JP2017002626A - Decorative material for floor and floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative material for a floor and a floor material capable of reducing discomfort of a color pattern between a decorative sheet layer and a powder-including resin layer, without requiring a separate process for color adjustment, even when applying cutting work.SOLUTION: A powder-including resin layer 1 colored in a preset color and a decorative sheet layer 7 having a colored original fabric layer 3, are laminated in this order, and a color difference ΔE between the powder-including resin layer 1 and the colored original fabric layer 3 is within 5. Thus, a groove part is formed by applying V-shaped processing to the upper surface side of a decorative material 10 for a floor, or a taper part is formed by appling chamfering processing to the upper surface side of the decorative material 10 for the floor, and even when the powder-including resin layer 1 is exposed from under the decorative sheet layer 7, the powder-including resin layer 1 can be made inconspicuous.SELECTED DRAWING: Figure 3

Description

    The present invention relates to a floor decorative material and a floor material, and for example, relates to a floor decorative material and a floor material suitable for use on a floor surface of a house, a store, an office, a gymnasium, or the like.

  As a flooring material, a sheet flooring material in which a decorative sheet is bonded to the surface side of a wood base material such as plywood, MDF, particle board or the like has been widely used. In this background, if the surface is a veneer as in the past, problems such as the color of the surface layer not matching at the construction site will occur, and if you want a higher design veneer, use a high-grade material It may become a very expensive flooring material. Further, as sheet flooring materials become widespread, the sheet flooring has a problem in that the quality of the wooden base material varies due to variations in impact resistance and caster resistance.

Therefore, a specification in which a backer material is bonded to the back side of the decorative sheet has been put on the market. For the backer material, a polyethylene terephthalate film of about 0.1 mm to 0.6 mm, a wood powder-containing resin sheet, or the like is used. A specification using a wood powder-containing resin sheet as a backer material has been widely spread.
In addition, these flooring materials are frequently used because the surface is subjected to groove processing such as V-shape or chamfering is performed on the corners, and the design is excellent (for example, Patent Document 1). reference.).

Japanese Patent No. 4815652

The grooving or chamfering is usually performed by sticking a decorative sheet on the surface of the wood-based substrate and then cutting the floor material from the decorative sheet side with a cutting machine or the like. For this reason, the backer material may appear after processing, and the color pattern (that is, the color itself or the pattern) may be uncomfortable between the decorative sheet and the backer material. In that case, it becomes necessary to add a process for color adjustment, such as applying a transparent or colored paint to the surface of the flooring, or attaching a separate decorative sheet.
Therefore, the present invention has been made in view of such circumstances, and even when cutting is performed, it is possible to reduce the discomfort of the color pattern between the decorative sheet layer and the powder-containing resin layer. An object of the present invention is to provide a flooring decorative material and a flooring material that do not require a separate process for color adjustment.

In order to solve the above-described problems, a floor decorative material according to an aspect of the present invention includes a powder-containing resin layer colored in a preset color and a decorative sheet layer having a colored raw fabric layer in this order. The color difference ΔE between the powder-containing resin layer and the colored raw fabric layer is 5 or less.
The flooring which concerns on 1 aspect of this invention is equipped with said decorative material for floors, and the base material attached to the lower surface side of the said decorative material for floors, It is characterized by the above-mentioned.

  According to one aspect of the present invention, even when cutting is performed, the discomfort of the color pattern can be reduced between the decorative sheet layer and the powder-containing resin layer, and a separate process for color adjustment is performed. A flooring decorative material and a flooring which are not required can be provided.

It is sectional drawing which shows the structural example of the decorative material 10 for floors concerning embodiment of this invention. It is sectional drawing which shows the structural example of the flooring 50 which concerns on embodiment of this invention. It is sectional drawing which gave the V-shaped process to the upper surface side of the decorative material for floors 10, and formed the groove part 11. FIG. It is sectional drawing which gave the chamfering process to the upper surface side of the decorative material for floors 10, and formed the taper part. It is sectional drawing which shows the state which has arrange | positioned the multiple sheets of flooring 50 in the mutual side part.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that, in each drawing described below, parts having the same configuration are denoted by the same reference numerals, and repeated description thereof is omitted.
<Configuration>
FIG. 1 is a cross-sectional view illustrating a configuration example of a floor decorative material 10 according to an embodiment of the present invention.
A floor decorative material 10 shown in FIG. 1 is a decorative material used for floors of houses, stores, offices, gymnasiums, and the like, for example. The floor decorative material 10 includes a powder-containing resin layer 1 colored in a preset color (that is, a predetermined color) and a decorative sheet layer 7 located on the powder-containing resin layer 1. Here, the color difference ΔE between the powder-containing resin layer 1 and the colored raw fabric layer 3 is 5 or less. In addition, the decorative sheet layer 7 includes, for example, a colored original fabric layer 3 and a design pattern layer 5 positioned on the colored original fabric layer 3. The thickness of the powder-containing resin layer 1 is, for example, 200 μm or more and 1000 μm or less. Hereinafter, the present embodiment will be specifically described with examples.

