JP2012041675A - Floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material which has an impact absorption characteristic to reduce an impact from the floor that is received by a falling person and prevents excessive sinking in walking without impairing walking feel and generating unevenness.SOLUTION: A floor material comprises a first base material 2, a first cushioning material 3, a second base material 4, and the second cushioning material 5 which are laminated in this order from a surface side. The first cushioning material is made of an independent foam body and has a thickness of 0.5 to 2.5 mm, and the second cushioning material has a thickness of 3.0 to 5.0 mm. Preferably the first base material has a thickness of 0.5 to 1.5 mm and an Asker C hardness of 20 to 70 degrees (more preferably 35 to 60 degrees), and the second cushioning material has an Asker C hardness of 20 to 70 degrees (more preferably 25 to 45 degrees). The floor material has a maximum acceleration of less than 100 G that is measured by a method according to JIS A 6519 and has an excellent impact absorption characteristic. A surface of the first base material and a substance at a cut end of the second base material are not damaged even when the floor material is subject to an impact.

Description

  The present invention relates to a flooring, and more particularly to a flooring excellent in shock absorbing performance.

  There are frequent accidents in which injuries are caused by the impact of flooring when an elderly person or a disabled person falls in the room where the flooring is laid, and there are many cases of serious injury such as broken bones. For this reason, it is desired to develop a flooring material having a function of reducing the impact from the flooring material when it falls, that is, a shock absorbing performance. According to a report from the Architectural Institute of Japan Floor Work WG, if the value of the maximum acceleration (G value) measured by the measuring method of JIS A6519 is 100G or less, when a human falls and hits his head etc. on the floor Even if there is, it is said that it is hard to suffer injury.

  Against this background, Patent Document 1 discloses a shock absorbing performance with a maximum acceleration of 80 G or less according to the above measurement by laminating an impact absorbing material having an Asker C hardness of 70 degrees or less and a thickness of 2 mm or more on the back surface of the surface material. It is described that a wooden flooring having the following can be obtained.

JP 2010-47979 A

  In the wooden flooring described in Patent Document 1, plywood or wood fiber board having a thickness of about 2 to 13 mm is used as the surface material (2 mm and 4 mm thick plywood in the embodiment), and the thickness is used as the shock absorbing material. Synthetic resin foams or rubber foams of 2 mm or more are supposed to be used. However, a certain amount of thickness is required for the impact absorbing material to exhibit the desired impact absorbing performance, and the flooring material as a whole. Tended to be thick.

  In addition, it is generally performed that floor materials are formed with male seeds at the end of two adjacent sides and female ends at the other end of the two ends, and the flooring is connected to each other through the fitting between the fruits. However, since a fruit cannot be formed on a shock absorber made of a soft synthetic resin foam or rubber foam, the back surface of the shock absorber as described in claim 2 of the patent document 1 and the examples. Further, it is necessary to provide a back material such as a 4 mm thick plywood on the side to form fruit on the back material, and the overall thickness of the floor material has become large.

  For this reason, a step is created between a room where a thick flooring material having shock absorption performance is constructed and a room where a thin flooring material without impact absorption performance is constructed, and a new level such as a fall over the level difference is created. There was a risk of problems. Although it is possible to eliminate the step by providing a height adjusting material such as joists or plywood on the back surface of the floor material, it is not preferable because it requires extra work and cost.

  In addition, it is possible to reduce the step by making the surface material thinner for floor materials with shock absorption performance, or thicker surface material for floor materials that do not have shock absorption performance. However, in the former case, the thin surface material is bent and easily broken and the durability is lowered. In the latter case, the use of the thick surface material increases the cost. Furthermore, since the amount of deflection when receiving a load varies depending on the thickness of the surface material, this may cause actual breakage.

  In addition, when the shock absorbing material is thick, the shock absorbing performance is improved, but when the person walks, the shock absorbing material sinks more and the walking feeling becomes worse. In addition, there is a step between the floor material that receives the load of the person walking and the floor material that does not receive the load adjacent to it, which may cause tripping during walking or the adjacent floor material that appears due to the step. There is a risk that an object may collide with the side end and damage the flooring.

