JP2005212106A - Floor material manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor material manufacturing method capable of enhancing the castor resistance and durable capacity of a floor material against the reciprocating load of a castor and facilitating the control of an adhesive coating process in a manufacturing process. <P>SOLUTION: In the method for manufacturing the floor material by bonding a surface finish material 5 to one side of a woody board 1 through an adhesive, resin impregnated paper 3 is bonded to one side of the woody board 1 through an undercoating urethane adhesive and the surface finish material 5 is placed and bonded on the upper surface of the resin impregnated paper 3 through a rubbery adhesive applied as an undercoating layer. As the resin impregnated paper 3, one obtained by curing a paper base material impregnated with a melamine resin under heating and pressure may be used. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention is composed of a wooden board and a surface finishing material such as a decorative veneer or a decorative sheet attached to one side of the wooden board via an adhesive, and is suitable for a flooring finished floor, a step board for stairs, etc. The present invention relates to a method for producing a flooring used.

  Wooden flooring used to finish flooring in residential rooms has been used since it is easy to care for, such as cleaning, and has recently suppressed the occurrence of ticks that are a cause of sick house syndrome. As such effects are also expected, the use is expanding rapidly, especially in apartment buildings. Conventional wood-based floor materials, for example, have been mainly produced by sticking a decorative veneer or a decorative sheet or the like as a surface finish on one side of a wooden board such as plywood.

  In a room with such flooring finish, for example, when a chair with a caster is installed together with a computer desk, it cannot withstand long-term use such as when a load reciprocating against the flooring is applied for a long period of time. It has been reported that the surface finish is peeled off when the surface is damaged or a load exceeding the hardness of the flooring surface is applied due to movement of furniture.

  Due to the above improvement, the present applicant can improve the durability against reciprocating loads of casters and the like, and disclosed in JP-A-2003-211420, a method for manufacturing a flooring as shown in FIG. Has proposed. The flooring 100 is prepared by undercoating and drying a mixed adhesive 102 obtained by mixing a rubber adhesive and a resin adhesive on one side of a wooden board 101, and further applying the mixed adhesive 103 on the upper surface. Next, the surface finishing material 104 is placed on and attached to the upper surface.

By the way, when such a flooring manufacturing method is employed, the mixed adhesive is filled in the gaps 101b, 101b... By the fibers 101a, 101a... Constituting the wood board 101 (portion 102b), and the wood board 101 is filled. Although the adhesion between the surface finishing material 104 and the surface finishing material 104 is improved, the thickness of the adhesive layer by the mixed adhesives 102 and 103 is increased, so that a movement occurs between the surface finishing material 104 and the wooden board. It has been found that the variation in the adhesion of the finishing material 104 increases. As a result, there is a concern that the process management of the adhesive application in the manufacturing process becomes complicated.
JP 2003-21420 A

  The present invention has been made in view of the above-mentioned background art, and the problem is that the flooring material can be improved in durability performance against the reciprocating load of the caster-resistant and can be easily managed in the process of applying the adhesive in the manufacturing process. It is intended to provide a manufacturing method.

  In order to solve the above-mentioned problems, a method for manufacturing a flooring material according to the present invention includes a wooden board, and a flooring manufacturing method in which a surface finishing material is bonded to one side of the wooden board via an adhesive. After the urethane-based adhesive is primed on one side of the board and the resin-impregnated paper is adhered, the rubber-based adhesive is further primed and the surface finish is placed on the upper surface of the resin-impregnated paper. .

  Moreover, it is preferable that the resin-impregnated paper is one obtained by impregnating a paper base material with a melamine resin and then heat-pressure curing.

  Further, the wooden board is a long fiber mat using an aggregate in which long fibers obtained from at least one of kenaf, jute, sisal hemp, oil palm and coconut are oriented and assembled. A fiberboard formed by hot pressing is preferable.

