushioning properties cannot be imparted, and if it is too large, the sinking becomes too large, so that it is 1.1 times to 3 times is preferable, and 1.2 times to 2 times is more preferable.

In the illustrated example, the reinforcing layer 23 is provided between the front surface layer 21 and the back surface layer 22. As shown in the figure, when the intermediate layer 24 is provided, the reinforcing layer 23 is preferably provided between the back surface layer 22 and the intermediate layer 24.
The reinforcing layer 23 is bonded to the intermediate layer 24 and the back surface layer 22 through an appropriate adhesive as necessary. However, the adhesive is not shown. In addition, when the reinforcement layer 23 adhere | attaches directly on the back surface layer 22 etc., it is not necessary to use the said adhesive agent. As a method of directly bonding the reinforcing layer 23, for example, a method of bonding the reinforcing layer 23 to the back layer 22 and / or the intermediate layer 24 by calendering, heat laminating, heating / pressurizing, etc., the back layer 22 and / or Alternatively, a method of impregnating the reinforcing layer 23 with a resin material such as a paste vinyl chloride resin that forms the intermediate layer 24 may be used.

Although it does not specifically limit as the said reinforcement layer 23, For example, a nonwoven fabric, a woven fabric, etc. are mentioned. The material of the fibers constituting the nonwoven fabric or the woven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; natural fibers and the like. In particular, since the dimensional change due to temperature is small, it is preferable to use a nonwoven fabric or a woven fabric containing glass fibers as the reinforcing layer 23. It is more preferable to use a non-woven fabric from the viewpoints of dimensional stability, suppression of cover-up, and unevenness of construction surface. In particular, the glass mat is excellent in dimensional stability, suppression of cover-up, and uneven surface concealment, and when the resin material such as paste vinyl chloride resin is impregnated in this, the resin is integrated around the glass fiber. Can be used most suitably in the present invention.
The nonwoven fabric or woven fabric having a thickness constituting the reinforcing layer 23 is not particularly limited, for example, a 0.1 mm to 1 mm, the weight per unit area ^{is 10g / m 2 ~100g / m 2} .

  The intermediate layer 24 is provided as necessary. The intermediate layer 24 is usually composed of a resin layer. Although the resin material which forms the intermediate | middle layer 24 is not specifically limited, In order to comprise the flooring 1 which has favorable softness | flexibility, it is preferable that it is formed with comparatively soft resin. Examples of the relatively soft resin include the above-described soft thermoplastic resin, and since the resin is firmly bonded to the reinforcing layer 23 and the decorative layer 212, a vinyl chloride resin such as a paste vinyl chloride resin is used. Is preferred.

[Backside structure of flooring]
As shown in FIGS. 6 to 9, a plurality of independent protrusions 3 are formed on the back surface of the flooring main body 2.
6 is an enlarged plan view in which a part of the back surface structure of the sheet-like flooring 1 is enlarged, and FIGS. 7 to 9 are lines parallel to the first direction, lines parallel to the second direction, and It is an expanded sectional view which appears when cut | disconnecting by the line | wire inclined at 45 degree | times with respect to the 1st direction. The elongated belt-like flooring 1 shown in FIGS. 1 and 2 has the same structure as the enlarged plan view and the enlarged cross-sectional view, and is not shown.

Each convex portion 3 is formed on the back surface of the flooring main body 2 by forming the back surface layer 22 into an uneven shape. Concave portions 4 are formed between the plurality of convex portions 3. The unevenness is determined by the relative relationship between the concave and convex portions, and the convex portion 3 is a portion protruding downward with reference to the bottom surface of the concave portion 4.
Each convex portion 3 is formed in a substantially rectangular shape in plan view with a length × width of 2 mm to 3 mm × 2 mm to 3 mm, or a substantially rhombus shape with a side length of 2 mm to 3 mm.
In the example of illustration, each convex part 3 is formed in the planar view substantially square shape whose length of 1 side is 2 mm-3 mm.
The convex portions 3 are not in contact with each other and are independent, and a concave portion 4 is formed between the adjacent convex portions 3. The width of the concave portion 4 formed between the adjacent convex portions 3 is more than 0.5 mm and less than 2 mm.

