JPH0635754B2 - Rollable floor coverings and method for manufacturing the same - Google Patents

Description

Description: FIELD OF THE INVENTION The present invention mainly relates to a wooden floor material that can be rolled up,
That is, the present invention relates to a flooring material generally called "wood carpet" and a method for manufacturing the flooring material.

Conventional technology Recently, as a floor material for easily changing part or all of the floor of a fiber carpet floor or the floor of a tatami floor to a wood flooring floor, a narrow strip on the surface of a flexible backing sheet. There has been proposed a simple floor material for laying down, which can be wound by arranging and fixing plate-like bodies made of decorative plywood in parallel.

A conventional product of this type is, for example, Shoukai 62-9423.
As shown in Japanese Patent Publication No. 5, a cloth, a synthetic resin sheet or the like is used as a backing sheet, and a plate-like surface plate such as a decorative plywood is pasted on the backing sheet with an adhesive layer, and then only the surface plate is attached. Separated into narrow strip-shaped unit surface plates by engraving slit grooves in parallel at predetermined intervals, or in actual use Sho 63-
As shown in Japanese Patent Publication No. 47775, it is known that a strip-shaped wood surface plate is laid side by side on a soft synthetic resin sheet and adhered to the resin sheet.

DISCLOSURE OF THE INVENTION Problems to be Solved by the InventionHowever, in the former case of the conventional product, in addition to the fact that a large number of slit grooves are formed in the wooden decorative board layer, that is, a large number of deep gaps are formed between the strip-shaped unit decorative boards, the wound state There is a risk of pinching your fingertips etc. between the grooves when deploying from
Furthermore, the presence of the corners of the groove edges may cause clothes or the like to be caught, so that the suitability as a flooring material is only lacking.

On the other hand, in the latter conventional product, due to the presence of the synthetic resin sheet of the backing material, the weight is heavy, and it is difficult to handle. Often, it is easy to create gaps between the plate-like bodies, and when using a natural wood board for the plate-like bodies, the arrangement or rearrangement of the plate-like bodies may be changed or rearranged depending on the color difference of the decorative surface, etc. It is often necessary to perform operations such as pulling in to close the space between the plate-shaped bodies, but since the plate-shaped bodies are bonded using a tacky adhesive on the resin sheet, However, there is a problem in that the plate-like body is often soiled with an adhesive and that defective parts and low-quality parts are likely to occur and the yield rate of non-defective products is low.

The present invention has been made in view of the above-mentioned conventional techniques, and an object of the present invention is to provide a windable floor covering for laying a floor and a method for manufacturing the same, which solves these drawbacks.

Means for Solving the Problems In the above object, the present invention provides an adhesive made of a heat-meltable resin on the surface of a backing sheet made of a heat-shrinkable nonwoven fabric having a tensile strength in the longitudinal direction larger than that in the width direction. While the layer is provided, the narrow strip-shaped decorative plate-like body is arranged in parallel on the adhesive layer with the longitudinal direction thereof arranged in the width direction of the backing sheet, and the adhesive by heat and pressure is applied. Provided is a flooring material for laying, which can be wound, characterized in that the plate-like body is joined and integrated with a backing sheet due to the development of heat fusion adhesiveness of the layer.

As the plate-like body, a wooden decorative plywood is most suitable and generally used. In addition, in order to improve the design by showing shallow fine grooves in parallel on the flooring surface, chamfering pressure is applied to both upper edges of the plate body, and both side surfaces including the chamfered part have the same color tone as the decorative surface. It is also recommended that it be colored.

This invention also uses, as a backing sheet, a heat-shrinkable non-woven fabric having a tensile strength in the longitudinal direction greater than that in the width direction, as a method for producing the flooring, and bonding the backing sheet with a heat-meltable resin. A step of providing an adhesive layer, and a step of arranging a narrow strip-shaped decorative plate-like body in a lengthwise direction in the width direction of the backing sheet so as to be in parallel with each other and in close contact with each other on the adhesive layer And then, by heating from the backing sheet side and applying pressure from above and below, thereby causing the adhesive layer to exhibit heat fusion adhesiveness, and bonding and integrating the plate-like body with the backing sheet. Provided is a possible method for manufacturing a floor material for underlaying.

In the production method, in order to continuously carry out this and increase the production efficiency, a backing sheet provided with an adhesive layer is pulled out from the winding layer and introduced onto a conveyor, and the plate-shaped body is arranged on the conveyor. It is preferable to sequentially perform the steps and the heating / pressurizing joining step.

Embodiment An embodiment of the present invention will be described below with reference to the accompanying drawings.

1 and 2 show a floor material for floor laying (A) according to the present invention.
Indicates.

The flooring material (A) comprises, on a backing sheet (1) made of a non-woven fabric, a plurality of narrow strip-shaped decorative plate-like bodies (3) arranged side by side via an adhesive layer (2), and They are arranged in close contact with each other and are joined and integrated with the backing sheet (1) by the adhesive layer (2), and particularly have the main features of the respective constituents described below.