  In the floor material manufacturing method of the present invention, the surface finishing material is bonded to the wooden board via a rubber adhesive applied to the surface of the resin-impregnated paper bonded via a urethane adhesive. The system adhesive and the resin adhesive are stably mixed and bonded, and the adhesion between the surface finish and the wood board is made uniform. In addition, the water impregnation from the surface is prevented by the resin-impregnated paper intermediate between the surface finish and the wood board, and the water resistance of the flooring is improved.

  In addition, urethane adhesive and rubber adhesive are mixed with the paper base material impregnated with melamine resin and then hot-pressed resin impregnated paper. More improved.

  Further, a wood board made of fiberboard formed by hot-pressing a long fiber mat of an assembly in which long fibers obtained from at least one of kenaf, jute, sisal, oil palm and coconut are oriented and assembled is The dimensional change accompanying the change in the moisture content in the fiber direction is very small, and therefore excellent in crack resistance as a flooring material.

  1-3 has shown the manufacturing method of the flooring which is one Embodiment corresponding to all Claims 1-3 of this application. As shown in FIGS. 1 and 2, the floor material manufacturing method according to this embodiment includes a wooden board 1 and a floor material in which a surface finishing material 5 is bonded to one side of the wooden board 1 with an adhesive. In the method, after applying the urethane adhesive 2 to one side of the wood board 1 and adhering the resin impregnated paper 3, further applying the rubber adhesive 4 and placing the surface finish 5 on the upper surface of the resin impregnated paper 3. It is placed and stuck.

  In the floor material manufacturing method of this embodiment, as shown in FIG. 1, the resin-impregnated paper 3 is obtained by impregnating a paper base material 31 with a melamine resin and subsequently heat-pressing it. In this case, the wood board 1 is formed into a long fiber mat using an aggregate in which long fibers obtained from at least one of kenaf, jute, sisal hemp, oil palm and coconut are oriented and assembled, and then the long fibers It is also considered to be a fiber plywood formed by hot pressing a mat.

  Hereinafter, the manufacturing method of the flooring of this embodiment will be described in more detail. The flooring manufacturing method of this embodiment is a manufacturing method related to a wooden flooring used for flooring a living room in a house. As shown in FIG. 1, first, a wooden board 1 and a resin impregnated paper 3 are used. Then, a cold adhesive step ST1 is applied, and then a rubber adhesive is primed on the upper surface of the resin-impregnated paper 3 and a decorative veneer such as oak and hippo is used as a surface finish 5 on the upper surface of the resin-impregnated paper 3. It is mounted and pasted through a cold press step ST2.

  In this case, the wood board 1 is obtained by forming a long fiber mat by using an aggregate in which kenaf long fibers are oriented and assembled, and then hot pressing the long fiber mat. This is a fiber plywood which is disclosed in 2000-263519, etc., and is formed into a long fiber mat using an aggregate in which the kenaf long fibers are oriented and assembled, and then this long fiber mat is hot-press molded. Such a long fiber obtained from at least one of kenaf or jute, sisal hemp, oil palm and coconut is approximately 2 to 14 times that of a coniferous fiber obtained from a conifer or a broadleaf fiber obtained from a broadleaf tree. It has a high tensile strength, and by using a fiberboard formed by orienting these fibers, the high tensile strength of the fiber itself can be effectively utilized, and the bending performance, and the length due to temperature and humidity changes can be increased. It is preferable because a flooring material having very excellent performance against a change in thickness can be obtained.

  The density of the fiberboard is not particularly limited, but is preferably set to 400 kg / cubic meter or more, more preferably 500 kg / cubic meter or more. When the fiberboard density is less than 400 kg per cubic meter, a large number of voids exist on the surface and inside of the fiberboard, and the adhesive strength with the surface finish tends to be lowered. In addition, the bonded portion between the fibers and the entangled portion between the fibers are reduced, and the high strength due to the bonded portion between the fibers inherent to the long fiber and the entangled portion between the fibers can be sufficiently exhibited. It becomes difficult and the bending rigidity of the fiberboard tends to decrease.

