JP5248076B2 - Wood grain flooring and method for producing wood grain flooring - Google Patents

Description

  The present invention relates to a wood-grained floor material having a grain pattern on its surface and a method for producing the floor material.

Conventionally, a wood-grained flooring material expressing a natural wood grain pattern is known.
For example, Patent Document 1 discloses a flooring in which a pattern sheet printed with a wood grain pattern is attached to the upper surface of a base material via a colored adhesive, and a V-groove is formed on the upper surface of the base material. .
Further, in Patent Document 2, the surface of the decorative plywood is ground-treated, a solid coating-like concealing layer is formed, and a transfer printing layer is formed on the concealing layer by transferring and printing a wood grain pattern with a plate roll, A wood-based flooring material is disclosed in which the surface of the transfer printing layer is finish-coated with an ultraviolet curable transparent paint.

Further, in Patent Document 3, a thermoplastic resin-colored underlayer is laminated on a base material, mechanical embossing is imparted to the surface of the underlayer, and a color different from that of the underlayer in a portion synchronized with the contour of at least the bottom of the embossed recess. A floor material (interior material) in which a thin chip piece is filled and a transparent resin layer is filled in the concave portion up to the same position as the surface of the base layer is disclosed.
Japanese Patent Laid-Open No. 9-88304 JP 2007-31995 A Japanese Utility Model Publication No. 7-26131

  However, since the flooring materials described in Patent Documents 1 and 2 show a wood grain pattern by printing, they do not have a three-dimensional effect and do not exhibit the appearance of natural wood. Moreover, since the surface of the flooring is an approximately mirror surface or a mat-like fine uneven surface, it does not have the feel of natural wood.

On the other hand, the flooring described in Patent Document 3 is formed linearly between the bottom of the embossed recess and the surface of the underlayer (having a sharp mechanical embossed pattern contour), and a sharp design is obtained. It is characterized by that.
However, since the difference in light and darkness of natural wood gradually changes, even if a wood grain pattern is formed using a technique for forming a sharp design as described in Patent Document 3, the natural wood has an appearance. Absent. Furthermore, since the floor material of Patent Document 3 is filled with a thin chip piece at the bottom of the embossed recess, the transparent resin layer is filled in the recess to the same position as the surface of the base layer. It is almost a mirror surface and does not have the feel of natural wood.

  An object of the present invention is to provide a grain-like flooring material that approximates natural wood not only in appearance but also in tactile sensation, and a method for producing the flooring material.

The grain pattern of natural wood differs depending on the direction from which it is cut out with respect to the eyes of the annual rings, but generally it can be broadly divided into squares and planks.
In addition, annual rings appear in a ring shape by early and late woods formed alternately. The early wood is a soft and rough part of the wood and looks thin in appearance. Evening wood is a dense and hard part of wood and looks dark in appearance. In both the grid and the plate, the late wood part has a glossy and smooth feel (hereinafter referred to as "mirror feel"), while the early part has a glossy feel. This is a tactile sensation that is low and rough (hereinafter, this tactile sensation is referred to as “rough texture”). Further, the glossiness gradually decreases as the material moves from the late material to the early material, and the tactile sensation gradually becomes rough.
The inventors of the present invention have completed the present invention by considering the characteristics of the grain of the natural wood and conducting intensive studies to reproduce it.

In the woodgrain floor material of the present invention, a convex portion and a concave portion are formed by embossing the surface of the resin layer of the floor material body to imitate a wood grain pattern, and the concave portion is recessed from the boundary portion of the convex portion. A portion formed with an inclined surface that is inclined toward the bottom of the resin, and the concave portion is filled with a short fiber-containing resin layer containing short fibers, and contains short fibers in the vicinity of the boundary between the convex portions. The thickness of the resin layer is thinner than the thickness of the short fiber-containing resin layer at the bottom of the recess, and the short fibers are synthetic resin fibers or natural fibers .

