JP2003253869A - Flooring - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide flooring reducible in warping while having excellent strength and hardness and reducing a dimensional change related to a temperature change and a humidity change. <P>SOLUTION: In this flooring 3 with a surface finishing material 2 bonded to the surface of a woody board, the woody board is a fiberboard 1 formed by laminating a plurality of lint mats 1a, 1b, 1c formed by dispersing an adhesive in a lint aggregate, and then molding them by thermopressing, and the surface finishing material 2 is bonded to both front and rear faces of the woody board. The lint is obtained from either one of kenaf, jute, sisal, oil coconut and coconut. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material used for a flooring finished floor, a step board of stairs, etc. in the field of housing.

[0002]

2. Description of the Related Art In the field of housing, wooden flooring with a flooring finish has advantages such as easy maintenance such as cleaning and suppressing the occurrence of mites, which is one of the causes of sick house syndrome. As a result of having it, its use is expanding rapidly, mainly in multi-family houses.

In recent years, the market for thin floor materials (thickness of 5 mm or less) that is directly applied on the conventional floor materials for refurbishment and remodeling is expanding. A feature of the conventional flooring is that it does not need to be peeled off and is directly attached on the flooring to save construction work. If the floor material is thick, the floor level of the room becomes large, and opening and closing of the door may be inconvenient. Further, a thin floor material is required to have a small thickness and to maintain basic performance as a floor material.

[0004] The conventional wood-based flooring materials are mainly composed of a wood-based board such as plywood to which a surface finishing material such as a decorative veneer or a decorative sheet is attached. However, such a flooring material has a problem that the flooring material warps due to changes in humidity and the like, especially when the thickness is thin, and improvement thereof is desired.

Furthermore, the smoothness and hardness of the surface are not sufficient, and the surface is damaged when a reciprocating load is applied to the floor material such as the movement of chairs or furniture with casters, and long-term use. There is a problem that the surface finish material peels off because it cannot be used.

Therefore, in recent years, many floor materials have improved scratch resistance by using MDF (medium quality fiberboard) having a relatively high surface smoothness and hardness as a wood board that adheres to a surface finish material. Has been adopted.

However, since MDF and the like used for such a floor material having improved scratch resistance has a larger dimensional change due to room temperature changes and humidity changes than general plywood, warping or pushing up of the floor material, Also, there is a problem that an abnormality such as a crack occurs in the surface finish material. Also MD
F and the like generally have lower strength against loads such as bending and impact than plywood, and in particular, when the thickness of the floor material is thin, it is difficult to secure the necessary strength as the floor material. is there.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a flooring material capable of reducing warpage. Furthermore, it has excellent strength and hardness,
An object of the present invention is to provide a flooring material capable of reducing dimensional changes due to temperature changes and humidity changes.

[0009]

The floor material of the invention according to claim 1 is a floor material in which a surface finishing material is adhered to the surface of a wooden board, wherein the wooden board disperses an adhesive in an aggregate of long fibers. It is characterized in that it is a fiber board formed by laminating a plurality of long-fiber mats thus obtained and then thermocompression-molded, and that the surface finishing material is adhered to both front and back surfaces of the wood board.

The floor material of the invention according to claim 2 is the floor material according to claim 1, wherein the long fibers are kenaf, jute,
It is a long fiber obtained from at least one of sisal, oil palm, and coconut.

A flooring material according to a third aspect of the present invention is the flooring material according to the first or second aspect, in which the surface finishing material is an adhesive bond by aligning the wood grain directions of logs or small square timbers substantially in one direction. It is a decorative veneer that is formed by slicing the same, and the wood grain direction is aligned, and the wood grain direction of the decorative veneer is
To be in a direction substantially parallel to the longitudinal direction of the floor material,
The fiber board and the decorative veneer are bonded together.

[0012] A flooring material according to a fourth aspect of the present invention is the flooring material according to the third aspect, wherein the fiber board is obtained by dispersing an adhesive in an aggregate of long fibers oriented in one direction. The mat is used, and the floor material is formed so that the orientation of the oriented long fibers is substantially parallel to the lateral direction of the floor material formed in a rectangular shape. Characterize.

A flooring material according to a fifth aspect of the present invention is the flooring material according to any one of the first to third aspects, wherein the fiber board is adhered to an aggregate of long fibers oriented substantially in one direction. A plurality of long-fiber mats in which the agent is dispersed are alternately laminated so that the oriented long-fiber directions of these long-fiber mats are substantially laminated, and the lengths are substantially orthogonal. It is characterized in that the floor material is formed so that one of the fiber directions is substantially parallel to the lateral direction of the rectangular floor material.

A floor material according to a sixth aspect of the present invention is the floor material according to any one of the first to fifth aspects, wherein the floor material has a thickness of 1 mm to 5 mm.

The floor material of the invention according to claim 7 is the floor material according to any one of claims 1 to 6, characterized in that the density of the fiberboard is 600 kg / m ³ or more. .

