JP6639923B2 - Floor material and method of manufacturing the same - Google Patents

Description

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

  The flooring used for detached houses, condominiums, and other buildings is made of solid flooring made of solid wood, plywood, a surface of a wooden base made of MDF, or a laminate of these wooden bases. There is a decorative flooring material in which a precious wood decorative material is adhered to the surface of a wooden base material (hereinafter, a laminated wooden base material is also simply referred to as a "wood base material").

  The decorative flooring material uses a base material that has less expansion and contraction due to moisture than solid wood, and the surface is coated with various coatings to prevent moisture from entering the interior. It has been used in many construction sites because of its low warpage and easy handling in the usage environment.

  The wood decorative material used for the decorative flooring material is roughly classified into a thin plate having a thickness of about 0.2 to 0.6 mm and a thick plate having a thickness of about 0.7 to 3.0 mm. The thin plate is manufactured by cutting and bonding a combination of a plurality of wood blocks with a slicer. A plate manufactured by such a manufacturing method is called a veneer. On the other hand, as a thick plate, in addition to a veneer plate, a relatively thick one is often manufactured by cutting wood with a band saw or the like. A plate manufactured by such a manufacturing method is called a ground plate.

  Generally, grooves are often provided on the surface of the decorative flooring material between the bonded wood blocks from the viewpoint of practicality and design. As a cross-sectional shape of a groove formed on the floor material surface, a V-shape is often used.

  However, a floor material having a V-shaped groove in cross section has a drawback that the material feeling and the three-dimensional appearance are inferior to the floor material using solid wood. Therefore, Patent Literatures 1 to 3 propose floor materials having a groove formed by combining the wall surface of the groove with a flat surface and a curved surface, or a combination of a plurality of flat surfaces. In particular, Patent Literature 1 describes a method in which a predetermined groove is formed by cutting, then the surface layer is polished by a ring polisher, and further pressed by a press. Patent Literature 2 discloses a method in which grooves are formed by stepwise cutting using a plurality of types of circular saws having different cutting angles.

  In Patent Literature 3, the cross-sectional shape of the slope of the vertical groove provided on the surface side of the wooden decorative material has a first straight line portion and a curved portion protruding outward from the slope in order from the surface side of the wooden decorative material. And an invention relating to a wooden flooring material having a second straight portion. The first straight portion, the curved portion, and the second straight portion of the cross section of the vertical groove may be formed separately. However, from the viewpoint of productivity, the first straight portion, the curved portion, and the second straight portion may be formed separately. It is preferable to form them simultaneously using a circular saw having a corresponding shape.

JP 2001-353706 A JP 2003-220602 A JP 2014-163199 A

  In each of the methods described in Patent Documents 1 to 3, a plurality of grooves (grooves whose opening angle becomes narrower as the depth increases) are formed by cutting such as a circular saw and a router. In this case, the saw blade is worn, and the angle of the blade edge of the saw blade is limited. Therefore, it is difficult to stably form a groove having a narrow opening angle. When the thickness of the decorative material is thin as in the case of the floor material described in Patent Literature 1, a portion where the base material is exposed in the groove (base material exposed portion) may be generated. If the area of the material exposed portion is large, there is a problem that the aesthetic appearance is impaired and fuzzing occurs at the bottom of the groove.

  The present invention has been made in order to solve the problems of the related art, and has as its first object to provide a method of manufacturing a flooring material capable of stably manufacturing a plurality of grooves. . A second object of the present invention is to provide a flooring material in which the thickness of the decorative material is thin and the appearance of the base material is not impaired even when the exposed portion of the base material is present in the groove, and the fluffing is unlikely to occur.

  The gist of the present invention is the following flooring materials and a method for producing the same.

(A) A method for manufacturing a flooring material comprising a decorative material, a base material, and a groove formed on the surface of the decorative material and having a base material exposed portion,
(1) forming a first groove having an opening angle of 100 to 150 ° on the surface of the decorative material;
(2) a step of forming a second groove having an opening angle of 15 to 40 °,
In the step (2), the deepest part of the first groove is embossed to form the second groove.
The method of manufacturing flooring.

  (B) The method for producing a flooring material according to (A), wherein in the step (1), the first groove is formed by cutting.

  (C) In the step (1), the depth of the first groove is greater than the thickness of the decorative material and is equal to or less than (the thickness of the decorative material + 0.2 mm), and B) The method for producing a flooring material.

  (D) The method for producing a flooring material according to any one of the above (A) to (C), wherein a stamping roll is used in the step (2).

  (E) The method for producing a flooring material according to any one of the above (A) to (D), wherein the width of the exposed portion of the base material is 0.1 to 0.5 mm.