(1) Powder-containing resin layer The powder-containing resin layer 1 is, for example, added to a resin powder made of cellulose such as wood powder and paper powder and inorganic substances such as calcium carbonate, talc (talc), mica (mica), etc. Formed. By adding powdery cellulose and an inorganic substance to the resin, the linear expansion of the resin is suppressed so that problems such as push-up and excessive steps when the floor decorative material 10 is laid on the floor surface do not occur. can do.

However, simply increasing wood powder, paper powder, and inorganic substances to the dark clouds to suppress linear expansion will improve impact resistance and caster resistance, which are the original objectives, and realize molding stability during production. It is difficult. Therefore, it is necessary to clarify the linear expansion coefficient and optimize the blending of wood powder, paper powder, and inorganic substances to be added.
A thermoplastic resin can be used as the resin. The ratio of the thermoplastic resin in the powder-containing resin layer 1 is preferably 30% by mass or more and 45% by mass or less. When the ratio of the thermoplastic resin is less than 30% by mass, the binder effect is weakened, and the powder-containing resin layer 1 becomes brittle during molding, and may be broken when pulled after extrusion molding. Moreover, when the ratio of a thermoplastic resin is more than 45 mass%, the linear expansion coefficient of the powder-containing resin layer 1 becomes 6 × 10 ⁻⁵ or more, and the floor decorative material 10 is pushed up or excessively laid on the floor surface. Problems such as steps are likely to occur.

Examples of the thermoplastic resin include polypropylene, ethylene-vinyl alcohol copolymer, polymethylene, polymethylpentene, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyarylate, polyethylene naphthalate-isophthalate copolymer, polyimide, polystyrene, Examples thereof include polyamide and ABS.
The ratio of the powder in the powder-containing resin layer 1 is preferably 10% by mass or more and 30% by mass or less. When the proportion of the powder is less than 10% by mass, the linear expansion coefficient in the flow direction becomes 6 × 10 ⁻⁵ or more, and problems such as push-up and excessive steps when the flooring decorative material 10 is laid on the floor surface occur. It becomes easy to do. On the other hand, when the proportion of the powder is more than 30% by mass, the powder-containing resin layer 1 becomes brittle at the time of molding and may be broken when pulled after extrusion molding.

  The powder is preferably a fine powder having a particle size of about 10 μm to 100 μm. When the particle size of the powder exceeds 100 μm, the thermoplastic resin is used as the sea in the cross section of the powder-containing resin layer 1, and the sea-island pattern (sea-island structure) due to the powder is easily recognized visually, which is not preferable in design. The powder is preferably particles of a woody material such as wood powder or paper powder. As wood flour, cutting scraps such as cedar and tsuga generated in a sawmill or the like can be used. As the paper powder, virgin pulp, cut pieces in the paper making stage, processing loss in the processing stage, cutting out in the printing stage, and waste paper such as waste paper can be used. However, the powder is not actually limited to these examples. For example, woody biomass can be used as the powder. In consideration of the molding stability of the powder-containing resin layer 1, it is preferable that the powder be used in a limited variety.

The proportion of the inorganic filler in the powder-containing resin layer 1 is preferably 25% by mass or more and 60% by mass or less. When the proportion of the inorganic filler is less than 25% by mass, the linear expansion coefficient of the powder-containing resin layer 1 is 6 × 10 ⁻⁵ or more, and the push-up or excessive step when the floor decorative material 10 is laid on the floor surface. Etc. are likely to occur. Moreover, when there are more ratios of an inorganic filler than 60 mass%, the powder containing resin layer 1 will become weak at the time of shaping | molding, and if it is pulled after extrusion molding, it may be broken.
The inorganic filler is preferably a scale-like material such as talc or mica rather than a spherical material such as calcium carbonate.

