JP2000230310A - Manufacture of floor decorated material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture simply and inexpensively floor decorated materials, the surface materials of which are tiles, and improve the productivity and the yield. SOLUTION: A frame 1 of a synthetic resin (an olefin resin for example) is molded by injection-molding, and after the frame 1 is taken out from a mold, before the frame 1 is cooled down completely and while the resin is still flexible, surface material 2 are fitted into the frame 1. After the frame is taken out from a mold, the frame 1 is once cooled, and heated again (for 24 hours at 80 deg.C for example), before the frame after this reheating is cooled down completely and while the resin is still flexible, a surface materials are fitted to the frame.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a unit type floor covering material to be laid on a floor such as a balcony, a veranda or a roof.

[0002]

2. Description of the Related Art Conventionally, as a structure for laying floor materials (deck materials) on balconies, verandas and the like, as shown in, for example, Japanese Utility Model Publication No. 56-51563, a fixed substrate having a locking groove is mounted on a joist. With several screws,
A structure has been adopted in which a ridge on the back side of a long deck material cut to fit the dimensions of a balcony or the like is press-fitted into a locking groove of each fixed substrate.

On the other hand, in recent years, as a floor material for covering the floor of a balcony or veranda made of concrete or the like, as shown in FIG. Alternatively, a unit-type floor decorative material having a structure in which a surface material 102 such as a tile is engaged and fixed or bonded and fixed has been put to practical use. In the floor decorative material 100 shown in FIG. 6, a plurality of units (floor decorative materials) can be connected to each other using the female connecting portion 103 and the male connecting portion 104 provided on the resin mat 101.

In such floor decorative materials, when the frame is made of an olefin resin, there are no adhesives having an adhesive effect, and therefore, some structures for fixing the frames to each other have been proposed.

[0005] For example, as shown in FIG.
0, a surface material 202 is arranged with its back surface facing upward, and a resin mat (frame) 201 is placed on the surface thereof, and an adhesive 230 is applied to the bonding portion 201a from the back side of the resin mat 201.
The solidified adhesive 230 and the resin mat 201 are engaged with each other, and the solidified adhesive 230 and the surface material 202 are bonded to each other, thereby fixing the resin mat 201 and the surface material 202. There is a method (Japanese Utility Model Laid-Open No. 6-14344).

However, in such a fixing method, since the bonding operation is performed from the back side of the frame, the positioning of the surface member 202 must be performed using the positioning member 220.
There is a problem in that the bonding operation is troublesome, and that the adhesive needs to be cured after bonding, which requires a lot of work. further,
Since an adhesive is used, there is also a problem that the cost of the adhesive increases.

One of the methods for solving the above problems is as follows.
A groove is provided on the outer peripheral portion (side surface) of the surface material, and while the surface material is arranged in an injection mold for frame molding, a molten resin is poured into the molding die to form a frame. With
A method of manufacturing a decorative flooring material has been proposed in which a resin is filled in a groove of a surface material to engage and integrate the surface material and a frame body (Japanese Patent Application Laid-Open No. 9-32248). According to this method,
Since an adhesive process such as applying or curing an adhesive is not required,
A floor decorative material in which the frame is an olefin-based resin and the surface material is a tile or the like can be easily obtained.

[0008]

However, the above-mentioned method of manufacturing a floor decorative material is a method of insert molding a surface material, so that equipment such as an injection molding machine and a molding die becomes complicated and large-scale, and equipment cost is increased. Is expensive.
In addition, an extra step of inserting a surface material is required, and 1
The molding time per shot becomes longer. In addition, since the finished dimensional accuracy of the tile (surface material) is not very good, there is also a problem in yield such as the tile interfering with the mold at the time of mold clamping and the tile being cracked.

The present invention has been made in view of such circumstances, and it is possible to easily and inexpensively manufacture a floor decorative material having a surface material such as a tile, and to improve productivity and yield. It is an object of the present invention to provide a method of manufacturing a floor decorative material that can be used.

