JP2015017372A - Floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material having sufficient sound insulation performance and impact absorption performance.SOLUTION: A floor material 10 includes: a decorative surface layer 1; a base material layer 2 having a thickness of 4-12 mm made of a plywood with a plurality of single plates 2a-2e laminated and provided on the rear surface side of the decorative surface layer 1; a sound insulation layer 3 having a thickness of 2-6 mm provided on the rear surface side of the base material layer 2; and an impact absorption layer 4 having a thickness of 2-10 mm provided on the rear surface side of the base material layer 2. The base material layer 2 has a plurality of rear grooves 6a parallel to a transverse direction X of the floor material 10 on the rear surface side thereof. A top edge of the rear groove 6a is provided in the single plate 2b as the second top layer of the base material layer 2. The sound insulation layer 3 consists of at least one of a synthetic resin foam and a nonwoven cloth, and the impact absorption layer 4 consists of at least one of the synthetic resin foam, the nonwoven cloth, and a rubber system expanded material.

Description

  The present invention relates to a flooring having sound insulation performance and shock absorption performance.

  The flooring material is required to have various performances as well as the warmth of wood. Therefore, floor materials having various performances have been developed.

  For example, Patent Documents 1 and 2 disclose floor materials that have the performance of reducing the impact received by a human body during a fall.

  The flooring described in Patent Document 1 has a configuration in which a wood surface material, an impact absorbing material, and a back material are laminated in order. Patent Document 1 describes that by using an impact absorbing material having an Asker C hardness of 70 degrees or less and a thickness of 2 mm or more, the G value at the time of impact can be made 80 G or less.

  The flooring described in Patent Document 2 has a configuration in which a wood surface material and an impact absorbing material are laminated. Patent Document 2 uses a wood surface material that satisfies a predetermined condition and uses an impact absorbing material having an Asker C hardness of 40 to 50 degrees and a thickness of 6 mm or more, so that the G value at the time of impact is 100 G or less. It is described that it can be. Patent Document 2 uses a wood surface material that satisfies a predetermined condition, and uses an impact absorbing material having an Asker C hardness of 9 to 50 degrees and a thickness of 7 mm or more, so that the G value at the time of impact is obtained. It is also described that it can be made 100G or less.

JP 2011-190672 A JP 2011-190673 A

  By the way, flooring materials used in apartment houses such as apartment buildings are required not only to reduce the impact at the time of falling but also to provide sound insulation performance. However, the flooring materials described in Patent Documents 1 and 2 are not sufficiently considered for sound insulation performance. Therefore, the flooring materials described in Patent Documents 1 and 2 may not be able to satisfy the sound insulation performance required for flooring materials such as apartments.

  Therefore, the present inventors have considered adding a sound insulating material to the floor materials described in Patent Documents 1 and 2 so that they can be appropriately used in an apartment or the like. However, as a result of the study by the present inventors, it has been found that the sound insulation performance of the flooring material cannot be sufficiently improved by simply adding the sound insulation material.

  The present invention solves such problems of the prior art, and an object thereof is to provide a flooring material having sufficient sound insulation performance and shock absorption performance.

  The present inventors first considered that the flooring is configured to include a decorative layer, a base material layer, a sound insulating layer, and a shock absorbing layer. As the base material layer, it was considered to use a plywood laminated with a plurality of single plates. And in the floor material which has said four layers, earnestly researched about the preferable structure for improving sound-insulation performance. As a result, it was found that the condition of the back groove provided on the back surface of the base material layer is important.

  The gist of the present invention is the following flooring.

  (1) A base layer having a thickness of 4 to 12 mm which is formed of a decorative layer, a plywood obtained by laminating a plurality of single plates, and is provided on the back side of the decorative layer, and a thickness which is provided on the back side of the base layer. Including a 2 to 6 mm sound insulation layer and a shock absorbing layer having a thickness of 2 to 10 mm provided on the back surface side of the base material layer, and the base material layer on the back surface side in the short direction of the flooring A plurality of parallel back grooves, and an upper end of the back groove is provided on the second single plate of the plurality of single plates, and the sound insulation layer is at least one of a synthetic resin foam and a nonwoven fabric. A flooring material comprising the shock absorbing layer comprising at least one of a synthetic resin foam, a nonwoven fabric, and a rubber foam.

