JP5643566B2 - Floor material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a flooring and a method for producing the same.

  As a flooring material, a material in which a thin wooden board is laminated and integrated on the surface of a wooden substrate via an adhesive has been put into practical use.

  For example, Patent Document 1 discloses a flooring material in which a thin wooden board is laminated and integrated on the surface of a hard wooden substrate with an adhesive, and the thickness of the adhesive layer is 30 to 75 μm and It is disclosed that the hardness measured with a type A durometer is 30 ° or less, and paper is provided between the adhesive layer and the thin wood veneer.

JP 2009-79427 A

  In recent years, the number of natural thin wood veneers with excellent appearance has decreased, and therefore, it has been unavoidable to use wood thin veneers of tree species that have not been used in the past as a flooring material. In addition, a unique pattern that has never existed for flooring has been demanded.

  Therefore, by applying the floor material disclosed in Patent Document 1 and using printed paper with a pattern printed on paper, the combination of the grain of wood thin veneer and the pattern that appears on the surface through the wood thin veneer It is conceivable to obtain excellent design properties.

  By the way, for printing the pattern on the paper, it is preferable to use a pigment that is superior in water resistance and weather resistance to the dye and excellent in the concealing property of the substrate. However, when a pigment is used, the pigment layer impedes the impregnation of the adhesive, and as a result, stress may be applied due to vibration or temperature change (for example, floor heating), and the pigment layer of the printing paper may be peeled off.

  In addition, if the thin wood veneer is made thin in order to show the pattern on the surface through the thin wood veneer, the strength is reduced, so cracks such as cracks and cracks are likely to occur, and furniture with casters has passed. In this case, the surface is likely to be dented.

  An object of the present invention is to obtain high crack resistance and caster resistance on a wood thin veneer while suppressing peeling on printing paper in a flooring material.

The invention according to claim 1 includes a substrate, a printing paper laminated on the substrate and integrated with a substrate-side adhesive of an ethylene / vinyl acetate copolymer resin adhesive and provided with a pigment layer on the surface side, and the printing A thin wood veneer having a surface that is laminated on paper and integrated with a single plate side adhesive of melamine-based adhesive, and is subjected to shot blasting to form irregularities, and the thin wood veneer on the thin wood veneer and a surface resin coating layer formed by the ultraviolet curable resin coating material composed mainly of urethane acrylates which are laminated such irregularities are embedded in the surface becomes a flat surface of the surface of the veneer, said from the surface A flooring in which the pigment layer of the printing paper is visible through a surface resin coating layer and the wood thin veneer,
The rubber hardness measured by a type A durometer based on JIS K6253 of the cured product of the substrate side adhesive is A45 / 15 or less, and the rubber hardness of the cured product of the single plate side adhesive is A70 / 15 or more. characterized in that there.

  According to the above configuration, the cured product of the substrate side adhesive has a relatively low rubber hardness, while the cured product of the single plate side adhesive has a relatively high rubber hardness. Peeling can be suppressed. Moreover, since the hardened | cured material of a single board | plate side adhesive agent has relatively high rubber hardness, the high crack resistance and caster resistance can be obtained to a wooden thin single board by the reinforcement effect.

The invention according to claim 2
Laminating printing paper having a pigment layer on the surface side on the substrate and integrating with a substrate side adhesive of ethylene / vinyl acetate copolymer resin adhesive ;
Laminating a thin wood veneer on printing paper integrated with the substrate, and integrating with a single plate side adhesive of a melamine adhesive ,
A step of performing shot blasting on the surface side of the wood thin veneer to form irregularities on the surface of the wood veneer;
After applying a resin coating mainly composed of UV curable urethane acrylate so that the surface irregularities are completely embedded on the thin wood veneer, the surface is flattened, and then cured by irradiating it with UV. Forming a surface resin coating layer
Comprising a surface resin coating layer and a wood thin veneer from which the printing paper pigment layer can be visually recognized through a method for producing a flooring,
As the substrate-side adhesive, a material whose rubber hardness measured by a type A durometer based on JIS K6253 of the cured product is A45 / 15 or less,
A single plate side adhesive, rubber hardness of the cured product is characterized Rukoto using more than A70 / 15.

  In this way, the flooring of the present invention can be manufactured.

Further, it is possible to obtain a variety of designs by varying the grinding amount of the wood thin veneer according to handle appearing in the pigment layer of the printing paper.