  In order to reduce the sinking amount due to the thickness of the shock absorber, methods such as reducing the thickness of the shock absorber or increasing the hardness of the shock absorber can be considered. This is actually a difficult method to adopt.

  Accordingly, the problem to be solved by the present invention is that a floor material having a shock absorbing performance that reduces the impact received from the floor when a person falls down is a step difference in floor construction height with a room that does not require the shock absorbing performance. And a novel structure for preventing a decrease in walking feeling and generation of a step by preventing excessive sinking during walking.

  In order to solve this problem, the present invention according to claim 1 is formed by sequentially laminating a first base material, a first buffer material, a second base material, and a second buffer material from the surface side. It is a flooring material, the first buffer material is made of closed-cell foam and has a thickness of 0.5 to 2.5 mm, and the second buffer material has a thickness of 3.0 to 5 0.0 mm.

  According to a second aspect of the present invention, in the flooring according to the first aspect, the Asker C hardness of the first shock absorbing material and the second shock absorbing material is 20 to 70 degrees.

  The present invention provides a closed cell foam as a first buffer material in a flooring material having a laminated structure of a first base material / first buffer material / second base material / second buffer material. Since the body is used, even if the adhesive applied to the front and back surfaces of the first buffer material is bonded to the first base material and the second base material, It does not penetrate into the material and harden. That is, since the adhesive is cured only in a state where it adheres and penetrates substantially only on the front and back surfaces and the vicinity thereof, the thickness and hardness of the first cushioning material are substantially maintained, While improving the accuracy of thickness and hardness, the expected shock absorbing performance as the first buffer material is not lowered.

  Moreover, by making the thickness of the first buffer material 0.5 to 2.5 mm, the impact performance is ensured, and even if the first base material is bent when subjected to the impact, Since the maximum sinking amount can be suppressed to less than 2.5 mm, cracking of the first base material can be prevented. In addition, by setting the thickness of the second cushioning material to 3.0 to 5.0 mm, the shock absorbing performance is secured, and a step is generated in the floor construction height with the room that does not require the shock absorbing performance. It is possible to prevent the deterioration of walking feeling caused by excessive subsidence.

  Furthermore, by setting the Asker C hardness of the first cushioning material and the second cushioning material to 20 to 70 degrees, the G value received when the person falls can be reduced to 100 G or less, so that the person falls. Injury can be effectively prevented even when the head is hit against the floor.

It is sectional drawing which shows the structure of the flooring by this invention.

  First, the structure of the flooring according to the present invention will be described with reference to FIG. As shown in FIG. 1, the flooring 1 according to the present invention has a laminated structure of a first base material 2 / first buffer material 3 / second base material 4 / second buffer material 5 from the surface side.

  The first base material 2 is made of, for example, a wood fiber board such as MDF or HDF, a wood board such as a plywood, a solid board, a laminated board or a laminated board. A decorative sheet such as a resin sheet is attached. Moreover, arbitrary coating can be given to the surface of the 1st base material 2, or the surface of the decorative sheet stuck on this surface. The coating is preferably performed using an anti-slip paint having anti-slip performance.

  The thickness of the first base material 2 is preferably 0.5 to 1.5 mm. If the thickness is less than 0.5 mm, the surface strength is weak, and damage or dents are likely to occur upon impact. If it is thicker than 1.5 mm, the shock absorbing performance of the first cushioning material 3 laminated on the back surface is impaired.

  Examples of the first buffer material 3 include synthetic resin foams such as ethylene vinyl acetate copolymer (EVA), polyethylene (PE), and vinyl chloride (PVC), and rubber foams such as synthetic rubber and natural rubber. Use a closed-cell type. When the first base material is pressure-bonded to the first base material and the second base material in the manufacturing process of the flooring 1, the adhesive is compressed in a state of penetrating into the first buffer material 3. And the thickness and hardness of the first cushioning material will change greatly, and the accuracy of the thickness and hardness of the entire flooring material will be impaired, and the impact absorption performance by the first cushioning material will be greatly reduced, By using the closed-cell foam as the material 3, the thickness and hardness of the first buffer material are substantially maintained, and the accuracy of the flooring material and the expected shock absorbing performance by the first buffer material are not impaired.

