JP7542370B2 - Flooring manufacturing method - Google Patents

Description

The present invention relates to flooring materials with patterns or designs on the surface, and to a method for manufacturing flooring materials.

Flooring materials with patterns or textured patterns on the surface have been known for some time (see, for example, Patent Document 1). The flooring material in Patent Document 1 is composed of a laminate in which multiple layers are stacked together and fused together by passing them between a pair of rolls under pressure and heat. This laminate is passed between an embossing roll and a receiving roll, during which the textured pattern of the embossing roll is transferred to the surface of the laminate.

In addition to the above-mentioned heat fusion bonding, other known means for integrating multiple layers include bonding by "cold pressing," in which multiple layers are stacked together with an adhesive interposed between them and pressed at room temperature, and bonding by "hot pressing," in which further heat is applied after cold pressing (see, for example, Patent Documents 2 and 3).

Now, regarding cold pressing, a method for manufacturing a resin molded product has been put into practical use in which a resin material is heated to a plasticizing temperature higher than the softening temperature (softening point) of the base thermoplastic resin to put it into a plastic state, and then placed inside a mold consisting of an upper mold and a lower mold, and then molded into a predetermined shape by applying pressure while cooling in the mold (see, for example, Patent Document 4).

JP 2017-20248 A International Publication No. 2012/053036 JP 2002-18807 A JP 2017-177692 A

The flooring material described in Patent Document 1 can be given a certain degree of designability because an embossing roll can be used to form an uneven pattern on the surface. However, the laminate that constitutes the flooring material is formed by passing multiple layers, while overlapping them, between a pair of rolls and applying pressure and heat. Due to the constraints of the manufacturing process, the molded product is limited to a flat sheet-like shape, and it is difficult to mold it into a free-form shape with a three-dimensional feel, especially a three-dimensional shape that exceeds the thickness of the sheet.

Even with the integration method using cold pressing as disclosed in Patent Document 2, the molded product is limited to a flat sheet-like shape due to constraints in the manufacturing process. In Patent Document 3, a hot pressing process is carried out in addition to the cold pressing process. For example, if the surface layer is made of polyvinyl chloride resin with a pattern or textured design, the pattern or textured design on the surface will be crushed by thermal deformation and the pressure during the pressing process, making it impossible to maintain the design.

In the cold press molding used in the manufacturing method of resin molded products disclosed in Patent Document 4, a plasticized resin material is filled along the shape of the molded cavity formed by clamping the upper and lower dies of a molding die, so it is possible to mold into any shape according to the shape of the molded cavity, but it is not good at adding fine decoration such as patterns or uneven patterns to the surface.

The present invention was made in consideration of the above problems, and aims to provide a flooring material that can achieve both high designability and flexible moldability, and a manufacturing method for said flooring material.

The characteristic configuration of the flooring material according to the present invention to solve the above problems is as follows:
The sheet is formed by laminating a surface layer and a cold press molded layer.

According to the flooring material of this configuration, the surface layer and the cold press molded layer are laminated, so that a high design can be applied to the surface side of the surface layer. Examples of the design include a three-dimensional uneven pattern and a two-dimensional pattern. For example, the uneven pattern can be obtained by forming unevenness on the surface by embossing or the like. The pattern means a color or design, and can be obtained by providing a design layer made of a printed film or multicolor chips. The cold press molded layer is a layer formed by pressing the base material of the cold press molded layer, which has been brought to a state above its softening point, while cooling it with a mold. The boundary between the surface layer and the cold press molded layer is integrated by thermal fusion due to the heat of the base material of the cold press molded layer, which has been brought to a state above its softening point, and the pressure during the press process. In the flooring material of this configuration, the surface side of the surface layer is cooled by the mold, although the pressure during the press process acts on it. For this reason, the thermal deformation of the surface side of the surface layer can be suppressed, and as a result, the pattern or uneven pattern applied to the surface side of the surface layer remains without being crushed, and high design can be ensured. On the other hand, in the cold press molding layer, the base material, which is kept above its softening point, can be molded into any shape until it solidifies by cooling. Therefore, it is possible to achieve both high design quality and free moldability that could not be achieved with conventional flooring materials.

In the flooring material according to the present invention,
The surface layer and the cold-press molded layer are preferably made of the same type of material.

In this flooring material, the surface layer and the cold-press molded layer are made of the same material, so the boundary between the surface layer and the cold-press molded layer can be more firmly integrated by heat fusion.

In the flooring material according to the present invention,
It is preferable that the surface layer and the cold-press molded layer are made of different materials, and that both layers are laminated via a bonding layer.

In this flooring material, the surface layer and the cold-press molded layer are made of different materials and are laminated together via a bonding layer. Therefore, even if the surface layer and the cold-press molded layer are made of different materials, the surface layer and the cold-press molded layer can be firmly integrated together via the bonding layer.

In the flooring material according to the present invention,
The surface layer preferably has an uneven pattern.

In the flooring material of this configuration, the surface layer has an uneven pattern. This increases the eye-catching effect in terms of design, and enhances the texture to create a sense of luxury. Meanwhile, in terms of functionality, the unevenness in the uneven pattern acts as an anti-slip agent, improving slip resistance. In addition, the elasticity and partial contact of the curved surfaces of the unevenness in the uneven pattern provide a comfortable feel that is not available on a smooth surface.

In the flooring material according to the present invention,
The cold-press molded layer preferably has a three-dimensional structure formed in a vertical or horizontal direction relative to the lamination surface.

According to the flooring material of this configuration, the cold press molded layer has a three-dimensional structure formed in a vertical or horizontal direction relative to the lamination surface. Here, "vertical or horizontal" includes not only a vertical or horizontal direction relative to the lamination surface, but also an oblique direction inclined relative to the lamination surface. Therefore, the three-dimensional structure includes at least one of a structure having a portion extending vertically, a structure having a portion extending horizontally, and a structure having a portion extending obliquely. As a result, in addition to the function of the surface layer, a specific function performed by the three-dimensional structure of the cold press molded layer is added, and the added value of the flooring material can be increased. In detail, in the technology disclosed in Patent Documents 1 to 3, as described above, due to the constraints of the manufacturing process, the molded product is limited to a sheet-like planar shape, and even if the member corresponding to the surface layer of the flooring material of the present invention can be molded, it is not possible to mold a protruding portion with a protruding length greater than the thickness of the surface layer. In the present invention, the cold press molded layer can be molded into any shape until the base material, which has been brought to a state of above its softening point, is solidified by cooling. Therefore, by setting the shape of the molding cavity of the mold, it is possible to form a protrusion in the cold-press molded layer with a protruding length equal to or greater than the thickness of the surface layer. Thus, the flooring material of this configuration has both the uneven pattern of the surface layer and the three-dimensional structure of the cold-press molded layer, and can be formed by superimposing a relatively large three-dimensional structure and a small one. This allows for a high level of control over anti-slip properties and drainage. Furthermore, the curved surface of the uneven pattern and the three-dimensional structure cause diffuse sound reflection, providing soundproofing, sound insulation and sound absorption effects.

Next, the characteristic configuration of the manufacturing method of the flooring material according to the present invention is as follows:
A method for manufacturing a flooring material comprising laminating a surface layer and a cold-press molded layer,
a first placement step of placing the surface layer in a mold;
a second disposing step of disposing a thermoplastic resin in a state of not less than its softening point so as to be in contact with the surface layer;
a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin;
a recovery step of removing the laminated molded body formed by the pressing step from the mold;
The purpose of this study is to encompass the above.

