JP2001328105A - Floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material which is excellent in bending strength and surface hardness and good in dimensional change to temperature change and humidity change. SOLUTION: The floor material comprises basic materials 1 and a sliced veneer 4 sticking to a surface of the basic materials 1. At least a surface layer of the basic materials 1 to which the sliced veneer 4 sticks comprises a fiber board layer 3 wherein a long fiber mat comprising an aggregate of a plurality of long fibers in which adhesives are dispersed. Then, the long fiber mat is provided wherein the long fibers obtained from at least either of kenaf, oil palm or coconut palm, are oriented in almost one direction.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material comprising a base material and a veneer attached to the surface of the base material, and used for floors, steps on stairs and the like.

[0002]

2. Description of the Related Art In the field of housing, wooden flooring materials with a wooden floor finish are easy to clean and clean, and also reduce the occurrence of ticks which are a cause of sick house syndrome. Use is expanding rapidly, mainly in housing. As such a flooring material, there is known a base material made of Lauan plywood or the like and a veneer attached to the surface of the base material for the purpose of surface decoration.

[0003]

The above-mentioned flooring material has insufficient surface hardness, so that when a desk, chair, furniture with casters, etc. are concentrated and subjected to a load, the surface of the flooring material is scratched or dented. There was a drawback that it was easy to drip.

For this reason, the flooring material is provided on the surface of the base material 42 on the side where the veneer plate 4 is adhered as shown in FIG. 9 by using MDF (medium fiberboard: medium density fiberboard).
and (ard) 41 formed as a reinforcing material layer. The MDF 41 has a length of 6 from wood.
It is formed by molding fine fibers of less than mm. As the fiber, a fiber obtained by processing a small piece obtained from softwood or hardwood with a defibrating machine or the like is used. MDF41 used for this flooring
Has an excellent effect on scratch resistance, but has a small strength against loads such as bending and impact. Therefore, a floor material using MDF41 as a reinforcing material layer has a thickness of the base material 42 to maintain strength. Need to be thicker. In addition, MDF41
Because the dimensional change with respect to indoor temperature change and humidity change is larger than plywood such as Lauan plywood, floor materials using MDF41 as a reinforcing material layer may be warped or pushed up, and cracks may occur on the shingle. is there.

[0005] On the other hand, attempts have been made to use unused plant resources such as coconut fibers as wastes as building material resources instead of wood fibers. It is known that the above-mentioned material has a large number of voids inside, and is therefore lightweight and excellent in load resistance. However, it has not yet been fully utilized as a building material.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a flooring material which is excellent in bending strength and surface hardness, and has good dimensional change with respect to temperature change and humidity change. is there.

[0007]

The flooring material according to claim 1 is:
In the base material and a flooring made of a veneer adhered to the surface of the substrate, at least the surface layer of the substrate to which the veneer is adhered is composed of a number of long fibers in which an adhesive is dispersed. It is formed of a fiberboard layer formed by hot-pressing a long fiber mat made of an aggregate, and this long fiber mat orients long fibers obtained from at least one of kenaf, oil palm and coconut in substantially one direction. It is characterized by having been done.

The present inventor has set out the following in order to achieve the above object.
As a result of diligent research, a fiberboard obtained by hot-pressing a long fiber mat that is oriented in almost one direction by dispersing an adhesive into many long fibers obtained from kenaf, oil palm, or coconut The present inventors have found that excellent tensile strength is exhibited at a high level, and have completed the present invention.

The fiber board formed of the long fibers oriented substantially in one direction can control the rigidity against bending load, that is, the mechanical strength against bending deformation by the tensile strength of the long fibers. The bending strength of a plate made of fibers is formed not only by the strength of the fibers themselves, but also by the entanglement of the fibers and the bonding strength of the bonded portion between the fibers. The fiber board formed from the long fibers has a large number of entanglements of the long fibers inside, and can increase the portion to which the adhesive per one long fiber adheres, thereby increasing the bending strength.

The cause of the floor material being damaged or dented by the concentrated load due to the low strength of the material constituting the portion close to the surface of the floor material, the surface of the floor material, or the like. And the surface hardness is locally reduced due to variation in the void structure of the layer constituting the portion close to. The fiberboard has a high strength of the fibers themselves and the long fibers are oriented in substantially one direction, so that the internal void structure can be a uniform and dense structure. As a result, the flooring material of the present invention can maintain a high surface hardness in any part against a concentrated load.

