Decorative materials and flooring

Abstract

The present invention provides a decorative material that prevents poor fitting and resulting construction defects when a female tongue and groove on one decorative material are fitted together with a male tongue and groove on another decorative material, and a flooring material made using the same decorative material. [Solution] A decorative material comprising a base layer having a side surface on which female and / or male fruits are formed, wherein a female locking portion is formed on the female fruit and a male locking portion is formed on the male fruit, and the female locking portion and the male locking portion are structured to interlock and lock with each other when a decorative material having at least the female fruit and another decorative material having at least the male fruit are fitted together. The decorative material is characterized in that the female locking portion and the male locking portion have a gap between them in a direction parallel to the upper or lower surface of the base material layer when they are interlocked.

Description

[Technical Field]

[0001] This invention relates to a decorative material and a flooring material using the decorative material. [Background technology]

[0002] While there are various theories, the average lifespan of a house in Japan is said to be around 30 years, which is relatively short compared to Western countries. While houses may be demolished due to the deterioration of foundations, subflooring, and interior materials, advancements in housing construction have improved earthquake resistance and structural durability. Coupled with the growth of the used housing market, there is a growing demand for extending the lifespan of houses through maintenance and renovations. Furthermore, extending the lifespan of houses is an important initiative from the perspective of realizing a decarbonized society and a circular economy.

[0003] Currently, maintenance and renovations primarily involve improvements to plumbing and other facilities, but interior remodeling is also sometimes included. Flooring, in particular, is the part of the interior that suffers the most damage from use, but it's not as easy to replace as wallpaper or doors. Furthermore, replacing flooring materials, which involves extensive demolition work, is a heavy workload, physically exhausting for workers, and tends to take a long time. In addition, the generation of construction waste directly contributes to environmental burden. Therefore, the method of installing new flooring over existing flooring has been increasing in recent years.

[0004] Conventional decorative materials such as flooring and wall panels have protrusions and recesses on their sides, and the protrusions on the side of one decorative material can be fitted into the recesses on the side of another decorative material (see, for example, Patent Document 1). However, due to environmental factors and the use of heating appliances, especially underfloor heating, the floorboards dry out and shrink, creating gaps in the joints between them. These gaps are usually suppressed using adhesives or similar methods. In maintenance and renovations where simpler construction is required, it is preferable to use construction methods that utilize adhesives or adhesive tapes. However, it has been confirmed that the gaps during drying, whether using adhesives or glues, are larger than the standards for floor heating tests of floors constructed using nails and adhesives, and countermeasures are necessary.

[0005] As an easy-to-install type of overlay flooring that does not create gaps, for example, Patent Documents 2 and 3 disclose flooring materials that use an integrated mechanical locking mechanism to prevent the floorboards from shifting in a parallel direction and coming apart. Such flooring materials are often used overseas and are called Uniclick (registered trademark) manufactured by Unilyn. However, while conventional flooring materials using mechanical locking mechanisms are effective in preventing floorboards from coming apart, dimensional changes due to moisture absorption and release or heat can cause stress to concentrate on the mechanical locking mechanism, leading to breakage or causing lifting and distortion of the flooring material. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2004-92229 [Patent Document 2] Patent No. 3742658 [Patent Document 3] Patent No. 4463745 [Overview of the project] [Problems that the invention aims to solve]

[0007] The present invention aims to provide a decorative material that can prevent poor fitting and resulting construction defects when a female tongue and groove provided on one decorative material are fitted together with a male tongue and groove provided on another decorative material, and a flooring material using said decorative material. [Means for solving the problem]

[0008] As a result of diligent research to solve the above-mentioned problems, the present inventors have found that a decorative material having female and / or male joints on the side surface of a base layer, wherein the female and male joints interlock and lock together while forming a gap in a direction parallel to the upper surface or floor surface of the base layer when fitted together, thereby preventing poor fitting of the decorative material and enabling good installation, and thus completed the present invention.

[0009] The present invention relates to a decorative material comprising a base layer having a side surface on which female and / or male fruits are formed, wherein the female fruit has a female locking portion formed thereon, and the male fruit has a male locking portion formed thereon, and the female locking portion and the male locking portion are structured to interlock and lock with each other when at least one decorative material having the female fruit and at least another decorative material having the male fruit are fitted together. The decorative material is characterized in that the female locking portion and the male locking portion have a gap between them in a direction parallel to the upper or lower surface of the base material layer when they are interlocked.

[0010] In the decorative material of the present invention, it is more preferable that the female locking portion and the male locking portion have a gap of 0.5 mm ± 0.2 mm in a direction parallel to the upper or lower surface of the base material layer when they are interlocked with each other. Furthermore, the decorative material of the present invention preferably has a total thickness of 2 mm or more and 4.5 mm or less. Furthermore, it is preferable that the female and male fruits are mutually fixed, the female locking portion is formed on the upper surface of the lower jaw portion of the female fruit, and the male locking portion is formed on the lower surface of the upper jaw portion of the male fruit. Furthermore, it is preferable that the female and male fruits are the main fruits, the female locking portion is formed on the lower upper surface of the recess of the female fruit, and the male locking portion is formed on the lower surface of the protrusion of the male fruit. Furthermore, it is preferable that the female locking portion and the male locking portion have one or more interlocking protrusions and recesses that can be fitted together. Furthermore, it is preferable that the length from the tip to the other end of the female fruit and / or male fruit is 4 mm or more and 15 mm or less. In the above-mentioned female tongue and / or the above-mentioned male tongue, the thickness of the thinnest portion is preferably 0.5 mm or more. Further, the base material layer is preferably a woody base material. Further, a back surface sheet having a moisture permeability of 7 g / m 2 or less is preferably provided on the back surface of the base material layer. Further, it is preferable that a decorative sheet is provided on the upper surface of the base material layer, and a pressure-sensitive adhesive layer, a pressure-sensitive adhesive tape or an adhesive layer is provided on the lower surface of the base material layer. Further, the present invention is also a flooring material formed using the decorative material of the present invention. Effects of the Invention

[0011] When a floor surface, a wall surface panel or the like is formed using the decorative material of the present invention, when the female tongue provided on one decorative material and the male tongue provided on another decorative material are fitted to each other, the structure is such that they slightly move in the horizontal direction and are caught, and an appropriate play (fitting gap) is provided for the fitting, so that construction is facilitated, fitting defects and construction quality defects are prevented in advance, and in particular, since the dimensions of woody materials change due to moisture absorption and desorption, the decorative material is provided with a function of physically resisting the movement. Brief Description of the Drawings

[0012] [Figure 1] (a) to (c) are schematic views showing a preferred example of the decorative material of the present invention. [Figure 2] (a) to (c) are schematic views showing another preferred example of the decorative material of the present invention. [Figure 3] (a) to (c) are schematic views showing still another preferred example of the decorative material of the present invention. [Figure 4] (a) to (c) are schematic views showing still another preferred example of the decorative material of the present invention. [Figure 5] (a) to (c) are schematic views showing still another preferred example of the decorative material of the present invention. [Figure 6] (a) and (b) are schematic views showing still another preferred example of the decorative material of the present invention. [Figure 7]This is a schematic diagram showing yet another preferred example of the cosmetic material of the present invention. [Modes for carrying out the invention]

[0013] The decorative material of the present invention comprises a base layer having sides on which female and / or male fruits are formed. The decorative material of the present invention having such a base layer has a polygonal upper surface, but the polygon can be a triangle, a square, a pentagon, or any other shape as needed, and is not particularly limited.

[0014] In the decorative material of the present invention, both female and male fruits may be formed on the side surface of the base material layer, or only either female or male fruits may be formed. However, if both female and male fruits are formed on the side surface of the base material layer, multiple decorative materials can be continuously bonded together with the female and male fruits facing each other. In cases where both female and male fruits are formed on the side surface of the base material layer, one possible configuration is one in which a female fruit is formed on at least one side surface of the base material layer, and a male fruit shaped to fit into the female fruit is formed on at least one other side surface of the base material layer.

[0015] In the decorative material of the present invention, a female-side locking portion is formed on the female fruit, and a male-side locking portion is formed on the male fruit. The female locking portion and the male locking portion have a structure in which they interlock and lock with each other when a decorative material having at least the female joint and another decorative material having at least the male joint are fitted together.

