JP2009167763A - Cork floor material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a novel cork floor material demonstrating characteristics of Bakuhan-seki (a kind of porous stone) with keeping warmth and walking feeling peculiar to a cork floor material and excellent in rigidity, heat insulation and the like, and a manufacturing method for the same. <P>SOLUTION: The cork floor material A is made by bonding and integrating a Bakuhan-seki containing base layer 4 containing Bakuhan-seki particles 1 and solidified with a binder resin and a cork board layer 5 made by solidifying a large number of cork particles with a binder resin. The cork floor material A is produced by executing: a process of mixing at least the Bakuhan-seki particles 1 and the binder resin selected from the Bakuhan-seki particles 1, vulcanized rubber chips 2 and the cork particles 3 and the binder to make a Bakuhan-seki containing base material 40; a process of slicing a cork molded block 51 made by compression-molding a large number of the cork particles together with the binder in a predetermined thickness to make a cork board 52; and a process of laminating the Bakuhan-seki containing base material and the cork board and heating-and-compressing the laminated product before the binder resin in the base material is not cured to bond and integrate the laminated product. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a cork floor material containing barley-stone grains and a method for producing the same.

Cork flooring is a cork board made by bonding a large number of cork grains crushed from raw cork wood with a binder resin, and a rigid material such as plywood or rubber board, or a foam material for weight reduction. Laminated materials are widely used. These cork flooring materials are widely used for floors of ordinary houses, elderly facilities or childcare / infant facilities due to their unique elasticity and warm texture, as well as impact mitigation. Recently, barley stone (formal mineral name, granite porphyry), which is known to have characteristics such as emitting negative ions and far infrared rays, has come to be used in various fields. Patent Documents 1 to 3 disclose a floor material or panel board containing barley stone as part of the floor constituent material.
JP 2003-314043 A JP 2006-263402 A JP 2006-266658 A

  As described above, the cork floor material to which a rigid material such as a plywood or a rubber plate is bonded has a large weight, and thus has a difficulty in transportability and workability. In the case of a cork flooring laminated with a rubber plate, an unvulcanized rubber sheet is superimposed on the cork plate, and this is compressed and heated so that the rubber plate is vulcanized and bonded to the cork plate. Since the temperature during vulcanization is high, the color tone and physical properties of the cork board may be adversely affected. Moreover, the cork flooring which laminated | stacked the foaming material lacks rigidity, and the walk feeling peculiar to a cork flooring is also impaired. Furthermore, it is easy to dent due to impact, and warp and peeling due to shrinkage are likely to occur, and therefore it is necessary to increase the thickness.

  The floor material or panel panel disclosed in the above-mentioned patent document contains barley stone in a part of the floor constituent material. Therefore, when it is constructed as a flooring material for ondol (floor heating), etc., negative ions emitted from the barley stone And far infrared rays are said to bring health benefits such as thermal effects on the human body of residents and users. However, since no particular consideration was given to the feeling of walking, texture, etc., it could not be said that it had sufficient suitability as a flooring material for ordinary houses, elderly facilities or childcare facilities.

  The present invention has been made in view of the above circumstances, and a novel cork floor that exhibits the characteristics of barley stone while maintaining the peculiar gait and warmth of a cork floor material and is excellent in rigidity, heat insulation, and the like. It aims at providing material and its manufacturing method.

  In the cork flooring according to the first invention, a barleystone-containing base material layer containing barleystone grains and solidified with a binder resin, and a cork board layer obtained by solidifying a number of cork grains with a binder resin are laminated and integrated. It is characterized by being made.

  In the present invention, the cork board layer may be integrally laminated and fixed on both surfaces of the barleystone-containing base material layer. Further, the barleystone-containing substrate layer may be further solidified by including a vulcanized rubber chip, or further solidified by including cork grains.

  The method for producing a cork floor material according to the second invention is a step of preparing a barley stone-containing base material by kneading at least barley stone grains and a binder resin among barley stone grains, vulcanized rubber chips and cork grains, A step of preparing a cork board by slicing a cork molding block obtained by molding and solidifying a number of cork grains together with a binder resin into a predetermined thickness, laminating the barley stone-containing base material and the cork board, and containing the barley stone It is characterized by comprising a step of heating and pressurizing the laminate in a stage where the binder resin in the substrate is uncured and integrating the laminate and fixing.