The above-mentioned wood-grained flooring material is formed with convex portions and concave portions on the surface of the resin layer by embossing imitating a wood grain pattern, and synthetic resin fibers or natural fiber-containing resin of short fibers is formed in the concave portions. The layer is filled. Since the surface of the convex portion is the surface of the resin layer, it has high gloss and has a mirror-like touch. On the other hand, the surface of the short fiber-containing resin layer filled in the recesses has low gloss because the short fibers diffusely reflect light, and the short fibers of synthetic resin fibers or natural fibers are exposed. Have For this reason, the surface of the convex part approximates the appearance and feel of natural wood, and the surface of the short fiber-containing resin layer filled in the recess approximates the appearance and feel of natural wood. doing.
Further, the concave portion is formed with an inclined surface that is inclined downward from the boundary portion between the concave portion and the convex portion toward the bottom portion of the concave portion. According to the inclined surface of the concave portion, the thickness of the short fiber-containing resin layer filled in the concave portion is very thin in the vicinity of the boundary portion of the convex portion and becomes thicker toward the bottom portion of the concave portion. For this reason, the surface of the short fiber-containing resin layer gradually decreases in gloss as it goes from the boundary between the concave portion and the convex portion toward the center of the concave portion, and the tactile sensation gradually becomes rough. Go.
Therefore, the wood-grained flooring material has a natural wood grain evening material and early wood material that appear realistically, and the tactile sensation is inferior to that of natural wood.

In a preferred woodgrain flooring of the present invention, the fineness of the short fibers is 1.0 to 5.5 dtex and the fiber length is 0.05 to 1.00 mm.

By using short fibers having a fineness of 1.0 to 5.5 dtex, the surface of the short fiber-containing resin layer can have an appropriate roughness.
Further, by using short fibers having a fiber length of 0.05 to 1.00 mm, the surface of the short fiber-containing resin layer can have an appearance like an early material.

In a preferred woodgrain floor material of the present invention, the surface of the short fiber-containing resin layer is slightly recessed toward the center of the recess.

Since the early wood of natural wood is a soft and rough part of the wood, the feel of the early wood feels slightly recessed compared to the late wood.
The preferable wood grain flooring is formed so that the surface of the short fiber-containing resin layer is slightly recessed toward the center side of the recess, so that the feel of the early wood of natural wood can be expressed more realistically. .

Moreover, the method for producing a woodgrain floor material according to the present invention includes a convex portion and a convex portion extending in one direction of the resin layer, by embossing the surface of the resin layer of the floor material body, embossing that imitates a wood grain pattern . Forming a concave portion having an inclined surface inclined from the boundary portion toward the bottom portion, and coating the surface of the resin layer including the concave portion and the convex portion with a short fiber-containing resin including a synthetic resin fiber or a short fiber of natural fiber. A scraping plate applied to the surface of the resin layer, and scraping the short fiber-containing resin on the surface of the convex portion while moving at least one of the floor material body and the scraping plate in one direction. The surface of the convex part is exposed while leaving the short fiber-containing resin in the concave part.
According to the method for producing a wood-grained floor material, the wood-grained floor material can be easily produced.

According to the present invention, it is possible to provide a wood-grained flooring material that is very close to the natural wood grain pattern in both appearance and touch.
Moreover, according to the method for producing a wood-grained floor material of the present invention, the wood-grained floor material can be produced easily and reliably.

(Summary of wood-tone flooring)
Next, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a partial plan view of an embodiment of the wood-grained flooring material of the present invention. FIG. 2 is an end view taken along the line II of FIG. It should be noted that the actual dimensions are different in each drawing.

1 and 2, reference numeral 1 denotes a floor material body 2 having a resin layer 3, protrusions 4 and recesses 5 formed on the surface of the resin layer 3 of the floor material body 2, and the inside of the recess 5. The grain-tone flooring which has the short fiber containing resin layer 6 with which it filled in is shown. In the flooring body 2, an intermediate layer 7 is laminated below the resin layer 3, and a backing layer 8 is laminated below the intermediate layer 7.
The convex part 4 and the concave part 5 are formed by embossing the surface of the resin layer 3 simulating a wood grain pattern.

In the wood grain flooring 1, the surface of the convex portion 4 (surface of the resin layer 3) approximates the appearance and feel of a natural wood evening material, and the surface of the short fiber-containing resin layer 6 filled in the concave portion 5. Is close to the appearance and feel of natural wood.
Therefore, the wood-grained flooring 1 is very close to the natural wood grain pattern in both appearance and feel.
Hereinafter, the grain-tone flooring 1 of the present invention will be specifically described while explaining each constituent element.

