JP2003266408A - Floor material having crack resistant performance - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To inexpensively provide a floor material in which a surface veneer crack hardly occurs without lowering a warpage performance or finishing properties of a side face of the floor material even when there are a change in an environmental humidity, a strong sunshine, a rain blow-through, a blow-through splash or water droplet adhesion generating in a daily life and without lowering workability and productivity at a manufacturing time. <P>SOLUTION: The floor material comprises a woody decorative veneer laminated on a surface of a plywood base material via an adhesive layer so that the adhesive mixes an inorganic fibrous material in an aqueous synthetic resin adhesive. <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 interior of a house, and more particularly to a flooring material which hardly causes surface cracks on the flooring after construction.

[0002]

2. Description of the Related Art A floor material used for interior of a house, especially as a surface decorative material, using a natural wood veneer, after construction, in a humid room, due to a change in ambient humidity, Veneer surface veneer is absorbed and released by strong sunlight and rain on the floor near the window in a sunny room, and by the splashes and drops of daily life on floor materials in the kitchen and washroom. Repeat the dampness
As a result, the veneer expands and contracts, which causes cracking of the flooring surface. Therefore, as a floor material that is resistant to surface cracking, the wood base material that constitutes the floor material is not the normal plywood, but the fiber direction of the first layer veneer that forms the plywood is made orthogonal to the fiber direction of the surface decorative veneer. Or, in Japanese Patent Laid-Open No. 49-71114
As disclosed in Japanese Patent Laid-Open No. 52-105985 and Japanese Patent Laid-Open No. 52-105985, surface cracks are prevented by sticking a non-woven fabric or Japanese paper as a backing material to a single plate.

[0003]

However, a so-called reverse size veneer in which the fiber length direction is the direction orthogonal to the fiber direction of the surface decorative veneer is usually produced by laminating small pieces in that direction. High cost. The reverse dimension plywood having the reverse dimension veneer as the first layer is an intermediate layer of a plywood base material, for example, the third layer in the case of 5 ply plywood and the third layer in the case of 7 ply plywood. Since the veneer, the fifth layer, and the seventh layer veneers are also reverse-sized veneers, the manufacturing process differs from normal plywood during plywood manufacturing, resulting in poor manufacturing efficiency. When the cost is increased by making the single plate of the layers upside down, the cost becomes very high.

Further, in the case where such a reverse plywood is actually processed, for example, in the case of a 5-ply plywood, in the longitudinal direction of the floor material, male and female tips are the third layer of the reverse plywood. Since the wood fiber is cut, if the cutting ability of the cutting tool of the processing machine is slightly deteriorated, the processing finish is deteriorated and the quality of the floor material is deteriorated. In the case of a 7-ply plywood, there was a problem in the finish of working in the reverse-sized single plates of the third layer and the fifth layer.

Further, generally, the wood veneer has a lower bending rigidity in the fiber orthogonal direction than in the fiber length direction, and is the first of the veneers constituting each layer of the base plywood to be easily affected by bending stress. If the single-layer veneer and the back-side veneer layer are reverse-sized veneers, the rigidity of the flooring material in the longitudinal direction is lower than that of ordinary plywood, and warpage in that direction is likely to occur. In particular, when the floor material is concavely warped when viewed from above, the joint with the adjacent plywood is lifted upward, making construction difficult and troublesome.

[0006] Further, in the method of preventing surface cracks by pasting non-woven fabric or Japanese paper as a backing material on the single plate,
Since it is necessary to apply an adhesive to each of the single plates and to attach a sheet-like material such as a non-woven fabric or Japanese paper, there is a problem that workability is poor and productivity is low.

An object of the present invention is to provide a floor material which is unlikely to cause cracking of the surface veneer even if there is a change in environmental humidity, strong sunlight or rain, and splashes or drops of water generated in daily life. The purpose of the present invention is to provide at low cost without lowering the warp performance and workability on the side surface of the flooring material, and further, without lowering workability and productivity during manufacturing.

[0008]

In order to achieve the above object, in the flooring material having crack resistance according to the present invention, a wood decorative veneer is attached to the surface of a plywood base material via an adhesive layer. A floor material, characterized in that the adhesive is an aqueous synthetic resin adhesive mixed with an inorganic fibrous material.

Since the inorganic fibrous material does not undergo expansion / contraction of the fiber itself due to environmental changes, deformation such as bending, embrittlement, etc., a floor coated with a decorative decorative veneer with an adhesive mixed with the inorganic fibrous material. The material can prevent the surface-coated veneer from being deformed due to environmental changes, and can improve cracks caused by the deformation. Further, the inorganic fibrous material has a high affinity with water and can be easily and stably mixed with the water-based synthetic resin adhesive. The water-based adhesive is easy to apply evenly to the wood veneer, and the inorganic fibrous material does not penetrate the adhesive like natural pulp and fibers, so the adhesive strength depends on the amount of fibrous material mixed or environmental conditions such as temperature. Does not change, the surface decorative veneer is less likely to be deformed due to uneven adhesive strength, and thus the surface decorative veneer is less likely to crack.