  (F) The method for manufacturing a flooring material according to any one of (A) to (E), wherein an opening width of the second groove is smaller than a width of the exposed portion of the base material.

  (G) The method for producing a flooring material according to any one of (A) to (F), wherein the depth is 1.0 to 3.0 times the width of the exposed portion of the base material.

  (H) A flooring material including a decorative material having a thickness of 1.0 mm or less, a base material, and a groove formed on a surface of the decorative material, wherein the groove has an opening angle of 100 to 150 °. A first groove and a second groove having an opening angle of 15 to 40 ° at a position deeper than the first groove, wherein the groove has a width of 0.1 to 0.5 mm; The flooring, wherein the second groove is formed in the exposed base material, and the depth of the second groove is 1.0 to 3.0 times the width of the exposed base material.

  (I) The floor material according to (H), wherein the opening width of the first groove is 1.5 to 6.0 mm.

  (J) The floor material according to the above (H) or (I), wherein the opening width of the second groove is smaller than the width of the base exposed portion.

  In the flooring material according to the present invention, the decorative material has a small thickness, and even if there is an exposed base material in the groove, the aesthetic appearance is not impaired, and fluffing is unlikely to occur. Further, the floor material manufacturing method according to the present invention can stably manufacture a plurality of steps of grooves.

The figure which illustrated the flooring material which concerns on this embodiment. Conceptual diagram illustrating a grooving device Diagram illustrating floor material before groove processing Figure illustrating floor material after first groove processing Figure illustrating floor material after second groove processing

  A flooring according to the present embodiment and a method for manufacturing the same will be described with reference to FIGS.

1. Floor material according to the present embodiment As shown in FIG. 1, a floor material 10 according to the present embodiment is formed on a decorative material 1 having a thickness of 1.0 mm or less, a base material 2, and a surface of the decorative material. And a floor material provided with a groove 3. The groove 3 has a first groove 3a and a second groove 3b at a position deeper than the first groove 3a. The groove 3 is provided with a substrate exposed portion 3c, and the second groove 3b is formed in the substrate exposed portion 3c.

  As the decorative material 1 according to the present embodiment, a material obtained by processing wood such as a veneer or a ground plate is used. The thickness of the decorative board 1 increases as the thickness increases, and the dimensional change such as warpage increases, which makes it difficult to handle. The thickness of the decorative plate 1 is preferably 0.8 mm or less, more preferably 0.7 mm or less, and even more preferably 0.6 mm or less, since the thinner the decorative plate 1 is, the cheaper it is. However, if it is too thin, the production becomes difficult and the appearance may be impaired. Therefore, the thickness is preferably at least 0.2 mm, more preferably at least 0.3 mm.

  As the base material 2 according to the present embodiment, a plywood, a wood board such as MDF / PB, or a laminate of them can be used. The thickness is not particularly limited, and a base material having a thickness of 6 mm, 9 mm, 12 mm, or the like, which is used for a normal flooring material, may be used. Further, similarly to a normal flooring material, a groove may be provided on the back surface of the base material or a cushioning material may be provided to improve workability and sound insulation performance.

(Opening angle of the first groove)
The opening angle of the first groove 3a is 100 to 150 °. If the opening angle is less than 100 °, the groove becomes too deep to obtain a sufficient groove width, and if it exceeds 150 °, the depth of the groove cannot be sufficiently obtained, and the appearance is impaired. The lower limit of the opening angle is preferably 120 °, more preferably 130 °. On the other hand, the upper limit is preferably 140 °. Although the figure shows an example in which the inclination of the first groove 3a is configured as a straight line in the cross-sectional direction, it may be a curved shape such as an arc or a parabola. The opening angle in the case of being constituted by a curve is the angle between straight lines connecting the respective groove ends and the groove bottom.

(Width of the first groove)
The opening width of the first groove 3a (i.e., the width of the groove 3) _{W 1} is preferably set to 1.5～6.0Mm. This is because if it is too narrow or too wide, it will damage the aesthetics. In particular, 2.0 mm or more is preferable.

(Depth of the first groove)
The depth of the first groove 3a is good comparable to the thickness h ₁ of the decorative material 1. Specifically, the thickness h ₁ -0.2 mm or more of the decorative material 1 is preferable. However, because it may damage the exposed appearance of the decorative material 1 having a thickness of the h ₁ too deep than the base material, it is preferable to less thickness h _{1 +} 0.3 mm of the decorative material 1. More preferably, it is set to h ₁ +0.2 mm or less. The depth of the first groove 3a means the distance from the floor material surface to the intersection of the two slopes of the first groove 3a.