  The thickness of the first buffer material 3 is 0.5 to 2.5 mm. If the thickness is less than 0.5 mm, the impact absorption performance becomes insufficient, and it becomes difficult to obtain a value of 100 G or less in the floor hardness test. When it becomes thicker than 2.5 mm, the first base material 2 will bend deeply when the first base material 2 receives an impact, and the first base material 2 is easily cracked.

  The expansion ratio of the closed cell foam used as the first buffer material 3 is preferably about 5 to 30 times. If the expansion ratio exceeds 30 times, it becomes too soft, and the sinking when receiving a load becomes large, giving an uncomfortable feeling during walking. In addition, when a person falls, the impact received from the first base material 2 cannot be sufficiently buffered, and there is a risk that the head of the person who has fallen or the like will be strongly struck against the lower second base material 4. On the other hand, if the expansion ratio is less than 5 times, it becomes too hard and the impact absorbing performance is lowered. From these factors, the expansion ratio of the first buffer material 3 is preferably 5 to 30 times, more preferably 8 to 15 times.

  The closed cell foam used as the first buffer material 3 preferably has an Asker C hardness of 20 to 70 degrees. When the Asker C hardness is less than 20 degrees, the sinking when receiving a load is increased, and uncomfortable feeling is given during walking. In addition, when a person falls, the impact received from the first base material 2 cannot be sufficiently buffered, and there is a risk that the head of the person who has fallen or the like will be strongly struck against the lower second base material 4. On the other hand, if the Asker C hardness is greater than 70 degrees, it becomes too hard as a cushioning material, and the impact absorbing function cannot be sufficiently exhibited. From these factors, the Asker C hardness range of the first buffer material 3 is preferably 20 to 70 degrees, and more preferably 35 to 60 degrees.

  The second base material 4 is made of a wood material such as a wood fiber board such as MDF and HDF, a plywood, a solid material, a laminated board, and a laminated material, similarly to the first base material 2.

  The second base material 4 needs to have a large thickness so that the fruit (male, female) that fits with the floor material adjacent to the second base material 4 is formed on the quadruple front end. The thickness is 0 mm. If the thickness is less than 5.0 mm, it is difficult to form fruit in this thickness range. When it becomes thicker than 10.0 mm, the thickness of the entire flooring material becomes too large, and a level difference is likely to occur in the floor construction height with a room that does not require shock absorbing performance.

  The second buffer material 5 is, for example, a synthetic resin foam such as polyurethane (PU), ethylene vinyl acetate copolymer (EVA), polyethylene (PE), vinyl chloride (PVC), or rubber foam such as synthetic rubber or natural rubber. It may be a closed-cell foam or an open-cell foam. Moreover, it is preferable that a waterproof or moisture-proof sheet is attached to the back surface of the second cushioning material 5.

  The thickness of the second buffer material 5 is 3.0 to 5.0 mm. If this thickness is less than 3.0 mm, the impact absorbing performance becomes insufficient, and it becomes difficult to obtain a value of 100 G or less in the floor hardness test. When it becomes thicker than 5.0 mm, the thickness of the entire flooring material becomes too large, and a level difference is likely to occur in the floor construction height with the room that does not require the shock absorbing performance. Moreover, it is too soft and the sinking at the time of a walk becomes large, and uncomfortable feeling is given.

  It is preferable that the foaming ratio of the foam used as the second buffer material 5 is about 5 to 30 times. If the expansion ratio exceeds 30 times, it becomes too soft, and the sinking when receiving a load becomes large, giving an uncomfortable feeling during walking. Moreover, since the 2nd buffer material 5 is affixed on the back surface of the 2nd base material 4 in which a fruit is formed, when the 2nd base material 4 sinks, the fruit fitted with the adjacent flooring will be damaged. There is a risk. On the other hand, if the expansion ratio is less than 5 times, it becomes too hard and the impact absorbing performance is lowered. From these factors, the expansion ratio of the second buffer material 5 is preferably 5 to 30 times, more preferably 15 to 25 times.