  In addition, an adhesive may be used for forming the fiberboard, and the type of the adhesive and the method of dispersing the adhesive are not particularly limited. For example, urea resin, melamine resin, phenol Resins, resorcinol-based resins, epoxy-based resins, urethane-based resins, furfural-based resins, and thermosetting resins that are cured by heating such as isocyanate-based resins can be used. Furthermore, as a pressing method in hot press molding, there are a batch type flat plate press and a continuous press method, but there is no particular limitation, and the weight ratio of the adhesive to the press temperature, press time, press pressure, and fiber weight is not limited. Are appropriately set depending on the type of adhesive used, the thickness of the fiberboard, and the like.

  In this case, the resin-impregnated paper 3 uses recycled recycled paper as the paper base 31. After passing the paper base 31 through a melamine resin solution having a concentration of about 20 to 30% in the impregnated basket (ST6) ), And is allowed to stay for about 10 to 20 minutes in a warm air bath whose temperature is controlled at 60 to 80 ° C. (ST7). Next, a hot press roll is performed using a roll press whose temperature is controlled at about 130 to 150 ° C., and the impregnated melamine resin is cured by hot pressure (ST8). In this way, by using recycled recycled paper as the resin-impregnated paper 3, the reuse of resources is promoted, and in combination with the use of kenaf long fibers for the wooden board 1, in reducing the environmental burden. More preferred.

  The surface finishing material 5 is made by thinly slicing a single veneer made from a wood log of famous wood such as oak or hippopotamus with a cutting machine such as a slicer or a half rotary, or a laminated material, i.e., a piece of glued small timber. A single plate can be used. The thickness of the surface finish 5 is not particularly limited, but many products having a thickness of about 0.2 mm to 0.6 mm are manufactured. In addition, as the surface finishing material 5, there are other papers on which wood grain is printed, or a sheet material of polyvinyl chloride resin, etc., but those made of decorative veneer have natural grain of natural wood It is preferable because the flooring material has the highest wood texture.

  In the above-described embodiment, it is preferable that the fiber direction of the surface finishing material 5 in the flooring is substantially orthogonal to the fiber direction of the wooden board 1. The surface finish 5 made of a decorative veneer is very thin and has almost no strength in the direction perpendicular to the fiber direction. For this reason, when the wooden board part of the flooring produced by bonding the wooden board and the decorative veneer changes in dimensions with the moisture content change, the decorative veneer receives stress according to the dimensional change, cracks, Cracks will occur. If the fiber direction of the decorative veneer is perpendicular to the fiber direction of the wood board, the dimensional change accompanying the change in the moisture content in the fiber direction of the wood board is very small, so a flooring that is very unlikely to crack and crack is obtained. This is preferable.

  Examples of the present invention will be specifically described below.

First, waterborne vinyl urethane is used as a urethane-based adhesive and is coated on one side of a kenaf fiber board having a density of 800 kg per cubic meter and a thickness of 2.5 mm, which is a wood board 1, using a coal coater, and then the undercoated kenaf fiber board and the resin-impregnated paper described above. 3 was pressed at a pressure of 0.7 to 1 MPa for 30 to 40 minutes in a normal temperature atmosphere. (ST1)
Next, a styrene-butadiene rubber adhesive as a rubber adhesive is primed on the upper surface of the resin-impregnated paper with a roll coater, and the surface finish 5 is a surface finishing material 5 of 0.25 mm thick or cover. The decorative veneer is placed so that the fiber direction of the decorative veneer is perpendicular to the fiber direction of the kenaf fiber plate, and the condition is 120 to 130 ° C. and a pressure of about 0.7 MPa for 30 to 50 seconds. A flooring material was produced by hot-pressure curing using a hot press machine having a hot plate of a predetermined size. (ST2)
In the procedure according to the embodiment, the periphery of the flooring material is cut to a predetermined standard size (ST3), and the surface finish 5 is further coated with a surface protective agent such as urethane acrylate. (ST4), the process proceeds to the inspection and packing process (ST5).