The cause of the dimensional change of the flooring with respect to the temperature change and the humidity change is that the floor material changes with the temperature change and the humidity change.
It is presumed that this is because swelling due to moisture adsorption and shrinkage due to desorption of water occur in the material constituting the flooring material and the internal voids. Since the above-mentioned long fiber hardly permeates moisture, the change in length in the direction of orientation can be extremely reduced by orienting the long fiber. Further, since a fiber board formed of oriented long fibers has a large number of entangled fibers inside, it is possible to reduce the change in length even in a direction orthogonal to the orientation direction of the fibers. Furthermore, since the above fiberboard can increase the portion to which the adhesive per one long fiber adheres, this also makes it possible to reduce the length change in the direction orthogonal to the fiber orientation direction. It is. As a result, the flooring material of the present invention can reduce a dimensional change with respect to a temperature change and a humidity change.
In addition, it is possible to suppress the occurrence of cracks in the veneer plate.

The floor material according to claim 2 is the floor material according to claim 1, wherein the long fibers have an average fiber length of 100 to 4.
000 mm. By the above, while there are many entanglements of the fibers inside the fiberboard, it is possible to increase the portion where the adhesive per fiber is attached, and to reduce the seam portion between the fibers. is there.

According to a third aspect of the present invention, there is provided the flooring material according to the first or second aspect, wherein the base material is provided on the surface of the plate-like substrate on the side of the plate-like substrate to which the veneer is adhered. It is characterized in that the fiberboard layer is formed. By the above, it is possible to obtain a fiber board exhibiting excellent properties such as excellent bending strength and surface hardness and excellent dimensional change with respect to temperature change and humidity change.

According to a fourth aspect of the present invention, in the flooring material according to any one of the first to third aspects, the base material comprises a plate-like substrate and a fiber board on both sides of the plate-like substrate. It is characterized in that a layer is formed. By the above,
When the veneer is attached, the mechanical strength on the opposite side can be increased, so that it can have higher strength and form a structure that is substantially symmetric with respect to the thickness direction, such as warping or pushing up. Can be suppressed from changing in the thickness direction.

According to a fifth aspect of the present invention, in the flooring material according to any one of the first to fourth aspects, the base material is a plate-like substrate and a plate on the side to which the veneer of the plate-like substrate is adhered. A fiberboard layer comprising a plurality of layers is formed on the surface, and the layers in which the long fibers are oriented are alternately orthogonal to each other. According to the above, when the fiber direction of the veneer is formed in the longitudinal direction of the flooring material, the layer of the fiberboard layer forming the fiber direction in the same direction as the longitudinal direction of the flooring material is bent with respect to the longitudinal direction of the flooring material. Demonstrates the effect of increasing the strength, the longitudinal direction of the flooring material (the fiber direction of the veneer)
The fiberboard layer formed with the fiber direction in the direction perpendicular to the direction of the vertical direction can exert the effect of suppressing the occurrence of cracks in the veneer plate and favorably maintaining the dimensional change.

According to a sixth aspect of the present invention, in the flooring material according to any one of the third to fifth aspects, the plate-like substrate is formed by pulverizing at least one of kenaf, oil palm and coconut. It is characterized in that the obtained particles are molded. As described above, since the particles have high strength similarly to the long fibers and have uniform and fine voids inside, the density of the entire flooring material can be further reduced. The flooring material has both strength and lightness.

According to a seventh aspect of the present invention, in the flooring according to the first or second aspect, the base material is an aggregate of a plurality of layers formed by orienting the long fibers in substantially one direction. The layers are formed so that the directions in which the long fibers are oriented are alternately orthogonal to each other. By the above, in the flooring material in which the fiber direction of the veneer is formed in the longitudinal direction of the flooring material, the effect of increasing the bending strength and suppressing the occurrence of cracks in the veneer and favorably maintaining the dimensional change are exhibited. Can be done.

According to an eighth aspect of the present invention, in the flooring according to any one of the first to seventh aspects, the long fiber mat is formed by entanglement by needle punching. I do. By the above, the entanglement between the fibers is reinforced, and the bonding strength between the fibers can be further increased.

According to a ninth aspect of the present invention, in the flooring according to any one of the first to eighth aspects, the layer of the fiberboard layer forming the surface to which the veneer is adhered orients the long fibers. The direction is orthogonal to the direction in which the fibers of the veneer are oriented. By the above, the effect of suppressing the occurrence of cracks in the pushing plate is enhanced.

A floor material according to a tenth aspect is the floor material according to any one of the first to ninth aspects, wherein the long fiber mat is formed by knitting or knitting the long fibers. There is a feature. By the above, the adhesive strength between the fibers can be further increased.

[0021]

1 and 2 show an embodiment according to the first to third aspects of the present invention. FIG. 1 is a perspective view, and FIG. 2 is an enlarged schematic view of a fiberboard layer. FIG.

