JP2009061680A - Reinforced floor material and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reinforced floor material having superior damp-proofing property and crack resistance and hardly causing inside delamination due to the load of casters or the like. <P>SOLUTION: The reinforced floor material is formed by laminating a damp-proofing sheet like material 2 on the surface of a woody fiber board 1a forming a surface layer part of a woody base material 1 to adhere through a thermosetting resin adhesive 4b and further integrally laminating a decorative veneer 3 on the damp-proofing sheet like material 2 to adhere through a thermosetting resin adhesive 4a having elasticity and thereby, the occurrence of delamination between papers or inside the decorative veneer 3 is prevented even when the load due to the casters of wagons or the like is applied on the floor material. The damp-proofing sheet like material 2 has a three layer structure formed by integrally providing a thermosetting resin sheet 2c having heat resistant and damp-proofing property as a core layer and thermosetting resin-impregnated hardened paper layers 2a formed on the front and back surfaces of the core layer. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a reinforced flooring material excellent in moisture resistance and scratch resistance and a method for producing the same.

  Conventionally, in order to impart moisture resistance to a flooring material or a decorative board, for example, as described in Patent Document 1, paper is superimposed on the front and back surfaces of a moisture-proof thermoplastic resin film such as polyethylene. Using a moisture-proof sheet called poly-sand paper that is integrated by thermal fusion of the thermoplastic resin film, a decorative veneer is laminated and bonded to the surface of the wooden substrate via this moisture-proof sheet. It has been broken.

  Further, in Patent Document 2, in a decorative board in which a laminate of thermosetting resin-impregnated paper is integrally bonded to the surface of a substrate such as particle board or plywood, the laminate of the thermosetting resin-impregnated paper is described. A moisture-proof laminate is described that is configured to exert a moisture-proof function by interposing a resin film having a low water vapor permeability between arbitrary layers.

Japanese Patent Application Laid-Open No. 10-2111674 JP-A 61-160248

  However, according to the flooring and decorative plate described in Patent Document 1, the thickness of the front and back paper of the moisture-proof sheet that adheres to the surface of the wooden substrate and the back surface of the decorative veneer is about 10 to 20 μm. If it is thin, there is no problem, but if it is 20 μm or more, there is a problem that even if it is thin paper, a layer into which the adhesive does not permeate is generated, and separation between papers is likely to occur. In particular, in order to impart abrasion resistance and scratch resistance to the flooring material, at least the surface layer portion of the wood base material is formed of a hard wood fiber board having a specific gravity of 0.4 to 1.0, and the moisture-proof sheet is formed on the surface of the hard wood fiber board. When a veneer veneer is applied to the flooring material and a load is applied by a caster such as a wagon on the flooring, peeling between papers occurs in the above layer where the adhesive does not penetrate, and the surface makeup is applied. There was a problem that the veneer peeled off.

  In addition, since the moisture-proof performance will be reduced if the thermoplastic resin film interposed between the front and back paper of the moisture-proof sheet is melted and heat-sealed integrally with the front and back paper, usually cold pressure sticking In this case, since it is necessary to blow off the moisture contained in the adhesive used, the amount of adhesive applied should be as small as possible, and also when performing hot press In order to prevent the occurrence of puncture due to moisture, it is common to reduce the amount of adhesive applied as much as possible. Therefore, as described above, when the paper has a thickness of 20 μm or more, even if it is thin paper, A non-penetrating layer will occur.

  In order to eliminate such problems, paper such as inter-paper reinforced paper is used for the front and back of the moisture-proof sheet, and the paper is impregnated with a thermoplastic resin such as latex or acrylic emulsion in advance. Attempts to prevent interlaminar peeling have also been made, but when the wooden base material is a relatively soft plywood, the flooring material is formed by sticking a decorative veneer on the wooden base material via the moisture-proof sheet. Although the effect can be achieved, as described above, when the surface portion of the wood base material is formed of a hard wood fiber board, the decorative veneer is laminated and bonded to the wood base material via the moisture-proof sheet. When a load of casters such as a wagon is applied on the decorative veneer of the flooring material, a shear breaking force acts violently on the moisture-proof sheet, and it is difficult to prevent separation between papers at the strength of paper-reinforced paper. .