(Width of exposed part of substrate)
Groove 3 is provided with a substrate exposed portion 3c width _{W 3} is 0.1 to 0.5 mm. In flooring 10 according to the present embodiment, directed to a thickness 1.0mm below the decorative material, or the width _{W 3} is less than 0.1 mm, shallow depth of the groove 3 _(h 1 + h _2), It is necessary to reduce the width (w ₁ ) of the groove 3. On the other hand, when the width _{W 3} exceeds 0.5 mm, the exposed area of the substrate 2 is increased, impairing the appearance. Width _{W 3} it is preferably set to 0.4mm or less. As will be described later, a second groove 3b is formed in the exposed portion of the base material. When the second groove 3b is formed, the exposed portion 3c of the base material is partially pushed into the base material to form a curved shape. The width of the portion 3c means an interval (W _{3 in} FIG. 1) between boundaries between the decorative material 1 and the base material 2 in the groove 3.

(Opening angle of the second groove)
The opening angle of the second groove 3b is 15 to 40 °. Even with embossing, it is difficult to machine a groove with an opening angle of less than 15 °, and if the opening angle exceeds 40 °, the slope of the second groove 3b constituted by the cross section of the substrate 2 becomes This is because it becomes easy to see from above the flooring material, which impairs the aesthetic appearance. The lower limit of the opening angle is preferably 20 °, and the upper limit is preferably 30 °.

(Width and depth of the second groove)
Opening width _{W 2} of the second groove 3b is smaller than the width _{W 3} of the substrate exposed portion 3c, a depth _{h 2} is 1.0 to 3.0 times the width _{W 3} of the substrate exposed portion 3c ( _that, h 2 / _{W 3} is good in the range of 1.0 to 3.0). In the present embodiment, even if the base material exposed portion 3c is present in the groove 3, the exposed surface of the second groove is difficult to see from above the flooring material, and the decorative material 1 having a thickness of 1.0 mm or less is used. However, this is intended to make it easy to make an illusion that the cosmetic material has a thickness exceeding that. _However, if h 2 / _{W 3} is less than 1.0, it is difficult to decorative material is to be illusion and thicker than 1.0mm. If h ₂ / W ₃ exceeds 3.0, processing becomes difficult, the variation in groove width tends to be large, and the strength of the floor material may be reduced.

Note that the opening width W ₂ of the second groove 3b, a virtual line obtained by extending the inclined surface of the first groove 3a and (dashed line), two intersections between the virtual line (dotted line) obtained by extending the inclined surface of the second groove 3b Means the distance between them. Further, the depth h ₂ of the second groove 3b, means the difference between the depth of the interface between the depth and the groove bottom of the decorative material 1 and the base 2.

(Other)
At the end of the flooring 10, a half groove having the same shape as the groove 3 according to the present embodiment can be provided. This is because when the floor material 10 is constructed, the contact portions between the half grooves can have the same shape as the groove 3 according to the present embodiment. The groove 3 according to the present embodiment may be a so-called vertical groove provided in parallel with the longitudinal direction of the flooring material 10 or a so-called lateral groove provided in parallel with the short direction of the flooring material 10. Further, as described later, the first groove 3a is formed by cutting, and the second groove 3b is formed by embossing. However, the first groove 3a is partially pushed in during embossing, and as a result, Thus, a curved surface portion exists between the first groove 3a and the second groove 3b. Such a case is also included in the scope of the present invention.

2. FIG. 2 is a conceptual diagram of an apparatus for manufacturing the flooring according to the present embodiment. As shown in FIG. 2, for example, a work 20 including a decorative material 21 and a base material 22 (see also FIG. 3) is moved by a conveyor 50 in a direction of an arrow in the drawing with the decorative material 21 on the lower side. Sent. Then, the first groove 23a is formed in the work 20 by cutting such as the circular saw 30 (see also FIG. 4). At this time, the first groove 23a may be a groove reaching the base material, that is, a groove having a base material exposed portion. Subsequently, the deepest portion 24 of the first groove 23a is embossed on the work 20 having the first groove 23a formed thereon by embossing such as the embossing roll 40 to form the second groove 23b. 5). In the case where the first groove 23a has an exposed substrate, the second groove 23a is preferably formed in the exposed substrate.

  At this time, as shown in FIG. 4, the opening angle of the first groove 23a formed in the work 20 by cutting such as the circular saw 30 is 100 to 150 °. The depth of the first groove 23a preferably exceeds the thickness of the decorative material 21 and is equal to or less than (the thickness of the decorative material + 0.2 mm). The opening angle and width of the first groove 23a are as defined in the above-described FIG.

