JPH04238959A - Uneven surface pattern floor material - Google Patents

Abstract

PURPOSE:To provide a floor material having decorative properties and non-slip properties by a method wherein a substrate pattern layer is formed on a base material, e.g. a foam, and low protrusionlike pattern areas the tops of which are flat are formed on the substrate pattern layer. CONSTITUTION:A base material 1 is coated with a foamable or PVC paste substrate layer by means of a doctor blade and gelled by a heater to form a foamed layer 10. A substrate pattern layer 6 is formed on the foamed layer 10, and low protrusionlike pattern areas 13 with a thickness of approximate 0.3-1mm are formed on the substrate pattern layer 6. The low protrusionlike areas 13 are formed at intervals of a distance of approximate 3-30mm on the substrate pattern layer 6, and a protrusion top part 16 is flattened and mixed with antislip microparticles 15. This constitution provides an excellent walking feeling and non-slip properties.

Description

[Detailed description of the invention]

0001

FIELD OF INDUSTRIAL APPLICATION The present invention relates to a textured flooring material having a design and non-slip properties.

0002

[Prior Art and its Problems] Conventionally, flooring materials have been required to have good stepping comfort and non-slip properties, and the inventors of the present invention
In No. 186, we proposed a non-slip flooring material. However, a flooring material with a three-dimensional design with pattern contrast and non-slip properties has not been known to date.

0003

[Means for Solving the Problems] The present invention is an invention that solves the above problems, and includes forming a base pattern layer on a base material, and forming small convex pattern areas with substantially flat tops on the pattern layer. The gist of the present invention is to provide a concavo-convex pattern flooring material in which a recess is formed between the small convex pattern areas, and the bottom surface of the concave portion is the base pattern layer.

The present invention will be explained below based on the drawings. FIG. 1 is a diagram showing the manufacturing process of the present invention, in which a foamable or non-foamable polyvinyl chloride (PVC) paste lower layer 2 is applied onto a base material 1 with a doctor blade 3, and pregelled with a heater 4. The base material 1 may be a releasable sheet, or may be a woven or nonwoven fabric of glass or organic fiber. Next, a base pattern layer 6 is provided on the pregelled PVC layer. The surface of the base pattern layer is printed with ink using a transfer roll 5, or by rotary printing, gravure printing, or a non-printing method.
It is sufficient to form a relatively thin pattern portion of 50 μm. The base pattern layer may be formed by providing the thin pattern portion on the surface of a nonwoven fabric or the like. The base pattern layer preferably has a thickness of 0.2 to 0.6 mm. Note that a protective layer may be appropriately formed on the base pattern.

7 is a forming device for forming small convex pattern areas in the present invention, and a rotary screen, a flat screen, or other stencil device is used to form a PVC paste or other viscous liquid resin of 0.3 to 1. 0m
Printed on m. At this time, it is desirable that the opening of the printing device be large and that the thickness of the opening be thick so that a desired pattern can be obtained. In this way, the small convex pattern area 8 is obtained.

[0006] The small convex pattern area is formed with a flat top surface. Small convex pattern areas are formed on the base pattern layer at intervals of 3 to 30 mm, and after pregelling if necessary, the foamable resin layer is foamed at 180 to 220°C, and then led to an oven 9. The foam layer is gelled.

[0007] After this heat gelling step, the releasable sheet is removed if necessary. 10 is a foam layer. In this way, the flooring material 11 of the present invention is obtained.

In FIG. 1, a PVC paste is applied after pregelling the paste lower layer 2 using a heater 4, and before the paste layer is solidified, a base pattern layer on which a pattern has been formed in advance by the printing device is placed on a nonwoven fabric. It is also possible to form a small convex pattern area on the paste layer after pregelling it.

FIG. 2 is a cross-sectional view of the flooring material of the present invention, and 1 is a base material, which may be made of thin, soft thermoplastic resin such as PVC, woven fabric or nonwoven fabric of organic fiber or inorganic fiber, or Complexes of are preferred.

A foamed layer 10 made of PVC or the like is formed on the base material 1, and these foamed layers are preferably soft and have a thickness of 0.5 to 2.0 mm.

A base pattern layer 6 is formed on the upper surface of the foam layer,
Even if this base pattern layer is appropriately transferred and printed on the foam layer,
It may be a sheet printed on non-woven fabric, or in the case of a grain pattern, it may be a resin layer coated with a resin containing a colorant.