The flooring material of the invention according to claim 8 is the flooring material according to any one of claims 1 to 7, characterized in that tongues are arranged at the ends of the flooring material.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below based on embodiments shown in the accompanying drawings.

(First Embodiment) FIG. 1 shows a first embodiment. FIG. 1 (a) is a perspective view showing the appearance of a floor material, and FIG. 1 (b) is a floor. It is a perspective view which decomposed | disassembled and showed the structure of the material. After laminating several long fiber mats (1a, 1b, 1c) in which an adhesive is dispersed in an aggregate of long fibers [3 in FIG. 1 (b)], they are integrally molded by thermocompression molding, A fiberboard 1 is formed, and then a surface finish 2 is adhered to both front and back surfaces of the fiberboard 1 to form a flooring 3 as shown in FIG.

In a flooring material formed by laminating a plurality of materials, if the water content changes during production and during use, for example, an increase in water content due to the application of an adhesive during production or adhesion for adhesion may occur. The water content tends to change due to the reduction of the water content due to the press, and the fact that water as a liquid or water as a gas enters and leaves the flooring material during use. At this time, when a plurality of materials constituting the flooring material have different dimensional changes due to changes in water content, it is expected that warpage will occur. This phenomenon tends to be particularly noticeable when the desired floor material is thin. This warp can be suppressed by making the structure of the floor material symmetrical in the thickness direction.

In this embodiment, since the surface finishing material 2 is adhered not only to the front surface of the fiberboard 1 but also to the back surface thereof, even if the water content of the floor material 3 changes, each material is ,
Since the dimensions change more symmetrically, the warpage of the floor material 3 is reduced.

As the fiber board 1, a long fiber mat (1a, 1b, 1c) is prepared by dispersing an adhesive in an aggregate of long fibers obtained from at least one of kenaf, jute, sisal, oil palm and coconut. ) Is used for hot pressing.

Kenaf, jute, sisal, oil palm,
Long fibers obtained from at least one of coconut,
It has a tensile strength approximately 2 to 14 times higher than that of a softwood fiber obtained from a softwood or a hardwood fiber obtained from a hardwood. The strength of the fiber board 1 is the strength of the fiber itself and
Although it is determined by the entanglement of the fibers, the strength of the bonded portion between the fibers, and the like, in the fiber board 1 formed of the above-described long fibers, a large number of the entanglements of the fiber parts are present inside, and this action results in the fiber board 1 You can further increase your strength. However, in the first embodiment, as long fibers, fibers other than those described above have a fiber length of 1
It is also possible to use various plant fibers having a size of about 00 to 4000 mm.

Further, kenaf, jute and sisal are annual hemp herbs, which are cultivated mainly in Asia, South America and the like. By soaking them in water, long fibers can be easily obtained from the bast. be able to. In addition, oil palm and coconut are cultivated in Malaysia, Indonesia, the Philippines, etc., and the fruit bodies called empty fruit clusters other than the fruits used for oil extraction of palm oil and the petiole of oil palm are long fibers. It is configured. Long fibers can be easily obtained by adding physical shearing treatment such as a hammer mill to the empty fruit clusters and petioles. Although these fibers have been used as materials for grain bags and ropes, they are being replaced by synthetic fibers and the amount of waste is increasing at present. Therefore, by using the above long fibers, it is possible to reduce waste,
At the same time, it is possible to save wood resources, which is preferable.

The type of adhesive used for molding the fiber board 1 and the method of dispersing the adhesive are not particularly limited, but the type of adhesive may be, for example, urea resin, melamine resin, Examples include phenolic resins, resorcinol-based resins, epoxy-based resins, urethane-based resins, furfural-based resins, and thermosetting resins such as isocyanate-based resins that are cured by heating.

Further, the pressing method at the time of thermocompression molding includes batch type flat plate pressing and continuous pressing, but is not particularly limited, and the pressing temperature, the pressing time, the pressing pressure, and the adhesive weight with respect to the fiber weight are used. The weight ratio and the like are appropriately set depending on the type of adhesive used, the thickness of the fiberboard, and the like.

The length of the long fibers is not particularly limited,
It is preferable to use one having a thickness of 100 to 4000 mm. In this case, there are many entanglements of the fiber parts inside the fiber board, and it is possible to increase the adhered part of the adhesive per one, and it is possible to reduce the joint part between the long fibers, so that the fiber itself is high. By utilizing the tensile strength more effectively, it is possible to obtain a flooring material having high strength and hardness, and having a property that the dimensional change due to temperature change and humidity change is small. Since it is difficult to obtain a fiber having a fiber length of more than 4000 mm, it is considered that the upper limit of the fiber length of the continuous fiber is substantially 4000 mm.