  As described above, according to the present invention, the cured product of the substrate side adhesive has a relatively low rubber hardness, while the cured product of the single plate side adhesive has a relatively high rubber hardness. With this construction, peeling on the printing paper and the pigment layer can be suppressed, and the cured product of the veneer side adhesive has a relatively high rubber hardness. Cracking and caster resistance can be obtained.

It is sectional drawing of the flooring which concerns on embodiment. (A)-(f) is explanatory drawing of the manufacturing method of the flooring which concerns on embodiment.

  Hereinafter, embodiments will be described in detail based on the drawings.

  A flooring 10 according to the present embodiment includes a substrate 11, a printing paper 12, a wood thin veneer 13, and a surface resin coating layer 14 that are sequentially stacked thereon. The printing paper 12 is integrated with the substrate 11 by the substrate side adhesive 15, and the wood thin veneer 13 is integrated with the printing paper 12 by the single plate side adhesive 16.

  Examples of the substrate 11 include wood boards such as plywood, MDF, LVL, and particle board; wood composite boards obtained by laminating and bonding thin MDF on the surface of these wood boards; Wood substrate reinforced by providing a resin layer such as melamine resin, phenol resin, epoxy resin, urethane resin, isocyanate resin, etc. or reinforced by impregnating the resin surface layer with a resin and curing; inorganic Examples include inorganic boards such as fiber boards and volcanic glassy multilayer boards; synthetic resin boards and the like. The board | substrate 11 may be comprised with the single material and may be comprised with the laminated body of the some board | plate material. The thickness of the substrate 11 is, for example, 1 to 20 mm.

The printing paper 12 has a paper body 12a and a pigment layer 12b provided on the paper main body 12a, that is, on the surface of the wood thin veneer 13 side. The pigment layer 12 b of the printing paper 12 is visible from the surface of the flooring 10 through the wood thin veneer 13 and the surface resin coating layer 14. The printing paper 12 may be provided with the pigment layer 12b on the entire surface, or the pigment layer 12b may be provided only on a part of the surface. For example, the printing paper 12 has a thickness of 30 to 100 μm and a basis weight of 25 to 60 g / m ² .

  Examples of the paper body 12a include film-like or sheet-like paper-like materials such as titanium paper, craft paper, and inter-paper reinforced paper. For the purpose of concealing the substrate 11 from the surface of the flooring 10, the paper main body 12a may be bonded and composited with a concealing sheet such as aluminum foil on the back surface, or a white pigment may be internally added.

  The pigment layer 12b is patterned with printing ink. The printing ink used for the pattern construction may be water-based, solvent-based, or emulsion-based, and contains a binder, a color pigment, an extender pigment, and various additives. Examples of the binder include nitrified cotton, cellulose, vinyl chloride-vinyl acetate copolymer, and the like. Examples of the color pigment include titanium oxide, zinc white, iron oxide, chrome lead, phthalocyanine blue, and benzidine yellow. Examples of extender pigments include calcium carbonate, barium sulfate, talc, and quartz powder. The pigment layer 12b is provided with a resin layer that covers the entire surface or a part of the surface so as to cover the pattern for the purpose of giving the pattern a glitter or gloss such as a pearl tone or a metallic tone. It may be.

  Examples of the pattern appearing in the pigment layer 12b include a grain pattern such as a plate pattern or a grid pattern; a continuous or intermittent linear stripe pattern; a continuous or intermittent wave pattern; Examples include ground patterns such as spotted patterns and yuzu skin patterns; other irregular curved patterns and fine lattice patterns.

  Examples of the thin wood veneer 13 include natural wood materials such as conifers, hardwoods, so-called fast-growing trees, and thin slices (artificial veneers) obtained by slicing a laminate of natural wood materials. Specific examples of the thin wood veneer 13 include a soft walnut veneer and a hard birch veneer. Further, the thin wood veneer 13 may be a dry veneer or a raw veneer (wet veneer). The wood thin veneer 13 is transparent or translucent to such an extent that the pigment layer 12b of the printing paper 12 is visible from the surface of the flooring 10. Here, “transparent” usually means that the visible light transmittance exceeds 80%. “Translucent” means that the visible light transmittance exceeds 0% and is 80% or less. “Opaque” means a visible light transmittance of 0%.