(Floor material)
In one embodiment, the flooring main body 2 includes a resin layer 3, an intermediate layer 7, and a backing layer 8 in order from the top.
For the resin layer 3, a conventionally known synthetic resin can be used. The resin layer 3 is colored in a desired color. The color is not particularly limited, but the color of the resin layer 3 is preferably black, reddish brown, or ocher in order to approximate the color of a natural wood grain or a natural wood baking sheet.
However, as will be described later, when a design printing layer (colored layer) is provided below the resin layer 3, the resin layer 3 is transparent or translucent.

The resin component of the resin layer 3 is not particularly limited. For example, vinyl chloride resin (PVC); ethylene-vinyl acetate copolymer, ethylene / α-olefin copolymer, ethylene- (meth) acrylate copolymer Examples thereof include ethylene copolymers such as polymers; olefin resins such as polypropylene and polyethylene; acrylic resins; polyamide resins such as 6,6 nylon; and resins (including elastomers) such as urethane resins. These can be used individually by 1 type or in mixture of 2 or more types.
The resin layer 3 has a flame retardant such as a metal hydrated oxide such as aluminum hydroxide or magnesium hydroxide; calcium carbonate, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, depending on the type of resin. , Clay, talc, mica and other fillers; plasticizers such as di-2-ethylhexyl phthalate (DOP), dibutyl phthalate, dihexyl phthalate, diisononyl phthalate, phosphate ester, chlorinated paraffin, trimellitic acid ester; calcium stearate Various additives such as stabilizers such as inorganic salts and organic tin compounds; lubricants; antioxidants may be mixed as appropriate.

Among these, as the resin component of the resin layer 3, a vinyl chloride resin is preferable. The vinyl chloride resin may be a paste type or a suspension type.
When a vinyl chloride resin is used, a vinyl chloride resin having an average degree of polymerization of about 500 to 2500, and preferably an average degree of polymerization of about 700 to 2000 is used. By using a vinyl chloride resin having a relatively low average degree of polymerization as described above, the resin layer 3 having high surface gloss can be formed. Therefore, the glossiness of the surface of the convex part 4 can be improved, and the glossiness of the natural wood evening material can be expressed more realistically.
In addition, in this specification, an average degree of polymerization says the value calculated | required by JISK6720-2.
Although the thickness of the said resin layer 3 is not specifically limited, Usually, it forms in about 0.5 mm-2.5 mm.

Also for the intermediate layer 7, a conventionally known synthetic resin can be used. For the intermediate layer 7, a synthetic resin as exemplified in the resin layer 3 (various additives may be blended as necessary) can be used.
When a vinyl chloride resin is used as the resin layer 3, it is preferable to use a vinyl chloride resin for the intermediate layer 7 as well. This is because the resin layer 3 and the intermediate layer 7 can be more integrated, and the flooring body 2 can be easily manufactured. The intermediate layer 7 is preferably made of a vinyl chloride resin having a higher average degree of polymerization than the vinyl chloride resin of the resin layer 3. Specifically, the intermediate layer 7 is preferably made of a vinyl chloride resin having an average degree of polymerization of about 800 to 3,500, and preferably an average degree of polymerization of about 1000 to 3000. As described above, in order to improve the surface glossiness, it is preferable to use a vinyl chloride resin having a relatively low average degree of polymerization as the resin of the resin layer 3, but on the other hand, the strength of the resin layer 3 is lowered. For this reason, by using a vinyl chloride resin having an average degree of polymerization larger than that of the resin layer 3 as the intermediate layer 7, the overall strength of the flooring body 2 can be increased.
In addition, the thickness of the said intermediate | middle layer 7 is normally formed in about 0.5 mm-2.5 mm.

  The backing layer 8 is laminated for the purpose of improving the strength and dimensional stability of the flooring body 2 and improving the adhesion to the ground. Examples of the backing layer 8 include woven fabric and non-woven fabric. The material of the woven fabric or the nonwoven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as cellulosic fibers and polyester fibers; inorganic fibers such as glass fibers; natural fibers such as jute.

  In addition, the flooring main body 2 is not limited to the layer configuration including the resin layer 3, the intermediate layer 7, and the backing layer 8, and other layers may be further laminated. Further, the intermediate layer 7 and / or the backing layer 8 may be omitted from the flooring main body 2.

In other embodiment, the flooring main body 2 may be provided with a design printing layer 81 below the resin layer 3 as shown in FIG. The design print layer 81 is designed to approximate a natural wood grain or a natural wood baking sheet.
When the design print layer 81 is provided, the resin layer 3 is made of a transparent or translucent resin. The degree of transparency of the resin layer 3 is such that the light transmittance of the resin layer 3 is 50% or more, preferably 80% or more. However, the light transmittance is a value measured by a method according to JIS K 7105-1981 (plastic optical property test method), and is obtained by light transmittance (%) = (T2 / T1) × 100. . T2 represents the total light transmission amount (total light amount that has passed through the test piece), and T1 represents the incident light amount.