Therefore, from the structure according to the first aspect of the present invention, changes in the surrounding humidity, strong sunlight and blowing of rain,
Even if water splashes or water droplets are attached in daily life, expansion and contraction of the surface decorative veneer is suppressed, and therefore cracking of the surface decorative veneer can be prevented. Moreover, it is possible to prevent the occurrence of cracks in the surface decorative veneer at a low cost, without lowering the warpage of the flooring material and the workability of the finished product, and having good workability in manufacturing.

Further, the water-based synthetic resin adhesive is preferably a melamine urea vinyl acetate resin adhesive. The melamine urea vinyl acetate resin adhesive is a mixture of a melamine urea co-condensation adhesive and a vinyl acetate aqueous emulsion, and is stable after mixing. Since this adhesive has little expansion and contraction deformation of the adhesive itself and is also excellent in weather resistance, deformation of the veneer caused by expansion and contraction of the adhesive due to environmental changes is small, and cracking of the decorative veneer is improved accordingly. . Furthermore, this adhesive can be hot pressed by hot pressing,
Since it can be pressed with a cold press, it has excellent workability.

The inorganic fibrous material is preferably glass fiber. Glass fiber absorbs adhesive,
It has the advantages of no deformation due to environmental changes, stable mixing with an adhesive, inexpensive and easy availability.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION An example of an embodiment of a flooring material having crack resistance according to the present invention will be described in detail below with reference to the drawings. 1 is a perspective view showing an example of an embodiment of a flooring material having crack resistance according to the present invention, FIG. 2 is an enlarged sectional view taken along the line AA of FIG. 1, and FIG. 3 is an enlarged sectional view of a B portion of FIG. Is.

The flooring material 1 having crack resistance as shown in this example is
A wood decorative veneer 3 with an adhesive layer 6 on the surface of a plywood base material 2.
Are attached, and on the side surfaces of the plywood base material 2 that face each other in the longitudinal direction, a fitting protrusion portion 4 and a fitting groove portion 5 that can be fitted to each other are provided. In addition, fitting protrusions 4 and fitting grooves 5 that can be fitted to each other are also provided on side surfaces of the plywood base material 2 that face each other in the lateral direction.

As the plywood base material 2, in addition to South Sea materials such as Lauan, Meranti, Capoule, Merapi, Agathis, Joncon, and Apiton which have been often used, yellow pine, red cedar, cedar, larch. Those using softwood materials such as wood can be used, and the number of veneer laminated plies of plywood is preferably 3 to 7 plies, but other than these may be used.

The thickness of the plywood base material is about 5.0 m.
The optimum range is from m to 15.0 mm. When the thickness of the plywood base material is within this range, the strength, durability, walking feeling, workability, quality stability, etc. of the flooring material are well balanced and optimal. Further, the shape of the plywood base material is the same as that of a conventional conventional flooring material.

As the adhesive applied to the wood decorative veneer to be applied on the plywood base material, an aqueous synthetic resin adhesive mixed with an inorganic fibrous material is used. The amount of the adhesive applied depends on the thickness of the decorative veneer to be attached, but is approximately 90-
The optimum value is about 160 g / m ² .

A water-based adhesive is suitable as the type of the adhesive. For example, urea resin-based adhesives, melamine resin-based adhesives, acrylic resin emulsion-based adhesives, vinyl acetate resin emulsion-based adhesives, or those in which these are blended are relatively inexpensive and easy to use and have good workability. Are better. Among these, the melamine urea vinyl acetate resin adhesive is most suitable in consideration of workability and cost.

As the inorganic fibrous material mixed in these water-based adhesives to prevent cracking of the surface decorative veneer, metal fibers, mineral fibers, glass fibers and the like can be used, but they are easy to handle and manufactured. Considering easiness and cost, glass fiber is most suitable.

If the size of the glass fiber is too large, the workability at the time of production is poor, and since the thickness of the surface decorative veneer is extremely thin, about 0.2 to 1.0 mm, there is a problem in the smoothness of the floor material surface. Occurs. On the contrary, if the size of the glass fiber is too small, the effect of preventing cracking of the wood veneer on the surface cannot be exhibited. The optimum size of the glass fiber is 10 to 100 μm in thickness and 1.0 to 5.0 mm in length.

If the amount of the water-based adhesive added is too large, the adhesive strength of the wood decorative veneer may be reduced, and if it is too small, the crack preventing effect cannot be exerted. When the amount of glass fiber mixed with the weight of the adhesive is 5 to 20% by weight, the balance between the adhesive strength and the crack prevention effect of the wood decorative veneer is optimal. Mix a specified amount in the adhesive and stir well with a stirrer before use. As a method of coating the plywood base material, a conventional roll spreader or the like may be used.