  The cork flooring according to the present invention is floored so that the cork board layer is the upper surface. Accordingly, the elasticity unique to cork and the warm texture match, giving a comfortable walking feeling to the user (resident). In addition, since the barleystone-containing base material layer is laminated and integrated thereunder, the solid feeling of the stone material is imparted and rigidity is obtained, and it is not recessed by impact. In addition, barley stone is a natural rock containing countless fine pores, so it is lightweight, does not increase in weight, and is therefore excellent in transportability and workability. In addition, the cork board layer including a large number of pores and the structural characteristics of the barley stone synergistically provide excellent heat insulation. And barley rice stone is also known to emit negative ions and far-infrared rays, and because the living space is always in the radiation environment of such negative ions and far-infrared rays, you can enjoy its effects while you are. In addition, combined with the above characteristics of the cork board layer, the useful value increases as a flooring material for general houses, elderly facilities or childcare / infant facilities. Furthermore, research is being conducted in various fields on other medicinal properties (for example, adsorbability of various bacteria), and from this point of view, it is expected to be an excellent indoor environment improvement flooring material in the future. .

  When the cork board layer is laminated and integrated on both sides of the barleystone-containing base material layer, the walking feeling becomes even better due to the elasticity of both cork board layers positioned up and down in the floor construction state, and positioned in the middle A solid feeling is imparted by the base material layer containing barleystone, and the dent resistance against impact is also improved.

  When the barleystone-containing base material layer is further solidified by containing vulcanized rubber chips and / or cork grains, the barleystone-containing base material layer itself also has elasticity due to the vulcanized rubber chips and / or cork grains. Since it is given, the feeling of walking becomes better. In particular, if both vulcanized rubber chips and cork grains are included, the inherent elasticity of each of them is complicated, and the solid feeling of the barley stone grains is relaxed, and a kind of unique walking feeling is obtained.

  In the method for producing a cork floor material of the second invention, the cork board is obtained by slicing a cork molding block to a predetermined thickness, so that it is not necessary to separately prepare a mold for the cork board. Since the cork molding block can be prepared so that it can be used for other purposes, existing molds and slicing apparatuses can be used as they are, and manufacturing can be rationalized. In addition, the barleystone-containing base material is prepared by appropriately mixing and kneading barleystone grains and a binder resin, and then the cork board and the laminated fixed body are integrated, so that here the cutting and slicing steps are not involved, and the barleystone There is no concern about blade spilling. Furthermore, the lamination and fixation integration of the barleystone-containing base material and the cork board is performed by heating and pressurizing the binder resin in the barleystone-containing base material in an uncured stage, so that no separate adhesive is used. The lamination is firmly fixed. Further, since a relatively low heating temperature is sufficient, there is no fear of adversely affecting the color tone and physical properties of the cork board layer.

  The best mode for carrying out the present invention will be described below with reference to the drawings. 1 is a cross-sectional view conceptually showing a cork flooring according to an embodiment of the present invention, FIG. 2 is a view similar to FIG. 1 showing a cork flooring according to another embodiment, and FIGS. ) Is a cross-sectional view conceptually showing an example of the manufacturing method of the cork flooring, FIG. 4 is a view showing the result of measuring the generation state of negative ions from the cork flooring according to the present invention, and FIG. The same figure as FIG. 1 which shows the cork flooring of other embodiment, (b) is a perspective view of the cork frame used for the cork flooring, FIG. 6 shows the modification of the cork flooring, (a) Is a perspective view, (b) is a sectional view taken along line XX in (a), and (c) is a sectional view taken along line YY in (a).