In another embodiment, the floor material body 2 may be provided with a transparent overcoat layer 82 on the surfaces of the resin layer 3 and the short fiber-containing resin layer 6 as shown in FIG. The overcoat layer 82 can be formed using an ultraviolet curable resin, a thermosetting resin, a fluororesin, various waxes, or the like.
The overcoat layer 82 has a thickness of about 3 to 7 μm. This is because if the overcoat layer 82 that is too thick is provided, the glossiness and touch of the surface of the resin layer 3 and the surface of the short fiber-containing resin layer 6 may be impaired.

(Convex and concave)
The convex part 4 and the concave part 5 are formed by performing, for example, mechanical embossing on the surface of the resin layer 3. That is, the surface of the resin layer 3 is formed in an uneven shape.
As shown in FIG. 1, the planar shape of the convex portion 4 is formed in a relatively narrow curved shape extending in one direction X in the surface of the resin layer 3 so as to correspond to the natural wood latewood portion. ing. The concave portion 5 is a concave formed between the adjacent convex portions 4, and the planar shape of the concave portion 5 is in one direction X in the plane of the resin layer 3 so as to correspond to the portion of the early wood of natural wood. It is formed in a relatively wide curved shape that extends.
In addition, the planar shape of the convex part 4 and the recessed part 5 is extended substantially along the one direction X, and is not a strict meaning of extending in parallel with the one direction X.

Further, as shown in FIG. 2, the cross-sectional shape of the concave portion 5 is formed with an inclined surface 53 that is inclined from the boundary portion 51 between the concave portion 5 and the convex portion 4 toward the bottom portion 52 of the concave portion 5. The inclination angle of the inclined surface 53 is not particularly limited and can be arbitrarily set. When the inclination angle of the inclined surface 53 is reduced, the shallow portion of the recess 5 is elongated in the width direction (direction orthogonal to the one direction X), and when the inclination angle of the inclined surface 53 is increased, the depth of the recess 5 is increased. The shallow part becomes shorter. In the shallow portion of the recess 5, the thickness of the short fiber-containing resin layer 6 filled in the concave portion 5 is also thin, so that irregular reflection is small (that is, relatively glossy) and the degree of short fiber exposure is small. Therefore, the longer the shallow part of the concave part 5 is, the more gently the glossy feeling and the rough feeling when touched change from the surface of the convex part 4 toward the center of the surface of the short fiber-containing resin layer 6. . On the other hand, the shorter the depth of the concave portion 5 is, the steeper the glossy feeling and the rough feeling when touched are changed from the surface of the convex portion 4 toward the center of the surface of the short fiber-containing resin layer 6. .
Therefore, by forming the concave portion 5 having a small inclination angle of the inclined surface 53 and the concave portion 5 having a large inclination angle of the inclined surface 53 in the resin layer 3 by appropriately combining them, the wood-grained flooring material more similar to the wood grain pattern of natural wood 1 can be formed.

  It should be noted that all the recesses 5 formed in the resin layer 3 are not limited to the case where the inclined surface 53 is provided. ) It may be formed perpendicular to the surface of the convex portion 4.

  The depth at the bottom 52 of the concave portion 5 (the length from the bottom 52 of the concave portion 5 to the surface of the convex portion 4) is not particularly limited, but if it is too shallow, the effect of the present invention is not achieved. It does n’t change. Considering these, the depth at the bottom 52 of the recess 5 is preferably 0.08 mm to 0.4 mm, and more preferably 0.1 mm to 0.3 mm.

(Short fiber-containing resin layer)
The short fiber-containing resin layer 6 includes short fibers 61 and a resin. The short fiber-containing resin layer 6 is filled so as to be embedded in the recess 5.
The surface of the short fiber-containing resin layer 6 filled in the recesses 5 has low gloss because the contained short fibers diffusely reflect light, and the short fibers are exposed, resulting in a rough tactile feel. .
Preferably, the surface of the short fiber-containing resin layer 6 is formed to be slightly recessed toward the center side of the recess 5. Thus, when the center part of the surface of the short fiber containing resin layer 6 is slightly recessed, the part of the early wood of natural wood can be expressed more realistically.