Specifically, the convex portion 3 having a substantially square shape in plan view is provided over the entire back surface of the floor material body 2. The magnitude | size in planar view of the some convex part 3 may be the same, or may differ in the said range (length x width is in the range of 2 mm-3 mm x 2 mm-3 mm). Preferably, the planar view shapes of the plurality of convex portions 3 are the same shape and the same size.
The plurality of convex portions 3 may be arranged at equal intervals or may be arranged with unequal intervals. Since the gas can easily escape, the surface structure can be suppressed and the floor structure excellent in dynamic load resistance can be constructed, and the back surface structure can be homogenized as a whole. And regularly arranged. In addition, when the convex part 3 is arrange | positioned at equal intervals, the width | variety of the recessed part 4 becomes substantially constant.
The plurality of convex portions 3 having a substantially square shape in plan view has at least one side thereof being one edge 2a of the flooring body 2 (for example, the first of the edges of the flooring body 2 as shown in FIGS. 2 and 4). It may be arranged so as to be substantially parallel to the edge 2 a) extending in the direction, and at least one side thereof is arranged so as to be inclined at an acute angle with respect to one edge 2 a of the flooring body 2. Also good.

In the illustrated example, the plurality of convex portions 3 having a substantially square shape in plan view are arranged such that all sides thereof are inclined at an acute angle with respect to the respective edges 2 a of the flooring main body 2. The inclination angle of one side of the convex portion 3 with respect to one edge 2a of the flooring body 2 is not particularly limited as long as it is an acute angle, and examples thereof include 10 to 80 degrees, and further 30 to 60 degrees. Etc. are exemplified. Preferably, one side of the convex portion 3 is disposed so as to be inclined at approximately 45 degrees with respect to one edge 2 a of the floor material body 2. In this preferable arrangement, each convex portion 3 having a substantially square shape in plan view is arranged such that the diagonal line of the square is substantially parallel to one edge 2 a of the flooring body 2.
Since the floor material 1 (floor material body 2) having a substantially rectangular shape in plan view is often viewed by moving the line of sight in the direction of the edge 2a, one side of the plurality of convex portions 3 is edged as described above. By arranging to be inclined with respect to 2a, even if a slight appearance occurs, the slight appearance becomes almost inconspicuous visually.

Although the height 3H of each convex part 3 is not specifically limited, if it is too small, the convex part 3 will not be produced substantially, and if it is too large, there is a possibility that the appearance cannot be sufficiently suppressed. From this viewpoint, the height 3H of each convex portion 3 is preferably independently 0.08 mm to 0.5 mm, more preferably 0.1 mm to 0.45 mm, and 0.12 mm to 0.4 mm. Is more preferable.
However, the height 3H of the convex portion 3 refers to the straight line length in the vertical direction from the base of the convex portion 3 to the convex top surface (see FIG. 7).
In the example of illustration, the height of all the convex parts 3 is substantially the same.

Of the plurality of convex portions 3, at least some of the convex portions 3 may be formed with small dents 5 that are recessed in a substantially dish shape. The small dents 5 may be formed on all the convex portions 3, but preferably, some of the plurality of convex portions 3 have the small dents 5 and remain. The convex portion 3 does not have the small dent 5. In this case, although the ratio of the convex part 3 which has the small dent 5 is not specifically limited, When the whole convex part 3 is 100%, the convex part 3 which has the small dent 5 is 20%-95%. , Preferably 40% to 90%, more preferably 50% to 85%. The ratio of the convex portions 3 having the small dents 5 is obtained by the number of the convex portions 3 having the small dents 5 / the number of all the convex portions 3. The arrangement of the convex portions 3 having the small dents 5 and the convex portions 3 not having the small dents 5 may be regular or random. In the example of illustration, the case where the convex part 3 which has the small dent 5 is arrange | positioned at random is represented.
In addition, as for the convex part 3 which does not have the small dent 5, the whole convex top surface is flat shape.
Since the plurality of convex portions 3 include the convex portions 3 having the small dents 5, the surface area of the convex top surface is increased, the adhesive strength of the flooring 1 is increased, and the cross section of the central portion of the convex portions 3 is Since it becomes an arc shape as shown in the figure, the dynamic load resistance can be enhanced by the arch effect.