The cork flooring A shown in FIG. 1 has a lot of cork grains on one side of a barley stone-containing base material layer 4 in which barley stone grains 1, vulcanized rubber chips 2 and cork grains 3 are solidified with a binder resin. The cork board layer 5 solidified in (1) is laminated and fixed and integrated, and a coating protective layer 6 made of a clear paint is formed on the surface of the cork board layer 5. When performing floor construction using the cork floor material A of this embodiment, the cork board layer 5 is the front side, and the lower surface of the barleystone-containing base material layer 4 is fixed to the floor base (not shown) with an adhesive. Made by. Barley stone 1 is obtained by pulverizing barley stone, and those having a particle size of 1.0 to 3.0 mm are used. When the grain size of the barley stone grain 1 is less than 1.0 mm, the hardness increases and the elasticity as a flooring material decreases, and the microscopic pores decrease, so that the specific medicinal effect tends to be reduced. If the particle size exceeds 3.0 mm, the feeling of stagnation of the barley stone grains 1 is perceived through the cork plate layer 5 and the walking ability tends to deteriorate. Moreover, the compounding quantity of the barley stone grain 1 is set to be 50 to 60 g per 1 m ² , and if it is less than 50 g, the above-mentioned medicinal effect tends to be thinned, and if it exceeds 60 g, the solid feeling is too strong and the walking performance is poor. Tend to be.

  The vulcanized rubber chip 2 is obtained by pulverizing a vulcanized rubber material such as FKM, NBR, H-NBR, EPDM, CR, ACM, AEM, VMQ and FVMQ, and a desirable particle size range thereof is 3.0-5. 0 mm. When the particle size of the vulcanized rubber chip 2 is less than 3.0 mm, the elasticity tends to decrease, and when it exceeds 5.0 mm, the elasticity becomes excessive and the impact resistance tends to decrease. Moreover, the cork grain 3 is the same as the cork grain which comprises the cork board layer 5, Comprising: A cork raw wood is crushed and granulated. In view of elasticity and strength, the particle diameter range of the cork grain 3 is desirably 2.0 to 3.0 mm. As the binder resin of the barleystone-containing base material layer 4, a wet-curing one-component urethane adhesive, a latex adhesive, or the like is desirably used.

  The cork floor material B in FIG. 2 is formed by laminating and fixing the cork board layers 5 and 5A on both sides of the barleystone-containing base material layer 4, and further, on the surface of the cork board layer 5, a coating protective layer by a clear paint in the same manner as described above. 6 is formed. When performing floor construction using the cork floor material B of this embodiment, the cork board layer 5 is used as the surface side, and the lower surface of the cork board layer 5A is fixed on a floor base (not shown) with an adhesive. .

  An example of the manufacturing method of the cork flooring of the present invention will be described by taking the cork flooring B which is the second embodiment as an example. As shown in FIG. 3 (a), a kneaded product 50 of a large number of cork grains and a binder resin (for example, urethane resin, epoxy resin, etc.) is loaded into the cavity of the mold 7 and compressed by the upper and lower molds 7. High-frequency heating is performed to obtain a cork molding block 51 as shown in FIG. The cork molding block 51 is also used for other applications, and is prepared by slicing it into a predetermined thickness (for example, two types of 1.5 mm and 2 mm). On the other hand, as shown in FIG. 3 (c), in the kneader 8, the binder resin, barley stone grains, vulcanized rubber chips, and cork grains are kneaded in an appropriate blending ratio to obtain the barleystone-containing base material 40. . The blending ratio is, for example, 5 parts by weight of binder resin, 1.8 parts by weight of barley stone particles, 80 parts by weight of vulcanized rubber chips, and 15 parts by weight of cork grains, but is not limited thereto.

  Next, as shown in FIG. 3 (d), the cork plate 52 having a thickness of 2 mm is placed in the compression molding machine 9 adjusted to a predetermined size, and the barleystone-containing base material 40 is poured onto the cork board 52. Further, the cork plate 52 having a thickness of 1.5 mm is placed on top of it, and these are heated and pressurized. This heating / pressurization is performed when the barleystone-containing base material 40 is in an uncured stage, and the binder resin is cured with the heating / pressurization, and as shown in FIG. ... and the cork grain 3 ... are fixed with a binder resin to form a barleystone-containing base material layer 4, and the cork plate layers 5, 5A are laminated and fixed integrally on both sides of the barleystone-containing base material layer 4. Is done. After demolding, a clear coating is applied to the surface of the cork board layer 5 to form a coating protective layer 6. In addition, the lower surface of the cork plate layer 5A is sanded to ensure adhesion with the floor base during floor construction. The reason why the thickness of the cork plate 52 disposed on the lower side is set to 2 mm is in anticipation of thinning by sanding. The thickness of the barleystone-containing base material layer 4 is 1.5 to 8.5 mm, and the thickness of each layer is appropriately determined in terms of design according to the purpose and application.

