JP4603942B2 - Floor material with mosaic pattern on the surface and method for producing the same - Google Patents

Description

  The present invention relates to a flooring having a mosaic pattern on the surface and a method for producing the same.

  A floor having a mosaic pattern as a surface pattern is known and is called a mosaic floor or a parquet floor. At the time of construction, a flooring material having a mosaic pattern on the surface is made, and a plurality of the flooring materials are attached to the floor base using an adhesive. As a method of making a flooring material having a mosaic pattern on the surface, Patent Document 1 discloses that a large number of unit pieces having different surface pattern patterns are attached to a rectangular base material made of a flexible material. A method of making one floor material is described, and in Patent Document 2, a plurality of unit materials are stuck and assembled in a mosaic shape to make an assembly, and a surface decorative material obtained by slicing the unit is like plywood. A method is described in which a flooring material having a mosaic pattern as a surface pattern is applied to a core material.

Japanese Patent Laid-Open No. 10-280646 Japanese Patent Laid-Open No. 10-58406

  The floor material having a mosaic pattern on the conventional surface, as described in Patent Documents 1 and 2, is designed to form a surface layer on a single base material so as to form a mosaic pattern. When it is necessary to cut in the middle of the longitudinal direction for reasons such as dimensional alignment, it is not easy to cut properly. Even when manufacturing, separately prepare a large number of unit pieces and paste them one by one to the base material, or make a collection of multiple unit materials stuck in a mosaic shape, and use it as a surface cosmetic material A lot of work such as slicing and pasting to the base material was necessary.

  The present invention has been made in view of the above circumstances, and is relatively easy to manufacture, and when it becomes necessary to remove a part, the part can be easily removed. An object of the present invention is to provide a flooring material having a mosaic pattern on the surface and a manufacturing method thereof.

  A flooring material having a mosaic pattern on the surface according to the present invention is obtained by joining two or more unit pieces having sap on four sides with adhesives formed on the sides of adjacent unit pieces with an adhesive. It is a flooring material.

  In the flooring according to the present invention, a mosaic pattern is formed on the surface by the surface pattern of each unit piece being continuous in the longitudinal direction. Each unit piece is in a state where it is joined by an adhesive applied to the joint between saps (for example, one male sap and the other female sap), and when necessary, the unit piece can be easily separated from any sap joint can do. Therefore, it is very easy to align the floor material at the construction site. Separation can be further facilitated by using a hot-melt adhesive that is flexible even after curing. The shape of the sane processing is not particularly limited as long as it is easily separable and detachable, and this sane shape is preferable because it can be more easily separated.

  The unit piece may be a plywood as a base material or a processed wood material such as MDF with a decorative layer such as a veneer on the surface, or a decorative layer formed by painting on the top of a solid thin plate It is also possible that a decorative layer is formed by painting or the like on the upper surface of a laminate of a plurality of innocent thin plate materials.

  In the flooring of the present invention, the unit pieces constituting the flooring may all be unit pieces having the same shape, or may be composed of two or more types of unit pieces having different shapes. In the latter case, a floor material with higher design can be obtained by arranging unit pieces having different shapes in the longitudinal direction so as to repeat a certain pattern.

  In a preferred aspect of the flooring according to the present invention, each unit piece constituting the flooring has a wood grain pattern on the surface, and at least a portion where adjacent unit pieces are joined so that the direction of the wood grain pattern is different is provided. It is characterized by having it in one place. The wood grain patterns may all be the same, some may be different, or all may be different. By changing the direction of the adjacent grain pattern, a flooring material having a mosaic pattern rich in design can be obtained.

  In a preferred embodiment of the flooring according to the present invention, the surface side edge of the longitudinal side edge of the flooring and the surface side edge at the joint portion between the unit pieces are chamfered. By performing the chamfering process in this way, the accent feeling of the surface design appears. When the R-shaped chamfered portion is formed, the touch when touching the flooring material becomes soft, and a further high-class feeling is created.

