Flooring and manufacturing method for flooring

Abstract

To provide a floor material capable of adding the function which a surface layer has to a specific function executed by a three-dimensional structure of a cold press formation layer and enhancing an added value of the floor material while accomplishing a high design and a free formability.SOLUTION: A floor material 31A is composed of a surface layer 33A and a cold press formation layer 35A that are laminated, and the cold press formation layer 35A has a floor surface laying part 41 laid on a floor surface and a raised wall part 43 connected to the floor surface laying part 41 so as to project upwardly, and the surface layer 33A has a main surface part 61 anchored to the floor surface laying part 41 and a raised surface part 63 connected to the main surface part 61 and anchored to the raised wall part 43.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a flooring material having a pattern or design on its surface, and a method for manufacturing the flooring material. [Background technology]

[0002] Flooring materials with patterns or textured patterns on the surface have been known for some time (see, for example, Patent Document 1). The flooring material disclosed in Patent Document 1 is composed of a laminate in which multiple layers are stacked and fused together by passing them between a pair of rolls under pressure and heat. This laminate is then passed between an embossing roll and a receiving roll, during which the textured pattern of the embossing roll is transferred to the surface of the laminate.

[0003] In addition to the above-mentioned heat fusion bonding, other known means for integrating multiple layers include, for example, a method of bonding multiple layers together by "cold pressing," in which multiple layers are stacked together with an adhesive interposed therebetween and pressed at room temperature, and a method of bonding them by "hot pressing," in which further heat is applied after cold pressing (see, for example, Patent Documents 2 and 3).

[0004] Regarding cold pressing, a method for producing a resin molded product has been put into practical use, in which a resin material is heated to a plasticization temperature higher than the softening temperature (softening point) of the thermoplastic resin that is its base material to make it plastic, and then the resin material is placed inside a mold consisting of an upper mold and a lower mold, and then pressed while being cooled in the mold to form it into a predetermined shape (see, for example, Patent Document 4). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-20248 [Patent Document 2] International Publication No. 2012 / 053036 [Patent Document 3] Japanese Patent Application Laid-Open No. 2002-18807 [Patent Document 4] Japanese Patent Application Laid-Open No. 2017-177692 Summary of the Invention [Problem to be solved by the invention]

[0006] The flooring material disclosed in Patent Document 1 can be given a certain degree of designability because an embossed pattern can be formed on the surface using an embossing roll. However, the laminate that constitutes the flooring material is formed by passing multiple layers, in a superimposed state, between a pair of rolls and applying pressure and heat. Due to constraints in the manufacturing process, the formed product is limited to a flat sheet-like shape, and it is difficult to form it into a free three-dimensional shape, especially a three-dimensional shape that exceeds the thickness of the sheet.

[0007] Even with the integration method using cold pressing as disclosed in Patent Document 2, the molded product is limited to a flat sheet shape due to constraints in the manufacturing process. In Patent Document 3, a hot pressing process is carried out in addition to the cold pressing process, so that if the surface layer is made of a polyvinyl chloride resin with a pattern or textured pattern, for example, the pattern or textured pattern on the surface will be crushed by thermal deformation and pressure during the pressing process, making it impossible to maintain the design.

[0008] In the cold press molding used in the manufacturing method of resin molded products disclosed in Patent Document 4, a plasticized resin material is filled along the shape of a molding cavity formed by clamping an upper mold and a lower mold in a molding die. Therefore, it is possible to mold into any shape according to the shape of the molding cavity, but it is not good at adding fine decorations such as patterns or textured patterns to the surface.

[0009] The present invention has been made in consideration of the above-mentioned problems, and aims to provide a flooring material that can achieve both high designability and flexible formability, and that can add the functions of the surface layer to the specific functions provided by the three-dimensional structure of the cold-press molded layer, thereby increasing the added value of the flooring material, and a method for manufacturing such a flooring material. [Means for solving the problem]

[0010] The characteristic configuration of the flooring material according to the present invention to solve the above problems is as follows: A flooring material comprising a surface layer and a cold-press molded layer laminated together, The cold-press molded layer has a floor-laying portion laid on a floor surface and a rising wall portion connected to the floor-laying portion so as to protrude upward, The surface layer has a main surface portion fixed to the floor laying portion, and an upright surface portion connected to the main surface portion and fixed to the upright wall portion.

[0011] According to the flooring material of this configuration, the surface layer and the cold-press-molded layer are laminated, allowing for a high level of design to be imparted to the surface side of the surface layer. Examples of such design include three-dimensionally formed uneven patterns and two-dimensionally formed patterns. For example, uneven patterns can be obtained by forming unevenness on the surface using embossing or other methods. The pattern refers to colors or designs, and can be obtained by providing a design layer using a printed film or multicolor chips. The cold-press-molded layer is a layer formed by pressing a base material of the cold-press-molded layer that has been brought to a state above its softening point while being cooled using a mold. The boundary between the surface layer and the cold-press-molded layer is integrated by thermal fusion due to the heat of the base material of the cold-press-molded layer that has been brought to a state above its softening point and the pressure during pressing. In the flooring material of this configuration, the surface side of the surface layer is cooled by the mold, even though it is subjected to pressure during pressing. This prevents thermal deformation on the surface side of the surface layer, thereby preventing the pattern or uneven pattern imparted to the surface side of the surface layer from being crushed, ensuring a high level of design. On the other hand, in the cold-press-molded layer, the base material, which has been cooled above its softening point, can be molded into any shape until it solidifies by cooling. Therefore, it is possible to achieve both high design quality and flexible moldability, which were not possible with conventional flooring materials. Furthermore, according to the flooring material of this configuration, the cold-press-molded layer has a floor-laying portion laid on the floor surface and a rising wall portion connected to the floor-laying portion so as to protrude upward. The surface layer has a main surface portion fixed to the floor-laying portion and a rising surface portion connected to the main surface portion and fixed to the rising wall portion. This allows the surface layer to add functions to the specific functions provided by the three-dimensional structure of the cold-press-molded layer, thereby increasing the added value of the flooring material. Specifically, with the techniques disclosed in Patent Documents 1 to 3, as mentioned above, manufacturing process constraints limit the molded product to a planar, sheet-like shape. Therefore, even if a component corresponding to the surface layer of the flooring material of the present invention can be molded, it is not possible to mold a protrusion with a protrusion length greater than the thickness of the surface layer. In the present invention, the cold-press molded layer can be molded into any shape until the base material, which has been kept at a temperature equal to or higher than its softening point, is solidified by cooling.Therefore, by setting the shape of the molding cavity of the mold, it is possible to form a raised wall portion in the cold-press molded layer, which is a protruding portion with a protruding length greater than the thickness of the surface layer. Therefore, the flooring material of this configuration combines the uneven pattern of the surface layer and the three-dimensional structure of the cold-press molded layer, allowing for the formation of a relatively large three-dimensional structure and a small three-dimensional structure superimposed on each other. This allows for high levels of control over slip resistance and drainage. Furthermore, the curved surface of the uneven pattern and the three-dimensional structure cause diffuse sound reflection, providing soundproofing, sound insulation, and sound absorption effects. Furthermore, when the raised wall portion in the cold-press molded layer functions as a frame, the raised surface portion of the surface layer fixed to the raised wall portion can further enhance the design of the frame, thereby further increasing the added value of the flooring material of the present invention when used, for example, as a flooring material for an entrance hall.

[0012] In the flooring material according to the present invention, the raised surface portion includes two adjacent folded pieces that stand upright relative to the main surface portion to form corners; It is preferable that in the portion of the surface layer where the two folded pieces are adjacent, a notch is made so that the two folded pieces are in an upright state with a portion where the end face of one folded piece contacts the end face of the other folded piece.

[0013] In this flooring material, the surface layer has two adjacent folded pieces, each of which has a notch formed so that the two folded pieces are in an upright position with the end face of one folded piece in contact with the end face of the other folded piece. This prevents the two folded pieces from interfering with each other when a corner is formed by the two upright folded pieces. Furthermore, since the end face of one folded piece is in contact with the end face of the other folded piece, a gap is prevented from forming at the corner formed by the two upright folded pieces, preventing the constituent material of the cold-press-molded layer from being exposed at the corner during the pressing process. Therefore, the two folded pieces can reliably form a beautiful corner.

[0014] In the flooring material according to the present invention, The surface layer and the cold-press molded layer are preferably made of the same type of material.

[0015] In the flooring material of this configuration, the surface layer and the cold-press molded layer are made of the same type of material, so the boundary between the surface layer and the cold-press molded layer can be more firmly integrated by heat fusion.

[0016] In the flooring material according to the present invention, It is preferable that the surface layer and the cold-press molded layer are made of different materials, and that both layers are laminated via a bonding layer.

[0017] With this flooring material, the surface layer and the cold-press-molded layer are made of different materials and are laminated together via a joining layer. Therefore, even if the surface layer and the cold-press-molded layer are made of different materials, the surface layer and the cold-press-molded layer can be firmly integrated together via the joining layer.

[0018] In the flooring material according to the present invention, The surface layer preferably has an uneven pattern.

[0019] According to the flooring material of this configuration, the surface layer has a textured pattern. This enhances the eye-catching effect in terms of design, and also enhances the texture to create a luxurious feel. Meanwhile, in terms of functionality, the unevenness of the textured pattern acts as an anti-slip surface, enhancing slip resistance. Furthermore, the elasticity and partial contact of the curved surfaces of the textured pattern provide a comfortable feel that is not possible with a smooth surface.

[0020] Next, the characteristic configuration of the manufacturing method of the flooring material according to the present invention is as follows: A method for manufacturing a flooring material comprising laminating a surface layer and a cold-press molded layer, The cold-press molded layer has a floor-laying portion laid on a floor surface and a rising wall portion connected to the floor-laying portion so as to protrude upward, the surface layer has a main surface portion fixed to the floor laying portion, and a rising surface portion connected to the main surface portion and fixed to the rising wall portion, a first arrangement step of arranging the surface layer in a mold having a molding cavity formed therein for molding the floor laying portion, the rising wall portion, the main surface portion, and the rising surface portion so that the surface layer can be bent at the boundary between the portion that will become the main surface portion and the portion that will become the rising surface portion; a second disposing step of disposing a thermoplastic resin in a state of not less than its softening point so as to be in contact with the surface layer; a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin; a recovery step of removing the laminated molded body formed in the pressing step from the mold; The purpose is to encompass the above.