(2) Decorative sheet layer The decorative sheet layer 7 is a sheet-like member having a pattern. The pattern layer 5 is printed on the upper surface (that is, the front surface) side of the colored raw fabric layer 3. The colored raw fabric layer 3 is obtained by forming a polyolefin-based resin into a sheet shape by a calendar method, an inflation method, a T-die extrusion method, or the like. Examples of the polyolefin resin include polypropylene (PP), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polybutylene naphthalate (PBN). Can be mentioned.

The pattern layer 5 gives the decorative sheet layer 7 design characteristics with a desired pattern, and the type of the pattern is not particularly limited. Examples of the pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a fabric pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. Further, a transparent resin layer and a surface protective layer may be appropriately laminated on the upper surface (that is, the surface) side of the design pattern layer 5 in order to improve design properties and provide functionality. Moreover, it is also possible to use only the colored original fabric layer 3 without printing the pattern layer 5. Further, a known decorative sheet layer 7 may be used as the decorative sheet layer 7.
In addition, the thickness of the decorative sheet layer 7 is, for example, 100 to 500 μm. Moreover, the thickness of the colored raw fabric layer 3 is, for example, 50 to 200 μm. Moreover, when the decorative sheet layer 7 has the pattern layer 5 on the colored raw fabric layer 3, the thickness of the pattern layer 5 is, for example, 1 to 20 μm.

(3) Floor Material FIG. 2 is a cross-sectional view showing a configuration example of the floor material 50 according to the embodiment of the present invention. The flooring 50 shown in FIG. 2 is a flooring 50 used for the floor of a house, a store, an office, a gymnasium, etc., for example. The flooring 50 includes, for example, the flooring decorative material 10 described with reference to FIG. 1 and a base material attached to the lower surface (that is, the back surface) side of the flooring decorative material 10. As a base material, woody base materials, such as a plywood, MDF (Medium Density Fiberboard: Medium density fiber board), and a particle board, are mentioned, for example.

(4) Groove Part The floor decorative material 10 shown in FIGS. 1 and 2 may be cut (for example, V-shaped) on the upper surface 10a side to form a groove part.
FIG. 3 is a cross-sectional view in which the groove 11 is formed by performing V-shaped processing on the upper surface 10a side of the floor decorative material 10. When the depth from the upper surface 10a of the groove 11 is L1, the depth L1 is not less than 300 μm and not more than 900 μm. The groove 11 reaches the powder-containing resin layer 1. Further, when the angle of the V-shaped portion 13 which is the bottom of the groove 11 is θ1, the angle θ1 is 60 ° or more and 120 ° or less.

(5) Tapered portion Further, the floor decorative material 10 shown in FIGS. 1 and 2 may be chamfered (for example, C-surface processed) on the side portion on the upper surface 10a side to form a tapered portion. Good.
FIG. 4 is a cross-sectional view in which a taper portion 15 is formed by chamfering the upper surface 10 a side of the floor decorative material 10. When the depth from the upper surface 10a of the taper portion 15 is L2, the depth L2 is not less than 300 μm and not more than 900 μm. This tapered portion 15 reaches the powder-containing resin layer 1. Further, when the angle formed by the tapered portion 15 and the upper surface 10a is θ2, the angle θ2 is not less than 30 ° and not more than 60 °.

  In addition, C surface processing means the process which chamfers so that a corner | angular part may be cut off with a right-angled isosceles triangle. For this reason, when the chamfering process is a C-plane process, the depth L2 means the lengths of two sides sandwiching the right angle of this right isosceles triangle. Further, when the chamfering is C-plane processing, the angle θ2 is 45 °, which is the base angle of the right isosceles triangle.

<Effect of embodiment>
(1) According to the embodiment of the present invention, the color difference ΔE between the powder-containing resin layer 1 and the colored raw fabric layer 3 is 5 or less. Thereby, a cutting process (for example, V-shaped process) is performed on the upper surface 10a side of the flooring decorative material 10 to form a groove portion, or a chamfering process (for example, C) is performed on the side surface of the flooring decorative material 10 on the upper surface 10a side. Even if the powder-containing resin layer 1 is exposed from the bottom of the decorative sheet layer 7 by forming the taper portion 15 by performing surface processing, the powder-containing resin layer 1 is not conspicuous when viewed from the upper surface 10a side. It is possible to reduce the discomfort of the color pattern between the decorative sheet layer 7 and the powder-containing resin layer 1 (for example, to eliminate the discomfort). Thereby, for example, it is not necessary to separately color the floor decorative material 10 after performing V-shaped processing or C-surface processing, and the steps for color adjustment can be reduced. Therefore, the floor decorative material 10 and the floor material 50 using the floor decorative material 10 can be produced at low cost.