  The present invention provides a method for producing the above flooring, a step of cutting out the first long member from the first floor base material, a step of applying sane processing to at least the long side of the first long member, The step of forming a second floor base material by bonding together the sane formed by forming two or more first long members subjected to the sene processing on the side in the longitudinal direction with an adhesive, the second Cutting the second long member by cutting the floor base material in a direction perpendicular to the direction of the sap to which the floor base material is adhesively bonded, and applying a sane process to the long side of the second long member. Also disclosed is a method for producing a flooring having a mosaic pattern on the surface, characterized in that it has at least a surface.

  In the method of the present invention, the first floor base material as the starting material is a material of the unit piece constituting the above-described floor material, and as described above, such as plywood or MDF as the base material The surface of the processed wood material may have a decorative layer like a veneer, or the top surface of an innocent thin plate with a decorative layer formed by painting, etc. A decorative layer may be formed on the upper surface by painting or the like. The size and shape may be a rectangular plate having a vertical and horizontal dimension larger than the width of the floor material to be manufactured, but from the viewpoint of productivity, the short side of the floor material to be manufactured both vertically and horizontally. It is desirable that the width is several times the direction width.

  The lateral width of the first long member cut out from the first floor base material is determined in accordance with the lateral width of the mosaic pattern of the floor material to be manufactured. If you want to produce a flooring that has a repeat of a square mosaic pattern with the same vertical and horizontal lengths on the surface, the width equal to the width in the short direction of the flooring to be produced Then, the first floor base material is cut. Cutting (cutting out) can be performed using a running saw or the like.

  As in the case of the conventional flooring, at least the long side of the first long member that has been cut out is processed using a processing machine such as a tenor. Preferably, chamfering is also performed on the surface side edge of the side edge in the longitudinal direction. By applying this chamfering process, the accent of the surface design appears. In particular, when the chamfered portion has an R shape, a floor material that is soft to the touch is finally produced.

  The second floor base material is formed by joining together the sanes formed by forming two or more first long members after processing on the sides in the longitudinal direction with an adhesive. The number of the first long members to be joined is determined in consideration of the width in the longitudinal direction of the floor material to be manufactured. The adhesive is optional, but preferably a hot melt adhesive that is flexible even after curing is used. Thereby, the operation | work which isolate | separates a required unit piece from the manufactured flooring can be facilitated.

  The manufactured 2nd floor base material is cut | judged in the direction orthogonal to the direction of the sane which adhere | attached and joined 1st elongate members, and a 2nd elongate member is cut out. The width (width in the short direction) of the second long member to be cut out is the width in the short direction including the sane processed portion of the floor material to be manufactured. This cutting (cutting out) can be performed using a running saw or the like. The long side of the second long member that has been cut out is sanitized using a processing machine such as a tenoner, and preferably, the chamfering is also performed on the surface side edge of the sacrificial surface. Thereby, the flooring having a mosaic pattern on the surface according to the present invention is completed.

  In the manufacturing method described above, all the steps can be performed using one type of first floor base material having a decorative pattern (for example, a continuous grain pattern) on the surface. Even in such a case, since a contact surface that is preferably chamfered exists at the joint portion between the unit pieces, a person looking at the flooring can visually recognize a mosaic pattern separated into a rectangular shape on the surface. it can. However, the directionality of the pattern is substantially the same and is often insufficient as a design.

  In order to avoid this, in another aspect of the production method according to the present invention, two or more first floor base materials having different surface grain patterns are used as the first floor base material, and they are used to The first long member cut out from the same first floor base material after performing the step of cutting out the first long member, performing the sane processing on at least the long side of the cut out first long member The second floor base material has at least one state where the first long member cut out from the other first floor base material is located between the first long base member and the first long base member. The process of forming is performed.

  In this aspect, the pattern of adjacent unit pieces can be greatly varied, and the design of the mosaic pattern, that is, the commercial value as a flooring material is increased. By using two or more kinds of first floor base materials having different pattern directions as well as the wood grain pattern, a mosaic pattern with higher design properties can be obtained. When using a plate material with a decorative veneer attached to the surface of the base material as the first floor base material, by cutting out the first elongate member in a state where the direction is changed by 90 degrees, The same results can be produced as using two or more first floor substrates with different surface grain patterns.