  The second cushioning material 5 preferably has an Asker C hardness of 20 to 70 degrees. If the Asker C hardness of the second cushioning material 5 is less than 20 degrees, it will be too soft and the sinking during walking will become large, giving an uncomfortable feeling. Moreover, since the 2nd buffer material 5 is affixed on the back surface of the 2nd base material 4 in which a fruit is formed, when the 2nd base material 4 sinks, the fruit fitted with the adjacent flooring will be damaged. There is a risk. On the other hand, if the Asker C hardness is larger than 70 degrees, it becomes too hard as a buffer material and cannot sufficiently exhibit the impact absorbing function. From these factors, the Asker C hardness range of the first buffer material 3 is preferably 20 to 70 degrees, more preferably 25 to 45 degrees.

  Hereinafter, the configuration and operational effects of the present invention will be more specifically demonstrated by describing examples of the present invention in comparison with comparative examples. In addition, this invention is not limited to the following Example, It cannot be overemphasized that various deformation | transformation and change are accept | permitted within the range of the invention defined by description of a claim.

  In the flooring 1 having the laminated structure of the first base material 2 / first buffer material 3 / second base material 4 / second buffer material 5 shown in FIG. 1, as shown in Tables 1 to 5 for each layer, Various flooring samples were obtained by varying the thickness and the buffer material hardness, and connected to the floor substrate through fitting between the real pieces. Then, for each flooring sample, the maximum acceleration is measured by the measuring method of JIS A6519 to evaluate the impact absorption performance, and whether or not the surface of the first base material 2 is damaged when receiving an impact is visually confirmed. Further, after the impact test, the flooring material sample was peeled off to visually check whether the fruit was damaged. These evaluations are also shown in Tables 1 to 3. Floor material samples a-2 to a-4 in Table 1, floor material samples b-3 to b-5 in Table 2, floor material samples c-3 to c-5 in Table 3, and floors in Table 4 The material samples d-2 to d-6 and the floor material samples e-2 to e-6 in Table 5 are examples of the present invention, and these all have a G value of 100 G or less and have sufficient impact absorbing performance. It was confirmed that the surface of the first base material was not damaged even when subjected to an impact, and the fruit formed on the end of the second base material was not damaged. In addition, although different sample numbers are attached | subjected to each table | surface, flooring material sample a-2, b-4, c-4, d-3, e-2 is the same Example of this invention.

  Explaining in more detail, Table 1 shows the thickness of the first base material in the flooring material having the laminated structure of the first base material / first buffer material / second base material / second buffer material in the range of 0.5 to 1. In the range of 5 mm, the floor material samples a-1 to a-3 were prepared under the same conditions for the first buffer material, the second base material, and the second buffer material, and the thickness of the first base material The data and results of the tests conducted to confirm the effects of are shown. As can be seen from the results shown here, the samples a-1 to a-3 in which the thickness of the first base material is 0.5 to 1.5 mm are all excellent in impact absorption performance with a G value of 100 G or less, Even when subjected to an impact, the surface and the fruit of the first base material were not damaged, and the durability was excellent. On the other hand, when the same test was performed on samples having a thickness of the first substrate of less than 0.5 mm and more than 1.5 mm, the former had no problem in impact absorption performance, but when subjected to an impact. The surface of the first base material may be damaged, and the latter has reduced impact absorption performance. From this result, it is preferable that the first substrate 2 has a thickness of 0.5 to 1.5 mm in order to prevent damage to the first substrate due to impact while exhibiting sufficient shock absorbing performance. confirmed.

  Table 2 shows a flooring material having the same laminated structure, and the thickness of the first cushioning material is changed in five ways in the range of 0 (that is, no first cushioning material) to 3.6 mm. For flooring materials and second cushioning materials, floor samples b-1 to b-6 were prepared under the same conditions, and the data and results of tests conducted to confirm the influence of the presence and thickness of the first cushioning material were used. Show. As can be seen from the results shown here, the samples b-3 to b-5 having the first buffer material having a thickness of 0.8 to 2.4 mm all have a G value of 100 G or less and excellent shock absorption performance. Although the surface and the fruit of the first base material were not damaged even when receiving, the first buffer material was omitted and the three-layer laminated structure of the first base material / second base material / second buffer material Sample b-1 and sample b-2 having a first buffer material having a thickness of 0.3 mm both had G values exceeding 100 G, and were not able to fully exhibit impact absorbing performance. Sample b-6 having a first buffer material having a thickness of 3.6 mm was sufficiently excellent in impact absorption performance, but the surface of the first base material was damaged by the impact. From this result, in order to prevent damage to the first base material due to impact while exhibiting sufficient shock absorbing performance, the first cushioning material is essential, and the thickness is 0.5 to 2.5 mm. It was confirmed that it should be within the range.