  On the other hand, according to Patent Document 2, since a resin film having a low water vapor permeability is interposed as an intermediate layer between arbitrary layers of the laminate of thermosetting resin-impregnated paper, a moisture-proof effect can be expected by this intermediate layer. In addition, the occurrence of peeling between papers can be eliminated, but when the resin film having a low water vapor permeability is interposed as an intermediate layer between arbitrary layers of the laminate of the thermosetting resin-impregnated paper, this resin film In addition to causing a decrease in productivity, it is necessary to perform surface treatment on the floor, and a decorative veneer is laminated and integrated on a hard wooden base material through a laminate of this thermosetting resin-impregnated paper. When the material is configured, there is no layer that exhibits a cushioning function in the intermediate layer. Therefore, when a continuous load is applied by a caster, shear failure occurs in the inner layer of the decorative veneer. Was Tsu.

  The present invention has been made in view of such problems, and its purpose is to exhibit sufficient scratch resistance and strength even for the use of casters, etc. while maintaining excellent moisture resistance. It is another object of the present invention to provide a reinforced floor material that can be easily peeled off and shear breakage of a single plate and a method for producing the reinforced floor material.

  In order to achieve the above object, the reinforced flooring material of the present invention, as described in claim 1, has a wood base material comprising at least a hard wood fiberboard having a specific gravity of 0.4 to 1.0, heat resistance and moisture resistance. A moisture-proof sheet-like material obtained by superimposing upper and lower paper layers impregnated and cured with a thermosetting resin on the front and back surfaces of a thermoplastic resin sheet having heat resistance and integrally welding these upper and lower paper layers to the thermoplastic resin sheet. And a decorative veneer are sequentially laminated and integrated.

  In the reinforced flooring material configured as described above, the invention according to claim 2 is directed to the surface of the upper paper layer of the moisture-proof sheet-like material on the back surface of the decorative veneer and the back surface of the lower paper layer on the surface of the wooden substrate. They are bonded together by thermosetting resin adhesives, and these upper and lower paper layers are impregnated and cured at the time of bonding, and the upper paper layer has a thickness of 30 to 50 μm. The thermosetting resin adhesive that bonds the upper paper layer to the decorative veneer is an elastic adhesive, and the adhesive is impregnated and cured throughout the upper paper layer. It is characterized by letting

  The invention according to claim 3 is a method for producing the above-mentioned reinforced flooring, wherein at least the surface layer portion is coated with a thermosetting resin adhesive on the surface of a wood base material made of a hard wood fiber board having a specific gravity of 0.4 to 1.0. A moisture-proof sheet formed by superimposing upper and lower paper layers on the front and back surfaces of a thermoplastic resin sheet having heat resistance and moisture resistance on the surface of a wooden substrate via this thermosetting resin adhesive and integrally heat-welding them. By placing a product, and further applying a thermosetting resin adhesive on the moisture proof sheet, and then stacking a decorative veneer on the surface of the moisture proof sheet via the thermosetting resin adhesive, A laminate composed of a wooden substrate, a moisture-proof sheet and a decorative veneer is formed, and the laminate is heated and pressed to impregnate and cure the thermosetting resin adhesive on the upper and lower paper layers of the moisture-proof sheet, respectively. These thermosetting resin contacts And characterized in that integrally laminating a decorative sliced veneer through the moisture-proof sheet on the surface of the wood substrate by agents.

  The invention according to claim 4 is a method for manufacturing a reinforced flooring material different from the above manufacturing method, wherein at least the surface layer part has a thermosetting resin on the surface of a wooden base material made of a hard wood fiberboard having a specific gravity of 0.4 to 1.0. After the adhesive is applied, the upper and lower paper layers are superposed on the front and back surfaces of the thermoplastic resin sheet with heat resistance and moisture resistance on the surface of the wooden substrate via this thermosetting resin adhesive. An intermediate laminate composed of a wooden substrate and a moisture proof sheet is formed by placing the moisture proof sheet, and the intermediate laminate is hot-pressed on the lower paper layer of the moisture proof sheet. The thermosetting resin adhesive is impregnated and cured throughout the thermosetting resin adhesive, and the moisture-proof sheet-like material is integrally bonded to the surface of the wooden substrate, and the thermosetting resin adhesive is applied on the intermediate laminate. After applying, through this thermosetting resin adhesive The above-mentioned thermosetting resin adhesion applied on the intermediate laminate to the upper paper layer of the moisture-proof sheet by forming a final laminate by placing a decorative veneer on the interlaminate and then heat-pressing this final laminate And a second hot-pressing step in which the decorative veneer is integrally bonded onto the moisture-proof sheet-like material while impregnating and curing the agent.

