JP2006152757A - Flooring - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide flooring which prevents appearance deficiencies caused by execution conditions and a change in humidity caused by a use environment, which prevents the generation of floor sound, and has little unevenness in execution by workers. <P>SOLUTION: The flooring comprises a multilayered body shaped like a nearly rectangle, and a hard plate-shaped body 21 is laminated on a hard foam body 1. Then a male tongue 23 is formed at least on one side, and a female tongue 24 is formed on the other side of the flooring. At least the convexity 25 of the male tongue 23 is formed from one side end part of the hard plate-shaped body 21, and the lower convexity 26 of the female tongue 24 is formed at one side end part of either the hard foam body 1 or the hard plate-shaped body 21. At the time of execution, when the male tongue 23 is engaged with the female tongue 24 of the adjacent flooring, the hard foam bodies 1 are brought into contact with each other. Then clearance d1, d2 are provided between the upper concavity 28 of the male tongue 23 and the upper convexity 29 of the female tongue 24 which are adjacent to each other, and between the convexity 25 of the male tongue 23 and the concavity 30 of the female tongue 24 which are adjacent to each other, respectively. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a flooring, and more particularly to a flooring with improved appearance defects and floor noise due to changes in humidity.

  Conventionally, in floor materials using hard plate-like bodies, floor materials having both soundproofing performance and walking feeling and excellent workability have been demanded. For example, Patent Document 1 discloses a thermoplastic resin foam. A floor material in which a hard plate is laminated on one side, the thermoplastic resin foam is a sheet-like continuous foam layer, and a plurality of high foam portions arranged on at least one surface of the continuous foam layer, A low foamed thin film covering the entire surface of the high foamed portion together with the continuous foamed layer, and the high foamed portion covered with the low foamed thin film is formed in a convex shape from the continuous foamed layer, Disclosed is a flooring or the like characterized in that irregularities are formed on the back surface of the thermoplastic resin foam by forming concave portions between the foamed portions.

  However, depending on the construction conditions and the usage environment, the floor materials as described above may expand due to changes in humidity, etc., resulting in the appearance of seams and poor appearance, or floor noise during walking. It was.

JP 2000-45503 A

  In view of the above-mentioned conventional problems, an object of the present invention is to prevent a poor appearance due to a change in humidity depending on a construction state or a use environment, to prevent floor noise, and to reduce flooring variation by an operator. It is to provide.

  The flooring according to claim 1 is a flooring comprising a substantially rectangular laminated body in which a hard plate is laminated on a hard foam, wherein a male fruit is formed on at least one side and a female fruit is formed on the other side. And at least the male convex part is formed from one side end part of the hard plate-like body, and the lower convex part of the female fruit is formed from one side end part of the hard foam or hard plate-like body. At the time of construction, when the male is fitted to the female of the adjacent floor material, the hard foams are in contact with each other, and between the upper concave of the adjacent male and the upper convex of the female, and the male A gap is provided between the real convex part and the female real concave part.

  A flooring material according to a second aspect is the flooring material according to the first aspect, wherein an uneven shape is formed on the upper surface and / or the lower surface of the hard foam.

  A flooring material according to a third aspect is the flooring material according to the first or second aspect, wherein a non-land absorbing layer is laminated on the lowermost layer.

  Hereinafter, the present invention will be described in detail.

  The hard plate-like body used in the present invention is not particularly limited as long as it is a material that is not easily broken or damaged by a load normally applied to a flooring material. For example, 1) wood veneer, plywood, particle board , Wood materials such as medium density fiberboard (MDF), high density fiberboard (HDF), hardboard, parallel plywood (LV), 2) thermoplastic resin such as polyethylene, polypropylene, polyvinyl chloride, polyester And resin materials made of thermosetting resins such as epoxy resins, and 3) composite materials such as fiber reinforced thermosetting resins and fiber reinforced thermoplastic resins.