[0016] In the decorative material of the present invention, the female locking portion and the male locking portion are interlocked and have a gap between them in a direction parallel to the upper or lower surface of the base material layer. The presence of the above-mentioned gap prevents poor fitting and construction defects from occurring even if the dimensions of the decorative materials change due to dimensional changes caused by moisture absorption or release after the female joint of one decorative material and the male joint of another decorative material have been fitted together, as the gap absorbs these changes.

[0017] In the present invention, the gap is preferably 0.5 mm ± 0.2 mm in a direction parallel to the upper or lower surface of the base material layer. If the gap is less than 0.3 mm, dimensional changes due to moisture absorption and release may cause dimensional changes in the decorative material, resulting in poor fitting or poor installation of the decorative material. If the gap exceeds 0.7 mm, the gap may become noticeable and unsightly, and the gap between fitted decorative materials may become larger, potentially allowing dirt and dust to enter.

[0018] The decorative material according to the present invention preferably has a total thickness of 2 mm or more and 4.5 mm or less. If it is less than 2 mm, the strength of the female and male parts may be insufficient and cracks may occur. If it exceeds 4.5 mm, dimensional changes due to moisture absorption and release may become large, and interference with joinery may not be avoided when installed on existing flooring.

[0019] The structure of the female and male fruits described above is not particularly limited and may be either a juxtaposition or a single fruit. Furthermore, in the present invention, it is preferable that the female and male fruits are mutually determined, the female locking portion is formed on the upper surface of the lower jaw portion of the female fruit, and the male locking portion is formed on the lower surface of the upper jaw portion of the male fruit. Furthermore, in the present invention, it is preferable that the female and male fruits are the main fruits, the female locking portion is formed on the lower upper surface of the recess of the female fruit, and the male locking portion is formed on the lower surface of the convex portion of the male fruit. This type of decorative material prevents improper fitting and resulting construction defects when the female joint on one decorative material is fitted with the male joint on another decorative material.

[0020] In the above-mentioned female and / or male joints, it is preferable that the thickness of the thinnest part is 0.5 mm or more. If the thickness of the thinnest part is less than 0.5 mm, cracks may occur, and when a female joint provided on one decorative material is fitted with a male joint provided on another decorative material, it may cause poor fitting and result in construction defects.

[0021] When the above-mentioned female and male fruits are determined to be the same, examples of the decorative material of the present invention include the embodiments shown in Figures 1 to 6. The decorative material shown in Figure 1(a) has a trapezoidal projection 13 in side view at the tip of the lower surface of the upper jaw portion 11 of the male fruit 10, and a recess 12 formed between the projection 13 and the base of the upper jaw portion 11. The female fruit 100 has a trapezoidal projection 103 in side view at the tip of the upper surface of the lower jaw portion 101, and a recess 102 formed between the projection 103 and the base of the lower jaw portion 101. The projection 13 and recess 12 serve as the male locking portion, and the projection 103 and recess 102 serve as the female locking portion. When the male fruit 10 is fitted into the female fruit 100, the female locking portion and the male locking portion interlock with each other, leaving a gap L, as shown in Figure 1(b). Here, the gap L is the distance between the projection 13 of the male fruit 10 and the projection 103 of the female fruit 100. As shown in Figure 1(c), when the decorative material on the male fruit 10 side and the decorative material on the female fruit 100 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0022] The decorative material shown in Figure 2(a) has a sawtooth-shaped recess 22 formed on the lower surface of the upper jaw portion 21 of the male fruit 20 when viewed from the side, and a sawtooth-shaped recess 202 formed on the upper surface of the lower jaw portion 201 of the female fruit 200 when viewed from the side, with the recess 22 serving as the male locking portion and the recess 202 serving as the female locking portion. When the male fruit 20 is fitted into the female fruit 200, the female locking portion and the male locking portion interlock with each other with a gap L between them, as shown in Figure 2(b). Here, the gap L is the distance between one recess 22 of the male fruit 20 and the recess 202 of the female fruit 200 that is opposite to the recess 22. As shown in Figure 2(c), when the decorative material on the male fruit 20 side and the decorative material on the female fruit 200 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0023] The decorative material shown in Figure 3(a) has a curved projection 33 at the tip of the lower surface of the upper jaw portion 31 of the male fruit 30, and a recess 32 formed between the projection 33 and the base of the upper jaw portion 31. The female fruit 300 has a curved projection 303 at the tip of the upper surface of the lower jaw portion 301, and a recess 302 formed between the projection 303 and the base of the lower jaw portion 301. The projection 33 and recess 32 serve as the male locking portion, and the projection 303 and recess 302 serve as the female locking portion. When the male fruit 30 is fitted into the female fruit 300, the female locking portion and the male locking portion interlock with each other, leaving a gap L, as shown in Figure 3(b). Here, the gap L is the distance between the projection 33 of the male fruit 30 and the projection 303 of the female fruit 300. As shown in Figure 3(c), when the decorative material on the male fruit 30 side and the decorative material on the female fruit 300 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0024] The decorative material shown in Figure 4(a) has a rectangular projection 43 at the lower tip of the upper jaw portion 41 of the male fruit 40 and a recess 42 formed between the projection 43 and the base of the upper jaw portion 41. The female fruit 400 has a projection 403 with a curved corner at the upper tip of the lower jaw portion 401 and a recess 402 formed between the projection 403 and the base of the lower jaw portion 401. The projection 43 and recess 42 serve as the male locking portion, and the projection 403 and recess 402 serve as the female locking portion. When the male fruit 40 is fitted into the female fruit 400, the female locking portion and the male locking portion interlock with each other, leaving a gap L, as shown in Figure 4(b). Here, the gap L is the distance between the projection 43 of the male fruit 40 and the projection 403 of the female fruit 400. As shown in Figure 4(c), when the decorative material on the male fruit 40 side and the decorative material on the female fruit 400 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0025] The decorative material shown in Figure 5(a) has a trapezoidal projection 53a formed on the lower tip of the upper jaw portion 51 of the male fruit 50, a trapezoidal projection 53b formed on the base side of the upper jaw portion 51 from projection 53a, a recess 52a formed between projection 53a and projection 53b, and a recess 52b formed between projection 53b and the base of the upper jaw portion 51. In addition, a rectangular projection 503b formed on the upper tip of the lower jaw portion 501 of the female fruit 500, a trapezoidal projection 503a formed on the base side of the lower jaw portion 501 from projection 503b, a recess 52b formed between projection 503a and projection 503b, and a recess 502a formed between projection 503a and the base of the lower jaw portion 501. The protrusions 53a and 53b and the recesses 52a and 52b form the male locking portion, while the protrusions 503a and 503b and the recesses 502a and 502b form the female locking portion. When the male fruit 50 is fitted into the female fruit 500, the female locking portion and the male locking portion interlock with each other, leaving a gap L, as shown in Figure 5(b). Here, the gap L is the distance between the projection 53a of the male fruit 50 and the projection 503a of the female fruit 500. As shown in Figure 5(c), when the decorative material on the male fruit 50 side and the decorative material on the female fruit 500 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0026] The decorative material shown in Figures 6(a) and (b) is the same as the male joint 50 shown in Figure 5, but the female joint 600 in Figure 6(a) has the same configuration as the female joint 500 shown in Figure 5, except that a screw 603a is attached to the base side of the mandibular portion 501 in place of a trapezoidal projection 503a in a side view. The screw 603a, projection 503b, and the recess between them form the female locking portion. Furthermore, the female joint 610 in Figure 6(b) has the same configuration as the female joint 500 shown in Figure 5, except that a pin 613a is attached to the base side of the mandibular portion 501 in place of the trapezoidal projection 503a in a side view. The pin 613a, projection 503b, and the recess between them constitute the female locking portion. When the male fruit 50 is fitted into the female fruit 600 or female fruit 610, the female locking portion and the male locking portion interlock with each other with a gap L between them, as shown in Figures 6(a) and (b). Here, the gap L is the distance between the projection 53a of the male joint 50 and the screw 603a of the female joint 600 or the pin 613a of the female joint 610. When the decorative material on the male joint 50 side and the decorative material on the female joint 600 or female joint 610 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0027] When the above-mentioned female and male fruits are true fruits, examples of the decorative material of the present invention include the embodiment shown in Figure 7. The decorative material shown in Figure 7 comprises a male joint 70 having a protrusion 71 and a female joint 700 having a recess that can be fitted into the male joint 70. The male fruit 70 has a rectangular projection 73 in cross-section at the upper tip of the convex portion 71, and a recess 72 formed between the projection 73 and the base of the convex portion 71. The female fruit 700 has an upper protrusion 701 on the upper part of the recess that faces the upper surface of the protrusion 71 when fitted with the male fruit 70, and a rectangular projection 703 in cross-section is formed at the tip of the lower surface of the upper protrusion 701 that faces the protrusion 71, and a recess 702 is formed between the projection 703 and the bottom of the upper recess. In such a decorative material, the projection 73 and the recess 72 serve as the male locking portion, and the projection 703 and the recess 702 serve as the female locking portion. Furthermore, the male and female locking portions formed in this joint may have the same structure as the male and female locking portions formed in the interlocking structure shown in Figures 1 to 5, but instead of the male and female locking portions shown in Figure 7. When the male fruit 70 is fitted into the female fruit 700, the female locking portion and the male locking portion interlock with each other, as shown on the left side of Figure 7. Here, the gap L is the distance between the projection 73 of the male fruit 70 and the projection 703 of the female fruit 700. When the decorative material on the male fruit 70 side and the decorative material on the female fruit 700 side move apart from each other, they move by the amount of the gap L, and the male locking part and the female locking part interlock and lock together.