The small dent 5 is three-dimensionally recessed in a shallow dish shape. The small dent 5 is a dent recessed inward while drawing a gentle streamline continuously from the convex top surface of the convex portion 3. The shape of the small dent 5 in plan view is not particularly limited, and is formed in, for example, a substantially circular shape in plan view, a substantially elliptical shape in plan view, or the like.
In the convex part 3 which has the small dent 5, the planar view shape of the small dent 5 of all the convex parts 3 may be the same, or may differ. For example, some of the convex portions 3 have small dents 5 that are substantially circular in a plan view, and some of the convex portions 3 have small dents 5 that are substantially elliptical in a plan view.
The depth 5H of the small dent 5 is not particularly limited. However, if the depth is too small, the small dent 5 is not substantially generated. If the depth is too large, the strength of the convex portion 3 is reduced, and the adhesive is used for the small dent 5. It becomes difficult to be fully charged. From this viewpoint, the depth 5H of each small dent 5 is independently preferably 0.01 mm to 0.08 mm, and more preferably 0.02 mm to 0.05 mm. However, the depth 5H of the small recess 5 refers to a straight line length in the vertical direction from the convex top surface to the bottom of the small recess 5 (see FIG. 7).

As described above, a recess 4 having a width exceeding 0.5 mm and less than 2 mm is formed between adjacent protrusions 3. The width 4W of the concave portion 4 between the adjacent convex portions 3 may be the same length at an arbitrary position of all the concave portions, or may be different within the above range (over 0.5 mm and less than 2 mm). Also good.
In the case of the illustrated example in which a plurality of convex portions 3 having the same shape and the same size are arranged at equal intervals, the widths 4W of the concave portions 4 are all the same.
However, the width 4W of the concave portion 4 corresponds to the length of a line perpendicular to each of one side of one convex portion 3 and one side of another convex portion 3 adjacent thereto (see FIG. 6). ). In addition, when the width | variety of some recessed parts is different or is partially different, the width 4W of the said recessed part 4 shall point out the maximum value in it.
The width 4W of the concave portion 4 between the adjacent convex portions 3 is preferably 0.7 mm to 1.8 mm, more preferably 0.8 mm to 1.7 mm, and further preferably 0.9 mm to 1.6 mm.
In addition, the concave portions 4 formed between the adjacent convex portions 3 have a mesh shape in a plan view when viewed as a whole. In the case where the plurality of convex portions 3 are arranged so that one side of the convex portion 3 is inclined with respect to the first direction as in the illustrated example, the concave portion 4 is in the first direction in plan view. It is a long concave portion 4 that is inclined and extends linearly. Specifically, the concave portion 4 includes a plurality of long concave portions 4 that are inclined at ± 45 degrees with respect to the first direction.
The depth 4H of the concave portion 4 is the same as the height 3H of the convex portion 3 (see FIG. 7).