  If necessary, a surface decorative material such as a veneer, a synthetic resin or a synthetic resin foam sheet, decorative paper, or a synthetic resin impregnated sheet may be adhered to and laminated on the hard plate-like body. Furthermore, printing, painting, coloring, coating, and the like may be performed in order to impart designability, wood texture, scratch resistance, and the like.

  The hard plate-like body may be provided with a concave groove extending in an arbitrary direction on the laminated surface with the thermoplastic resin foam, thereby further reducing the bending rigidity of the hard plate-like body and further improving soundproofing. It is possible to improve. The shape of the concave groove is usually formed in a U-shape, V-shape, U-shape or the like, the groove width is 1 to 5 mm, and the groove depth is about 1 to 5 mm.

  If the thickness of the rigid plate-like body is too thin, it is easy to break when walking or placing a heavy object, and if it is too thick, the soundproofing property is reduced, so 2 to 12 mm is preferable, more preferably 2 to 9 mm. Preferably it is 2-6 mm.

  The ratio of the thickness of the hard plate to the thickness of the thermoplastic resin foam is such that if the thickness of the hard plate is too thick compared to the thickness of the thermoplastic resin foam, the rigidity of the flooring will increase and soundproofing When the thickness is too thin, it is likely to be destroyed when walking or placing a heavy object. Therefore, the thickness of the hard plate is preferably 1 to 10 times, more preferably 1 to 5 times, most preferably Preferably it is 1-3 times.

  The hard foam in the present invention is not particularly limited, and examples thereof include a resin foam made of a resin material and an inorganic foam made of an inorganic material. Examples of the resin foam include thermoplastic resin foam and thermosetting resin foam, and examples thereof include polystyrene foam, hard polyurethane foam, polyethylene foam, and polypropylene foam. Examples of the polystyrene foam include bead foam polystyrene foam and extruded foam polystyrene foam.

  The form of the hard foam of the present invention is not particularly limited, but a concavo-convex shape is formed on the upper surface (the surface on the side in contact with the hard plate-like body) and / or the lower surface (the surface on the side not in contact with the hard plate-like body). It is preferable at the point which becomes easy to compress with respect to a horizontal direction.

  If the depth of the concave portion in the concavo-convex shape is too small, it becomes difficult to compress in the horizontal direction, and if it is too large, the compressive strength in the vertical direction becomes insufficient and the amount of sinking may increase. 5 mm is preferable, More preferably, it is 1-3 mm.

  If the expansion ratio of the hard foam is too low, the floor material cannot be reduced in weight, and if it is too high, the sinking amount of the floor material increases, so 2 to 30 times is preferable, and more preferably 3 to 20 Times, more preferably 5 to 10 times.

  If the thickness of the hard foam is too thin, the soundproofing performance is lowered, and if it is too thick, the sinking amount of the flooring increases. Therefore, the thickness is preferably 3 to 50 mm, more preferably 3 to 30 mm, and particularly preferably 5 to 10 mm. It is.

  The hard foam has a sheet-like continuous foam layer, a plurality of high foam portions arranged on at least one surface of the continuous foam layer, and a low foam thin film that covers the entire surface of the high foam portion together with the continuous foam layer. In the case of a thermoplastic resin foam made of, it is preferable in terms of improving soundproof performance and a feeling of walking.

  The thermoplastic resin used in the continuous foam layer, the low foam thin film and the high foam part constituting the thermoplastic resin foam is not particularly limited. As such a thermoplastic resin, for example, low density polyethylene, high density polyethylene, linear low density polyethylene (hereinafter, “polyethylene” means low density polyethylene, high density polyethylene, linear low density polyethylene, or Olefin-based resins such as random polypropylene, homopolypropylene, block polypropylene (hereinafter, “polypropylene” refers to random polypropylene, homopolypropylene, block polypropylene, or a mixture thereof) and the like. These copolymers: polyethylene vinyl acetate, polyvinyl chloride, chlorinated polyvinyl chloride, ABS resin, polystyrene, polycarbonate, polyamide, polyvinylidene fluoride, polyphenylene sulfide, polysulfone, polyether Ketone, and copolymers and the like of these, they can also be used alone, may be used in combination.