[0028] Because a gap can be created at the bottom when the decorative material of the present invention is applied to a substrate, even if there are foreign objects such as dirt that could not be completely removed from the substrate being applied, the gap at the bottom allows the foreign objects to escape into that area, so it is possible to apply the material even if there are some foreign objects present. In addition, it is possible to prevent the adhesive from seeping out onto the surface of the decorative material by accumulating excess adhesive when attaching it to the substrate via adhesive.

[0029] (base material layer) The above-mentioned base material layer has been processed to form male and female fruits on its sides, and is a layer that mainly imparts shape stability, water resistance, moisture resistance, impact resistance, and scratch resistance to the decorative material of the present invention. Preferably, the distance from the top surface of the base material layer to the upper base of the male fruit is 2.0 mm or less. If it exceeds 2.0 mm, the joints when the decorative material of the present invention is bonded together to form, for example, a floor or wall surface will become deeper, making it easier for dirt to accumulate and potentially resulting in an unattractive appearance. More preferably, the distance from the top surface to the upper base of the male fruit is 1.5 mm or less. A larger distance between the top surface of the base material layer and the upper base also has the effect of preventing the gap from becoming more noticeable due to shadows.

[0030] Such a base layer is preferably 4.5 mm or less in thickness. A base layer thickness of 4.5 mm or less provides excellent resistance to dirt accumulation and a good groove appearance. In addition, it reduces the likelihood of stress warping caused by differences in expansion due to temperature, etc., between this layer and other layers such as the support layer described later. Furthermore, it is preferable that the thickness of the base layer be thinner than that of the support layer. This is because it reduces the likelihood of stress warping caused by differences in expansion due to moisture, etc., between the base layer and other layers such as the support layer. The thickness of the above-mentioned base material layer is more preferably 2.0 mm or more and less than 3.0 mm.

[0031] Furthermore, in the decorative material of the present invention, it is preferable that the thickness of the base portion of the male fruit is greater than the thickness of the tip portion. With this shape, a male fruit with sufficient strength can be formed even with an extremely thin base material layer. In the case of a male fruit of this shape, it is preferable that the thickness of the tip of the male fruit be 0.5 mm or more. A thickness of 0.5 mm or more at the tip of the male fruit makes it less likely for the formed male fruit to crack or chip from the base during the manufacturing of decorative materials, and also makes it less likely for the tip of the male fruit to crack or chip when fitted in order to install the decorative material.

[0032] Furthermore, it is preferable that the thickness of the tip of the male joint is 30% to 90% of the thickness of the base. If it is less than 30%, the thickness of the base of the male joint becomes too thick, making it difficult to form the male joint on a thin base material layer, or conversely, the thickness of the tip of the male joint becomes too thin, making it prone to cracking. On the other hand, if it exceeds 90%, the cross-sectional shape of the male joint becomes close to a rectangle, making it difficult to fit into the female joint of another decorative material, and making it prone to cracking. A more preferable lower limit for the above thickness ratio is 40%, and a more preferable upper limit is 80%.

[0033] In male fruits with different thicknesses at the base and tip, it is preferable that at least the upper surface of the male fruit is sloped. When a male fruit with a shape that satisfies the above-mentioned difference in thickness or ratio of thickness is sloped on the upper surface, a larger slope angle can be formed compared to when the same slope angle is formed on the upper surface and the lower surface opposite the upper surface. As a result, the male fruit can be made easier to fit into the female fruit and less prone to cracking. In this specification, the "angle of inclination" refers to the angle formed between the upper or lower surface of the male cone and the horizontal when a cross-section parallel to the thickness direction of the base material layer is observed. The angles of inclination of the upper surface and the angles of inclination of the lower surface refer to the angles α° and β° formed by the upper and lower surfaces of the convex male cone with respect to the horizontal plane.

[0034] In the present invention, when the decorative material has inclinations on the upper surface of the male joint and the lower surface opposite to the upper surface, it is preferable that the inclination angle of the upper surface is greater than the inclination angle of the lower surface. Providing an inclination with a larger angle on the upper surface of the male joint makes it easier to fit other decorative materials into the female joint.

[0035] The angle β° that the lower surface of the male fruit makes with respect to the horizontal plane is preferably within the range of 0°±2°. If the inclination angle on the lower surface of the male fruit is outside this range, the tip may become thin and prone to cracking. Note that 0°±2° means that the inclination angle of the lower surface of the male fruit is between -2° and 2° with respect to the horizontal.

[0036] In addition, the boundary between the upper and lower root portions of the male fruit and the side surface of the base layer may be unclear. When the upper root portion of the male fruit is rounded, and both the upper and lower root portions of the male fruit are rounded, the thickness D of the root portion of these male fruits and the "angle of inclination" described above are determined as follows. In other words, in any case of the male fruit, the intersection point P is found between the line extending the flat portion of the upper surface and the line extending the flat portion of the upper side surface of the base layer, and this intersection point P is defined as the upper root. A perpendicular line is then drawn from this intersection point P toward the lower surface of the male fruit, perpendicular to the horizontal plane, and the intersection point Q is defined as the lower surface of the male fruit or the line extending the flat portion of the lower surface of the male fruit. The distance between P and Q is defined as the thickness D of the root, the angle between the horizontal plane passing through the intersection point P and the flat surface of the upper surface of the male fruit is defined as "α°", and the angle between the horizontal plane passing through the intersection point Q and the flat surface of the lower surface of the male fruit is defined as "β°".

[0037] The raw materials for the above-mentioned base layer are not particularly limited; for example, thermoplastic resins, thermosetting resins, wood materials, metal materials, etc., can be used. Thermoplastic resins and thermosetting resins are less prone to cracking and chipping, but burrs may be generated during cutting, requiring adjustments to the cutting tool and cutting conditions. Wood materials are easy to cut, but depending on the shape (thickness), they are prone to cracking and chipping. Each material has its own characteristics, but the material should be selected as needed.

[0038] The above-mentioned base material layer preferably contains a thermoplastic resin. The thermoplastic resins mentioned above include polyvinyl resins such as polyvinyl chloride resin, polyvinyl acetate resin, and polyvinyl alcohol resin; polyolefin resins such as polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer resin (EVA), and ethylene-(meth)acrylic acid resin; polyester resins such as polyethylene terephthalate resin (PET resin); acrylic resins, polycarbonate resins, polyurethane resins, acrylonitrile-butadiene-styrene copolymer (ABS resin), and acrylonitrile-styrene copolymer, as well as individual thermoplastic resins, copolymers thereof, or mixed resins thereof. Among these, polyolefin resins, acrylonitrile-butadiene-styrene copolymers, and polyvinyl chloride resins are preferred. In particular, polypropylene and ABS resins are most preferred when recesses, protrusions, cuts, grooves, chamfers, etc., are created by cutting with a tenoner, router, cutter, etc.