According to the method for manufacturing a flooring material of this configuration, the surface layer is placed in a mold, and the thermoplastic resin, which is the base material of the cold press molded layer and has been brought to a state above its softening point, is placed so as to be in contact with the surface layer. Then, a pressing process is carried out in which the contents of the mold, i.e., the surface layer and the base material of the cold press molded layer, are pressed at a temperature lower than the softening point of the thermoplastic resin. As a result, while the molding of the cold press molded layer progresses with the pressing process, the boundary between the cold press molded layer and the surface layer during molding is integrated by thermal fusion due to the heat of the base material of the cold press molded layer, which has been brought to a state above its softening point, and the pressure during pressing. In this way, the laminated molded body formed by the pressing process is removed from the mold and collected. In the method for manufacturing a flooring material of this configuration, the surface side of the surface layer is cooled by the mold, although the pressure during pressing acts on it. For this reason, it is possible to suppress thermal deformation of the surface side of the surface layer, and as a result, the uneven pattern imparted to the surface side of the surface layer remains without being crushed, ensuring high designability. On the other hand, in the cold-press molded layer, the base material, which is at or above its softening point, can be molded into any shape until it solidifies by cooling. Therefore, it is possible to achieve both high designability and free moldability that could not be achieved with conventional flooring materials. Furthermore, compared to a method in which the surface layer and the cold-press molded layer are molded separately and then joined together, the manufacturing method of the flooring material of this configuration can be molded in a one-step process, so molding can be done quickly and easily, and even complex configurations can be molded accurately, resulting in excellent manufacturing efficiency.

FIG. 1 is a cross-sectional view showing a schematic layered structure of a flooring material according to a first embodiment of the present invention. FIG. 2 shows a schematic diagram of the laminated structure of the surface layer, where (a) is a cross-sectional view of a surface layer with enhanced anti-slip properties, and (b) is a cross-sectional view of a surface layer with enhanced cushioning properties. FIG. 3 is a cross-sectional view showing a schematic layered structure of a flooring material according to a second embodiment of the present invention. FIG. 4 shows a specific example (1) of a flooring material to which the present invention can be applied, where (a) is an overall perspective view of a staircase flooring material, and (b) is an enlarged view of a main part of the cross section taken along line A-A in (a). FIG. 5 shows a mold for molding a staircase floor material, where (a) is a diagram showing a mold release state and (b) is a diagram showing a mold clamping state. FIG. 6 shows the steps of a manufacturing method for a staircase flooring material, where (a) is an explanatory diagram of the surface layer arrangement step, (b) is an explanatory diagram of the thermoplastic resin arrangement step, (c) is an explanatory diagram of the pressing step, and (d) is an explanatory diagram of the recovery step. FIG. 7 shows a specific example (2) of a flooring material to which the present invention can be applied, where (a) is a plan view of a flooring material for an entrance hall, and (b) is an enlarged view of a main part of the cut end surface taken along line B-B of (a). FIG. 8 shows a molding die for molding an entrance hall floor material, where (a) is a diagram showing a mold release state and (b) is a diagram showing a mold clamping state. FIG. 9 shows the steps of a manufacturing method for molding an entrance hall floor material, where (a) is an explanatory diagram of the surface layer arrangement process, (b) is an explanatory diagram of the thermoplastic resin arrangement process, (c) is an explanatory diagram of the pressing process, and (d) is an explanatory diagram of the recovery process. Figure 10 shows the bonding layer arrangement step in the manufacturing method of the flooring material of the present invention, where (a) is an explanatory diagram of the bonding layer arrangement step in the manufacturing method of a flooring material for a staircase, and (b) is an explanatory diagram of the bonding layer arrangement step in the manufacturing method of a flooring material for an entrance hall.

The flooring material of the present invention and the method for manufacturing the flooring material will be described below with reference to the drawings. Note that in each drawing, the flooring material of the present invention is shown to be composed of multiple layers, but the thickness relationships of each layer have been appropriately exaggerated or simplified for ease of explanation, and do not strictly reflect the size relationships (scale) of the thicknesses of each layer in the actual flooring material.

In this specification, the "top surface" or "above" of a layer refers to the surface or direction away from the floor surface (horizontal surface) on which the flooring material will be laid, and the "bottom surface" or "below" refers to the surface or direction on the opposite side (the side closer to the floor surface on which the flooring material will be laid).

First Embodiment
<Overall composition of flooring material>
Fig. 1 is a cross-sectional view showing a laminated structure of a flooring material according to a first embodiment of the present invention. The flooring material 1A shown in Fig. 1 has a surface layer 2 and a cold-press molded layer 3, and the surface layer 2 and the cold-press molded layer 3 are laminated in this order from top to bottom.

<Surface layer>
FIG. 2 is a schematic diagram showing the laminated structure of the surface layer, where (a) is a cross-sectional view of a surface layer with enhanced anti-slip properties, and (b) is a cross-sectional view of a surface layer with enhanced cushioning properties. The surface layer 2 has an uneven pattern (not shown) formed thereon to enhance the design of the flooring material. Examples of the uneven pattern include embossing, foam structure, debossing, and graining. For example, the surface layer 2A shown in FIG. 2(a) and the surface layer 2B shown in FIG. 2(b) can be used as the surface layer 2. When the anti-slip properties of the flooring material 1A are to be enhanced, the surface layer 2A shown in FIG. 2(a) is used, and when the cushioning properties of the flooring material 1A are to be enhanced, the surface layer 2B shown in FIG. 2(b) is used.

First, the surface layer 2A, which can enhance the anti-slip properties of the flooring material 1A, will be described with reference to FIG. 2(a). The surface layer 2A shown in FIG. 2(a) is made up of an abrasion-resistant layer 11, a protective layer 12, a design layer 13, an upper resin layer 14, a resin-impregnated glass sheet 15, and a lower resin layer 16, layered from top to bottom in the order listed.

[Wear-resistant layer]
The wear-resistant layer 11 is the layer located on the outermost side, and is not an essential component of the surface layer 2A, but prevents scratches and improves wear resistance. The wear-resistant layer 11 may be transparent or opaque, but is preferably transparent so that the pattern of the design layer 13 and the like provided on the back side of the protective layer 12 can be seen. The wear-resistant layer 11 preferably has a layer thickness of 2 to 50 μm, more preferably 5 to 35 μm, for the reasons that it exhibits scratch resistance while not becoming brittle as a whole and has excellent impact resistance. In particular, a layer thickness of 2 μm or more provides sufficient scratch resistance, and a layer thickness of 50 μm or less provides the flooring material with a rigidity that is not too high as a whole, is less likely to crack, and is excellent in processability.

For the wear-resistant layer 11, it is more preferable to use an ionizing radiation curable resin such as an ultraviolet curable resin, since it is versatile. Examples of the curable resin include ionizing radiation curable resins such as ultraviolet curable resins, as well as thermosetting resins and resins cured by non-ionizing radiation. When an ionizing radiation curable resin composition is used, the wear-resistant layer 11 contains a polymerization initiator, various other additives, and aggregates as necessary. As the resin cured by ionizing radiation, it is preferable to use ultraviolet curable resins such as urethane-based, epoxy-based, and acrylic-based resins, since they are easy to process and versatile, and fluororesins, silicone resins, etc. may be added. Inorganic particles such as alumina can be used as the aggregate, which can improve anti-slip properties, wear resistance, and durability.

[Protective Layer]
The protective layer 12 is a layer provided to facilitate the removal of dirt adhering to the surface layer 2A. That is, the protective layer 12 imparts dirt removability to the surface layer 2A. The protective layer 12 is provided as necessary. The protective layer 12 may be either transparent or opaque, but is preferably transparent so that the pattern and coloring of the design layer 13 provided on the back side of the protective layer 12 can be visually observed.