  (2) The flooring as described in (1) above, wherein the thickness of the first single plate from the top of the plurality of single plates is 0.2 to 0.8 mm.

  (3) The sound insulation layer is made of a synthetic resin foam having a foaming ratio of 25 to 60 times, and the shock absorbing layer is a synthetic resin foam and / or a rubber-based foam having a foaming ratio of 5 to 24 times. The flooring material according to the above (1) or (2), characterized by comprising:

  (4) The above-mentioned (1) to (3), wherein the distance from the surface of the first single plate of the base material layer to the upper end of the back groove is 0.4 to 3.3 mm. Floor material according to any of the above.

  (5) The flooring material according to any one of (1) to (4), wherein a width of the back groove is 1 to 3 mm.

  (6) The flooring material according to any one of (1) to (5), wherein an interval between the adjacent back grooves is 5 to 15 mm.

  The flooring of the present invention has sufficient sound insulation performance and shock absorption performance.

The perspective view which illustrated the flooring concerning one embodiment of the present invention The front view and side view which illustrated the flooring which concerns on one Embodiment of this invention Sectional drawing which illustrated the flooring which concerns on one Embodiment of this invention Bottom view illustrating the base material layer

  The present invention will be described below with reference to the drawings. FIG. 1 is a perspective view illustrating a flooring 10 according to an embodiment of the present invention, FIG. 2A is a front view illustrating the flooring 10, and FIG. It is the illustrated side view. The flooring 10 according to the present invention can satisfy the criteria of ΔLL (I) -4 grade in sound insulation performance, and the G value at the time of impact measured based on JIS A6519 is, for example, 80 or less (preferably Is configured to be 60 or less). Hereinafter, the configuration of the flooring 10 will be described in detail.

  As shown in FIGS. 1 and 2, the flooring 10 has, for example, a substantially rectangular shape, and includes a decorative layer 1, a base material layer 2, a sound insulating layer 3, and a shock absorbing layer 4. In the present embodiment, the decorative layer 1, the base material layer 2, the sound insulation layer 3, and the shock absorbing layer 4 are laminated in order from the top.

  As shown in FIG. 1, a male body (convex portion) 5 a and a female body (concave portion) 5 b for joining the floor materials 10 to each other are provided on the side surfaces of the floor material 10. Specifically, the male fruit 5a is provided in an L shape along one long side and one short side of the flooring 10, and the female fruit 5b is formed on the other long side and the other short side of the flooring 10. It is provided in an L shape along the side. In the present embodiment, the male fruit 5 a and the female fruit 5 b are formed on the base material layer 2. In addition, in order to avoid drawing becoming complicated, illustration of the male fruit 5a and the female fruit 5b is abbreviate | omitted in FIG. 2 and FIG. 4 mentioned later.

  The dimensions of the floor material 10 in the lateral direction X and the longitudinal direction Y are not particularly limited. The dimension (short direction X × longitudinal direction Y) of the flooring 10 may be set to, for example, 145 mm × 909 mm, 303 mm × 909 mm, or 303 mm × 1818 mm. Moreover, the thickness of the flooring 10 is appropriately set according to the use environment and the like. The thickness of the flooring 10 is set to, for example, 10 to 20 mm, preferably set to 12 to 18 mm, and more preferably set to 12 to 15 mm.

  As the decorative layer 1, for example, a natural veneer, an artificial veneer, a wooden board such as a saw board, a synthetic resin sheet such as polyethylene or polypropylene, a paper sheet such as a resin-impregnated paper or a printed paper, or a composite sheet thereof Can be used. Moreover, the coating material comprised by urethane type resin etc. is apply | coated to the surface of the decorative layer 1 as needed. For joining the base material layer 2 and the decorative layer 1, for example, an adhesive such as urea melamine, ethylene vinyl acetate, PUR (polyurethane reactive) is used.