  The wood thin veneer 13 is subjected to brushing and / or shot blasting grinding on the surface side to form irregularities, and the thickness of the wood thin veneer 13 is, for example, 0.15 to 1.0 mm. Preferably, the thickness is 0.25 to 0.6 mm, and various designs can be obtained by changing the grinding amount of the thin wood sheet 13 according to the pattern appearing on the pigment layer 12b of the printing paper 12 in such a manner. Can be obtained. For example, when the pattern of the pigment layer 12b is a wood grain with a narrow gradation width, the amount of grinding is increased to form the thin wood veneer 13 thin, thereby increasing the degree of transmission of the wood thin veneer 13; The color pattern of the grain of the pigment layer 12b can be clearly displayed on the surface of the flooring 10 through the thin wood board 13.

  As a resin paint for forming the surface resin paint layer 14, for example, light in which a photo-curing agent such as a UV curing agent is blended with an uncured resin such as a urethane acrylate resin, an epoxy acrylate resin, or a meta acrylate resin. Examples thereof include curable resin paints. The resin paint may be composed of a single type or may be composed of a plurality of types. The surface resin coating layer 14 may be composed of a single layer or may be composed of a plurality of layers. The surface resin coating layer 14 is transparent or translucent. The surface resin coating layer 14 is provided so as to cover the uneven surface of the thin wood veneer 13 and form a flat surface, and the thickness thereof is, for example, 0.01 to 0.4 mm.

  Examples of the substrate-side adhesive 15 include thermoplastic resins such as acrylic resins, vinyl acetate resins, urethane resins, and modified resins thereof; urea melamine resins, epoxy resins, phenol resins, isocyanate resins, and the like. A resin adhesive in which a mixture of a thermoplastic resin and a thermosetting resin or the like is dissolved in a solvent. The substrate-side adhesive 15 may be increased in viscosity by adding a thickener or a bulking agent in order to increase the coating amount. Examples of the thickener include wheat flour and poval. Examples of the bulking agent include calcium carbonate, alumina, titanium oxide and the like. The cured product of the substrate-side adhesive 15 may be transparent or translucent, but from the viewpoint of concealing the substrate 11 from the surface of the flooring 10, it is opaque by blending a concealing agent such as titanium oxide. It is preferable that concealability is imparted.

  The board | substrate side adhesive 15 may form the layer of the board | substrate side adhesive 15 between the board | substrate 11 and the printing paper 12, In that case, the thickness is 30-75 micrometers, for example. The substrate side adhesive 15 may be impregnated into the substrate 11 and / or the paper body 12a of the printing paper 12 and cured. The cured product of the substrate-side adhesive 15 preferably has a rubber hardness measured by a type A durometer based on JIS K6253 of A45 / 15 or less, and more preferably A30 / 15 or less.

  Examples of the single plate side adhesive 16 include thermoplastic resins such as acrylic resins, vinyl acetate resins, urethane resins, and modified resins thereof; urea melamine resins, epoxy resins, phenol resins, and isocyanate resins. And a resin adhesive obtained by dissolving a mixture of a thermoplastic resin and a thermosetting resin in a solvent. The cured product of the substrate side adhesive 15 is transparent or translucent so that the pattern of the printing paper 12 appears on the surface.

  The veneer-side adhesive 16 may form a layer of the veneer-side adhesive 16 between the printing paper 12 and the thin wood veneer 13, and in that case, the thickness is, for example, 5 to 30 μm. The veneer side adhesive 16 may be impregnated into the printing paper 12 and / or the thin wood veneer 13 and cured. The cured product of the veneer side adhesive 16 has a rubber hardness measured by a type A durometer based on JIS K6253 higher than the cured product of the substrate side adhesive 15, specifically, A70 / 15 or more. It is preferable that it is A90 / 15 or more.

  According to the flooring 10 according to the above embodiment, the cured product of the substrate side adhesive 15 has a relatively low rubber hardness, while the cured product of the single plate side adhesive 16 has a relatively high rubber hardness. Therefore, peeling with the printing paper 12 can be suppressed by these configurations, and the hardened material of the veneer-side adhesive 16 has a relatively high rubber hardness. 13, high crack resistance and caster resistance can be obtained.

  Below, the manufacturing method of the flooring 10 which concerns on this embodiment is demonstrated.

  First, as shown in FIG. 2A, a substrate-side adhesive 15 is applied to the surface of the substrate 11 using a coating apparatus such as a roll coater or a flow coater.