Although it does not specifically limit as a resin component of the short fiber containing resin layer 6, Since the manufacturing method of the woodgraining flooring material 1 can be performed simply, resin which has fluidity at normal temperature is preferable.
The resin component includes a paste type (or suspension type) vinyl chloride resin; a solvent type resin or emulsion type resin in which an ethylene-vinyl acetate copolymer, an acrylic resin, a styrene resin, etc. are dissolved in a solvent; Examples include ionizing radiation curable resins such as curable resins.

The short fibers 61 are not particularly limited, and examples thereof include cellulose fibers, polyester fibers such as polyethylene terephthalate, polyamide fibers such as nylon 66, synthetic resin fibers such as olefin fibers such as polypropylene, and natural fibers. Among these, cellulose fibers and / or polyester fibers are preferable because of excellent touch feeling.
Although the fineness of the said short fiber 61 is not specifically limited, Preferably it is 1.0-5.5 dtex, More preferably, it is 1.5-3.5 dtex. This is because when the short fibers are too thin, the surface roughness of the short fiber-containing resin layer 6 is almost eliminated, whereas when the short fibers are too thick, the surface roughness becomes too large.

  Although the fiber length of the said short fiber 61 is not specifically limited, Preferably it is 0.05-1.00 mm, More preferably, it is 0.10-0.08 mm. If the fiber length of the short fiber is too short, the surface of the short fiber-containing resin layer 6 is unlikely to have an appearance like an early material, and further, the short fibers are likely to fall out of the short fiber-containing resin layer 6. On the other hand, if the fiber length of the short fiber is too long, it is difficult to apply the short fiber-containing resin to the surface of the resin layer 3.

Although content of the short fiber 61 is set suitably, it is 1-20 mass% per short fiber containing resin whole quantity, Preferably it is 3-15 mass%, More preferably, it is 3-6 mass%.
When the content of the short fiber is too small, the gloss of the surface of the short fiber-containing resin layer 6 cannot be suppressed, and the texture of the surface of the short fiber-containing resin layer 6 and the surface of the resin layer 3 (surface of the convex portion 4) is reduced. There is no difference. On the other hand, if the content of the short fiber is too large, the short fiber-containing resin layer 6 may be peeled off or cracked, and further, the amount of the short fiber exposed on the surface of the short fiber-containing resin layer 6 becomes too large. It is.

The short fiber-containing resin layer 6 may be transparent or colored. When the short fiber-containing resin layer 6 is colored, it is preferably thinner than the color tone of the resin layer 3 in order to resemble an early natural wood material.
In addition, the said short fiber containing resin layer 6 may be mix | blended with the additive suitably. As the additive, the additives exemplified in the resin layer 3 can be appropriately selected and used.

(Method for producing wood-grained flooring)
The woodgrain flooring 1 can be manufactured, for example, by the following method.
In one embodiment, the woodgrain flooring 1 is formed in a long shape. The long shape refers to a shape in which the length in one direction is sufficiently longer than the other direction, for example, the length in one direction is 10 times or more the length in the other direction. It is.

FIG. 4 is a reference diagram showing each step of a method for producing a long wood-grained flooring material.
First, a resin composition (main component: paste vinyl chloride, etc.) that forms an intermediate layer is coated on a long backing layer (for example, a long nonwoven fabric), and further a resin layer is formed thereon. A resin composition (main component: paste vinyl chloride or the like) is formed, and this is pregelled through an oven to integrate the layers. In this manner, the floor material main body elongated object 28 can be obtained.

The long flooring 28 is guided to a pair of embossing rollers 91, and the surface of the long flooring 28 is embossed.
By embossing, a convex portion and a concave portion imitating a wood grain pattern are formed on the surface of the resin layer of the floor material main body elongated object 28. The convex portion and the concave portion are formed so as to extend in the longitudinal direction of the floor material main body elongated object 28.
An embossed protrusion corresponding to the shape of the recess is formed on the surface of the embossing roller 91, and the recess is formed by pressing the embossed protrusion on the surface of the resin layer. The part remains as a convex part without being concave.

Next, a short fiber-containing resin 92 (main component: paste vinyl chloride or the like) is applied to the surface of the floor material main body 28 on which the concave and convex portions of the resin layer are formed.
The viscosity of the short fiber-containing resin 92 is not particularly limited, but is adjusted to 2000 to 4000 mPa · s in consideration of good coating properties of the short fiber-containing resin and easy scraping of the resin. It is preferable.