The density of the fiber board 1 is 600 kg.
/ M ³ or more is preferable. It is possible to use even if the density of the fiber board 1 is less than 600 kg / m ³ , but if the density of the fiber board 1 is less than 600 kg / m ³ , the bonded portions between the fibers and the fibers Since the entangled parts are reduced, it becomes difficult to sufficiently exhibit high strength due to the originally bonded parts of the fibers and the entangled parts of the fibers, which reduces the bending rigidity of the fiberboard. Tend to do. Further, since a large number of voids are present on the surface and inside of the fiber board 1, the hardness is lowered, the adhesive strength with the surface finish material 2 is also lowered, and the warp tends to occur easily. The upper limit of the density of the fiberboard 1 is not particularly set, but practically 1200
kg / m ³ is the upper limit. In order to obtain a fiberboard 1 having a density higher than this, it is necessary to highly compress it,
The fibers tend to be broken and the improvement in mechanical strength tends to be small.

In the present embodiment, as the surface finish material 2, a decorative veneer having a uniform grain direction, which is obtained by thinly slicing a log or a small square timber with the grain directions aligned and bonded together, can be used. Decorative veneer is made of logs such as teak, zelkova, etc. or laminated wood with a cutting machine such as a slicer or a half rotary, and the thickness is not particularly limited, but those of about 0.2 mm to 0.6 mm are manufactured. Is preferable because it is easy. In addition, it is also possible to use a paper with a grain printed on it, a sheet of polyvinyl chloride resin, or the like, but since the decorative veneer has the grain of a natural tree, it is preferable because a flooring with the highest wood texture can be manufactured.

As the adhesive used when the surface finishing material 2 is adhered to both surfaces of the fiber board 1, a synthetic rubber adhesive can be used. Synthetic rubber adhesives include styrene butadiene rubber (SBR), butadiene rubber,
A latex adhesive in which components such as chloroprene rubber-based, nitrile rubber-based, and silicone rubber-based components are dispersed in water, and thermosetting resin and latex adhesive such as urea-based resin, melamine-based resin, and phenol-based resin that are heat-curable Mixed adhesives are mentioned.

As a method for applying the adhesive, a roll coating method can be used, but a spray method or a brush coating method can also be used. If the adhesive contains a thermosetting resin, it needs to be hot pressed, and if the adhesive does not contain a thermosetting resin, it needs to be pressed without raising the temperature. The pressing method at this time is not particularly limited, and the pressing temperature, the pressing time, the pressing pressure, the amount of adhesive applied, and the like are appropriately set depending on the type of adhesive used and the like.

Further, in the present embodiment, the floor material 3 may have a thickness of 1 mm to 5 mm. As the fiberboard 1, kenaf, jute, sisal, oil palm,
A long fiber mat (1a, 1) in which an adhesive is dispersed in an aggregate of long fibers obtained from at least one of coconut palms.
When the fiber board 1 obtained by thermo-pressing b, 1c) is used, the strength and hardness of the fiber board 1 are excellent. Therefore, even if the floor material 3 using the fiber board 1 has a small thickness, It is possible to obtain sufficient strength and hardness of the floor material 3. Further, since the flooring material 3 has the surface finishing material 2 adhered to not only the front surface of the fiberboard 1 but also the back surface thereof, even if the thickness of the flooring material 3 is thin, the warpage or the dimensional change due to the change in the water content of the flooring material Is less likely to occur.

(Second Embodiment) FIG. 2 shows a second embodiment. FIG. 2 (a) is a perspective view showing the appearance of a floor material, and FIG. 2 (b) is a floor. It is a perspective view which decomposed | disassembled and showed the structure of the material. Long fiber mat (1a, 1b, 1c) in which an adhesive is dispersed in an aggregate of long fibers oriented in substantially one direction
After stacking several sheets [three in FIG. 2 (b)] so that the directions (a, b, c) of oriented long fibers of vertically adjacent long fiber mats are substantially parallel [FIG. In 2 (b),
The oriented long fiber direction a of the upper layer, the oriented long fiber direction b of the middle layer, and the oriented long fiber direction c of the lower layer are all substantially parallel to the lateral direction], and integrally molded by thermocompression molding Then, the fiber board 1 is obtained. Then, the fiber board 1 is so arranged that the directions (a, b, c) of the oriented long fibers are substantially parallel to the lateral direction of the flooring 3 formed in a rectangular shape.
After arranging, the surface finishing material 2 is adhered to both front and back surfaces of the fiber board 1 to form the flooring material 3 as shown in FIG. 2 (a).

As the surface finishing material 2, a decorative veneer having a uniform grain direction, which is obtained by thinly slicing a log or a small square timber having the grain directions aligned and bonded together, is used. Then, the decorative veneer and the fiber board 1 are bonded so that the grain direction of the decorative veneer is substantially parallel to the longitudinal direction of the flooring 3. With this configuration, it is possible to form the floor material 3 having the grain of natural wood in the longitudinal direction of the floor material 3.

In this embodiment, long fibers obtained from at least one of kenaf, jute, sisal, oil palm and coconut are used as the long fibers. Since these long fibers themselves have a high tensile strength, a plurality of long fiber mats formed by orienting the long fibers in substantially one direction are used. The fibrous board 1 formed by laminating so that the directions are aligned, and then thermocompression-molded has high strength and improved dimensional change in the oriented direction.

