JP2010196362A - Cork flooring material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cork flooring material suitable for a place where water is used. <P>SOLUTION: The cork flooring material A is integrally laminated with an upper layer 1 and a lower layer 2, which are respectively formed by extruding granular cork materials fixed with a binder resin. The granular cork material used for forming the upper layer is a granular virgin cork material obtained by crushing an unprocessed natural cork. The density of the upper layer is 0.37-0.43 g/cm<SP>3</SP>, and the density of the lower layer is 0.30-0.35 g/cm<SP>3</SP>. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a flooring material used as a building material for a house or the like, and more particularly, to a cork flooring material suitable as a flooring material around water such as a toilet or a washroom.

Conventionally, cork flooring has been used for many floor surfaces of buildings such as houses because it has a unique texture and is excellent in heat insulation and sound insulation, for example, a square plate of 300 mm x 300 mm. It is well known that a cork floor material formed into a body or a rectangular plate of 145 to 300 mm × 600 to 900 mm is combined and used on the floor.
When such a cork flooring is used as a flooring around water such as a toilet or a washroom, water or urine penetrates from the seam between the cork flooring, and the floor foundation provided under the cork flooring Corrosion and mold etc. may occur between the cork flooring and the floor base. Therefore, it is conceivable to lay a single large sheet and use a seamless one.

  However, such a method for producing a cork flooring is a method in which a cork granule mixed with a binder is charged into a rectangular box-shaped mold and then compressed in the thickness direction and heated to form a thick cork block. After that, the cork floor material is determined by the size of the mold, so if you want to make a long floor material, make a mold of that size. There is a need to. In the case of flooring around water, a high-density cork flooring that eliminates gaps between cork granule materials and prevents clogging so that water or urine does not penetrate is required. It is difficult to form cork flooring.

In Patent Document 1 below, cork grains are continuously supplied into a plate-shaped mold, and compressed with a pressing body that reciprocates perpendicularly to the thickness direction of the mold from one side. A manufacturing method is disclosed in which extrusion is continuously performed in a plate shape while forming a flat shape upright in the thickness direction of the mold.
According to this, it is said that a long cork flooring with stable quality can be obtained.

  Further, as the cork floor material as described above, there is known a sheet body having a two-layer structure with different densities, such as the one described in Patent Document 2 below, including an insulator for an automobile interior material, etc. A laminated cork sheet used for the above is disclosed.

Japanese Patent Publication No. 5-52761 Utility registration No. 2503893

However, when the cork flooring is used around the water, as described above, a high-density cork flooring that is clogged so that water or urine does not penetrate is required. A raw cork grain obtained by pulverizing raw natural cork to which a binder or the like is not attached (hereinafter referred to as virgin cork grain) is preferred. Since the cork grains have a large elastic force to bulge, it is difficult to compress each of the cork grains until they are flattened upright in the thickness direction of the mold, and it is necessary to devise a manufacturing method.
In addition, the cork flooring of Patent Document 2 is intended for use as an insulator for automobile interior materials, and is not a flooring used as a building material for a house, but is suitable for water. is not.

  The present invention has been made in view of the above circumstances, and an object thereof is to provide a cork flooring suitable for water.

The cork floor material of the present invention is a cork floor material in which the upper layer and the lower layer are both laminated and integrated, which are produced by fixing and extruding a granular cork material with a binder resin, and are used for forming the upper layer. The cork material is virgin cork grains obtained by pulverizing unprocessed natural cork, and the density of the upper layer is 0.37 to 0.43 g / cm ³ and the density of the lower layer is 0.30 to 0.35 g / cm ³ . It is characterized by that.

  Moreover, the cork flooring of this invention WHEREIN: The said virgin cork grain consists of a mixture of 2 types of cork grain, a 1st cork grain, and a 2nd cork grain, and a 1st cork grain is a cork grain of a particle size of 8-14 mesh. , And the second cork grain is sized so as to contain 70% by weight or more of cork grains having a particle size of 5 to 8 mesh, and the first cork grain and The mixing ratio with the second cork grains may be a weight ratio of 1.5 to 2.5: 1.

  Furthermore, in the cork flooring of the present invention, the granular cork material used for forming the lower layer is a regenerated cork particle obtained by pulverizing a cork processed product, and the regenerated cork particle is a cork particle having a particle size of 6 to 10 mesh. It is good also as what was sized so that it may contain weight% or more.

