JP2011025563A - Method for manufacturing composite base material for floor board, and method for manufacturing surface makeup flooring using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a composite base material 5 for a surface makeup flooring obtained by laminating a half-cut wooden fiber board 1a with optional thickness on one face of a top board 2, using a relatively thicker wooden fiber board 1 as it is which is a commercially available product and can be easily obtained. <P>SOLUTION: The base plates 2, 2 are affixed to both faces of the wooden fiber board 1 which is a commercially available product. The wooden fiber board 1 affixed between the base plates 2, 2 is bisected in a thickness direction after affixing. According to this manufacturing method, manufacturing is easier and manufacturing cost can be reduced comparing to a conventional method using a thin wooden fiber board half cut in advance. Further, the damage of the wooden fiber board with half-cutting is reduced and thus the product yield is raised. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for producing a composite substrate for floorboard and a method for producing a surface decorative floor material using the composite substrate for floorboard produced by the method.

  Surface decorative flooring materials in which a decorative layer made of a veneer or decorative paper is laminated on the surface of a base plate are known, and are widely used as ordinary flooring materials or flooring materials for floor heating. As a base plate, many things, such as a plywood board, OSB, and a particle board, are used.

  In recent years, flooring materials such as those described above have a performance that is difficult to be dented and scratched even when a repeated load is applied, for example, by a chair with casters or a heavy object falls, according to the lifestyle. There is a need for a product with it. In the case of a surface decorative floor material in which a decorative veneer is directly bonded to the surface of the base plate, the surface hardness is not sufficient and the target performance value cannot be obtained. A composite base material is formed by laminating various wood fiber boards, and a decorative veneer is attached to the surface of the wood fiber board in the composite base material, thereby ensuring the impact resistance and dent resistance of the surface decorative flooring material. Things have been done.

  Generally, a wood fiber board like MDF has a large dimensional change rate with respect to a temperature change. When the surface decorative flooring produced using the above-mentioned composite base material is used as a flooring for floor heating in particular, if the thickness of the wood fiber board is large, a dimensional change that cannot be ignored may occur. Therefore, when the purpose of use is for floor heating, it is common to use MDF having a thickness of about 1.0 mm. However, since it is difficult to manufacture a thin MDF having a thickness of about 1.0 mm, the MDF having a thickness of about 2.5 to 5.0 mm, which is easy to manufacture, is divided into two in the thickness direction, for example, 1.0 mm. It has been proposed to use an MDF that is bonded to a base plate after being ground to a predetermined thickness (see, for example, Patent Document 1).

  Therefore, a method and an apparatus for dividing a wood fiber board such as MDF into two in the thickness direction have been proposed in Patent Document 2 or 3 and put into practical use. In the case of a wood fiber board such as MDF, on the front and back surfaces, there is a high density layer having a density of 0.9 to 1.0 called a rock layer, but the average density of the central portion in the thickness direction is 0.7 to Generally, it is a little lower at 0.8. Therefore, when dividing in the thickness direction, it is half-cut by a dividing blade aiming at a low-density layer (division into two), but in the half-cut wood fiber board, a difference in density occurs between the front and back surfaces, It is inevitable that the balance will be lost and the curl phenomenon will occur.

  Therefore, in the apparatus described in Patent Document 2 or 3 described above, in order to prevent the wood fiber board to be divided from being deformed or broken due to the division, the division treatment is performed by previously softening the material by heat treatment or water absorption treatment. Special equipment, such as making a lot of fine holes in the material with a “piercing body” provided on the feed roll, and dividing while correcting the curl phenomenon due to the collapse of the internal stress balance of the divided material The advanced cutting method by is adopted.

JP-A-10-286805 JP-A-9-272106 JP 2004-243660 A

  As described above, a so-called half-cut wood fiberboard, which is currently used to manufacture the composite base material and is divided into two in the thickness direction, is formed by a “piercing body” at the time of division. It has a large number of holes (hereinafter referred to as gang holes). For this reason, when the half-cut wood fiber board is bonded to the base plate using an adhesive, the adhesive is ejected from the escape hole, and the composite base materials after manufacture are bonded to each other. There was a case. In addition, the thin wood fiber board that has been thinned in half is easy to chip, and careful handling is required to prevent damage during handling, and the work of attaching to the base plate also requires sufficient care. .

  The present invention has been made in view of the circumstances as described above, and can easily produce a composite base material for floor boards in which a wood fiber board is laminated on one surface of a base plate. It is a first object of the present invention to disclose a method for manufacturing a composite base material for floor board, which can avoid the co-attachment of the composite base material for floor board. Moreover, it is set as the 2nd subject to disclose the manufacturing method of the surface decorative flooring using the composite base material for floorboards manufactured with the manufacturing method.

  According to the present invention, there is provided a method for producing a composite substrate for floor board in which a wood fiber board is laminated on one surface of a base plate, a bonding step of attaching the base plate to both surfaces of the wood fiber board, and a bonding between the base plates. And a dividing step of dividing the combined wood fiber board into two in the thickness direction.