Further, the decorative veneer with the aligned wood grain direction has high strength in the wood grain direction, but weak strength in the direction orthogonal to the wood grain direction. When stress due to dimensional change is applied, the decorative veneer is likely to crack.

In the flooring material 3 of the present embodiment, the lateral direction of the flooring material 3 (the direction orthogonal to the grain direction of the decorative veneer 3) is provided on both sides of the fiberboard 1 whose dimensional change is improved in the lateral direction of the flooring material 3. ) Is bonded to a weak decorative veneer, the generation of stress due to the dimensional change of the fiberboard 1 in the lateral direction is suppressed, and as a result, the floor veneer 3 is cracked in the decorative veneer. Less likely to occur.

Since it is extremely difficult to orient all the long fibers so that they are exactly aligned in one direction, all the long fibers have an inclination of +30 to − with respect to the reference one direction. The long fibers are oriented in one direction so as to fall within the range of 30 °. Furthermore, it is more preferable to orient in the range of +20 to −20 °.

As a method for orienting the long fibers in one direction, for example, an orienting device as shown in FIG. 6 can be used. This orienting device is formed by including a plurality of sets of drawing portions 22 composed of a pair of upper and lower rollers and a comb-shaped combing portion 23. Then, after passing a large number of entangled long fibers 11 between the rollers of the drawing portion 22, the combing portion 2
It can be oriented substantially in one direction by passing it between the comb pieces 24 of No. 3 and passing between the rollers of the other drawing portion 22. Thereafter, an adhesive is dispersed in an aggregate of long fibers oriented in approximately one direction to obtain a long fiber mat, and the long fiber mat is appropriately laminated and thermocompression-molded,
It is possible to form a fiber board in which long fibers are oriented in one direction.

In the present embodiment, the length of the long fibers, the adhesive for dispersing in the aggregate of the long fibers, the pressing method at the time of thermocompression molding of the long fiber mat, the density of the fiber board, and the surface finishing material are adhered. The adhesive to be applied, the method of applying the adhesive, and the thickness of the floor material can be the same as in the first embodiment.

(Third Embodiment) FIG. 3 shows a third embodiment, FIG. 3 (a) is a perspective view showing the appearance of a floor material, and FIG. 3 (b) is a floor. It is a perspective view which decomposed | disassembled and showed the structure of the material. Long fiber mat (1a, 1b, 1c) in which an adhesive is dispersed in an aggregate of long fibers oriented in substantially one direction
Several sheets [three sheets in FIG. 3 (b)] are laminated so that the orientations (a, b, c) of oriented long fibers of vertically adjacent long fiber mats are alternately substantially orthogonal to each other [FIG. In b), the oriented long fiber direction a of the upper layer and the oriented long fiber direction b of the middle layer.
Are substantially orthogonal to each other, and the oriented long fiber direction b of the middle layer is substantially orthogonal to the oriented long fiber direction c of the lower layer], and they are integrally molded by thermocompression molding to obtain a fiber board 1. Next, one of the directions of the long fibers that are substantially orthogonal to each other [a and b in FIG. 3 (b)]
Are arranged so that they are in a direction substantially parallel to the lateral direction of the floor material 3 formed in a rectangular shape, and the surface finishing material 2 is adhered to both front and back surfaces of the fiber board 1. Thus, the flooring material 3 as shown in FIG. 3 (a) is formed.

As the surface finishing material 2, there is used a decorative piece having a uniform grain direction, which is obtained by thinly slicing a log or a small square timber having the grain directions aligned and bonded together. And
The decorative veneer 1 and the fiberboard 1 are arranged such that the grain direction of the decorative veneer is substantially parallel to the longitudinal direction of the flooring 3.
And are glued together. With this configuration, it is possible to form the floor material 3 having the grain of natural wood in the longitudinal direction of the floor material 3.

In the present embodiment, long fibers obtained from at least one of kenaf, jute, sisal, oil palm and coconut are used as the long fibers. Since these long fibers themselves have high tensile strength, a plurality of long fiber mats obtained by orienting the long fibers in substantially the same direction,
The fiberboard 1 formed by the long fiber mats obtained by laminating the long fiber mats in such a manner that the oriented long fiber directions of the long fiber mats are alternately orthogonal to each other. It has high strength and improved dimensional change.

Further, in the flooring material 3 of the present embodiment, both sides of the fiberboard 1 having improved dimensional changes in both the lateral direction and the longitudinal direction of the flooring material 3 are attached to the lateral direction of the flooring material 3 (decorative veneer). Since a decorative veneer with low strength is bonded in the direction (perpendicular to the wood grain direction), the generation of stress due to the dimensional change of the fiberboard 1 in the lateral direction is suppressed, and as a result, the flooring 3 is , It becomes difficult for the decorative veneer to crack.

It should be noted that the number of layers and the thickness of each layer when laminating the long fiber mat are not limited to this, but in consideration of the reduction of the warp of the fiberboard, the thickness direction of the long fiber mat It is preferable to stack so as to be symmetric with respect to the center of.