  According to the first aspect of the present invention, at least the surface layer portion of the wood base material is formed of the hard wood fiber board having a specific gravity of 0.4 to 1.0, and thus the decorative veneer is disposed on the wood base material via the moisture-proof sheet-like material. In addition to being able to give strength to prevent the occurrence of dents due to falling objects and movement of furniture on the flooring that is laminated integrally, it is interposed between the wooden substrate and the decorative veneer It is possible to prevent moisture from entering from the surface into the wooden substrate by the thermoplastic resin sheet in the moisture-proof sheet, and to maintain dimensional stability. In addition, the thermoplastic resin sheet The upper and lower paper layers, which are integrally heat-sealed on the front and back surfaces of this sheet and form a moisture-proof sheet-like material together with this thermoplastic resin sheet, are impregnated and cured throughout, so that flooring To provide excellent scratch resistance In addition, the use of a hard wood fiberboard for the surface layer of the wood base material prevents the paper from peeling and shearing breakage of the decorative veneer even if shearing force acts on the moisture-proof sheet. be able to.

  Furthermore, by arbitrarily selecting the hardness of the thermosetting resin adhesive impregnated in the upper and lower paper layers having a certain thickness in the moisture-proof sheet and the hardness of the resin sheet used for the core of the moisture-proof sheet In addition, the resin sheet is made of a thermoplastic resin having heat resistance, so that the paper layer superimposed on the front and back surfaces is impregnated with the thermoplastic resin. Even when the hot pressing is performed, stable production is possible without deteriorating the moisture-proof performance of the resin sheet.

  According to the invention according to claim 2, the thermosetting resin adhesive that bonds the upper paper layer of the moisture-proof sheet and the decorative veneer is an elastic adhesive, Since the adhesive is impregnated and cured over the entire upper paper layer, even if a load is applied by a caster such as a wagon, the load is elastically absorbed and the paper layer and the decorative veneer are not affected by the paper. It is possible to prevent interlaminar peeling and delamination.

  As a manufacturing method of the reinforced flooring, as described in claim 3, at least the surface layer part has a specific gravity of 0.4 to 1.0 on the surface of a wooden base material made of hard wooden fiberboard, through a thermosetting resin adhesive, The top and bottom paper layers are stacked on the front and back surfaces of the thermoplastic resin sheet, and a moisture-proof sheet-like material that is integrally heat-welded is stacked, and a decorative veneer is stacked on the moisture-proof sheet-like material via a thermosetting resin adhesive. Since the laminate is hot-pressed, the thermosetting resin adhesive can be impregnated and cured in the upper and lower paper layers of the moisture-proof sheet to form a paper layer in which separation between papers hardly occurs. In addition, it is possible to efficiently produce a reinforced flooring material excellent in moisture resistance and scratch resistance, in which a wooden base material, a moisture-proof sheet-like material, and a decorative veneer are firmly laminated and integrated through a thermosetting resin adhesive.

  In addition, as described in claim 4, first, at least the surface layer portion is not based on the method in which the laminated body of the wooden base material, the moisture-proof sheet-like material, and the decorative veneer is fixed integrally at the same time by hot pressing. Is formed by placing the moisture-proof sheet-like material on the surface of a wood substrate made of a hard wood fiber board having a specific gravity of 0.4 to 1.0 via a thermosetting resin adhesive. A first hot-pressing step in which the lower paper layer of the moisture-proof sheet-like material is impregnated and cured with the thermosetting resin adhesive, and the moisture-proof sheet-like material is integrally bonded to the surface of the wooden substrate by hot pressing; The final laminate is formed by placing a decorative veneer on the intermediate laminate via a thermosetting resin adhesive, and the intermediate laminate is formed on the upper paper layer of the moisture-proof sheet by hot pressing the final laminate. After coating on the laminate By a second hot pressing step to bond together a decorative sliced veneer in the moisture-proof sheet on with impregnated cured thermosetting resin adhesive, may be produced reinforcing flooring.