[0010]

According to a first aspect of the present invention, there is provided a frame made of a synthetic resin and a surface material disposed on the frame. A method for manufacturing a floor decorative material fixedly engaged with a body, wherein a frame made of synthetic resin is formed by injection molding, and after removing the frame from a molding die, the frame is completely cooled. It is characterized by fitting a surface material into the frame when the resin is flexible before.

According to the first aspect of the present invention, when the molded frame is hardly contracted by cooling, that is, when the fitting portion of the surface material has a dimensional margin, and the frame is flexible. Since the surface material is fitted in the state, the surface material can be easily attached to the frame without using insert molding. Moreover, when the frame is completely cooled and solidified, the gap between the frame and the surface material disappears due to the cooling shrinkage of the frame, so that the surface material can be removed from the frame without rattling or the like. Can be fixed.

According to the first aspect of the present invention, after the surface material is fitted, the frame is reheated (for example, at 80 ° C., 24 ° C.).
Time). When such reheating is performed, the dimensions of the frame that has been cooled after the reheating are smaller than the dimensions of the frame that has been cooled after molding, so that the surface material is more firmly fixed to the frame. be able to. Further, by performing the reheating treatment, the molding distortion generated during the injection molding is also reduced.

According to the first aspect of the present invention, the work of fitting the surface material into the frame is performed before the frame is completely cooled after the frame is removed from the mold (when the frame is at room temperature or so). The process may be completed while the resin has flexibility before cooling down to above), but is preferably performed as soon as possible after the removal from the mold (immediately after the removal).

According to a third aspect of the present invention, there is provided a method of manufacturing a decorative flooring material comprising a synthetic resin frame and a surface material disposed on the frame, the surface material being fixedly engaged with the frame. Then, a synthetic resin frame is formed by injection molding, the frame is removed from the mold, once cooled, and then reheated (for example, 80 ° C. (dry heat) for 24 hours). When the resin is flexible before the reheated frame has completely cooled down again, it is characterized by fitting the surface material into the frame.

According to the third aspect of the invention, the frame after molding is reheated to expand (extend), and the expansion of the reheated frame causes a dimensional margin in the fitting portion of the surface material. Since the surface material is fitted in a certain state and in a state where the frame body is flexible, the surface material can be easily arranged on the frame body without insert molding. In addition, the size of the frame after reheating and cooling is smaller than the size of the frame after cooling after injection molding due to cooling shrinkage after reheating and distortion removal by heat treatment. Can be fixed.

According to the third aspect of the present invention, the work of fitting the surface material into the frame is performed after the frame is reheated and before the frame is completely cooled (the frame is cooled to about room temperature). It should be completed while the resin is flexible before cooling)
After the reheating of the frame is completed, it is preferably performed as early as possible (for example, immediately after being taken out of the heating furnace).

The frame material of the floor decorative material to which the production method of the present invention is applied includes polyethylene (PE), polypropylene (PP), ethylene-vinyl acetate co-aggregate (EVA), acrylonitrile-butadiene-styrene. Resin (ABS resin) and the like.

[0018]

Embodiments of the present invention will be described below with reference to the drawings. First Embodiment First, as shown in FIG. 1, a square (nominal size:
One surface material (porcelain tile of 294 mm × 294 mm) 20 is placed on the frame 10 formed into 300 mm × 300 mm).
The embodiment of the manufacturing method (molding shrinkage) of the present invention will be described by taking the case of engaging as an example. In this example, the reference size of the frame 10 is set to 297 mm in length × 297 mm in width, and the cavity of the mold (not shown) for forming the frame is expected to have a cooling shrinkage allowance with respect to the reference size. The dimensions are set to

First, the frame 10 is formed by injection molding. Molding of the frame is performed by clamping → injection (resin filling and cooling)
→ Open the mold → Take out the molded product, 300mm x 3
When molding a frame 10 of 00 mm (nominal size), 30
A molding time of about 40 seconds is required.