The material of the protective layer 12 is preferably a resin material. The resin material may be a thermoplastic resin such as polyvinyl chloride resin, polyolefin resin, polyacrylic acid resin, or polyester resin, of which polyvinyl chloride resin is preferred. The thickness of the protective layer 12 is 0.03 to 1 mm, and preferably 0.1 to 0.8 mm.

[Design layer]
The design layer 13 is a layer that expresses a desired pattern and imparts design to the surface of the surface layer 2A. For example, the design layer 13 is formed of a thermoplastic resin. Examples of the thermoplastic resin include vinyl chloride resin, olefin resin, acrylic resin such as ethylene-vinyl acetate copolymer and ethylene-methacrylate resin, amide resin, ester resin, vinyl acetate, olefin elastomer, styrene elastomer, and various elastomers, rubber, and the like. Among them, vinyl chloride resin is preferable because of its excellent durability and processability. In addition, various additives such as fillers, plasticizers, flame retardants, stabilizers, antioxidants, lubricants, colorants, and foaming agents may be blended into the thermoplastic resin.

The design layer 13 may be formed from a printed film, may be molded from a thermoplastic resin to which a colorant has been added, or may be formed by adding and kneading together resin chips of multiple colors.

The thickness of the design layer 13 is 0.50 to 1.50 mm, preferably 0.60 to 1.00 mm, and more preferably 0.65 to 0.80 mm.

In addition, if a pattern is to be created by adding a colorant or the like to the upper resin layer 14, the design layer 13 may be omitted.

[Upper Resin Layer and Lower Resin Layer]
The upper resin layer 14 and the lower resin layer 16 are the main components that determine the strength and weight of the surface layer 2A. The thicknesses of the upper resin layer 14 and the lower resin layer 16 are not particularly limited and can be set appropriately. The thickness of the upper resin layer 14 and the thickness of the lower resin layer 16 may be the same or different. The thickness of the upper resin layer 14 is 0.05 to 1.0 mm, and preferably 0.1 to 0.8 mm. The thickness of the lower resin layer 16 is 0.5 to 3.0 mm, and preferably 0.7 to 2.0 mm.

Thermoplastic resins are suitable as materials for the upper resin layer 14 and the lower resin layer 16. Examples of thermoplastic resins include polyvinyl chloride resins such as polyvinyl chloride and vinyl chloride-vinyl acetate copolymers; polyolefin resins; polystyrene resins; polyvinyl acetate resins such as ethylene-vinyl acetate copolymers; polyacrylate resins such as polymethyl methacrylate; polyamide resins; polyester resins; various elastomers such as olefin elastomers and styrene elastomers. These may be used alone or in combination. At least one of the upper resin layer 14 and the lower resin layer 16 has excellent flexibility and is easily bonded to the resin-impregnated glass sheet 15, so it is preferable that the resin layer is mainly composed of polyvinyl chloride resin, and it is more preferable that both the upper resin layer 14 and the lower resin layer 16 are mainly composed of polyvinyl chloride resin. The surface layer 2A, which has a resin layer mainly composed of polyvinyl chloride resin, has excellent flexibility, so it feels good to walk on, and can be curved while being applied to the floor surface. In addition, polyvinyl chloride resin is inexpensive, and using it makes it easy to manufacture the surface layer 2A. When both the upper resin layer 14 and the lower resin layer 16 are mainly composed of polyvinyl chloride resin, the polyvinyl chloride resins may have the same type of monomer and different degrees of polymerization.

In this specification, the main component refers to the resin component excluding additives, and when there are multiple components (excluding additives) that constitute the layer, it refers to the component with the largest content (by weight). Examples of additives include plasticizers, fillers, stabilizers, etc. The content of the main component is more than 50% by mass, preferably 70% by mass or more, and more preferably 80% by mass or more, when the total components that constitute the layer are taken as 100% by mass. The upper limit of the content of the main component is 100% by mass. When the content of the main component is less than 100% by mass, the components other than the main component contained in the layer are not particularly limited, and may include conventionally known components.

[Resin-impregnated glass sheet]
The resin-impregnated glass sheet 15 is used to suppress the size variation of the surface layer 2A due to shrinkage and expansion over time, and is a glass sheet containing glass fibers impregnated with resin, although detailed illustrations are omitted. The resin-impregnated glass sheet 15 has the characteristics of glass fibers, such as high strength and small size variation due to temperature, and can increase the mechanical strength such as the size stability and rigidity of the surface layer 2A, and can suppress size change and warping due to temperature change, shrinkage over time, and expansion. The glass sheet, which is the base material of the resin-impregnated glass sheet 15, is made of a layer of multiple fibers overlapping each other, and can be made of glass nonwoven fabric, glass woven fabric, etc., but glass nonwoven fabric is preferably used. Since glass nonwoven fabric has excellent size stability, it greatly contributes to the overall size stability of the surface layer 2A, and can improve the bending strength and tensile strength of the surface layer 2A. In addition, since the fibers of the glass woven fabric are generally regularly arranged, the weave may appear on the surface of the surface layer 2A and affect the appearance of the uneven pattern, but when a glass nonwoven fabric is used, the uneven pattern of the surface layer 2A can be maintained as it is without affecting it. Note that the resin-impregnated glass sheet 15 may be omitted in cases where large size variations are acceptable or where size variations can be suppressed by other configurations.

The resin to be impregnated into the glass sheet is not particularly limited as long as it adheres to both the upper resin layer 14 and the lower resin layer 16, and any conventionally known resin can be used. Examples of resins include thermoplastic resins such as those exemplified for the upper resin layer 14 and the lower resin layer 16. When the upper resin layer 14 and the lower resin layer 16 are mainly composed of polyvinyl chloride resin, it is preferable that the resin to be impregnated into the glass sheet is also mainly composed of polyvinyl chloride resin, since it exhibits excellent adhesion to the upper resin layer 14 and the lower resin layer 16. Regarding the properties of the resin to be impregnated into the glass sheet, a paste-like resin is preferable because it is easy to impregnate and has excellent processability.

Next, the surface layer 2B, which can improve the cushioning properties of the flooring material 1A, will be described with reference to FIG. 2(b). The surface layer 2B shown in FIG. 2(b) comprises a foam layer 23, a design layer 24 laminated on the upper surface of the foam layer 23, a protective layer 22 laminated on the upper surface of the design layer 24, and a glass fiber cloth 21 embedded and laminated in the foam layer 23. In the surface layer 2B, the glass fiber cloth 21 is embedded and laminated in the foam layer 23 on the upper side of the center line S of the entire thickness of the surface layer 2B. If necessary, a decorative layer (not shown) having design properties may be provided between the protective layer 22 and the glass fiber cloth 21.

[Glass fiber cloth]
The glass fiber cloth 21 preferably has an appropriate gap so that the foamable resin composition can be impregnated. Specifically, a sheet-like or mat-like nonwoven or woven fabric having a basis weight of about 15 to 80 g/ ^m2 and an average thickness of about 0.15 to 0.60 mm can be used. When the basis weight is less than 15 g/ ^m2 , the foamable resin composition easily penetrates into the fiber gaps, but this mainly depends on the strength of the foamable resin composition. When the basis weight is more than 80 g/ ^m2 , the foamable resin composition does not easily penetrate into the fiber gaps, and the entanglement between the fibers and the foamable resin composition is insufficient. In either case, there is a risk that a sufficient anchor effect cannot be obtained.

As a method for laminating the glass fiber cloth 21, any method can be applied, such as a method in which a paste-like foamable resin composition in which the glass fiber cloth 21 is embedded is foamed with a normal heater such as an infrared heater to embed the glass fiber cloth 21 in the foamed product and laminate it, a method in which a foamable resin composition in a fluid state is coated on the glass fiber cloth 21 and forcibly impregnated, or a method in which a foamable resin composition in a fluid state is coated on a carrier such as release paper with a knife coater, etc., and then the glass fiber cloth 21 is placed on top of the foamed resin composition, impregnated with the foamable resin composition, and heated to foam.