  Next, a specific embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a simplified longitudinal sectional view of a reinforced flooring A, and the reinforced flooring A is a wooden substrate 1 having a certain thickness. The decorative veneer 3 is laminated and integrated on the surface (upper surface) of the decorative veneer 3 via the moisture-proof sheet-like material 2.

  Specifically, as the above-mentioned wood base material 1, a board material is used in which a hard wood fiber board 1 a having a specific gravity of 0.4 to 1.0 is attached to the surface of a wood board 1 b such as plywood, particle board, OSB or the like. In addition, the entire base material may be formed of a wood fiber board. In short, the wood base material 1 may be formed of the hard wood fiber board 1a having at least a surface layer portion having a specific gravity of 0.4 to 1.0.

  The hard wood fiber board 1a as described above has a specific gravity of 0.4 to 1.0 as described above, among general medium specific gravity wood fiber boards (hereinafter referred to as MDF) and hard boards (hereinafter referred to as HDF). Use wood fiberboard. It should be noted that the wood fiberboard having a specific gravity of 0.4 or less cannot easily obtain a flooring material having high surface scratch resistance because it tends to cause dents and scratches when impacted from the surface of the decorative veneer 3, When an HDF having a specific gravity exceeding 1.0 is used, it is not preferable because swelling in the thickness direction increases due to moisture.

  In addition, wood fiberboards, for example, those using urea melamine resin as the binder, U type, those using melamine resin, M type, using phenolic resin, depending on the type of bonding agent used Is a P type, but any type can be used. However, in particular, when used for flooring applications, among the above types, the U type should be avoided because it is poor in water resistance and easily swells against moisture. Furthermore, a hard wood fiber board using a binder such as an isocyanate compound or a polyol compound as a binder can also be employed. It is preferable to use a hard wood fiber board in which a water repellent such as wax is added.

  Furthermore, the MDF and HDF are classified into softwood and hardwood depending on the type of wood fiber used, but generally hardwood wood fiber is more resistant to moisture than softwood wood fiber. Because of excellent dimensional stability, it is desirable to use MDF or HDF made of hardwood wood fibers.

  As the decorative veneer 3 formed by laminating and integrating the moisture-proof sheet-like material 2 on the surface of the wooden substrate 1, a thin wooden veneer having a thickness of 0.15 to 1.0 mm made of natural wooden material is used. The tree species is not limited and may be a dry veneer or a so-called wet veneer. However, as will be described later, in order to produce the reinforced flooring of the present invention, the thermosetting resin adhesive 4a for bonding the decorative veneer 3 to the wooden substrate 1 through the moisture-proof sheet-like material 2 is used. Since a large amount of coating is required, the surface of the decorative veneer 3 is likely to seep out of the thermosetting resin adhesive 4a. Therefore, the decorative veneer 3 having a thickness of about 0.35 to 0.6 mm is preferably used. . It should be noted that the surface of the decorative veneer 3 may be grooved, floated, colored or painted.

  As the moisture-proof sheet-like material 2 in which the decorative projecting board 3 is integrally laminated and adhered to the surface of the hard wood fiber board 1a of the wood substrate 1, heat resistance and moisture resistance are provided between the upper paper layer 2a and the lower paper layer 2b. The upper and lower paper layers 2a are attached to the front and back surfaces of the thermoplastic resin sheet 2c by hot-pressing a sheet-like material having a three-layer structure in which a resin sheet 2c made of a thermoplastic resin having a core layer is interposed in a sandwich shape. , 2b has a structure that is integrally fused, but as another manufacturing method, a thermoplastic resin sheet 2c in a semi-molten state is fed between the upper and lower paper layers 2a and 2b from the nozzle of the molding machine, and the upper and lower paper layers 2a 2b may be laminated and integrated by pressing the opposite surfaces of 2b to the front and back surfaces of the thermoplastic resin sheet 2c, respectively.

  The moisture-proof sheet-like material 2 has a lower paper layer 2b superimposed on a wood fiber board 1a of the above-mentioned wood substrate 1 and is integrally bonded with a thermosetting resin adhesive 4b, and the upper surface of the upper paper layer 2a is decorated. The decorative veneer 3 is integrally laminated and bonded to the lower surface of the veneer 3 with the thermosetting resin adhesive 4a on the wood fiber board 1a of the wood substrate 1 via the moisture-proof sheet-like material 2. At the same time, the upper and lower paper layers 2a and 2b of the moisture-proof sheet-like material 2 constitute a reinforced floor material A in which the thermosetting resin adhesives 4a and 4b are impregnated and cured over the whole (all layers). Yes.