Moreover, it is preferable that the convex part 3 and the recessed part 4 are arranged in parallel by turns in the direction parallel to the edge 2a of the flooring 1 like the example of illustration.
Specifically, as shown in FIG. 6, for example, when a virtual line X extending in the first direction (a direction parallel to the edge 2a of the flooring material) is drawn on the back surface of the flooring material 1, The convex portions 3 and the concave portions 4 are alternately present. Preferably, the entire back surface of the flooring 1 satisfies the relationship that the convex portions 3 and the concave portions 4 are alternately and continuously present on the virtual line X in the first direction. In other words, even if the virtual line X extending in the first direction is drawn at any location on the back surface of the flooring 1, the convex portions 3 and the concave portions 4 are continuously present on the virtual line X alternately.
Furthermore, even if the convex part 3 and the recessed part 4 draw the virtual line Y extended in a 2nd direction notionally, the convex part 3 and the recessed part 4 exist alternately on the virtual line Y, Preferably, In the entire back surface of the flooring 1, the relationship is satisfied.

People tend to act naturally with something as a landmark, and when moving on the flooring, they tend to walk or move trolleys, casters, etc., almost parallel to the edge of the flooring 1, especially near passageways and entrances Such a tendency is remarkable. When the shape of the flooring main body 2 is substantially rectangular in plan view, the edge 2a is often laid so as to coincide with the moving direction, and casters and people move along the direction of the edge 2a. As described above, the convex portions 3 and the concave portions 4 are alternately arranged in the direction parallel to the edge 2a of the flooring 1, so that when a heavy object such as a carriage is moved, the load is dispersed, The flooring 1 is less likely to have dents and, as a result, the dynamic load resistance is particularly good.
Furthermore, the arrangement in which the convex portions 3 and the concave portions 4 exist alternately and continuously on the virtual line Y, and the arrangement in which one side of the plurality of convex portions 3 is inclined at an acute angle with respect to the edge 2a of the flooring body 2 With the combination of, it is difficult to display the surface and the dynamic load resistance can be improved synergistically. In particular, when the diagonal line of the convex portion 3 is arranged so as to be substantially parallel to one edge 2a of the floor material body 2, the load is easily dispersed evenly in the direction parallel to the edge 2a, and the floor material 1 has dents. It becomes difficult to stick.

Further, from the viewpoint of effectively suppressing the appearance, when the width of the concave portion is 1.5 mm ≦ the width of the concave portion <2 mm, it is preferable that the concave / convex ratio represented by the following formula exceeds 1, and the concave / convex ratio Is more preferably 1.2 or more.
Formula: Concavity and convexity ratio = length of one side of convex portion (mm) / width of concave portion (mm).
Regarding the length of one side of the convex portion in the above formula, when the convex portion is rectangular in plan view, one side of the formula is (rectangular short side + long side) / 2.

In addition, it is preferable that the embossed unevenness 6 is formed on the surface of the flooring main body 2 as needed because the surface appearance can be made inconspicuous (see FIGS. 5 to 9). The embossed irregularities 6 are provided to give the flooring 1 a design. The depth of the embossed unevenness 6 (the height difference of the unevenness) is not particularly limited, and is, for example, 0.01 mm to 0.1 mm. By forming the embossed unevenness 6 having the depth, even if a slight appearance is generated, it becomes inconspicuous, and the appearance can be effectively inconspicuous in synergy with the back surface structure of the flooring 1.
Moreover, the surface of the flooring main body 2 is not limited to being formed in an uneven shape, and may be a flat surface. The method of flattening the surface of the flooring body 2 is, for example, a method of pressing the surface with a mirror roller after the surface layer 21 is formed, or when the surface layer 21 is flat when formed. It is not necessary to perform any processing as it is.

[Production method of flooring]
The flooring 1 of the present invention can be manufactured, for example, as follows.
A back layer forming material is applied on the reinforcing layer 23 such as a glass nonwoven fabric, and a layer made of the back layer forming material is formed on the reinforcing layer 23.
As the back layer forming material, a resin material mainly composed of paste vinyl chloride resin can be used.
Next, on the surface of the layer made of the back surface layer forming material, by using a concavo-convex forming device such as an embossing roller, the convex portion 3 having no small dent and the convex portion 3 having the small dent 5 and the concave portion 4 are formed. At the same time, the back surface layer 22 having a plurality of convex portions 3 is formed by heating and gelling the vinyl chloride resin.