  FIG. 3 is an enlarged view illustrating a cross section parallel to the longitudinal direction Y of the flooring 10. As shown in FIG. 3, the base material layer 2 consists of a plywood (5 ply plywood in this embodiment) which laminated | stacked the single plate 2a-2e of multiple (5 in this embodiment), for example. The single plates 2a to 2e are stacked so that, for example, the fiber directions of the single plates vertically adjacent to each other are different by 90 °. In the present embodiment, the fiber directions of the odd-numbered (ie, first, third, and fifth) single plates 2a, 2c, and 2e from the top are parallel to the longitudinal direction Y, and are even-numbered from the top (ie The single plates 2a to 2e are arranged so that the fiber directions of the single plates 2b and 2d of the second layer and the fourth layer are parallel to the short direction X. The thickness of the base material layer 2 is set to 4 to 12 mm, a preferable lower limit is 5 mm, and a preferable upper limit is 9 mm. In this embodiment, the base material layer 2 is attached to the back surface of the decorative layer 1, but a wood fiberboard (MDF, HDF, etc.) is used as a protective layer between the decorative layer 1 and the base material layer 2. ) Or a resin-impregnated sheet or the like may be provided.

  In order to ensure sufficient sound insulation performance of the flooring 10 without deteriorating the feeling of walking, the first single plate 2a and the lowest single plate 2e from the top of the base material layer 2 are the other single plates 2b to 2d. It is preferable to form it thinner. The single plate 2a and the single plate 2e may have the same thickness or different thicknesses.

  If the veneer 2a is too thick, the sound insulation performance of the flooring 10 is lowered, and if it is too thin, the rigidity of the flooring 10 is lowered. For this reason, the thickness of the single plate 2a is set to 0.2 to 0.8 mm, and a preferable upper limit is 0.5 mm. If the veneer 2e is too thick, the balance with the veneer 2a is deteriorated, and warping may occur. For this reason, the thickness of the single plate 2e is set to, for example, 0.2 to 1.5 mm, the preferable upper limit is 0.8 mm, and the more preferable upper limit is 0.5 mm. The thicknesses of the other single plates 2b, 2c, and 2d are set to 1 to 3 mm, for example. In the present embodiment, the single plate 2c is formed thinner than the single plates 2b and 2d.

  Although the manufacturing method of the base material layer 2 is not specifically limited, For example, you may manufacture the base material layer 2 by scraping the 1st layer of a common 5-ply plywood. Specifically, for example, 8.7 mm plywood (first layer: 1.1 mm, second layer: 2.6 mm, third layer: 1.3 mm, fourth layer: 2.6 mm, fifth layer: 1. The base layer 2 may be manufactured by cutting the first layer of 1 mm).

  As the veneers 2a to 2e, wood such as lauan, capol, kempas, acacia mangum, falcata, eucalyptus, chameleon, hippopotamus, cedar, spruce, todomatsu, larch, and radiata pine can be used. It is not necessary for all of the single plates 2a to 2e to be made of the same wood, but all of the single plates 2a to 2e may be made of the same wood.

  FIG. 4 is a bottom view illustrating the base material layer 2. As shown in FIGS. 2 and 4, the base material layer 2 has, for example, a plurality of back grooves 6 a (19 in the present embodiment) parallel to the lateral direction X and a longitudinal direction Y on the back surface side. A plurality of (six in this embodiment) back grooves 6b are provided. In addition, the number of the back grooves 6a and the back grooves 6b is appropriately changed according to the configuration of the flooring 10, the function required for the flooring 10, and the like.

