JP2003161028A - Woody floor material and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a woody floor material which is obtained by press-molding an impregnated sheet onto a surface of a substrate inclusive of its recessed slots, and carrying out thermowelding, thereby improving the appearance and quality thereof, and to provide a method for producing the woody floor material. <P>SOLUTION: According to the method, the recessed slots 2 are formed in the surface of the woody substrate 1, and the impregnated sheet 3 which has been impregnated with a thermosetting resin is mounted on the surface of the substrate 1. Then, the impregnated sheet 3 is pressed onto the substrate 1 by a press die 8. The press die 8 includes a pressing surface 5 which has linear projections 6 at locations corresponding to the recessed slots 2 so as to be fitted into the recessed slots 2, and a cushion layer 7 over the entire area of the pressing surface 5. Further, the impregnated sheet 3 is thermowelded to the surface of the substrate 1 inclusive of the recessed slots 2. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wooden flooring material in which a resin-impregnated sheet is heat-welded to the surface of a wooden base material and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, there is a wood flooring material produced by heat-welding a resin-impregnated sheet impregnated with a resin such as a melamine resin onto a wood-based substrate by pressing. . However, when the resin-impregnated sheet 3 is heated and welded to the surface of the grooved substrate 1 in which the groove 1 is provided on the surface of the substrate 1 to improve the appearance, as shown in FIG. There is a problem that the resin impregnated sheet 3 is not attached inside, and the part corresponding to the concave groove 2 becomes cloudy to form a cloudy part 4. Therefore, the surface of the base material 1 could not be changed. Further, if the resin-impregnated sheet 3 is forcibly pressed into the recessed groove 2 provided in the base material 1, the resin-impregnated sheet is cut (the nonwoven fabric of the base material of the resin-impregnated sheet is torn), and the resin is applied to the entire recessed groove 2. It is difficult to get a good quality wood flooring.

The present invention has been made in view of the above points, and a wood flooring material that can be heat-welded by press molding a resin-impregnated sheet including concave grooves on the surface of a base material to improve the appearance and quality, and It is an object to provide a manufacturing method thereof.

[0004]

A wood flooring material of the present invention for solving the above problems is a resin-impregnated sheet in which a groove 2 is bored in a surface of a wood base material 1 and a thermosetting resin is impregnated. 3 is placed on the surface of the base material 1, a convex strip 6 capable of engaging with the concave groove 2 is provided at a position corresponding to the concave groove 2 on the press surface 5, and a cushion layer 7 is provided on the entire press surface 5. Press die provided 8
The resin-impregnated sheet 3 is pressed so as to be pressed against the base material 1, and the resin-impregnated sheet 3 is heat-welded on the surface of the base material 1 including the concave grooves 2.

Further, according to the method of manufacturing a wood flooring material of the present invention, a concave groove 2 is formed on the surface of a wood base material 1 and a resin impregnated sheet 3 impregnated with a thermosetting resin is placed on the surface of the base material 1. Then, a ridge 6 which can be fitted into the groove 2 is provided at a position corresponding to the groove 2 on the pressing surface 5, and a cushion layer 7 is provided on the entire surface of the pressing surface 5 to impregnate the resin with a press die 8. The sheet 3 is pressed so as to be pressed against the base material 1, and the resin-impregnated sheet 3 is heat-welded on the surface of the base material 1 including the concave grooves 2.

As described above, the press die 8 is provided with the ridge 6 which can be fitted in the concave groove 2 at the position corresponding to the concave groove 2 of the pressing surface 5 and the cushion layer 7 is provided on the entire pressing surface 5. By pressing the resin-impregnated sheet 3 against the base material 1 and heat-welding the resin-impregnated sheet 3 including the concave groove 2 on the surface of the base material 1 so that the convex-concave fitting of the projections 6 and the cushion layer are performed. With the cushioning property of 7, the resin-impregnated sheet 3 can be adhered to the inside including the concave groove 2 and heat-welded so as not to tear the resin-impregnated sheet 3. As a result, it is possible to obtain a wood flooring material having good quality and appearance.

