JP2012041747A - Composite floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite floor material having performance equivalent to that of conventional floor materials mainly composed of a lauan plywood, regardless of use of a plywood from raw material plantation such as eucalyptus or use of a low-quality plywood produced from other raw material plantation having a high specific gravity.SOLUTION: A composite floor material comprises a plywood 1, a melamine resin impregnated paper 2 that is integrated onto the plywood 1 under heated and pressurized conditions, and an olefin resin decorative sheet 3 attached onto the melamine resin impregnated paper 2. A thermoplastic resin sheet 4 may be attached to a rear face of the plywood 1 to integrate into the composite floor material. In addition, a low-quality plywood produced from raw material plantation may be used as the plywood 1.

Description

  The present invention relates to a flooring material, and more particularly, to a composite flooring material mainly composed of low-quality plywood, which is produced by using planted trees with high specific gravity, such as plywood, particularly eucalyptus plywood.

  In recent years, in the residential field, wooden floor materials are easy to clean, etc., and have the advantage of suppressing the occurrence of ticks that are a cause of sick house syndrome. Its use is expanding.

  However, with the depletion of timber resources worldwide, it has become difficult to obtain solid timber, and the price has been rising, so various things such as plywood, laminated wood, medium density fiberboard (MDF), particle board, etc. A wood composite material in which a surface decorative material is attached to a wood base material and is subjected to a flooring finish is in widespread use.

  Conventionally, thick plywood has been mainly used as the above-mentioned wooden base material in terms of ease of processing, availability, etc., but felling the southern sea wood that is the raw material of plywood, such as lauan and kapol. However, the regulation of logging has been strengthened from the viewpoint of resource protection, such as in the rainforest, and it has become difficult to stably obtain a large quantity of high-quality South Sea trees suitable for use in plywood, and the price has also risen.

  This problem is predicted to become more serious in the future, plywood using eucalyptus etc. grown by planting as a raw material, or low-quality plywood manufactured using other high-specific gravity planted wood as a raw material, so-called second-class plywood It is becoming a situation that must be used.

  On the other hand, in Japanese Patent Laid-Open No. 2000-265652, the floor material is mainly composed of a wood fiberboard having uniform physical properties throughout, and melamine resin-impregnated paper is laminated and integrated on the front and back surfaces of this base material. In order to give flexibility to the back of the flooring material, and to make it possible to accurately perform actual processing and chamfering processing. In addition, a plurality of concave grooves reaching the depth where the remaining thickness of the flooring material is 1 to 3 mm is engraved in parallel to the short side, and the male and female real parts are formed on the four side end faces, and the four side ridge corners on the surface side. There is disclosed a wooden decorative flooring material that has been subjected to a thread chamfering made of a gently inclined surface or a convex arc surface.

  Further, the effect is described when a wooden decorative flooring material comprising a low-pressure melamine decorative board having high surface hardness, high wear resistance, hardly causing scratches and excellent workability is described. However, in this case, since the cured melamine resin is exposed on the surface, the appearance is not good.

Japanese Patent Laid-Open No. 2000-265652

  The present invention has been made in view of the above-mentioned background art, and its purpose is to provide a plywood using eucalyptus as a raw material, which is a planted tree, or an uneven surface on a surface produced using another planted tree having a high specific gravity as a raw material. It is to provide a composite flooring that has the same performance and good appearance as a flooring mainly composed of lauan plywood and the like that have been used conventionally, even if low quality plywood is used.

  In order to solve the above-mentioned problem, in the composite flooring according to the first aspect of the present invention, the melamine resin-impregnated paper is integrated on the plywood under heat and pressure, and the olefin-based resin cosmetic is applied on the melamine resin-impregnated paper. It is characterized by sticking a sheet. As the above-mentioned decorative sheet made of olefin resin, for example, a known olefin resin such as polyvinyl chloride resin, polyethylene resin, polypropylene resin, polystyrene resin, polyester resin or the like is molded into a sheet shape, and for example, it is made of wood grain. Used.

  The composite flooring according to the second aspect of the present invention is characterized in that in the composite flooring according to the first aspect, a thermoplastic resin sheet is bonded and integrated on the back surface of the plywood. As the thermoplastic resin sheet, in addition to the polyvinyl chloride resin, polyethylene resin, polypropylene resin, polystyrene resin, polyester resin, etc., for example, polyvinyl acetate, polymethyl methacrylate, polyε-caprolactone, saturated polyester, polybutadiene, Polystyrene-acrylic acid copolymer, polystyrene-polyvinyl acetate copolymer, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer, acrylonitrile-styrene copolymer, and other thermoplastic resins are processed into sheets. And a backing material.

  In the composite flooring according to the first aspect of the present invention, the melamine resin impregnated paper is integrated on the plywood under heat and pressure, and the olefin resin decorative sheet is further stuck on the melamine resin impregnated paper. Therefore, even if a plywood made from eucalyptus or the like, which is a planted tree, is used as a raw material for the above plywood, or a low-quality plywood made from another planted tree having a high specific gravity, the melamine resin is cured by covering the surface irregularities. Therefore, it is possible to obtain a composite flooring having a hard and smooth surface without a rough feeling.