  Among the above thermoplastic resins, olefinic resins such as polyethylene and polypropylene or a mixture thereof are preferable because they are excellent in thermal stability and transferability, and are easy to form irregularities. Surface smoothness and walking of the resulting flooring material are preferable. In order to achieve both prevention of sinking in time, high-density polyethylene, homopolypropylene, or a mixture containing at least one of these is particularly preferable.

  Further, the thermoplastic resin is preferably partially crosslinked. This is because, by crosslinking, foam breakage at the time of foaming can be prevented, the expansion ratio is increased, and the floor material is reduced in weight.

  The resin used for the continuous foam layer, the high foam, and the low foam thin film constituting the thermoplastic resin foam does not have to be the same resin, but the obtained flooring is placed when walking and placing heavy objects. It is preferable to use the same kind of resin from the point of being difficult to break. At this time, it is preferable in terms of adhesiveness that the resins used for the high foam and the low foam thin film are formed of the same resin.

  If the expansion ratio of the continuous foam layer is too low, it becomes difficult to reduce the weight of the flooring material, and the elastic modulus increases, so that the soundproofing performance decreases, and if it is too high, the sinking amount of the flooring material increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 1.1-10 times are preferable, More preferably, it is 2-8 times, 2-7 times is especially preferable.

If the thickness of the continuous foamed layer is too thin, the resulting flooring material is likely to break when walking and when a heavy object is placed, and if it is too thick, the proportion of the thermoplastic foam is relatively increased. Since it becomes difficult to reduce the weight of the flooring material and the soundproofing performance decreases, the thickness is preferably 100 μm to 5 mm, more preferably 300 μm to 3 mm, and particularly preferably 500 μm to 2 mm.
The thickness of the continuous foam layer does not need to be uniform and may be non-uniform. Moreover, the continuous foam layer does not need to be a complete flat plate, and may have some unevenness. Here, the thickness of the continuous foam layer refers to the average thickness of the continuous foam layer having a cross section parallel to the thickness direction of the thermoplastic resin foam.

  If the expansion ratio of the high foam is too low, it becomes difficult to reduce the weight of the flooring material, and the elastic modulus increases, so that the soundproofing performance decreases, and if it is too high, the amount of sinking of the flooring increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 2-100 times are preferable, More preferably, it is 5-50 times, 10-35 times is especially preferable.

If the size of the high foam is too small, it will be difficult to reduce the weight of the flooring. If the size is too large, the resulting flooring will be easily destroyed when walking and placing heavy objects, so 3-50 mm. Preferably, it is 5-30 mm.
Note that the size of the highly foamed portion does not have to be uniform and may be non-uniform.
Here, the size of the highly foamed portion refers to the maximum value of the size of the cross section parallel to the thickness direction of the thermoplastic resin foam.

  When the foaming ratio of the low foamed thin film is too low, it becomes difficult to reduce the weight of the flooring material and the elastic modulus increases, so that the soundproofing performance decreases, and if it is too high, the amount of sinking of the flooring material increases. Moreover, since it becomes easy to destroy at the time of walking and mounting a heavy article, 1.1 to 10 times is preferable, 1.2 to 7 times is more preferable, and 1.2 to 5 times is particularly preferable.

If the thickness of the low-foamed thin film is too thin, the high foam portion is relatively large, the compressive strength of the resulting flooring material is reduced, and if it is too thick, the soundproofing performance is reduced, so 30-500 μm is preferable. Preferably it is 40-400 micrometers, and 50-400 micrometers is especially preferable.
In addition, the thickness of the low foam thin film does not need to be uniform, and may be non-uniform.
Here, the thickness of the low foamed thin film refers to the average thickness of the cross section parallel to the thickness direction of the thermoplastic resin foam of the thermoplastic resin foam.