[0039] Examples of preferred thermosetting resins include epoxy resins, phenolic resins, urea resins, unsaturated polyester resins, melamine resins, alkyd resins, polyimide resins, silicone resins, hydroxyl-functionalized acrylic resins, carboxyl-functionalized acrylic resins, amide-functionalized copolymers, and urethane resins.

[0040] Furthermore, two-component curable resins are also preferred as the thermosetting resin, and specifically, two-component curable resins of polyol and isocyanate are preferred. Here, examples of preferred polyols include acrylic polyols, polyester polyols, and epoxy polyols. Furthermore, the above-mentioned isocyanate may be any polyvalent isocyanate having two or more isocyanate groups in its molecule. For example, aromatic isocyanates such as 2,4-tolylene diisocyanate (TDI), xylene diisocyanate (XDI), naphthalene diisocyanate, and 4,4'-diphenylmethane diisocyanate, and aliphatic (or alicyclic) isocyanates such as 1,6-hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), methylene diisocyanate (MDI), hydrogenated tolylene diisocyanate, and hydrogenated diphenylmethane diisocyanate can be used. Alternatively, adducts or polymers of these various isocyanates, such as adducts of tolylene diisocyanate and trimers of tolylene diisocyanate, can also be used.

[0041] Furthermore, the wood-based material may be any of the following: plywood (including LVL), medium-density fiberboard (MDF), high-density fiberboard (HDF), particleboard, veneer, wood, laminated wood, or laminated material obtained by appropriately laminating these materials. Examples of the above-mentioned metal materials include iron, aluminum, and copper.

[0042] In the present invention, it is preferable that the base material layer contains an inorganic compound. By including an inorganic compound, the coefficient of thermal expansion of the base material layer can be reduced, and as a result, the warping resistance and machinability during cutting of the decorative material of the present invention can be further improved. Examples of the inorganic compounds mentioned above include talc, calcium carbonate, silica, and mica. Among these, talc is preferred because it is a filler that can reduce shrinkage without excessively increasing material hardness. The inorganic compound content is preferably 10 parts by mass or more and 70 parts by mass or less per 100 parts by mass of the resin component in the base layer. If it is less than 10 parts by mass, the coefficient of linear expansion of the base layer may not be sufficiently reduced, and if it exceeds 70 parts by mass, the tensile modulus of elasticity of the base layer may be insufficient. A more preferred range for the inorganic compound content is 10 to 65 parts by mass.

[0043] Furthermore, the above-mentioned base material layer may consist of one layer or a laminate consisting of two or more layers. Preferably, it is a laminate consisting of two or more layers, with at least one layer containing a glass component. That is, it is preferable that the base material layer is a laminate consisting of two or more layers, with at least one layer being a thermoplastic resin layer and the other layer being a glass component layer containing a glass component. Such a configuration provides excellent impact resistance and improved shape stability. The glass component layer containing glass components is preferably, for example, a layer composed of glass fibers.

[0044] In the present invention, the base layer is preferably a laminate in which a thermoplastic resin layer and a glass component layer are alternately laminated, and in particular, a laminate having a first thermoplastic resin layer, a glass component layer, and a second thermoplastic resin layer in that order. When the base layer has multiple thermoplastic resin layers, the types of resins forming the multiple thermoplastic resin layers may be the same or different, and the thicknesses of the multiple thermoplastic resin layers may be the same or different.

[0045] In the present invention, the back surface of the above-mentioned substrate layer has a moisture permeability of 7 g / m². 2 It is preferable that the back sheet has the following characteristics. The moisture permeability of the backing sheet mentioned above is 7g / m². 2 If the moisture permeability exceeds this level, the amount of moisture that penetrates into the substrate layer will increase, which can cause warping or poor adhesion. The above moisture permeability is 5 g / m 2 It is more preferable that the timeframe be 24 hours or less. As the backing sheet mentioned above, for example, a synthetic resin base layer such as an olefin-based thermoplastic resin or an ester-based thermoplastic resin can be used alone; a synthetic resin base layer with a surface coating layer such as polyvinyl alcohol or polyvinylidene chloride can be used; a synthetic resin base layer with a vapor-deposited layer can be used; a synthetic resin base layer with a vapor-deposited layer and further with a surface coating layer such as polyvinyl alcohol or polyvinylidene chloride can be used; and so on.

[0046] Examples of synthetic resin substrate layers include olefin-based thermoplastic resins such as polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl alcohol copolymer, and mixtures thereof; ester-based thermoplastic resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyethylene naphthalate-isophthalate copolymer, polycarbonate, and polyarylate; acrylic-based thermoplastic resins such as polymethyl methacrylate, polyethyl methacrylate, and polybutyl acrylate; and non-halogenated thermoplastic resins such as polyimide, polyurethane, polystyrene, and acrylonitrile-butadiene-styrene resin.

[0047] The synthetic resin substrate layer may be a sheet stretched uniaxially or biaxially, or it may be unstretched. However, since it is the substrate on which the vapor-deposited layer described later will be formed, a sheet stretched biaxially is preferred for reasons such as high mechanical strength and excellent dimensional stability. The thickness of the synthetic resin substrate layer is preferably 9 μm to 60 μm.

[0048] Examples of surface coating layers include polyvinyl alcohol-based resins (PVA), urethane-based resins, and polyvinylidene chloride resins. A surface coating layer can be obtained by applying these to a synthetic resin substrate layer using well-known coating methods such as roll coating or gravure coating. The thickness is preferably 0.1 μm or more and 10 μm or less.

[0049] Examples of vapor-deposited layers include inorganic vapor-deposited layers consisting of thin metal films such as aluminum, and inorganic oxide vapor-deposited layers consisting of thin inorganic oxide films such as silicon oxide, magnesium oxide, and aluminum oxide. The vapor-deposited layer can be formed on a synthetic resin substrate layer using well-known vapor deposition methods such as vacuum deposition or plasma-activated chemical reaction deposition.

[0050] To further improve the gas barrier properties of the vapor-deposited layer, the above-described surface coating layer may be provided on the vapor-deposited layer. The surface coating layer also functions as a protective layer for the vapor-deposited layer, and its thickness is preferably between 0.1 μm and 10 μm.

[0051] Furthermore, the moisture permeability of the backing sheet can be adjusted by the materials and thicknesses of the synthetic resin base layer, surface coating layer, and vapor-deposited layer. Note that the moisture permeability was measured in accordance with JIS Z0208 (Moisture Permeability Test Method (Cup Method)) under conditions of 40°C and 90% RH.

[0052] (Support layer) The decorative material of the present invention may have a support layer formed on the back side of the base layer. The above-mentioned support layer not only serves as a floor base but also functions as a layer that provides insulation and reduces weight depending on the material specifications. The material that constitutes such a support layer is not particularly limited, and for example, thermoplastic resins, thermosetting resins, wood materials, metal materials, etc., similar to those used in the base layer described above can be used. Such a support layer can be selected as appropriate depending on the application, but it is preferable that it be 15 mm or less in thickness. The above-mentioned support layer may consist of a single layer, or it may be a laminate composed of two or more layers.

[0053] (Decorative layer) The decorative material of the present invention preferably has a decorative layer on the upper side of the base material layer described above. The decorative layer described above is a layer that imparts decorative properties to the decorative material of the present invention and may be formed by directly printing various pattern inks onto the base layer, or by creating patterns using a transfer method or the like. Alternatively, thin slices of wood veneer or sawn board may be laminated. Furthermore, a coating layer may be provided to protect the surface of these patterns, or the coating layer may be applied directly to the base layer. In particular, it is more preferable that the decorative layer is a decorative sheet and that the decorative sheet is present on the surface of the base layer. The decorative sheet is not particularly limited, but a preferred embodiment is one in which a base sheet has at least a pattern layer, an adhesive layer, a transparent resin layer, and a transparent protective layer, with the transparent protective layer being the outermost layer. Furthermore, the outermost layer of the decorative sheet may be given a textured pattern by embossing.