  Table 3 shows that in the floor material having the same laminated structure, the thickness of the second buffer material is changed in five ways in the range of 0 (that is, no second buffer material) to 8.0 mm, and the first base material and the first buffer material are changed. For flooring materials and second cushioning materials, flooring samples c-1 to c-6 were prepared under the same conditions, and the data and results of tests conducted to confirm the influence of the presence and thickness of the second cushioning material were used. Show. As can be seen from the results shown here, the samples c-3 to c-5 having the second cushioning material having a thickness of 3.0 to 5.0 mm all have a G value of 100 G or less, excellent shock absorption performance, The surface and the fruit of the first base material were not damaged even when receiving the test, but the second buffer material was omitted and the first base material / first buffer material / second base material was laminated in three layers The sample c-1 and the sample c-2 having the second buffer material having a thickness of 2.5 mm both had G values exceeding 100 G, and were not able to sufficiently exhibit the impact absorbing performance. Sample c-6 having a second cushioning material with a thickness of 8.0 mm was sufficiently excellent in impact absorption performance, but the fruit of the second base material was damaged by the impact. From this result, it was confirmed that the second buffer material is essential and the thickness thereof should be in the range of 3.0 to 5.0 mm.

  Table 4 fixes the thickness of the first cushioning material to 1.2 mm, which is the approximate center value in the range of 0.5 to 2.5 mm confirmed from the results of Table 2 above, in the flooring material having the same laminated configuration. However, the Asker C hardness was changed to 5 in the range of 25 to 65 degrees, and the flooring samples d-1 to d-5 were all set under the same conditions for the first base material, the second base material, and the second cushioning material. The data and the result of the test which were produced and confirmed in order to confirm the influence by the hardness of a 1st buffer material are shown. As can be seen from the results shown here, samples d-1 to d-5, whose first buffer material has a hardness of 25 to 65 degrees, all have a G value of 100 G or less, have excellent shock absorption performance, and receive impact. However, the surface and the fruit of the first base material were not damaged. In particular, samples d-2 to d-4, in which the hardness of the first buffer material is 40 to 55 degrees, all had an excellent shock absorbing performance with a G value of 90 G or less. On the other hand, when the test was similarly performed on samples in which the hardness of the first buffer material was less than 25 degrees and greater than 65 degrees, it was difficult to obtain a G value of 100 G or less. The reason for this is that in the former, the first cushioning material is too soft, and the impact received by the first substrate is transferred as it is to the second substrate on the back side without buffering, and in the latter, Since the first buffer material was too hard and rebounded without buffering the impact received by the first base material, it was considered that none of them could exhibit sufficient shock absorbing performance. From this result, it was confirmed that the Asker C hardness of the first buffer material is preferably 20 to 70 degrees, and more preferably 35 to 60 degrees.

  Table 5 shows a flooring material having the same laminated structure, and the thickness of the second cushioning material is fixed to 4.0 mm, which is the center value in the range of 3.0 to 5.0 mm confirmed from the results of Table 3 above. However, the Asker C hardness was changed in five ways in the range of 20 to 65 degrees, and floor material samples e-1 to e-5 were prepared under the same conditions for the first base material, the first buffer material, and the second base material. And the data and result of the test conducted in order to confirm the influence by the hardness of a 2nd buffer material are shown. As can be seen from the results shown here, the samples e-1 to e-5 in which the hardness of the second cushioning material is 20 to 65 degrees all have a G value of 100 G or less, have excellent shock absorption performance, and receive impact. However, the surface and the fruit of the first base material were not damaged. In particular, the samples e-2 to e-4, in which the hardness of the second buffer material is 30 to 40 degrees, all have a G value of 90 G or less and have extremely excellent impact absorbing performance. On the other hand, when the same test was performed on samples having a hardness of the second buffer material of less than 20 degrees and greater than 65 degrees, it was difficult to obtain a G value of 100 G or less. The reason for this is that in the former, the second cushioning material becomes too soft, sinks greatly due to the impact received by the first base material, and the impact transmitted almost directly to the floor base material rebounds greatly, In the latter case, the second cushioning material is too hard to absorb the impact received by the first base material, and the impact transmitted to the floor base material bounces back greatly. It was thought that the performance could not be demonstrated. From this result, it was confirmed that the Asker C hardness of the second buffer material is preferably 20 to 70 degrees, and more preferably 25 to 45 degrees.