As the wood veneer 3 for the surface, there are oak and oak as tree species that have been often used for flooring materials.
Although sliced veneer or rotary veneer such as black, zelkova, cherry, sen, taro, pine, cypress, etc. is most suitable, it may be other than these. The thickness of the veneer is 0.2
A floor veneer crack prevention effect is sufficiently exhibited in a thin veneer having a thickness of about mm to 1.0 mm. The wood decorative veneer may be attached by either hot pressing with a hot press or cold pressing with a cold press. Use properly depending on the adhesive used.

Further, the surface of the floor material is painted by a conventional paint or method. For example, a roll coater or a flow coater using a thermosetting type, ultraviolet ray curing type, electron beam curing type urethane resin or aminoalkyd resin coating material.
Painted. Further, it may be other than these.

[0024]

EXAMPLES Next, examples and comparative examples will be described below. [Example 1] A 5-mm ply 12-mm thick lauan regular-sized plywood was used as a base material and a melamine urea vinyl acetate resin adhesive was used to hot-press a 0.3 mm-thick oak veneer at a temperature of 110 ° C. Pressure 8.0 kg / cm ² , clamping time 2
Affixed under a pressure condition of 1 minute. The amount of adhesive applied is 1 wet
It was 10 g / m ² . At this time, as the inorganic fibrous material mixed in the adhesive, glass fibers having a thickness of 50 μm and a length of 3.0 mm were used. The amount of admixture in the adhesive is 3%, 5%, 10%, 15%, 20%, 30% with respect to the weight of the adhesive.
%. The surface was painted and finished with a UV-curable urethane resin paint to prepare the flooring material of Example 1.

Comparative Example 1 A flooring material of Comparative Example 1 was produced in the same manner as in Example 1 except that glass fiber was not mixed in the adhesive at all.

[Floor Material Test] The floor material produced as described above was subjected to the following surface veneer cracking test and veneer adhesive strength test. Table 1 shows the total length of cracks and the total length of peeled portions. Table 1: Floor material test results

[Test Method] Veneer Cracking Test: Tested by the cold heat repeat test B test method of the special plywood standard of Japan Agriculture and Forestry Standard (JAS). The length of the crack was measured with a caliper. Adhesive strength test of veneer: Tested by the 2nd class immersion peeling test method of the special plywood standard of Japan Agriculture and Forestry Standard (JAS). The peel length was measured with a caliper. [Judgment Criteria] Evaluation was carried out in four levels according to the following judgment criteria.

[Discussion of Test Results] It is understood that the crack resistance of the flooring material of the present invention is greatly improved as compared with the standard Comparative Example 1. Further, the amount of glass fibers mixed in the adhesive is 3% or more in terms of the effect of preventing veneer cracking, and 30% or less in terms of the adhesive force of the veneer, which can be said to be no problem. Considering the balance between the crack prevention effect of the veneer and the adhesive strength of the veneer, it is found that the optimum amount of glass fiber mixed in the adhesive is 5 to 20% by weight ratio to the adhesive. In addition, the crack resistance of Example 1 has a crack resistance comparable to that of the reverse plywood.

[0029]

INDUSTRIAL APPLICABILITY As described above, the floor of the present invention using an aqueous synthetic resin adhesive containing an inorganic fibrous material as an adhesive when sticking a wood decorative veneer on the surface of a floor material. The material is a flooring surface decorative veneer that is comparable to a reverse plywood even if there is a change in environmental humidity, strong sunlight or rain blown, and splashes or drops of water generated in daily life after the flooring is applied. In addition to having the performance, there are no drawbacks of reverse dimensioned plywood such as deterioration of construction efficiency due to deformation such as warp of plywood due to environmental changes, deterioration of accuracy in actual machining, deterioration of finish quality It can be manufactured at low cost and is extremely effective in practice.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of an embodiment of a flooring material having crack resistance according to the present invention.

FIG. 2 is an enlarged cross-sectional view taken along the line AA of FIG.

FIG. 3 is an enlarged cross-sectional view of portion B in FIG.

[Explanation of symbols]

1 Flooring material having crack resistance of the present invention 2 Plywood substrate 3 wood makeup veneer 4 Fitting protrusion 5 Fitting groove 6 Adhesive layer P Inorganic fibrous material

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 2B200 BA01 CA09 CA11 HA03 HA20                 2B250 AA05 BA05 CA11 EA13 GA03                 2E220 AA11 AA26 AA39 BA01 BB03                       DA02 EA03 GA12X GA22                       GA22X GA25X GA27X GB01X                       GB12X GB28X GB32X GB44X                       GB45X GB45Y

Claims (3)

[Claims] 1. A flooring material in which a wood decorative veneer is attached to the surface of a plywood base material via an adhesive layer, wherein the adhesive agent mixes an inorganic synthetic fibrous material with an aqueous synthetic resin adhesive. A flooring material having cracking resistance, which is characterized by being 2. The flooring material having cracking resistance according to claim 1, wherein the water-based synthetic resin adhesive is a melamine urea vinyl acetate resin adhesive. 3. The flooring material having cracking resistance performance according to claim 1, wherein the inorganic fibrous material is glass fiber.