  As the thermoplastic resin sheet 2c, a low-density polyethylene sheet is generally employed. However, in the present invention, the thermoplastic resin sheet 2c has a higher heat resistance than a low-density polyethylene sheet and has a softening temperature characteristic of 110 ° C. or higher. A heat-resistant resin sheet such as a density polyethylene, a crosslinked polyethylene sheet, a high-density crosslinked polyethylene sheet, or a polyethylene terephthalate sheet is preferably used. Incidentally, high density polyethylene resin refers to those with a density of about 0.94 or more.

As the upper and lower paper layers 2a and 2b layered on the front and back surfaces of the thermoplastic resin sheet 2c, kraft paper, thin paper, titanium paper or the like of about ²⁰ to 50 g / m ² is used. More preferably, a paper-reinforced sheet-like material impregnated and cured with latex or synthetic resin is used. However, the inter-paper reinforcing sheet needs to be inter-paper reinforced so as not to prevent the penetration of the thermosetting resin adhesives 4a and 4b.

  The upper and lower paper layers 2a, 2b of the moisture-proof sheet 2 are impregnated and cured, and the decorative veneer 3 is integrally laminated and bonded onto the wood fiber board 1a of the wooden substrate 1 through the moisture-proof sheet 2. As the thermosetting resin adhesives 4a and 4b, any resin having thermosetting properties can be used. For example, urea melamine resin, urea resin, polyester resin, vinyl acetate An adhesive obtained by adding a melamine resin or an isocyanate resin to a polymer resin or a latex resin can be suitably used.

  In order to improve the scratch resistance, the thermosetting resin adhesive 4b for adhering the lower paper layer 2b of the moisture-proof sheet 2 to the wood fiber board 1a forming the surface layer portion of the wood substrate 1 Relatively hard urea melamine resin can be used, and in order to improve caster resistance, elastic acrylic resin, vinyl acetate resin or latex resin, melamine resin or isocyanate resin, etc. It is preferable to use an adhesive to which a thermosetting agent is added.

  Furthermore, the thermosetting resin adhesive 4a for bonding the upper paper layer 2a of the moisture-proof sheet 2 and the decorative veneer 3 has elasticity in order to improve the crack resistance and caster resistance of the decorative veneer 3. It is preferable to use a thermosetting resin adhesive, and in particular, the above-mentioned adhesive in which a thermosetting agent such as a melamine resin or an isocyanate resin is added to an acrylic resin, a vinyl acetate resin or a latex resin is preferably used. Is done. In this case, the thermosetting resin adhesive 4a and the thermosetting resin adhesive 4b in which the lower paper layer 2b of the moisture-proof sheet 2 is bonded onto the wood fiber board 1a have the same composition. Or an adhesive having a different composition.

  Next, the manufacturing method of the reinforced flooring A comprised as mentioned above is described. FIG. 2 shows an embodiment of the present invention. As shown in FIG. 2A, a roll coater is used on the surface of a wood substrate 1 in which a wood fiber board 1a having a specific gravity of 0.4 to 1.0 is integrally provided on the surface layer portion. A moisture-proof sheet in which the thermosetting resin adhesive 4b is uniformly applied over the entire surface, and the thermoplastic resin sheet 2c is used as a core layer, and the paper layers 2a and 2b are integrally provided on the front and back surfaces of the thermoplastic resin sheet 2c. Layer 2 is stacked. Further, a thermosetting resin adhesive 4a is applied onto the upper paper layer 2a of the moisture-proof sheet-like material 2 by a roll coater, and then a decorative veneer is placed on the moisture-proof sheet-like material 2 via the thermosetting resin adhesive 4a. By stacking 3, a laminate A ′ composed of the wooden substrate 1, the moisture-proof sheet-like material 2, and the decorative veneer 3 is obtained. At this time, it is preferable that the thermosetting resin adhesive 4a applied on the moisture-proof sheet-like material 2 is cured for a short period of time before the decorative veneer 3 is stacked, and the water is volatilized slightly.