The flooring material of the present invention is obtained by sticking a veneer plate 4 to a base material 1. The substrate 1 has a plate-shaped substrate 2 and a fiberboard layer 3 formed on a surface of the plate-shaped substrate 2 to which a veneer plate 4 is adhered. The base material 1 has a real part on its side end surface, and has a male nut 5 on one side end surface and a female nut 6 on the other side end surface. The veneer plate 4 is a thin veneer veneer having a thickness of about 0.2 to 0.3 mm for the purpose of surface decoration, and is obtained by slicing a natural tree.

The fiber board layer 3 will be described. The fiberboard layer 3 is composed of a number of long fibers 1 in which an adhesive 12 is dispersed.
1 is a fiberboard obtained by hot-pressing a plate-like long fiber mat prepared from the aggregate of No. 1. The long fiber 11
Is a fiber obtained from any of kenaf, oil palm and coconut palm.

The above-mentioned kenaf is an annual plant of hemp and is cultivated in China, Southeast Asia, etc., and can be easily immersed in water to obtain the long fiber 11 from the bast portion thereof. it can. Oil palm and coconut palm are grown in Malaysia, Indonesia, Philippines, etc.
The fruit body called empty fruit bunches other than the fruit used for palm oil pressing and the petiole of the oil palm are composed of long fibers.
The long fibers 11 can be easily obtained by a physical shearing treatment such as a hammer mill on the empty fruit cluster or petiole. Long fibers 11 obtained from the above kenaf, oil palm, coconut palm, etc.
The use of wood is generally preferred from the viewpoint of saving timber resources, because it generally uses what is discarded.

Fibers obtained from such kenaf, oil palm, coconut palm and the like generally have a tensile strength of about 2 to 14 times as compared with fibers obtained from coniferous or hardwood. In order to exhibit this tensile strength at a high level, the long fiber mat has a fiber length of 100 to 4000 mm.
It is preferable to use long fibers 11. The long fiber 11 having a fiber length in the above-described range has a large number of entanglements between the fibers inside the fiber board, and can increase a portion to which an adhesive is attached per fiber, and a seam portion between the fibers. Can be reduced. The fiber length of the long fiber 11 is more preferably 200 to 3000 mm, and further preferably 1000 to 2000 mm.

In addition, the long fiber mat is used for the long fiber 1
1 is oriented in substantially one direction. The long fiber 11
Has the property that the tensile strength in the fiber direction is high. Therefore, the fiberboard can exhibit excellent tensile strength by aligning the fiber direction (orientation direction) of the long fibers 11, and as a result, the flooring material can increase its bending strength. it can. Also, the fiberboard is
By aligning the fiber directions of the long fibers 11, a change in length in the fiber direction can be suppressed, and as a result, the floor material can reduce a dimensional change with respect to a temperature change and a humidity change.

It is extremely difficult to orient and align all the long fibers in one direction exactly. Therefore,
With respect to one direction of the fiber board, the fiber directions of all the long fibers are preferably oriented in substantially one direction so that the inclination is in a range of +30 to -30 °, more preferably, It is in the range of +20 to -20 °.

As a method for orienting the long fibers 11 in substantially one direction, for example, an orientation device as shown in FIG. 8 can be used. The orienting device includes a plurality of sets of drawing portions 22 each including a pair of upper and lower rollers,
It is formed with a comb-shaped combing portion 23. After passing the entangled long fibers 11 between the rollers of the drawing portion 22, the fibers are passed between the comb pieces 24 of the combing portion 23, and further passed between the rollers of the other drawing portion 22. It is oriented in the direction. Thereafter, the long fibers 11 oriented in substantially one direction
Are appropriately laminated and hot-pressed to obtain long fibers 11.
Can be formed in which the fiberboard is oriented in substantially one direction.

Further, the long fiber mat can be formed by knitting the long fibers and entanglement by weaving. By performing such processing, the long fiber mat can reinforce the entanglement between the fibers and increase the adhesive strength between the fibers. As a result, the fiberboard exhibits excellent tensile strength, and the bending rigidity can be further increased.

The method of weaving and weaving long fibers in the long fiber mat is not limited. For example, long fibers oriented in one direction are collected to form a bundle, and then spun into a thread. +30 to-in the fiber direction
An assembly of long fibers is produced by weaving (weaving) the fastening thread in the direction of 30 °. Then, a fiber board in which long fibers are woven (woven) can be formed by appropriately laminating the woven materials and performing hot-press molding.

By subjecting the long fiber mat to a punching treatment with a needle, it is possible to form a long fiber mat in which the long fibers are entangled with each other.

