JP2006336460A - Method of manufacturing floor material using native wood - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a floor material that can eliminate infiltration of moisture into a base member from a floor surface member. <P>SOLUTION: The method of manufacturing the floor material by sticking the floor surface member 6 formed of a native wood to the base member 4 installed on a floor face, comprises steps of laminating the floor surface member 6 on the base member 4 through an intermediate impermeable synthetic resin sheet 8 interposed, heating and pressure-bonding of the base member 4, intermediate impermeable synthetic resin sheet 8 and floor surface member 6 as they are in the laminated state, and cold-pressurizing the base member 4, intermediate impermeable synthetic resin sheet 8 and floor surface member 6 in the laminated state after heated and pressure-bonded. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a flooring material provided with a floor surface member formed from a natural material.

  Conventionally, a floor material using a natural material as a floor surface member of the floor material has been proposed (see, for example, Patent Document 1). This floor material is comprised from the base member formed from the foaming synthetic resin, and the floor surface member provided in the surface side of the base member, and the floor surface member is formed from rattan. In this floor material, the floor surface member is made of rattan, so it is easy to absorb moisture, and when used on the floor surface of a dressing room, the moisture of wet feet is absorbed and the feeling of comfort after bathing can get. Also, since the surface of the flooring is rattan, it feels calm and matches the space of Japanese-style architecture.

Japanese Patent Laid-Open No. 9-25705

  However, this type of conventional flooring has the following problems. First, rattan has the property of absorbing and releasing moisture, and has the property of expanding when absorbing moisture and contracting when releasing moisture. When such rattan is used for the floor surface member, the lower base member is maintained at a substantially constant size regardless of moisture, whereas the surface side floor surface member absorbs when moisture is high. It expands somewhat, and when there is little water, it releases water and shrinks somewhat. Therefore, when used on the floor surface of a dressing room, the floor surface member repeatedly expands and contracts, and when used for a certain period of time, the floor surface member expands and contracts to cause the peripheral edge of the floor material to bend and the floor material to the floor surface. There is a problem that it partially floats from the floor or peels off from the floor.

  Second, since the floor surface member is simply fixed to the base member, moisture absorbed by the floor surface member penetrates into the base member, and the base member comes to contain moisture. When the base member contains moisture as described above, a part of the moisture is released little by little through the floor surface member, but the floor surface is also easily moistened by the moisture of the base member, which is an unfavorable environment for the floor surface.

The objective of this invention is providing the manufacturing method of the flooring which hardly generate | occur | produces even if a floor surface member discharge | releases a water | moisture content.
Another object of the present invention is to provide a method for producing a flooring that can eliminate moisture permeation from the floor surface member to the base member.

In the floor material manufacturing method according to claim 1 of the present invention, in the manufacturing method for manufacturing a floor material by fixing a floor surface member formed from a natural material and a base member installed on the floor surface,
A laminating step of interposing an intermediate water-impermeable synthetic resin sheet on the base member and stacking the floor surface member, and thermocompression bonding the base member, the intermediate impermeable synthetic resin sheet and the floor surface member in a laminated state The method includes a thermocompression bonding step and a cold pressurizing step of cold-pressing the base member, the intermediate water-impermeable synthetic resin sheet, and the floor surface member in a laminated state after the thermocompression bonding. And

  Further, in the floor material manufacturing method according to claim 2 of the present invention, the floor surface member is formed of any one of rattan, bamboo, and natural wood.

  According to the floor material manufacturing method of the first aspect of the present invention, the floor surface member is laminated on the base member via the intermediate water-impermeable synthetic resin sheet. The synthetic resin sheet is melted by heat, and the floor surface member and the base member can be securely fixed through the sheet while ensuring water impermeability. In addition, since the cold pressing is performed after the thermocompression bonding, a very flat flooring can be formed. Furthermore, since the floor surface member is heat-pressed in a normal state that does not contain much moisture, the floor surface member hardly shrinks even if the humidity is low. Therefore, even if it is used over a long period of time in an environment where there is not much moisture, it does not bend and can be conveniently used as a flooring material for a living room, for example.

  According to the method for manufacturing a flooring material according to claim 2 of the present invention, the floor surface member is formed of any one of rattan, bamboo and natural wood. When the amount is small, the absorbed moisture is released, and the humidity can be adjusted in this way, so that the room can be maintained in a comfortable environment. In particular, when used on the floor surface of a dressing room, it absorbs moisture from wet feet after bathing, and provides a comfortable feeling after bathing.