An intermediate layer forming material is applied to the opposite surface of the reinforcing layer 23 on which the back surface layer 22 is formed, and a decorative layer 212 such as a design printing sheet is laminated and adhered. After applying 1 resin layer forming material, it is heated to form a flooring having a laminated structure consisting of back layer / reinforcing layer / intermediate layer / decorative layer / first resin layer (surface layer). As the intermediate layer forming material and the first resin layer forming material, a resin material mainly composed of a paste vinyl chloride resin can be used.
If necessary, a flooring having embossed unevenness can be obtained by forming the embossed unevenness 6 from the surface side of the first resin layer using an unevenness forming device such as an embossing roll.
If necessary, the second resin layer is formed by applying an ionizing radiation curable resin to the surface of the first resin layer not forming the embossed unevenness or the surface of the first resin layer forming the embossed unevenness, and then curing it. A flooring having a (surface protective layer) can be obtained.

[Use of flooring]
The flooring 1 of the present invention is used by adhering to the construction surface using an adhesive, as in the case of the conventional flooring 1, and constructing a floor structure having the construction surface, the adhesive, and the flooring 1 in order from the bottom. it can.
The adhesive is not particularly limited, and examples thereof include acrylic resin adhesives, rubber adhesives, urethane resin adhesives, epoxy resin adhesives, and emulsion-type aqueous adhesives such as vinyl acetate. The flooring 1 of the present invention can be applied without hindrance even when a urethane resin adhesive or an epoxy resin adhesive that generates a relatively large amount of gas is used.
The material of the construction surface is not particularly limited, for example, concrete surface, mortar surface, gypsum board surface, wood surface, synthetic resin surface, ceramic surface such as ceramic tile or ceramic tile, stone surface, metal surface such as iron plate, etc. Can be mentioned. The construction surface is preferably a flat surface, more preferably a flat and relatively hard surface, regardless of the material.

Usually, after applying adhesive to the construction surface using a comb iron, laying the flooring 1 on it, applying a mirror roller to the surface of the flooring 1 and rolling the roller back and forth, the construction surface In many cases, an air venting operation is performed in which the gas between the floor material 1 and the floor material 1 is guided to the edge of the floor material 1. As such a roller, for example, a trade name “Large Tile Roller” manufactured by Toli Corporation can be used. In the rolling operation of the roller, since the edge 2a of the flooring 1 becomes a visual reference, the roller is often rolled in a direction substantially parallel to the edge of the flooring 1, but as described above, By arranging the diagonal line so as to be substantially parallel to one edge 2 a of the floor material body 2, the gas can be smoothly guided to the edge of the floor material 1.
The flooring 1 of the present invention can be satisfactorily bonded to a construction surface using an adhesive.
The flooring 1 of the present invention is provided on the back surface thereof with a plurality of convex portions 3 having a substantially square shape in plan view, each having a side length of 2 mm to 3 mm, with an interval of more than 0.5 mm and less than 2 mm. Therefore, it is difficult to print out and has excellent dynamic load resistance.

In the above-described embodiment, the convex portion 3 is formed in a substantially square shape in plan view. However, the present invention is not limited to this. For example, as shown in FIG. Alternatively, as shown in FIG. 11, it may be formed in a substantially rectangular shape in plan view.
The convex portion 3 having a substantially rhombus shape in plan view shown in FIG. 10 has one diagonal 2a of the floor material body 2 (for example, as shown in FIG. 2 and FIG. 4, of the edges of the floor material body 2). 11 is arranged so as to be substantially parallel to the edge 2 a) extending in the first direction, and the convex portion 3 having a substantially rectangular shape in plan view shown in FIG. 11 has a diagonal line with respect to one edge 2 a of the flooring body 2. It is arranged to incline. However, in both cases of FIGS. 10 and 11, the plurality of convex portions 3 are arranged so that at least one side of the convex portion forms an acute angle with respect to one edge 2 a of the flooring body 2.
Further, in both cases of FIG. 10 and FIG. 11, similarly to the above-described embodiment, the convex portions 3 and the concave portions 4 are alternately arranged in parallel on virtual lines parallel to the first direction and the second direction (imaginary). Line not shown).