[Protective Layer]
For the protective layer 22, the components exemplified in the description of the protective layer 11 above can be used.

<Cold press molding layer>
In the flooring material 1A shown in FIG. 1, the cold press molded layer 3 is a layer formed by pressing the base material (resin) of the cold press molded layer 3, which is in a state above its softening point, while cooling it with the molding dies 60 (upper die 61, lower die 62) and 90 (upper die 91, lower die 92) described below. Here, the "softening point" is the temperature at which the resin becomes plastically deformable when subjected to external stress, and the softening point is usually between the glass transition temperature (Tg) and melting temperature (Tm) of the resin. As the base material of the cold press molded layer 3, the thermoplastic resins exemplified in the description of the components of the upper resin layer 14 and the lower resin layer 16 described above can be used, and polyvinyl chloride resins are particularly suitable. Incidentally, polyvinyl chloride, a representative example of polyvinyl chloride resin, has a glass transition point (Tg) of approximately 60 to 85°C and a melting temperature (Tm) of approximately 210°C, although this varies depending on the amount of plasticizer added. Therefore, the softening point can be estimated to be, for example, 60 to 200°C.

The cold-press molded layer may be formed only from resin as the base material, but other materials such as wood or metal can be embedded or joined as a core or base material. Suitable wood materials include plywood, MDF, particle board, hardboard, etc. Suitable metal materials include iron, aluminum, stainless steel, etc. If the cold-press molded layer is formed on wood or metal as the base material, it can be easily joined or incorporated into a building, improving convenience.

In the flooring material 1A of the first embodiment, the surface layer 2 and the cold-press molded layer 3 are made of the same type of material. Here, the term "same type of material" means that the main components are the same, and the term "same type of main components" means that the materials are the same material and that the materials are of the same type. Examples of materials of the same type include materials in which the monomers constituting the repeating units of the resin are the same but have different degrees of polymerization, different degrees of crystallization, and different substituents on the side chains. By making the surface layer 2 and the cold-press molded layer 3 out of the same type of material, the boundary between the surface layer 2 and the cold-press molded layer 3 can be more firmly integrated by heat fusion.

The surface layer 2 and the cold press molding layer 3 may contain other components other than resin as necessary. Examples of other components include plasticizers, fibers, fillers, stabilizers, processing aids, antifungal agents, deodorants, antibacterial agents, flame retardants, antioxidants, lubricants, colorants, etc. Examples of plasticizers include dioctyl phthalate (DOP), diheptyl phthalate (DHP), diisononyl phthalate (DINP), trioctyl phosphate (TOP), triphenyl phosphate (TPP), dioctyl terephthalate (DOTP), dioctyl isophthalate (DOIP), diisononyl cyclohexyl phthalate (DINCH), etc. Examples of fibers include short fibers such as resin and glass. Among them, short glass fibers are preferred, as they can suppress warping of the product and increase dimensional stability and strength. The fiber length is 0.5 to 10 mm, preferably 2 to 9 mm, and more preferably 4 to 8 mm. Examples of fillers include calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, mica, heavy calcium carbonate, light calcium carbonate, silica sand, and aluminum hydroxide. In the cold-press molded layer 3, the plasticizer is 10 to 90 parts. The filler is 0 to 400 parts.

<Density>
The densities of the surface layer 2 and the cold-press molded layer 3 are particularly affected by the type and amount of the plasticizer and the type and amount of the filler, but are also affected by temperature changes during cooling and solidification in cold press molding using the molding dies 60 (upper die 61, lower die 62) and 90 (upper die 91, lower die 92) described below. That is, in cold press molding using the molding dies 60 and 90 described below, the part of the surface layer 2 that contacts the molding dies 60 and 90 (upper surface part) is cooled by the molding dies 60 and 90 from the beginning, while the part of the surface layer 2 that contacts the base material of the cold-press molded layer 3 (lower surface part) is once raised to a temperature equal to or higher than the softening point of the base material of the cold-press molded layer 3 by contact with the base material, and then cooled to approach the temperature of the molding dies 60 and 90. In contrast, the cold-press molded layer 3 is rapidly cooled from a state in which the base material of the cold-press molded layer 3 is at or above its softening point to the mold 60, 90 when it comes into contact with the mold 60, 90 during the molding stage, so that the temperature approaches the temperature of the mold 60, 90. In this way, the temperature change of the cold-press molded layer 3 is greater than the temperature change of the surface layer 2, so that the density of the cold-press molded layer 3 tends to be greater than the density of the surface layer 2. This tendency is particularly noticeable when the surface layer 2 contains a foamed resin. As a result, the cold-press molded layer 3 makes the entire flooring structure strong, while softening the surface layer 2 that is directly stepped on by the sole of the foot, improving the comfort of stepping on it, and also providing the effect of reducing fatigue in the lower limbs.

<Interlayer peel strength>
The interlayer peel strength between the surface layer 2 and the cold press molded layer 3 measured in accordance with the interlayer peel strength test method of JIS A 1454 is 8 to 100 N/50 mm, preferably 20 to 95 N/50 mm, and more preferably 30 to 90 N/50 mm. This can reliably prevent the surface layer 2 from peeling off from the cold press molded layer 3 during normal use of the flooring material 1A, and the function of the flooring material 1A can be stably maintained over a long period of time. If the interlayer peel strength is less than 8 N/50 mm, there is a risk that the welded state of the surface layer 2 and the cold press molded layer 3 cannot be maintained over a long period of time. If the interlayer peel strength exceeds 100 N/50 mm, the surface layer 2 and the cold press molded layer 3 formed of different materials cannot be separated, which is undesirable from the viewpoint of recyclability. In addition, when the surface layer 2 and the cold press molded layer 3 are formed of the same material, they may or may not be separated during recycling.

<Hardness>
The hardness of the surface layer 2 and the cold press molded layer 3 refers to the type A durometer hardness measured in accordance with JIS K 6253. Specifically, it is a value measured using GS-719N manufactured by Tecrock Corporation. The hardness of the surface layer 2 is 30 to 118, preferably 35 to 100, and more preferably 40 to 98. If the hardness is less than 30, the flexibility of the surface layer 2 is improved and the comfort of stepping is improved, but the surface layer 2 becomes easily deformed, so there is a risk of the uneven pattern collapsing. If the hardness exceeds 118, the uneven pattern of the surface layer 2 is less likely to collapse, but there is a risk of the comfort of stepping being deteriorated. The hardness of the cold press molded layer 3 is 75 to 115, preferably 90 to 100, and more preferably 94 to 96. When the hardness is less than 75, the flexibility of the cold-press molded layer 3 is improved and the comfort of stepping on the cold-press molded layer 3 is improved, but the cold-press molded layer 3 is easily deformed, so that the three-dimensional structure may be easily crushed. When the hardness is more than 115, the three-dimensional structure of the cold-press molded layer 3 is not easily crushed, but the comfort of stepping on the cold-press molded layer 3 may be deteriorated.