Further, in the present embodiment, as a method for orienting long fibers in substantially one direction, for example, an orienting device as shown in FIG. 6 can be used as in the second embodiment.

Further, in this embodiment, the length of the long fiber,
Adhesives dispersed in aggregates of long fibers, pressing method for thermocompression molding of long fiber mats, density of fiberboard, adhesives for adhering surface finishing materials and application method of the adhesives, thickness of flooring materials Can be the same as in the first embodiment.

(Fourth Embodiment) FIG. 4 shows a fourth embodiment. FIG. 4 (a) is a perspective view showing the appearance of a floor material, and FIG. 4 (b) is a floor. It is a perspective view which decomposed | disassembled and showed the structure of the material. When laminating several long fiber mats (1a, 1b, 1c) in which an adhesive is dispersed in an aggregate of long fibers [3 pieces in FIG. 4 (b)], the position of the end surface of the long fiber mat 1b in the central portion Are laminated by staggering, and integrally molded by thermocompression molding using a tongue-shaped mold to form a fiber board 1, and then a surface finish material 2 is adhered to both front and back surfaces of the fiber board 1. Thus, the male tongue 4a and the female tongue 4b are provided at the end of the flooring material 3.
The floor material 3 is formed as shown in FIG.

Since the fiber board 1 has excellent strength and hardness, by forming a tongue 4 on a part of the end surface of the fiber board 1, the tongue excellent in strength and hardness can be easily and cleanly applied. can do.

The method of forming the tongue 4 consisting of the male tongue 4a and the female tongue 4b is such that, when the fiber board 1 is formed, the long fiber mat is laminated by shifting the end faces thereof, and then the tongue 4 is formed. A method of forming by thermocompression molding using a shaped die can be used. In addition, a method of cutting the end face of the fiber board 1 can be used, but in this case, it is necessary to perform precise cutting for each sheet, and the manufacturing cost tends to increase.

(Fifth Embodiment) FIG. 5 shows a fifth embodiment, FIG. 5 (a) is a perspective view showing the appearance of a floor material, and FIG. 5 (b) is a floor. It is a perspective view which decomposed | disassembled and showed the structure of the material. Several long fiber mats (1a, 1b, 1c, 1d) in which an adhesive is dispersed in an aggregate of long fibers [Fig.
(4) in (b)] When stacking, the long fiber mat (1
a) and 1b) and the lower filament mats (1c, 1d) are laminated by shifting the positions of the end surfaces, and thermocompression-molded using a tongue-shaped mold to form a fiberboard 1. Then, the surface finishing material 2 is adhered to both the front and back surfaces of the fiber board 1 to provide the tongue 4 made of the interlocking tongue 4c at the end portion of the floor material 3, as shown in FIG. 5 (a). A floor material 3 as shown is formed.

Since the fiber board 1 has excellent strength and hardness, the tongue 4 having excellent strength and hardness can be easily and cleanly applied by forming a tongue 4 on a part of the end surface of the fiber board 1. can do.

It ’s made up of 4c.
As a forming method, when forming the fiber board 1 described above, a method is used in which the end faces of the long fiber mat are shifted and laminated, and then thermocompression molding is performed using a mold having the shape of the tongue 4. You can In addition, a method of cutting the end face of the fiber board 1 can be used, but in this case, it is necessary to perform precise cutting for each sheet, and the manufacturing cost tends to increase.

[0053]

EXAMPLES Examples of the present invention will be specifically described below.

Example 1 Fibers obtained by defibrating kenaf were cut to a length of 1000 to 2000 mm to obtain kenaf long fibers. Phenolic resin adhesive to this kenaf filament,
It was dispersed so that the content ratio was 15% by mass. Next, a long fiber mat (1a, 1b, 1c) composed of an assembly in which the kenaf long fibers were lined up in a mold and stacked was obtained.
By laminating three long fiber mats (1a, 1b, 1c) and thermocompressing them, a size of 1800 mm × 300
kenaf fiber board 1 mm × 3 mm, density 800 kg / m ³
Was obtained [see FIG. 1 (b)].

Next, on both sides of the kenaf fiber board 1, a mixed adhesive prepared by mixing 4 parts by mass of melamine-urea resin adhesive and 6 parts by mass of styrene-butadiene rubber latex adhesive and 0.02 parts by mass of ammonium chloride. 90 g / m ^{2 was} applied by a roll coater. Next, as the surface finishing material 2, a decorative laminar sheet (zelkova) having a thickness of 0.25 mm in which the wood grain direction is aligned along the longitudinal direction of the floor material 3 formed in a rectangular shape is applied to the kenaf. The fiberboard 1 is placed on both sides [see FIG. 1 (b)], and is integrally molded by thermocompression molding at a press temperature of 120 ° C., a press pressure of 0.8 MPa, and a press time of 1 minute.
Size: 1800 mm x 300 mm as shown in (a)
A floor material 3 having a size of 3.5 mm was obtained. (Here, 180
0 mm is the longitudinal direction of the floor material 3, 300 mm is the lateral direction,
The thickness is 3.5 mm. same as below. )

Example 2 Fibers obtained by defibrating kenaf were cut to a length of 1000 to 2000 mm to obtain kenaf long fibers. The kenaf filaments were oriented in substantially one direction by using an orienting device in which a drawing portion consisting of six pairs of upper and lower rollers and a comb-shaped combing portion were combined (see FIG. 6). Next, a phenol resin adhesive was dispersed in the kenaf filaments in an amount of 15% by mass, and then the filament mats (1a, 1b, 1c) made of an aggregate that were arranged in one direction in a frame. ) Got.