When the molding is completed, the frame 10 taken out of the mold is transferred to a conveyor or the like. At this time, the time required from the opening of the mold to the completion of transfer is usually about 5 to 15 seconds, and the temperature of the frame 10 at the time when this time has elapsed is 6 seconds.
It is about 0 ° C to 70 ° C. At this time, the frame 10
(The vertical and horizontal dimensions of the frame body 10) are about 4 to 5 mm larger than the dimensions after the cooling is completed (the dimensions 24 hours after the mold opening).

Next, the surface member 20 is fitted into the frame 10 taken out of the mold. It is preferable that the fitting operation be completed before a lapse of 120 seconds or more from the opening of the mold.

Here, the size of the frame 10 at the time when 120 seconds have passed from the mold opening is 3 to 4 mm with respect to the dimension after cooling is completed (the dimension after 24 hours from the mold opening).
About big. Therefore, if the work of fitting the surface material 20 is performed within 120 seconds or more after the opening of the mold,
As shown in FIG. 1, the surface material 20 can be fitted while the frame body 10 has sufficient dimensions (dimensions of the surface material arrangement portion), so that the operation can be easily performed. Thereby, for example, it is also possible to automate such that the surface material 20 is gripped by the suction device or the like and dropped into the frame body 10 to be fitted.

After the fitting of the surface material 20 is completed, the frame 10 is left to stand as it is (for example, for 24 hours), and the frame 10 is completely cooled by natural cooling. 20a, the surface material 20
Can be obtained as the floor decorative material fixed to the frame 10.
After the surface material 20 is fitted into the frame 10, the frame 10
May be cooled by forced cooling.

Here, in the above embodiment, after the fitting of the surface material 2 is completed, the floor decorative material is placed in a heating furnace and the frame 1 is reheated (80 ° C. (dry heat), 24 hours ) May be performed. <Second Embodiment> First, similarly to the previous embodiment, the frame 10 is formed by injection molding. Note that a molding die having the same shape and dimensions as those of the above embodiment is used for molding the frame 10.

In this example, the frames 10 sequentially molded by the injection molding machine are stored as they are in a primary storage location, and once cooled and solidified in the storage location.

Next, the frames 10 stored in the primary storage place are put into a heating furnace (not shown) at predetermined intervals, and reheated at 80 ° C. (dry heat) for 24 hours. Furnace frame 1
0 are sequentially taken out, and after the taking out, the surface material 20 is fitted into the frame 10 (see FIG. 1). This fitting work,
It is preferable to complete the process within 120 seconds or more after the removal from the heating furnace.

Here, the dimensions of the frame 10 at the time when 120 seconds have elapsed since the reheated frame 10 was removed from the heating furnace, are the dimensions after the completion of the cooling after the reheating (the removal). 3-4 for the dimensions after 24 hours have passed since)
mm larger. Therefore, if the work of inserting the surface material 20 is performed within 120 seconds or more after the opening of the molding die, the surface material 20 can be removed while the dimensions of the frame body 10 (dimensions of the surface material arrangement portion) are sufficient. Because it can be fitted (Fig. 1
), The task can be performed easily. Thereby, for example, it is also possible to automate such that the surface material 20 is gripped by the suction device or the like and dropped into the frame body 10 to be fitted.

After the fitting of the surface material 20 is completed, the surface material 20 is fixed to the frame 10 by leaving it as it is (for example, 24 hours) and completely cooling the frame 10 by natural cooling. It is possible to obtain a finished floor decorative material. After fitting the surface material 20 to the frame 10, the frame 10 may be cooled by forced cooling. <Embodiment 3> Next, an example of manufacturing a floor decorative material having another structure will be described. The floor decorative material is shown in FIG. 3 and FIG.
As shown in the figure, a frame 1 formed into a square (nominal size: 300 mm × 300 mm) using low-density polyethylene as a synthetic resin, and nine surface materials (95 mm × 95 mm porcelain tile) arranged on the upper surface thereof 2 ... 2.