  In another aspect of the production method according to the present invention, the method further includes a step of cutting out a third elongated member having a width different from that of the first elongated member from the same or different first floor base material, The step of forming the second floor base material is performed so that the third long member is positioned at least in one place between the long members.

  In the floor material manufactured by this method, unit pieces having different widths exist irregularly or regularly in one floor material, and the mosaic pattern has a higher design. The surface patterns of the unit pieces having different widths may be different from each other, and the same pattern may be included. All may be the same. In the above manufacturing method, it is desirable to further include a step of chamfering the surface side edge portion of the longitudinal side edge of the third elongate member, and thus chamfering (for example, R-shaped chamfering) is performed. By applying, it is possible to obtain a flooring material that feels soft when touched.

  According to the present invention, it is possible to obtain a flooring material having a mosaic pattern on the surface, which is relatively easy to manufacture and can be easily removed when a part needs to be removed. It is done.

  Hereinafter, the present invention will be described based on embodiments with reference to the drawings. FIG. 1 is a diagram for explaining a first embodiment of a method for producing a flooring material having a mosaic pattern on the surface according to the present invention in the order of steps, and FIG. 2 is a diagram for explaining a state in which the produced flooring material is spread on a floor base surface. It is a schematic diagram for. FIG. 3 is a diagram for explaining the second embodiment, and FIG. 4 is a diagram for explaining the third embodiment in the order of steps.

  In the embodiment shown in FIG. 1, two types of floor base materials 10a and 10b are used as the first floor base material which is a starting material, as shown in FIG. 1a. In this example, the two floor base materials 10a and 10b are each 12 mm thick by laminating 9 layers of birch thin plates having a size of 1525 mm × 1525 mm with the grain direction alternately orthogonal. In the floor base material 10a, the grain direction is used in the vertical direction, and in the floor base material 10b, the grain direction is used in the horizontal direction. Of course, the configuration and dimensions of the first floor base material are not limited to this, and for example, a veneer base material may be attached to a plywood base material.

  The two first floor base materials 10a and 10b are set on a running saw, and as shown in FIG. 1b, first long members 11a and 11b having appropriate dimensions are cut out. In this example, four long members 11a each having a size of 313 mm × 1284 mm are cut out from one first floor base material 10a, and the same dimensions are 313 mm × 1284 mm from the other first floor base material 10b. Four long members 11b are cut out. Since the cutting direction is the same, the grain direction of one long member 11a is the long side direction, and the grain direction of the other long member 11b is the short side direction. In this example, in relation to the dimensions of the cut long members 11a and 11b, the first surplus materials 12a and 12b (the grain direction is the long side direction) of 261 mm × 1284 mm and the second of 1521 mm × 238 mm Excess materials 13a and 13b (the grain direction is the short side direction) are cut out simultaneously. Such surplus material is effectively used as a floor material constituent material in a second embodiment to be described later. It is naturally possible to set the dimensions of the first floor base materials 10a and 10b in advance so that such surplus materials do not appear.

  Using the tenoner, the long members 11a and 11b that have been cut out are subjected to sane processing on the two long sides facing each other. This sane processing may be the same as that performed in conventional flooring, so that, as shown in FIG. 1c, male sane 14 is on one long side and female sane 15 is on the other long side. The formed long members 11a and 11b having actual dimensions of 303 mm × 1284 mm are obtained. Preferably, further, chamfering is performed on the surface side edge portion of the longitudinal side edge of each of the first long members 11a and 11b.

  Next, the two first long members 11 a and 11 b are assembled to form the second floor base material 20. At that time, another first floor base material (in this example, between the first long members 11a and 11a cut out from the same first floor base material (for example, the first floor base material 10a)). Assembling is performed so that the state in which the first long member 11b cut out from the first floor base material 10b) is located is formed in at least one place.