  Although the step of forming the first groove 23a has been described using the circular saw 30 as an example, the method is not limited to such a method, and a commonly used cutting tool such as a router can be used. Although the figure shows an example in which the inclination is formed by a straight line, the inclination may be a curve such as an arc or a parabola.

  As shown in FIG. 5, the opening angle of the second groove 23b formed in the work 20 in which the first groove 23a is formed by the embossing process of the embossing roll 40 or the like is 15 to 40 degrees. The opening width is preferably smaller than the width of the exposed substrate portion 23c, and the depth thereof is preferably 1.0 to 3.0 times the width of the exposed substrate portion 23c. The opening angle, opening width, and depth of the second groove are as defined in the above-described FIG.

  The step of forming the second groove 23b has been described by using the case where the embossing roll 40 is used as an example. However, the present invention is not limited to such a method, and a mold corresponding to the dimensions of the floor material and the arrangement of the grooves is prepared. Then, the grooves can be formed by pressing with a press machine or the like. Here, in the step of forming the second groove 23b, the first groove 23a is partially pressed in following the movement of the embossing tool at the time of embossing, and as a result, the first groove 23a and the second groove 23b There is a curved portion between the two.

  ADVANTAGE OF THE INVENTION According to the flooring material which concerns on this invention, although a groove width | variety is wide and there is a base material exposure part, since the exposed surface is a groove | channel which is hard to be visually recognized from above a flooring material, the thickness less than 1.0 mm Even if the flooring is provided with a material, it is easy to make an illusion that the decorative material has a thickness exceeding that, and the texture as the flooring is improved. Further, according to the method for manufacturing a flooring material according to the present invention, first, a groove (first groove: obtuse angle groove) near the surface is formed by cutting, and thereafter, a groove (portion near the groove bottom) is formed. (A second groove: an acute angle groove), a floor material having a groove having a wide groove width and having a base material exposed portion, but having an exposed surface that is difficult to be visually recognized from above the floor material can be easily and stably formed. It becomes possible to manufacture it. The method for manufacturing a flooring material according to the present embodiment is particularly useful when a groove is formed in a flooring material provided with a decorative material having a thickness of 1.0 mm or less.

Reference Signs List 1 cosmetic material 2 base material 3 groove 3a first groove 3b second groove 3c base material exposed portion 10 floor material 20 according to this embodiment work 21 decorative material 22 base material 23 groove 23a first groove 23b second groove 23c base material Exposed part 30 Circular saw 40 Embossing roll 50 Upper surface of conveyor

Claims (10)

A method of manufacturing a flooring material including a decorative material, a base material, and a groove formed on the surface of the decorative material and having a base material exposed portion,
(1) forming a first groove having an opening angle of 100 to 150 ° on the surface of the decorative material;
(2) forming a second groove having an opening angle of 15 to 40 ° ;
With
In the step (2), the deepest portion of the first groove is embossed, and the second groove is formed so that a curved portion exists at a boundary portion with the first groove. Method. In the step (1), the first groove is formed by cutting.
The method for producing a flooring material according to claim 1. In step (1), the depth of the first groove is greater than the thickness of the decorative material, Ru der below (the decorative material thickness + 0.2 mm) of,
The method for producing a flooring material according to claim 1. In the step (2), an embossing roll is used.
A method for manufacturing a flooring material according to any one of claims 1 to 3. The width of the substrate exposed portion is 0.1 to 0.5 mm,
A method for manufacturing a flooring material according to any one of claims 1 to 4. The opening width of the second groove is smaller than the width of the substrate exposed portion,
A method for manufacturing a flooring material according to any one of claims 1 to 5. The depth of the second groove is 1.0 to 3.0 times the width of the exposed portion of the base material,
A method for producing a flooring material according to any one of claims 1 to 6. A floor material having a decorative material having a thickness of 1.0 mm or less, a base material, and a groove formed on a surface of the decorative material,
The groove, the first groove having an opening angle of 100 to 150 °, the second groove having an opening angle of 15 to 40 ° at a position deeper than the first groove, and the first groove and the second groove And a curved surface portion provided at a boundary portion of
The groove includes a substrate exposed portion having a width of 0.1 to 0.5 mm,
The second groove is formed in the exposed substrate portion, and the depth of the second groove is 1.0 to 3.0 times the width of the exposed substrate portion.
Flooring. An opening width of the first groove is 1.5 to 6.0 mm;
The flooring according to claim 8. The opening width of the second groove is smaller than the width of the substrate exposed portion,
The flooring material according to claim 8.

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