Further, the resin-impregnated sheet 3 is placed at 160 ° C. to 230 ° C.
It is also preferable that the composition is characterized in that it is heated within the range of ° C and heat-sealed.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION A wooden base material 1 has a natural wood decorative veneer laminated on the surface of plywood so as to give the appearance of natural wood. The plywood is a parallel or cross plywood in which 5 ply or 7 ply is laminated, or MDF composite plywood, which is made from South Sea or softwood. The thickness of this plywood is about 12 mm, but various types can be used,
A thickness of approximately 6 mm to 15 mm is used. A concave groove 2 is preliminarily formed on the surface of a base material 1 obtained by laminating a natural wood decorative veneer to this plywood. The concave groove 2 is cut with a tenona or the like. The groove 2 has a V-shaped cross section and a round cross section. In the case of this example, the concave groove 2 is a groove having a V-shaped cross section, has a width of 1.5 mm to 4.0 mm, and a depth of 0.5 mm to.
It is 2.0 mm. In the case of this example, the concave groove 2 is formed on the surface of the base material 1.
When the groove is provided, a chamfer 2a having a width half that of the groove 2 is provided on the peripheral edge of the surface of the base material 1. The surface of the base material 1 is colored with a dye or a pigment.

The resin-impregnated sheet 3 is formed by impregnating a nonwoven fabric with a thermosetting resin and drying it. In the case of this example, the thermosetting resin is a melamine resin-impregnated sheet impregnated with a melamine resin. As the thermosetting resin to be impregnated, there is a phenol resin in addition to the melamine resin. When the resin-impregnated sheet 3 is a melamine resin-impregnated sheet, for example, a melamine resin is impregnated at a basis weight of 10 to 50 g / m ² .

After placing the resin-impregnated sheet 3 on the surface of the substrate 1, the press die apparatus for press-forming is the upper press die 8
And the press die 9 below. Lower press die 9
The pressing surface of the upper surface of the base is formed in a flat shape over the entire surface, but the pressing surface 5 of the lower surface of the upper press die 8 is provided with convex grooves that are fitted into the concave groove 2 of the base material 1 and the chamfer 2a. 6 is provided, and a cushion layer 7 is provided over the entire surface of the pressing surface 5 including the convex stripes 6. The cushion layer 7 is made of rubber such as butyl rubber and has a thickness of 1 to 5 m.
It is about m.

When press-molding the wooden floor material A, however, the base material 1 having the resin-impregnated sheet 3 placed on the upper surface thereof is placed on the lower press die 9 as shown in FIG. The mold 8 is lowered and heated and pressed to mold as shown in FIGS. At this time, as shown in FIG. 1 (b), the ridge 6 enters the concave groove 2 and is pressed so that the whole is pushed as shown in FIG. 1 (c). As a result, a resin such as a melamine resin is melted by the heat during pressing and fixed on the surface of the base material 1, and the wood floor material A as shown in FIG. 2 is obtained. A cushion layer covering the entire surface, even when the convex strip 6 portion is fitted in the concave groove 2 portion and the resin-impregnated sheet 3 is heat-sealed in the concave groove 2 when molding by heating and pressing as described above. At 7, the pressure is evenly applied to the entire surface including the recessed groove 2, and the nonwoven fabric of the resin-impregnated sheet 3 is molded in the recessed groove 2 so as not to tear. The resin spreads well and is molded with good appearance. Further, by molding through the cushion layer 7, the resin-impregnated sheet 3 is molded so as to have a rounded and smooth surface in the concave groove 2 portion, and is molded into a so-called soft groove shape as shown in FIG. . When molding by heating and pressing as described above, the temperature for heating the mold is about 160 ° C to 230 ° C (165 ° C).
The optimum pressure is 15 to 5
It is about 0 kg / cm ² and the pressing time is about 10 seconds. Also, when pressing, about 3 after starting the press
It is preferable to degas about once after a second. Further, the cushion layer 7 of the press die 8 is replaced after being used about 1000 times. If the groove is small, it is replaced about 10,000 times. Further, a female seed 10 and a male seed 11 for joining the wooden floor material A are formed on the base material 1 of the wooden floor material A as required.