  Furthermore, in order to stick the olefin resin decorative sheet on the surface of the cured melamine resin impregnated paper by laminating, the olefin resin decorative sheet is adhered exactly on the surface of the cured melamine resin impregnated paper. A composite flooring can be produced at low cost with high production efficiency. For example, when the surface is decorated with the grain of natural wood, it has a high surface hardness and rigidity, excellent physical properties such as scratch resistance and caster resistance, and a good appearance rich in nature. Flooring can be obtained.

  In addition, it is possible to reduce the amount of expensive southern ocean trees such as lauan and capol, and to provide a flooring material at a low cost by increasing the usage ratio of planted trees with a stable price. Furthermore, from the viewpoint of resource conservation, it is possible to provide an environmentally friendly flooring that prevents precious rainforests from being overcut.

  In the composite flooring according to claim 2 of the present application, in the composite flooring according to claim 1 of the present invention, since the thermoplastic resin sheet is bonded and integrated on the back surface of the plywood, it is backed by the thermoplastic resin sheet. Therefore, it is possible to prevent moisture and moisture from being absorbed from the floor base, and to prevent warping of the floor material (floor surface) due to moisture absorption after construction. Further, when used in a living room or the like, it is possible to prevent moisture from entering from under the floor and to keep the indoor air quality good.

Sectional drawing which shows the structure of the composite flooring which concerns on this invention. Sectional drawing which shows the composite flooring of the other structure which concerns on this invention.

  Hereinafter, embodiments of a composite flooring according to the present invention will be described in detail with reference to the drawings. In the present embodiment, a plywood made of eucalyptus or the like, which is a high-specific gravity planted tree, is used as the plywood constituting the main body of the composite flooring.

  FIG. 1 is a cross-sectional view showing a configuration of a composite flooring A according to the present invention. As shown in FIG. 1, in the composite flooring A, a melamine resin impregnated paper 2 is combined and integrated on the upper surface of a plywood 1 made of eucalyptus or the like under heat and pressure, and the surface of the melamine resin impregnated paper 2 is made of an olefin resin. The decorative sheet 3 (for example, a decorative sheet made of natural wood grain on the surface of a polyvinyl chloride resin) is attached to form.

  Here, first, for example, a melamine resin-impregnated paper 2 having a thickness of 0.3 mm is placed on the upper surface of the plywood 1 having a thickness of 11.2 mm and a length and width of 1830 mm × 920 mm. A composite board in which the melamine resin-impregnated paper 2 is laminated and integrated on the upper surface of the plywood 1 is obtained by hot pressing at 180 ° C., a pressure of 30 kg / cm 2 and a press time of 60 seconds.

  At this time, since the surface of the plywood 1 made of eucalyptus or the like is covered with the above-described melamine resin-impregnated paper 2, even if the surface of the plywood 1 has irregularities, they are absorbed and can be made a smooth surface without roughness. . Furthermore, since the melamine resin impregnated paper 2 hot-pressed by the hot press has the characteristics of the cured melamine resin, that is, high hardness and rigidity, the composite plate has excellent physical properties such as scratch resistance and caster resistance. Can be granted.

  Next, the surface of the cured melamine resin-impregnated paper 2 is laminated and pasted with an olefin-based resin decorative sheet 3 having a thickness of 0.2 to 0.3 mm designed in a wood grain pattern. By this laminating process, the decorative sheet 3 made of an olefin resin is adhered exactly to the surface of the hard and smooth melamine resin-impregnated paper 2, and a composite flooring A that is productive and low in cost and rich in nature can be obtained. .

  FIG. 2 is a cross-sectional view showing a configuration of another form of composite flooring B formed by sticking and integrating a thermoplastic resin sheet 4 to the back surface of the plywood 1 of the composite flooring A. The thermoplastic resin sheet 4 may have a paper layer formed on one side or both sides.

  As shown in FIG. 2, a known adhesive such as an SBR adhesive, a vinyl acetate adhesive, an ethylene-vinyl acetate adhesive, a melamine adhesive, or a urea resin is formed on the back surface of the plywood 1 made of eucalyptus or the like. A thermoplastic adhesive or the like is applied to firmly adhere the thermoplastic resin sheet 4.

  By backing with the thermoplastic resin sheet 4 in this way, it is possible to prevent moisture and moisture from being absorbed from the floor base, and to prevent warping of the floor material (floor surface) due to construction and moisture. Moreover, when the said composite flooring B is used for a living room etc., the penetration | invasion of the moisture from under a floor can be prevented and indoor air quality can be kept favorable.

  In the above embodiment, as plywood, plywood using eucalyptus or the like which is a second-class plywood having a rough feeling due to surface unevenness has been described, but thick plywood made of not only plywood such as eucalyptus but also ordinary lauan material etc. May be used. Even in this case, a composite flooring having high surface hardness and rigidity and excellent scratch resistance, caster resistance, and the like can be obtained. As described above, the composite flooring according to the present invention can be freely changed in design, and all cases belong to the technical scope of the present invention unless departing from the scope of the claims.

A Composite floor material according to the present invention B Composite floor material according to another configuration of the present invention 1 Plywood 2 Melamine resin impregnated paper 3 Olefin-based resin decorative sheet 4 Thermoplastic resin sheet

Claims (2)

  A composite flooring in which melamine resin-impregnated paper is integrated on a plywood under heat and pressure, and an olefin-based resin decorative sheet is stuck on the melamine resin-impregnated paper.   The composite flooring according to claim 1, wherein a thermoplastic resin sheet is bonded and integrated on the back surface of the plywood.

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