Since all the cork flooring materials according to the present invention are produced by fixing and extruding granular cork materials with a binder resin, a long and large size flooring material (for example, 910 × 1820 mm) can be produced. . Therefore, when making flooring around a relatively small space such as a toilet or washroom, it is possible to use a single piece of flooring that is seamless and water or urine penetrates from the joint. Can be prevented.
In addition, since the granular cork material used for forming the upper layer is virgin cork grain obtained by pulverizing unprocessed natural cork, it is difficult to create a gap between the cork grains due to the strong elasticity that is unique to virgin cork grain. A high-density upper layer with good clogging can be provided. Therefore, it can be set as the cork flooring provided with the upper layer into which liquids, such as water, do not osmose | permeate, and if it can be set as a seamless flooring as mentioned above, it will become a more suitable thing as a flooring around water.
Further layer of density 0.37~0.43g / cm ^3, since the lower density is 0.30~0.35g / cm ^3, moderate cushioning property as the upper layer is dense impermeable and flooring The lower layer can be a layer having a reinforcing function as a flooring material or a heat insulating performance. When the density of the upper layer is less than 0.37 g / cm ³ , the permeability of water and the like becomes high, and it cannot be said that the floor material is suitable for water, and when it exceeds 0.43 g / cm ³ , extrusion molding It becomes difficult and the productivity is hindered, and the cushioning property as a moderate flooring tends to be poor. When the density of the lower layer is less than 0.30 g / cm ³ , the impact absorption is excellent, but the strength as a flooring tends to decrease and the walking performance tends to deteriorate, exceeding 0.35 g / cm ³ . And the density of the lower layer also becomes high, and the appropriate cushioning property tends to be reduced as the whole flooring material.

The virgin cork grains used for the upper layer are the first cork grains sized so that 8-14 mesh contains 85% by weight or more and the second cork grains sized so that 5-8 mesh contains 70% by weight or more. When the mixing ratio of the first cork grains and the second cork grains is a weight ratio of 1.5 to 2.5: 1, moderate cushioning characteristics and cork-specific design properties (cork grain grains It is possible to obtain a flooring material excellent in design properties resulting from the interval. When the blending ratio of the first cork grains is larger than the weight ratio 2.5: 1, the flooring material becomes hard and the cushioning property tends to be poor, and the elasticity of the virgin cork grains cannot be utilized. Further, since the number of particles having a small particle size increases, for example, the density distribution between the upper side and the lower side is different with respect to the thickness at the time of extrusion molding, and the density variation as a whole tends to increase.
On the other hand, if the blending ratio of the first cork grains is smaller than 1.5: 1 by weight, the gaps between the cork grains become large and the density tends to be low, and there is a tendency for water leakage. In addition, as the mixing ratio of the second cork grains increases in production, the pressure during extrusion molding tends to increase, and the cork grains may expand and burst due to the pressing.

In addition, when the granular cork material used for forming the lower layer is a regenerated cork grain obtained by pulverizing a cork processed product, it can be a product that takes into consideration environmental problems and resource saving, and can suppress an increase in cost. .
Further, if the regenerated cork grains are sized so as to contain 80% by weight or more of cork grains having a particle size of 6 to 10 mesh, they can have appropriate strength and hardness as the lower layer of the flooring.

It is a perspective view which shows one Embodiment of the cork flooring of this invention, and is a figure containing a part X section enlarged sectional view. It is the table | surface which put together the conditions of the upper layer of the cork flooring. It is the table | surface which put together the particle size distribution of the 1st cork grain which comprises the upper layer of the cork flooring, and the 2nd cork grain. It is the table | surface which put together the conditions of the lower layer of the cork flooring. It is the table | surface which put together the particle size distribution of the reproduction | regeneration cork grain which comprises the lower layer of the cork flooring. It is a flowchart which shows an example of the manufacturing method of the cork flooring.

Embodiments of the present invention will be described below with reference to the drawings.
The cork flooring material A shown in FIG. 1 is produced by fixing a granular cork material with a binder resin and extruding it, and forming a rectangular upper layer 1 and a rectangular lower layer 2 as an integral laminate. On the surface of the upper layer 1, a coating film 1a made of urethane paint (clear paint) having fading, water resistance, ammonia resistance, high chemical resistance and the like is formed. The upper layer 1 and the lower layer 2 are overlapped with each other via an adhesive, and are integrally laminated. In the figure, 3 indicates an adhesive layer.
The cork flooring A is, for example, a 910 × 1820 mm long rectangular plate, and is applied with an adhesive appropriately applied to a concrete slab or the like, which is a work surface, and then the lower layer 2 is placed downward. The
In addition, the cork flooring A is not limited to the one that is applied on the concrete slab or the like as described above, and is a flooring type that is directly laid on the flooring or the like. Good.

First, the upper layer 1 of the cork flooring A will be described with reference to FIGS.
Virgin cork grains are used for the granular cork material used for forming the upper layer 1, and the upper layer 1 is formed to have a density of 0.37 to 0.43 g / cm ³ (see FIG. 2). Virgin cork grains are crushed raw natural cork, and unlike regenerated cork grains described later, they are unprocessed raw cork grains, so no adhesives or paints are mixed in, and Since it has not been pressed yet, it has a characteristic that when it is pressed, its elastic reaction force is large when it is pressed because it has a larger force to swell when pressed.