Wood floor material A obtained by molding as described above
Uses a natural wood decorative veneer on the surface of the base material 1, and colors it if necessary, and heat-bonds the resin-impregnated sheet 3 to the surface to coat the surface with a thermosetting resin. Therefore, not only can you obtain a natural wood-like appearance with good appearance, but the surface is coated with a thermosetting resin, so the impact resistance, caster resistance, and weather resistance of the floor surface can be greatly improved. VOC (Volatil
e Organic Compounds) can be eliminated. In addition, since the resin-impregnated sheet 3 including the concave groove 2 is heat-fused and covered with the thermosetting resin in the state where the concave groove 2 is provided on the base material 1, the appearance becomes grooved and the appearance is improved. Can be improved. Further, as described above, the resin-impregnated sheet 3 can be heat-sealed through the cushion layer 7 to form the soft groove, so that the stocking is less likely to be caught and dust is less likely to be accumulated in the groove.

[0013]

As described above, according to the present invention, a concave groove is formed on the surface of a wooden base material, a resin-impregnated sheet impregnated with a thermosetting resin is placed on the surface of the base material, and The resin-impregnated sheet is pressed by pressing the resin-impregnated sheet against the base material using a press die in which a convex strip that can be fitted into the concave groove is provided at a position corresponding to the concave groove and a cushion layer is provided on the entire press surface. Since it is heated and welded to the surface of the base material including the concave groove,
The uneven fitting of the ridges and the cushioning property of the cushion layer allow the resin-impregnated sheet to be adhered to the inside including the concave groove and can be heat-welded so that the resin-impregnated sheet does not tear. It is possible to obtain a wooden flooring material having a good quality and appearance even if it has a change.
Further, even if the appearance is improved by providing the groove, since the surface is covered with the thermosetting resin, the impact resistance, caster resistance and weather resistance of the floor surface can be improved. Further, since the ridges are pressed against the cushion layer for molding, a soft groove having a smooth surface can be formed to prevent the stocking from being caught and prevent dust from being accumulated in the groove.

[Brief description of drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing method according to an example of an embodiment of the present invention, in which (a), (b), and (c) show respective steps.

2A and 2B show a wooden flooring material obtained by the same as above, wherein FIG. 2A is a sectional view and FIG. 2B is a perspective view.

FIG. 3 is a sectional view illustrating a conventional example.

[Explanation of symbols]

1 base material 2 groove 3 Resin impregnated sheet 5 Press surface 6 convex stripes 7 cushion layer 8 Press type

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Takuya Yamamoto             135 Idogami-cho, Numata City, Gunma Prefecture             Le Building Materials Industry Co., Ltd.

Claims (3)

[Claims] 1. A recessed groove is formed on the surface of a wooden base material, a resin-impregnated sheet impregnated with a thermosetting resin is placed on the surface of the base material, and the pressed surface is placed at a position corresponding to the recessed groove. The resin-impregnated sheet is pressed into the base material with a press die that has convex grooves that can be fitted in concave and convex portions and a cushion layer is provided on the entire press surface, and the resin-impregnated sheet is recessed on the surface of the base material. A wood flooring material that is heat-welded, including grooves. 2. A wood base material is provided with a groove on the surface thereof, and a resin-impregnated sheet impregnated with a thermosetting resin is placed on the surface of the base material, and the press surface is placed at a position corresponding to the groove. The resin-impregnated sheet is pressed into the base material with a press die that has convex grooves that can be fitted in concave and convex portions and a cushion layer is provided on the entire press surface, and the resin-impregnated sheet is recessed on the surface of the base material. A method for manufacturing a wood flooring material, which comprises heat welding including grooves. 3. The resin-impregnated sheet is heated within a range of 160 ° C. to 230 ° C. to be heat-sealed.
The method for producing a wooden floor material as described above.