[0054] Examples of the decorative sheet described above include a configuration in which a pattern layer (pattern layer), an adhesive layer, a transparent resin layer, and a transparent surface protection layer are sequentially laminated on one side of a base sheet, and a backer layer is laminated on the other side of the base sheet via a back primer layer. ≪Base Sheet≫ The above-mentioned base sheet has layers of patterns and designs sequentially laminated onto its surface (front side). The above-mentioned base sheet is preferably made of a thermoplastic resin, for example. Specifically, examples include polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, acrylic acid ester, methacrylic acid ester, etc. Among the above, polyolefins such as polypropylene are preferred.

[0055] The above-mentioned base sheet may be colored. In this case, the thermoplastic resin described above can be colored by adding a coloring agent (pigment or dye). As coloring agents, for example, inorganic pigments such as titanium dioxide, carbon black, and iron oxide, organic pigments such as phthalocyanine blue, and various dyes can be used. One or more of these can be selected from publicly known or commercially available products. The amount of coloring agent added can also be set appropriately according to the desired color, etc.

[0056] The above-mentioned base sheet may contain various additives as needed, such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, UV absorbers, and light stabilizers.

[0057] The thickness of the above-mentioned base sheet can be set as appropriate depending on the application and method of use of the final product, but generally, a thickness of 30 μm to 250 μm is preferred.

[0058] The above-mentioned base sheet may, if necessary, be subjected to corona discharge treatment on its surface (front side) to improve the adhesion of the ink forming the pattern layer. The method and conditions for corona discharge treatment should be carried out according to known methods. In addition, if necessary, corona discharge treatment may be applied to the back side of the base sheet, or a backing layer such as a primer layer or backer layer may be formed on the back side.

[0059] ≪Pattern Layer (Pattern Layer)≫ The above pattern layer applies a desired pattern (design) to the decorative sheet, and the types of patterns are not limited. Examples include wood grain patterns, stone patterns, sand patterns, tile patterns, brick patterns, fabric patterns, leather patterns, geometric figures, letters, symbols, abstract patterns, etc.

[0060] The method for forming the above-mentioned pattern layer is not particularly limited. For example, it may be formed on the surface of the substrate sheet by a printing method using an ink obtained by dissolving (or dispersing) a known coloring agent (dye or pigment) together with a binder resin in a solvent (or dispersion medium).

[0061] Examples of the above-mentioned colorants include inorganic pigments such as carbon black, titanium white, zinc oxide, iron oxide, Prussian blue, and cadmium red; organic pigments such as azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments; metallic powder pigments such as aluminum powder and bronze powder; pearlescent pigments such as titanium dioxide-coated mica and bismuth oxide; fluorescent pigments; and luminescent pigments. These colorants can be used individually or in combination of two or more. These colorants may also be further formulated with fillers such as silica, extender pigments such as organic beads, neutralizing agents, surfactants, etc.

[0062] In addition to polyester-based urethane resins and hydrophilically treated polyester-based urethane resins, other binder resins that can be used include polyester, polyacrylate, polyvinyl acetate, polybutadiene, polyvinyl chloride, chlorinated polypropylene, polyethylene, polystyrene, polystyrene-acrylate copolymer, rosin derivatives, alcohol adducts of styrene-maleic anhydride copolymer, and cellulose-based resins.

[0063] More specifically, for example, polyurethane-polyacrylic resins, polyacrylamide resins, poly(meth)acrylic acid resins, polyethylene oxide resins, poly-N-vinylpyrrolidone resins, water-soluble polyester resins, water-soluble polyamide resins, water-soluble amino resins, water-soluble phenolic resins, and other water-soluble synthetic resins; water-soluble natural polymers such as polynucleotides, polypeptides, and polysaccharides; etc. can also be used. In addition, for example, natural rubber, synthetic rubber, polyvinyl acetate resins, (meth)acrylic resins, polyvinyl chloride resins, polyurethane-polyacrylic resin modified or mixed resins, and other resins can also be used. The above-mentioned binder resins can be used individually or in combination of two or more types.

[0064] Printing methods used to form the above-mentioned pattern layer include, for example, gravure printing, offset printing, screen printing, flexographic printing, electrostatic printing, and inkjet printing. Furthermore, when forming a solid-color pattern layer (also called a colored opaque layer), various coating methods such as gravure coating, gravure reverse coating, roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating can also be used.

[0065] In addition to the above, other methods such as hand-drawing, suminagashi (marbling), photography, transfer, laser beam drawing, electron beam drawing, partial deposition of metals, etching, etc. may be used, or they may be used in combination with other formation methods.

[0066] The thickness of the pattern layer is not particularly limited and can be set appropriately according to the product characteristics, but the layer thickness is approximately 0.1 μm to 10 μm.

[0067] ≪Adhesive layer≫ The adhesive layer described above can be appropriately provided between the pattern layer and the transparent resin layer. The adhesive used in the adhesive layer can be appropriately selected according to the components that make up the pattern layer or the transparent resin layer. For example, various adhesives containing polyurethane resin, polyacrylic resin, polycarbonate resin, epoxy resin, etc. can be used. In addition to reaction-curing type adhesives, hot-melt type, ionizing radiation-curing type, ultraviolet-curing type adhesives, etc., may also be used.

[0068] The adhesive layer described above may be transparent or semi-transparent, as long as the pattern layer is still recognizable. Furthermore, in this invention, known easy-adhesion treatments such as corona discharge treatment, plasma treatment, degreasing treatment, and surface roughening treatment can be applied to the bonding surface as needed.

[0069] The adhesive layer described above can be formed, for example, by applying the adhesive onto the pattern layer, allowing it to dry, and then laminating a transparent resin. The method of applying the adhesive is not particularly limited, and methods such as roll coating, curtain flow coating, wire bar coating, reverse coating, gravure coating, gravure reverse coating, air knife coating, kiss coating, blade coating, smooth coating, and comma coating can be used.

[0070] The thickness of the adhesive layer mentioned above varies depending on the transparent protective layer, the type of adhesive used, etc., but generally, a thickness of 0.1 μm to 30 μm is sufficient.

[0071] ≪Transparent resin layer≫ The transparent resin layer described above may be colored as long as it remains transparent, and may be semi-transparent as long as the pattern layer is visible.

[0072] Examples of the above resins include polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, polymethylpentene, acrylic acid ester, methacrylic acid ester, polycarbonate, and cellulose triacetate. Among these, polyolefin resins such as polypropylene are preferred. More preferably, polyolefin resins having stereoregularity are used. When using polyolefin resins, it is desirable to form a transparent resin layer by extrusion of the molten polyolefin resin.

[0073] The transparent resin layer may contain various additives as needed, such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, UV absorbers, light stabilizers, radical scavengers, and softening components (e.g., rubber).

[0074] The thickness of the transparent resin layer is not particularly limited, but generally it should be between 10 μm and 400 μm.

[0075] <Primer layer> A primer layer may be provided on the transparent resin layer described above. The primer layer can be formed by applying a known primer to the surface of the transparent resin layer. Examples of primers include urethane resin primers made of acrylic-modified urethane resin (acrylic urethane resin), primers made of urethane-cellulose resin (for example, a resin made by adding hexamethylene diisocyanate to a mixture of urethane and nitrate), and resin primers made of a block copolymer of acrylic and urethane. Additives may be added to the primer as needed. Examples of additives include fillers such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, ultraviolet absorbers, and light stabilizers. The amount of additives can be appropriately set according to the product characteristics.

[0076] The amount of primer applied is not particularly limited, but is usually between 0.1 μm and 100 μm.

[0077] ≪Transparent surface protective layer≫ A transparent surface protection layer is formed on top of the transparent resin layer described above. The transparent surface protection layer is not limited, but it is preferable that it contains an ionizing radiation-curable resin or a two-component curable urethane resin as a resin component. Substantially, it is preferable that it is formed from these resins. When the transparent surface protection layer is formed with an ionizing radiation-curable resin or a two-component curable urethane resin, it is easy to improve the abrasion resistance, impact resistance, stain resistance, scratch resistance, weather resistance, etc. of the decorative sheet 3. In the present invention, among these, it is preferable that the outermost layer is an ionizing radiation-curable resin layer.