[0021] According to this method for manufacturing a flooring material, a surface layer is placed in a mold having molding cavities for forming the floor laying portion, the upright wall portion, and the main surface portion and the upright surface portion so that it can be bent at the boundary between the portion that will become the main surface portion and the portion that will become the upright surface portion, and a thermoplastic resin that is the base material of the cold-press molded layer and has been brought to a state above its softening point is placed in contact with the surface layer. Then, a pressing step is carried out in which the contents of the mold, i.e., the surface layer and the base material of the cold-press molded layer, are pressed at a temperature below the softening point of the thermoplastic resin. As a result, the cold-press-molded layer is molded during the pressing process, spreading to cover the entire surface layer. The press pressure acting on the surface layer through the cold-press-molded layer, which covers the entire surface layer, causes the surface layer to bend at the boundary between the main surface portion and the raised surface portion. The boundary between the cold-press-molded layer and the surface layer is integrated by thermal fusion due to the heat of the base material of the cold-press-molded layer, which has been heated to a temperature above its softening point, and the pressure during pressing. The laminated molded body formed by the pressing process is then removed from the mold and recovered. In this flooring material manufacturing method, the surface side of the surface layer is cooled by the mold, even though it is subjected to pressure during pressing. This minimizes thermal deformation on the surface side of the surface layer, thereby preserving the textured pattern imparted to the surface side of the surface layer and ensuring high designability. Meanwhile, the cold-press-molded layer can be molded into any shape until the base material, which has been heated to a temperature above its softening point, solidifies upon cooling. Therefore, it is possible to achieve both high designability and flexible formability, which was not possible with conventional flooring materials. Furthermore, compared to methods in which the surface layer and the cold-press molded layer are molded separately and then joined together, the manufacturing method of the flooring material of this configuration allows molding in a one-step process, so molding can be done quickly and easily, and even complex structures can be molded accurately, resulting in excellent manufacturing efficiency. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 1 is a cross-sectional view that schematically shows the laminated structure of a flooring material according to a first embodiment of the present invention. [Figure 2] FIG. 2 shows a schematic view of the laminated structure of the surface layer, where (a) is a cross-sectional view of a surface layer with enhanced anti-slip properties, and (b) is a cross-sectional view of a surface layer with enhanced cushioning properties. [Figure 3] FIG. 3 is a cross-sectional view that schematically shows the laminated structure of a flooring material according to a second embodiment of the present invention. [Figure 4] FIG. 4 is a diagram showing a floor material for an entrance hall, which is a specific example (1) of a floor material to which the present invention is applied. [Figure 5] FIG. 5 is a diagram showing the surface layer of a flooring material for an entrance hall as a specific example (1) of the flooring material. [Figure 6] FIG. 6 is a diagram showing another aspect of the surface layer of the entrance hall floor material of the specific example (1) of the floor material. [Figure 7] FIG. 7 is a diagram showing a molding die for molding a floor material for an entrance hall as a specific example (1) of the floor material. [Figure 8] FIG. 8 is a diagram showing the steps of a manufacturing method for forming an entrance hall floor material, which is a specific example (1) of the floor material. [Figure 9] FIG. 9 is a diagram showing a floor material for an entrance hall, which is a specific example (2) of a floor material to which the present invention is applied. [Figure 10] FIG. 10 is a diagram showing the surface layer of a flooring material for an entrance hall as a specific example (2) of the flooring material. [Figure 11] FIG. 11 is a diagram showing another surface layer of the entrance hall floor material, which is a specific example (2) of the floor material. [Figure 12] FIG. 12 is a diagram showing a molding die for molding a floor material for an entrance hall as a specific example (2) of the floor material. [Figure 13] FIG. 13 is a diagram showing the steps of a manufacturing method for forming an entrance hall floor material, which is a specific example (2) of the floor material. [Figure 14] FIG. 14 is a diagram showing the bonding layer arrangement step in the flooring manufacturing method of the present invention. [Figure 15] FIG. 15 is a plan view showing a floor material for an entrance hall, which is a specific example (3) of a floor material to which the present invention is applied. [Figure 16] FIG. 16 is a diagram showing a modified example (1) of the surface layer of the entrance hall floor material, which is a specific example (2) of the floor material. [Figure 17] FIG. 17 is a diagram showing a modified example (2) of the surface layer of the entrance hall floor material, which is a specific example (2) of the floor material. DETAILED DESCRIPTION OF THE INVENTION

[0023] The flooring material and the method for manufacturing the flooring material of the present invention will be described below with reference to the drawings. In the drawings, the flooring material of the present invention is shown to be composed of multiple layers, but the thickness relationships of the layers have been appropriately exaggerated or simplified for ease of explanation, and do not strictly reflect the relative thicknesses (scales) of the layers in an actual flooring material.

[0024] In this specification, the "top surface" or "above" of a layer refers to the surface or direction away from the floor surface (horizontal surface) on which the flooring is laid, and the "bottom surface" or "below" refers to the surface or direction on the opposite side (the side closer to the floor surface on which the flooring is laid).

[0025] First Embodiment <Overall composition of flooring materials> Fig. 1 is a cross-sectional view showing a schematic diagram of the laminated structure of a flooring material 1A according to a first embodiment of the present invention. The flooring material 1A shown in Fig. 1 has a surface layer 2 and a cold-press molded layer 3, which are laminated from top to bottom in this order.

[0026] <Surface layer> FIG. 2 shows a schematic diagram of the laminated structure of the surface layer 2, with FIG. 2(a) being a cross-sectional view of a surface layer 2A with enhanced slip resistance, and FIG. 2(b) being a cross-sectional view of a surface layer 2B with enhanced cushioning. The surface layer 2 has a textured pattern (not shown) formed thereon to enhance the design of the flooring material. Examples of textured patterns include embossing, a foam structure, debossing, and graining. The surface layer 2 can be, for example, either the surface layer 2A shown in FIG. 2(a) or the surface layer 2B shown in FIG. 2(b). When the slip resistance of the flooring material 1A is to be enhanced, the surface layer 2A shown in FIG. 2(a) is employed, and when the cushioning property of the flooring material 1A is to be enhanced, the surface layer 2B shown in FIG. 2(b) is employed.

[0027] First, the surface layer 2A, which can enhance the slip resistance of the flooring material 1A, will be described with reference to Fig. 2(a). The surface layer 2A shown in Fig. 2(a) is composed of an abrasion-resistant layer 11, a protective layer 12, a design layer 13, an upper resin layer 14, a resin-impregnated glass sheet 15, and a lower resin layer 16, layered in this order from top to bottom.

[0028] [Abrasion resistant layer] The abrasion-resistant layer 11 is the outermost layer and is not an essential component of the surface layer 2A, but it prevents scratches and improves abrasion resistance. The abrasion-resistant layer 11 may be transparent or opaque, but is preferably transparent so that patterns such as the design layer 13 provided on the back side of the protective layer 12 can be seen. The abrasion-resistant layer 11 preferably has a thickness of 2 to 50 μm, more preferably 5 to 35 μm, for the reasons of exhibiting scratch resistance while not becoming brittle overall and having excellent impact resistance. In particular, a layer thickness of 2 μm or more provides sufficient scratch resistance, while a layer thickness of 50 μm or less does not make the overall rigidity of the flooring material too high, making it less likely to crack and providing excellent processability.

[0029] For the abrasion-resistant layer 11, an ionizing radiation-curable resin such as an ultraviolet-curable resin is preferably used because it is versatile. Examples of the curable resin include ionizing radiation-curable resins such as ultraviolet-curable resins, thermosetting resins, and resins cured by non-ionizing radiation. When an ionizing radiation-curable resin composition is used, the abrasion-resistant layer 11 contains a polymerization initiator, various other additives, and, if necessary, an aggregate. As the resin cured by ionizing radiation, ultraviolet-curable resins such as urethane-based, epoxy-based, and acrylic-based resins are preferably used because of their good processability and versatility, and fluororesins, silicone resins, etc. may also be added. Furthermore, inorganic particles such as alumina can be used as the aggregate, which can improve slip resistance, abrasion resistance, and durability.

[0030] [Protective layer] The protective layer 12 is a layer provided to facilitate the removal of dirt adhering to the surface layer 2A. That is, the protective layer 12 imparts dirt removability to the surface layer 2A. The protective layer 12 is provided as needed. The protective layer 12 may be either transparent or opaque, but is preferably transparent so that the pattern and coloring of the design layer 13 provided on the back side of the protective layer 12 can be seen.

[0031] Resin materials are suitable for the material of the protective layer 12. Examples of suitable resin materials include thermoplastic resins such as polyvinyl chloride resins, polyolefin resins, polyacrylic acid resins, and polyester resins, with polyvinyl chloride resins being preferred. The thickness of the protective layer 12 is 0.03 to 1 mm, and preferably 0.1 to 0.8 mm.

[0032] [Design layer] The design layer 13 is a layer that expresses a desired pattern and imparts design to the surface of the surface layer 2A. For example, the design layer 13 is formed from a thermoplastic resin. Examples of the thermoplastic resin include vinyl chloride resin, olefin resin, acrylic resin such as ethylene-vinyl acetate copolymer and ethylene-methacrylate resin, amide resin, ester resin, vinyl acetate, various elastomers such as olefin elastomer and styrene elastomer, and rubber. Among these, vinyl chloride resin is preferred because of its excellent durability and processability. In addition, various additives such as fillers, plasticizers, flame retardants, stabilizers, antioxidants, lubricants, colorants, and foaming agents may be blended into the thermoplastic resin.

[0033] The design layer 13 may be formed from a printed film, may be molded from a thermoplastic resin to which a coloring agent has been added, or may be formed by adding and kneading together resin chips of multiple colors.

[0034] The thickness of the design layer 13 is 0.50 to 1.50 mm, preferably 0.60 to 1.00 mm, and more preferably 0.65 to 0.80 mm.

[0035] Furthermore, when a pattern is to be revealed by adding a coloring agent or the like to the upper resin layer 14, the design layer 13 may be omitted.

[0036] [Upper resin layer and lower resin layer] The upper resin layer 14 and the lower resin layer 16 are the main components that determine the strength and weight of the surface layer 2A. The thicknesses of the upper resin layer 14 and the lower resin layer 16 are not particularly limited and can be set appropriately. The thickness of the upper resin layer 14 and the thickness of the lower resin layer 16 may be the same or different. The thickness of the upper resin layer 14 is 0.05 to 1.0 mm, preferably 0.1 to 0.8 mm. The thickness of the lower resin layer 16 is 0.5 to 3.0 mm, preferably 0.7 to 2.0 mm.

[0037] Thermoplastic resins are suitable as materials for the upper resin layer 14 and the lower resin layer 16. Examples of thermoplastic resins include polyvinyl chloride resins such as polyvinyl chloride and vinyl chloride-vinyl acetate copolymers; polyolefin resins; polystyrene resins; polyvinyl acetate resins such as ethylene-vinyl acetate copolymers; polyacrylate resins such as polymethyl methacrylate; polyamide resins; polyester resins; and various elastomers such as olefin elastomers and styrene elastomers. These may be used alone or in combination. At least one of the upper resin layer 14 and the lower resin layer 16 is preferably a resin layer primarily composed of polyvinyl chloride resin, as this layer has excellent flexibility and is easily bonded to the resin-impregnated glass sheet 15. It is more preferable that both the upper resin layer 14 and the lower resin layer 16 be primarily composed of polyvinyl chloride resin. The surface layer 2A, which has a resin layer whose main component is polyvinyl chloride resin, has excellent flexibility, providing a good walking feel and allowing it to be curved while being applied to the floor surface. Polyvinyl chloride resin is inexpensive, and its use simplifies the manufacture of the surface layer 2A. When both the upper resin layer 14 and the lower resin layer 16 are made primarily of polyvinyl chloride resin, the polyvinyl chloride resins may be the same or different in type and degree of polymerization of the monomer.