In the above-described embodiment, the convex portion 3 having a substantially square shape in plan view is arranged such that its diagonal line is substantially parallel to one edge 2a of the flooring main body 2. For example, as shown in FIG. The convex portion 3 having a substantially square shape in plan view may be arranged so that one side thereof is substantially parallel to one edge 2 a of the flooring main body 2.
Further, the convex portion 3 having a substantially rhombus shape in plan view is not limited to the arrangement as shown in FIG. 10, and the diagonal line of the convex portion 3 having a substantially rhombus shape in plan view is inclined with respect to one edge 2 a of the flooring body 2. Or it may be arrange | positioned so that one side of the convex part 3 of a substantially rhombus shape planar view may become substantially parallel to one edge 2a of the flooring 1 (not shown).
Further, the convex portion 3 having a substantially rectangular shape in plan view is not limited to the arrangement as shown in FIG. 11, and one side of the convex portion 3 having a substantially rectangular shape in plan view is substantially parallel to one edge 2 a of the flooring 1. (Not shown).

  EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.

[Materials used]
(1) Back layer Paste vinyl chloride resin. Trade name “PSH985” manufactured by Kaneka Corporation. K value: 70.
(2) Reinforcing layer Glass nonwoven fabric. Trade name “MBPP057” manufactured by Olivest Co., Ltd. Weight per unit area: 57 g / m ² .
(3) Intermediate layer and first resin layer Paste vinyl chloride resin. Trade name “PSM162” manufactured by Kaneka Corporation. K value: 70.
(4) Cosmetic layer Design printing sheet. Product name “NS4800” manufactured by Toppan Cosmo. This design printing sheet is approximately the same size as the reinforcing layer and has a thickness of about 150 μm, a vinyl chloride film, and a design printing with a thickness of about 1 μm formed on the film by a known printing method using a known printing method. And consists of layers. The design print layer shows a marble-like design.
(5) Second resin layer (surface protective layer)
UV curable resin. Trade name “TLI-112M” manufactured by Dainichi Seika Kogyo Co., Ltd.

[Example 1]
A glass nonwoven fabric (reinforcing layer) is cut into length × width = 300 mm × 300 mm, and a paste vinyl chloride resin as a back layer forming material is applied to the first surface of the glass nonwoven fabric (reinforcing layer) at 1600 g / m ² . A solid coating was applied to form an uncured back layer having a thickness of about 1.2 mm.
After preheating the uncured back layer at about 140 ° C. using a heater, one side of the uncured back layer (one side is the side opposite to the side on which the glass nonwoven fabric is laminated) Then, an embossing roller provided with a heater was pressed to form convex portions, small dents, and concave portions, and at the same time, the resin material was cured to form a back layer.
In design, the convex part, the concave part, and the small dent were set as follows. The protrusions are approximately square in plan view with a length × width of 2 mm × 2 mm and a height of 0.4 mm, and all the protrusions have the same shape and size. The recess has a depth of 0.4 mm and a width of 1 mm. In addition, the depth of a recessed part and the height of a convex part are synonymous, and the width | variety of a recessed part is equal to the space | interval of an adjacent convex part. The convex portions were arranged at equal intervals with an interval of 1 mm, which is the width of the concave portions, so that the diagonal lines of the convex portions having a substantially square shape in plan view were parallel to the lateral direction of the nonwoven fabric. Furthermore, small concaves having a depth of about 0.03 mm and having a substantially circular shape in plan view were formed on the convex top surfaces of several convex portions (see FIG. 6).