A transparent protective layer 12 preferably made of ultraviolet curing resin, PVC paste, acrylic resin, etc. is formed on the base pattern layer 6 for antifouling purposes. The total thickness of the base pattern layer is 0.2~
It is formed to have a thickness of 0.6 mm.

[0013] On this base pattern layer, a thickness of 0.3 to 1.0
A small convex pattern area 13 of mm is formed. This convex pattern area can be printed with a viscous resin such as PVC paste in a sharp shape on the base pattern layer using a printing device such as a rotary screen, improving the three-dimensional effect and design. 14 is constituted by a base pattern layer on the bottom surface of the recess.

[0014] The small convex pattern area is 3.0 to 30 m above the pattern layer.
The convex bodies are formed at intervals of m, and the tops 16 of the convex bodies are flat.

If desired, anti-slip fine particles 15 are mixed into the small convex pattern areas. Examples of the granules include polymer materials such as PVC with a high degree of polymerization (degree of polymerization of 2000 or more), crosslinked PVC, polyurethane, polyurethane-vinyl chloride graft copolymers, and inorganic granules such as natural sand and silica sand. The fine particles may be appropriately colored. Since some of these fine particles are exposed on the surface of the patterned area, non-slip performance can be achieved more effectively. In this way, the uneven pattern flooring 17 of the present invention is obtained.

In the present invention, the small convex pattern area is of course different in shape from the base pattern layer, but by making it a different color, the contrast becomes marked and the design is improved.

FIG. 3 is a perspective view of the flooring material of the present invention, where 10 is a foam layer, 13 is a small convex pattern area, and 6 is a base pattern. As shown in FIG. 3, a three-dimensional uneven pattern flooring material with a sharp pattern can be obtained.

[0018]

[Example] A PVC paste of Formulation Table A in Table 1 was applied to a thickness of 0.3 mm on a release paper and pregelled.

[0019]

[Table 1]

After cooling the above PVC pregel sheet, 0.5 m of foamable PVC paste of recipe B in Table 2 was applied on top of it.
A base pattern layer made of a glass fiber non-woven fabric coated to a thickness of m thick and previously printed with a pattern was laminated thereon, heated again to pre-gel the foamable paste, and cooled.

[0021]

[Table 2]

Next, on this pattern layer, an ink layer with an average thickness of 0.5 mm is formed intermittently from relatively large openings using a rotary screen using PVC paste ink containing 8% of the paste of high polymerization degree PVC as fine particles. Then, a resin layer having a sharp shape having a gap around each of different colors was formed on the base pattern layer having a smooth surface to form a small convex pattern area with a substantially flat top.

The above uncured PVC paste was heated at 200° C. to gel the pattern layer and the small convex pattern areas and foam the foamable layer to obtain the uneven pattern flooring material of the present invention.

Although the obtained flooring material has a foam layer with good cushioning properties, it has a clear uneven pattern.
There was a gap of m, and the floor friction slip coefficient according to the JIS A 1407 method was U=0.6, and extremely good non-slip properties were obtained. Furthermore, excellent design properties were obtained due to the color and pattern contrast between the small convex pattern area and the base pattern layer below it.

[0025]

[Effects of the Invention] - A three-dimensional effect and design were obtained due to the color contrast and pattern changes between the base pattern layer that forms the ground color pattern and the small convex pattern areas. ■Non-slip property was obtained. ■Using a foam layer as the backing layer provides an excellent walking feel and non-slip properties, resulting in an excellent flooring material for walkways and home use.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing the manufacturing process of the uneven pattern flooring material of the present invention.

FIG. 2 is a sectional view of the uneven pattern flooring material of the present invention.

FIG. 3 is a perspective view of the uneven pattern flooring of the present invention.

[Explanation of symbols] 2 PVC paste lower layer 6 Base pattern layer 8 Small convex pattern area 10 Foam layer

Claims (1)

[Claims] [Claim 1] A base pattern layer is formed on a base material, small convex pattern areas with substantially flat tops are formed on the pattern layer, and concave portions are formed between the small convex pattern areas. , an uneven patterned flooring material characterized in that the bottom surface of the recessed portion is the base pattern layer described above.