In addition, by making the hardness of the cold-press molded layer 3 higher than that of the surface layer 2, the cold-press molded layer 3 makes the entire flooring structure strong, while the surface layer 2 that is directly stepped on by the soles of the feet is softened to improve the comfort of stepping on it and also provides the effect of reducing fatigue in the lower limbs. In this case, the hardness difference between the cold-press molded layer 3 and the surface layer 2 is preferably 30 or more, more preferably 40 or more. The upper limit is preferably 65 or less, more preferably 50 or less. The hardness difference here is calculated by the following formula.
Hardness difference = (hardness of cold press molded layer 3) - (hardness of surface layer 2)

[Modification (1) of the first embodiment]
As a modified example (1) of the first embodiment, a flooring material in which a core material is contained in a cold press molded layer can be given. Examples of the core material include a member formed into a plate-like, lattice-like, mesh-like, or other shape made of metal, wood, resin, or a composite material thereof.

The core material may be entirely contained within the cold-press molded layer, or a required portion may have a protruding portion protruding from the surface of the cold-press molded layer. An example of a protruding portion is a screw shaft having a male screw. By adopting a configuration in which the screw shaft protrudes from the surface of the cold-press molded layer in this way, the flooring material can be easily and firmly fixed to the installation location by tightening the nut screwed onto the screw shaft of the flooring material when the flooring material is installed.

In addition, the surface side of the cold-press molded layer may be provided with the necessary openings to expose the key parts of the core material, and a female screw, for example, may be formed in the part of the core material that corresponds to the opening. In this way, by adopting a configuration in which a bolt can be screwed into the female screw formed in the core material through the opening provided on the surface side of the cold-press molded layer, the floor material can be easily and firmly fixed to the installation location by tightening the bolt screwed into the female screw of the floor material when the floor material is installed.

By using wooden boards as the core material, the flooring can be easily and firmly fixed to the installation location using nails or wood screws. The required parts of the wooden boards may be exposed from the cold press molding layer. In this case, for example, if the floor surface to be installed is a wooden base, the flooring can be easily and firmly fixed to the installation location by a construction method in which an adhesive layer formed of wood adhesive or the like is interposed between the exposed wooden part and the wooden base.

According to the flooring material of the above modification (1), the core material is contained in the cold press molded layer, so that the strength of the core material is added to the strength of the surface layer and the cold press molded layer, and the strength of the entire flooring material can be increased. Also, according to the flooring material of the above modification (1), the function of the core material is added to the functions of the surface layer and the cold press molded layer, respectively, so that added value can be increased. Also, according to the flooring material of the above modification (1), since the core material is contained in the cold press molded layer, it is not necessary to consider the bonding strength between the cold press molded layer and the core material, and it is possible to adopt a core material made of a different material, such as metal or wood, that is made of a different material from the cold press molded layer made of a resin material, and the options for materials used as the core material can be increased.

The flooring material according to the above modification (1) can be manufactured by a manufacturing method including the following steps (1) to (6).
(1) a first arrangement step of arranging a surface layer in a mold; (2) a second arrangement step of arranging a thermoplastic resin at or above its softening point so that it is in contact with the surface layer; (3) a third arrangement step of arranging a core material so that it is in contact with the thermoplastic resin arranged in the second arrangement step; (4) a fourth arrangement step of arranging a thermoplastic resin at or above its softening point so that it is in contact with the core material; (5) a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin; and (6) a recovery step of removing the laminated molded body formed by the pressing step from the mold.

The above manufacturing method allows for both high design quality and flexible formability that could not be achieved with conventional flooring materials, while also allowing for a core material made of a different material, such as metal or wood, to be easily embedded in the cold-press molded layer, which is made of a resin material.

[Modification (2) of the First Embodiment]
As a modified example (2) of the first embodiment, a flooring material formed by laminating a surface layer, a cold press molded layer, and a substrate in the order described above can be mentioned. In this way, by adopting a configuration in which a substrate is laminated in addition to the surface layer and the cold press molded layer, the strength of the flooring material can be increased. Examples of the substrate include a member formed into a plate-like, lattice-like, mesh-like, or other shape made of metal, wood, resin, or a composite material thereof.

For example, if the floor surface to be installed is a wooden substrate, a wooden board can be used as the base material for the flooring, and an adhesive layer formed with wood adhesive or the like can be placed between the base material and the wooden substrate, allowing the flooring to be easily and firmly fixed to the installation location.

The flooring material according to the above modification (2) can be manufactured by a manufacturing method including the following steps (1) to (6).
(1) a first arrangement step of arranging a surface layer in a mold; (2) a second arrangement step of arranging a thermoplastic resin at or above its softening point so that it is in contact with the surface layer; (3) a third arrangement step of arranging a substrate so that it is in contact with the thermoplastic resin arranged in the second arrangement step; (4) a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin; and (5) a recovery step of removing the laminated molded body formed by the pressing step from the mold.

The above manufacturing method allows for both high design quality and flexible formability that could not be achieved with conventional flooring materials, while also allowing for easy lamination of substrates made of different materials, such as metal or wood, that are different from the cold-press molded layer made of a resin material, by adding them to the surface layer and cold-press molded layer.

Second Embodiment
3 is a cross-sectional view showing a laminated structure of a flooring material according to a second embodiment of the present invention. In the second embodiment, the same or similar parts as those in the first embodiment are given the same reference numerals in the figure, and detailed descriptions thereof are omitted. In the following, the description will be focused on the parts unique to the second embodiment.

As shown in FIG. 3, in the second embodiment of flooring material 1B, the surface layer 2 and the cold-press molded layer 3 are laminated via a bonding layer 4. The surface layer 2 and the cold-press molded layer 3 are made of different types of thermoplastic resins.

The bonding layer 4 is not particularly limited as long as it is made of a material that can exert an anchor effect. Examples of materials for the bonding layer 4 include jute, glass fiber nonwoven fabric, spunbond nonwoven fabric, and foamed resin having a porous structure. As an example, a case where a spunbond nonwoven fabric is used for the bonding layer 4 will be described. In cold press molding using the molding dies 60 (upper die 61, lower die 62) and 90 (upper die 91, lower die 92) described later, due to the heat of the base material of the cold press molding layer 3 that is in a state above its softening point and the pressure during pressing, a part of the side of the surface layer 2 facing the cold press molding layer 3 and a part of the base material of the cold press molding layer 3 facing the surface layer 2 each enter into the fiber gaps of the spunbond nonwoven fabric in a molten state, and then, by cooling and solidifying, the surface layer 2 and the cold press molding layer 3 are firmly integrated via the bonding layer 4 (spunbond nonwoven fabric) by the anchor effect. When the surface layer 2 and the cold-press molded layer 3 are made of different materials, the two may not bond well together. However, by interposing the bonding layer 4 in this way, the surface layer 2 and the cold-press molded layer 3 can be firmly integrated through the bonding layer 4, even if the surface layer 2 and the cold-press molded layer 3 are made of different materials.

<Specific example of flooring material (1)>
Fig. 4 shows a specific example (1) of a flooring material to which the present invention is applied, (a) is an overall perspective view of the staircase flooring material, and (b) is an enlarged view of the main part of the cross section along line A-A in (a). The staircase flooring material 31 shown in Fig. 4(a) has a surface layer 32 (the part hatched in the figure) formed in a rectangular sheet shape in a plan view, and a cold-press molded layer 33 that supports the surface layer 32 from below.

<Surface layer>
4(b), the surface layer 32 has a plurality of recesses 35 and protrusions 36 formed by subjecting the surface (upper surface) of the surface layer 2 to uneven processing imitating a wood grain pattern. The recesses 35 and protrusions 36 mainly constitute the wood grain uneven pattern.

The recess 35 has an inclined surface that slopes downward from the boundary between the recess 35 and the protrusion 36 toward the bottom of the recess 35. The recess 35 has a low gloss and a rough feel. On the other hand, the surface of the protrusion 36 has a high gloss and a mirror-like feel. As a result, the surface of the protrusion 36 resembles the appearance and feel of late wood of natural wood, and the surface of the recess 35 resembles the appearance and feel of early wood of natural wood. In this way, the grain of natural wood is reproduced in the surface layer 32, and the feel is also close to that of natural wood.