  In the method for producing a composite material for floor board according to the present invention, a thick wood fiber board is used as it is instead of pasting a half-cut wood fiber board that has been divided into two in the thickness direction in advance into the base board, and the base board is provided on both sides After that, by dividing the wood fiber board portion into two in the thickness direction, two composite boards for floor boards in which a thin wood fiber board is laminated on one surface of the base plate are obtained at the same time To.

  According to this manufacturing method, since the wood fiber board is already bonded to the base plate when the wood fiber board is divided, the curling phenomenon due to the division does not occur as in the prior art. In addition, half-cutting is possible without drilling holes. Furthermore, since the half-cut wood fiberboard is in an integrated state with the base plate, damage to the wood fiberboard during handling can be reduced as much as possible. Since it is not necessary to attach the wood fiber board, which has been thinned in half, to the base plate, the entire manufacturing process becomes very easy.

  The method for producing a composite substrate for floor board according to the present invention preferably further includes a grinding step of adjusting the thickness of the divided wood fiber board by grinding the split surface of the wood fiber board after the splitting process. By performing this grinding step, it is possible to smooth the divided surface simultaneously with the adjustment of the thickness, and the surface decorative material such as the decorative veneer can be bonded well. The grinding method is arbitrary and is not limited, but as an example, a surface grinding process using a wide belt sander or the like is exemplified.

  In the method for producing a composite material for floor board according to the present invention, a wood fiber board to which the base plate is bonded can be of any thickness, but is easily available and can be easily divided into two parts. Therefore, it is preferable to use a wood fiber board having a thickness of about 2 to 3 mm.

  In the method for producing a composite material for floor board according to the present invention, the wood fiber board used can be exemplified by MDF, HDF, etc., but the impact resistance and dent resistance of the surface decorative floor material produced using the composite board material for floor board are exemplified. From the viewpoint of ensuring the security, MDF is most suitable. Moreover, there is no restriction | limiting in particular in the base plate to be used, A plywood, OSB, a block board, a laminated material, a particle board etc. can be used suitably. Its thickness is also arbitrary. Of these, plywood and particle board are particularly preferable from the viewpoint of easy availability and ease of processing.

  In the method for producing a composite substrate for floor board according to the present invention, the adhesive used for bonding the wood fiber board and the base board is not particularly limited, and vinyl acetate adhesive, acrylic adhesive, urethane adhesive, urea resin Adhesives used for laminating conventional composite base materials such as system adhesives may be used as they are.

  The method for producing a surface decorative flooring according to the present invention includes at least a step of forming a decorative layer on the divided surface side of the half-cut wood fiber board in the composite base material for floorboard produced by any one of the production methods described above. The material for forming the decorative layer may be arbitrary, and examples thereof include a decorative veneer and a decorative printing sheet. It may be a surface decorative layer by coating. From the viewpoint of the quality of the surface decorative flooring material, it is most preferable to stick a decorative veneer.

  According to the present invention, a relatively thick wooden fiberboard that is a commercial product and can be easily obtained is used as it is, and a wooden fiberboard having an arbitrary thickness is laminated on one surface of a base plate. The composite substrate can be obtained. Therefore, compared with the conventional method using a thin wood fiber board that has been preliminarily cut in half, the production is easy and the production cost can be reduced. Furthermore, since the damage of the wood fiber board accompanying a half cut is also reduced, the improvement of a product yield can also be anticipated.

The schematic diagram explaining the manufacturing method of the composite base material for floor boards by this invention in order of a process. The schematic diagram explaining the manufacturing method of the surface decorative flooring by this invention.

  Hereinafter, the present invention will be described based on embodiments. FIG. 1 is a schematic diagram for explaining an embodiment of a method for producing a composite base material for floor board according to the present invention in the order of steps.

  In FIG. 1, 1 is a commercially available MDF having a thickness of about 2 to 3 mm, for example, and is an example of the “wood fiberboard” in the present invention. First, as shown in FIG. 1A, the base plates 2 and 2 are arranged on both sides of the MDF 1, and next, as shown in FIG. 1B, using an appropriate adhesive, The base plates 2 and 2 are bonded and integrated on both surfaces to form a laminate 3. The base plate 2 to be used may be a plywood such as a lauan plywood or a particle board. The thickness of the base plate 2 may be the same as the thickness of the composite base material in the surface decorative floor material 10 (see FIG. 2) to be manufactured, or may be thinner. In the latter case, after making a composite substrate for a floor board, a plywood or particle board of a necessary thickness is bonded and laminated to the base plate 2 to have a required thickness. The two base plates 2 and 2 may have the same thickness or different thicknesses.