The amount of the thermosetting resin adhesives 4a and 4b applied to the surface of the wood fiber board 1a of the wood substrate 1 and the upper paper layer 2a of the moisture-proof sheet 2 is respectively the upper and lower papers of the moisture-proof sheet 2 Although depending on the paper thickness of the layers 2a and 2b, the upper and lower paper layers 2a and 2b are impregnated throughout, and the adhesion to the wood fiber board 1a and the adhesion to the decorative veneer 3 are entirely performed. in order to reliably performed, the upper and lower paper layers 2a, 2b is 75 g / m ² approximately when consisting of tissue paper of 30 g / m ^2, the upper and lower paper layers 2a, if 2b consists kraft paper 50 g / m ² It is necessary to apply an adhesive of about 130 g / m ² .

  Next, this laminate A ′ is inserted between the upper and lower presses of the hot press machine and hot pressed for 30 to 90 seconds under hot pressure conditions of a temperature of 100 to 130 ° C. and a pressure of 0.3 to 1.5 MPa. At this time, the amount of the thermosetting resin adhesive 4a, 4b applied on the surface of the wood fiber board 1a of the wood substrate 1 and the upper paper layer 2a of the moisture-proof sheet-like material 2 is large. In order to prevent the occurrence of puncture due to the water content, it is desirable to perform the hot press in two stages. That is, the thermosetting resin adhesives 4a and 4b are obtained by first hot pressing the laminate A ′ with a press schedule of a temperature of 100 to 130 ° C., a pressure of 0.3 to 0.5 MPa, and a hot pressing time of about 10 to 30 seconds. After the moisture contained in the water is blown out as water vapor, the hot-pressure treatment is performed with a press schedule of a temperature of 100 to 130 ° C., a pressure of 0.8 to 1.5 MPa, and a hot press time of about 30 to 60 seconds.

  With this hot press, the thermosetting resin adhesives 4a and 4b are impregnated over the whole (all layers) of the upper and lower paper layers 2a and 2b of the moisture-proof sheet 2 and then cured. The decorative veneer 3 is laminated and bonded to the surface of the wood fiber board 1a of the wood substrate 1 through the moisture-proof sheet-like material 2 by 4a and 4b to obtain a reinforced flooring A as shown in FIG. Although this reinforced flooring A may be used as it is as a flooring, it may be subjected to a makeup process such as floating or painting on the surface.

  When coloring is performed in such a cosmetic treatment, the colorant is not particularly limited, but pigment-based colorants such as organic pigments and inorganic pigments, and dye-based colorants are preferably used. Also, in the case of cosmetic treatment by painting, the coating material is not particularly limited, but various paints such as a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin can be used. As the floor coating material, a solvent-free ultraviolet curable acrylate resin with few VOC problems can be preferably used.

  FIG. 3 shows another method for producing the reinforced flooring A of the present invention. First, as shown in FIG. 3 (a), a wood base having a wood fiber board 1a having a specific gravity of 0.4 to 1.0 integrally formed on the surface layer portion. After the thermosetting resin adhesive 4b is uniformly applied over the entire surface of the material 1 by a roll coater, the paper layers 2a and 2b are formed on the front and back surfaces of the thermoplastic resin sheet 2c using the thermoplastic resin sheet 2c as a core layer. By stacking the moisture-proof sheet-like material 2 integrally formed by heat-sealing, an intermediate laminate A1 composed of the wooden substrate 1 and the moisture-proof sheet-like material 2 is obtained.

  Next, the intermediate laminate A1 is inserted between the upper and lower presses of the hot press machine and hot pressed under the same press schedule conditions as in the production of the reinforced flooring A in the above embodiment, thereby providing thermosetting. The resin adhesive 4b is melted and impregnated over the whole (all layers) of the lower paper layer 2b of the moisture-proof sheet material 2 and then cured, and the wood substrate 1 is made of wood with this thermosetting resin adhesive 4b. A moisture-proof sheet-like material 2 is integrally laminated and bonded to the surface of the fiber board 1a. The adhesion treatment between the wooden base material 1 and the moisture-proof sheet-like material 2 by this heat pressure is defined as a first heat pressure step.

  Thereafter, as shown in FIG. 3 (b), a thermosetting resin adhesive 4a is uniformly applied over the entire surface by a roll coater on the upper paper layer 2a of the moisture-proof sheet 2 in the intermediate laminate A1. The final laminate A ″ is formed by superimposing the decorative veneer 3 on the moisture-proof sheet-like material 2 through the thermosetting resin adhesive 4a. In this case, the thermosetting resin adhesive 4a is preferably cured for a short period of time before the decorative veneer 3 is placed, so that the water is volatilized slightly.