  Here, as shown in FIG. 1d, two first long members 11a and two first long members 11b are alternately arranged, and a total of four first long members are used. The second floor base material 20 is used. Thereby, as for the 2nd floor base material 20 after an assembly | attachment, the grain direction of the assembled 1st elongate member differs for every sheet. The number of the first long members to be assembled is determined by the length of the floor material to be manufactured. In this example, the dimension of the second floor base material 20 is 1212 mm × 1284 mm, The flooring 30 having an actual dimension of 1212 mm is finally produced.

  When each first elongate member is hit, the male sash 14 and the female sash 15 formed on the side in the longitudinal direction are assembled so as to form a sane connection. Adhesive is applied to the steel joints to such an extent that they do not easily separate. As the adhesive, a hot melt adhesive is preferably used.

  The second floor base material 20 is hung on a running saw, and as shown in FIG. 1e, it is cut with a predetermined width in a direction perpendicular to the direction of the adhesively bonded sun. The width of cutting is determined by the width of the short side of the flooring material to be manufactured. In this example, cutting is performed with a width of 313 mm, and the four second long members 21 are cut. Trying to get.

  Next, as shown in FIG. 1f, sane processing is performed on the two opposing long sides of each obtained second long member 21 using a tenoner. This sane processing may be the same as that performed in the conventional flooring material, whereby the male sane 16 is formed on the upper long side and the female sap 17 is formed on the lower long side. Preferably, a chamfering process is further performed on the surface side edge portion of the longitudinal side edge. Since the male sash 14 and the female sash 15 have already been formed on the left and right side sides (short side side), the four unit pieces P are formed by adhesive bonding by performing sane processing on the long side. In addition, a flooring 30 having an actual dimension of 303 mm × 1212 mm and having sash on four circumferences is formed. The surface is a mosaic pattern in which a substantially square wood grain pattern (a wood grain pattern on the surface of the unit piece P) is arranged in the longitudinal direction so that the directions are alternately orthogonal.

  FIG. 2 shows an example when the flooring 30 shown in FIG. 1f is spread on the floor base. In order to form a mosaic pattern having the same pattern on the floor surface, it is necessary to sequentially spread a large number of flooring materials 30 in a posture shifted by one unit piece P constituting the flooring material 30. On the wall surface of the floor, after removing one or more unit pieces P1 from the floor material 30, it is necessary to lay it on the floor substrate. In the flooring 30 according to the present invention, since a plurality of unit pieces P are connected to each other by means of sunk bonding and an adhesive, the separation work of the unit pieces Pa becomes extremely easy, and the workability on site is greatly improved. To do.

  Further, in manufacturing the flooring 30, only the first floor base material manufactured in advance by an appropriate method is used, and the configuration in the middle is only cutting and sunk processing. It becomes easy.

  Based on FIG. 3, the 2nd form of the manufacturing method by this invention is demonstrated. In this example, as shown in FIG. 3a, only one type of first floor base material 10a is used. The 1st elongate member 11a is cut out from the 1st floor base material 10a like the 1st form. Thereby, as shown in FIG. 3b, together with the four first long members 11a, the first surplus material 12a that is 261 mm × 1284 mm (the grain direction is the long side direction) and the second that is 1521 mm × 238 mm The excess material 13a (the grain direction is the short side direction) is cut out simultaneously. In this aspect, the second surplus material 13a (the grain direction is the short side direction) is effectively used.

  As shown in FIG. 3b, a third elongated member 11c having a length (1284 mm) that is the same as the first elongated member 11a and having an arbitrary width is cut out from the second surplus material 13a. As shown in FIG. 3c, when the third long member 11c cut out is arranged so that the long side direction thereof is the same as the long side direction of the first long member 11a, the third long member 11c is arranged. The grain direction is a direction orthogonal to the grain direction of the first elongate member 11a.