  The method for producing the thermoplastic resin foam is not particularly limited. For example, a foamed thermoplastic resin pellet containing a foaming agent is foamed and the outer surface excluding the fusion surface is made of a thermoplastic resin. A continuous foam layer made of a thermoplastic resin formed in a separate process after molding a plurality of high foam portions made of a thermoplastic resin covered with a foam thin film, heat-sealing them together via a low foam thin film After heat sealing, there is a method of forming in a concavo-convex shape with a hot press, etc., but the foamable thermoplastic resin granules containing a foaming agent are arranged substantially uniformly in a plane, And a step of heating the foamable thermoplastic resin sheet in which the foamable thermoplastic resin granules are integrally connected via a foamable thermoplastic resin thin film to a temperature equal to or higher than the decomposition temperature of the foaming agent, and foaming. The foam obtained by foaming is How and a step of cooling in the cooling mold having the above gaps to be filled is most preferred.

  When the foamable thermoplastic resin sheet is foamed, the portion of the foamable thermoplastic resin granules foams, but at this time, the outer surface of the thermoplastic resin granules is difficult to hold the bubbles generated by foaming, The foaming ratio is lower than that of the film, resulting in a low foamed thin film. As a result, the outer surface of the high foaming portion having a high foaming ratio inside the granular material is covered with the low foaming thin film. Moreover, the foamable thermoplastic resin thin film which connects the granular material of a foamable thermoplastic resin sheet-like body becomes a continuous foamed layer, and will be in the state by which multiple high foaming parts were arrange | positioned on this continuous foamed layer. Note that the continuous foamed layer is also thin and low in foaming because it is difficult to hold the bubbles. Such a low-foaming thin film is close to the low-foaming thin film of the adjacent granular material and thermally fused by foaming inside the granular material. By setting more than the full filling of the plastic resin sheet, the fusion proceeds only partially, and an uneven thermoplastic resin foam that is not completely filled is obtained.

The thickness of the flooring of the present invention is not particularly limited, but if it is too thick, the ceiling of the room is lowered and the sinking during walking is increased, so that it is preferably 65 mm or less.

  The flooring of the present invention includes, for example, a resin sheet, a woven fabric, and the like laminated between a hard plate-like body and a hard foam to improve buffering, vibration damping, sound insulation, etc., if necessary. A nonwoven fabric or a foam sheet may be laminated.

  The flooring of the present invention may be one in which a non-land absorbing layer is laminated on the lowermost layer. The uneven absorption layer is not particularly limited as long as it adjusts unevenness with the floor slab, and examples thereof include elastic bodies such as soft foams, non-woven fabrics, and thermoplastic elastomers, but further improve the soundproofing performance. A soft foam and a nonwoven fabric are preferable at the point which can do. Among them, when using a soft foam, one having a relatively low compression modulus relative to the thermoplastic resin foam, for example, a polyethylene foam having an expansion ratio of 10 to 30 times, an expansion ratio of 20 to 40 times Examples thereof include polyurethane foam.

The compression elastic modulus of the soft foam is not particularly limited, but if it is too small, the walking feeling is lowered, and if it is too large, the soundproofing performance is lowered, so 0.2 to 3 kg / cm ² is preferable.

  If the thickness of the non-land absorbing layer is too thick, sinking of the flooring material becomes large, and if it is too thin, the non-land absorbing effect cannot be expressed, so 300 μm to 10 mm is preferable, 500 μm to 5 mm is more preferable, and 1 to 3 mm is the most. preferable.

  Examples of a method for laminating the hard plate-like body and the hard foam include a laminating method using an adhesive or an adhesive. Examples of the adhesive used include vinyl acetate-based and vinyl ester-based adhesives and chloroprene-based adhesives, and examples of the pressure-sensitive adhesive include acrylic pressure-sensitive adhesives.

  In order to improve adhesion and tackiness, it is also preferable to perform corona treatment or primer treatment on at least one surface of the thermoplastic resin foam.