  The final laminate A ″ thus obtained is subjected to a second hot-pressing process using the hot-pressing process for the intermediate laminate A1 as a first hot-pressing step, thereby performing a reinforced flooring as shown in FIG. Get A. At this time, in the second hot-pressing process, as in the above, the final laminate A ″ is inserted between the upper and lower press panels of the hot-pressing machine, and the press schedule is the same as that for manufacturing the reinforced flooring A in the above embodiment. By thermo-pressing under conditions, the thermosetting resin adhesive 4a is completely impregnated into the upper paper layer 2a of the moisture-proof sheet 2 and then cured, and the thermosetting resin adhesive 4a prevents moisture. The decorative veneer 3 is integrally bonded to the sheet-like material 2.

  The obtained reinforced flooring A has substantially the same physical properties as the reinforced flooring A obtained by the above manufacturing method, and the surface of the decorative veneer 3 is subjected to any cosmetic processing in the same manner as described above and has an excellent appearance. A reinforced flooring material having stable quality can be obtained. Next, specific examples of the present invention will be described.

〔Example〕
First, a wood fiber board having a thickness of 2.7 mm and a specific gravity of 0.8 was attached to the surface of a lauan plywood having a thickness of 9 mm and a five-layer structure to prepare a composite wood substrate. A thermosetting resin adhesive having a resin rate of 50%, which is obtained by adding 15 parts by weight of a latex resin to 100 parts by weight of urea melamine resin, was applied to the surface of the composite wood substrate by a roll coater at 75 g / m ² . . Subsequently, 30 g / m ² of thin paper was superimposed on the front and back surfaces of the high-density polyethylene resin sheet having a softening point of 130 ° C. in a sandwich shape, and the front and back surfaces of the high-density polyethylene resin sheet were heat-sealed to the thin paper. After three-layer poly sand paper (moisture-proof sheet-like material) is layered on the thermosetting resin adhesive layer, 50 parts by weight of latex resin is added to 100 parts by weight of urea melamine resin on this poly sand paper. A thermosetting resin adhesive having a resin ratio of 50% was applied by a roll coater at 75 g / m ² . This state was left at room temperature for 60 seconds.

  After that, a decorative veneer was placed on the thermosetting resin adhesive layer, and immediately subjected to 120 ° C. and 0.5 MPa hot pressure for 15 seconds by a flat plate hot press machine, followed by 120 ° C. and 0.8 MPa. Reinforced flooring was obtained by hot pressing with a press schedule for 45 seconds. The surface of the decorative veneer in the thus obtained reinforced flooring was colored with a pigment-based water-based colorant, dried with a dryer, and a transparent coating layer was formed on the surface with an acrylate-based ultraviolet curable resin. A caster resistance test was performed on the reinforced flooring. This caster resistance test is a test in which a steel wheel caster with a diameter of about 30 cm on which a 25 kg weight is placed is reciprocated 500 times on the same surface of the reinforced flooring and the surface condition after the test is observed. As a result of this test, no delamination between sheets or delamination within the decorative veneer occurred.

[Comparative example]
First, a wood fiber board having a thickness of 2.7 mm and a specific gravity of 0.8 was attached to the surface of a lauan plywood having a thickness of 9 mm and a five-layer structure to prepare a composite wood substrate. 50 g / m ^{2 of a} thermosetting resin adhesive having a resin ratio of 50% obtained by adding 15 parts by weight of a latex resin to 100 parts by weight of urea melamine resin was applied to the surface of this composite wood substrate by a roll coater. . Subsequently, 30 g / m ² of thin paper was superimposed on the front and back surfaces of the high-density polyethylene resin sheet having a softening point of 130 ° C. in a sandwich shape, and the front and back surfaces of the high-density polyethylene resin sheet were heat-sealed to the thin paper. After three-layer poly sand paper (moisture-proof sheet-like material) is layered on the thermosetting resin adhesive layer, 50 parts by weight of latex resin is added to 100 parts by weight of urea melamine resin on this poly sand paper. A thermosetting resin adhesive having a resin ratio of 50% was applied by a roll coater at 50 g / m ² .