  Hereinafter, with reference to an accompanying drawing, the manufacturing method of the flooring according to the present invention is explained. FIG. 1 is a partially enlarged cross-sectional view showing an enlarged part of an embodiment of a flooring manufactured by the manufacturing method according to the present invention, and FIG. 2 is a perspective view of the flooring of FIG. FIG. 3 is a simplified explanatory view for explaining a hydrolytic expansion step in the floor material production method of FIG. 1, and FIG. 4 explains a thermocompression bonding step in the floor material production method of FIG. FIG. 5 is a simplified explanatory diagram for explaining a cold pressurizing step in the floor material manufacturing method of FIG. 1.

  In FIG. 1, the illustrated flooring 2 includes a base member 4 installed on the floor surface, a floor surface member 6 provided on the surface side of the base member 4, and between the base member 4 and the floor surface member 6. The intermediate water-impermeable sheet 8 interposed between the two. The floor surface member 6 is formed from a natural material. By forming the floor surface member 6 from a natural material, the floor surface member 6 absorbs moisture when the humidity is high, and releases the absorbed moisture when the humidity is low. Can do. The natural material is preferably made of rattan, bamboo, or natural wood. By forming from these materials, moisture absorption and release performance can be improved and matching with Japanese-style building is enhanced. be able to. In the case of using rattan, the floor surface member 6 is formed by connecting the rattan members with connecting members such as threads and strings. When bamboo or natural wood is used, the floor surface member 6 is formed of a plurality of bamboo members and natural wood.

  The illustrated base member 4 is composed of a pair of plate-like members 10a and 10b, and each plate-like member 10a and 10b has substantially the same structure, and one side portions 12a and 12b thereof are felt, urethane foam, rubber. The other side portions 14a and 14b are made of a synthetic rubber such as styrene butadiene rubber (SBR). Since such synthetic rubber has a relatively high strength, the strength of the plate-like members 10a and 10b is maintained and water-impermeable, and the other side portions 14a and 14b function as a water-impermeable sheet of the base member 4. To do. As shown in FIG. 1, the pair of plate-like members 10 a and 10 b are preferably configured such that their other side portions 14 a and 14 b are on the outer side. The other side portions 14a and 14b of the plate-like members 10a and 10b are located on the both sides of the base member 4, so that both surfaces of the base member 4 can be impermeable. The pair of plate-like members 10a and 10b are fixed by, for example, an adhesive. In this embodiment, the base member 4 is formed of two plate-like members 10a and 10b, but for example, one (in this case, the other side is preferably the back side) or three or more It may be formed from a plate-like member, or a non-water-permeable sheet (which constitutes a back-side non-permeable sheet) by an adhesive or the like on the back side of the plate-like member formed of felt, foamed urethane, or the like. You may make it stick.

  The intermediate water-impermeable sheet 8 is preferably formed from a synthetic resin such as a urethane-based resin, for example. By forming the intermediate water-impermeable sheet 8 from such a material, the water impermeable sheet can be maintained and the base member 4 can be heated. The floor surface member 6 can be welded through the sheet 8.

  As understood from FIG. 1, the floor material 2 has the following characteristics because the base member 4 is installed on the floor surface and the floor surface member 6 is on the surface side and has the above-described configuration. First, since the intermediate water-impermeable sheet 8 is interposed between the base member 4 and the floor surface member 6, even if the floor surface member 6 absorbs moisture, the moisture does not penetrate into the base member 4. The base member 4 can be prevented from absorbing moisture from the surface side. Second, since the back surface of the base member 4 is covered with the water-impermeable member 14a (functioning as a back-side water-impermeable sheet), moisture from the floor surface does not enter the base member 4 and the base member 4 Absorption of moisture from the back side can also be prevented. Third, since the surface of the base member 4 is also covered with the water-impermeable member 14b (functioning as a front-side water-impermeable sheet), the penetration of moisture from the surface side of the base member 4 is prevented, and the intermediate water-impermeable water is prevented. The moisture sheet 8 and the water-impermeable member 14b can more reliably prevent moisture from penetrating from the floor surface member 6 side.