Next, a scraping plate 93 is applied to the surface of the resin layer to scrape off the excess short fiber-containing resin 92. The scraping plate 93 is not particularly limited, and examples thereof include various coaters, squeegees, and metal spatulas. As shown in FIG. 5, the scraping plate 93 is applied with the tip end portion 93 a of the scraping plate 93 extending in the width direction Y of the floor material main body elongated object 28.
The short fiber containing resin on the surface of the convex portion can be scraped by moving the floor material main body elongated object 28 in the longitudinal direction with the scraping plate 93 applied. Thereby, the floor material main body elongate 28 which the short fiber containing resin remains in the recessed part and the surface of the convex part was exposed can be obtained.

The scraping plate 93 is applied to the surface of the resin layer while applying pressure. By applying the scraping plate 93 under pressure in this way, the short fiber-containing resin 92 on the surface of the convex portion can be reliably removed, and further, the surface of the convex portion is smoothed by the scraping plate 93. The surface gloss of the convex portion can be increased.
Further, the scraping plate 93 may be applied perpendicular to the surface of the resin layer, but the scraping plate 93 has an acute angle (or obtuse angle) with respect to the surface of the resin layer as illustrated. ). When the floor material main body long object 28 swings up and down, the tip end portion 93a of the scraping plate 93 (the end applied to the resin layer) follows and bends up and down, and the short fiber containing resin 92 on the surface of the convex portion. This is because it can be surely scraped off.

Moreover, the flooring main body elongated object 28 is moved in the longitudinal direction with the scraping plate 93 applied. Accordingly, the tip portion of the scraping plate 93 extending in the direction (width direction Y) orthogonal to the extending direction (longitudinal direction) of the convex portion and the concave portion is contained in the short fiber while closely contacting the surface of the convex portion. The resin 92 is scraped off. Accordingly, the short fiber-containing resin 92 on the surface of the convex portion can be surely scraped, and the short fiber-containing resin 92 located in the central portion of the concave portion of the short fiber-containing resin 92 in the concave portion is removed from the surface of the convex portion. Can be scraped down slightly. Even if the scraping plate 93 is moved, the short fiber-containing resin 92 can be scraped off in the same manner as described above.
When scraped off in this manner, the wood-grained flooring 1 in which the surface of the short fiber-containing resin layer 6 is slightly recessed toward the center of the recess 5 as shown in FIG. 2 can be manufactured.

  Next, the floor material main body long object 28 is guided to a heating device 94 such as an oven and heated to a predetermined temperature (for example, about 180 to 250 ° C.), whereby the resin layer and the intermediate of the floor material main body long object 28 are obtained. The layer and the short fiber-containing resin are gelled. By cooling this, an elongated wood grain flooring can be obtained. The long wood-grained flooring material is usually wound around a roll 95 for storage and transportation.

  In other embodiments, the woodgrain flooring 1 is formed in a tile shape. The dimension of the tile-like wood-grained flooring material is not particularly limited, and is formed, for example, in a 500 mm square.

FIG. 6 is a reference diagram showing each step of the method for manufacturing a tile-like wood-grained flooring material.
Apply a resin composition (main component: paste vinyl chloride, etc.) that forms an intermediate layer on a long backing layer (for example, a long non-woven fabric), and then form a resin layer on top of this. A resin composition (main component: paste vinyl chloride, etc.) to be applied is applied, and this is passed through an oven to gel. The obtained floor material main body long object 28 can be used as a floor material as it is. However, in the present invention, the floor material main body long object 28 is guided to a pair of embossing rollers 91 and is used. Embossing is applied to the surface of
The specific method of embossing is the same as the manufacturing method of the above-mentioned long grained flooring.
The floor material main body long object 28 in which convex portions and concave portions are formed on the surface of the resin layer by embossing is punched into a predetermined shape by a cutting machine 96. By this cutting, the flooring main body tile 29 is obtained.

A short fiber-containing resin 92 (main component: UV curable resin or the like) is applied to the surface of the floor material main body 29 on which the concave and convex portions of the resin layer are formed.
Next, a scraping plate 92 is applied to the surface of the resin layer to scrape off the excess short fiber-containing resin 92.
The method for scraping the short fiber-containing resin 92 with the scraping plate 93 is the same as the method for manufacturing the long wood-grained flooring. Briefly, the scraping plate 93 is applied to the surface of the resin layer with an acute angle (or obtuse angle) while pressure is applied. Further, the tip of the scraping plate 93 is applied so as to extend in a direction orthogonal to the extending direction of the convex portion and the concave portion.