  Thereafter, a decorative veneer was placed on the thermosetting resin adhesive layer, and a reinforced flooring was obtained by immediately applying a hot pressure of 120 ° C. and 0.8 MPa for 60 seconds with a flat plate hot press machine. The surface of the decorative veneer in the thus obtained reinforced flooring was colored with a pigment-based water-based colorant, dried with a dryer, and a transparent coating layer was formed on the surface with an acrylate-based ultraviolet curable resin. The same caster resistance test as that of the above example was performed on this reinforced flooring. As a result, separation between papers was confirmed at a portion of the reinforced flooring material that was not impregnated with the thermosetting resin adhesive in the lower paper layer of the Bolly sand paper.

The simplified longitudinal cross-sectional view of a reinforced flooring. The simplified process drawing which shows the manufacturing method of a reinforced flooring. The simplified process drawing which shows another manufacturing method of a reinforced flooring.

Explanation of symbols

A Reinforced flooring 1 Wood base
1a Wood fiber board 2 Moisture-proof sheet
2a, 2b Top and bottom paper layers
2c thermoplastic resin sheet 3 decorative veneer
4a, 4b Thermosetting resin adhesive

Claims (4)

  At least the surface layer part is made of a hard wood fiberboard having a specific gravity of 0.4 to 1.0, and upper and lower paper layers impregnated and cured with a thermosetting resin on the front and back surfaces of a thermoplastic resin sheet having heat resistance and moisture resistance. In addition, a reinforced flooring material comprising a moisture-proof sheet-like product obtained by integrally heat-sealing these upper and lower paper layers with the thermoplastic resin sheet and a decorative projecting board, which are sequentially laminated and integrated.   The surface of the upper paper layer of the moisture-proof sheet is adhered to the back surface of the decorative veneer, and the back surface of the lower paper layer is integrally bonded to the surface of the wooden substrate with a thermosetting resin adhesive. The upper and lower paper layers are impregnated and cured with a thermosetting resin adhesive, and the upper paper layer has a thickness of 30 to 50 μm and is bonded to the decorative veneer. The reinforced flooring material according to claim 1, wherein the thermosetting resin adhesive is an adhesive having elasticity, and the adhesive is impregnated and cured over the entire upper paper layer.   After applying a thermosetting resin adhesive to the surface of a wood substrate made of hard wood fiberboard with a specific gravity of 0.4 to 1.0 at least in the surface layer, heat resistance is applied to the surface of the wood substrate through this thermosetting resin adhesive. A moisture-proof sheet-like material obtained by superimposing upper and lower paper layers on the front and back surfaces of a thermoplastic resin sheet having heat resistance and moisture-proof and integrally heat-sealing is further mounted on the moisture-proof sheet-like material. After applying the adhesive, the decorative veneer is stacked on the surface of the moisture-proof sheet through this thermosetting resin adhesive to form a laminate composed of the wooden substrate, the moisture-proof sheet, and the decorative veneer. The laminate is heated and pressed so that the upper and lower paper layers of the moisture-proof sheet are impregnated and cured with the thermosetting resin adhesive, and the moisture-proof sheet is applied to the surface of the wooden substrate by these thermosetting resin adhesives. Through makeup Method for producing a reinforcing flooring for causing integrally laminated plate.   After applying a thermosetting resin adhesive to the surface of a wood substrate made of hard wood fiberboard with a specific gravity of 0.4 to 1.0 at least in the surface layer, heat resistance is applied to the surface of the wood substrate through this thermosetting resin adhesive. Between a wooden substrate and a moisture-proof sheet by placing a moisture-proof sheet in which the upper and lower paper layers are superposed on the front and back surfaces of the thermoplastic and moisture-proof thermoplastic resin sheet By forming a laminate and heat-pressing the intermediate laminate, the lower paper layer of the moisture-proof sheet is impregnated and cured over the entire surface and the moisture-proof sheet on the surface of the wooden substrate. A first heat-pressure step for bonding the two pieces together, and applying a thermosetting resin adhesive on the intermediate laminate, and then placing a decorative veneer on the intermediate laminate via the thermosetting resin adhesive To form the final laminate. The second heat is applied to the upper paper layer of the moisture-proof sheet by impregnating and curing the thermosetting resin adhesive applied on the intermediate laminate, and the decorative veneer is integrally bonded to the moisture-proof sheet. A method for producing a reinforced floor material, comprising a pressing step.

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