  When the cork flooring A shown in FIG. 1 is produced, the barleystone-containing base material 40 is poured directly into the compression molding machine 9, and the cork plate 52 is placed thereon, and these are heated and pressurized in the same manner as described above. Then, the cork board layer 5 is laminated and fixed integrally on one side of the barleystone containing substrate layer 4, and after removing the mold, a clear paint is applied to the surface of the cork board layer 5 to form the coating protective layer 6.

  In the cork flooring materials A and B of these embodiments, since the barleystone-containing base material layer 4 contains barleystone particles 1..., The living space on the floor where the cork flooring materials A and B are constructed is minus. Since it is in an ion or far-infrared radiation environment, the resident can enjoy the effect while staying. FIG. 4 shows the result of measuring the generation state of negative ions when the above-mentioned cork flooring B is laid on a wooden floor with floor heating, and there is no floor heating (non-energized) and with floor heating (energized). ing. When negative ions are generated, positive ions are generated at the same time. The generation of negative ions means that more negative ions are generated than positive ions. As shown in FIG. 4, many negative ions are generated, particularly in the case of floor heating, and it is said that the floor heating installation floor can effectively enjoy its effect in winter. be able to.

In the cork flooring materials A and B of these embodiments, the barleystone-containing base material layer 4 includes barleystone grains 1..., Vulcanized rubber chips 2... And cork grains 3. In addition, the presence of the vulcanized rubber chips 2 and the cork grains 3 makes the barleystone-containing substrate layer 4 elastic, and this and the specific elasticity of the cork plate 52 synergize, and the barleystone grains 1 give a solid feeling. In addition, the excessive solid feeling (rolling feeling) is alleviated, and the cork flooring materials A and B are excellent in walking feeling. In particular, when it is installed on the floor of an aged facility, childcare facility, or kindergarten, the impact when it falls on the floor is mitigated, and scratches can be prevented in advance, making it very suitable for these applications. It is.
In addition, it may be a combination of barley stone grains 1..., A combination of barley stone grains 1 and vulcanized rubber chips 2, or a combination of barley stone grains 1 and cork grains 3. It is appropriately selected and adopted accordingly.

  Fig.5 (a) has shown the cork flooring C of other embodiment. In general, cork flooring is molded to a standard size and is laid on the floor base. Depending on the shape and size of the construction site, the cork floor may be at the end or corner. It is necessary to cut the material into a suitable size for construction. In the case of the cork flooring materials A and B shown in the above embodiment, the barleystone grains 1 contained in the barleystone-containing base material layer 4 are cut by field work including the barleystone-containing base material layer 4. Depending on ..., the cut may not be made smoothly or the cutter may spill. The cork floor material C of the present embodiment is made in view of such a point. That is, this cork flooring C is placed on a cork plate 52 (see FIG. 3) a cork frame body 10 as shown in FIG. 5 (b) formed by punching the cork plate into a lattice shape, The barley stone-containing base material 40 (see FIG. 3) is loaded into the space 10b between the lattice frame portions 10a of the cork frame body 10, and a cork plate 52 (same as above) is further placed thereon. The cork board layers 5 and 5A are laminated and fixed integrally on both sides of the barleystone-containing base material layer 4 including the cork frame 10 under pressure, and a coating protective layer 6 made of a clear paint is formed on the surface of the cork board layer 5 can get. In the example of the drawing, an example is shown in which the groove 5a that also serves as a surface pattern along the lattice of the cork frame 10 is formed on the surface of the cork plate layer 5 during heating and pressurization. 5a may be provided on the cork plate layer 5A side.

  When it is necessary to cut the cork floor material C during the above-described floor construction, if the cork frame 5 is cut along the concave groove 5a corresponding to the required size, the cork frame 10 is cut at the cut location. Since the lattice frame portion 10a is present and no barley grain is included, the cutting can be performed without any trouble, and there is no fear of cutter spillage. Accordingly, it is desirable that the lattice spacing of the cork frame 10 is mixed so that it can correspond to various aspects of the cut required portion as much as possible. The punching shape is not limited to the square as shown in the figure, but is round or other. It can also be a polygon.