  Next, as shown in FIG. 2 (b), the printing paper 12 is placed on the surface of the uncured substrate-side adhesive 15, and the substrate-side adhesive 15 is pressed or heated and pressed by a hot press or the like. Is cured. At this time, the printing paper 12 is laminated and integrated on the substrate 11. The pressurizing pressure is, for example, 0.2 to 1.0 MPa. The heating temperature is, for example, 100 to 130 ° C. The processing time is, for example, 30 to 90 seconds.

  Next, as shown in FIG. 2C, the single plate side adhesive 16 is applied to the surface of the printing paper 12 using a coating apparatus such as a roll coater or a flow coater.

  Subsequently, as shown in FIG. 2 (d), the wood thin veneer 13 is placed on the surface of the uncured veneer side adhesive 16, and is pressed or heated and pressed by a hot press or the like. The adhesive 15 is cured. At this time, the wood thin veneer 13 is laminated and integrated on the printing paper 12. The pressurizing pressure is, for example, 0.2 to 1.0 MPa. The heating temperature is, for example, 100 to 130 ° C. The processing time is, for example, 30 to 90 seconds. In addition, the woody thin veneer 13 may be temporarily fixed by preliminarily removing moisture by high frequency or the like and solidifying the veneer side adhesive 16.

  And as shown in FIG.2 (e), the cutting process of a brushing process and / or a shot blasting process is given to the surface side of the thin wood board | plate 13, and an unevenness | corrugation is formed in the single board surface.

  Finally, as shown in FIG. 2 (f), a resin coating is applied to the surface of the thin wood veneer 13 so that the unevenness is completely buried and the surface becomes a flat surface, and then irradiated with ultraviolet rays or the like. The surface resin coating layer 14 is formed by curing. Thus, the flooring 10 according to the present embodiment is manufactured.

  In the above embodiment, the surface of the wood thin veneer 13 is uneven. However, the present invention is not limited to this, and the surface of the wood thin veneer 13 is formed as a flat surface. May be. In this case, the surface of the flat wood thin veneer 13 may be exposed, or the surface resin coating layer 14 may be provided so as to cover the surface of the flat wood thin veneer 13. Also good.

Example 1
Reinforced printing paper (Shirakawa) coated with a substrate side adhesive (Koyo Sangyo Co., Ltd. ethylene / vinyl acetate copolymer resin adhesive KR470) on a substrate made of W hard base plywood, and then gravure-printed with pigment on the surface. Product name: Hard sheet α, 30 g / m ² per unit area) were laminated so as to be pasted and integrated by a hot press. The rubber hardness measured with a type A durometer based on JIS K6253 of the cured product of the substrate side adhesive is A30 / 15.

  Next, a veneer side adhesive (a hard adhesive in which 5 parts of SBR adhesive is added to 95 parts by weight of melamine adhesive) is applied on the printing paper, and a thin wood veneer (sawagurumi veneer) is laminated thereon. And integrated with a hot press. The rubber hardness of the cured product of the single plate side adhesive is A90 / 15.

  Subsequently, the surface side of the wood thin veneer is shot blasted and cut to form irregularities on the surface of the veneer, and the irregularities are completely embedded on the wood thin veneer so that the surface is flat. After applying an ultraviolet curable resin coating (resin containing urethane acrylate as a main component), it was cured by irradiating it with ultraviolet to form a surface resin coating layer. The obtained flooring was taken as Example 1.

  On the flooring of Example 1, a test (hereinafter referred to as a “caster resistance test”) in which a steel single wheel caster having a diameter of 50 mm on which a load of 25 kg was placed was reciprocated 500 times at a distance of 300 mm was performed. The moving speed of the caster was 2 seconds / reciprocation.

  It was 0.15 mm when the amount of dents on the flooring surface was measured after the test. Further, visual observation was performed after the test, but no material destruction was observed.

(Comparative Example 1)
A flooring material having the same configuration as that of Example 1 was prepared except that the same urea melamine resin adhesive as the single plate side adhesive was used as the substrate side adhesive, and this was used as Comparative Example 1.

  The flooring material of Comparative Example 1 was subjected to a caster resistance test.

  When visual observation was performed after the test, peeling between the paper body and the pigment layer in the reinforced printing paper was observed along with material destruction.