  In this manner, the short fiber-containing resin 92 on the surface of the convex portion of the floor material main body tile 29 is scraped, and the short fiber-containing resin 92 located in the central portion of the concave portion of the short fiber-containing resin 92 in the concave portion is removed. Can be scraped slightly.

  Next, the floor material main body tile 29 is guided to an ultraviolet irradiation device to perform ultraviolet irradiation, thereby curing the short fiber-containing resin 92. The obtained wood-grained flooring 1 is put in a storage case 98 or the like for storage and transportation.

  In the above-described method for producing a tile-like wood-grained flooring material, as a resin component of the short fiber-containing resin, an ionizing radiation curable resin such as an ultraviolet curable resin is used without using a resin curable by heating. It is preferable to use it. In the manufacturing method of the tile-like woodgrain floor material illustrated above, since it is in a state that can be used as a flooring material before embossing, after that, when heating the short fiber-containing resin, This is because there is a risk of deformation of the flooring main body.

(Appearance and feel of wood-tone flooring)
The wood-grained flooring 1 of the present invention is very close to the natural wood grain pattern in both appearance and feel.
Specifically, the surface of the convex part 4 which is the surface of the resin layer 3 is highly glossy and has a specular tactile sensation. Therefore, the surface of the convex part 4 approximates the natural wood evening material. Further, the surface of the short fiber-containing resin layer 6 filled in the concave portion 5 has low gloss because the short fibers diffusely reflect light, and the short fibers are exposed, resulting in a rough texture. Therefore, the surface of the short fiber-containing resin layer 6 filled in the concave portion 5 is close to an early material of natural wood.

  Further, as shown in FIG. 2, the concave portion 5 is formed with an inclined surface 53 that is inclined downward from the boundary portion 51 of the convex portion 4 toward the bottom portion 52 of the concave portion 5. According to the inclined surface 53 of the concave portion 5, the thickness of the short fiber-containing resin layer 6 filled in the concave portion 5 is very thin in the vicinity of the boundary portion of the convex portion 4 and becomes thicker toward the bottom portion of the concave portion 5. . For this reason, the gloss of the surface of the short fiber-containing resin layer 6 gradually decreases as it goes from the boundary portion 51 between the concave portion 5 and the convex portion 4 toward the center side of the concave portion 5. Similarly, the tactile sensation gradually becomes rougher toward the center of the recess 5.

The surface of the short fiber-containing resin layer 6 is slightly recessed toward the center of the recess 5. Usually, the feel of the early part of natural wood feels slightly recessed compared to the late part of the wood, so the surface of the short fiber-containing resin layer 6 is recessed as described above. The feel of the material can be expressed more realistically.
In particular, according to the method in which the short fiber-containing resin is applied and then scraped off as in the above-described manufacturing method, the short fiber in the vicinity of the boundary portion 51 It can be scraped deeper than the contained resin. For this reason, a relatively large amount of short fibers are exposed in the slightly recessed portion of the surface of the short fiber-containing resin layer 6. Therefore, the feel of the early wood of natural wood can be expressed more realistically.

  EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.

Example 1
After laminating the following resin composition A having a thickness of 1.2 mm on a non-woven fabric made of polyester, and laminating the following resin composition B having a thickness of 0.8 mm on this, it was heated at 160 to 180 ° C. for 2 minutes, Pregelled. A concave portion (depth 0.2 mm) and a convex portion having an inclined surface were formed on the surface of the obtained resin layer using an embossing roller imitating a wood grain pattern.
Next, after applying the following resin composition C containing 5% by mass of cellulose short fibers (fiber length: 0.2 mm, fineness: 1.9 dtex) on the surface of the resin layer, a metal spatula is used. Then, the surface of the resin layer was rubbed to remove the short fiber-containing resin composition C on the surface of the convex portion.
This was heated in an oven at 180 to 200 ° C. for 5 minutes to obtain a woodgrain flooring.