  As shown in FIG. 2, the vertical length of the back groove 6a is longer than that of the back groove 6b. In other words, the depth of the back groove 6a is deeper than that of the back groove 6b. With reference to FIG. 3, if the distance d1 from the surface of the base material layer 2 (the surface of the single plate 2a) to the upper end of the back groove 6a is too large, the sound insulation performance of the flooring 10 is deteriorated. The rigidity of the is reduced. For this reason, the upper end of the back groove 6 a is provided on the second single plate 2 b from the top of the base material layer 2. Moreover, the distance d1 is set to 0.4-3.3 mm, for example, a preferable upper limit is 3.0 mm, a more preferable upper limit is 2.0 mm, and a more preferable upper limit is 1.7 mm.

  If the number of back grooves 6a is too large, the rigidity of the flooring material 10 is lowered, and if the number of back grooves 6a is too small, the sound insulation performance of the flooring material 10 is lowered. Considering these, the distance d2 is set to 5 to 15 mm, for example, and the width W1 of the back groove 6a is set to 1 to 3 mm, for example. For example, when the width of the flooring 10 is 145 mm, about 4 to 6 back grooves 6b may be provided, but the back grooves 6b may not be provided. Although a detailed description is omitted, the upper end of the back groove 6b is provided, for example, on the single plate 2d of the fourth layer from the top (second layer from the bottom) of the base material layer 2.

  With reference to FIGS. 1-3, as the sound insulation layer 3, a synthetic resin foam, a nonwoven fabric, or what compounded these can be used, for example. Among these, it is preferable to use a synthetic resin foam. If the sound insulation layer 3 is too thin, the sound insulation performance of the flooring 10 is lowered, and if it is too thick, the walking feeling may be deteriorated. For this reason, the thickness of the sound insulation layer 3 is set to 2 to 6 mm, and a preferable upper limit is 4 mm.

  Examples of the synthetic resin foam of the sound insulating layer 3 include a continuous foam such as polyurethane, and an independent foam such as polyethylene, ethylene vinyl acetate, and polypropylene. Among these, it is preferable to use polyurethane. As the synthetic resin foam of the sound insulation layer 3, one having an expansion ratio of 25 to 60 times is preferable, and one having 30 to 50 times is more preferable. Examples of the material for the nonwoven fabric of the sound insulating layer 3 include polyester and rayon.

  The adhesion between the base material layer 2 and the sound insulation layer 3 is preferably performed using an adhesive that does not contain formaldehyde, such as an aqueous vinyl urethane adhesive or a rubber adhesive. Although detailed description is omitted, if the adhesive is absorbed by the sound insulation layer 3, the sound insulation performance of the sound insulation layer 3 may be deteriorated. Therefore, a moisture-proof layer (not shown) may be provided on the surface of the sound insulation layer 3 in order to prevent the adhesive from being absorbed by the sound insulation layer 3. Similarly, a moisture-proof layer (not shown) may be provided on the back surface of the sound insulation layer 3 and the front and back surfaces of the shock absorbing layer 4. As the moisture-proof layer, for example, a polyolefin film such as polyethylene or polypropylene, a film having a low moisture permeability such as a PET film, a sheet obtained by bonding these resin film and a metal sheet, or a composite of these can be used. . Examples of the metal sheet include aluminum oxide and aluminum foil.

  As the shock absorbing layer 4, for example, a synthetic resin foam, a nonwoven fabric, a rubber foam, or a composite of these can be used. Among these, it is preferable to use a synthetic resin foam. If the shock absorbing layer 4 is too thin, the shock absorbing performance is lowered, and if it is too thick, the walking feeling may be deteriorated. For this reason, it is preferable that the thickness of the shock absorbing layer 4 is 2 to 10 mm, a more preferable lower limit is 3 mm, and a more preferable upper limit is 6 mm.

  Examples of the synthetic resin foam of the shock absorbing layer 4 include a continuous foam such as polyurethane, and an independent foam such as polyethylene, ethylene vinyl acetate, and polypropylene. Among these, it is preferable to use polyethylene. As the synthetic resin foam of the shock absorbing layer 4, it is preferable to use a foam having an expansion ratio of 5 to 24 times, and a more preferable upper limit is 20 times.

