JP4996360B2 - Floor decorative material and method for producing the floor decorative material - Google Patents

Description

  The present invention relates to a floor decorative material laid on a concrete floor such as an outdoor veranda or a balcony, and a method for manufacturing the floor decorative material.

In recent years, rubber floors, porcelain tiles, wooden bricks, etc. have been placed on the top surface of a rigid synthetic resin molded frame (resin mat) as a flooring material that is laid and covered on concrete floors such as outdoor verandas and balconies. A unit-type floor decorative material having a structure in which a block-like surface material is fixedly fixed or bonded and fixed is put into practical use (for example, see Patent Document 1).
In addition, as a floor decorative material using a surface material such as wood, a plurality of holding partition walls for holding a rectangular surface material (wood brick, etc.) are formed inside a synthetic resin laying frame, and this holding A structure in which the locking piece is integrally formed on the partition wall, and the surface material is fixed to the laying frame by grooving the lumber surface material and fitting the locking claw of the laying frame into the groove estuary. There is also.

  For example, in the laying frame described in Patent Document 2, partition walls that form holding partitions are provided in a lattice pattern at a pitch corresponding to one side of a square surface material. Locking claws for fixing the tiles are integrally formed on the peripheral wall of the laying frame and the upper part of each partition wall.

  The laying frame of the floor decorative material is provided with a plurality of annular female connecting portions at regular intervals on the side walls of two sides adjacent to each other. A columnar male connecting portion is provided on each opposite side in a positional relationship corresponding to the female connecting portion, and a plurality of floor decorative materials can be connected to each other using these male and female connecting portions. It is like that.

Further, as a method for producing a plate-like material such as a tile, for example, Patent Document 3 discloses that a resin plate that fills a molding space with a tile powder material and disappears by heating when the molded product is fired is used as a powder material. A manufacturing method is described in which a groove is formed by embedding in the interior and dry pressing the powder raw material in that state.
Japanese Utility Model Publication No. 5-85929 JP 2002-129735 A JP-A-6-293014

  However, in the conventional floor decorative material, it takes work labor and material cost to fix the block-shaped surface material using an adhesive. In addition, in order to fix the surface material with a locking member such as a locking claw, the surface material also has to be processed with a certain width along the side surface. It was time consuming and costly.

  In addition, in the conventional manufacturing method, since the resin plate for forming the groove of the surface material uses a relatively expensive synthetic resin material such as an acrylic resin or a polycarbonate resin, the manufacturing cost increases and press molding is performed. Since it was buried at times, productivity was hindered. Moreover, although the groove | channel of the said plate-shaped material is shape | molded by making a resin plate lose | disappear at the time of baking, possibility that a molten material will adhere to a baking equipment was high and could not become a realistic means. .

  Therefore, the floor has a structure that can improve the durability so that it can withstand long-term use as a decorative material for floors such as balconies and decks, and can accurately carry out manufacturing operations such as grooving in consideration of workability in the manufacturing process. There was a need to develop cosmetic materials.

  The present invention has been made in view of the circumstances as described above, and is excellent in productivity, strength, weather resistance and durability, and further made of a synthetic resin floor decorative material realizing good workability and It aims at providing the manufacturing method of this floor decorative material.

  In order to achieve the above-described object, the present invention includes a synthetic resin frame and a surface material disposed on the frame, and each of the four side surfaces of the surface material has at least one parallel surface. An engagement groove is formed, and the surface material is engaged and fixed to the frame body by engaging each of the engagement grooves with an engagement protrusion protruding from the frame body. The engaging groove of the surface material has a tapered shape in which the inner upper surface is inclined upward in the opening end direction, and the inner and lower surfaces are concave grooves formed in parallel to the lower surface of the surface material. The engaging convex portion is characterized in that the outer upper surface has a tapered shape inclined downward in the distal direction, and the outer lower surface has a convex shape formed in parallel with the bottom surface of the frame.