  After the adhesive is cured, as shown in FIG. 1C, the region of the MDF 1 in the laminate 3 is divided into two at appropriate positions in the thickness direction using the dividing blade 4. Thereby, as shown in FIG.1 (d), the two base materials 5 and 5 for floor boards are manufactured from the one laminated body 3. FIG. Each composite base material 5 for floor boards is equipped with the base plate 2 and the structure by which the half-cut MDF1a with thin thickness which MDF1 was divided | segmented into 2 was bonded on the one surface. The position in the thickness direction of the MDF 1 divided by the dividing blade 4 may be the center position in the thickness direction, or may be a position shifted to one side.

  If necessary, the divided surface of the half-cut MDF 1a is ground by means such as a wide belt sander to smooth the surface. Further, if necessary, grinding is continued until the thickness of the half-cut MDF 1a reaches a specified thickness. Thereby, the composite base material 5 for floor boards bonded by the attitude | position which orient | assigned the bedrock layer side of half-cut MDF1a of required thickness (for example, 0.5 mm thickness) to the baseplate 2 is completed.

  As shown in FIG. 2A, for example, a decorative veneer 6 as a decorative layer is disposed on the half-cut MDF 1a side of the composite base material 5 for floor board manufactured as described above, and if necessary, a base plate The moisture-proof sheet or balance sheet 7 is disposed on the back side of the sheet 2 and bonded together using an adhesive, thereby producing the surface decorative flooring 10 according to the present invention as shown in FIG. Is done. When the manufactured surface decorative flooring 10 is used as a sound insulation surface decorative flooring for direct tension, on the back side of the base plate 2, although not shown, a heat insulating sheet such as a buffer sheet such as a nonwoven fabric or a synthetic resin foam is used. Sheets are laminated. Or the sheet | seat of 2 layers lamination | stacking of a buffer sheet and a heat insulation sheet is laminated | stacked.

Hereinafter, the present invention will be described with reference to examples.
[Example 1]
MDF (2.7 mm x 945 mm x 1840 mm) coated with vinyl acetate adhesive on both sides is placed on a base plate (11.5 mm x 945 mm x 1840 mm Lauan plywood), and the same base plate is further laminated thereon. Cold-pressed with a cold press. The pressure during cold pressing was 10 kgf / cm ² and the pressing time was 50 minutes. The composite was divided into two parts by applying a split blade to the central part in the thickness direction on the short side (945 mm side) of the composite of plywood-MDF-plywood and advancing the composite in the longitudinal direction (1840 mm direction).

  The MDF surface was ground with a wide belt sander with the MDF surface of the divided plywood-half-cut MDF composite as the upper surface. For grinding, # 80 sandpaper was used for a two-head iron roll, and the grinding amount was 0.75 to 0.80 mm. The MDF composite base material for floor boards of 12.0mmx945mmx1840mm size (MDF layer thickness 0.5mm) was obtained in the above process.

[Example 2]
MDF (2.7 mm x 945 mm x 1840 mm) coated with vinyl acetate adhesive on both sides is placed on a base plate (15 mm x 945 mm x 1840 mm particle board). Cold pressed with a press. The pressure during cold pressing was 10 kgf / cm ² and the pressing time was 50 minutes. The composite is divided into two parts by applying a split blade to the central part in the thickness direction on the short side (945 mm side) of the particle board-MDF-particle board composite, and advancing the composite in the long direction (1840 mm direction). did.

  The MDF surface was ground with a wide belt sander in a state where the MDF surface of the divided particle board-half-cut MDF composite was the upper surface. For grinding, # 80 sandpaper was used for a two-head iron roll, and the grinding amount was 0.75 to 0.80 mm. The MDF composite base material for floor boards of a 15.5mmx945mmx1840mm size (MDF layer thickness 0.5mm) was obtained in the above process.

1 ... MDF (an example of “wood fiberboard” in the present invention),
1a ... Senior MDF
2 ... base plate,
3 ... Laminate of base plate-MDF-base plate,
4 ... split blade,
5 ... Composite substrate for floorboard (base plate-half-cut MDF),
6 ... Veneer for makeup,
7 ... Dampproof sheet or balance sheet,
10: Surface decorative flooring.

Claims (6)

  A method for producing a composite base material for floor boards in which a wood fiber board is laminated on one surface of a base plate, wherein the base plate is attached between both sides of the wood fiber board and the base plate. And a splitting step of splitting the wood fiber board into two in the thickness direction.   The manufacturing method of the composite base material for floor boards of Claim 1 which further includes the grinding process which adjusts the thickness of the divided | segmented wood fiber board by grinding the division | segmentation surface of a wood fiber board after a division | segmentation process.   The method for producing a composite substrate for floorboard according to claim 1 or 2, wherein the wood fiberboard is MDF.   The manufacturing method of the composite base material for floor boards as described in any one of Claim 1 thru | or 3 whose base plate is a plywood or a particle board.   A method for producing a surface decorative flooring, comprising at least a step of forming a decorative layer on the divided surface side of the wood fiber board in the composite base material for floorboard produced by the production method according to any one of claims 1 to 4.   The method for producing a surface decorative flooring according to claim 5, wherein the decorative layer is a decorative veneer.

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