Then, the filament mats (1a, 1b,
1c) The direction of the long fibers in each of which three pieces are oriented is
The size is 1800 mm × 300 mm × 3 m by stacking and stacking so that they are in a direction substantially parallel to each other and thermoforming
A kenaf fiber board 1 having m and a density of 800 kg / m ³ was obtained [see FIG. 2 (b)]. Next, the kenaf fiberboard 1 was arranged so that the oriented long fibers were oriented in a direction substantially parallel to the lateral direction of the flooring 3 to be formed.

Next, both front and back surfaces of the kenaf fiber board 1
6 kinds of styrene-butadiene rubber latex adhesive
4 parts by weight of melamine-urea resin adhesive,
Mixed adhesive containing 0.02 parts by mass of ammonium chloride
90g / m with a roll coater ²Applied one by one. Next
Then, as the surface finishing material 2, the longitudinal direction of the floor material 3 to be formed.
Veneer with a thickness of 0.25 mm with the grain direction aligned along the edges
Arrange (zelkova) on both sides of the above kenaf fiberboard 1
[See FIG. 2B], press temperature 120 ° C., press pressure
Thermocompression molding at 0.8 MPa and pressing time of 1 minute
Then, by integrally molding it, size 1 as shown in Fig. 2 (a)
A floor material of 800 mm × 300 mm × 3.5 mm was obtained.

Example 3 Fibers obtained by defibrating kenaf were cut to a length of 1000 to 2000 mm to obtain kenaf long fibers. The kenaf filaments were oriented in substantially one direction by using an orienting device in which a drawing portion consisting of six pairs of upper and lower rollers and a comb-shaped combing portion were combined (see FIG. 6). Next, a phenol resin adhesive was dispersed in the kenaf filaments in an amount of 15% by mass, and then the filament mats (1a, 1b, 1c) made of an aggregate that were arranged in one direction in a frame. ) Got.

Then, the filament mats (1a, 1b,
1c) Three pieces are laminated so that the oriented long fiber directions of vertically adjacent long fiber mats are alternately orthogonal to each other and subjected to thermocompression molding to obtain a size of 1800 mm × 300 mm × 3.
A kenaf fiber board 1 having a size of mm and a density of 800 kg / m ³ was obtained [see FIG. 3 (b)]. Then, this kenaf fiber board 1
The oriented long fibers were arranged so that the direction of the oriented long fibers was substantially parallel to the lateral direction of the floor material 3 to be formed.

Next, on both sides of the kenaf fiber board 1, mixed adhesion was prepared by mixing 4 parts by mass of melamine-urea resin adhesive and 6 parts by mass of styrene-butadiene rubber latex adhesive and 0.02 parts by mass of ammonium chloride. The agent was applied at 90 g / m ² by a roll coater. Next, as the surface finishing material 2, a decorative veneer (zelkova) with a thickness of 0.25 mm in which the grain direction is aligned along the longitudinal direction of the floor material 3 to be formed.
On both sides of the kenaf fiberboard 1 [Fig.
(B)], press temperature 120 ° C., press pressure 0.8
The pressure is 1 minute and the pressure is 1 minute, so that it is integrally molded to have a size of 1800 m as shown in FIG.
A floor material of m × 300 mm × 3.5 mm was obtained.

(Embodiment 4) In the same manner as in Embodiment 3, the size is 1800 mm × 300 mm × 3 mm and the density is 800 k.
A kenaf fiberboard of g / m ³ was obtained. Then, on both front and back surfaces of this kenaf fiber board, roll a mixed adhesive prepared by mixing 4 parts by mass of melamine-urea resin adhesive and 6 parts by mass of styrene-butadiene rubber latex adhesive and 0.02 parts by mass of ammonium chloride. 90 g / m ^{2 was} applied by a coater. Next, as the surface finish material 2, a thickness of 0.2
5 mm wood grain paper (paper grain printed) is placed on both sides of the kenaf fiber board coated with the mixed adhesive,
A floor material having a size of 1800 mm × 300 mm × 3.5 mm was obtained by thermocompression molding at a pressing temperature of 120 ° C., a pressing pressure of 0.8 MPa, and a pressing time of 1 minute to perform integral molding.