The fiber board is obtained by hot-pressing a plate-like long fiber mat prepared by preparing an aggregate of many long fibers 11 in which an adhesive 12 is dispersed. The density of the fiberboard formed by the long fibers is not particularly limited, but when high mechanical strength is required, 0.3 to
It is preferably set to 1.0 g / cm ^3, more preferably set to 0.5~0.9g / cm ^3. If the density is less than 0.3 g / cm ³ of fiber board, will be numerous voids are present inside the fiberboard, supposed to decrease the adhesion portion and the fibers entangled portions between between fibers, The effect of reinforcing the fiberboard by the bonded portions of the fibers or the entangled portions of the fibers cannot be exhibited, and the mechanical strength of the fiberboard may be reduced. If the density of the fiberboard exceeds 1.0 g / cm ³ , the pressure at the time of hot pressing is so high that the fibers themselves are damaged, and the effect of improving the mechanical strength of the fiberboard is reduced.

The adhesive 12 is not particularly limited, but generally includes a urea resin, a melamine resin, a phenol resin, a resorcinol resin, an epoxy resin,
A thermosetting resin that is cured by heating, such as a urethane resin, a furfural resin, and an isocyanate resin, can be used.

Further, the temperature, time and pressure at the time of hot pressing are appropriately set depending on the kind of the adhesive, the thickness and density of the fiberboard, etc., for example, the temperature is 20 to 180 ° C., preferably 100 ° C. １７０170 ° C. As a pressing method at the time of hot pressing, a batch-type flat plate press, a continuous press, or the like can be employed, but is not particularly limited.

The plate-like substrate 2 constituting the substrate 1 will be described. Since the plate-shaped substrate 2 has the fiberboard layer 3 formed on the surface, it is possible to use a material that is not widely used, such as a material widely used as the substrate 1 of the flooring material. Examples of the plate-like base material 2 include a veneer or a plywood made of a hardwood such as conifer or Lauan, or LVL.
(Single veneer laminated material: Laminated Veneer L
laminate), wafer board, OSB
(Oriented board: Oriented StrandBo
ard), wood board such as particle board, MDF
It is possible to use various materials such as a fiber board such as a fiber board, a non-fiber board such as a rock wool board, or a fiber reinforced board obtained by combining these materials with short fibers such as whiskers, and a chemically treated board obtained by treating these materials with a resin or an inorganic substance. it can.

As the plate-like base material 2, as shown in FIG. 7, a particle board formed by molding particles 8 obtained by pulverizing at least one of kenaf, oil palm and coconut is used. It is preferable because it is possible to obtain a flooring material that is lightweight and that exhibits the effects of the present invention more remarkably. The particles 8 are used by pulverizing the above material to a thickness of 5 mm or less, a width of about 1 to 10 mm, and a length of about 5 to 20 mm. The particles 8 have a higher strength than other materials like the long fibers obtained from kenaf, oil palm, and coconut palm. The particle board is obtained by hot-pressing an aggregate of particles 8 in which an adhesive is dispersed. Examples of the adhesive include the adhesive used for the above-mentioned long fiber. The particles 8 are
Since it has uniform and fine voids inside, a very lightweight particle board can be obtained. as a result,
The flooring material can further reduce the density of the entire flooring material and has both strength and lightness.

The floor material is formed by attaching a fiber board to the plate-like substrate 2 to form a fiber board layer 3, further attaching a veneer 4 on the fiber board layer 3, and laminating by heat and pressure. Can be obtained by The method of attaching is styrene butadiene (SBR)
It can be carried out via an adhesive based on water, an aqueous vinyl urethane based adhesive, a vinyl acetate based adhesive or the like. The conditions of the heat pressure are not particularly limited.
150 ° C., pressure 10-15 kg / cm ² , time 60
About 120 seconds.

The floor material of the present invention has a fiber length of 100 to 400.
Since the fiberboard layer 3 obtained by hot-pressing the long fiber mat in which the long fibers 11 of 0 mm are oriented in substantially one direction is used as a layer on the surface of the substrate 1 to which the veneer 4 is adhered, the bending strength and It has excellent surface hardness and small dimensional change with temperature and humidity changes.

Next, another embodiment of the present invention will be described. FIG. 3 is a perspective view showing an example of an embodiment corresponding to the first, second, and fourth aspects of the present invention. Only different points from the above floor material will be described.

In the flooring material, the base material 1 has a plate-like substrate 2 and a fiberboard layer 3 formed on the side of the plate-like substrate 2 on which the veneer plate 4 is to be adhered. The fiberboard layer 7 is also formed. Since the floor material has such a layer configuration, the mechanical strength on the side opposite to the side where the veneer plate 4 is adhered can also be increased, so that the floor material can have higher strength. In the floor material, the weight ratio of the fiberboard layer 3 is preferably 5 to 50% by weight, more preferably 10 to 40% by weight. This weight ratio can increase the mechanical strength of the flooring. Further, since the floor material has a structure that is substantially symmetrical with respect to the thickness direction, it is possible to suppress changes in the thickness direction such as warpage and push-up. As a result, the flooring can more effectively utilize the excellent dimensional change with respect to temperature change and humidity change. Further, since the floor material can maintain a high surface hardness even when the low-strength plate-like substrate 2 is used, it is possible to use a material having a low hardness but hardly causing a dimensional change. Push-up and the like can be further reduced.