(Example 2)
A substrate side adhesive (manufactured by Koyo Sangyo Co., Ltd., ethylene / vinyl acetate copolymer resin adhesive KR470 with 5 parts of titanium oxide added as a concealing agent) is applied onto a substrate made of an MDF composite material, and a pigment is coated on the surface The reinforced printing paper (trade name: hard sheet α, manufactured by Shirakawa Paper Co., Ltd., weight per unit area: 30 g / m ² ) that was gravure-printed was laminated and integrated by a hot-press press. The rubber hardness measured with a type A durometer based on JIS K6253 of the cured product of the substrate side adhesive is A30 / 15.

  Next, a veneer side adhesive (a hard adhesive in which 5 parts of an SBR adhesive is added to 95 parts by weight of a melamine adhesive) is applied onto the printing paper, and a thin wood veneer (birch veneer) is laminated thereon. And integrated with a hot press. The rubber hardness of the cured product of the single plate side adhesive is A90 / 15.

  Subsequently, the surface side of the wood thin veneer is shot blasted and cut to form irregularities on the surface of the veneer, and the irregularities are completely embedded on the wood thin veneer so that the surface is flat. After applying an ultraviolet curable resin coating (resin containing urethane acrylate as a main component), it was cured by irradiating it with ultraviolet to form a surface resin coating layer. The obtained flooring was taken as Example 2.

  The flooring material of Example 2 was subjected to a caster resistance test.

  It was 0.15 mm when the amount of dents on the flooring surface was measured after the test. Further, visual observation was performed after the test, but no material destruction was observed.

(Comparative Example 2)
A flooring material having the same configuration as that of Example 2 was prepared except that a urea melamine resin adhesive added with 5 parts of titanium oxide as a masking agent was used as the substrate side adhesive, and this was used as Comparative Example 2. . The rubber hardness of the cured substrate-side adhesive is A90 / 15.

  The flooring material of Comparative Example 2 was subjected to a caster resistance test.

  When visual observation was performed after the test, no material destruction was observed, but peeling between the paper body and the pigment layer in the reinforced printing paper was observed.

  The present invention is useful for flooring and a method for producing the same.

DESCRIPTION OF SYMBOLS 10 Floor material 11 Board | substrate 12 Printing paper 12a Paper main body 12b Pigment layer 13 Wood thin veneer 14 Surface resin paint layer 15 Board | substrate side adhesive 16 Single board | plate side adhesive

Claims (2)

A substrate, a printing paper laminated on the substrate and integrated with a substrate side adhesive of ethylene / vinyl acetate copolymer resin adhesive, and a pigment layer provided on the surface side, and a melamine-based adhesive laminated on the printing paper A thin wood veneer with irregularities formed by shot blasting on the surface integrated with the adhesive on the veneer side of the adhesive, and the irregularities on the surface of the wood thin veneer are embedded on the wood thin veneer A surface resin coating layer formed of an ultraviolet curable resin coating mainly composed of urethane acrylate and laminated so that the surface becomes a flat surface, and the surface resin coating layer and the woody thin layer from the surface. A flooring in which the pigment layer of the printing paper is visible through a veneer,
The rubber hardness measured by a type A durometer based on JIS K6253 of the cured product of the substrate side adhesive is A45 / 15 or less, and the rubber hardness of the cured product of the single plate side adhesive is A70 / 15 or more. flooring, characterized in that. Laminating printing paper having a pigment layer on the surface side on the substrate and integrating with a substrate side adhesive of ethylene / vinyl acetate copolymer resin adhesive ;
Laminating a thin wood veneer on printing paper integrated with the substrate, and integrating with a single plate side adhesive of a melamine adhesive ,
A step of performing shot blasting on the surface side of the wood thin veneer to form irregularities on the surface of the wood veneer;
After applying a resin coating mainly composed of UV curable urethane acrylate so that the surface irregularities are completely embedded on the thin wood veneer, the surface is flattened, and then cured by irradiating it with UV. Forming a surface resin coating layer
Comprising a surface resin coating layer and a wood thin veneer from which the printing paper pigment layer can be visually recognized through a method for producing a flooring,
As the substrate-side adhesive, a material whose rubber hardness measured by a type A durometer based on JIS K6253 of the cured product is A45 / 15 or less,
A single plate side adhesive, the manufacturing method of flooring rubber hardness of the cured product is characterized Rukoto using more than A70 / 15.

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