JP2018087436A - Floor material and manufacturing method thereof - Google Patents

Floor material and manufacturing method thereof Download PDF

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JP2018087436A
JP2018087436A JP2016230774A JP2016230774A JP2018087436A JP 2018087436 A JP2018087436 A JP 2018087436A JP 2016230774 A JP2016230774 A JP 2016230774A JP 2016230774 A JP2016230774 A JP 2016230774A JP 2018087436 A JP2018087436 A JP 2018087436A
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veneer
single plate
flooring
veneer layer
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晶子 福田
Akiko Fukuda
晶子 福田
貴史 谷本
Takashi Tanimoto
貴史 谷本
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Asahi Woodtec Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a floor material small in warping and a dimensional change.SOLUTION: A floor material 10 of the present invention is 7.0 mm or less in the total thickness, and comprises a wooden base material layer 2 having a first veneer layer 2a, a second veneer layer 2b, a third veneer layer 2c, a fourth veneer layer 2d and a fifth veneer layer 2e in order and a decorative material layer 1 adhered to a surface of the first veneer layer 2a and being 1.0-2.0 mm in a thickness, and the first veneer layer 2a, the third veneer layer 2c and the fifth veneer layer 2e are a cloth veneer layer orthogonal to the longitudinal direction of the floor material in the fiber direction, and the second veneer layer 2b and the fourth veneer layer 2d are a parallel veneer layer being parallel to the longitudinal direction of the floor material in the fiber direction, and a thickness of the first veneer layer 2a is larger than a thickness of the fifth veneer layer 2e.SELECTED DRAWING: Figure 1

Description

本発明は、床材およびその製造方法に関する。   The present invention relates to a flooring and a manufacturing method thereof.

戸建住宅、マンションその他の建築物に用いられるフローリングには、無垢の木材からなる無垢床材のほか、合板、MDF、パーティクルボードなどからなる木質基材の表面、または、これらの木質基材を積層してなる木質基材(以下、積層してなる木質基材も単に「木質基材」と呼ぶ。)の表面に銘木の化粧材を貼り付けた化粧貼床材などがある。   For flooring used in detached houses, condominiums and other buildings, in addition to solid flooring made of solid wood, the surface of a wooden substrate made of plywood, MDF, particle board, or these wooden substrates For example, there is a decorative flooring material in which a decorative material of a name tree is pasted on the surface of a laminated wood base material (hereinafter, the laminated wood base material is also simply referred to as a “wood base material”).

化粧貼床材は、無垢材よりも水分に起因する膨張・収縮が少ない基材を用いており、表面には各種の塗装が施され内部への水分の侵入を防止しているため、施工後の使用環境において反りが少なく扱いが容易であるなどの理由から、多くの建築現場で用いられるようになってきている。   The decorative flooring material uses a base material that has less expansion and contraction due to moisture than solid wood, and various coatings are applied to the surface to prevent moisture from entering the interior. It has been used in many construction sites because it has less warpage and is easy to handle.

化粧貼床材に用いられる木質化粧材は、厚さ0.2〜0.6mm程度の薄板と、厚さ0.7〜3.0mm程度の厚板とに大別される。薄板は、複数の木材ブロックを組み合わせ接着したものをスライサーで切削して製造される。このような製法で製造された板は突き板と呼ばれる。これに対して、厚板としては、突き板の場合もあるが、1.0mm以上の比較的厚いものは木材を帯鋸などで切り出して製造されることが多い。このような製法で製造された板は挽き板と呼ばれる。   Woody decorative materials used for decorative sticking flooring materials are roughly classified into thin plates having a thickness of about 0.2 to 0.6 mm and thick plates having a thickness of about 0.7 to 3.0 mm. The thin plate is manufactured by cutting a combination of a plurality of wood blocks bonded together with a slicer. The board manufactured by such a manufacturing method is called a veneer. On the other hand, the thick plate may be a veneer, but a relatively thick one of 1.0 mm or more is often manufactured by cutting a piece of wood with a band saw or the like. A board manufactured by such a manufacturing method is called a saw board.

出願人は、特開2014−66126号公報(特許文献1)において、厚さ1.0〜3.0mmの木質化粧材と、厚さ1.0〜3.0mmであって、木質化粧材1と繊維方向が直交する単板と、厚さ5.0〜12mmの合板と、厚さ1.5〜10mmの緩衝材とを順に積層し、接合した木質床材であって、合板が、木質床材の長手方向と直交する裏溝によって複数に分断されている木質床材を提案している。この発明によれば、防音性および剛性に優れるとともに、1.0mm以上の厚さを有する化粧材を用いても反り、寸法変化等を抑制することが可能である。   In the Japanese Patent Application Laid-Open No. 2014-66126 (Patent Document 1), the applicant has a wooden decorative material having a thickness of 1.0 to 3.0 mm and a wooden decorative material 1 having a thickness of 1.0 to 3.0 mm. And a veneer in which the fiber directions are orthogonal to each other, a plywood having a thickness of 5.0 to 12 mm, and a buffer material having a thickness of 1.5 to 10 mm are sequentially laminated and bonded, and the plywood is made of wood. A wooden flooring that has been divided into a plurality by back grooves perpendicular to the longitudinal direction of the flooring is proposed. According to this invention, while being excellent in soundproofing and rigidity, even if a decorative material having a thickness of 1.0 mm or more is used, it is possible to suppress warpage, dimensional change, and the like.