[0038] In this specification, the term "main component" refers to the resin component excluding additives, and when a layer is made up of multiple components (excluding additives), the term refers to the component with the largest content (by weight). Examples of such additives include plasticizers, fillers, and stabilizers. The content of the main component is greater than 50% by mass, preferably 70% by mass or more, and more preferably 80% by mass or more, assuming that the total components making up the layer are 100% by mass. The upper limit of the content of the main component is 100% by mass. When the content of the main component is less than 100% by mass, the components other than the main component contained in the layer are not particularly limited and may include conventionally known components.

[0039] [Resin-impregnated glass sheet] The resin-impregnated glass sheet 15 is used to suppress size fluctuations of the surface layer 2A due to shrinkage and expansion over time. Although detailed illustrations are omitted, it is a glass sheet containing glass fibers impregnated with resin. The resin-impregnated glass sheet 15 has the properties of glass fibers, such as high strength and minimal size fluctuations due to temperature. This enhances the size stability and mechanical strength, such as rigidity, of the surface layer 2A, and suppresses size changes and warping due to temperature changes and shrinkage and expansion over time. The glass sheet that serves as the base material for the resin-impregnated glass sheet 15 is composed of multiple overlapping fibers forming layers. While glass nonwoven fabrics and glass woven fabrics can be used, glass nonwoven fabrics are preferred. Glass nonwoven fabrics have excellent size stability, which significantly contributes to the overall size stability of the surface layer 2A and can also improve the bending strength and tensile strength of the surface layer 2A. Furthermore, since the fibers of a glass woven fabric are generally regularly arranged, the weave may be visible on the surface of the surface layer 2A, affecting the appearance of the uneven pattern, but when a glass nonwoven fabric is used, the uneven pattern of the surface layer 2A is not affected and can be maintained as is. Note that the resin-impregnated glass sheet 15 may be omitted in cases where large size variations are acceptable or where size variations can be suppressed by other configurations.

[0040] The resin to be impregnated into the glass sheet is not particularly limited as long as it adheres to both the upper resin layer 14 and the lower resin layer 16, and any conventionally known resin can be used. Examples of resins include the thermoplastic resins exemplified for the upper resin layer 14 and the lower resin layer 16. When the upper resin layer 14 and the lower resin layer 16 are primarily composed of a polyvinyl chloride resin, it is preferable that the resin to be impregnated into the glass sheet also be primarily composed of a polyvinyl chloride resin, as this will exhibit excellent adhesion to the upper resin layer 14 and the lower resin layer 16. Regarding the properties of the resin to be impregnated into the glass sheet, a paste-like resin is preferable as it is easy to impregnate and has excellent processability.

[0041] Next, the surface layer 2B, which can enhance the cushioning properties of the flooring material 1A, will be described with reference to Figure 2(b). The surface layer 2B shown in Figure 2(b) includes a foam layer 23, a design layer 24 laminated on the top surface of the foam layer 23, a protective layer 22 laminated on the top surface of the design layer 24, and a glass fiber cloth 21 embedded in the foam layer 23. In the surface layer 2B, the glass fiber cloth 21 is embedded in the foam layer 23 above the center line S of the entire thickness of the surface layer 2B. If necessary, a decorative layer (not shown) having a design property may be provided between the protective layer 22 and the glass fiber cloth 21.

[0042] [Glass fiber cloth] The glass fiber cloth 21 preferably has an appropriate gap so that it can be impregnated with the foamable resin composition. Specifically, the glass fiber cloth 21 has a basis weight of 15 to 80 g / m 2 A sheet-like or mat-like nonwoven or woven fabric having an average thickness of about 0.15 to 0.60 mm can be used. 2 If the weight is less than 80 g / m, the foamable resin composition will easily enter the gaps between the fibers, but the strength will depend mainly on the strength of the foamable resin composition. 2 If the thickness exceeds this value, the foamable resin composition will have difficulty penetrating into the gaps between the fibers, resulting in insufficient entanglement between the fibers and the foamable resin composition. In either case, there is a risk that a sufficient anchoring effect will not be obtained.

[0043] As a method for laminating the glass fiber cloth 21, any method can be applied, such as a method in which a paste-like foamable resin composition in which the glass fiber cloth 21 is embedded is foamed using a normal heater such as an infrared heater, thereby embedding the glass fiber cloth 21 in the foamed product and laminating it; a method in which a foamable resin composition in a fluid state is coated on the glass fiber cloth 21 and forcedly impregnated; or a method in which a carrier such as release paper is coated with a foamable resin composition in a fluid state using a knife coater or the like, and then the glass fiber cloth 21 is placed on top of the carrier, impregnated with the foamable resin composition, and heated to foam it.

[0044] [Protective layer] For the protective layer 22, the components exemplified in the description of the protective layer 12 above can be used.

[0045] <Cold press molding layer> In the flooring material 1A shown in FIG. 1, the cold-press-molded layer 3 is formed by pressing the base material (resin) of the cold-press-molded layer 3, which has been brought to a state above its softening point, while cooling it using molding dies 200 (upper die 201, lower die 203) and 300 (upper die 301, lower die 303), which will be described later. Here, the "softening point" refers to the temperature at which a resin becomes plastically deformable when subjected to external stress, and the softening point is usually between the glass transition temperature (Tg) and melting temperature (Tm) of the resin. The base material of the cold-press-molded layer 3 can be any of the thermoplastic resins exemplified in the description of the components of the upper resin layer 14 and the lower resin layer 16, with polyvinyl chloride resins being particularly suitable. Incidentally, polyvinyl chloride, a typical example of polyvinyl chloride resin, has a glass transition point (Tg) of approximately 60 to 85°C and a melting temperature (Tm) of approximately 210°C, although this varies depending on the amount of plasticizer added. Therefore, the softening point can be estimated to be, for example, 60 to 200°C.

[0046] The cold-press molded layer 3 may be formed only from a resin base material, but other materials such as wood or metal may be embedded or joined as a core material or substrate. Suitable wood materials include plywood, MDF, particle board, and hardboard. Suitable metal materials include iron, aluminum, and stainless steel. Forming the cold-press molded layer 3 on a wood or metal substrate allows for easy joining or incorporation into a building, improving convenience.

[0047] In the flooring material 1A of the first embodiment, the surface layer 2 and the cold-press-molded layer 3 are made of the same material. Here, "same material" means that the main components are the same, and "same main components" refers to both the same material and materials of the same type. Examples of materials of the same type include materials in which the monomers constituting the resin repeating units are the same but have different degrees of polymerization, different degrees of crystallinity, or different side chain substituents. By making the surface layer 2 and the cold-press-molded layer 3 out of the same material, the boundary between the surface layer 2 and the cold-press-molded layer 3 can be more firmly integrated by heat fusion.

[0048] The surface layer 2 and the cold-press molded layer 3 may contain components other than resins as necessary. Examples of other components include plasticizers, fibers, fillers, stabilizers, processing aids, antifungal agents, deodorizers, antibacterial agents, flame retardants, antioxidants, lubricants, and colorants. Examples of plasticizers include dioctyl phthalate (DOP), diheptyl phthalate (DHP), diisononyl phthalate (DINP), trioctyl phosphate (TOP), triphenyl phosphate (TPP), dioctyl terephthalate (DOTP), dioctyl isophthalate (DOIP), and diisononyl cyclohexyl phthalate (DINCH). Examples of fibers include short fibers of resins and glass. Among these, short glass fibers are preferred, as they can reduce warping of the product and improve dimensional stability and strength. The fiber length is 0.5 to 10 mm, preferably 2 to 9 mm, and more preferably 4 to 8 mm. Examples of fillers include calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, mica, heavy calcium carbonate, light calcium carbonate, silica sand, aluminum hydroxide, etc. In the cold-press molded layer 3, the plasticizer is contained in an amount of 10 to 90 parts, and the filler is contained in an amount of 0 to 400 parts.

[0049] <density> The densities of the surface layer 2 and the cold-press-molded layer 3 are particularly affected by the type and amount of plasticizer and the type and amount of filler, but are also affected by temperature changes during cooling and solidification in cold-press molding using molding dies 200 (upper die 201, lower die 203) and 300 (upper die 301, lower die 303), which will be described later. That is, in cold-press molding using molding dies 200 and 300, which will be described later, the portion of the surface layer 2 that comes into contact with the molding dies 200 and 300 (upper surface portion) is initially cooled by the molding dies 200 and 300, while the portion of the surface layer 2 that comes into contact with the base material of the cold-press-molded layer 3 (lower surface portion) is once heated to a temperature above the softening point of the base material of the cold-press-molded layer 3 by contact with the base material, and then cooled to approach the temperature of the molding dies 200 and 300. In contrast, during the molding stage, the base material of the cold-press-molded layer 3, which is at or above its softening point, comes into contact with the molding dies 200, 300 and is rapidly cooled to approach the temperature of the molding dies 200, 300. Because the temperature change of the cold-press-molded layer 3 is greater than the temperature change of the surface layer 2, the density of the cold-press-molded layer 3 tends to be greater than the density of the surface layer 2. This tendency is particularly pronounced when the surface layer 2 contains a foamed resin. This allows the cold-press-molded layer 3 to provide a durable structure for the entire flooring material, while softening the surface layer 2 that is directly stepped on by the soles of the feet, improving comfort and reducing leg fatigue.

[0050] <Interlayer peel strength> The interlayer peel strength between the surface layer 2 and the cold-press-molded layer 3, measured in accordance with the interlayer peel strength test method of JIS A 1454, is 8 to 100 N / 50 mm, preferably 20 to 95 N / 50 mm, and more preferably 30 to 90 N / 50 mm. This reliably prevents the surface layer 2 from peeling off from the cold-press-molded layer 3 during normal use of the flooring material 1A, ensuring stable performance of the flooring material 1A over a long period of time. If the interlayer peel strength is less than 8 N / 50 mm, the welded state between the surface layer 2 and the cold-press-molded layer 3 may not be maintained over a long period of time. If the interlayer peel strength exceeds 100 N / 50 mm, the surface layer 2 and the cold-press-molded layer 3, which are made of different materials, cannot be separated, which is undesirable from the standpoint of recyclability. Note that if the surface layer 2 and the cold-press-molded layer 3 are made of the same material, they may or may not be separated during recycling.

[0051] <Hardness> The hardness of the surface layer 2 and the cold-press molded layer 3 refers to the Type A durometer hardness measured in accordance with JIS K 6253. Specifically, the value is measured using a GS-719N made by Teclock Corporation. The hardness of the surface layer 2 is 30 to 118, preferably 35 to 100, and more preferably 40 to 98. If the hardness is less than 30, the flexibility of the surface layer 2 is improved and the comfort of stepping on it is improved, but the surface layer 2 becomes more susceptible to deformation, which may cause the uneven pattern to collapse. If the hardness exceeds 118, the uneven pattern of the surface layer 2 is less likely to collapse, but the comfort of stepping on it may deteriorate. The hardness of the cold-press molded layer 3 is 75 to 115, preferably 90 to 100, and more preferably 94 to 96. If the hardness is less than 75, the flexibility of the cold-press molded layer 3 is improved and the comfort of stepping on the cold-press molded layer 3 improves, but the cold-press molded layer 3 becomes more susceptible to deformation, which may cause the three-dimensional structure to be easily crushed.If the hardness is more than 115, the three-dimensional structure of the cold-press molded layer 3 becomes less susceptible to crushing, but the comfort of stepping on the cold-press molded layer 3 may be worsened.