<Cold press molded layer>
The cold-press molded layer 33, in the cold-press molded layer 3 of the first embodiment, comprises a tread laying portion 41 laid on the tread of the staircase, a riser surface laying portion 42 laid on at least the upper part of the riser surface of the staircase, and a stair nosing laying portion 43 laid on the stair nosing portion of the staircase.

The surface layer 32 is placed integrally on the upper surface of the tread laying section 41. The tread laying section 41 and the step nosing laying section 43 are integrally arranged so as to be continuous in the horizontal direction. The step nosing laying section 43 and the riser surface laying section 42 are integrally arranged so as to be approximately perpendicular to each other. The cold press molded layer 33 has a three-dimensional structure including a part that extends vertically (the riser surface laying section 42) and a part that protrudes horizontally (the step nosing laying section 43) with respect to the tread laying section 41, which has a layering surface on which the surface layer 32 is layered.

The step nosing section 43 has a plurality of groove-shaped recesses 45 and a plurality of streak-shaped protrusions 46 formed therein. The groove-shaped recesses 45 and streak-shaped protrusions 46 form the uneven section 50. The groove-shaped recesses 45 and streak-shaped protrusions 46 extend in a horizontal direction perpendicular to the direction from the step nosing section 43 toward the tread section 41. The groove-shaped recesses 45 and streak-shaped protrusions 46 are arranged alternately in the direction from the step nosing section 43 toward the tread section 41. The depth of the groove-shaped recesses 45 is set to be equal to or greater than the thickness of the surface layer 32. The protruding length of the streak-shaped protrusions 46 when the top surface of the tread section 41 is taken as the reference plane is set to be equal to or greater than the thickness of the surface layer 32.

The riser surface laying part 42 is designed to cover at least the upper part of the riser surface of the stairs, so that the downward protrusion length from the tread surface laying part 41 is set to 2 to 12 times, preferably 4 to 10 times, and more preferably 6 to 8 times the thickness of the surface layer 32.

<Molding mold for staircase flooring>
Fig. 5 shows a mold for molding the staircase flooring, (a) is a diagram of the mold release state, and (b) is a diagram of the mold clamping state. As shown in Fig. 5(a), the mold 60 for molding the staircase flooring 31 includes an upper mold 61 having a convex portion 61a and a lower mold 62 having a concave portion 62a corresponding to the convex portion 61a. When the convex portion 61a and the concave portion 62a are combined in the mold clamping state shown in Fig. 5(b), a molding cavity 65 for molding the staircase flooring 31 is formed between the convex portion 61a and the concave portion 62a.

As shown in FIG. 5(a), the upper die 61 has a pressing surface 66 for pressing the base material of the cold-press molded layer 33, which has been brought to a state above its softening point. The upper die 61 has a cutout portion 67 for forming the riser surface laying portion 42 (see FIG. 4(a)) in the cold-press molded layer 33. The lower die 62 has a surface layer mounting portion 68 on which the surface layer 32 (see FIG. 4(a)) can be placed within the recess 62a. The lower die 62 has an uneven portion molding portion 69 for forming the uneven portion 50 (see FIG. 4(a)) in the cold-press molded layer 33, formed adjacent to the surface layer mounting portion 68.

<Method of manufacturing staircase flooring material>
FIG. 6 shows the steps of a manufacturing method for a staircase flooring material, where (a) is an explanatory diagram of the surface layer arrangement step, (b) is an explanatory diagram of the thermoplastic resin arrangement step, (c) is an explanatory diagram of the pressing step, and (d) is an explanatory diagram of the recovery step.

[Surface layer arrangement process]
6(a), in a state where the upper die 61 is positioned above the lower die 62 and the molding die 60 is open, the surface layer 32 is placed upside down, with the upper surface of the surface layer 32 facing downward and the lower surface facing upward, on the surface layer placement portion 68 of the lower die 62. This surface layer placement step corresponds to the "first placement step" of the present invention.

[Thermoplastic resin placement process]
Next, as shown in FIG. 6B, a thermoplastic resin, which is a base material of the cold-press molded layer 33 in a plasticized state, is placed on the surface layer 32 placed on the surface layer placement unit 68 in an upside-down state. The resin 33M is placed. Note that "plasticization" here means that the thermoplastic resin 33M is plasticized at a temperature higher than its softening point (for example, in the case of polyvinyl chloride, the softening point (90 to 200°C) + ( This means that the thermoplastic resin is heated to a temperature of about 10 to 30° C. to make it flowable. This thermoplastic resin disposing step corresponds to the “second disposing step” of the present invention.

[Pressing process]
Next, while cooling the upper mold 61 and the lower mold 62 by a cooling means (not shown), such as circulating cooling water through each of the upper mold 61 and the lower mold 62, the upper mold 61 is lowered relative to the lower mold 62 as shown in FIG. 6(c) to be in a mold clamping state, and the surface layer 32, which is the content of the mold 60, and the thermoplastic resin 33M in a plastic state (the base material of the cold press molded layer 33) are pressed at a temperature lower than the softening point of the thermoplastic resin 33M, for example, at room temperature or near room temperature. The pressing pressure in this pressing step is 0.1 to 20 MPa, preferably 0.2 to 15 MPa, and more preferably 0.5 to 10 MPa. Note that, according to JIS Z8703, "room temperature" is 20°C ± 15°C, i.e., 5 to 35°C, but "room temperature or near room temperature" may include a temperature range wider than "room temperature", and may be, for example, 20 to 50°C. If the pressing pressure is less than 0.1 MPa, the thermoplastic resin 33M may not fill the entire molding cavity 65, resulting in molding defects. If the pressing pressure exceeds 20 MPa, the mold releasability may deteriorate.

In the pressing process, the thermoplastic resin 33M pressed by the convex portion 61a of the upper die 61 is spread on the surface layer 32, and part of it is filled into the concave-convex portion molding portion 69 of the lower die 62, while the remaining part is filled between the notch portion 67 of the upper die 61 and the concave portion 62a of the lower die 62. In this way, the molding of the cold press molded layer 33 progresses as the pressing process progresses. Also, during the molding of the cold press molded layer 33, the boundary between the cold press molded layer 33 and the surface layer 32 is integrated by thermal fusion due to the heat of the thermoplastic resin 33M, which is at or above its softening point (plasticization temperature), and the pressure during the pressing process.

The surface side of the surface layer 32 (the lower side in Figs. 6(a)-(c)) is cooled by the lower die 62, although pressure is applied during press processing. Therefore, thermal deformation of the surface side of the surface layer 32 is suppressed, and the pattern or uneven pattern (in this example, a wood grain uneven pattern) applied to the surface side of the surface layer 32 remains without being crushed. Even if the surface layer 32 has a wood grain design layer, the pattern does not deform due to thermal deformation. In the cold press molding layer 33, the base material (thermoplastic resin 33M) that is in a plasticizing temperature state spreads along the shape of the molding cavity 65 (see Fig. 5(b)), and is solidified by cooling with the molding die 60 (mainly the upper die 61), and is molded into a shape according to the shape of the molding cavity 65. Therefore, it is possible to achieve both high design and free moldability with a three-dimensional feel.

[Recovery process]
Once the pressing step is complete, as shown in Figure 6(d), the upper die 61 is raised relative to the lower die 62 to open the molding die 60, and the laminated molded body (staircase flooring material 31) is removed and collected from the molding die 60. At this time, in order to facilitate the release of the laminated molded body from the molding die 60, the molding die 60 may be vibrated or the laminated molded body may be sucked with air.