[0078] The above-mentioned ionizing radiation-curable resin is not particularly limited, and transparent resins mainly composed of prepolymers (including oligomers) and / or monomers containing radically polymerizable double bonds in the molecule that can undergo polymerization and crosslinking reactions by irradiation with ionizing radiation such as ultraviolet rays and electron beams can be used. These prepolymers or monomers can be used individually or in combination. The curing reaction is usually a crosslinking curing reaction.

[0079] Specifically, the prepolymer or monomer may be a compound having radically polymerizable unsaturated groups such as (meth)acryloyl groups or (meth)acryloyloxy groups, or cationically polymerizable functional groups such as epoxy groups in its molecule. Polyene / thiol-based prepolymers formed by a combination of polyene and polythiol are also preferred. Here, (meth)acryloyl group means acryloyl group or methacryloyl group.

[0080] Examples of prepolymers having the above-mentioned radically polymerizable unsaturated groups include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, and silicone (meth)acrylate. The molecular weight of these is usually preferably between 250 and 100,000.

[0081] Examples of monomers having the above-mentioned radically polymerizable unsaturated group include monofunctional monomers such as methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, and phenoxyethyl (meth)acrylate. Examples of polyfunctional monomers include diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0082] Examples of prepolymers having the cationic polymerizable functional group mentioned above include epoxy resins such as bisphenol-type epoxy resins and novolac-type epoxy compounds, and vinyl ether resins such as fatty acid-based vinyl ethers and aromatic vinyl ethers. Examples of thiols include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate. Examples of polyenes include polyurethanes with allyl alcohol added to both ends, such as diols and diisocyanates.

[0083] The ionizing radiation used to cure the above-mentioned ionizing radiation-curable resin is electromagnetic waves or charged particles having energy sufficient to cause a curing reaction of molecules in the ionizing radiation-curable resin (composition). While ultraviolet light or electron beams are usually used, visible light, X-rays, ion beams, etc., may also be used.

[0084] As for the ultraviolet light sources mentioned above, light sources such as ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black lights, and metal halide lamps can be used. The wavelength of the ultraviolet light is usually preferably between 190 nm and 380 nm.

[0085] As electron sources, various types of electron beam accelerators can be used, such as Cockcroft-Walton type, Van de Graft type, resonant transformer type, insulated core transformer type, or linear type, dynamitron type, and high-frequency type. Among these, those capable of irradiating electrons with energies of 100 keV to 1000 keV, preferably 100 keV to 300 keV, are particularly preferred.

[0086] The above-mentioned two-component curing urethane resin is not particularly limited, but in particular, those containing a polyol component having an OH group as the main component (acrylic polyol, polyester polyol, polyether polyol, epoxy polyol, etc.) and an isocyanate component as a curing agent (toluylene diisocyanate, hexamethylene diisocyanate, metaxylene diisocyanate, etc.) can be used.

[0087] The transparent surface protective layer described above may, if necessary, contain plasticizers, stabilizers, fillers, dispersants, dyes, pigments, and other colorants.

[0088] The transparent surface protective layer described above can be formed, for example, by applying an ionizing radiation-curable resin or a two-component curable urethane resin onto a transparent polypropylene resin layer using a known coating method such as gravure coating or roll coating, and then curing the resin. In the case of an ionizing radiation-curable resin, the resin is cured by ultraviolet irradiation or electron beam irradiation.

[0089] The thickness of the transparent surface protective layer described above is not particularly limited and can be set appropriately according to the characteristics of the final product, but is usually between 0.1 μm and 50.0 μm, preferably between 1 μm and 20 μm.

[0090] <<Primer layer on the back side>> A primer layer may be provided on the back surface of the base sheet (the surface opposite to the surface on which the pattern layer is laminated) as needed to further enhance adhesion to the adherend.

[0091] The above-mentioned backside primer layer can be formed by applying a known primer to a substrate sheet. Examples of primers include urethane resin primers made of acrylic-modified urethane resin (acrylic urethane resin), primers made of urethane-cellulose resin (for example, a resin made by adding hexamethylene diisocyanate to a mixture of urethane and nitrate), and resin primers made of acrylic and urethane block copolymers. Additives may be added to the primer as needed. Examples of additives include fillers such as calcium carbonate and clay, flame retardants such as magnesium hydroxide, antioxidants, lubricants, foaming agents, UV absorbers, and light stabilizers. The amount of additives can be appropriately set according to the product characteristics.

[0092] The thickness of the primer layer on the back surface is not particularly limited, but is usually between 0.01 μm and 20.00 μm.

[0093] Embossing The above decorative sheet intermediate may be embossed from the side of the transparent surface protective layer.

[0094] The above embossing process is performed to impart a desired texture, such as a wood grain pattern, to a decorative sheet. For example, after heating and softening a transparent protective layer, the texture is imparted by applying pressure and molding with an embossing plate having the desired shape of raised and recessed pattern, and then cooling and fixing it. Embossing can be performed using a known sheet-fed or rotary embossing machine.

[0095] Examples of embossed patterns include wood grain grooves, raised grain patterns (raised annual rings), hairline finishes, sandblasted textures, and pear-skin finishes.

[0096] When the above embossing is applied, ink may be filled into the embossed recesses by wiping, if necessary. For example, ink can be filled into the embossed recesses by scraping the surface with a doctor blade. Typically, a two-component curing type urethane resin binder ink can be used as the filling ink (wiping ink). In particular, by performing a wiping process on the wood grain grooves and irregularities, it is possible to express a design that is closer to the actual wood grain, thereby increasing the value of the product.

[0097] In the present invention described above, other components may be included in the transparent surface protective layer. For example, additives such as solvents, UV absorbers, antioxidants, dispersants, light stabilizers, gloss adjusters, anti-blocking agents, and lubricants can be incorporated.

[0098] ≪Backers≫ The above-mentioned decorative sheet may have a so-called backer layer (synthetic resin layer) on the back side of the base sheet. The backer layer is a relatively thick synthetic resin layer that can be optionally provided as part of the decorative sheet and gives the decorative sheet cushioning properties.

[0099] The above synthetic resin layer preferably contains a polyolefin resin as a resin component.

[0100] Examples of the polyolefin resins mentioned above include polyethylene (high-density polyethylene, medium-density polyethylene, low-density polyethylene), polypropylene, etc. These can be used individually or in combination of two or more. Among these, polypropylene is particularly preferred. Examples of polypropylene include homopolypropylene, random polypropylene, and block polypropylene. Among these, homopolypropylene is particularly desirable.

[0101] In addition, resin components other than the polyolefin resins mentioned above may be used as the resin component of the synthetic resin layer. Examples include vinyl chloride resin, polystyrene, polyamide resin, polyimide resin, polyamide-imide resin, fluororesin, urethane resin, polysulfone, polycarbonate, polyacetal, polyphenylene ether, methacrylic resin, acrylonitrile styrene resin, acrylonitrile butadiene styrene resin, polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyarylate, amorphous polyethylene terephthalate (so-called A-PET) [Mitsubishi Chemical Corporation: Novaclear (trade name)], polyethylene terephthalate copolymer (PETG), etc. Among these, A-PET is particularly preferred. It is preferable to use A-PET together with PEN for the purpose of imparting heat resistance.

[0102] The content of the polyolefin resin in the synthetic resin layer is preferably 90% by weight or more and 100% by weight or less, and more preferably 95% by weight or more and 100% by weight or less.

[0103] The above-mentioned synthetic resin layer may be formed by laminating a resin composition containing the above-mentioned resin components onto a substrate sheet using, for example, a calendering method, an inflation method, or a T-die extrusion method. Alternatively, a pre-existing film may be used as the synthetic resin layer.

[0104] The thickness of the synthetic resin layer is not particularly limited, but is usually between 50 μm and 210 μm, preferably between 100 μm and 200 μm.

[0105] The decorative material of the present invention, having each of the above layers, is suitable for window sills such as bay windows in residences, flooring, especially for use in wet areas such as toilets, washrooms, and kitchens, as well as for wall panels and ceiling materials. Furthermore, when used as flooring, it is preferable to use the same thickness as the wood flooring materials installed in areas other than wet areas, such as living rooms and hallways.