Here, the fiber direction of the veneer 4 and the fiberboard layer 3
Will be described. FIG. 4 is an explanatory diagram showing an example of an embodiment corresponding to the ninth aspect of the present invention and exploded for each layer. The arrow a in the drawing indicates the fiber direction of the veneer plate 4, and the arrow b indicates the fiber direction of the fiber plate layer 3.

The cracks generated in the veneer plate 4
Occurs in the same direction as the fiber direction. Therefore, in order to suppress the occurrence of the crack, it is preferable that the fiberboard layer 3 to which the veneer plate 4 is adhered has little change in a direction perpendicular to the fiber direction of the veneer plate 4. In the flooring material shown in FIG. 4, the fiber direction of the fiberboard layer 3 to which the veneer 4 is attached is formed in a direction orthogonal to the fiber direction of the veneer 4. The flooring material can more effectively utilize the characteristics related to the excellent dimensional change with respect to the temperature change and humidity change of the fiberboard layer 3.

FIG. 5 shows an embodiment according to the first, second and fifth aspects of the present invention. FIG.
(B) is explanatory drawing which showed typically the structure for every layer of a fiberboard layer. Only different points from the above floor material will be described.

In the flooring material, a substrate 1 is formed with a plate-shaped substrate 2 and a fiberboard layer 3 composed of three layers on the side of the plate-shaped substrate 2 to which the veneer plate 4 is adhered. The fiberboard layer 3 is shown in FIG.
As shown in (b), the direction in which the long fibers in the vertically adjacent layer are oriented alternately orthogonally. In the fiberboard layer 3, the uppermost layer 3a to which the veneer plate 4 is attached forms a fiber direction b in a direction orthogonal to the fiber direction a of the veneer plate 4. And, the fiberboard layer 3 is a central layer 3b.
Form a fiber direction c in the same direction as the fiber direction a of the veneer 4, and the lowermost layer 3c forms a fiber direction d in a direction orthogonal to the fiber direction a of the veneer 4.

Regarding the bending strength of the entire flooring material, it is preferable that the bending strength is high in the longitudinal direction of the flooring material in practical use.
Therefore, it is preferable that the fiberboard layer 3 of the flooring material forms a fiber direction (arrangement direction) in the longitudinal direction of the entire flooring material. On the other hand, as the veneer 4 of the flooring material, the one in which the longitudinal direction of the flooring material is the fiber direction is generally used. In the flooring, the fiberboard layer 3 is composed of a plurality of layers 3a, 3b, 3c.
Since the directions in which the long fibers of b and 3c are oriented are orthogonal to each other, the central layer 3b of the fiberboard layer 3 in which the fiber direction is formed in the same direction as the longitudinal direction of the floor material is bent in the longitudinal direction of the floor material. The uppermost layer 3a and the lowermost layer 3c of the fiberboard layer 3 having the effect of increasing the strength and forming the fiber direction in the direction orthogonal to the longitudinal direction of the flooring material (the fiber direction of the veneer 4) are cracked. The effect of suppressing the occurrence of dimensional change and maintaining a good dimensional change can be exhibited.

FIG. 6 shows an example of an embodiment corresponding to the first, second and seventh aspects of the present invention.
(B) is explanatory drawing which showed typically the structure for every layer of a base material.

The flooring material is formed of a fiberboard layer 3 in which the base material 1 has three layers. The fiberboard layer 3 is shown in FIG.
As shown in (1), the direction in which the long fibers of the vertically adjacent layers are oriented is alternately orthogonal to each other. In the fiberboard layer 3, the uppermost layer 3a to which the veneer plate 4 is attached forms a fiber direction b in a direction orthogonal to the fiber direction a of the veneer plate 4. In the fiberboard layer 3, the center layer 3 b forms the fiber direction c in the same direction as the fiber direction a of the veneer 4, and the lowermost layer 3 c is in the direction orthogonal to the fiber direction a of the veneer 4. It is formed in the fiber direction d. Thereby, the flooring material exhibits the effect of increasing the bending strength in the longitudinal direction of the flooring material in the central layer 3b of the fiberboard layer 3 in which the fiber direction is formed in the same direction as the longitudinal direction of the flooring material. The uppermost layer 3a and the lowermost layer 3c of the fiberboard layer 3 whose fiber direction is formed in a direction orthogonal to the longitudinal direction of the veneer 4 (fiber direction of the veneer 4) suppress generation of cracks in the veneer 4 and maintain good dimensional change The effect that can be exhibited.