特開2014−66126号公報JP 2014-66126 A

化粧貼床材に、表面材としての天然木化粧材の厚さを増加させつつも、床材の厚さは減少させたいという要望がある。これは、薄い床材であれば、施工が容易であり、また、リフォームで用いた場合には納まりが良くなり、また、木材の使用が少なく、廃材が少ないというメリットがあるからである。具体的には、厚さ1.0mm以上の天然木化粧材を用いつつ、床材の総厚さは7.0mm以下に抑えたいという要望である。しかし、このような構成では、木質基材層を相対的に薄くせざるを得ず、その製造過程において反りを発生させ、また、その使用時の寸法変化が大きくなる。   There is a demand for a decorative flooring material to reduce the thickness of the flooring material while increasing the thickness of the natural wood decorative material as a surface material. This is because a thin flooring material can be easily constructed, and when used in renovation, it can be stored better, and there is a merit that less wood is used and less waste material is used. Specifically, there is a demand to use a natural wood decorative material having a thickness of 1.0 mm or more and to suppress the total thickness of the floor material to 7.0 mm or less. However, in such a configuration, the wood base layer has to be relatively thin, warping occurs in the manufacturing process, and dimensional changes during use increase.

特許文献1は、合板を、木質床材の長手方向と直交する裏溝によって複数に分断することにより、1mm以上の厚さを有する化粧材を用いても反り、寸法変化等を抑制することができるものである。しかし、裏溝を形成し、また、裏面に厚さ1.5〜10mmの緩衝材を設けるため、製造コストを上昇させる。   In Patent Document 1, the plywood is divided into a plurality of back grooves perpendicular to the longitudinal direction of the wooden flooring, thereby suppressing warpage, dimensional change and the like even when a decorative material having a thickness of 1 mm or more is used. It can be done. However, since the back groove is formed and a buffer material having a thickness of 1.5 to 10 mm is provided on the back surface, the manufacturing cost is increased.

本発明者らは、このような構成を採用しなくても、反りおよび寸法変化が小さい床材を提供することを目的としている。   The present inventors have aimed to provide a flooring that is small in warpage and dimensional change without adopting such a configuration.

〔1〕第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に接着された、厚さが1.0〜2.0mmである化粧材層とを備える、総厚さが7.0mm以下である床材であって、前記第1単板層、前記第3単板層および前記第5単板層が、その繊維方向が前記床材の長手方向と直交するクロス単板層であり、前記第2単板層および前記第4単板層が、その繊維方向が前記床材の長手方向と平行である平行単板層であり、前記第1単板層の厚さが前記第5単板層の厚さよりも大きい、床材。   [1] A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer and a fifth veneer layer in order, and a surface of the first veneer layer A flooring material having a total thickness of 7.0 mm or less, wherein the first single plate layer and the third single layer are provided. The plate layer and the fifth single plate layer are cross single plate layers whose fiber direction is orthogonal to the longitudinal direction of the flooring, and the second single plate layer and the fourth single plate layer have the fiber direction. A flooring material, which is a parallel single plate layer parallel to a longitudinal direction of the floor material, wherein the thickness of the first single plate layer is larger than the thickness of the fifth single plate layer.

〔2〕前記第1単板層の厚さが前記第5単板層の厚さの1.5倍以上である、上記〔1〕の床材。   [2] The flooring according to [1], wherein the thickness of the first single plate layer is 1.5 times or more the thickness of the fifth single plate layer.

〔3〕前記第1単板層の厚さが1.0〜2.0mmであり、前記第5単板層の厚さの0.3〜1.0mmである、上記〔1〕または〔2〕の床材。   [3] The thickness of the first veneer layer is 1.0 to 2.0 mm, and the thickness of the fifth veneer layer is 0.3 to 1.0 mm. ] Flooring.

〔4〕前記木質基材層が、厚さが2.5〜3.5mmの3プライ合板に、前記第1単板層および前記第5単板層を接着した、上記〔1〕〜〔3〕のいずれかの床材。   [4] The above [1] to [3], wherein the wood substrate layer is obtained by bonding the first single plate layer and the fifth single plate layer to a three-ply plywood having a thickness of 2.5 to 3.5 mm. ] Any flooring.

〔5〕前記木質基材層の総厚さtに対する、前記第1単板層、前記第3単板層および前記第5単板層の合計厚さtの比(t/t)、0.60〜0.75である、上記〔1〕〜〔4〕のいずれかの床材。 [5] Ratio (t c / t t) of the total thickness t c of the first single plate layer, the third single plate layer, and the fifth single plate layer to the total thickness t t of the wood base layer ), The flooring material according to any one of [1] to [4], which is 0.60 to 0.75.