  Examples of the material for the nonwoven fabric of the shock absorbing layer 4 include polyester and rayon. Examples of the rubber foam of the shock absorbing layer 4 include foams such as natural rubber and styrene butadiene rubber. As the rubber foam of the shock absorbing layer 4, it is preferable to use a foam having a foaming ratio of 5 to 24 times, and a more preferable upper limit is 20 times.

  The sound insulation layer 3 and the shock absorbing layer 4 may be bonded using, for example, an adhesive that does not contain formaldehyde, such as a urethane adhesive, an ethylene vinyl acetate adhesive, or a rubber adhesive. You may go by. The sound insulating layer 3 and the shock absorbing layer 4 may be provided on the back side of the base material layer 2, and the positions of the sound insulating layer 3 and the shock absorbing layer 4 may be switched. That is, the flooring may have a configuration in which the decorative layer 1, the base material layer 2, the shock absorbing layer 4, and the sound insulating layer 3 are laminated in order from the top.

<Reference evaluation>
In order to confirm the effect of the base material layer according to the present invention, the floor materials of Reference Examples 1 to 12 and the floor material of Comparative Example 1 were prepared, and the impact sound reduction performance (ΔL grade) was measured. The flooring materials of Reference Examples 1 to 12 satisfy the conditions defined in the present invention except that the shock absorbing layer 4 is not provided. Table 1 shows the configurations of Reference Examples 1 to 12 and Comparative Example 1, and Table 2 shows the measurement results. As the sound insulation layer 3, polyurethane having a foaming ratio of 49 times was used. Further, “reference” in Table 2 indicates a reference of ΔLL (I) -4 grade (impact sound reduction amount).

  When the floor materials of Reference Examples 1 to 4 and the floor materials of Reference Examples 10 to 12 having the same sound insulation layer thickness are compared, as shown in Table 2, the floor material of Reference Examples 1 to 4 has an impact at a frequency band of 250 Hz. The amount of sound reduction is larger. Furthermore, in the flooring materials of Reference Examples 2 and 4, the amount of reduction in impact sound in the frequency band of 125 Hz was sufficiently large. From these facts, it was found that by reducing the thickness of the first single plate 2a of the base material layer 2 appropriately, the reduction amount of the impact sound in the low frequency band can be increased. Moreover, since the impact sound reduction amount of the flooring material of Comparative Example 1 is smaller than the impact sound reduction amount of other flooring materials, the upper end of the back groove 6a is connected to the second single plate 2b of the base material layer 2. It has been found that the sound insulation performance of the flooring material is greatly improved by providing it on the floor.

  Further, when Reference Examples 1 to 4 and Reference Examples 5 to 9 having different sound insulation layer thicknesses were compared, there was no significant difference in sound insulation performance in each frequency band. Therefore, if the decorative layer 1, the base material layer 2, and the sound insulation layer 3 satisfy the conditions defined in the present invention, sufficient sound insulation can be achieved even if the thickness of the sound insulation layer 3 is reduced to about 2.5 mm. It turns out that performance is obtained. In other words, when the decorative layer 1, the base material layer 2, and the sound insulation layer 3 satisfy the conditions defined in the present invention, it has been found that sufficient sound insulation performance can be obtained while making the sound insulation layer 3 thin. Thereby, sufficient sound insulation performance can be obtained while preventing deterioration in the feeling of walking.