In FIGS. 5 and 6, the floor material is
Although one having three fiberboard layers 3 is shown, the number of layers and the thickness of each layer can be appropriately set. The fiberboard layer 3
In order to reduce the warping caused by the fiberboard layer 3,
Is preferably formed in an odd-numbered layer.

[0049]

EXAMPLES (Example 1) A fiber obtained by fibrillating kenaf was cut into a length of 1,000 to 2,000 mm to obtain a kenaf long fiber. The phenolic adhesive was dispersed in the kenaf filaments so as to be 15% by weight. This kenaf long fiber is 6
Orientation was performed in one direction by using an orientation device in which a drawing portion composed of a pair of upper and lower roller pairs and a comb-shaped combing portion were combined. Next, the kenaf long fibers were arranged in a single direction in a mold and stacked to obtain a long fiber mat formed of an aggregate. This long fiber mat is hot-pressed to a density of 80.
A fiberboard having a thickness of 0 kg / m ³ and a thickness of 2.7 mm was obtained.

The plate-like substrate has a density of 600 kg / m ³ ,
9mm thick lauan plywood, 0.3m thick as veneer
m. One of the fiberboards was stacked on the Rawan plywood, and a veneer was further stacked thereon. Each is adhered via an SBR-based adhesive, and is integrally molded by hot pressure.
As a result, a floor material having a thickness of 12 mm was obtained. In addition, this flooring material was formed so that the fiber direction of the veneer was the longitudinal direction, and the fiber direction of the veneer was perpendicular to the fiber direction of the fiberboard layer.

Example 2 A long fiber mat was obtained in the same manner as in Example 1. This long fiber mat was hot-pressed to obtain a fiberboard having a density of 800 kg / m ³ and a thickness of 2.1 mm.

The plate-like substrate has a density of 600 kg / m ³ ,
Rawan plywood with a thickness of 7.5 mm is used as a veneer and has a thickness of 0.5 mm.
A 3 mm one was used. One of the fiberboards was stacked on the upper and lower sides of the Rawan plywood, and a veneer was stacked on one side. Each was bonded via an SBR-based adhesive, and was integrally formed by hot pressing to obtain a floor material having a thickness of 12 mm as shown in FIG.
The flooring was formed such that the fiber direction of the veneer and the fiber direction of the fiberboard layer were orthogonal to each other.

Example 3 A long fiber mat was obtained in the same manner as in Example 1. Using this long fiber mat, the layers were laminated such that the fiber directions of the layers were orthogonal to each other such that the thickness ratio became 1: 2: 1. This is hot-pressed to a thickness of 2.7 mm.
Was obtained.

As a plate-like substrate, a density of 600 kg / m ³ ,
9mm thick lauan plywood, 0.3m thick as veneer
m. One of the fiberboards was stacked on the Rawan plywood, and a veneer was further stacked thereon. Each is bonded via an SBR-based adhesive, and is integrally formed by hot pressing.
A 12 mm thick floor material as shown in FIG.

Example 4 The following particle board was used as a plate-like substrate. A phenolic adhesive was dispersed in kenaf particles having an average thickness of 0.5 mm, an average width of 4 mm, and an average length of 8 mm so as to be 10% by weight, and then hot-pressed to form a 9 mm-thick particle board. Obtained. A long fiber mat was obtained and hot-pressed in the same manner as in Example 1 to obtain a density of 800 kg / m ³ and a thickness of 2.7.
mm fiberboard was obtained. A veneer having a thickness of 0.3 mm was used.

One of the fiberboards was stacked on the particle board, and a veneer was further stacked thereon. Each is SBR
Adhered via a system adhesive and integrally formed by hot pressure, a floor material having a thickness of 12 mm as shown in FIG. 1 was obtained. The flooring was formed such that the fiber direction of the veneer and the fiber direction of the fiberboard layer were orthogonal to each other.

(Example 5) Fiber obtained by defibrating the oil palm fruit portion was cut into a length of 100 to 200 mm to obtain an oil palm long fiber. In Example 1, a floor material having a thickness of 12 mm was obtained in the same manner as in Example 1, except that this oil palm long fiber was used instead of the kenaf long fiber.

(Example 6) Fiber obtained by defibrating the oil palm fruit portion was cut into a length of 100 to 200 mm to obtain an oil palm long fiber. In Example 4, a floor material having a thickness of 12 mm was obtained in the same manner as in Example 4, except that this oil palm long fiber was used instead of the kenaf long fiber.