[0106] [Method of manufacturing cosmetic materials] The cosmetic material of the present invention can be manufactured, for example, through the following steps.

[0107] A decorative layer is formed by directly applying various ink compositions to the above-mentioned substrate layer. The above ink composition may be applied by methods such as gravure printing, offset printing, screen printing, flexographic printing, or inkjet printing. Furthermore, when forming an opacity layer (solid print layer), it may be formed by various coating methods such as gravure coating, bar coating, roll coating, reverse roll coating, or comma coating. Furthermore, the decorative layer may be provided on the base layer by a transfer method or the like. Alternatively, thin slices of wood veneer or sawn board may be laminated with adhesive. In this case, the adhesive can be a two-component curing resin such as urethane or vinyl acetate, or a PUR-type moisture-curing resin, and the adhesive can be applied in the same manner as in the method of forming the decorative layer using the ink composition to form the adhesive layer. Furthermore, a coating layer may be applied to protect the directly applied patterns or the surface of the veneer or sawn board, or the coating layer may be applied directly to the base layer. Then, the decorative sheet is applied to the surface of the base layer either via an adhesive or directly. The adhesive is the same as that used to attach the veneer or sawn board as described above, and direct application includes methods such as heat lamination, where heat is applied to create layers.

[0108] (Bonding process between support layer and substrate layer) The support layer and the substrate layer on which the decorative layer is formed can be bonded using, for example, a heat-sensitive adhesive, a pressure-sensitive adhesive, or a hot-melt adhesive. As a hot-melt adhesive, a reactive hot-melt adhesive such as urethane-based reactive hot-melt (hereinafter referred to as "PUR") is preferred. This PUR contains a functional group (isocyanate group) that reacts with moisture in its components, and after cooling and curing, it reacts with moisture adhering to the substrate or decorative sheet, or moisture supplied through them. After the reaction, it does not melt even when heated and has the characteristic of possessing high adhesive strength.

[0109] After the step of forming a support layer over the entire surface of one side of the base layer in this manner, for example, a male part is formed on at least one side of the base layer on which the support layer is formed, and a female part into which the male part can be fitted is formed on at least one other side of the base layer. The method for providing the male and female parts is not particularly limited and includes conventionally known methods. In the process of forming the male and female parts, it is preferable to cut the base material layer so that it has the predetermined shape of the male and female parts as described above. Such decorative material of the present invention can be manufactured by a method comprising the steps of forming a support layer on the entire surface of one side of a base layer, forming a male fruit portion and a female fruit portion, and cutting the support layer below the male fruit portion and the female fruit portion, respectively.

[0110] In the present invention, since the decorative material has predetermined male and female parts formed in the base layer, when it is used to form a floor or the like, the joints between one decorative material and other decorative materials become shallower, making it less likely for dirt to accumulate and easier to clean. Such decorative materials of the present invention are suitably used, for example, as flooring materials for residences, window sills in bay windows, walls, ceilings, and the like. [Examples]

[0111] Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited in any way by these examples.

[0112] (Evaluation and measurement methods) The decorative materials obtained in each example and comparative example were evaluated and measured using the following methods.

[0113] (Construction quality) The female tongue-and-groove portion of one decorative material was fitted into the male tongue-and-groove portion of another decorative material, and the aesthetic evaluation of steps, gaps, adhesive overflow, scratches, and stains upon completion of the work was performed according to the following criteria. 3. The aforementioned aesthetic problems are absent, the gaps in the mating parts are uniform and neat, and the step difference is within 0.1 mm. 2: There are no aesthetic problems as mentioned above, the step is within 0.3 mm, and there is no noticeable gap due to the fitting. 1: There is something odd about the gaps or uneven surfaces.

[0114] (Gap in the fitting part during heating (drying)) After 1100 hours of running 80°C hot water under the existing floor, the gap in the fitting section was observed and the size of the gap was measured. Up to 3:0.5mm is fine. 2: Although it exceeds 0.5mm, there is no noticeable difference in appearance. There is a gap of more than 1:1.0 mm, which feels uncomfortable.

[0115] (Securing to the base) Evaluation regarding floating, displacement, etc. The construction time was evaluated relative to the method of Comparative Example 2 according to the following criteria. 3: Shorter construction time 2: Construction time remains unchanged 1: Construction time is longer <Substrate preparation> 3: Can be applied regardless of small unevenness of about 1 mm in the substrate, dust, or small foreign objects. 2: Steps must be kept to less than 1 mm, and foreign objects must be removed. 1: If dust remains, it will affect the quality of the work.

[0116] • Decorative sheet (Base sheet, primer layer on the back) Corona discharge treatment was applied to both sides of a substrate sheet made of 60 μm thick colored polypropylene film. A urethane cellulose resin (a mixture of urethane and nitrated cotton with 5 parts by weight of hexamethylene isocyanate added to 100 parts by weight) was applied to one side by gravure coating to form a primer layer on the back. The thickness of the primer layer on the back was 1 μm.

[0117] (Pattern layer) Next, a solid ink layer and a patterned ink layer were sequentially formed on the front surface of the base sheet using gravure printing with a printing ink containing an acrylic urethane resin (100 parts by weight of acrylic polyol with 5 parts by weight of hexamethylene diisocyanate added) as a binder, thereby forming a wood grain pattern layer. The pattern layer was 3 μm thick. (Transparent adhesive layer) Furthermore, a transparent adhesive layer (3 μm thick) was formed on the patterned layer using a urethane-based adhesive. (Transparent resin layer) Next, a transparent resin layer (80 μm thick) was formed on the transparent adhesive layer by heating, melting, and extruding a polypropylene-based resin using a T-die extruder. (Primer layer for surface protection) The transparent resin layer described above was subjected to corona discharge treatment, and an acrylic urethane resin (100 parts by weight of acrylic polyol with 5 parts by weight of hexamethylene diisocyanate added) was applied to the treated surface by gravure coating to form a primer layer for surface protection. The thickness of the primer layer for surface protection was 1 μm. (Surface protective layer) A urethane acrylate-based electron beam-curable resin was applied to a primer layer for the surface protection layer using a roll-coating method. After drying, the uncured electron beam-curable resin layer was cured by irradiating it with an electron beam (acceleration voltage 175 keV, irradiation dose 5 mrad) in an environment with an oxygen concentration of 2000 ppm or less, forming a surface protection layer made of electron beam-curable resin. The thickness of the surface protection layer was 15 μm. (Embossed) Next, an embossed pattern A resembling wood grain pores was formed by embossing the surface protective layer side with a wood-grain-like embossed plate. (Thickness of decorative sheet) The thickness of the decorative sheet was 0.163 mm. (Backside sheet) A 13μm thick backing sheet (purchased item) was prepared. According to JIS Z0208 (Test method for moisture permeability of moisture-proof packaging materials - cup method), the moisture permeability at 40℃ and 90%RH is 1.0 g / m². 2 It was 24 hours.

[0118] (Example 1) ·Base material I prepared an MDF board (purchased) that was 1837mm long, 947mm wide, and 8.8mm thick. • Decorative laminate The corona discharge treated surface of the backing sheet and the base material were bonded together using a urethane-modified ethylene-vinyl acetate emulsion adhesive (5g / shaku 2wet). Subsequently, a base material was laminated to the back of the decorative sheet for flooring that had been manufactured to create a decorative floor panel. A urethane-modified ethylene-vinyl acetate emulsion adhesive (8g / 2 ft wet) was used for bonding. The laminated decorative panels are pressed using a press machine at a rate of 2 kgf / cm². 2 After being pressed under pressure for 30 minutes, they were stacked and cured overnight (approximately 18 hours). Subsequently, the tongue-and-groove structure shown in Figure 7 was formed on the side surface of the base material at the end of the rectangular board cut using a circular saw, using a tenoner. After the adhesive had cured, a single sheet measuring 900mm in length, 150mm in width, and 9.1mm in thickness was taken, and then cut to produce a total of 12 decorative panels. • Decorative materials Using adhesive (Sekisui Fuller Co., Ltd.'s modified silicone adhesive for floors 55SL), the adhesive was applied with a gap of approximately 2 mm from the long edge of the decorative panel, and two pieces were installed, one at each end in the long direction. The decorative flooring material was 900 mm long, 150 mm wide, and 9.1 mm thick, and flooring material was created with two pieces of adhesive, 900 mm long and 20 mm wide, attached to the ends in the width direction. Regarding the stated thickness, the total thickness was approximately 9.1 mm, consisting of a decorative sheet (0.163 mm), a wood-based base material (8.8 mm), a backing sheet (0.013 mm), and an adhesive (0.130 mm). ·Construction The installation process involved aligning the planks with the reference lines drawn on the subfloor material, and then applying adhesive and staples to a single row along the length of the planks, following the standard tongue-and-groove installation method. Subsequently, additional planks were applied parallel to the first row using only adhesive. The installation area was expanded to ensure a consistent gap between the planks.