  The flooring of the present invention comprises a substantially rectangular laminate in which the above-mentioned hard plate-like body is laminated on a hard foam, and a male fruit is formed on at least one side surface and a female fruit is formed on the other side surface. 1, in the shape of the male fruit 23 and the female fruit 24, at least the convex part 25 of the male fruit 23 is formed from one side end of the hard plate-like body 21. As shown in the enlarged view of FIG. 2, the lower convex portion 26 is formed at one end of the hard foam 1 or, as shown in the enlarged view of FIG. It is formed by one side edge part.

  In particular, as shown in FIG. 3, when the lower convex portion 26 of the female seed 24 is formed at one end portion of the thin hard plate-like body 21, the upper surface portion 27 of the hard foam 1 It is possible to supplement the strength of one side end of the thin hard plate-like body 21.

  Further, as illustrated in FIG. 1, the shape of the actual processing is such that the adjacent hard foams 1 and 1 are in contact with each other, and the upper concave portion 28 of the adjacent male fruit 23 and the upper convex portion 29 of the female fruit 24 are A gap d1 is provided between the projections 25 of the male fruit 23 and the recesses 30 of the female fruit 24, and a gap d2 is provided.

  If the gaps d1 and d2 are too small, appearance defects due to changes in humidity are likely to occur. If the gaps are too large, the gap after construction may be too conspicuous, so 0.05 to 0.55 mm is preferable. More preferably, it is 0.15-0.45 mm, Most preferably, it is 0.25-0.35 mm. Further, in order to facilitate rework after construction, d2 is preferably larger than d1 (d1 <d2).

  According to the present invention, there is provided a flooring material comprising a substantially rectangular laminate in which a hard plate-like body is laminated on a hard foam, wherein a male fruit is formed on at least one side surface and a female fruit is formed on the other side surface. At least the male convex part is formed from one side end of the hard plate-like body, and the lower side convex part of the female fruit is formed from one side end part of the hard foam or hard plate-like body. When the male body is fitted to the female body of the adjacent floor material, the hard foams are in contact with each other, and between the adjacent male upper side concave part and the female upper side convex part, and the male convex part. Since the gap is provided between the wall and the female recess, the rigid foam is horizontal to the floor material that is prone to change due to changes in humidity depending on the construction condition and usage environment. Hard plate-like body that can be suppressed by compressing and deforming in the direction and absorbing the elongation. The poor appearance is prevented due to the push-up of, and without floor sounds occur, it is possible to provide a small flooring variation in construction by the operator.

  When the concave and convex shapes are formed on the upper surface and / or the lower surface of the hard foam, it becomes easy to compress appropriately in the horizontal direction, and the above-described effect is further ensured.

  Moreover, in addition to the said effect, the feeling of walking can further be improved as the said flooring material is a thing formed by laminating | stacking a non-land | buck absorption layer in the lowest layer.

The present invention will be described in more detail with reference to examples.
Example 1
Thermoplastic resin foam high density polyethylene (Mitsubishi Chemical Corporation, trade name “HY340”, MI = 1.5 g / 10 min) 50% by weight, silane grafted polypropylene (Mitsubishi Chemical Corporation, trade name “XPM800H”, MI = 11 g) / 10 minutes, 20% by weight of the gel fraction after cross-linking 20% by weight, polypropylene (trade name “MA3” manufactured by Mitsubishi Chemical Co., Ltd., melt index (MI) = 11 g / 10 min) 30% by weight thermoplastic resin A composition containing 100 parts by weight, 4 parts by weight of azodicarbonamide (manufactured by Otsuka Chemical Co., Ltd., trade name: SO-20, decomposition temperature 210 ° C.) and 0.1 part by weight of dibutyltin dilaurate as a silane crosslinking catalyst The biaxial extruder 11 shown in FIG.