[0052] Furthermore, by making the hardness of the cold-pressed layer 3 higher than that of the surface layer 2, the cold-pressed layer 3 can provide a strong structure for the entire flooring material, while softening the surface layer 2 that is directly stepped on by the soles of the feet, improving comfort and reducing fatigue in the lower limbs. In this case, the difference in hardness between the cold-pressed layer 3 and the surface layer 2 is preferably 30 or more, more preferably 40 or more. The upper limit is preferably 65 or less, more preferably 50 or less. The hardness difference here can be calculated using the following formula: Hardness difference = (hardness of cold-pressed layer 3) - (hardness of surface layer 2)

[0053] [Modification (1) of the first embodiment] A variation (1) of the first embodiment is a flooring material in which a core material is embedded in a cold-press molded layer. Examples of the core material include a member formed into a plate, lattice, mesh, or other shape, made of metal, wood, resin, or a composite of these materials.

[0054] The core material may be entirely contained within the cold-press-molded layer 3, or may have a protruding portion where a required portion protrudes from the surface of the cold-press-molded layer 3. An example of a protruding portion is a screw shank with a male thread. By adopting a configuration in which the screw shank protrudes from the surface of the cold-press-molded layer 3 in this way, the flooring material can be easily and firmly fixed to the installation location by tightening a nut threaded onto the screw shank of the flooring material during installation.

[0055] Alternatively, openings may be provided on the surface of the cold-press-molded layer 3 to expose key areas of the core material, and female screws, for example, may be formed in the portions of the core material that correspond to these openings. By adopting a configuration in which bolts can be threaded into the female screws formed in the core material through the openings provided on the surface of the cold-press-molded layer 3, the flooring material can be easily and firmly fixed to the installation location by tightening the bolts threaded into the female screws of the flooring material when the flooring material is installed.

[0056] By using wooden boards as the core material, the flooring can be easily and firmly fixed to the installation location using nails or wooden screws. Also, a required portion of the wooden board may be exposed from the cold-press molded layer 3. In this case, for example, if the floor surface to be installed is a wooden substrate, the flooring can be easily and firmly fixed to the installation location by a construction method in which an adhesive layer formed with wood adhesive or the like is interposed between the exposed wooden portion and the wooden substrate.

[0057] In the flooring material according to the above-mentioned modified example (1), the core material is contained within the cold-press-molded layer 3, which adds strength to the strength of the surface layer 2 and the cold-press-molded layer 3, thereby increasing the strength of the entire flooring material. Furthermore, in the flooring material according to the above-mentioned modified example (1), the core material's functions are added to the functions of the surface layer 2 and the cold-press-molded layer 3, respectively, thereby increasing added value. Furthermore, in the flooring material according to the above-mentioned modified example (1), the core material is contained within the cold-press-molded layer 3, which eliminates the need to consider the bonding strength between the cold-press-molded layer 3 and the core material, and it becomes possible to use a core material made of a different material, such as metal or wood, from the cold-press-molded layer 3 made of a resin material, thereby increasing the options for materials used for the core material.

[0058] The flooring material according to the above modification (1) can be manufactured by a manufacturing method including the following steps (1) to (6). (1) First placement step of placing the surface layer 2 on the mold (2) A second disposing step of disposing a thermoplastic resin in a state above its softening point so as to contact the surface layer 2. (3) a third placement step in which a core material is placed so as to be in contact with the thermoplastic resin placed in the second placement step; (4) A fourth placement step of placing a thermoplastic resin at a temperature above its softening point so as to contact the core material. (5) A pressing process in which the contents of the mold are pressed at a temperature below the softening point of the thermoplastic resin. (6) A recovery step of removing the laminated molded body formed by the pressing step from the mold.

[0059] According to the above manufacturing method, it is possible to easily incorporate a core material made of a different material, such as metal or wood, into the cold-press molded layer 3, which is made of a resin material, while achieving both high design quality and flexible moldability that could not be achieved with conventional flooring materials.

[0060] [Modification (2) of the first embodiment] A modified example (2) of the first embodiment is a flooring material formed by laminating a surface layer 2, a cold-press-molded layer 3, and a substrate in this order. By adopting a configuration in which a substrate is laminated in addition to the surface layer 2 and the cold-press-molded layer 3, the strength of the flooring material can be increased. Examples of the substrate include members formed into a plate-like, lattice-like, mesh-like, or other shape made of metal, wood, resin, or a composite material thereof.

[0061] For example, if the floor surface to be installed has a wooden base, a wooden board can be used as the base material for the flooring, and an adhesive layer formed with wood adhesive or the like can be placed between the base material and the wooden base, allowing the flooring to be easily and firmly fixed to the installation location.

[0062] The flooring material according to the above modification (2) can be manufactured by a manufacturing method including the following steps (1) to (5). (1) First placement step of placing the surface layer 2 on the mold (2) A second disposing step of disposing a thermoplastic resin in a state above its softening point so as to contact the surface layer 2. (3) a third placement step in which a substrate is placed so as to be in contact with the thermoplastic resin placed in the second placement step; (4) A pressing process in which the contents of the mold are pressed at a temperature lower than the softening point of the thermoplastic resin. (5) A recovery step of removing the laminated molded body formed by the pressing step from the mold.

[0063] According to the above manufacturing method, it is possible to easily laminate a substrate made of a different material, such as metal or wood, which is made of a different material from the cold-press-molded layer 3 made of a resin material, to the surface layer 2 and the cold-press-molded layer 3, while achieving both high design quality and flexible formability that could not be achieved with conventional flooring materials.

[0064] Second Embodiment 3 is a cross-sectional view showing a laminated structure of a flooring material 1B according to a second embodiment of the present invention. In the second embodiment, the same or similar components as those in the first embodiment are denoted by the same reference numerals in the drawings, and detailed descriptions thereof are omitted. The following description focuses on the components specific to the second embodiment.

[0065] As shown in Fig. 3, in the flooring material 1B of the second embodiment, a surface layer 2 and a cold-press molded layer 3 are laminated via a bonding layer 4. The surface layer 2 and the cold-press molded layer 3 are made of different types of thermoplastic resins.

[0066] The bonding layer 4 is not particularly limited as long as it is made of a material that can exert an anchoring effect. Examples of materials for the bonding layer 4 include jute, glass fiber nonwoven fabric, spunbond nonwoven fabric, and foamed resin having a porous structure. As an example, a case where a spunbond nonwoven fabric is used for the bonding layer 4 will be described. During cold press molding using molding dies 200 (upper die 201, lower die 203) and 300 (upper die 301, lower die 303), which will be described later, the heat of the base material of the cold-press-molded layer 3, which is kept at a temperature above its softening point, and the pressure during pressing cause a portion of the surface layer 2 facing the cold-press-molded layer 3, and a portion of the base material of the cold-press-molded layer 3 facing the surface layer 2, to penetrate in a molten state into the fiber gaps of the spunbond nonwoven fabric. Subsequently, they are cooled and solidified, and the surface layer 2 and the cold-press-molded layer 3 are firmly integrated via the bonding layer 4 (spunbond nonwoven fabric) due to the anchoring effect. If the surface layer 2 and the cold-press-molded layer 3 are made of different materials, the two may not bond well together. However, by interposing the bonding layer 4 in this way, the surface layer 2 and the cold-press-molded layer 3 can be firmly integrated through the bonding layer 4, even if the surface layer 2 and the cold-press-molded layer 3 are made of different materials.

[0067] <Examples of flooring materials (1)> Figure 4 shows an entrance hall flooring material 31A, which is a specific example (1) of a flooring material to which the present invention can be applied. Figure 4(a) is a plan view, and Figure 4(b) is an enlarged view of a main portion of the cross-sectional end surface taken along line AA in Figure 4(a). The entrance hall flooring material 31A shown in Figure 4(a) comprises a surface layer 33A and a cold-press molded layer 35A that supports the surface layer 33A from below.

[0068] <Cold press molding layer> As shown in FIGS. 4( a) and 4(b), the cold-press-molded layer 35A has a floor-laying portion 41 that is rectangular in plan view and is laid on a floor surface, and an upright wall portion 43 that is connected to the floor-laying portion 41 so as to protrude upward. The upright wall portion 43 includes a first side wall 51, a second side wall 52, and a third side wall 53 that are rectangular in side view. The first side wall 51, the second side wall 52, and the third side wall 53 are integrally connected to the remaining three of the four sides of the floor-laying portion 41, except for the lower side in FIG. 4(a). The first side wall 51 and the second side wall 52 are arranged at a right angle, and their ends are integrally joined, forming a first corner 55 where the first side wall 51 and the second side wall 52 intersect. Similarly, the second side wall 52 and the third side wall 53 are arranged at a right angle with their ends joined together, and a second corner 57 is formed by the corner where the second side wall 52 and the third side wall 53 intersect.

[0069] In this example, the raised wall portion 43 includes three side walls 51, 52, and 53, and the three side walls 51, 52, and 53 are arranged continuously around three of the four sides of the floor-laying portion 41 in a direction surrounding the floor-laying portion 41. However, this is not limited to this, and the raised wall portion 43 may include one, two, or four side walls, and side walls may be arranged on only one side, only two arbitrarily selected sides, or all of the four sides of the floor-laying portion 41. In other words, when the floor-laying portion 41 is polygonal, side walls may be arranged on only one side, or on two or more arbitrarily selected sides.

[0070] In the floor laying section 41, if necessary, a predetermined drainage gradient may be provided from the upper edge in Figure 4(a) where the second side wall 52 is arranged to the lower edge in Figure 4(a) where no side wall is arranged.

[0071] The cold-press-molded layer 35A has a three-dimensional structure including a raised wall portion 43 extending perpendicular to the floor-laying portion 41, which has a layering surface on which the surface layer 33A is laminated. In this way, the present invention allows for molding of a flooring material 31A with any desired three-dimensional structure. In particular, the three-dimensional structure in which the first side wall 51, the second side wall 52, and the third side wall 53 surround the surface layer 33A on three sides is a three-dimensional structure that cannot be obtained by extrusion molding. The raised wall portion 43 is not limited to a shape extending perpendicular to the vertical direction, and may also have a shape that opens outward in the vertical direction (for example, a shape similar to the peripheral wall of a bathtub).

[0072] <Surface layer> The surface layer 33A has a main surface portion 61 formed in the form of a rectangular sheet in a plan view and fixed to the upper surface side of the floor laying portion 41, and a raised surface portion 63 connected to the main surface portion 61 and fixed to the inner wall surface side of the raised wall portion 43.