  In order to confirm the effect of the present invention, a flooring material having the same configuration as the above-described flooring material 10 was prepared, and the impact sound reduction performance (ΔL grade) was measured. The specific configuration of the flooring material to be measured was as follows. The total thickness of the flooring was 17.46 mm, the width was 145 mm, and the length was 909 mm. As the decorative layer 1, a resin sheet having a thickness of 0.16 mm was used. As the base material layer 2, a 5-ply plywood having a thickness of 5.4 mm (first layer: 0.7 mm, second layer: 1.4 mm, third layer: 1.2 mm, fourth layer: 1.4 mm, 5th layer: 0.7 mm) was used. An MDF sheet having a thickness of 0.4 mm was provided between the decorative layer 1 and the base material layer 2. As the sound insulation layer 3, polyurethane having a thickness of 2.5 mm and a foaming ratio of 39 times was used. As the shock absorbing layer 4, polyethylene having a thickness of 9 mm and an expansion ratio of 10 times was used. The distance d1 from the surface of the base material layer 2 (the surface of the single plate 2a) to the upper end of the back groove 6a is set to 1.4 mm, the distance d2 between the adjacent back grooves 6a is set to 10 mm, and the width of the back groove 6a W1 was set to 1.5 mm. The interval between the adjacent back grooves 6b was set to 10 mm, and the width of the back grooves 6b was 1.5 mm. The evaluation results are shown in Table 3. “Reference (dB)” in Table 3 indicates a reference (impact sound reduction amount) of ΔLL (I) -4 grade.

  As shown in Table 3, the flooring material of this example was able to satisfy the standard of ΔLL (I) -4 grade and had sufficient sound insulation performance. Further, even when compared with the flooring materials (sound insulation layer thickness: 2.5 mm) of Reference Examples 5 to 9 having no shock absorbing layer 4, there was no significant difference in sound insulation performance. Furthermore, as a result of measuring the G value at the time of impact on the flooring material of this example based on JIS A6519, it was 55 G, and the flooring material of this example had sufficient impact absorption performance. For these reasons, when the flooring material satisfies the conditions stipulated in the present invention, it is possible to sufficiently prevent the deterioration of the sound insulation performance due to the provision of the shock absorption layer 4 or the deterioration of the shock absorption performance due to the provision of the sound insulation layer 3. I understood that I could do it. That is, it was found that the floor material satisfying the conditions defined in the present invention can achieve both sound insulation performance and impact absorption performance.

  The flooring of the present invention has sufficient impact absorption performance and sound insulation performance. Therefore, it can be suitably used in an apartment house such as an apartment.

DESCRIPTION OF SYMBOLS 1 Decorative layer 2 Base material layer 2a-2e Single board 3 Sound insulation layer 4 Shock absorption layer 5a Male fruit 5b Female fruit 6a, 6b Back groove 10 Flooring according to the present invention

Claims (6)

A makeup layer,
A base material layer having a thickness of 4 to 12 mm, which is formed of a plywood obtained by laminating a plurality of single plates and provided on the back side of the decorative layer;
A sound insulating layer having a thickness of 2 to 6 mm provided on the back side of the base material layer;
Including a shock absorbing layer having a thickness of 2 to 10 mm provided on the back side of the base material layer,
The base material layer has a plurality of back grooves parallel to the short direction of the flooring on the back surface side thereof,
An upper end of the back groove is provided on the single plate of the second layer from above among the plurality of single plates,
The sound insulation layer is made of at least one of a synthetic resin foam and a nonwoven fabric,
The flooring material, wherein the shock absorbing layer is made of at least one of a synthetic resin foam, a nonwoven fabric, and a rubber foam.   The flooring according to claim 1, wherein the thickness of the first single layer from the top of the plurality of single plates is 0.2 to 0.8 mm. The sound insulation layer is made of a synthetic resin foam having an expansion ratio of 25 to 60 times,
The flooring according to claim 1 or 2, wherein the shock absorbing layer is made of a synthetic resin foam and / or a rubber foam having an expansion ratio of 5 to 24 times.   The distance from the surface of the said 1st single plate of the said base material layer to the upper end of the said back groove is 0.4-3.3 mm, The any one of Claim 1 to 3 characterized by the above-mentioned. Flooring.   The flooring material according to any one of claims 1 to 4, wherein a width of the back groove is 1 to 3 mm.   The flooring material according to any one of claims 1 to 5, wherein an interval between the adjacent back grooves is 5 to 15 mm.

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