The non-woven fabric used as the backing sheet (1) is formed so that its tensile strength is greater in the length direction, that is, in the direction indicated by the arrow (a) in Fig. 1 than in the width direction orthogonal to this. Has been done. That is, the fiber is used by increasing the fiber orientation in the lengthwise direction and increasing the tensile strength to extend the fiber. The ratio of the tensile strength is preferably such that the tensile strength in the length direction is 130% or more with respect to that in the width direction. Due to this consideration of strength, it is possible to use a non-woven fabric that is as thin as possible, that is, one that has a small basis weight, and the flooring material can be constructed to be comparable in strength.

The nonwoven fabric of the backing sheet is a heat-shrinkable one. This heat shrinkability, by contracting by the heat treatment at the time of laminating the plate-like body (3), acts to narrow the interval between adjacent plate-like bodies, useful for reliably obtaining the density array It is a thing. Therefore, this heat shrinkability is
It is preferable that the shrinkage rate is about 40 to 70% at 130 ° C. for 1 minute.

Furthermore, although there are spunbond type, needlepunched type, and the like in the non-woven fabric, the spunbond type is preferred, and the type of the fiber is not particularly limited. Polyester fibers are preferable because of their excellent heat resistance. Moreover, the basis weight of the non-woven fabric is preferably about 120 to 250 g / m ² .

The adhesive layer (2) is made of a heat-melting resin of a type that exhibits almost no tackiness at room temperature, particularly what is called a hot-melt adhesive is used. Examples of such heat-fusible resin include polyethylene, polypropylene, ethylene-vinyl acetate copolymer, vinyl chloride, etc. Among them, polyethylene is preferably used because of its low melting temperature. The adhesive layer (2) is formed on the backing sheet (1) made of a non-woven fabric, in particular, only on one surface of the backing sheet, and after melting, the backing sheet becomes paper-like due to the influence of the impregnated resin. Care should be taken to prevent breakage and tearing. And, the adhesion formation of the adhesive layer is most easily carried out by a method of adhering to the backing sheet (1) using the hot-melt resin in the form of a film, but it may be applied by using a powder or a liquid material. good. Also, the amount of adhesive adhered is 20 to 50 g /
It is usually about m ² .

As the decorative plate-like body (3), it is common to use a wood-made decorative plywood having a decorative veneer (3a) adhered to its surface, but other particle boards, hard boards, medium-quality fiberboard (MDF), insulation In addition to wood boards such as aeration boards, wafer boards, oriented sledland boards (OSB) and laminated veneer boards (LVL), hard synthetic resin boards such as phenol resin boards and acrylic resin boards, as well as hard synthetic resin foaming. A plate or the like may be used. The decorative plate-like body (3) has a width of 10 to 10
A narrow strip having a thickness of 0 mm, a thickness of 3 to 10 mm, and a length of 500 mm or more is usually used, and it is preferable to chamfer the upper edges of both sides to show a shallow V-shaped narrow groove at the time of laying. Both sides (4) including the chamfered portion (4a) are colored in the same or similar color tone as the decorative surface (5) by the decorative veneer (3a).

Thus, the flooring material for underlaying according to the present invention (A) has an adhesive layer (2) made of a heat-fusible resin on the surface of the backing sheet (1), and then a plate-shaped body ( After laying 3) in a state in which their longitudinal directions are oriented in the width direction of the backing sheet (1) in close contact with each other, heating from the backing sheet (1) side,
Further, by pressing the whole so that the adhesive layer (2) exhibits heat-melt adhesiveness, the adhesive layer (2) can be applied to the plate-like body.
It is manufactured by integrally bonding (3) on the backing sheet (1).

An example of a preferable manufacturing method for continuously carrying out the above-described manufacturing is as shown in FIG. That is, on the intermittently driven belt conveyor (6) made of heat-resistant cloth, the backing sheet (1) having the heat-fusible resin film as the adhesive layer (2) previously attached to the surface thereof is wound into a coil. (1 ') is pulled out and guided, and the plate-like bodies (3) are arranged on the conveyor (6). At this time, the plate-like body (3) is an adhesive layer
(2) Since it is removable from above, the plate-like body (3) is replaced or reassembled as necessary while considering the uniformity of the color pattern design on the surface, and finally it is moved in. Then, the plates (3) and (3) are brought into close contact with each other. Then the conveyor
The hot platen (7) of the press machine provided on the lower surface side of (6) is raised, and the adhesive layer (2) is melted by heating from the lower surface side of the backing sheet (1), and at the same time, the pressing plate from the upper surface side. The plate-like body (3) is joined and fixed to the backing sheet (1) by descending (8) and pressing and pressing.

The concrete example of the production of the flooring material according to the present invention is as follows.

As the backing sheet (1), a spunbond type nonwoven fabric made of polyester fiber having the following configuration was used.

[Nonwoven fabric]

Unit weight: 185 g / m ² Thermal shrinkage: 50% at 130 ° C x 1 minute Tensile strength: Longitudinal direction 40 kg / 5 cm Width direction 30 kg / 5 cm Adhesive of 35 g / m ² on the surface side of the backing sheet (1) layer
A hot-melt resin film made of polyethylene resin is previously laminated as (2), the backing sheet (1) with the adhesive layer (2) is guided onto a conveyor (6), and a length of 900 m is provided thereon.
Decorative plate-like bodies (3) made of narrow strip-like wood plywood (m, width 60 mm, thickness 6 mm) were arranged in close contact with each other.