The virgin cork grain which comprises the upper layer 1 consists of a mixture of two types of cork grains, the 1st cork grain and the 2nd cork grain, and the mixing ratio of the 1st cork grain and the 2nd cork grain is 1.5 weight ratio. Mixed to ~ 2.5: 1. Here, virgin cork grains that are sized so as to contain 85% by weight or more of cork grains having a particle size of 8 to 14 mesh are used as the first cork grains. Moreover, the virgin cork grain adjusted so that the cork grain of a particle size of 5-8 mesh may be 70 weight% or more is used as a 2nd cork grain.
This mixing ratio is a mixing ratio that the inventors have reached through various trials, and the mixing ratio of the first cork grains and the second cork grains is 1.5 to 2.5: 1 by weight. In this case, the flooring can be made excellent in moderate cushioning properties and cork-specific design properties (design properties resulting from cork grain spacing).
When the blending ratio of the first cork grains is larger than the weight ratio 2.5: 1, the flooring material becomes hard and the cushioning property tends to be poor, and the elasticity of the virgin cork grains cannot be utilized. Further, since the number of particles having a small particle size increases, for example, the density distribution between the upper side and the lower side is different with respect to the thickness at the time of extrusion molding, and the density variation as a whole tends to increase.
On the other hand, if the blending ratio of the first cork grains is smaller than 1.5: 1 by weight, the gaps between the cork grains become large and the density tends to be low, and there is a tendency for water leakage. In addition, as the mixing ratio of the second cork grains increases in production, the pressure during extrusion molding tends to increase, and the cork grains may expand and burst due to the pressing.
In addition, the mesh metal mesh sieve according to JISZ8801 is used for the sizing of the cork grains, and the mesh here refers to the fineness of the sieve mesh converted to a mesh. The mesh is a unit representing the fineness of the wire mesh, and represents the fineness of the mesh per inch (see FIGS. 3 and 5). Therefore, as the numerical value of the mesh increases, it can be said that the cork grain passes through a finer screen, so the particle diameter of the cork grain becomes smaller. Further, the smaller the numerical value of the mesh, the more cork grains that pass through the coarse sieve, the larger the grain diameter of the cork grains.

The table shown in FIG. 3 summarizes the particle size distribution of the first cork grains and the second cork grains.
As can be seen from FIG. 3, the first cork grain is 85 to 100% by weight of virgin cork grain sized to 8 to 14 mesh, and 5 to less than 6 mesh is 0 to 15 weight. %, 14 mesh or more and 16 mesh or less is 0 to 10% by weight, and 16 mesh or more is 0 to 5% by weight. Moreover, what was made into the 2nd cork grain is 70-100 weight% of the virgin cork grain sized to the particle size of 5-8 mesh, 0-30 weight%, 10 mesh or more are 8 mesh or more and 10 mesh or less. It is sized so as to have a particle size distribution of 0 to 5% by weight.
Then, a binder resin mainly composed of an epoxy resin adhesive or a urethane resin adhesive is kneaded with a mixture of the first cork grains and the second cork grains prepared in a predetermined mixing ratio, and then extruded, compressed and molded. The upper layer 1 is obtained by fixing and obtaining a block body having a predetermined size and slicing it to a predetermined thickness. The manufacturing method will be described in detail later.

Next, the lower layer 2 of the cork floor material A will be described with reference to FIGS. 4 and 5.
Recycled cork grains are used for the granular cork material used for forming the lower layer 2, and the lower layer 2 is formed so that its density is 0.30 to 0.35 g / cm ³ (see FIG. 4). . Regenerated cork grains are crushed cork products. In other words, it is a crushed cork product that has been fixed with an adhesive and the surface is coated, etc., so that adhesive or paint is mixed in the crushed grains and compressed during molding. Since most of them have less force to swell than the virgin cork grains described above, there is an advantage that extrusion molding is easy.
In addition, the granular cork material used for the lower layer 2 is not limited to the recycled cork grain, but when the recycled cork grain is used, it can be a product in consideration of environmental problems and resource saving. Even if virgin cork grains having a high cost are used for 1, the increase in cost of the entire flooring material can be suppressed.
The table in FIG. 5 is a result of examining the particle size distribution of an example of the lower layer 2, and as shown here, the regenerated cork particles used in the lower layer 2 are 80% by weight or more of regenerated cork particles having a particle size of 6 to 10 mesh. It is sized to contain. Then, a binder resin mainly composed of an epoxy resin adhesive or a urethane resin adhesive is kneaded, extruded, compressed, molded and fixed to obtain a block body having a predetermined size, and this is made into a predetermined thickness. The sliced material is the lower layer 2. The manufacturing method will be described next.
In addition, the particle size distribution of the lower layer 2 is not limited to the numerical value of FIG. 5, and the regenerated cork particles having a particle size of 6 to 10 mesh may be 80 to 100% by weight. It is possible to reinforce the lower surface (rear surface) of the lower layer 2 of the cork flooring A with a nonwoven fabric or the like and to use the above-described flooring type. For example, a non-woven fabric made of polyester having a thickness of 0.4 t can be used, and the lower surface of the lower layer 2 can be reinforced with the non-woven fabric to prevent warping.