(2) The thickness of the powder-containing resin layer 1 is, for example, not less than 200 μm and not more than 1000 μm. By setting the thickness of the powder-containing resin layer 1 within this range, it has molding stability and roll winding while maintaining impact resistance and caster resistance, and V-shaped processing and C-surface processing are performed. When it does, the powder containing resin layer 1 in which the groove part 11 and the taper part 15 do not reach the lowest part can be produced.

(3) About the groove part 11 formed in the upper surface 10a side of the decorative material 10 for floors, the depth L1 is 300 micrometers or more and 900 micrometers or less, for example. Further, the angle θ1 of the V-shaped portion 13 of the groove 11 is, for example, 60 ° or more and 120 ° or less. By setting the depth L1 and the angle θ1 of the groove 11 within this range, the floor decorative material 10 that prevents a feeling of strangeness felt on the soles during walking and catching of the soles, and the powder-containing resin layer 1 is not exposed excessively. Can be provided.

(4) Further, the depth L2 of the tapered portion 15 formed on the side portion on the upper surface 10a side of the floor decorative material 10 is, for example, not less than 300 μm and not more than 900 μm. Further, an angle θ2 formed by the upper surface 10a of the floor decorative material 10 and the tapered portion 15 is, for example, 30 ° or more and 60 ° or less. By setting the depth L2 and the angle θ2 of the taper portion 15 within this range, when a plurality of flooring materials 50 are arranged with their side portions aligned as shown in FIG. Thus, it is possible to provide a floor decorative material 10 that prevents a sense of incongruity in the design resulting from the difference in size, a feeling of incongruity felt on the soles during walking, and catching of the soles, and the powder-containing resin layer 1 is not excessively exposed.

(5) In addition, when forming both the groove part 11 and the taper part 15 in the decorative material 10 for floors, it is good also as L1 = L2, and good also as (theta) 2 = (180 degrees- (theta) 1) / 2. For example, when L1 = L2 and θ2 = (180 ° −θ1) / 2, in FIG. 5, the groove 11 included in each of the plurality of floor decorative materials 10 and the plurality of floor decorative materials 10 The shape and size of the groove portion 17 formed so that the tapered portions 15 face each other coincide with each other in a sectional view. Thereby, the groove parts 11 and 17 may be harmonized with each other, and the design of the floor decorative material 10 may be further improved.

Next, Examples 1 to 5 of the present invention and comparative examples will be described.
<Example 1>
(1) Creation of decorative material for flooring 40% by mass of commercially available homopolypropylene resin (bending initial elastic modulus 1500 MPa), 15% by mass of paper powder obtained by grinding virgin paper to a particle size of 50 μm using a ball mill, for coloring 5% by mass of pigment and 3% by mass of calcium stearate were mixed and extruded by a twin screw extruder, and formed into a rectangular shape having a thickness of 700 μm and a width of 450 mm in a sectional view. Next, the front and back of this molded product were subjected to corona discharge treatment to obtain a powder-containing resin layer. Further, when the powder-containing resin layer was produced, the color of the powder-containing resin layer was adjusted so that the color difference ΔE was within 5 compared to the colored raw fabric layer used for the decorative sheet layer to be bonded in a later step. .
Next, 50 μm of a PUR adhesive was applied to the upper surface side of the powder-containing resin layer, and a decorative sheet layer having a thickness of 160 μm was adhered through the PUR adhesive to obtain a floor decorative material having a total thickness of 910 μm.