[0073] As shown in FIG. 4(b), the main surface portion 61 of the surface layer 33A has a plurality of recesses 67 and a plurality of protrusions 77 formed by carrying out a cold press molding process described below. The plurality of recesses 67 and the plurality of protrusions 77 are arranged adjacent to each other vertically and horizontally. The plurality of recesses 67 are formed between adjacent protrusions 77. The plurality of recesses 67 and the plurality of protrusions 77 as a whole form a tile-like uneven pattern.

[0074] [Convex] The multiple protrusions 77 are formed in a generally square shape in a plan view. In this specification, "plan view" refers to a view perpendicular to the surface of the surface layer 33A, and "plan view shape" refers to the outline in a plan view. The multiple protrusions 77 all have the same size in a plan view and are regularly arranged at equal intervals vertically and horizontally. This prevents variations in the drainage and slip resistance of the entrance floor material 31A from varying from location to location.

[0075] Each protrusion 77 has a generally flat top surface at its protruding end. To enhance design and slip resistance, the top surface is provided with mesh-like protrusions 79 that protrude in a lattice-like pattern when viewed from above. The mesh-like protrusions 79 form a lattice-like uneven pattern.

[0076] Recess The plurality of recesses 67 are connected to form drainage grooves 80, which are formed in a lattice shape in plan view so as to surround each of the protrusions 77.

[0077] As shown in FIG. 4( a), in the surface layer 33A, the raised surface portion 63 includes a first folded-up piece 81, a second folded-up piece 82, and a third folded-up piece 83, each of which has a rectangular shape in a side view and stands upright relative to the main surface portion 61. The first folded-up piece 81, the second folded-up piece 82, and the third folded-up piece 83 are integrally connected to three of the four sides of the main surface portion 61, except for one side on the lower side in FIG. 4( a). With regard to the first folded-up piece 81, the second folded-up piece 82, and the third folded-up piece 83, the first folded-up piece 81 is fixed to the inner wall surface of the first side wall 51, the second folded-up piece 82 is fixed to the inner wall surface of the second side wall 52, and the third folded-up piece 83 is fixed to the inner wall surface of the third side wall 53. The first folded-up piece 81 and the second folded-up piece 82 are adjacently arranged to form a first right-angled corner 85. Similarly, the second folded-up piece 82 and the third folded-up piece 83 are disposed adjacent to each other so as to form a second right-angled corner portion 87 .

[0078] FIG. 5 is a diagram showing the surface layer 33A of the entranceway flooring material 31A, a specific example (1) of the flooring material. FIG. 5(a) is a plan view of the surface layer 33A in an unfolded state. In FIG. 5(a), fold lines 91, 92, and 93 are drawn to indicate the positions of folds formed at the boundaries between the main surface portion 61 and each of the folded-up pieces 81, 82, and 83 when the folded-up pieces 81, 82, and 83 are folded up (raised) relative to the main surface portion 61. However, in reality, such fold lines 91, 92, and 93 are not drawn on the surface layer 33A (the same applies to FIGS. 6(a), 10(a), and 11(a)). FIG. 5(b) is an enlarged perspective view of a main portion of the surface layer 33A shown in FIG. 5(a) after two adjacent folded-up pieces 81 and 82 are folded up to form a first corner 85 (see FIG. 4(a)). 5(c) is an enlarged perspective view of a main part of the surface layer 33A shown in FIG. 5(a) in a state where two adjacent folded-up pieces 82, 83 are folded up to form a second corner 87 (see FIG. 4(a)). In FIGS. 5(b) and 5(c), the thickness relationship between the folded-up pieces 81, 82, 83 is exaggerated to clearly show the contact state (butting state) of the two adjacent folded-up pieces 81, 82; 82, 83, and does not strictly reflect the relative size (scale) of the thicknesses of the actual folded-up pieces 81, 82, 83 (the same applies to FIGS. 6(b) and (c), FIGS. 10(b) and (c), and FIGS. 11(b) and (c)).

[0079] As shown in the enlarged view of the main part on the left side of Figure 5(a), a notch 95 of a length equivalent to the thickness of the first folded piece 81 is formed at the end of the second folded piece 82 closer to the first folded piece 81, i.e., at the boundary between the left end of the second folded piece 82 in Figure 5(a) and the first folded piece 81, so as to be located on an extension of the fold line 92. 5(b), the provision of such notches 95 allows the first folded-up piece 81 and the second folded-up piece 82, which are raised relative to the main surface portion 61 to form the first corner 85, to be raised in a state where the end face 81a of the first folded-up piece 81 and the end face 82b of the second folded-up piece 82 are in contact with each other (in this example, the entire end face 81a of the first folded-up piece 81 and the end face 82b of the second folded-up piece 82 are in complete contact with each other), thereby preventing the first folded-up piece 81 and the second folded-up piece 82 from interfering with each other when forming the first corner 85 and preventing gaps from being generated at the first corner 85. The first folded-up piece 81 and the second folded-up piece 82 not interfering with each other prevents problems such as the formation of unnecessary protrusions. However, slight mutual interference is permissible, and it is also possible to more actively and intentionally cause the first folded-up piece 81 and the second folded-up piece 82 to interfere with each other to form a special shape.

[0080] As shown in the enlarged view of the main part on the right side of Figure 5(a), a notch 96 of a length equivalent to the thickness of the third folded piece 83 is formed at the end of the second folded piece 82 closer to the third folded piece 83, i.e., at the boundary between the right-hand end of the second folded piece 82 in Figure 5(a) and the third folded piece 83, so as to be located on an extension of the fold line 92. 5(c), the provision of such notches 96 allows the second folded-up piece 82 and the third folded-up piece 83, which are raised relative to the main surface portion 61 to form the second corner 87, to be raised in a state where the end face 83a of the third folded-up piece 83 and the end 82b of the second folded-up piece 82 are in contact with each other (in this example, the entire end face 31a of the third folded-up piece 83 and the end 82b of the second folded-up piece 82 are in complete contact with each other), thereby preventing the second folded-up piece 82 and the third folded-up piece 83 from interfering with each other when forming the second corner 87 and preventing a gap from being generated at the second corner 87. The fact that the second folded-up piece 82 and the third folded-up piece 83 do not interfere with each other prevents problems such as the formation of an unnecessary protrusion. However, slight mutual interference is permissible, and it is also possible to more actively and intentionally cause the second folded-up piece 82 and the third folded-up piece 83 to interfere with each other to form a special shape.

[0081] In this way, in the pressing step described below, it is possible to prevent the thermoplastic resin that is the constituent material of the cold-press-molded layer 35A from being exposed at the first corner 85 and the second corner 87, and it is possible to reliably form the first corner 85 and the second corner 87 in an aesthetically pleasing manner by the first folded piece 81, the second folded piece 82, and the third folded piece 83. It is also possible to prevent the thermoplastic resin from leaking onto the surface layer 33A from the gaps between the first corner 85 and the second corner 87, which could cause problems such as impairing the aesthetic appearance and the physical properties of the surface layer 33A.

[0082] Figure 6 shows another example of a surface layer 33A in an entrance hall flooring material 31A according to specific example (1) of the flooring material. Figure 6(a) is a plan view of the surface layer 33A in an unfolded state. Figure 6(b) is an enlarged perspective view of a main part of the surface layer 33A shown in Figure 6(a) when two adjacent folded-up pieces 81, 82 are folded up (standing up) to form a first corner 85 (see Figure 4(a)). Figure 6(c) is an enlarged perspective view of a main part of the surface layer 33A shown in Figure 6(a) when two adjacent folded-up pieces 82, 83 are folded up to form a second corner 87 (see Figure 4(a)).

[0083] As shown in the enlarged view of the main part on the left side of Figure 6(a), a notch 97 of a length equivalent to the thickness of the second folded piece 82 is formed at the end of the first folded piece 81 closer to the second folded piece 82, i.e., at the boundary between the upper end of the first folded piece 81 in Figure 6(a) and the second folded piece 82, so as to be located on an extension of the fold line 91. By providing such a notch 97, as shown in Figure 6(b), in the adjacent portions of the first folded-up piece 81 and the second folded-up piece 82 that stand up relative to the main surface portion 61 to form the first corner portion 85, the folded-up pieces 81, 82 are raised in a state where there is a portion where the end face 82a of the second folded-up piece 82 and the end 81b of the first folded-up piece 81 are in contact (in this example, a butt-fit state where the entire end face 82a of the second folded-up piece 82 and the end 81b of the first folded-up piece 81 are in complete contact).This prevents the first folded-up piece 81 and the second folded-up piece 82 from interfering with each other when forming the first corner portion 85, and also prevents gaps from occurring at the first corner portion 85.

[0084] As shown in the enlarged view of the main part on the right side of Figure 6(a), a notch 98 of a length equivalent to the thickness of the second folded piece 82 is formed at the end of the third folded piece 83 closer to the second folded piece 82, i.e., at the boundary between the upper end of the third folded piece 83 in Figure 6(a) and the second folded piece 82, so as to be located on an extension of the fold line 93. By providing such a notch 98, as shown in Figure 6(c), the second folded-up piece 82 and the third folded-up piece 83, which stand up relative to the main surface portion 61 to form the second corner portion 87, are arranged so that there is a portion where the end face 82a of the second folded-up piece 82 and the end face 83b of the third folded-up piece 83 are in contact (in this example, a butt-fit state where the entire end face 82a of the second folded-up piece 82 and the end face 83b of the third folded-up piece 83 are in complete contact).This prevents the second folded-up piece 82 and the third folded-up piece 83 from interfering with each other when forming the second corner portion 87, and also prevents gaps from occurring at the second corner portion 87.

[0085] In this way, in the pressing process described below, the thermoplastic resin that is the constituent material of the cold-press molded layer 35A can be prevented from being exposed from the first corner portion 85 and the second corner portion 87, and the first folded piece 81, the second folded piece 82, and the third folded piece 83 can reliably form the first corner portion 85 and the second corner portion 87 in an aesthetically beautiful manner. In addition, in Figure 5(b), the contact between the end face 81a of the first folded-up piece 81 and the end face 82b of the second folded-up piece 82 is illustrated, and described, as being between the end face 83a of the third folded-up piece 83 and the end face 82b of the second folded-up piece 82; in Figure 5(c), the contact between the end face 83a of the third folded-up piece 83 and the end face 82b of the second folded-up piece 82; in Figure 6(b), the contact between the end face 82a of the second folded-up piece 82 and the end face 81b of the first folded-up piece 81; and in Figure 6(c), the contact between the end face 82a of the second folded-up piece 82 and the end face 83b of the third folded-up piece 83. Each of these illustrates and describes a butting state in which the two pieces are in complete contact, but the contact of the present invention is not limited to this and also includes a state in which there is partial contact. Contact also includes a state in which at least a portion of the end face 81a of the first folded-up piece 81 and the end face 82b of the second folded-up piece 82, at least a portion of the end face 83a of the third folded-up piece 83 and the end face 82b of the second folded-up piece 82, at least a portion of the end face 82a of the second folded-up piece 82 and the end face 81b of the first folded-up piece 81, and at least a portion of the end face 82a of the second folded-up piece 82 and the end face 83b of the third folded-up piece 83 overlap.