On the second surface of the reinforcing layer (the second surface is the surface opposite to the first surface on which the back surface layer is laminated) of the laminate of the back surface layer and the reinforcing layer on which the convex portions are formed, After applying paste vinyl chloride resin, which is an intermediate layer forming material, to a thickness of about 300 μm, overlaying a design printing sheet, which is a decorative layer, on the surface, and pressing the design printing sheet to the intermediate layer side using a pressing roller The paste vinyl chloride resin, which is the first resin layer forming material, is applied to the surface of the design printing sheet to a thickness of about 200 μm and heated to about 200 ° C. using a heater, and the intermediate layer forming material and the first resin layer By curing the forming material, a laminate composed of a back surface layer having a convex portion / reinforcing layer / intermediate layer / decorative layer / first resin layer was formed.
Next, an embossed concavo-convex pattern (depth of about 0.05 mm) is formed on the surface of the first resin layer using an embossing roller, and then an ultraviolet curable resin is applied to the surface to a thickness of about 20 μm. The second resin layer was formed by curing the resin by irradiating ultraviolet rays.
In this way, floor materials having a layer structure as shown in FIGS. 4 and 7 to 9 were produced.

[Examples 2 to 6, Comparative Examples 1 to 7]
A flooring was produced in the same manner as in Example 1 except that the plan view shape of the convex portion, the width of the concave portion, and / or the depth of the concave portion were changed as shown in Tables 1 and 2. In addition, about a small dent, it is the same as that of Example 1. FIG.
In Tables 1 and 2, the concavo-convex ratio is a value of the length of one side of the convex part (mm) / the width of the concave part (mm). However, when it is not divisible, the second decimal place is rounded off.

[Comparative Example 8]
A flooring was produced in the same manner as in Example 1 except that the convex portion was not formed (that is, the back surface was formed flat).

[Dimension measurement]
In order to confirm the difference from the design value for the convex and concave dimensions of the flooring material produced in each example and comparative example (whether the unevenness by the embossing roller based on the design value is actually formed in the back surface layer We measured them by the following method.
For each of the examples and comparative examples, five convex portions were arbitrarily selected, and the length of one side of the convex portion was measured using a microscope (trade name “VC7700” manufactured by OMRON Corporation). However, all were as designed.
For each of the examples and comparative examples, five concave portions between adjacent convex portions were arbitrarily selected, and the widths of the concave portions were measured using the same microscope, and all were as designed.
For each of the examples and comparative examples, five concave portions were arbitrarily selected, and the depth (height of the convex portion) was measured using the same microscope, and some of them did not match the design values. . Therefore, the average value was calculated | required.
In addition, although the small dent can be confirmed visually, since the depth of the small dent is very small, it was difficult to measure, so it was not measured.

[Adhesion test]
Under an environment of 23 ° C., an epoxy adhesive (trade name “Epoxy Gray” manufactured by Tori Co., Ltd.) was used on a flat mortar surface using an adhesive application tool (comb iron) specified in JIS A 5536. S ") was applied.
The floor material of each Example and the comparative example was affixed on the mortar surface which apply | coated the adhesive agent, and the floor material was adhere | attached on the mortar surface (construction surface) by acclimatizing the surface with a roller.
After bonding, the substrate was allowed to stand at room temperature and normal pressure for 3 hours, and then the surface condition was visually observed. The results are shown in Tables 1 and 2. In the table, ◯, Δ, and X represent the following. In Comparative Example 8, since the unevenness is not formed on the back surface, the surface print does not occur.
◯: No contour due to the convex portions and concave portions on the back surface was confirmed on the surface of the flooring.
(Triangle | delta): When staring at the surface of a flooring, the outline resulting from the convex part and recessed part of a back surface was confirmed slightly.
X: The outline resulting from the convex part and the recessed part of the back surface appeared clearly on the surface of the flooring.