(Embodiment 5) As a surface finish material, a thickness of 0.2 in which the grain direction is aligned along the lateral direction of the floor material to be formed.
A flooring material having a size of 1800 mm × 300 mm × 3.5 mm was obtained in the same manner as in Example 3, except that 5 mm decorative veneer (zelkova) was placed on both front and back surfaces of the kenaf fiber board and thermocompression molding was performed. It was

Example 6 A long fiber mat was obtained in the same manner as in Example 3. The nine long fiber mats are laminated so that the directions of the long fibers oriented in the vertically adjacent long fiber mats are alternately orthogonal to each other, and thermocompression molding is performed to obtain size 1
800 mm x 300 mm x 9 mm, density 800 kg / m
A kenaf fiberboard of ³ was obtained.

A size of 1800 mm × 300 mm × was obtained in the same manner as in Example 3 except that this kenaf fiber board was used.
A flooring material of 9.5 mm was obtained.

Example 7 The density of the kenaf fiber board was 55.
A size of 1800 mm was obtained in the same manner as in Example 3 except that a kenaf fiber board adjusted to give 0 kg / m ³ was used.
A floor material of × 300 mm × 3.5 mm was obtained.

(Comparative Example 1) As a wood board, size 180
Using 0 mm x 300 mm x 3 mm MDF with a density of 800 kg / m ³ , only one side of the MDF (medium fiber board)
As a surface finishing material, size 1800 was applied in the same manner as in Example 1 except that a decorative veneer (zelkova) having a thickness of 0.25 mm in which the grain direction was aligned in the longitudinal direction of the floor material to be formed was adhered.
A floor material of mm × 300 mm × 3.5 mm was obtained.

(Comparative Example 2) As a wood board, size 180
Lauan plywood with a size of 0 mm x 300 mm x 3 mm and a density of 550 kg / m ³ is used as a surface finish material on only one side of the lauan plywood. A size of 1800 mm x was obtained in the same manner as in Example 1 except that the plate (zelkova) was adhered.
A floor material of 300 mm × 3.5 mm was obtained.

(Comparative Example 3) As a wood board, size 180
Laminated plywood with 0 mm x 300 mm x 3 mm and a density of 550 kg / m ³ , and a decorative veneer with a thickness of 0.25 mm with the grain direction aligned in the longitudinal direction of the flooring to be formed as a surface finishing material on only one side of the lauan plywood. In the same manner as in Example 1, except that (zelkova) was adhered, size 1800 mm × 3
A floor material having a size of 00 mm × 9.5 mm was obtained.

(Evaluation) The above Examples 1 to 7 and Comparative Examples 1 to 1
Table 1 shows the composition and production conditions of the floor material in No. 3 and the performance evaluation result of the obtained floor material.

[0071]

[Table 1]

In Table 1, as an index showing the strength of the flooring material, the amount of deflection (from the flooring material produced in each of the examples and comparative examples, 300 mm in the longitudinal direction and 100 mm in the lateral direction).
The both ends of the test piece cut out with the size of 200 mm were supported by a span of 200 mm, placed on a test stand, and the deflection amount of the central portion when a load of 3 kg was placed in the center was used. In addition, as an index indicating hardness, the amount of hard ball compression dent (from the flooring material produced in each of the examples and comparative examples, 300 mm in the longitudinal direction and 100 mm in the lateral direction, the surface of a test piece cut out with a diameter of 10 mm The dent amount when a load of 300 N was applied by the hard balls was used. In addition, as an index showing the dimensional change, the dimensional change rate in the longitudinal direction and the lateral direction before and after the test, which was evaluated based on the cold B test specified by JAS (special plywood) (each example and comparison) The dimensional change rate of the test piece cut out from the flooring material produced in the example in a size of 150 mm in the longitudinal direction and 150 mm in the lateral direction was used. In addition, the amount of warpage (the amount of warpage in the longitudinal direction of a test piece cut out in a size of 1000 mm in the longitudinal direction and 300 mm in the lateral direction from the flooring material manufactured in each of the examples and comparative examples) was used as an index of the warpage. .

As can be seen from Table 1, each of the examples has excellent performance with respect to the comparative example having the same thickness.

[0074]

The flooring material of the invention according to claims 1 to 9 is a flooring material in which a wood board and a surface finishing material are adhered to the surface of the wood board. The wood board is adhered to an aggregate of long fibers. After laminating a plurality of long fiber mats in which the agent is dispersed, the fiber board is formed by thermocompression molding, and the surface finishing material is adhered to both front and back surfaces of the fiber board, so warping It becomes the floor material which reduced.

Furthermore, in the flooring material of the invention according to claim 2, the long fibers are kenaf, jute, sisal, oil palm,
Since it is a long fiber obtained from at least one of coconut palms, it is a flooring material having excellent strength and hardness and reduced dimensional changes due to temperature changes and humidity changes.