  Further, the present invention includes a synthetic resin frame and a surface material disposed on the frame, and one engagement groove is formed on each of at least two parallel sides of the four side surfaces of the surface material. A method of manufacturing a floor decorative material in which a surface material is engaged and fixed to a frame body by engaging each of the engagement grooves with an engagement convex portion protruding from the frame body. The engaging groove of the material has a tapered shape in which the inner upper surface is inclined upward in the opening end direction, the inner and lower surfaces are concave grooves formed in parallel with the lower surface of the surface material, and the engaging protrusion of the frame body. The outer surface is a tapered shape whose outer upper surface is inclined downward in the tip direction, and the outer lower surface is a convex shape formed parallel to the bottom surface of the frame body, and the surface material is pressed into a plate-like body having a square shape in plan view. The engaging groove is formed in a substantially U-shaped cross-section using a diamond cutter that is molded and has a convex cutting section of the cutting blade. After the next cutting, the tip cross section of the cutting blade is further formed into the concave groove shape by secondary cutting the inner upper surface of the engagement groove using a substantially triangular diamond cutter. .

  According to such a configuration, maintaining a good engagement state between the frame body and the surface material so as to have durability enough to withstand long-term use as a floor decorative material such as a balcony or a deck, It can be manufactured efficiently, and the engaging groove of the surface material can be formed with high accuracy and with good workability and productivity.

  According to the floor decorative material of the present invention configured as described above and the method of manufacturing the floor decorative material, it is excellent in all of productivity, strength, weather resistance and durability, and further realizes good workability. Can do. In particular, the engagement groove of the floor decorative material has the form as described above, so that the fitting operation to the frame body can be easily performed and the engagement strength can be ensured, and furthermore, it is formed by two-stage cutting. Defects such as chipping can be greatly reduced, yield can be improved, and production can be efficiently carried out at a reduced manufacturing cost.

  Hereinafter, the best mode for carrying out a synthetic resin floor material according to the present invention will be described with reference to the drawings.

  1 to 3 show an example of a floor decorative material of the present invention, FIGS. 1 and 2 are sectional views of the floor decorative material, and FIG. 3 is a plan view of the floor decorative material. 4 and 5 are explanatory views showing a method for producing a floor decorative material according to the present invention.

  The floor decorative material 1 includes, for example, a square-shaped surface material 20 having a size of 294 mm × 294 mm as shown in FIG. 1 formed on a frame 10 formed using a soft synthetic resin material such as low-density polyethylene and having a nominal size of 300 mm × 300 mm. As shown in FIG. Moreover, as illustrated in FIGS. 2 and 3, a configuration may be employed in which the surface material 20 having a square shape in a top view of 98 mm × 98 mm is arranged in three rows with respect to the frame 10.

  In such a configuration, in the frame body 10, the partition walls 12 that form the holding sections 11 are provided in a lattice shape at a pitch corresponding to the size of the square surface material 20. On the upper part of the peripheral wall 13 and the partition wall 12 of the frame body 10, an engaging convex portion 14 for fixing the surface material 20 is projected.

  The engaging convex part 14 is formed in a cross-sectional shape as shown in FIGS. That is, the engaging convex portion 14 is disposed in a convex shape toward the inside of the holding section 11, and its outer lower surface protrudes as a surface parallel to the bottom surface of the holding section 11, and the outer upper surface is the tip. It is formed in a tapered shape inclined downward in the direction.

  In addition, as shown in FIG. 3, the frame body 10 is provided with a plurality of annular female connecting portions 15 at a constant pitch at the lower ends of the side walls of two sides adjacent to each other. On each opposite side, a plurality of cylindrical male connecting portions (not shown) are provided in a positional relationship corresponding to each female connecting portion 15, and a plurality of floor decorative materials are utilized using these male and female connecting portions 15. 1 can be connected to each other. Further, legs 16... 16 for securing a drainage space between the frame 10 and the floor surface to be laid are formed integrally with the frame 10.

  The material of the frame 10 of the floor decorative material 1 to which 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.