  According to the above embodiment, as shown in FIGS. 2A to 2C, the urethane-based adhesive 2 primed as described above is formed in the gaps of the fibers 1a, 1a,. After the resin-impregnated paper 3 is attached in the state of entering and filling, as shown in FIG. 4D, the surface finishing material 5 is passed through the rubber adhesive 4 applied to the surface of the resin-impregnated paper 3. Since the melamine resin contained in the resin-impregnated paper 3 and the rubber adhesive 4 are stably mixed and bonded, the thickness dimension is more stable and preferable. .

  Further, as shown in FIG. 3, the urethane-based adhesive 2 and the rubber-based adhesive 4 are hot-pressure cured by sandwiching a resin-impregnated paper 3 impregnated with a melamine resin in a paper base 31 and subsequently heat-pressure cured. It will be mixed through a process.

  Therefore, in the floor material manufacturing method of this embodiment, the surface finish 5 is made of wood board through the rubber adhesive 4 applied to the surface of the resin-impregnated paper 3 bonded through the urethane adhesive 2. Therefore, the rubber-based adhesive 4 and the resin-based adhesive are stably mixed and bonded, and the adhesion between the surface finish 5 and the wood board 1 is made uniform. In addition, the resin impregnated paper 3 between the surface finishing material 5 and the wood board 1 prevents moisture from penetrating from the surface, thereby improving the water resistance of the flooring material.

  Further, since the urethane-based adhesive 2 and the rubber-based adhesive 4 are mixed with the resin base paper 31 impregnated with the melamine resin and the resin-impregnated paper 3 that has been heat-pressure-cured later being sandwiched, the surface finish 5 Adhesion with the wooden board 1 is further improved, and the thickness dimension is more stable.

  Furthermore, the wood board 1 by the fiber board formed by hot-pressing a long fiber mat of an assembly in which long fibers obtained from at least one of kenaf, jute, sisal hemp, oil palm and coconut are oriented and assembled, The dimensional change accompanying the change in the moisture content in the fiber direction is very small, and therefore excellent in crack resistance as a flooring material.

Process explanatory drawing which shows the schematic procedure of the manufacturing method of the flooring which is one Embodiment of this invention. (A) is explanatory drawing which shows a wooden board in the manufacturing method of the flooring, (b) is explanatory drawing which shows the state which primed the urethane type adhesive agent to the wooden board, (c) is resin impregnated paper to the wooden board Explanatory drawing which shows the state which bonded | pasted, (d) is explanatory drawing which shows the state which stuck the surface finishing material 5 after sticking the resin impregnated paper. The expanded sectional view which shows the flooring detail by the manufacturing method of the flooring. The expanded sectional view which shows the flooring detail by the manufacturing method of the flooring which is a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Wood board 2 Urethane adhesive 3 Resin impregnated paper 31 Paper base material 4 Rubber adhesive 5 Surface finishing material

Claims (3)

In the manufacturing method of a flooring material in which a surface finishing material is adhered to one side of the wooden board and this wooden board via an adhesive,
After applying urethane adhesive on one side of the wooden board and adhering the resin-impregnated paper, further applying a rubber adhesive and placing the surface finish on the upper surface of the resin-impregnated paper A method for producing a characteristic flooring. 2. The method for producing a flooring material according to claim 1, wherein the resin-impregnated paper is obtained by impregnating a paper base material with a melamine resin and subsequently heat-pressure curing. The wood board is formed into a long fiber mat using an aggregate in which long fibers obtained from at least one of kenaf, jute, sisal hemp, oil palm and coconut are oriented and assembled, and then the long fiber mat is hot-pressed. 3. The flooring manufacturing method according to claim 1, wherein the flooring is a fiberboard formed by molding.

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