  As the biaxial extruder 11, the one having a diameter of 44 mm was used. In the twin-screw extruder 11, the composition was melt-kneaded at 180 ° C., and the sheet-like foamable thermoplastic resin in a softened state was extruded by a T-die 12 having a surface length of 500 mm and a lip of 1.0 mm.

Furthermore, a roll 13 having a diameter of 250 mm and a surface length of 500 mm, which is randomly arranged only on the shaping roll 13 so that the cylindrical recesses 13a having a depth of about 10 mm and a diameter of 4 mm have a density of 1 piece / cm ² . 14 (clearance 0.2 mm) by cooling the foamable thermoplastic resin sheet while shaping, and further by immersing the foamable thermoplastic sheet in water at 98 ° C. for 2 hours and then drying, Measured height, average 5.5 mm, standard deviation 1 mm; foamed as shown in Table 1 randomly configured so that the cylindrical foamable thermoplastic resin granules having a diameter of 4 mm have a density of 1 piece / cm ^2. A thermoplastic resin sheet was obtained.

  In the foamable thermoplastic resin sheet 1 obtained as described above, the foamable thermoplastic resin granules 2 are connected by the foamable thermoplastic resin thin film 3, and the foamable thermoplastic resin sheet 1 as a whole. Was configured.

  The obtained foamable thermoplastic resin sheet 1 was cut into 300 × 900 mm, and placed on the polyfluorinated ethylene sheet 15 as shown in FIGS. 5 (a) to 5 (e). 16 is arranged on the upper surface, and the thickness between the polyfluorinated ethylene sheets 15 and 16 is 10 mm by hand press and heated and foamed at 210 ° C. for 10 minutes, and then cooled by a 30 ° C. cooling press for 10 minutes. Thus, an uneven thermoplastic resin foam (FIG. 6) having an expansion ratio of 8 times and a thickness of 10 mm was obtained.

  The foam includes a plate-like continuous foam layer 3, a plurality of high foam portions 2 arranged on one side of the continuous foam layer 3, and a low foam covering the surface of the high foam portion 2 together with the continuous foam layer 3. Consisting of a foamed thin film 4, the high foamed portions 2 are each formed in a convex shape with respect to the continuous foamed layer 3, and the surface side of the continuous foam 3 in contact with each high foamed portion 2 is formed in a concave shape. The part corresponding to the convex part of the foam 3 was cut into a smooth shape.

  In addition, the expansion ratio of the obtained thermoplastic resin foam and the thickness of the foam were measured by the following methods.

(Foaming ratio)
The expansion ratio was measured according to JIS K6767.
(Thickness of foam)
Using calipers, the thickness of the obtained thermoplastic resin foam was measured.

(Fabric production)
A laminating plywood with a 0.3 mm thick veneer (made by Kitasansha, trade name “White Oak”) is bonded with an aqueous vinyl urethane resin (trade name “KR120”, produced by Koyo Sangyo Co., Ltd.), and a thickness of 4.0 mm A hard plate was obtained.
The thermoplastic resin foam adjusted to a thickness of 8 mm using an acrylic pressure-sensitive adhesive (manufactured by Sekisui Chemical Co., Ltd., trade name “# 5782) is bonded and laminated to the obtained hard plate, and the resulting laminate is obtained. The four sides were actually processed to obtain a flooring (thickness 12 mm).

  The obtained flooring material is in the shape of actual processing, the male convex part is formed from one end part of the hard plate-like body, and the lower convex part of the female fruit is hard and the part formed by the hard foam. The part formed in the one side edge part of the plate-shaped object was mixed. Further, as shown in FIG. 1, a gap d1 is provided between the upper concave portion 28 of the male fruit 23 and the upper convex portion 29 of the female fruit 24 at the time of construction. The gap d <b> 2 was provided between the actual 24 recesses 30. Moreover, the compression strength ratio (compression strength of a hard plate-like body / compression strength of a hard foam) of the hard plate-like body and the hard foam used was 150.