As in Examples 1 to 6, the floor material in which the length × width of the convex portion is 2 mm to 3 mm × 2 mm to 3 mm and the width of the concave portion is more than 0.5 mm and less than 2 mm (particularly 1 mm to 1.5 mm) It turns out that it is difficult to display.
On the other hand, when the width of the recess is 2 mm or more as in Comparative Examples 1 to 5, it can be seen that the appearance is likely to occur.
Furthermore, after visually observing the presence or absence of surface printing, an attempt was made to manually lift up from the edge of the flooring material, but none of the flooring materials of each Example and Comparative Example could be peeled off, and JIS related to the flooring material. The adhesive strength of 1 N / 1 mm or more, which is a standard value, was satisfied.

From Examples 1 to 6 and Comparative Example 7, when the width of the recesses is 1.5 mm or more and less than 2 mm, the surface effect is effectively improved when the unevenness ratio exceeds 1, preferably 1.3 or more. It turns out that it can suppress. Further, it can be seen that when the width of the recess is 1.5 mm or more and less than 2 mm and the unevenness ratio is 1 or less, the surface is likely to appear.
Moreover, from Examples 1 and 3 and Comparative Example 6, it can be seen that when the width of the recess is less than 1.5 mm, the appearance can be suppressed.

[Gas expansion test]
In an environment of 5 ° C., after applying an epoxy epoxy adhesive to the mortar surface using an adhesive application tool in the same manner as in the above [Adhesion test], the floor materials of each Example and Comparative Example were applied, and the surface was applied. After acclimating with a roller and adhering the flooring to the mortar surface, it was left at that temperature for 2 hours. Next, after leaving in a 20 ° C. environment for 3 hours, the presence or absence of gas swelling of the flooring was confirmed under oblique light.
The results are shown in Tables 1 and 2. O and X in the table represent the following.
○: No gas bulge was observed, or the bulge was of little concern.
X: Gas blistering was clearly observed.
When the width of the recess is 0.5 mm as in Comparative Example 6, it can be seen that gas is difficult to escape and gas swell is likely to occur. Therefore, it can be seen that gas expansion can be suppressed when the width of the recess exceeds 0.5 mm.

[Dynamic load resistance test]
About each flooring after confirming the said gas blistering, dynamic load resistance was measured.
The dynamic load resistance was evaluated based on a caster test specified in JIS A 1454 B method. As test conditions, a load of 2000 N was applied to a single caster (made of steel, diameter 110 mm, width 50 mm), and the caster was reciprocally rotated for 180 minutes, and then peeling or dent of the flooring material was confirmed. This test was performed three times. The results are shown in Tables 1 and 2. In the table, ◯, Δ, and X represent the following.
○: The flooring did not swell in all three times.
(Triangle | delta): The swelling was confirmed by the flooring once among 3 times.
X: Swelling was confirmed in the flooring material 3 times.

DESCRIPTION OF SYMBOLS 1 Floor material 2 Floor material main body 3 Convex part 4 Concave part 5 Small dent

Claims (4)

A floor material body, and a plurality of convex portions provided on the back surface of the floor material body,
The convex portion has a substantially rectangular shape in plan view of 2 mm to 3 mm x 2 mm to 3 mm in length x width or a plan view substantially rhombus shape in which the length of one side is 2 mm to 3 mm,
A flooring in which a width of a concave portion formed between the adjacent convex portions is more than 0.5 mm and less than 2 mm.   The flooring according to claim 1, wherein the height of each convex portion is 0.08 mm to 0.5 mm. The floor material body is substantially rectangular in plan view,
The plurality of convex portions are provided on the back surface of the floor material main body so that at least one side of the convex portion having the shape in plan view forms an acute angle with respect to one edge of the floor material main body. The flooring according to 2.   The flooring according to any one of claims 1 to 3, wherein the plurality of convex portions include a convex portion in which a small dent recessed in a substantially dish shape is formed on a convex top surface thereof.

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