The frame 1 is provided with an outer peripheral wall 11 extending along the peripheral edge (four sides) and a partition wall 12 for partitioning the inside of the outer peripheral wall 11 in a lattice shape. At the upper part of the wall 12, an engaging projection 1a for fixing the surface material 2 is integrally formed. Engaging grooves 2b are formed on the side surfaces (two opposing side surfaces) of the surface material 2 so that the engaging protrusions 1a of the frame 1 are hooked.
Each of the surface members 2 is engaged and fixed to the frame 1 by fitting of the engaging projection 1a into the frame 1b.

An embodiment in which a floor decorative material having the above structure is manufactured by the manufacturing method (forming shrinkage) of the present invention will be described with reference to FIG.

In this example, the reference size of the frame 1 is set to 297 mm in length × 297 mm in width, and the cavity of the mold (not shown) for forming the frame is cooled and shrunk to the reference size. The dimensions are set to allow for the cost.

First, the frame 1 is formed by injection molding.
The molding of the frame is performed in the order of mold clamping → injection (resin filling / cooling) → mold opening → molded product removal, 300 mm × 300 mm
When molding the frame 1 of mm, a molding time of about 30 to 40 seconds is required.

After the molding is completed, the frame 1 taken out of the mold is transferred to a conveyor or the like. At this time, the time required from the opening of the mold to the completion of transfer is usually about 5 to 15 seconds, and the temperature of the frame 1 at the time when this time has elapsed is 60 ° C.
About 70 ° C. At this time, the dimensions of the frame 1 (the vertical and horizontal dimensions of the frame 1) are 4 to 4 times larger than the dimensions after the cooling is completed (the dimensions 24 hours after the mold opening).
About 5 mm larger (see Table 1 below).

Next, the surface material 2 is fitted into the frame 1 taken out of the molding die. It is preferable that the fitting operation be completed before a lapse of 120 seconds or more from the opening of the mold.

The size of the frame 1 at the time when 120 seconds have passed since the mold opening is about 3 to 4 mm larger than the dimension after cooling is completed (the dimension after 24 hours from the mold opening). (See Table 1 below.) Also, when 120 seconds have elapsed since the mold was opened, the resin temperature is about 50 to 60 ° C., and the frame 1 maintains a flexible state.

As shown in FIG. 2B, the fitting of the surface material 2 is performed with the engagement groove 2 a of one side of the surface material 2 in the posture in which the surface material 2 is inclined with respect to the frame 1. In a state where the outer peripheral wall 11 (or the partition wall 12) on the opposite side is bent in accordance with the engagement convex portion 1a, the surface material 2 is pushed toward the frame 1, and the engagement groove 2a of the surface material 2 is formed. The engagement projection 1a of the frame 1 is fitted into the frame 1 (FIG. 2C). In this case, since the number of the surface materials 2 is nine, the surface material 2 arranged at the center of the frame 1 is first fitted in consideration of workability at the time of fitting.

When the fitting of all the nine surface materials 2 is completed, the frame 1 is left as it is (for example, 24 hours), and the frame 1 is completely cooled by natural cooling. As shown in ()), a floor decorative material in which the surface material 2 is fixed to the frame 1 can be obtained. After fitting the surface material 2 to the frame 1, the frame 1 may be cooled by forced cooling.

Here, the dimensions of the frame 1 (dimensions of the surface material arrangement portion) at the time of fitting the surface material 2 are as shown in FIG.
As shown in (A), the outer dimensions of the surface material 2: L0 = 95
When the distance between the inner surfaces of the engaging grooves 2a is ± 1 mm and M0 = 90 mm, the inner dimension of the surface material insertion portion of the frame 1 is L1 = 96.
mm, the distance between the opposing surfaces of the engaging projections 1a: M1 = 91 mm. In this way, as shown in FIG. 2C, the gap e between the surface material 2 and the frame 1 is formed.
(= 0.5 mm), the surface material 2 can be easily fitted into the frame 1. Moreover, when the frame 1 is completely cooled, the entire frame 1 contracts by 3 to 4 mm with respect to the time when the surface material 2 is fitted, so that the gap e is completely eliminated and the surface material 2 is It is firmly fixed to the body 1.