[0119] (Example 2) ·Base material A commercially available MDF board with a length of 1837 mm, a width of 947 mm, and a thickness of 2.7 mm was prepared. · Decorative board The corona discharge treated surface of the back sheet and the base material were bonded together using a urethane-modified ethylene-vinyl acetate emulsion adhesive (5 g / shi² wet). Thereafter, the base material was bonded to the back surface of the produced decorative sheet for flooring material to produce a decorative board for floor use. A urethane-modified ethylene-vinyl acetate emulsion adhesive (8 g / shi² wet) was used for the bonding. The bonded decorative board was pressed using a press machine at 2 kgf / cm 2 for 30 minutes, and then stacked and cured overnight (for about 18 hours). Thereafter, using a tenoner, a tongue-and-groove joint as shown in Figure 1 was formed on the side surface of the base material at the end of the rectangular board cut using a circular saw. After the adhesive was cured, the board was cut into pieces each having a length of 900 mm, a width of 150 mm, and a thickness of 3.0 mm, and a total of 12 decorative board pieces were obtained. · Decorative material An adhesive (modified silicone adhesive 55SL for floors, manufactured by Sekisui Fuller Co., Ltd.) was applied with a gap of about 2 mm from the longitudinal end of the decorative board, with one adhesive bead at each of the two ends in the longitudinal direction, for a total of two beads. A flooring material having a length of 900 mm, a width of 150 mm, and a thickness of 3.1 mm, and provided with two adhesive strips each having a length of 900 mm and a width of 20 mm at the ends in the width direction, was produced as the decorative material for floor use. Regarding the stated thicknesses, the total thickness was approximately 3.0 mm, consisting of 0.163 mm for the decorative sheet / 2.7 mm for the woody base material / 0.013 mm for the moisture-proof film / 0.130 mm for the adhesive layer. · Construction The release paper affixed on the adhesive of the flooring material provided with two adhesive beads on its back surface was peeled off, and the flooring materials were press-bonded and installed in a single row in the longitudinal direction in alignment with the reference line drawn on the underlayer material. Thereafter, additional flooring materials were laid parallel to the first row. The construction area was expanded while keeping the gap at the fitting portion constant.

[0120] (Example 3) Instead of the adhesive, an acrylic resin-based pressure-sensitive adhesive was applied at 50 g / m 2 (dry) and then dried (adhesive strength: 0.3 N / mm 2Except for using ), the flooring material was prepared in the same manner as in Example 2, and then installed.

[0121] (Example 4) The phase bond shown in Figure 4 is formed on the substrate, and instead of adhesive, an adhesive tape (acrylic resin double-sided adhesive tape (0.25 mm thick, adhesive strength 0.3 N / mm) is used) is applied. 2 Except for using ), the flooring material was prepared in the same manner as in Example 2, and then installed.

[0122] (Comparative Example 1) The structure of the female and male fruits was a conventionally known true fruit in which the male and female locking parts were not formed as shown in Figure 7. The flooring material was prepared and installed in the same manner as in Example 1, except that it was attached to the support layer with adhesive and a tacker.

[0123] (Comparative Example 2) The structure of the female and male fruits was a conventionally known phase-locking type in which the male and female locking parts are not formed as shown in Figure 1. The flooring material was prepared and installed in the same manner as in Example 1, except that it was attached to the support layer with adhesive.

[0124] (Comparative Example 3) Except for using adhesive tape instead of glue, the flooring material was prepared and installed in the same manner as in Comparative Example 2.

[0125] (Comparative Example 4) Except for replacing the female and male fruits with mechanical locking means (Uniclick® manufactured by Unilin Corporation) and not using adhesive, the flooring material was manufactured and installed in the same manner as in Example 1.

[0126] [Table 1]

[0127] The decorative material used in the example exhibited excellent workability, with a fitting gap of 0.5 mm or less, and demonstrated superior workability, stability in fixing to the support layer, and work time. On the other hand, none of the decorative materials used in the comparative examples were superior in terms of construction quality, spacing of interlocking gaps, construction quality, fixing stability with the support layer, or construction time. [Industrial applicability]

[0128] According to the present invention, when a female tongue-and-groove on one decorative material is fitted together with a male tongue-and-groove on another decorative material, the structure is designed to move slightly horizontally and catch, and an appropriate amount of play (gap in the fitting) is provided in the fitting, making installation easy and preventing poor fitting and poor workmanship. In addition, since wood materials change dimensions due to moisture absorption and release, the present invention provides a decorative material that has the function of physically resisting such movement. The decorative material of the present invention is suitably used as flooring for residences, window frames in bay windows, walls, ceilings, etc. [Explanation of symbols]

[0129] 10, 20, 30, 40, 50, 70 Yumi 11, 21, 31, 41, 51 Maxillary region 12, 22, 32, 42, 52a, 52b, 72, 102, 202, 302, 402, 702 depressions 13, 22, 33, 43, 53a, 53b, 73, 103, 303, 403, 503a, 503b, 703 Protrusion 71 Convex part 100, 200, 300, 400, 500, 600, 700 female fruits 101, 201, 301, 401, 501 Mandible 603a Screw 613a pin 701 Upper convex ridge

Claims

1. A decorative material comprising a base layer having sides on which female and / or male fruits are formed, The female fruit has a female-side locking portion, and the male fruit has a male-side locking portion. The female locking portion and the male locking portion have a structure in which they interlock and lock with each other when a decorative material having at least the female joint and another decorative material having at least the male joint are fitted together. The female locking portion and the male locking portion have a gap between them in a direction parallel to the upper or lower surface of the base material layer when they are interlocked. A decorative material characterized by the following features.

2. The decorative material according to claim 1, wherein the female locking portion and the male locking portion have a gap of 0.5 mm ± 0.2 mm in a direction parallel to the upper or lower surface of the base material layer when they are interlocked with each other.

3. The decorative material according to claim 1 or 2, wherein the total thickness is 2 mm or more and 4.5 mm or less.

4. The decorative material according to claim 1 or 2, wherein the female and male fruits are fixed together, the female locking portion is formed on the upper surface of the lower jaw portion of the female fruit, and the male locking portion is formed on the lower surface of the upper jaw portion of the male fruit.

5. The decorative material according to claim 1 or 2, wherein the female and male fruits are actual fruits, the female locking portion is formed on the lower upper surface of the recess of the female fruit, and the male locking portion is formed on the lower surface of the convex portion of the male fruit.

6. The decorative material according to claim 1 or 2, wherein the female locking portion and the male locking portion have one or more interlocking groove and groove shapes.

7. The decorative material according to claim 1 or 2, wherein the length from the tip to the other end of the female fruit and / or the male fruit is 4 mm or more and 15 mm or less.

8. The decorative material according to claim 1 or 2, wherein the thickness of the thinnest part of the female fruit and / or male fruit is 0.5 mm or more.

9. The decorative material according to claim 1 or 2, wherein the base material layer is a wood-based base material.

10. The back surface of the aforementioned substrate layer has a moisture permeability of 7 g / m². ２ The decorative material according to claim 1 or 2, having the following back sheet.

11. The decorative material according to claim 1 or 2, having a decorative sheet on the upper surface of the base material layer and an adhesive layer, adhesive tape, or adhesive layer on the lower surface of the base material layer.

12. A flooring material made using the decorative material described in claim 1 or 2.

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