  When this flooring 2 is installed on the floor of a room such as a dressing room, for example, it can be configured as shown in FIG. Referring mainly to FIG. 2, a double-sided adhesive tape 16 is adhered to an appropriate portion of the back surface of the base member 4 of the flooring 2, for example, the four corners and a portion between them. Can be attached to the surface. Alternatively, instead of the double-sided adhesive tape 16, a well-known suction tape (not shown) may be used. The suction tape is provided with a large number of suction recesses on the suction surface, and is attached to the floor surface using the suction action of these suction recesses. When the double-sided adhesive tape 16 (or adsorbing tape) is used, it can be easily removed from the floor surface, the flooring 2 can be dried or replaced, and its maintenance becomes easy. In order to make the removal of the flooring 2 even easier, the base member 4 of the flooring 2 may be provided with a removal piece (for example, formed from a string, a piece of cloth, etc.).

  Such a flooring 2 can be manufactured as follows, for example. First, as shown in FIG. 3, the floor surface member 6 is formed by spraying water substantially uniformly onto the front surface side (or the back surface side) of the floor surface member 6 formed from a natural material (for example, rattan). Is kept in an expanded state (hydrolysis expansion step). In order to expand the floor surface member 6 with moisture, the moisture may be sprayed and left for about 2 to 10 minutes, for example. Steam may be sprayed instead of water, and such spraying of water is performed using, for example, a sprayer 18.

  Next, as understood from FIG. 4, an intermediate water-impermeable sheet 8 is placed on the surface side of the base member 4 (a pair of plate-like members 10a and 10b fixed as described above). The floor surface member 6 expanded with moisture is placed on the surface side of the water permeable sheet 8, and these are laminated (lamination step).

  Thereafter, the laminated base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are subjected to thermocompression bonding (thermocompression bonding step). The thermocompression bonding can be performed using, for example, a heating and pressing apparatus 20 as shown in FIG. The illustrated heating and pressing apparatus 20 includes a lower stationary member 22 and an upper movable member 24, and the upper movable member 24 is moved up and down with respect to the lower stationary member 22 as indicated by a double arrow. The lower stationary member 22 and the upper movable member 24 incorporate heating means 26 and 28 such as heaters, respectively, and the lower stationary member 22 and the upper movable member 24 are heated by heat from the heating means 26 and 28. In such a heating state, the heating and pressing process is performed.

  In the heating and pressing process, the laminated base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are placed on the upper surface (processed surface) of the lower stationary member 22, and the upper movable member is placed in this state. 24 descends and presses these in the laminated state. At the time of pressing, the heating means 26 and 28 are energized, and the heat is applied to these in the laminated state via the lower stationary member 22 and the upper movable member 24. Heating by the heating means 26 and 28 is performed at about 85 to 100 ° C., for example. If the heating temperature is 85 ° C. or less, the intermediate water-impermeable sheet 8 may not be sufficiently melted, and the base member 4 and the floor surface member 6 may be insufficiently fixed, and the heating temperature is 100 ° C. If it exceeds 1, the natural material, for example, rattan fibers, is not stable, and the floor surface member 6 may be distorted after processing, and the flooring 2 may be distorted. Instead of placing the laminated state on the lower stationary member 22, the base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are placed on the upper surface of the lower stationary member 22 in the laminated state. You may do it.

  When heated and pressurized in this manner, the intermediate water-impermeable sheet 8 melts and melts into the base member 4 and the floor surface member 6, and the base member 4 and the floor surface member 6 are fixed via the intermediate water-impermeable sheet 8. In addition, non-permeability between the two is ensured. Further, since the floor surface member 6 is heated and pressurized in an expanded state, that is, in a state where the fiber is extended by absorption of moisture, the floor surface member 6 is fixed to the base member 4 in an expanded state. . Such heating and pressing is performed for about 3 to 5 minutes, for example. The heating and pressurizing device 20 shown in the figure is heated by the heating means 26 and 28 incorporated in the lower stationary member 22 and the upper movable member 24. However, the present invention is not limited to this configuration, and the lower stationary member 22 Alternatively, the heating means 26 or the heating means 28 of the upper movable member 24 may be used.

  At the time of this heating and pressurization, as shown in FIG. 4, it is preferable to cover the floor surface member 6 by placing an evaporation preventing sheet 30 on the surface side of the floor surface member 6. Moisture absorbed by the floor surface member 6 at the time of heating and pressurization is evaporated by heat and diffused to the outside. By configuring in this way, the diffusion of water vapor is prevented and the floor surface is expanded in a state containing moisture. The member 6 can be fixed to the base member 4. As the evaporation preventing sheet 30, for example, a water-impermeable sheet such as wax paper that is difficult to be thermally deformed can be used.