[Joint layer arrangement process]
10(a) is an explanatory diagram of the bonding layer arrangement step in the manufacturing method of the staircase flooring material. The manufacturing method of the staircase flooring material 31 is applied when the surface layer 32 and the cold press molded layer 33 are made of the same type of thermoplastic resin. When the surface layer 32 and the cold press molded layer 33 are made of different types of thermoplastic resin, a bonding layer arrangement step is added between the surface layer arrangement step and the thermoplastic resin arrangement step. In the bonding layer arrangement step, the bonding layer 4 that exerts an anchor effect is arranged on the surface layer 32 that is placed on the surface layer placement part 68 in an upside-down state by the surface layer arrangement step. Then, in the thermoplastic resin arrangement step, the thermoplastic resin 33M (see FIG. 6(b)) in a plasticized state is arranged on the bonding layer 4.

The case where spunbond nonwoven fabric is used as the bonding layer 4 will be described. In the pressing process of cold press molding using the mold 60, due to the heat of the thermoplastic resin 33M that is in a state above its softening point and the pressure during pressing, a part of the side of the surface layer 32 facing the thermoplastic resin 33M and a part of the side of the thermoplastic resin 33M facing the surface layer 32 each enter into the fiber gaps of the spunbond nonwoven fabric in a molten state, and then cooled and solidified, the surface layer 32 and the cold press molding layer 33 are firmly integrated through the bonding layer 4 (spunbond nonwoven fabric) by the anchor effect. In this way, by interposing the bonding layer 4, even if the surface layer 32 and the cold press molding layer 33 are made of different materials, the surface layer 32 and the cold press molding layer 33 can be firmly integrated through the bonding layer 4. The bonding layer 4 may be laminated on the back surface of the surface layer 32 in advance.

<Specific examples of flooring materials (2)>
Fig. 7 shows a specific example (2) of a flooring material to which the present invention is applied, where (a) is an overall perspective view of the entrance flooring material, and (b) is an enlarged view of the main part of the cut end surface along line B-B in (a). The entrance flooring material 71 shown in Fig. 7(a) has a surface layer 72 formed in a rectangular sheet shape in a plan view, and a cold-press molded layer 73 that supports the surface layer 72 from below.

<Surface layer>
As shown in Fig. 7(b), the surface layer 72 has a plurality of recesses 75 and a plurality of protrusions 76 formed by carrying out a cold press molding process described below. The plurality of recesses 75 and the plurality of protrusions 76 are arranged adjacent to each other vertically and horizontally. The plurality of recesses 75 are formed between adjacent protrusions 76. The plurality of recesses 75 and the plurality of protrusions 76 as a whole form a tile-like uneven pattern.

[Convex part]
The multiple protrusions 76 are formed in a substantially square shape in plan view. In this specification, the plan view refers to a view from a direction perpendicular to the surface of the surface layer 72, and the plan view shape refers to the outline in plan view. The multiple protrusions 76 all have the same size in plan view and are regularly arranged at equal intervals vertically and horizontally. This makes it possible to prevent the drainage and anti-slip properties of the entrance floor material 71 from varying from place to place.

Each protrusion 76 has a generally flat top surface at its protruding end. To enhance design and anti-slip properties, the top surface is formed with a mesh-like protrusion 78 that protrudes in a lattice-like net shape when viewed from above. The mesh-like protrusion 78 forms a lattice-like uneven pattern.

[Recess]
The recesses 75 are connected to each other to form a drainage groove 79, which is formed in a lattice shape in a plan view so as to surround each of the protrusions 76.

<Cold press molded layer>
7(a) and (b), the cold press molded layer 73 includes a rectangular floor laying portion 81 having a predetermined drainage gradient toward the drainage portion 80, a protruding portion 82 protruding horizontally from the floor laying portion 81 toward the drainage portion 80, and a water stop plate portion 83 erected on each of the remaining three sides of the floor laying portion 81 except for the side on which the protruding portion 82 is provided. As shown in FIG. 7(b), the surface layer 72 is integrally placed on the upper surface of the floor laying portion 81.

As shown in FIG. 7(b), the outer side of the water stop portion 83 is formed with a vertical surface 83a that extends perpendicular to the upper surface of the floor laying portion 81, i.e., in a straight line in the vertical direction. The inner side of the water stop portion 83 is formed with an inclined surface 83b that slopes outward in a direction away from the upper surface of the floor laying portion 81, i.e., upward.

The cold-press molded layer 73 has a three-dimensional structure formed vertically or horizontally with respect to the lamination surface. That is, the cold-press molded layer 73 has a three-dimensional structure including a part extending vertically (vertical surface 83a of the water stop portion 83), a part protruding horizontally (projecting portion 82), and a part extending diagonally (inclined surface 83b of the water stop portion 83) with respect to the floor surface laying portion 81 having the lamination surface on which the surface layer 72 is laminated. In this way, the present invention can mold flooring materials with any three-dimensional structure. In particular, it has a three-dimensional structure in which three vertical surfaces 83 surround the surface layer 72 from three sides, which is a three-dimensional structure that cannot be obtained by extrusion molding.

<Molding mold for entrance flooring>
Fig. 8 shows a mold for molding the entrance floor material, (a) is a diagram of the mold release state, and (b) is a diagram of the mold clamping state. As shown in Fig. 8(a), the mold comprises an upper mold 91 having a convex portion 91a and a lower mold 92 having a concave portion 92a corresponding to the convex portion 91a. When the convex portion 91a and the concave portion 92a are combined as shown in the figure in the mold clamping state shown in Fig. 8(b), a molding cavity 95 for molding the entrance floor material 71 is formed between the convex portion 91a and the concave portion 92a.

The upper die 91 has a pressing surface 96 for pressing the base material of the cold-press molded layer 73, which has been brought to a state above its softening point. The lower die 92 has a surface layer mounting portion 98 on which the surface layer 72 can be mounted within the recess 92a. The lower die 92 has a waterstop molding portion 99 for molding the waterstop portion 83 (see Figures 7(a) and (b)) in the cold-press molded layer 73, formed adjacent to the surface layer mounting portion 98.

<Method of manufacturing entrance flooring>
FIG. 9 shows the steps of a manufacturing method for molding an entrance hall floor material, where (a) is an explanatory diagram of the surface layer arrangement process, (b) is an explanatory diagram of the thermoplastic resin arrangement process, (c) is an explanatory diagram of the pressing process, and (d) is an explanatory diagram of the recovery process.

[Surface layer arrangement process]
9(a), in a state where the upper die 91 is positioned above the lower die 92 and the molding die 90 is open, the surface layer 72 is placed upside down, with the upper surface of the surface layer 72 facing downward and the lower surface facing upward, on the surface layer placement portion 98 of the lower die 92. This surface layer placement step corresponds to the "first placement step" of the present invention.

[Thermoplastic resin placement process]
Next, as shown in FIG. 9B, the thermoplastic resin, which is the base material of the cold-press molded layer 73 in a plasticized state, is placed on the surface layer 72 placed on the surface layer placement unit 98 in an upside-down state. Resin 73M is placed. This thermoplastic resin placing step corresponds to the "second placing step" of the present invention.

[Pressing process]
Next, while cooling the upper mold 91 and the lower mold 92 by a cooling means (not shown), such as circulating cooling water through each of the upper mold 91 and the lower mold 92, the upper mold 91 is lowered relative to the lower mold 92 as shown in FIG. 9(c) to clamp the mold, and the surface layer 72, which is the content of the mold 90, and the thermoplastic resin 73M in a plastic state (base material of the cold press molded layer 73) are pressed at a temperature lower than the softening point of the thermoplastic resin 73M, for example, at room temperature or near room temperature. The pressing pressure in this pressing step is 0.1 to 20 MPa, preferably 0.2 to 15 MPa, and more preferably 0.5 to 10 MPa. If the pressing pressure is less than 0.1 MPa, the thermoplastic resin 73M may not be filled into the entire molding cavity 95, resulting in molding failure. If the pressing pressure exceeds 20 MPa, there is a risk of deterioration in releasability.