In the above embodiment, after the fitting of the surface material 2 is completed, the floor decorative material is placed in a heating furnace and the frame 1 is reheated (80 ° C. (dry heat), 24 hours). May be performed. When such a reheating treatment is performed, the dimensions of the frame 1 that has been cooled after the reheating are smaller than the dimensions of the frame 1 that has been cooled after the injection molding (see Table 2 below). The surface material 2 can be firmly fixed to the frame 1. Further, by performing the reheating treatment, there is an advantage that molding distortion generated during injection molding is reduced, deformation such as warpage and twist of the frame 1 is reduced, and a floor decorative material having a stable shape can be obtained. is there. <Fourth Embodiment> An embodiment in which the floor decorative material shown in FIGS. 3 and 2A is manufactured by the manufacturing method (reheating) of the present invention will be described below.

First, as in the previous embodiment, the frame 1 is formed by injection molding. It should be noted that a molding die having the same shape and dimensions as those of the previous embodiment is used for molding the frame 1.

In this example, the frames 1 sequentially molded in the injection molding machine are stored as they are in a primary storage place, and once cooled and solidified in the storage place.

Next, the frames 1 stored in the primary storage place are put into a reheating heating furnace (not shown) at predetermined intervals, and
After reheating at 24 ° C. (dry heat) for 24 hours, the frames 1 are sequentially taken out of the heating furnace, and after taking out, the surface material 2 is fitted into the frame 1. The fitting of the surface material 2 is performed in the manner shown in FIGS. 2B and 2C. The work of fitting the surface material 2 is preferably completed before the time of 120 seconds or more elapses after the removal of the frame 1 from the heating furnace.

It should be noted that the dimensions of the frame 1 after 120 seconds have elapsed since the reheated frame 1 was taken out of the heating furnace, are the dimensions after the completion of the cooling after the reheating (after taking out). 3 to 4 mm (see Table 2 below), and the resin temperature is about 50 to 60 ° C. until 120 seconds have elapsed from the time of removal. The body 1 remains flexible.

When the fitting of all nine surface materials 2 is completed, the surface material 2 is completely cooled by natural cooling, and is left as it is (24 hours). A floor decorative material fixed to the body 1 can be obtained (FIG. 2 (D)). After fitting the surface material 2 to the frame 1, the frame 1 may be cooled by forced cooling.

According to the reheating method described above, the frames 1 sequentially molded in the injection molding machine are sequentially stored in the primary storage place, and the stored frames 1 are reheated by the heating furnace. Thus, since the surface material 2 is fitted, there is an advantage that the surface material can be mounted in an outline regardless of the molding cycle (the number of shots) of the injection molding machine.

In each of the above embodiments, it is preferable that the work of fitting the surface material be completed within 120 seconds after opening the mold or 120 seconds or more after removal from the heating furnace. The elapsed time limit is
It is a value (an example) when the frame is made of low-density polyethylene and naturally cooled at room temperature of 20 ° C., and is not particularly limited. Is changed, it may be set appropriately according to the condition.

Here, the manufacturing method of the present invention is not limited to the above embodiment, but can be applied to various types of floor decorative materials.

For example, as the form of the surface material, FIG.
As shown in FIG.
a, or in place of such an engagement groove, as shown in FIGS.
Arc-shaped engaging recesses 22a, 23
a is provided.

As a form of the frame, for example, FIG.
As shown in (A), a structure in which the thickness of the joint portion 30 of the frame body 31 is reduced to give flexibility to this portion is exemplified. According to the structure shown in FIG. 5A, even if the surface material 2 located on the center side of the frame 31 is fitted first, the frame 31
Joints 30 are flexible, so that the outer surface material 3
1 can be easily fitted. In addition, since the entire floor decorative material can have flexibility, it is possible to prevent the floor decorative material from becoming uneven when laying, and it is also possible to absorb warpage, twist, etc. of the entire floor decorative material after cooling and shrinking. . In the structure shown in FIG.
The joint portion 30 may be provided with a drain hole, and in this case, the flexibility of the joint portion 30 of the frame 31 can be further increased.