  Thereafter, as shown in FIG. 5, the floor material 2 (base member 4, intermediate water-impermeable sheet 8 and floor surface member 6) subjected to heat and pressure processing is pressurized at normal temperature (cold pressure step). The cold pressurization can be performed using, for example, a pressurization device 32 as shown in FIG. 5, and the pressurization device 32 shown includes a lower stationary member 34 and an upper movable member 36, and the upper movable member 36. Is moved up and down with respect to the lower stationary member 34 as shown by a double-headed arrow.

  In the cold pressing process, the base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 that have been subjected to the heating and pressing process are mounted on the upper surface (processed surface) of the lower stationary member 34, and are thus mounted. In this state, the upper movable member 36 descends and presses them, for example, for about 3 to 5 minutes. When cold pressing is performed in this manner, the heated and pressurized flooring 2 is in a very flat state and is suitable as the flooring 2. Note that when the flooring 2 is hardly distorted after the heat pressing process, the cold pressing process can be omitted.

  Since the floor material 2 manufactured in this way is fixed to the base member 4 in a state where the fiber of the floor surface member 6 is extended, the floor material 2 hardly extends even if it contains moisture in the usage state installed on the floor surface. It can be advantageously used as a flooring material that does not bend even when used over a long period of time in a humid environment and is installed on a floor surface that gets wet with water, for example, a floor surface such as a dressing room.

  In the manufacturing method described above, moisture is added to the floor surface member 6 and expanded before heating and pressing, but the floor surface member 6 can also be manufactured without being expanded. That is, the intermediate water-impermeable sheet 8 is placed on the surface side of the base member 4, and the floor surface member 6 is placed on the surface side of the intermediate water-impermeable sheet 8 to be in a laminated state (lamination step). The base member 4 in the laminated state, the intermediate water-impermeable sheet 8 and the floor surface member 6 are subjected to heat and pressure processing as described above using the heat and pressure apparatus 20 shown in FIG. 4 (heat pressure bonding step), and then The pressure-processed floor material 2 (the base member 4 in the laminated state, the intermediate water-impermeable sheet 8 and the floor surface member 6) is subjected to pressure processing as described above using the pressure device 32 shown in FIG. (Pressurizing step).

  The floor material 2 manufactured in this way is fixed to the base member 4 with the floor surface member 6 fixed to the base member 4 at room temperature, in other words, the fiber of the floor surface member 6 hardly extends. The floor does not shrink due to the release of moisture even when it is dried in the usage state installed on the floor, and does not bend even when used for a long time in a normal or easy-to-dry environment, and does not have much moisture It can be conveniently used as a flooring material to be installed on a surface such as a living room floor.

  As mentioned above, although embodiment of the manufacturing method of the flooring according to this invention was described, this invention is not limited to these embodiment, A various deformation | transformation thru | or correction | amendment are possible without deviating from the scope of the present invention. .

It is a partial expanded sectional view which expands and shows a part of one Embodiment of the flooring manufactured by the manufacturing method according to this invention. It is the perspective view which looked at the flooring of FIG. 1 from the back surface side. FIG. 2 is a simplified explanatory diagram for explaining a hydrolysis expansion step in the floor material manufacturing method of FIG. 1. FIG. 2 is a simplified explanatory diagram for explaining a thermocompression bonding step in the floor material manufacturing method of FIG. 1. It is a simple explanatory view for explaining a cold pressurization step in the manufacturing method of the flooring of FIG.

Explanation of symbols

2 Floor material 4 Base member 6 Floor surface member 8 Intermediate water-impermeable sheet 10a, 10b Plate-like member 14a, 14b Non-water-permeable member 16 Double-sided adhesive tape 20 Heating and pressing device 22, 34 Lower stationary member 24, 36 Upper movable member 26, 28 Heating means 30 Evaporation prevention sheet 32 Pressure device

Claims (2)

In a manufacturing method for manufacturing a flooring material by fixing a floor surface member formed from a natural material and a base member installed on the floor surface,
A laminating step of interposing an intermediate water-impermeable synthetic resin sheet on the base member and stacking the floor surface member, and thermocompression bonding the base member, the intermediate impermeable synthetic resin sheet and the floor surface member in a laminated state The method includes a thermocompression bonding step and a cold pressurizing step of cold-pressing the base member, the intermediate water-impermeable synthetic resin sheet, and the floor surface member in a laminated state after the thermocompression bonding. A method for producing a flooring.   The said floor surface member is formed from either rattan, bamboo, and natural wood, The manufacturing method of the flooring of Claim 1 characterized by the above-mentioned.

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