Then, from the lower surface side of the conveyor (6), a heating plate of 110 ° C.
At the same time as heating with (7), pressurizing plate (8) applies a pressure of 3 kg / cm ² for 20 minutes, and thereafter air cooling is repeated while intermittently driving conveyor (6) to obtain a long continuous shape. A floor material (A) for standing was obtained.

In the flooring material (A), the plate-like bodies (3) are completely in close contact with each other, and the plate-like bodies can be wound downward with the positions of the plate-like bodies being bent portions, and the strength and the appearance are improved. It was excellent.

EFFECTS OF THE INVENTION According to the present invention, according to the above, the present invention can be freely wound and can be laid as easily as a fiber carpet to form a desired wooden floor or the like. Has various features and effects.

First, since a heat-shrinkable non-woven fabric is used as the backing sheet, the backing sheet undergoes heat shrinkage due to the heating at the time of laminating the plate-like bodies, and as a result, the plate-like bodies on the surface are surely brought into close contact with each other. Thus, a product without a gap between them can be obtained.

Further, the backing sheet, which has a tensile strength in the longitudinal direction larger than that in the width direction, is used.
It is a lightweight floor that is made of a thin non-woven fabric with a low basis weight and can be made to have excellent rupture resistance at the positions between plate-shaped bodies, which is tough, easy to roll in, and has good laying stability. Material can be provided. Moreover, the adhesive layer is provided on the front surface side of the non-woven backing sheet, and it is possible to prevent the non-woven fabric from becoming paper-like and easy to tear due to the entire impregnation thereof. It can be done.

In addition, since the adhesive made of a heat-melting resin is used for joining and fixing the plate-shaped body to the backing sheet, it is possible to prevent the plate-shaped body from being soiled by the adhesive during the laminating step of the plate-shaped body. It is possible to avoid, of course, in the process of arranging the plate-shaped bodies before bonding, when the color difference or scratches are found, the plate-shaped bodies are replaced, recombined, or the misalignment is corrected. Can be freely performed on the adhesive layer, such as pulling work for closely contacting
Workability during the manufacturing process can be improved. Furthermore, the work of forming the adhesive layer on the backing sheet can be performed extremely easily as compared with the case where a tacky adhesive is used,
The drying efficiency of the adhesive is not necessary and the manufacturing efficiency can be improved. Further, by using the above heat-fusible resin adhesive, it is possible to impart water repellency to the backing sheet surface and to make it excellent in water-resistant adhesive strength, so that when water is spilled during use. Also, it is possible to prevent water from penetrating into the laying base surface, easily dry, and surely prevent peeling of the plate-like body.

[Brief description of drawings]

The drawings show an embodiment of the present invention. FIG. 1 is a partially crushed perspective view, FIG. 2 is a sectional view, and FIG. 3 is a schematic side view showing a continuous manufacturing facility. (A) …… floor material, (1) …… lining sheet, (2) …… adhesive layer,
(3) …… Plate, (4) …… Side, (4a) …… Chamfer, (6)
…… Conveyor, (7) …… Hot plate, (8) …… Pressing plate.

Claims (5)

[Claims] 1. An adhesive layer made of a heat-fusible resin is provided on the surface of a backing sheet made of a heat-shrinkable non-woven fabric having a tensile strength in the longitudinal direction larger than that in the width direction.
The narrow strip-shaped decorative plate is laid in parallel on the adhesive layer with its longitudinal direction arranged in the width direction of the backing sheet, and the heat-melt adhesiveness of the adhesive layer by heating and pressing. The above-mentioned plate-like body is joined and integrated with a backing sheet by the expression of the above, and a foldable flooring material for underlaying is provided. 2. The plate-shaped body is made of wood decorative plywood.
(1) A floor material for bedding that can be wound. 3. The plate-shaped body is chamfered on both upper edges,
The rollable floor covering for laying down according to claim (1) or (2), wherein both side surfaces including the chamfered portion are colored in the same color tone as the decorative surface. 4. A step of using a heat-shrinkable nonwoven fabric having a tensile strength in the longitudinal direction greater than that in the width direction as a backing sheet, and providing an adhesive layer made of a heat-meltable resin on the backing sheet, A narrow strip-shaped decorative plate, a step of arranging the lengthwise direction of the backing sheet in the width direction of the backing sheet and laying them in parallel and intimately on each other on the adhesive layer, and then from the backing sheet side. Manufacture of a floor material for a layable floor, which comprises a step of causing the adhesive layer to exhibit heat fusion adhesiveness by heating and applying pressure from above and below to join and integrate the plate-like body with a backing sheet. Method. 5. A backing sheet provided with an adhesive layer is pulled out from the wound layer and guided onto a conveyor, and the step of arranging the plate-like bodies and the heating and pressure bonding step are sequentially carried out on the conveyor. (4) The method for producing a floor material for bedding which can be wound as described in (4).