[0086] In the entranceway flooring material 31A described above, the cold-press molded layer 35A has a floor-laying portion 41 that is laid on the floor surface and a rising wall portion 43 that is connected to the floor-laying portion 41 so as to protrude upward, and the surface layer 33A has a main surface portion 61 that is fixed to the floor-laying portion 41 and a rising surface portion 63 that is connected to the main surface portion 61 and fixed to the rising wall portion 43. This makes it possible to add the functions of the surface layer 33A to the specific functions provided by the three-dimensional structure of the cold-press molded layer 35A, thereby increasing the added value of the entranceway flooring material 31A.

[0087] In the entranceway flooring material 31A described above, the cold-pressed layer 35A can be freely molded into any shape until the base material, which is heated above its softening point, solidifies upon cooling. Therefore, by designing the molding cavity of the molding die 200 (described below), the cold-pressed layer 35A can be molded into a raised wall 43, which is a protruding portion with a protruding length greater than the thickness of the surface layer 33A. Thus, the entranceway flooring material 31A combines the uneven pattern of the surface layer 33A with the three-dimensional structure of the cold-pressed layer 35A, allowing for the formation of relatively large and small three-dimensional structures superimposed on each other. This allows for high levels of control over slip resistance and drainage. Furthermore, the curved surface of the uneven pattern and the three-dimensional structure diffuse sound reflection, providing soundproofing, sound insulation, and sound absorption effects.

[0088] In the entrance floor material 31A described above, if the raised wall portion 43 and the raised surface portion 63 are extended upward so as to be connectable to the edge of the floor so as to hide the edge of the floor surface at the entrance entrance, alcove, veranda, etc., they can function as a frame, and in this example, in particular, the raised structural portion including the second side wall 52 and the second folded-up piece 82 can function as a frame. In this way, when the raised wall portion 43 and the raised surface portion 63 in the cold-press molded layer 35A function as a frame, the raised surface portion 63 of the surface layer 33A fixed to the raised wall portion 43 can further enhance the design of the frame, thereby further increasing the added value of the entrance floor material 31A.

[0089] <Molding mold for entrance hall flooring> Figure 7 shows a molding die 200 for molding entranceway flooring 31A, a specific example of flooring (1). Figure 7(a) shows a mold-release state, and Figure 7(b) shows a mold-clamped state. As shown in Figure 7(a), molding die 200 includes an upper die 201 having a recess 201a and a lower die 203 having a protrusion 203a corresponding to recess 201a. When recess 201a and protrusion 203a are mated as shown in the figure in the mold-clamped state shown in Figure 7(b), a molding cavity 205 is formed between recess 201a and protrusion 203a for molding entranceway flooring 31A, including floor-laying portion 41, rising wall portion 43, main surface portion 61, and rising surface portion 63.

[0090] As shown in Figure 7(a), the recess 201a in the upper mold 201 has a floor laying portion forming portion 211 that presses the base material of the cold-press-molded layer 35A, which has been brought to a state above its softening point, to form a floor laying portion 41, and a rise-up wall portion forming portion 213 that presses the base material of the cold-press-molded layer 35A, which has been pressed and spread by the floor laying portion forming portion 211, perpendicular to the floor laying portion 41 in the process of being formed, to form a rise-up wall portion 43.

[0091] As shown in Figure 7(a), the convex portion 203a of the lower mold 203 has a main surface portion placing portion 215 on which the portion that will become the main surface portion 61 of the surface layer 33A is placed, a mountain-shaped corner portion 217 that is formed so that it can be abutted against the boundary between the portion that will become the main surface portion 61 of the surface layer 33A and the portion that will become the raised surface portion 63, and a raised surface portion receiving portion 219 that receives the portion that will become the raised surface portion 63 that is bent perpendicular to the portion that will become the main surface portion 61 of the surface layer 33A.

[0092] <Method of manufacturing entrance flooring> Figure 8 shows the steps of the manufacturing method for molding entrance hall flooring 31A, which is specific example (1) of the flooring material. Figure 8(a) is an explanatory diagram of the surface layer arrangement step, Figure 8(b) is an explanatory diagram of the thermoplastic resin arrangement step, Figure 8(c) is an explanatory diagram of the pressing step, and Figure 8(d) is an explanatory diagram of the recovery step.

[0093] [Surface layer placement process] 8(a), in a state where the upper mold 201 is positioned above the lower mold 203 and the molding die 200 is open, the portion of the surface layer 33A that will become the main surface portion 61 in an inverted state with the upper surface of the surface layer 33A facing downward and the lower surface facing upward is placed on the main surface portion placing portion 215 of the lower mold 203. At this time, to enable folding at the boundary between the portion that will become the main surface portion 61 and the portion that will become the raised surface portion 63 in the surface layer 33A, the surface layer 33A is positioned using a jig (not shown) so that the boundary corresponds to an angled corner 217 of the lower mold 203, and then placed on the lower mold 203. This surface layer placing step corresponds to the "first placing step" of the present invention.

[0094] [Thermoplastic resin placement process] 8(b), the thermoplastic resin M, which is the base material of the cold-press-molded layer 35A in a plasticized state, is placed on the surface layer 33A placed upside down on the main surface portion mounting portion 215. This thermoplastic resin placing step corresponds to the "second placing step" of the present invention.

[0095] [Pressing process] Next, while cooling the upper mold 201 and the lower mold 203 using a cooling means (not shown), such as circulating cooling water through each of the upper mold 201 and the lower mold 203, the upper mold 201 is lowered relative to the lower mold 203 and clamped as shown in FIG. 8(c), and the surface layer 33A and the thermoplastic resin M in a plastic state (the base material of the cold-press-molded layer 35A), which are the contents of the molding die 200, are pressed at a temperature lower than the softening point of the thermoplastic resin M, for example, at or near room temperature. Note that, for product shapes and mold structures that provide good cooling efficiency, cooling can be performed without circulating cooling water. The pressing pressure in this pressing step is 0.1 to 20 MPa, preferably 0.2 to 15 MPa, and more preferably 0.5 to 10 MPa. According to JIS Z8703, "room temperature" is defined as 20°C ± 15°C, i.e., 5 to 35°C, but "room temperature or near room temperature" can include a wider temperature range than "room temperature," such as 20 to 50°C. If the pressing pressure is less than 0.1 MPa, the thermoplastic resin M may not be able to fill the entire molding cavity 205 (see FIG. 7(b)), resulting in molding defects. If the pressing pressure exceeds 20 MPa, the life of the molding die may be shortened and demolding properties may be impaired.

[0096] In the pressing step, the thermoplastic resin M pressed by the floor laying portion forming portion 211 of the upper mold 201 is spread over the surface layer 33A. In this way, the molding of the cold-press-molded layer 35A progresses as the pressing step progresses. During the molding of the cold-press-molded layer 35A, the boundary between the thermoplastic resin M and the surface layer 33A is integrated by thermal fusion due to the heat of the thermoplastic resin M, which has been brought to a state above its softening point (plasticization temperature), and the pressure during the pressing process.

[0097] In the above pressing step, when the thermoplastic resin M pressed and spread by the floor laying portion forming portion 211 is pressed perpendicular to the floor laying portion 41 in the process of being formed to form the standing wall portion 43, the recessed portion 201a of the upper mold 201 and the protruding portion 203a of the lower mold 203 cooperate to press the portion of the surface layer 33A that will become the standing surface portion 63 so as to bend the standing wall portion 43 in the process of being formed at the boundary between the portion that will become the main surface portion 61 and the portion that will become the standing surface portion 63. In this way, the main surface portion 61 and the standing surface portion 63 are formed in the surface layer 33A.

[0098] The surface side of the surface layer 33A (the lower side in FIGS. 8(a) to 8(c)) is cooled by the lower mold 203 despite the pressure during press processing. This prevents thermal deformation of the surface side of the surface layer 33A, and the pattern or textured pattern (in this example, a tile-like textured pattern or a lattice-like textured pattern) provided on the surface side of the surface layer 33A remains intact. In the cold-press molded layer 35A, the thermoplastic resin M, which has been brought to a plasticizing temperature, spreads along the shape of the molding cavity 205 (see FIG. 7(b)). It solidifies upon cooling by the molding mold 200 (mainly the upper mold 201), and is molded into a shape corresponding to the shape of the molding cavity 205. This allows for both high design quality and flexible moldability with a three-dimensional effect.

[0099] [Recovery process] Once the pressing process is completed, as shown in Figure 8(d), the upper mold 201 is raised relative to the lower mold 203 to open the molding die 200, and the laminated molded body (entranceway flooring material 31A) formed by the pressing process is removed from the molding die 200 and collected.

[0100] [Joining layer placement process] FIG. 14(a) is an explanatory diagram of a bonding layer arrangement step in a manufacturing method for an entranceway flooring material 31A, which is a specific example (1) of a flooring material. The manufacturing method for the entranceway flooring material 31A described above is applicable when the surface layer 33A and the cold-press-molded layer 35A are made of the same type of thermoplastic resin. When the surface layer 33A and the cold-press-molded layer 35A are made of different types of thermoplastic resin, a bonding layer arrangement step is performed between the surface layer arrangement step and the thermoplastic resin arrangement step. In the bonding layer arrangement step, a bonding layer 4 that exhibits an anchor effect is arranged on the surface layer 33A that has been placed upside down on the main surface portion mounting portion 215 in the surface layer arrangement step. Then, in the thermoplastic resin arrangement step, a plasticized thermoplastic resin M (see FIG. 8(b)) is arranged on the bonding layer 4.

[0101] A case where a spunbond nonwoven fabric is used as the bonding layer 4 will be described. During the pressing step of cold-press molding using the mold 200, due to the heat of the thermoplastic resin M, which is heated to a temperature above its softening point, and the pressure during pressing, a portion of the surface layer 33A facing the thermoplastic resin M and a portion of the thermoplastic resin M facing the surface layer 33A each penetrate in a molten state into the fiber gaps of the spunbond nonwoven fabric. Then, by cooling and solidifying, the surface layer 33A and the cold-press-molded layer 35A are firmly integrated via the bonding layer 4 (spunbond nonwoven fabric) due to an anchor effect. Thus, by interposing the bonding layer 4, the surface layer 33A and the cold-press-molded layer 35A can be firmly integrated even if they are made of different materials. The bonding layer 4 may be laminated in advance on the back surface of the surface layer 33A.

[0102] <Examples of flooring materials (2)> Figure 9 shows an entranceway flooring material 31B, a specific example (2) of a flooring material to which the present invention can be applied. Figure 9(a) is a plan view, and Figure 9(b) is an enlarged view of a main portion of the cross-sectional end surface along line BB in Figure 9(a). The entranceway flooring material 31B shown in Figure 9(a) comprises a surface layer 33B and a cold-pressed layer 35B that supports the surface layer 33B from below. In the entranceway flooring material 31B, specific example (2) of the flooring material, components that are the same as or similar to the entranceway flooring material 31A, specific example (1) of the flooring material, are simply given the same reference numerals in the figure and detailed descriptions thereof are omitted. The following description will focus on the parts unique to the entranceway flooring material 31B, specific example (2) of the flooring material.