Example 7 A floor material composed of only a long fiber layer as a base material was produced. A long fiber mat was obtained in the same manner as in Example 1. Using this long fiber mat, the layers were laminated such that the fiber directions of the layers were orthogonal to each other such that the thickness ratio became 1: 2: 1. This is hot-pressed to a density of 750 kg / m
^{3. A} fiberboard consisting of three layers having a thickness of 8.7 mm was obtained. A veneer having a thickness of 0.3 mm was used.

A veneer is placed on one side of the fiberboard via an SBR-based adhesive, and is integrally formed by heat and pressure.
As a result, a floor material having a thickness of 9 mm was obtained.

Example 8 In Example 3, the particle board used in Example 4 was used as the plate-like substrate. Except for this particle board, a floor material having a thickness of 12 mm was obtained in the same manner as in Example 3.

(Example 9) In the same manner as in Example 3, the layers were stacked so that the fiber directions of the layers were orthogonal to each other so that the thickness ratio was 1: 2: 1, and the layers were hot-pressed. 2.7mm
A fiber board A consisting of three layers was obtained. Further, similarly to Example 1, a fiberboard B having a density of 800 kg / m ³ and a thickness of 0.9 mm was used.
I got

As a plate-like substrate, a density of 600 kg / m ³ ,
Rawan plywood with a thickness of 8.7 mm is used as a veneer and has a thickness of 0.
A 3 mm one was used. The fiberboard A was laid on the upper side of the Rawan plywood, a veneer was further laid on the fiberboard A, and the fiberboard B was laid on the lower side of the Rawan plywood. Each was bonded via an SBR-based adhesive, and was integrally formed by hot pressing to obtain a floor material having a thickness of 12 mm. In the fiberboard A, the fiber direction of the veneer was perpendicular to the fiber direction of the uppermost fiberboard layer.

Example 10 A fiber obtained by fibrillating kenaf was cut into a length of 200 to 500 mm to obtain a kenaf long fiber. A floor material having a thickness of 12 mm was obtained in the same manner as in Example 1 except that this kenaf long fiber was used.

Example 11 A fiber obtained by fibrillating kenaf was cut to a length of 200 to 500 mm to obtain a kenaf long fiber. A floor material having a thickness of 12 mm was obtained in the same manner as in Example 3 except that this kenaf long fiber was used.

Example 12 A fiber obtained by fibrillating kenaf was cut into a length of 3000 to 4000 mm to obtain a kenaf long fiber. A floor material having a thickness of 12 mm was obtained in the same manner as in Example 1 except that this kenaf long fiber was used.

Example 13 A fiber obtained by fibrillating kenaf was cut into a length of 50 to 100 mm to obtain a kenaf long fiber. A floor material having a thickness of 12 mm was obtained in the same manner as in Example 1 except that this kenaf long fiber was used.

(Comparative Example 1) A 0.3 mm-thick veneer is laminated on a Rawan plywood having a density of 600 kg / m ³ and a thickness of 11.7 mm via an SBR-based adhesive, and integrated by heat and pressure. It was molded to obtain a floor material having a thickness of 12 mm.

Comparative Example 2 A density of 750 kg / m ³ was applied to one side of a rawan plywood having a density of 600 kg / m ³ and a thickness of 9 mm.
An MDF having a thickness of 2.7 mm was stacked, and a veneer having a thickness of 0.3 mm was further stacked thereon. Each was adhered via an SBR-based adhesive, and was integrally molded by hot pressing to obtain a floor material having a thickness of 12 mm as shown in FIG.

(Comparative Example 3) In Example 1, kenaf long fibers were stacked in a mold without deciding a direction to obtain a long fiber mat composed of an aggregate. The long fiber mat was hot-pressed to obtain a fiber board having a density of 800 kg / m ³ and a thickness of 2.7 mm.

A floor material having a thickness of 12 mm was obtained in the same manner as in Example 1 except that the above fiberboard was used.

(Evaluation) The floor materials obtained in Examples and Comparative Examples were evaluated. As an evaluation, a dimensional change with respect to a bending strength, a surface hardness, a temperature change and a humidity change was measured.

The bending strength was determined by an equivalent bending Young's modulus which is a bending Young's modulus when the entire flooring material is assumed to have a homogeneous structure. The surface hardness was determined by the amount of hard ball compression dent. The hard ball compression dent amount was measured by using a hard sphere having a diameter of 10 mm and applying a load of 300 N to the veneer surface of the floor material.

The above dimensional change was determined by the repeated cold test (80 ± 3 ° C., 2 hours and 20 ± 3 ° C.) specified by JAS “Japanese Agricultural and Forestry Standards for Special Plywood” (enforced on December 15, 1989).
2 hours were repeated twice), and the dimensional change rate in the longitudinal direction of the floor material before and after the treatment was determined.

The results are shown in Table 1. In each of the examples, the bending strength, the surface hardness, and the dimensional change were better than those of the comparative example.