Further, the flooring material of the invention according to claim 3 is formed by slicing the surface finishing material obtained by gluing the log or the small square timbers in a substantially one direction with the grain direction aligned.
A fiber veneer and a decorative veneer so that the decorative veneer has a uniform grain direction, and the grain direction of the decorative veneer is substantially parallel to the longitudinal direction of the flooring formed in a rectangular shape. Since the and are bonded together, it is a flooring material that has the grain of natural wood and a high wood feel.

Further, the flooring material of the invention according to claim 4 is the flooring material according to claim 3, wherein the fiber board disperses an adhesive in an aggregate of long fibers oriented substantially in one direction. The floor material is formed so that the oriented long fibers are oriented in a direction substantially parallel to the lateral direction of the rectangular floor material. Therefore, even if a decorative veneer having a weak strength is used in the lateral direction of the flooring material, cracks are less likely to occur in the decorative veneer as the flooring material.

Further, the flooring material of the invention according to claim 5 is the flooring material according to any one of claims 1 to 4.
The fiber board is a plurality of long fiber mats obtained by dispersing an adhesive in an aggregate of long fibers oriented in substantially one direction, and the directions of oriented long fibers of these long fiber mats are substantially orthogonal to each other. The floor materials are used so that one of the directions of the long fibers that are substantially orthogonal to each other is substantially parallel to the lateral direction of the floor material formed in a rectangular shape. Since the floor material is formed, the floor material has reduced dimensional changes in both the lateral direction and the longitudinal direction of the floor material.

Further, the flooring material of the invention according to claim 8 is the flooring material according to any one of claims 1 to 7.
Since the tongue is arranged at the end of the floor material, the floor material has the tongue excellent in strength and hardness in addition to the above effects.

[Brief description of drawings]

1A and 1B show a first embodiment of the present invention, in which FIG. 1A is a perspective view showing an appearance of a floor material, and FIG. 1B is a perspective view showing an exploded floor material configuration.

2A and 2B show a second embodiment of the present invention, in which FIG. 2A is a perspective view showing an appearance of a flooring material, and FIG. 2B is a perspective view showing an exploded configuration of the flooring material.

3A and 3B show a third embodiment of the present invention, in which FIG. 3A is a perspective view showing an appearance of a flooring material, and FIG. 3B is a perspective view showing an exploded configuration of the flooring material.

4A and 4B show a fourth embodiment of the present invention, in which FIG. 4A is a perspective view showing an appearance of a flooring material, and FIG. 4B is a perspective view showing an exploded configuration of the flooring material.

5A and 5B show a fifth embodiment of the present invention, in which FIG. 5A is a perspective view showing an appearance of a flooring material, and FIG. 5B is an exploded perspective view showing a configuration of the flooring material.

FIG. 6 is a perspective view schematically showing an alignment device.

[Explanation of symbols]

1 fiberboard 1a, 1b, 1c Long fiber mat 2 Surface finish 3 floor materials 4 4a Male 4b female rat 4c Ajakuri zane

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Kazunori Umeoka             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Kenji Onishi             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Hideyuki Ando             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company F-term (reference) 2B250 AA05 BA05 DA03 EA13                 2B260 AA12 BA02 BA19 CB04 CD03                       EA03

Claims (8)

[Claims] 1. A flooring material having a surface finish adhered to the surface of a wood board, wherein the wood board comprises a plurality of long fiber mats obtained by laminating a plurality of long fiber mats obtained by dispersing an adhesive in an aggregate of long fibers.
A flooring material which is a fibrous board formed by thermocompression molding, and the surface finishing material is adhered to both front and back surfaces of a wooden board. 2. The flooring material according to claim 1, wherein the long fibers are long fibers obtained from at least one of kenaf, jute, sisal, oil palm and coconut. 3. The decorative surface veneer having a uniform grain direction, which is formed by slicing a log or a small square lumber with the grain directions aligned in substantially one direction, and adhering the laminated grain. The fiber board and the decorative veneer are bonded so that the grain direction of the decorative veneer is substantially parallel to the longitudinal direction of the flooring formed in a rectangular shape. Alternatively, the flooring material according to claim 2. 4. The fiber board uses a long fiber mat in which an adhesive is dispersed in an aggregate of long fibers oriented in substantially one direction, and the orientation of the oriented long fibers is ,
The flooring material according to claim 3, wherein the flooring material is formed so as to be substantially parallel to the lateral direction of the rectangular flooring material. 5. A plurality of long fiber mats, wherein the fiber board has an adhesive dispersed in an aggregate of long fibers oriented in substantially one direction, and Using the laminated alternately so that the directions are substantially orthogonal, and one of the directions of the substantially orthogonal long fibers is a direction substantially parallel to the lateral direction of the rectangular flooring material. The flooring material according to any one of claims 1 to 3, wherein the flooring material is formed as follows. 6. The flooring material according to claim 1, wherein the flooring material has a thickness of 1 mm to 5 mm. 7. The density of the fiber board is 600 kg / m ³
It is above, The flooring material in any one of Claim 1 thru | or 6 characterized by the above-mentioned. 8. The flooring material according to claim 1, further comprising a tongue provided at an end portion of the flooring material.