[0103] <Cold press molding layer> 9(a) and 9(b), the cold-press-formed layer 35B includes a floor-mounted portion 41 having a rectangular shape in a plan view and laid on a floor surface, a rising wall portion 43 connected to the floor-mounted portion 41 so as to protrude upward, and a lateral protrusion portion 45 connected to the rising wall portion 43 so as to protrude horizontally outward. The lateral protrusion portion 45 includes a first flange 101, a second flange 102, and a third flange 103. The first flange 101 is connected to the upper end of the first side wall 51 so as to protrude horizontally outward from the upper end of the first side wall 51. The second flange 102 is connected to the upper end of the second side wall 52 so as to protrude horizontally outward from the upper end of the second side wall 52. The third flange 103 is connected to the upper end of the third side wall 53 so as to protrude horizontally outward from the upper end of the third side wall 53. The lateral extension portion 45 is formed in a U-shape in which a first flange 101, a second flange 102, and a third flange 103 are integrated together so as to surround the upright wall portion 43 from three sides.

[0104] <Surface layer> The surface layer 33B has a main surface portion 61 which is rectangular in plan view and is fixed to the floor laying portion 41, a standing surface portion 63 which is connected to the main surface portion 61 and is fixed to the standing wall portion 43, and a lateral extension surface portion 65 which is connected to the standing surface portion 63 and is fixed to the standing wall portion 43 and the lateral extension portion 45.

[0105] The laterally extending surface portion 65 includes a first outer bent piece 121, a second outer bent piece 122, and a third outer bent piece 123 that are bent outward at right angles to the raised surface portion 63. The first outer bent piece 121 is connected to the upper end of the first folded-up piece 81 so as to extend horizontally outward from the upper end of the first folded-up piece 81. The second outer bent piece 122 is connected to the upper end of the second folded-up piece 82 so as to extend horizontally outward from the upper end of the second folded-up piece 82. The third outer bent piece 123 is connected to the upper end of the third folded-up piece 83 so as to extend horizontally outward from the upper end of the third folded-up piece 83. With regard to the first outer bent piece 121, the second outer bent piece 122, and the third outer bent piece 123, the first outer bent piece 121 is fixed to the upper surface sides of the first folded-up piece 81 and the first flange 101, the second outer bent piece 122 is fixed to the upper surface sides of the second folded-up piece 82 and the second flange 102, and the third outer bent piece 123 is fixed to the upper surface sides of the third folded-up piece 83 and the third flange 103. The laterally protruding surface portion 65 is formed in a U-shape, with the first outer bent piece 121, the second outer bent piece 122, and the third outer bent piece 123 integrated to surround the raised surface portion 63 from three sides.

[0106] Figure 10 shows the surface layer 33B of an entrance hall flooring material 31B, a specific example (2) of the flooring material. Figure 10(a) is a plan view of the surface layer 33B in an unfolded state. Figure 10(b) is an enlarged perspective view of a main part of the surface layer 33B shown in Figure 10(a) when two adjacent folded-up pieces 81, 82 are folded up (standing up) to form a first corner 85 (see Figure 9(a)). Figure 10(c) is an enlarged perspective view of a main part of the surface layer 33B shown in Figure 10(a) when two adjacent folded-up pieces 82, 83 are folded up to form a second corner 87 (see Figure 9(a)).

[0107] Figure 11 shows another example of a surface layer 33B in an entranceway flooring material 31B, which is a specific example (2) of the flooring material. Figure 11(a) is a plan view of the surface layer 33B in an unfolded state. Figure 11(b) is an enlarged perspective view of a main part of the surface layer 33B shown in Figure 11(a) when two adjacent folded-up pieces 81, 82 are folded up (standing up) to form a first corner 85 (see Figure 9(a)). Figure 11(c) is an enlarged perspective view of a main part of the surface layer shown in Figure 11(a) when two adjacent folded-up pieces 82, 83 are folded up to form a second corner 87 (see Figure 9(a)).

[0108] 10(a) and 11(a), fold lines 141, 142, and 143 are provided to indicate the positions of folds formed at the boundaries between the folded-up pieces 81, 82, and 83 and the outer folded pieces 121, 122, and 123 when the outer folded pieces 121, 122, and 123 are folded horizontally outward relative to the folded-up pieces 81, 82, and 83, respectively. However, in reality, such fold lines 141, 142, and 143 are not provided on the surface layer 33B. Also, in FIGS. 10(b) and (c) and 11(b) and (c), the outer folded pieces 121, 122, and 123 are drawn with imaginary lines to clearly show the state in which the first corner 85 and the second corner 87 are formed.

[0109] 10(a) and 11(a), the entrance hall flooring material 31B of the specific example (2) of the flooring material has the same notches 95, 96, 97, and 98 as the entrance hall flooring material 31A of the specific example (1) of the flooring material. Therefore, as with the entrance hall flooring material 31A of the specific example (1) of the flooring material, the thermoplastic resin that is the constituent material of the cold-press-molded layer 35B can be prevented from being exposed from the first corner 85 and the second corner 87 in the pressing process described below, and the first folded-up piece 81, the second folded-up piece 82, and the third folded-up piece 83 can reliably form the first corner 85 and the second corner 87 in an aesthetically pleasing manner.

[0110] In the entrance floor material 31B of the specific floor material example (2) above, if the rising wall portion 43 and rising surface portion 63, as well as the lateral protrusion portion 45 and lateral protrusion surface portion 65 are extended upward so as to be connectable to the edge of the floor so as to hide the edge of the floor surface at the entrance entrance, alcove, veranda, etc., these can function as a stile. In particular, the entrance floor material 31B of the specific floor material example (2) is configured by adding the lateral protrusion portion 45 and lateral protrusion surface portion 65 to the entrance floor material 31A of the specific floor material example (1), so it can function as a stile with a more solid and luxurious feel, further increasing the added value of the entrance floor material 31B.

[0111] <Molding mold for entrance hall flooring> Figure 12 shows a molding die 300 for molding entranceway flooring 31B, a specific example of flooring (2). Figure 12(a) shows a mold-released state, and Figure 12(b) shows a mold-clamped state. As shown in Figure 12(a), molding die 300 includes an upper mold 301 having a recess 301a and a lower mold 303 having a protrusion 303a corresponding to recess 301a. When recess 301a and protrusion 303a are mated as shown in the figure in the mold-clamped state shown in Figure 12(b), a molding cavity 305 for molding entranceway flooring 31B is formed between recess 301a and protrusion 303a, including floor-laying portion 41, rising wall portion 43, lateral protrusion portion 45, main surface portion 61, rising surface portion 63, and lateral protrusion surface portion 65.

[0112] As shown in Figure 12(a), the recess 301a in the upper mold 301 has a floor laying portion forming portion 311 that presses the base material of the cold-press-molded layer 35B, which has been brought to a state above its softening point, to form a floor laying portion 41, a standing wall portion forming portion 313 that presses the base material of the cold-press-molded layer 35B, which has been pressed and spread by the floor laying portion forming portion 311, perpendicular to the floor laying portion 41 in the process of being formed, to form a standing wall portion 43, and a lateral protrusion portion forming portion 314 that presses the same base material perpendicularly outward to the standing wall portion 43 in the process of being formed, to form a lateral protrusion portion 45.

[0113] As shown in Figure 12(a), the convex portion 303a of the lower mold 303 has a main surface portion placing portion 315 on which the portion that will become the main surface portion 61 in the surface layer 33B is placed, a mountain-shaped corner portion 317 formed so that it can be abutted against the boundary between the portion that will become the main surface portion 61 in the surface layer 33 and the portion that will become the raised surface portion 63, a raised surface portion receiving portion 319 that receives the portion that will become the raised surface portion 63 that is bent perpendicular to the portion that will become the main surface portion 61 in the surface layer 33B, and a horizontally protruding surface portion receiving portion 321 that receives the portion that will become the horizontally protruding surface portion 65 that is bent outward perpendicular to the portion that will become the raised surface portion 63 in the surface layer 33B.

[0114] <Method of manufacturing entrance flooring> Figure 13 shows the steps of the manufacturing method for molding entrance hall flooring 31B, which is specific example (2) of the flooring material. Figure 13(a) is an explanatory diagram of the surface layer arrangement step, Figure 13(b) is an explanatory diagram of the thermoplastic resin arrangement step, Figure 13(c) is an explanatory diagram of the pressing step, and Figure 13(d) is an explanatory diagram of the recovery step.

[0115] [Surface layer placement process] 13(a), in a state where the upper mold 301 is positioned above the lower mold 303 and the molding die 300 is open, the portion of the surface layer 33B that will become the main surface portion 61 in an inverted state with the upper surface of the surface layer 33B facing downward and the lower surface facing upward is placed on the main surface portion placing portion 315 of the lower mold 303. At this time, in order to enable folding at the boundary between the portion that will become the main surface portion 61 and the portion that will become the raised surface portion 63 in the surface layer 33B, the surface layer 33B is positioned using a jig (not shown) so that the boundary corresponds to an angled corner 317 of the lower mold 303, and then placed on the lower mold 303. This surface layer placing step corresponds to the "first placing step" of the present invention.

[0116] [Thermoplastic resin placement process] 13(b), the thermoplastic resin M, which is the base material of the cold-press-molded layer 35B in a plasticized state, is placed on the surface layer 33B placed upside down on the main surface portion mounting portion 315. This thermoplastic resin placing step corresponds to the "second placing step" of the present invention.

[0117] [Pressing process] Next, while cooling the upper mold 301 and the lower mold 303 using a cooling means (not shown), such as circulating cooling water through each of the upper mold 301 and the lower mold 303, the upper mold 301 is lowered relative to the lower mold 303 and clamped as shown in FIG. 13(c). The surface layer 33B and the thermoplastic resin M in a plastic state (the base material of the cold-press molded layer 35B), which are the contents of the molding die 300, are pressed at a temperature lower than the softening point of the thermoplastic resin M, for example, at or near room temperature. The pressing pressure in this pressing step is 0.1 to 20 MPa, preferably 0.2 to 15 MPa, and more preferably 0.5 to 10 MPa. If the pressing pressure is less than 0.1 MPa, the thermoplastic resin M may not be able to fill the entire molding cavity 305 (see FIG. 12(b)), resulting in molding defects. If the pressing pressure is more than 20 MPa, the mold releasability may be impaired.

[0118] In the pressing step, the thermoplastic resin M pressed by the floor laying portion forming portion 311 of the upper mold 301 is spread over the surface layer 33B. In this way, the formation of the cold-press-molded layer 35B progresses as the pressing step progresses. During the formation of the cold-press-molded layer 35B, the boundary between the thermoplastic resin M and the surface layer 33B is integrated by thermal fusion due to the heat of the thermoplastic resin M, which has been brought to a state above its softening point (plasticization temperature), and the pressure during the pressing process.