Examples 2-4
A foamable thermoplastic resin sheet-like material as shown in Table 1 was obtained in the same manner as in Example 1, except that the roll recess arrangement mode was changed to obtain the foamable thermoplastic resin-sheet-like material shown in Table 1. . In the table, the roll concave portion arrangement mode is “random”, which means that the concave portions 13a are randomly arranged to have a density of 1 piece / cm ² , and the “lattice” is the concave portion 13a. Is in a grid pattern (see FIG. 7) at intervals shown in Table 1, and “staggered” indicates that the recesses 13a are arranged in a staggered pattern (see FIG. 8) at intervals shown in Table 1.

  In the foamable thermoplastic resin sheet 1 obtained as described above, the foamable thermoplastic resin granules 2 are connected by the foamable thermoplastic resin thin film 3, and the foamable thermoplastic resin sheet 1 as a whole. Was configured.

  The obtained foamable thermoplastic resin sheet 1 was cut into 300 × 900 mm, and placed on the polyfluorinated ethylene sheet 15 as shown in FIG. 5, and further the polyfluorinated ethylene sheet 16 was placed on the upper surface thereof. Then, with a hand press, the polyfluorinated ethylene sheets 15 and 16 are made to have the gaps shown in Table 1 and heated and foamed at 210 ° C. for 10 minutes, then cooled at 30 ° C. for 10 minutes, and the expansion ratio An uneven thermoplastic resin foam (Fig. 9) having a size of 8 times and a thickness of 8 mm was obtained.

  The foam is composed of a continuous foam layer of a plate-like body, a plurality of high foam portions disposed on at least one side of the continuous foam layer, and a low foam thin film that covers the surface of the high foam portion together with the continuous foam layer. Further, the high foamed portions are each formed in a convex shape with respect to the continuous foamed layer, and the surface side 3a of the continuous foam corresponding to each high foamed portion is formed in a concave shape.

  In addition, the expansion ratio of the obtained thermoplastic resin foam and the thickness of the foam were measured in the same manner as in Example 1.

  Further, in the same manner as in Example 1, the thermoplastic resin foam obtained on the hard plate was bonded and laminated, and four sides of the obtained laminate were actually processed to obtain a flooring (thickness 12 mm). Further, in Examples 3 and 4, the non-land absorbing layer made of polyurethane foam (foaming ratio 40 times, 2.5 mm thickness) is placed on the surface opposite to the surface on which the thermoplastic resin hard plate is laminated. Adhesive lamination was performed.

  The obtained flooring material is in the shape of actual processing, the male convex part is formed from one end part of the hard plate-like body, and the lower convex part of the female fruit is hard and the part formed by the hard foam. The part formed in the one side edge part of the plate-shaped object was mixed. Further, as shown in FIG. 10 (Example 2) and FIG. 11 (Examples 3 and 4), a gap d1 is provided between the upper concave portion 28 of the male fruit 23 and the upper convex portion 29 of the female fruit 24 at the time of construction. And a gap d2 is provided between the convex part 25 of the male fruit 23 and the concave part 30 of the female fruit 24. Moreover, the compression strength ratio of the hard plate-like body and the hard foam used was 150.

Example 5
A flooring similar to that of Example 1 was produced except that the dimensions of the gaps (d1 and d2) were changed.

Comparative Example 1
As illustrated together with the construction state in FIG. 12, only the hard plate-like body having a thickness of 12 mm obtained by adhering the same 0.3 mm veneer to Lauan plywood as Example 1 and Four sides with the same shape were actually processed to make a flooring.

Comparative Example 2
A flooring similar to that of Example 1 was produced except that the gaps (d1 and d2) were not provided.

  Table 2 shows the dimensions of the gaps (d1 and d2) during construction in the obtained flooring material, the overall thickness, the thickness of the hard foam, the presence or absence of the uneven shape, and the presence or absence of the uneven absorption layer.