  On the other hand, the surface material 20 is made of, for example, a flat tile material having a square shape in a top view, and a single engagement groove 21 and 21 is formed on at least two parallel side surfaces of the four circumferential side surfaces that face each other. .

  As the material of the surface material 20, wood, brick, concrete, synthetic resin material, and other various materials can be selected, but the case where porcelain tiles are used will be described as an example. In addition to porcelain tiles, it may be a stoneware tile, a ceramic tile, or the like.

  The surface material 20 can be engaged and fixed to the frame 10 by the engagement grooves 21 and 21 on the side surfaces.

  As shown in the cross-sectional shape of FIG. 1, each engagement groove 21 of the surface material 20 has a concave groove shape along the side surface of the surface material 20, and the inner and lower surfaces 21 a of the grooves are parallel to the lower surface of the surface material 20. The inner upper surface 21b is formed in a tapered shape inclined upward in the direction of the opening end. As described above, the inner upper surface 21b of the engagement groove 21 is tapered so that when the engagement protrusion 14 of the frame 10 is engaged, it can be smoothly fitted without being caught. It has become.

  Further, the engagement groove 21 may be provided by being grooved on all the four circumferential side surfaces of the surface material 20, and the engagement of the frame body 10 without checking the orientation of the surface material 20 at the site. This is preferable because it can be fitted into the convex portion 14. Further, the upper end of the four circumferences of the surface material 20 is chamfered to form a stepped portion 22.

  In order to attach such a surface material 20 to the frame body 10, the surface material 20 is fitted into the substantially square holding sections 11 in three rows and columns in a lattice shape defined by the peripheral wall 13 and the partition wall 12 of the frame body 10. At this time, the surface material 20 is fixed to the frame body 10 by fitting the engagement convex portions 14 provided on the peripheral wall 13 and the partition wall 12 into the engagement grooves 21 of the surface material 20.

  At this time, as shown in FIG. 2, the engaging groove 21 on one side surface of the surface material 20 is engaged with the engaging convex portion 14 of the frame body 10 while the surface material 20 is slightly inclined, and then facing each other. The engagement protrusion 14 is engaged with the engagement groove 21 on the side surface. Since the engagement groove 21 of the surface material 20 has an inner upper surface 21b that is tapered, it is easy to fit into the engagement convex portion 14 of the frame body 10, and it is difficult to come off and the engagement strength is increased. 20 and the frame 10 can be fixed satisfactorily.

  Further, when the surface material 20 is fitted into the frame body 10, as shown in FIG. 2, a concave groove 30 is formed between the adjacent surface materials 20 and 20, so that the floor decorative material 1 having a good appearance and a beautiful appearance can be obtained. Can be formed.

  Next, a method for producing a floor decorative material according to the present invention will be described. Here, the groove processing of the surface material 20 of the floor decorative material 1 will be particularly described.

  All the manufacturing steps of the surface material 20 can be performed in-line. That is, the surface material 20 is press-molded into a plate-like body having a square shape in plan view by filling and clamping with a molding die, demolding, and taking out a molded product. Subsequently, an engaging groove 21 is provided on the side surface of the molded body of the surface material 20 on the same line.

  The engaging groove 21 is formed by performing groove processing in two stages using a disc-shaped cutting cutter set in a production line at a factory. For the groove processing of the engaging groove 21, it is preferable to use diamond cutters 4a and 4b capable of cutting a material having high hardness. The general shape of the diamond cutters 4a and 4b is such that a diamond layer is provided on the outer periphery of a thin circular disk, and the diamond layer is slightly thicker than the thickness of the disk.

  As shown in FIG. 4, first, the engagement groove 21 is first cut into a substantially U-shaped cross section using a diamond cutter 4a having a convex tip section of the cutting blade. By this primary cutting, a groove having a substantially U-shaped cross section can be formed along the side surface of the molded body of the surface material 20 on, for example, two opposing side surfaces.