[0076]

[Table 1]

[0077]

The floor material according to any one of claims 1 to 10 can exhibit excellent tensile strength of long fibers at a high level.
It has excellent bending strength and surface hardness, and has good dimensional change with temperature and humidity changes. As a result, the flooring material can suppress warping, pushing up, and cracking of the pushing plate.

Further, the flooring material according to claim 2 has a large number of entanglements between the fibers inside the fiberboard, and can further increase the portion to which the adhesive is attached per fiber. Further, since the joint portion between the fibers can be reduced, the dimensional change with respect to the bending strength, the surface hardness, the temperature change and the humidity change becomes more favorable.

Furthermore, the floor material according to claim 4 can have a higher strength because the mechanical strength on the opposite side can be increased particularly when a veneer is attached.
Since a structure that is substantially symmetrical with respect to the thickness direction is formed, it is possible to suppress changes in the thickness direction such as warpage and push-up.

Further, the flooring material according to the sixth aspect has both strength and lightness because the particles have high strength similarly to long fibers and have uniform and fine voids inside. It is.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of an embodiment of the present invention.

FIG. 2 is an explanatory diagram schematically showing an enlarged fiber board layer.

FIG. 3 is a perspective view showing an example of another embodiment of the present invention.

FIG. 4 is an explanatory view showing an example of another embodiment of the present invention and exploded for each layer.

FIG. 5 shows an example of another embodiment of the present invention, in which (a)
Is a perspective view, and (b) is an explanatory view schematically showing the configuration of each fiberboard layer.

FIG. 6 shows an example of another embodiment of the present invention, in which (a)
Is a perspective view, and (b) is an explanatory view schematically showing the configuration of each fiberboard layer.

FIG. 7 is a cross-sectional view schematically showing a fiberboard layer.

FIG. 8 is a perspective view schematically showing an orientation device.

FIG. 9 is a conventional perspective view.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Plate-like board 3,7 Fiberboard layer 4 Veneer board

Continued on the front page (72) Inventor Kazunori Umeoka 1048 Odakadoma, Kadoma, Osaka Prefecture Inside Matsushita Electric Works, Ltd. Inventor Ryo Sugawara 1048 Kazuma Kadoma, Kadoma City, Osaka Prefecture F-term in Matsushita Electric Works Co., Ltd. BA07 BA10A BA10B BA10D BA13 BA22 CB00 DB03 DG04C DG04D DG06C DG06D DG12C DG12D DG13C DG13D EC09C EC09D EJ17C EJ17D EJ42C EJ42D GB08 JK04 JK12 JK14 JL03 JL04 YY00Y

Claims (10)

[Claims] 1. A flooring comprising a substrate and a veneer attached to the surface of the substrate, wherein at least the surface layer of the substrate to which the veneer is adhered has a large number of layers in which an adhesive is dispersed. A long fiber mat formed of an aggregate of the long fibers is formed by a fiber plate layer formed by hot-pressing, and the long fiber mat is a kenaf, an oil palm, a long fiber obtained from at least one of coconut palms, A flooring material characterized by being oriented in substantially one direction. 2. The long fiber has an average fiber length of 100 to 100.
The flooring according to claim 1, wherein the flooring is 4000 mm. 3. The substrate according to claim 1, wherein the substrate is a plate-like substrate, and the fiberboard layer is formed on a surface of the plate-like substrate on a side to which a veneer is adhered. The floor material according to claim 2. 4. The substrate according to claim 1, wherein the substrate is a plate-like substrate and a fiberboard layer is formed on both surfaces of the plate-like substrate. The described flooring. 5. The substrate according to claim 1, wherein the base material is a plate-like substrate, and a fibrous plate layer composed of a plurality of layers is formed on a surface of the plate-like substrate on a side to which the veneer is to be attached. The flooring according to any one of claims 1 to 4, wherein the directions in which the long fibers are oriented are alternately orthogonal. 6. The plate-like substrate according to claim 3, wherein said plate-like substrate is formed by molding particles obtained by pulverizing at least one of kenaf, oil palm and coconut. Or the flooring described. 7. The base material is an aggregate of a plurality of layers formed by orienting the long fibers in substantially one direction, and is formed such that the directions in which the long fibers are oriented are orthogonal to each other. The flooring according to claim 1 or 2, wherein the flooring is provided. 8. The flooring material according to claim 1, wherein the long fiber mat is formed by entanglement by needle punching. 9. The layer of the fiberboard layer forming the surface to which the veneer is attached, wherein the direction in which the long fibers are oriented is a direction orthogonal to the direction in which the fibers of the veneer are oriented. The flooring material according to any one of claims 1 to 8, wherein 10. The flooring material according to claim 1, wherein the long fiber mat is formed by knitting or weaving the long fibers.