  In this state, as shown in FIG. 3d, the first elongate members 11a and the third elongate members 11c are alternately arranged, and in the same manner as shown in FIG. And Hereinafter, through the same process as the first embodiment shown in FIG. 1, the second long member 21a is made (FIG. 3e), and is further used as the flooring 30a (FIG. 3f). The floor material 30a to be manufactured is a combination of two kinds of unit pieces P and Pa. The unit piece P is the same as the unit piece P constituting the floor material 30 shown in FIG. Pa is defined according to the lateral width when the third long member 11c is cut out from the second surplus material 13a. In this case, since the surplus material 13a is used and a wide width cannot be secured, in the normal case, the lateral width of the unit piece Pa is narrower than the unit piece P as shown in the figure.

  The third embodiment shown in FIG. 4 is substantially the same as the first embodiment shown in FIG. However, the dimensions of the first elongate members 11a and 11b are as narrow as 162 mm × 1525 mm, and in order to obtain a square mosaic pattern, the second elongate member 21b is removed from the second floor base material 20b. The width when cutting out is also as narrow as 162 mm. Finally, a floor material 30b having an actual size of 151.5 mm × 1212 mm and having sap on four circumferences is formed. Thus, even if the same first floor base material 10 is used, the floor material 30b having a different mosaic pattern can be manufactured by changing the width when the first long member 11 is cut out.

  In the above description, an example in which two types of first long members are used has been described. However, three or more types of first long members having different widths or patterns and directions are used. The second floor base material can also be made by appropriately arranging. Thereby, a flooring material having a more varied mosaic pattern on the surface can be obtained. In addition, all numerical values indicating dimensions are merely examples, and it is needless to say that those having arbitrary dimensions can be used and manufactured as desired.

The figure explaining the 1st embodiment of the manufacturing method of the flooring which has a mosaic pattern on the surface by this invention in order of a process. The schematic diagram for demonstrating the state which spreads the manufactured flooring on a floor base surface. The figure explaining 2nd Embodiment of the manufacturing method by this invention to process order. The figure explaining 3rd Embodiment of the manufacturing method by this invention to process order.

Explanation of symbols

  10a, 10b ... 1st floor base material, 11a, 11b ... 1st elongate member, 11c ... 3rd elongate member, 12a, 12b ... 1st surplus material, 13a, 13b ... 2nd surplus material , 14, 15, 16, 17 ... sane, 20, 20a, 20b ... second floor base material, 21, 21a ... second long member, P, Pa ... unit piece, 30, 30a, 30b ... floor material

Claims (6)

A step of cutting out the first elongated member from the first floor base material,
Applying a sane process to at least the long side of the first elongate member;
A step of forming a second floor base material by joining together the sane formed on the side in the longitudinal direction with two or more first long members subjected to the sane processing;
Cutting the second long member by cutting the second floor base material in a direction perpendicular to the direction of the sash that is adhesively bonded to the second floor base material;
A step of applying long side sag processing of the second long member;
And a method for producing a flooring material having a mosaic pattern on the surface. Two or more first floor base materials having different surface grain patterns are used as the first floor base material, and the first long member is cut out using them. After performing the process of sane processing on at least the long side of the long member, from the other first floor base material between the first long member cut out from the same first floor base material 2. The surface according to claim 1 , wherein the step of forming the second floor base material is performed so as to have at least one state where the cut first long member is located. Of flooring with mosaic pattern. Mosaic on a surface thereof according to claim 1 or 2, characterized in that it further comprises a step of chamfering the surface side edges of the longitudinal side edges of said first elongated member and the second elongate member Manufacturing method of flooring. The method further includes a step of cutting out a third long member having a width different from that of the first long member from the same or different first floor base material, and the third long member is interposed between the first long members. The mosaic pattern is formed on the surface according to any one of claims 1 to 3 , wherein the step of forming the second floor base material is performed so that the member is positioned at least in one place. Manufacturing method of flooring. The surface according to claim 4 , further comprising a step of chamfering the surface side edge portions of the longitudinal side edges of the third elongate member and the second elongate member. A method for manufacturing flooring. The method for producing a flooring material having a mosaic pattern on the surface according to any one of claims 1 to 5 , wherein a hot-melt adhesive having flexibility is used as the adhesive.

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