  Next, as shown in FIG. 5, the engaging groove 21 is subjected to secondary cutting using a diamond cutter 4b having a substantially triangular tip section. In the secondary cutting process, the tapered portion of the inner upper surface 21b of the engagement groove 21 is cut. At this time, in the substantially U-shaped engaging groove 21 formed by primary cutting, the inner and lower surfaces 21a are not cut, and the grooves are cut so that only the inner upper surface 21b is cut.

  The molded body of the surface material 20 thus grooved is heated at a high temperature and fired. Thereby, the desired surface material 20 which has the said recessed groove-shaped engagement grooves 21 and 21 can be obtained.

  In the two-step grooving of the engaging groove 21, the thickness of the cutting blades of the diamond cutters 4a and 4b is selected in accordance with the thickness of the engaging groove 21 to be formed, so that one grooving is performed. By the operation, the primary cutting of the single engagement groove 21 along the side surface of the surface material 20 can be easily performed.

  In addition to the porcelain tiles described above, the surface material 20 can be manufactured by a similar dry-type molding process using a porcelain tile, a ceramic tile, and the like, and can be molded and fired in-line. It can be produced efficiently at low cost.

  In addition, since the engaging groove 21 of the surface material 20 has a concave groove-like cross-sectional shape as described above and is formed by two-stage cutting, defects such as chipping can be greatly reduced. Thus, the yield can be improved.

  The surface material 20 formed through the above steps is gripped by an appropriate suction device or the like and fitted into the frame body 10, and the molded frame body 10 is completely cooled to engage with the engagement convex portion 14. By engaging with the groove 21, the floor decorative material 1 in which the surface material 20 is stably fixed to the frame body 10 can be obtained.

  INDUSTRIAL APPLICABILITY The present invention can be suitably used by laying on a floor surface such as a balcony or a veranda in a building such as a house.

It is sectional drawing which shows an example of the floor decorative material which concerns on this invention. It is a fragmentary sectional view which shows an example of the floor decorative material which concerns on this invention. It is a top view of the floor decoration material. It is explanatory drawing which shows the manufacturing method of the floor decorative material of this invention. It is explanatory drawing which shows the next process of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Floor decoration material 10 Frame 14 Engagement convex part 20 Surface material 21 Engagement groove 21a Inner lower surface 21b Inner upper surface

Claims (2)

A synthetic resin frame body and a surface material disposed on the frame body, and at least two parallel side surfaces of the surface material are each provided with a single engagement groove, and each of these engagements By engaging a groove with an engaging convex portion protruding from the frame body, the surface material is a floor decorative material that is engaged and fixed to the frame body,
The engaging groove of the surface material has a tapered shape in which the inner upper surface is inclined upward in the direction of the opening end, and the inner and lower surfaces are concave grooves formed in parallel with the lower surface of the surface material, and the engagement of the frame body. The mating convex portion has a tapered shape in which an outer upper surface is inclined downward in a distal direction, and an outer lower surface is a convex shape formed in parallel with a bottom surface of the frame body. A synthetic resin frame body and a surface material disposed on the frame body, and at least two parallel side surfaces of the surface material are each provided with a single engagement groove, and each of these engagements A method of manufacturing a floor decorative material in which a surface material is engaged and fixed to a frame body by engaging a groove with an engaging convex portion protruding from the frame body,
The engaging groove of the surface material has a tapered shape in which the inner upper surface is inclined upward in the direction of the opening end, and the inner and lower surfaces are concave grooves formed in parallel with the lower surface of the surface material, and the engagement of the frame body. The joint convex part is a convex shape in which the outer upper surface is a tapered shape inclined downward in the distal direction, and the outer lower surface is formed in parallel with the bottom surface of the frame,
The surface material is press-molded into a plate-like body having a square shape in a plan view, and the engagement groove is first cut into a substantially U-shaped cross section using a diamond cutter having a convex cross section at the tip of the cutting blade, and further cut A method for producing a flooring decorative material, wherein the inner surface of the engagement groove is subjected to secondary cutting using a diamond cutter having a substantially triangular cross-section at the tip of the blade.

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