  The cork flooring D in FIGS. 6 (a), 6 (b) and 6 (c) shows a modification of the cork flooring C. That is, a part of the lattice frame portion 11a of the cork frame body 11 is formed so as to be exposed on the surface of the cork plate layer 5, and the same barleystone-containing base material 40 (see FIG. 3) is formed in the lattice space 11b. And a cork plate 52 (see FIG. 3) formed in a shape matching the compartment space in the compartment space formed by the upper surface of the loaded barleystone containing base material 40 and the lattice frame portion 11a of the cork frame body 11. ) Are fitted, and these are heated / pressurized so that the barleystone-containing base material layer 4, the cork frame 11 and the cork plate layer 5 are engaged with each other as shown in the figure on the cork plate layer 5A. In this state, it is integrated into a laminated and fixed state. And the coating protective layer 6 by a clear paint is formed in the surface of the cork board layer 5 similarly to the above, and the cork flooring D is obtained. In this case, the cork board layer 5 and the cork board layer 5A may be turned upside down, and the coating protective layer 6 made of clear paint may be formed on the surface of the cork board layer 5A to form the cork floor material D.

  In the case of this cork floor material D, since a part of the lattice frame portion 11a of the cork frame body 11 is exposed through the coating protective layer 6, this has a pattern effect. In addition, when it is necessary to cut the floor as described above, if the cut is made along the exposed lattice frame portion 11a, the barley stone grains are present in the cut portion as described above. Therefore, the cut is made smoothly without being affected by the influence, and there is no concern that the cutter spills.

  In the above-described method for producing a cork floor material, the base resin-containing base material in which the binder resin is uncured and the cork board are laminated, and these are heated and pressed to form a laminated fixed integral. The stone-containing base material may be formed into a plate shape, and a cork plate may be bonded to the plate-like material to form a laminated fixed integral. Moreover, although the result verified experimentally about the point in which barley stone produces | generates a negative ion was shown, when floor heating is arranged in parallel, it has also been demonstrated that many far infrared rays are emitted.

It is sectional drawing which shows notionally the cork flooring of one Embodiment of this invention. It is a figure similar to FIG. 1 which shows the cork flooring of other embodiment. (A) (b) (c) is sectional drawing which shows notionally an example of the manufacturing method of the cork flooring. It is a figure which shows the result of having measured the generation | occurrence | production state of the negative ion from the cork flooring by this invention. (A) is a figure similar to FIG. 1 which shows the cork flooring of other embodiment, (b) is a perspective view of the cork frame used for the cork flooring. The modification of the cork flooring is shown, (a) is a perspective view, (b) is a cross-sectional view taken along line XX in (a), and (c) is a cross-sectional view taken along line YY in (a). It is.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Barley stone grain 2 Vulcanized rubber chip 3 Cork grain 4 Barley stone containing base material layer 40 Barley stone containing base material 5 Cork board layer 5A Cork board layer 51 Cork molding block 52 Cork board A, B, C, D Cork flooring

Claims (5)

  A cork floor comprising a barleystone-containing base material layer containing barleystone grains and solidified with a binder resin, and a cork board layer obtained by solidifying a number of cork grains with a binder resin, which are laminated and integrated. Wood. In the cork flooring according to claim 1,
The cork board is characterized in that the cork board layer is laminated and fixed integrally on both surfaces of the barleystone-containing base material layer. In the cork flooring according to claim 1 or 2,
The said barleystone containing base material layer is a cork flooring characterized by further solidifying including a vulcanized rubber chip. In the cork flooring according to any one of claims 1 to 3,
The said barley stone containing base material layer is a cork flooring characterized by further solidifying including the cork grain.   A step of preparing a barleystone-containing base material by kneading at least a barleystone grain and a binder resin among the barleystone grains, vulcanized rubber chips and cork grains, and a cork formed by compression molding a number of cork grains together with a binder resin A step of preparing a cork board by slicing a molding block to a predetermined thickness, and laminating the barleystone-containing base material and the cork board, and laminating the binder resin in the barleystone-containing base material in an uncured stage A method for producing a cork flooring comprising the step of heating and pressurizing a body to form a laminated and integrated body.

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