[0119] In the above pressing process, when the thermoplastic resin M pressed and spread by the floor laying portion forming portion 311 is pressed perpendicular to the floor laying portion 41 in the process of being formed to form the raised wall portion 43, the recess 301a of the upper mold 301 and the protrusion 303a of the lower mold 303 cooperate to press the portion that will become the raised surface portion 63 so that the raised wall portion 43 in the process of being formed is bent at the boundary between the portion that will become the main surface portion 61 in the surface layer 33B and the portion that will become the raised surface portion 63. Furthermore, in the above pressing step, when the thermoplastic resin M pressed and spread by the floor laying portion forming section 311 is pressed outward perpendicular to the rising wall section 43 in the process of being formed to form the lateral protrusion section 45, the recessed section 301a of the upper mold 301 and the protruding section 303a of the lower mold 303 cooperate to press the section of the surface layer 33B that will become the lateral protrusion section 65 so as to bend the lateral protrusion section 45 in the process of being formed at the boundary between the section that will become the rising surface section 63 and the section that will become the lateral protrusion section 65. In this way, the main surface section 61, the rising surface section 63 and the lateral protrusion section 65 are formed in the surface layer 33B.

[0120] The surface side of the surface layer 33B (the lower side in FIGS. 13(a) to 13(c)) is cooled by the lower mold 303 despite the pressure applied during press processing. This prevents thermal deformation of the surface side of the surface layer 33B, and the pattern or textured pattern (in this example, a tile-like textured pattern or a lattice-like textured pattern) provided on the surface side of the surface layer 33B remains intact. In the cold-press molded layer 35B, the thermoplastic resin M, which has been brought to a plasticizing temperature, spreads along the shape of the molding cavity 305 (see FIG. 12(b)). It solidifies upon cooling by the molding mold 300 (mainly the upper mold 301), and is molded into a shape corresponding to the shape of the molding cavity 305. This allows for both high design quality and flexible moldability with a three-dimensional effect.

[0121] [Recovery process] Once the pressing process is completed, as shown in Figure 13(d), the upper mold 301 is raised relative to the lower mold 303 to open the molding die 300, and the laminated molded body (entranceway flooring material 31B) formed by the pressing process is removed from the molding die 300 and collected.

[0122] [Joining layer placement process] FIG. 14(b) is an explanatory diagram of a bonding layer arrangement step in a manufacturing method for an entranceway flooring material 31B, which is a specific example (2) of a flooring material. The manufacturing method for the entranceway flooring material 31B described above is applicable when the surface layer 33B and the cold-press-molded layer 35B are made of the same type of thermoplastic resin. When the surface layer 33B and the cold-press-molded layer 35B are made of different types of thermoplastic resin, a bonding layer arrangement step is performed between the surface layer arrangement step and the thermoplastic resin arrangement step. In the bonding layer arrangement step, a bonding layer 4 that exerts an anchor effect is arranged on the surface layer 33B that has been placed upside down on the main surface portion mounting portion 315 in the surface layer arrangement step. Then, in the thermoplastic resin arrangement step, a plasticized thermoplastic resin M (see FIG. 13(b)) is arranged on the bonding layer 4.

[0123] A case where a spunbond nonwoven fabric is used as the bonding layer 4 will be described. During the pressing step of cold-press molding using the mold 300, due to the heat of the thermoplastic resin M, which is heated to a temperature above its softening point, and the pressure during pressing, a portion of the surface layer 33B facing the thermoplastic resin M and a portion of the thermoplastic resin M facing the surface layer 33B each penetrate in a molten state into the fiber gaps of the spunbond nonwoven fabric. Then, by cooling and solidifying, the surface layer 33B and the cold-press-molded layer 35B are firmly integrated via the bonding layer 4 (spunbond nonwoven fabric) due to an anchor effect. Thus, by interposing the bonding layer 4, the surface layer 33B and the cold-press-molded layer 35B can be firmly integrated even if they are made of different materials. The bonding layer 4 may be laminated in advance on the back surface of the surface layer 33B.

[0124] In the manufacturing method of the entranceway flooring material 31A, 31B, the concave-convex pattern of the surface layer 33A, 33B is preferably imparted to the surface layer 33A, 33B before lamination. As described above, in the step of laminating the surface layer 33A, 33B and the cold-press-molded layer 35A, 35B to form the cold-press-molded layer 35A, 35B integrally, a press process is performed to form the cold-press-molded layer 35A, 35B. This press process is performed by bringing the concave-convex pattern imparted to the surface layer 33A, 33B before lamination into contact with the molding die 200, 300. Although the pressure during the press process acts on the concave-convex pattern, the concave-convex pattern is cooled by the molding die 200, 300. Therefore, even if the concave-convex pattern is imparted to the surface layer 33A, 33B before lamination, thermal deformation of the concave-convex pattern can be suppressed, and the shape of the concave-convex pattern can be maintained. According to flooring materials 31A and 31B, it is not necessary to carry out a step of imparting a concave-convex pattern to surface layers 33A and 33B by, for example, embossing after press working, thereby improving production efficiency.

[0125] [Another embodiment] In this specification, a corner refers to a convex or concave portion including an intersection line formed at the intersection of two non-parallel surfaces. 4 and 9 show corners 55, 57, 85, 87 formed by two perpendicular surfaces and protruding outward in a convex shape (i.e., a mountain-shaped corner), but the intersection angle between the two surfaces may be either an obtuse angle or an acute angle.

[0126] Figure 15 is a plan view showing an entrance hall floor material 31C, which is a specific example (3) of a floor material to which the present invention can be applied. As shown in Figure 15, there is also an embodiment in which two planes intersect at an angle greater than 180° and include corners 59, 89 that are recessed inward (i.e., valley-shaped).

[0127] In this specification, "fixing the main surface portion 61 to the floor-laying portion 41" includes both a case where the main surface portion 61 is directly fixed to the floor-laying portion 41 and a case where the main surface portion 61 is indirectly fixed to the floor-laying portion 41 via the bonding layer 4. Furthermore, "fixing the upright surface portion 63 to the upright wall portion 43" includes both a case where the upright surface portion 63 is directly fixed to the upright wall portion 43 and a case where the upright surface portion 63 is indirectly fixed to the upright wall portion 43 via the bonding layer 4. Furthermore, "fixing the lateral protrusion surface portion 65 to the upright wall portion 43 and the lateral protrusion portion 45" includes both a case where the lateral protrusion surface portion 65 is directly fixed to the upright wall portion 43 and the lateral protrusion portion 45 and a case where the lateral protrusion surface portion 65 is indirectly fixed to the upright wall portion 43 and the lateral protrusion portion 45 via the bonding layer 4.

[0128] FIG. 16 shows a modified example (1) of the surface layer 33B in the entranceway flooring material 31B, which is a specific example (2) of the flooring material. FIG. 17 shows a modified example (2) of the surface layer 33B. In the example of the surface layer 33B shown in FIGS. 10 and 11 above, the outer folded pieces 121, 122, and 123 that are adjacent in the unfolded state (see FIGS. 10(a) and 11(a)) and adjacent after press molding (see FIGS. 10(b) and (c) and 11(b) and (c)) are trapezoidal with one or both ends cut obliquely. The embodiment is not limited to the examples shown in FIGS. 10 and 11 . There are also possible embodiments in which the outer folded pieces 121, 122, and 123 are rectangular (oblong), as shown in modified example (1) of FIG. 16 and modified example (2) of FIG. 17. According to variants (1) and (2), compared to when each outer bent piece 121, 122, 123 is trapezoidal as shown in Figures 10 and 11, there is an advantage that adjacent outer bent pieces 121, 122, 123 (see Figures 16(b) and (c) and Figures 17(b) and (c)) can be joined with higher precision after press molding. [Industrial Applicability]

[0129] The present invention can firmly integrate a cold-pressed layer that is hard and capable of being formed into a three-dimensional shape with a flexible surface layer that has a fine uneven structure and is excellent in design. Therefore, the present invention is a technology that can be widely used in the construction industry, renovation industry, etc., and is particularly useful in constructing floor surfaces in various buildings such as ordinary houses, apartment buildings, condominiums, commercial malls, office buildings, factories, stores, stations, schools, hospitals, and public facilities. [Explanation of symbols]

[0130] 1A, 1B Flooring 2,2A,2B surface layer 3 Cold press molding layer 4 Bonding layer 31A, 31B, 31C Flooring 33A,33B Surface layer 35A, 35B Cold press molding layer 41 Floor laying section 43 Raised wall 55,57 Corner 61 Main surface 63 Raised surface 81, 82, 83 Folded pieces 85,87 Corner 95, 96, 97, 98 Cut 200,300 mold

Claims

1. A flooring material comprising a surface layer and a molding layer laminated together, The molding layer has a floor-laying portion laid on a floor surface and a rising wall portion connected to the floor-laying portion so as to protrude upward, the surface layer has a main surface portion fixed to the floor laying portion, and a rising surface portion connected to the main surface portion and fixed to the rising wall portion, the raised surface portion includes two adjacent folded pieces that stand upright relative to the main surface portion to form corners; In the portion of the surface layer where the two folded pieces are adjacent, a notch is provided on the extension of the fold formed at the boundary between the main surface portion and the other folded piece, so that the two folded pieces are in an upright state with a portion where the end face of one folded piece comes into contact with the end face of the other folded piece.

2. A flooring material as described in Claim 1, wherein the length of the cut is equivalent to the thickness of one of the folded-up pieces.

3. 3. The flooring material according to claim 1, wherein the surface layer and the molding layer are made of the same material.

4. 3. The flooring material according to claim 1, wherein the surface layer and the molding layer are made of different materials, and the two layers are laminated together via a bonding layer.

5. The flooring material according to any one of claims 1 to 4, wherein the surface layer has an uneven pattern.

6. A method for manufacturing a flooring material comprising laminating a surface layer and a cold-press molded layer, The cold-press molded layer has a floor-laying portion laid on a floor surface and a rising wall portion connected to the floor-laying portion so as to protrude upward, the surface layer has a main surface portion fixed to the floor laying portion, and a rising surface portion connected to the main surface portion and fixed to the rising wall portion, the raised surface portion includes two adjacent folded pieces that stand upright relative to the main surface portion to form corners; In a portion of the surface layer where the two folded-up pieces are adjacent to each other, a notch is provided on an extension line of a fold formed at the boundary between the main surface portion and the other folded-up piece so that the two folded-up pieces are in an upright state with a portion where an end face of one folded-up piece contacts an end face of the other folded-up piece, a first arrangement step of arranging the surface layer in a mold having a molding cavity formed therein for molding the floor laying portion, the rising wall portion, the main surface portion, and the rising surface portion so that the surface layer can be bent at the boundary between the portion that will become the main surface portion and the portion that will become the rising surface portion; a second disposing step of disposing a thermoplastic resin in a state of not less than its softening point so as to be in contact with the surface layer; a pressing step of pressing the contents of the mold at a temperature lower than the softening point of the thermoplastic resin; a recovery step of removing the laminated molded body formed in the pressing step from the mold; A method for manufacturing a flooring material comprising the steps of:

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