An example of a specific method for manufacturing the cork flooring A will be described below with reference to the flowchart of FIG.
First, an upper layer plate that is the upper layer 1 is prepared.
As described above, virgin cork granules that have been sized and have a predetermined blending ratio are blended with a binder resin such as an epoxy resin adhesive, a curing agent, and wax, and then kneaded and extruded. At this time, by slowly pressing at a speed 1.5 times slower than usual, a virgin cork grain having a strong force to swell can be strongly compressed and no gap can be produced between the cork grains. .
Thus, it compresses, extruding, and forms so that the density of a block body may be 0.37-0.43g / cm < ³ >. Then, the block body is cut into a predetermined size and cracked to obtain an upper layer plate.

Next, a lower layer plate-like body to be the lower layer 2 is produced.
The regenerated cork granules sized as described above are blended with a binder resin such as an epoxy resin adhesive, a curing agent, and wax and extruded. Here, since the force which tries to swell as virgin cork grains does not work, it is compressed while being extruded at a normal speed to form a block body having a density of 0.30 to 0.35 g / cm ³ . Then, the block body is cut into a predetermined size and cracked to obtain a lower plate member.
In addition, although the process of grind | polishing the slice surface of a block body is not demonstrated here when forming the upper layer plate-shaped body and the lower layer plate-shaped body, for example, plate thickness is 7t or 12t from a block body. Needless to say, if the surface state of the slice surface varies when it is split into thick plate-like bodies, polishing may be performed.

The upper layer plate and the lower layer plate obtained above are appropriately overlapped with an adhesive, inserted into a press machine, and both plate members are pressure-bonded to obtain a laminate. Then, both surfaces of the laminate are polished, and a urethane paint (clear paint) having fading, water resistance, ammonia resistance, high chemical resistance, etc. is applied to the surface, and the laminate is fixed in size (for example, 7 t × 910 × 1820 mm, 12t × 910 × 1820 mm, etc.) to obtain a cork floor material A as shown in FIG.
According to this, unlike the manufacturing method by block molding that is manufactured using a mold, a cork flooring material A having a high-density upper layer 1 that is clogged so that water does not permeate is obtained. be able to. Moreover, since the cork flooring A having such a large size can be obtained, if the floor is a small space such as a toilet, the flooring can be composed of a single piece of seamless material, such as water or urine from the joint. It can be assumed that there is no risk of intrusion.

  Here, in order to use a seamless flooring, the long and large cork flooring A has been described. However, the size and the like are not limited to those described above, and a plurality of cork flooring is combined to be adjacent to each other. It is applicable also to what butt | matches and fits each. Therefore, it is good also as what applies a tongue process to the edge part of the cork flooring A. FIG. Further, the overall shape of the cork flooring A is not limited to the rectangular shape as shown in the figure, and does not exclude squares, regular hexagons, and other shapes. Furthermore, it goes without saying that the floor substrate on which the cork flooring A of the present invention is applied is not limited to a concrete slab but may be other floor substrates such as plywood.

A Cork flooring 1 Upper layer 2 Lower layer

Claims (3)

Both are cork floor materials in which the upper layer and the lower layer, which are produced by fixing and extruding the granular cork material with a binder resin, are integrated,
The granular cork material used for forming the upper layer is virgin cork granules obtained by pulverizing raw natural cork, the upper layer has a density of 0.37 to 0.43 g / cm ³ , and the lower layer has a density of 0.30. Cork flooring characterized in that it is ˜0.35 g / cm ³ . In the cork flooring according to claim 1,
The virgin cork grain is composed of a mixture of two kinds of cork grains, a first cork grain and a second cork grain, and the first cork grain is sized so as to contain 85% by weight or more of cork grains having a particle size of 8 to 14 mesh. The second cork grains are sized so as to contain 70% by weight or more of cork grains having a particle size of 5 to 8 mesh, and the mixing ratio of the first cork grains and the second cork grains Cork flooring characterized in that the weight ratio is 1.5 to 2.5: 1. In the cork flooring according to claim 1 or 2,
The granular cork material used for forming the lower layer is a regenerated cork grain obtained by pulverizing a cork processed product, and the regenerated cork grain is sized so as to contain 80% by weight or more of a cork grain having a particle size of 6 to 10 mesh. Cork flooring characterized by being.

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