In the pressing process, the thermoplastic resin 73M pressed by the convex portion 91a of the upper die 91 is spread over the surface layer 72, and a part of it is filled into the waterstop molding portion 99 of the lower die 92. In this way, the molding of the cold press molded layer 73 progresses as the pressing process progresses. Also, during the molding of the cold press molded layer 73, the boundary between the thermoplastic resin 73M and the surface layer 72 is integrated by thermal fusion caused by the heat of the thermoplastic resin 73M, which is at or above its softening point (plasticization temperature), and the pressure during the pressing process.

The surface side of the surface layer 72 (the lower side in Figs. 9(a)-(c)) is subjected to pressure during press processing, but is cooled by the lower die 92. This prevents thermal deformation of the surface side of the surface layer 72, and the pattern or uneven pattern (in this example, a tile-like uneven pattern or a lattice-like uneven pattern) applied to the surface side of the surface layer 72 remains intact. In the cold press molding layer 73, the thermoplastic resin 73M, which is at a plasticizing temperature, spreads along the shape of the molding cavity 95, and is solidified by cooling with the molding die 90 (mainly the upper die 91), thereby being molded into a shape that corresponds to the shape of the molding cavity 95. This allows for both high design quality and free moldability with a three-dimensional feel.

[Recovery process]
Once the pressing process is completed, as shown in Figure 9 (d), the upper die 91 is raised relative to the lower die 92 to open the molding die 90, and the laminated molded body (entrance hall flooring material 71) formed by the pressing process is removed from the molding die 90 and recovered.

[Joint layer arrangement process]
10(b) is an explanatory diagram of the bonding layer arrangement step in the manufacturing method of the entrance floor material. The manufacturing method of the entrance floor material 71 is applied when the surface layer 72 and the cold press molded layer 73 are made of the same type of thermoplastic resin. When the surface layer 72 and the cold press molded layer 73 are made of different types of thermoplastic resin, a bonding layer arrangement step is performed between the surface layer arrangement step and the thermoplastic resin arrangement step. In the bonding layer arrangement step, the bonding layer 4 that exerts an anchor effect is arranged on the surface layer 72 that is placed on the surface layer placement part 98 in an upside-down state by the surface layer arrangement step. Then, in the thermoplastic resin arrangement step, the thermoplastic resin 73M (see FIG. 9(b)) in a plasticized state is arranged on the bonding layer 4.

The case where spunbond nonwoven fabric is used as the bonding layer 4 will be described. In the pressing process of cold press molding using the mold 90, due to the heat of the thermoplastic resin 73M that is in a state above its softening point and the pressure during pressing, a part of the side of the surface layer 72 facing the thermoplastic resin 73M and a part of the side of the thermoplastic resin 73M facing the surface layer 72 each penetrate into the fiber gaps of the spunbond nonwoven fabric in a molten state, and then cooled and solidified, and the surface layer 72 and the cold press molding layer 73 are firmly integrated through the bonding layer 4 (spunbond nonwoven fabric) by the anchor effect. In this way, by interposing the bonding layer 4, the surface layer 72 and the cold press molding layer 73 can be firmly integrated even if they are made of different materials.

It is preferable that the uneven pattern of the surface layer 32, 72 is given to the surface layer 32, 72 before lamination. As described above, in the process of laminating the surface layer 32, 72 and the cold press molded layer 33, 73 so as to be integrated, a press process is performed to mold the cold press molded layer 33, 73. This press process is performed by contacting the uneven pattern given to the surface layer 32, 72 before lamination with the mold 60, 90. At this time, although the pressure during the press process acts on the uneven pattern, the uneven pattern is cooled by the mold 60, 90. Therefore, even if the uneven pattern is given to the surface layer 32, 72 before lamination, the thermal deformation of the uneven pattern can be suppressed and the shape of the uneven pattern can be maintained. According to the flooring material 31, 71, it is not necessary to perform a process of giving an uneven pattern to the surface layer 32, 72 by, for example, embossing after the press process, so that production efficiency can be improved.

[Another embodiment]
The present invention can be implemented by partially modifying the configuration of the flooring material according to each of the above-described embodiments (including the modified examples). Such modified examples will be described below as other embodiments.

<Another embodiment 1>
In the above second embodiment, as a specific example (1) of the flooring to which the present invention is applied, a flooring material for stairs in which the step nosing laying part 43 and the riser surface laying part 42 are substantially perpendicular to each other is shown, but the connection form between the step nosing laying part 43 and the riser surface laying part 42 can be changed in various ways. For example, in FIG. 4, the connection part between the step nosing laying part 43 and the riser surface laying part 42 can be curved so that the entire cold press molded layer 33 has a rounded shape without corners (not shown). In addition, the uneven part 50 consisting of a plurality of groove-like recesses 45 and streak-like protrusions 46 formed in the step nosing laying part 43 can also be curved along the longitudinal direction or the corners of the unevenness can be chamfered to emphasize a rounded and soft impression.

<Another embodiment 2>
In the above second embodiment, as a specific example (2) of a flooring material to which the present invention is applied, a flooring material for an entrance hall having a cold-press molded layer 73 with a floor surface laying portion 81, an overhanging portion 82, and a water stop portion 83 is shown, but the cold-press molded layer 73 can also be configured to include a frame of the flooring material (flooring). For example, in Fig. 7, if the water stop portion 83 of the cold-press molded layer 73 is further extended in the vertical direction and connected to the edge of the flooring material (flooring) not shown, the water stop portion 83 of the cold-press molded layer 73 can function as a frame of the flooring material (flooring).

The present invention can firmly integrate a cold-pressed layer that is hard and capable of being formed into a three-dimensional shape with a flexible surface layer that has a fine uneven structure and is excellent in design. For this reason, the present invention is a technology that can be widely used in the construction and remodeling industries, and is particularly useful in constructing floor surfaces in various types of structures, such as ordinary houses, apartment buildings, condominiums, commercial malls, office buildings, factories, stores, stations, schools, hospitals, and public facilities.

Reference Signs List 1A, 1B Flooring 2, 2A, 2B Surface layer 3 Cold-press molded layer 4 Bonding layer 31 Staircase flooring 32 Surface layer of staircase flooring 33 Cold-press molded layer of staircase flooring 35 Concave portion (wood-like uneven pattern)
36 Convex part (wood grain pattern)
37 Short fiber-containing resin layer (wood-like uneven pattern)
42 Riser surface installation part (three-dimensional structure)
43 Nose laying part (three-dimensional structure)
60 Molding mold (for molding flooring for stairs)
71 Entrance flooring material 72 Surface layer of entrance flooring material 73 Cold press molded layer of entrance flooring material 75 Concave portion (tile-like uneven pattern)
76 Convex part (tile-like uneven pattern)
78 Net-like convex part (lattice-like uneven pattern)
82 Overhang (three-dimensional structure)
83 Water stop plate part (three-dimensional structure)
90 Molding mold (for molding entrance flooring)

Claims (1)

A method for manufacturing a flooring material comprising a surface layer and a cold-press molded layer,
a first placement step of placing the surface layer in a mold;
a second placing step of placing a thermoplastic resin in a state of not less than its softening point so as to be in contact with the surface layer;
a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin;
a recovery step of removing the laminated molded body formed by the pressing step from the mold;
A method for manufacturing a flooring material comprising the steps of:

Images