Further, as another embodiment, a modified example of the structure for fixing the surface material to the frame can be mentioned. For example,
As shown in FIG. 5 (B), beveling processing is performed on the corners of the upper surface (lower surface) of the surface material 42, and an engaging projection 32 a having a triangular cross section is provided on the frame 32. Convex part 3
2A, a structure in which the beveled portion 42a of the surface material 42 is locked and the surface material 42 is fixed to the frame 32, and FIG.
As shown in FIG. 5, an engagement step 43a is provided on the side surface of the surface material 43, and an engagement protrusion 33a is provided on the frame 33. The engagement between the engagement step 43a and the engagement protrusion 33a causes the surface Structure in which the member 43 is fixed to the frame 33, or FIG.
As shown in (D), the surface material 44 is formed into a trapezoidal shape with the side surface inclined, and the outer peripheral wall of the frame 34 and the inner surface of the partition wall are formed in an inversely tapered shape, and the tapered surface 3 of the frame 34 is formed.
A structure in which the surface material 44 is fixed to the frame body 34 by engaging the side surface 4a with the side surface (inclined surface) of the surface material 44 is exemplified.

Here, for reference, experimental data on cooling shrinkage of the injection molded frame (made of low density polyethylene) is shown in Table 1 below. Table 2 below shows experimental data on cooling shrinkage of the reheated frame (made of low-density polyethylene). The cooling of the frame after injection molding and reheating was performed by natural cooling (room temperature: left at 20 ° C.).

[0052]

[Table 1]

[0053]

[Table 2]

[0054]

As described above, the method for manufacturing a decorative flooring material of the present invention utilizes the cooling shrinkage after injection molding of the frame or the cooling shrinkage after reheating the frame to make use of the frame. Since the surface material is fitted into the body, the surface material can be engaged and fixed to the frame without using insert molding. Therefore, equipment costs such as an injection molding machine and a molding die can be reduced as compared with the method by insert molding, and floor decorative materials can be manufactured at low cost. In addition, productivity can be improved.

In addition, even if the surface material is a tile with poor dimensional accuracy, the surface material can be firmly fixed to the frame without rattling. In addition, there is no possibility that a problem that a surface material such as a tile is cracked at the time of manufacturing.

[Brief description of the drawings]

FIG. 1 is an explanatory view of an embodiment of a manufacturing method of the present invention.

FIG. 2 is an explanatory view of another embodiment of the manufacturing method of the present invention.

FIG. 3 is a plan view showing an example of a floor decorative material to which the manufacturing method of the present invention is applied.

FIG. 4 is a diagram showing a modification of the surface material.

FIG. 5 is a diagram showing another example of a floor decorative material to which the manufacturing method of the present invention is applied.

FIG. 6 is a perspective view showing an example of a floor decorative material.

FIG. 7 is a sectional view of a main part showing a conventional example of a method of fixing a surface material to a resin mat.

[Explanation of symbols]

 1, 10 Frame body (made of synthetic resin) 1a, 10a Engagement convex part 2, 20 Surface material (tile) 2a, 20a Engagement groove

Claims (3)

[Claims] 1. A method for manufacturing a decorative flooring material comprising a synthetic resin frame and a surface material disposed on the frame, wherein the surface material is engaged and fixed to the frame. After molding the synthetic resin frame, remove the frame from the mold, and fit the surface material to the frame when the resin is flexible before the frame has completely cooled down. A method of manufacturing a floor decorative material, characterized by incorporating 2. The method for producing a floor decorative material according to claim 1, wherein the frame body fitted with the surface material is reheated. 3. A method of manufacturing a floor decorative material comprising a synthetic resin frame and a surface material disposed on the frame, wherein the surface material is fixedly engaged with the frame, the method comprising: injection molding. A frame made of a synthetic resin is molded from the mold, the frame is taken out of the mold, and once cooled, the frame is reheated, and before the frame after reheating completely completes cooling again. A method of manufacturing a floor decorative material, characterized in that a surface material is fitted into a frame when the resin has flexibility.