(Example 2)
After laminating the following resin composition A having a thickness of 2.5 mm on the nonwoven fabric and laminating the following resin composition B having a thickness of 0.5 mm on the non-woven fabric, heating was performed at 180 to 200 ° C. for 5 minutes. It was completely gelled and integrated. On the surface of the obtained resin layer, an embossing roller imitating a wood grain pattern was used to form a concave portion (depth 0.2 mm) and a convex portion having an inclined surface, and then this was formed into a tile shape of 10 × 90 cm in length and width. Punched out.
Next, an ultraviolet curable resin (manufactured by China Paint Co., Ltd., trade name “Aulex”) containing 3% by mass of polyester short fibers (fiber length: 0.5 mm, fineness: 2.5 dtex) on the surface of the resin layer. No. 190 ") was applied, and the surface of the resin layer was rubbed with a metal spatula to remove the short fiber-containing UV curable resin on the surface of the convex portion.
This was irradiated with ultraviolet rays to cure the ultraviolet curable resin, thereby obtaining a woodgrain flooring material.

(Resin composition A)
PVC resin (paste resin, average degree of polymerization 1500): 100 parts by mass.
Dioctyl phthalate: 60 parts by mass.
Calcium carbonate ... 80 parts by mass.
Stabilizer: 5 parts by mass.
Titanium oxide: 2 parts by mass.
(Resin composition B)
PVC resin (paste resin, average degree of polymerization 720): 100 parts by mass.
Dioctyl phthalate: 45 parts by mass.
Calcium carbonate: 35 parts by mass.
Stabilizer: 5 parts by mass.
Colored toner: 2 parts by mass.
(Resin composition C)
PVC resin (paste resin, average polymerization degree 1000): 100 parts by mass.
Dioctyl phthalate: 35 parts by mass.
Stabilizer ... 3 parts by mass.

  When the appearance of the wood grain flooring material obtained in Example 1 and Example 2 was seen, it was no different from natural wood, and it felt as if it was touching natural wood.

The partially abbreviated top view which shows one Embodiment of a grain-like flooring material. The end view cut | disconnected by the II line | wire of FIG. (A), (b) is an end view which shows other embodiment of a woodgrain flooring. The reference drawing which shows one Embodiment of the manufacturing method of a woodgrain flooring. FIG. 5 is a partially omitted reference plan view seen from the direction of arrow II in FIG. 4. The reference drawing which shows other embodiment of the manufacturing method of a woodgrain flooring.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Wood grain-like flooring material, 2 ... Floor material main body, 3 ... Resin layer, 4 ... Convex part, 5 ... Concave part, 51 ... Boundary part of a convex part and a concave part, 52 ... Bottom part of a concave part, 53 ... Inclined surface of a concave part, 6 ... Short fiber-containing resin layer, 7 ... Intermediate layer, 8 ... Backing layer, 91 ... Embossing roll, 92 ... Short fiber-containing resin, 93 ... Scraping plate, 94 ... Heating device

Claims (4)

By embossing imitating a wood grain pattern on the surface of the resin layer of the flooring main body, convex portions and concave portions are formed,
The concave portion has a portion where an inclined surface is formed which is inclined from the boundary portion of the convex portion toward the bottom portion of the concave portion,
The concave portion is filled with a short fiber-containing resin layer ,
The thickness of the short fiber-containing resin layer in the vicinity of the boundary of the convex portion is thinner than the thickness of the short fiber-containing resin layer at the bottom of the concave portion ,
The wood-grained flooring material , wherein the short fibers are synthetic resin fibers or natural fibers . The wood-grained flooring material according to claim 1, wherein the fineness of the short fibers is 1.0 to 5.5 dtex and the fiber length is 0.05 to 1.00 mm . The woodgrain-like flooring material according to claim 1 or 2, wherein the surface of the short fiber-containing resin layer is slightly recessed toward the center side of the recess . A concave portion having a convex portion extending in one direction of the resin layer and an inclined surface inclined from the boundary portion of the convex portion to the bottom portion by embossing the surface of the resin layer of the floor material main body, emulating a wood grain pattern And form the
Applying a short fiber-containing resin containing synthetic resin fibers or short fibers of natural fibers to the surface including the concave and convex portions of the resin layer,
A scraping plate is applied to the surface of the resin layer, and the short fiber-containing resin on the surface of the convex portion is scraped off while moving at least one of the floor material body and the scraping plate in one direction, A method for producing a wood-grained floor material, wherein the surface of a convex portion is exposed while leaving a short fiber-containing resin in the concave portion.

Images