The following evaluation was performed about the flooring obtained by the said Example and comparative example. The evaluation results are shown in Table 2.
(appearance)
Perform construction in a constant temperature and humidity room, observe the state after 5 days with 30 ° C. and 50% RH (dry), then observe the state after 5 days with 30 ° C. and 95% RH (wet), The following criteria were used for four-level evaluation.
◎: No problem at all ○: There is a slight change, but there is no problem △: A change is recognized and a little worrisome ×: A large change is recognized and anxious

(Flooring)
Construction was carried out in a constant temperature and humidity room, and after walking on the flooring material after 5 days in a state of 30 ° C. and 95% RH (wet), four levels were evaluated according to the following criteria.
◎: No sound at all ○: Slightly, but not worried △: Slightly anxious sound ×: Sounds of concern every time you walk

(Soundproof performance)
The light floor impact sound level was measured according to JIS A1418.
(Non-land absorption)
Three flooring materials were arranged in parallel, and the degree of contact with a pseudo flat plate having a 2 mm concavo-convex portion was visually confirmed, and four levels were evaluated according to the following criteria.
◎: Completely close ○: The gap between the flat plate and the flooring material is less than 0.5 mm △: The gap between the flat plate and the flooring material is 0.5 to 1.5 mm
X: The clearance between the flat plate and the flooring is 1.5 mm or more.

  From Tables 1 and 2, in the examples of the present invention, it was found that a good appearance was maintained even when humidity was changed depending on the use environment, and flooring was difficult to occur. It was also found to be excellent.

It is sectional drawing which illustrates the flooring of this invention with a construction state. It is explanatory drawing which expands and shows an example of the real part in FIG. It is explanatory drawing which expands and shows another example of the real part in FIG. It is process drawing for demonstrating an example of the manufacturing method of the foamable thermoplastic resin which can be used for this invention. (A)-(e) is sectional drawing for demonstrating an example of the manufacturing method of the thermoplastic resin foam which can be used for this invention. 1 is a cross-sectional view showing a thermoplastic resin foam obtained in Example 1. FIG. It is a top view for demonstrating the state by which the foamable thermoplastic resin granular material is arrange | positioned at the grid | lattice form. It is a top view for demonstrating the form by which a foamable thermoplastic resin granular material is arrange | positioned in zigzag form. It is sectional drawing which shows the thermoplastic resin foam obtained by Examples 2-4. It is sectional drawing which shows the flooring obtained by Example 2 with a construction state. It is sectional drawing which shows the flooring obtained by Example 3, 4 with a construction state. It is sectional drawing which shows the flooring obtained by the comparative example 1 with a construction state.

Explanation of symbols

1 Hard foam (thermoplastic resin foam)
2 High Foam 3 Continuous Foam Layer 3a Continuous Foam Layer 4 Low Foam Thin Film 5 Foam Thermoplastic Resin Sheet 6 Foam Thermoplastic Resin Granule 7 Foam Thermoplastic Resin Thin Film 11 Twin Screw Extruder 12 T Die 13 Addition Mold roll 14 Molding roll 15 Sheet 16 Sheet 21 Hard plate 22 Non-land absorbing layer 23 Male fruit 24 Female fruit 25, 26, 29 Convex part 27 Upper surface part 28, 30 Concave part

Claims (3)

  A flooring material comprising a substantially rectangular laminate in which a hard plate is laminated on a rigid foam, with a male body on at least one side and a female body on the other side, and at least a convexity of the male body The part is formed from one side end of the hard plate-like body, and the lower convex part of the female fruit is formed from one side end of the hard foam or hard plate-like body. When fitted to the female body of the flooring, the hard foams are in contact with each other, between the adjacent male upper concave part and the female upper convex part, and between the male convex part and the female concave part. A flooring characterized in that a gap is provided between the flooring and the flooring.   The flooring material according to claim 1, wherein an uneven shape is formed on the upper surface and / or the lower surface of the hard foam.   The flooring according to claim 1 or 2, wherein a non-land absorbing layer is laminated on the lowermost layer.

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