  In the floor samples shown in Tables 1 to 5, MDF was used for the first base material and the second base material, and open-cell PU was used for the second buffer material. When the same test was conducted for the second base material instead of other materials (for example, plywood as one or both of them), no significant difference was found from the above results. Moreover, even if it replaced with other materials (for example, closed-cell EVA) and the same test was done about the 2nd buffer material, the said result and the significant difference were not seen. Therefore, it was confirmed that the material used for each of these layers is not limited in the present invention.

Next, in these flooring samples, the closed cell type EVA was used as the first cushioning material, but the first cushioning materials in the flooring samples b-3 to b-5 that showed good results in Table 2 were continuously used. Floor material samples b-7 to b-9 were prepared under the same conditions except that the bubble type PU was used, and a test for measuring the thickness change before and after pressing was performed. Table 6 shows the data and results of each sample in this test.

  As can be seen from the results shown in Table 6, all the samples b-3 to b-5 using closed cell EVA as the first buffer material showed almost no change in thickness before and after pressurization, whereas open cells In all of samples b-7 to b-9 using PU, the thickness of the first buffer material was greatly changed by pressurization after lamination adhesion, and the thickness was reduced to almost half. This is because the first cushioning material is a closed-cell foam when the first cushioning material is pressure-bonded to the first and second substrates with an adhesive interposed therebetween. In this case, the adhesive applied to the front and back does not penetrate into the inside of the first cushioning material, and it hardens in a state where it only adheres and penetrates only to the front and back surfaces and the vicinity thereof. While the thickness of the first cushioning material is almost unchanged, when the first cushioning material is an open-cell foam, the adhesive penetrates into the inside when pressed and is compressed in that state. Since it hardened | cured, it was thought that the thickness of the 1st shock absorbing material decreased greatly. If the thickness of the first cushioning material is greatly reduced during pressure bonding in the flooring manufacturing process as in samples b-6 to b-8, the first cushioning material is thinned and the shock absorbing performance is impaired. . In this case, it is conceivable to select a thick cushioning material in anticipation of the thickness reduction in advance, but not only the material cost increases, but also the thickness varies depending on the manufacturing conditions (temperature, compressive strength, etc.). Sometimes a step is formed between adjacent flooring materials, which deteriorates the appearance and is a danger of tripping during walking. Moreover, since the hardness which the part which the adhesive agent which osmose | permeated the inside of the 1st shock absorbing material hardened | cured increases and buffer property is lost, it will reduce impact absorption performance also from this point. From this result, it was confirmed that a closed cell foam should be used as the first buffer material.

  In addition, even if it replaced with another closed cell foam (for example, closed cell PE) instead of the closed cell EVA as a 1st buffer material, the significant difference with the said result was not seen. Therefore, as for the first buffer material, it is an essential requirement of the present invention to use a closed-cell foam having a thickness of 0.5 to 2.5 mm, and the material is not particularly limited. Was confirmed.

1 Floor material 2 First base material 3 First buffer material 4 Second base material 5 Second buffer material

Claims (2)

From the surface side, a first base material, a first buffer material, a second base material, and a second buffer material are sequentially laminated, and the first buffer material is made of closed cell foam. The flooring material is characterized in that the thickness is 0.5 to 2.5 mm, and the second cushioning material is 3.0 to 5.0 mm. The floor material according to claim 1, wherein the first buffer material and the second buffer material have Asker C hardnesses of 20 to 70 degrees.

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