(2) Preparation of flooring material A water-soluble emulsion adhesive was applied to the lower surface side of the flooring decorative material, and the woody base material was bonded via the water-soluble emulsion adhesive. Lauan plywood (thickness 12 mm) was used as the wood-based substrate. Next, after cutting the laminated material obtained by laminating the flooring decorative material and the wooden base material into a predetermined size (303 mm × 1818 mm), the tenor is used to perform actual processing on four sides, and the upper surface (that is, the surface) V-shaped processing was performed from the side) to form a V-shaped groove having a depth reaching the powder-containing resin layer. Further, a chamfering process was performed on the side part (real part) of the flooring at the same angle as the V-shaped groove part to form a tapered part. The depth of the groove portion and the tapered portion from the top surface of the decorative material for flooring was 600 μm, and the angle of the groove portion and the tapered portion with respect to the horizontal surface of the flooring material (that is, the top surface of the decorative material for flooring) was 45 °.

<Example 2>
The thickness of the powder-containing resin layer was 200 μm, and the depths of the groove part and the taper part from the upper surface of the floor decorative material were 300 μm. Except this, it carried out similarly to Example 1, and obtained the decorative material for floors.
<Example 3>
The thickness of the powder-containing resin layer was 1000 μm, and the depth of the groove and taper portion from the upper surface of the floor decorative material was 900 μm. Except this, it carried out similarly to Example 1, and obtained the decorative material for floors.

<Example 4>
The angles of the groove part and the taper part with respect to the horizontal surface of the flooring were 20 °. Except for this, a flooring was obtained in the same manner as in Example 1.
<Example 5>
The angles of the groove part and the taper part with respect to the horizontal surface of the flooring were set to 70 °. Except for this, a flooring was obtained in the same manner as in Example 1.
<Comparative example>
Color adjustment was not performed at the time of preparation of the powder-containing resin layer, and the color difference ΔE from the colored raw fabric layer was 6.0. Except for this, a flooring was obtained in the same manner as in Example 1.

<Evaluation>
The following evaluation was performed about each flooring created in Examples 1-5 and a comparative example.
(1) Evaluation of color blur of groove part Color blur evaluation of a groove part and a taper part was performed by sensory evaluation by ten observers. Specifically, the floor material is laid in a room of 4 tatami mats, and a groove portion (for example, corresponding to the groove portion 11 shown in FIG. 5) with 10 observers sitting on the floor surface in this room, And the groove part (for example, corresponded to the groove part 17 shown in FIG. 5) formed so that a taper part faces each other was observed, and it was evaluated whether the difference in color was felt.
A: All members looked one color.
○: One to two people were seen in two colors.
Δ: 3 to 5 people Some people seemed to have two colors.
X: 6 or more people were seen in two colors.

(2) Evaluation of walking feeling in groove part In the above test environment, 10 observers walked on the floor surface, and evaluated the walking feeling in the groove part.
A: All members did not feel great discomfort.
○: 1 to 2 persons I felt a difference in the catch of the foot and the height.
Δ: 3 to 5 people I felt a difference in the height of the foot and the height.
X: 6 or more people felt the difference in the catch of the foot and the height.

DESCRIPTION OF SYMBOLS 1 Powder-containing resin layer 3 Colored original fabric layer 5 Picture pattern layer 7 Cosmetic sheet layer 10 Flooring decorative material 10a Upper surface 11, 17 Groove part 13 V-shaped part 15 Tapered part 50 Flooring material

Claims (6)

A powder-containing resin layer colored in a preset color and a decorative sheet layer having a colored raw fabric layer are laminated in this order,
A floor decorative material, wherein a color difference ΔE between the powder-containing resin layer and the colored raw fabric layer is within 5 or less.   The floor decorative material according to claim 1, wherein the decorative sheet layer has a pattern layer on the colored raw fabric layer.   The floor decorative material according to claim 1 or 2, wherein the powder-containing resin layer has a thickness of 200 µm or more and 1000 µm or less. It has a groove portion formed by V-shaped processing on the upper surface side of the floor decorative material,
The depth from the upper surface is 300 μm or more and 900 μm or less, and the groove reaches the powder-containing resin layer,
The floor decorative material according to any one of claims 1 to 3, wherein an angle of a V-shaped portion that is a bottom portion of the groove portion is 60 ° or more and 120 ° or less. The taper part by the chamfering process formed in the upper surface side of the said decorative material for floors is provided,
The depth of the tapered portion from the upper surface is 300 μm or more and 900 μm or less, and the tapered portion reaches the powder-containing resin layer,
The angle between the tapered portion and the upper surface is 30 ° or more and 60 ° or less, and the floor decorative material according to any one of claims 1 to 4, The floor decorative material according to claim 1;
A flooring material comprising a base material attached to a lower surface side of the flooring decorative material.

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