〔6〕第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(A1)〜(A4)の工程を有する、床材の製造方法。
(A1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、厚さが異なる2枚のクロス単板と、前記化粧材とを準備する工程、
(A2)前記3プライ合板の一方の面に、接着剤を塗布し、相対的に薄いクロス単板を接着して、前記第5単板層とする工程、
(A3)前記3プライ合板の他方の面に、接着剤を塗布し、相対的に厚いクロス単板を接着して、前記第1単板層とする工程、および、
(A4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
[6] On the surface of the first base plate layer, the wood base layer comprising the first single plate layer, the second single plate layer, the third single plate layer, the fourth single plate layer, and the fifth single plate layer in order. A method of manufacturing a flooring comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, which is affixed and having the following steps (A1) to (A4) Method.
(A1) a step of preparing a three-ply plywood, two cross veneers in which the fiber direction is orthogonal to the longitudinal direction of the flooring and having different thicknesses, and the decorative material,
(A2) a step of applying an adhesive to one surface of the three-ply plywood and bonding a relatively thin cross veneer to form the fifth veneer layer;
(A3) applying an adhesive to the other surface of the three-ply plywood to bond a relatively thick cross veneer to form the first veneer layer; and
(A4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

〔7〕前記工程(A1)、(A2)、(A3)および(A4)を順に行う、上記〔6〕の製造方法。   [7] The production method of the above [6], wherein the steps (A1), (A2), (A3) and (A4) are sequentially performed.

〔8〕第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(B1)〜(B4)の工程を有する、床材の製造方法。
(B1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、2枚のクロス単板と、前記化粧材とを準備する工程、
(B2)前記3プライ合板の一方の面に、接着剤を塗布し、一方のクロス単板を接着し、前記3プライ合板の他方の面に、接着剤を塗布し、他方のクロス単板を接着する工程、
(B3)前記2枚のクロス単板のうち、少なくとも一方のクロス単板を研削し、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(B4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
[8] On the surface of the first base plate layer, a wood substrate layer comprising a first single plate layer, a second single plate layer, a third single plate layer, a fourth single plate layer, and a fifth single plate layer in this order. A method for producing a flooring material comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, the flooring material comprising steps (B1) to (B4) below: Method.
(B1) a step of preparing a three-ply plywood, a fiber direction perpendicular to the longitudinal direction of the flooring, and preparing two cross single plates and the decorative material,
(B2) Adhesive is applied to one surface of the three-ply plywood, one cross veneer is bonded, the adhesive is applied to the other surface of the three-ply plywood, and the other cross veneer is Bonding process,
(B3) At least one of the two cross single plates is ground, the thicker single plate layer is defined as the first single plate layer, and the thin single plate layer is defined as the fifth single plate layer. The process of
(B4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

〔9〕クロス単板の接着および/または化粧材の接着に際し、ホットメルト接着剤を用い、冷間プレスにより接着する、上記〔6〕〜〔8〕のいずれかの床材の製造方法。   [9] The method for producing a flooring material according to any one of the above [6] to [8], wherein a hot melt adhesive is used and a cold press is used for bonding the cloth single plate and / or the decorative material.

〔10〕前記3プライ合板と前記第1単板層との接着を熱間プレスで行い、前記3プライ合板と前記第5単板層との接着を冷間プレスで行う、上記〔6〕〜〔9〕のいずれかの床材の製造方法。   [10] The bonding between the three-ply plywood and the first single plate layer is performed by a hot press, and the bonding between the three-ply plywood and the fifth single plate layer is performed by a cold press. [9] The method for producing a flooring material according to any one of the above.

〔11〕第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(C1)〜(C3)の工程を有する、床材の製造方法。
(C1)5プライのクロス合板を準備する工程、
(C2)前記5プライのクロス合板の少なくとも一方の表面を研削し、表面の単板層のうち、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(C3)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
[11] A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer and a fifth veneer layer in order, on the surface of the first veneer layer A method for producing a flooring material comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, the flooring material comprising steps (C1) to (C3) below: Method.
(C1) preparing a 5-ply cross plywood,
(C2) At least one surface of the five-ply cross plywood is ground, and among the single plate layers on the surface, the thicker single plate layer is used as the first single plate layer, and the thin single plate layer is used as the fifth single plate layer. A step of making a plate layer,
(C3) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

本発明によれば、反りおよび寸法変化が小さい床材を提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, a flooring with a small curvature and a dimensional change can be provided.

本実施形態に係る床材を例示した図The figure which illustrated the flooring concerning this embodiment

図1を用いて、本実施形態に係る床材およびその製造方法を説明する。   A flooring according to the present embodiment and a method for manufacturing the flooring will be described with reference to FIG.

1.本実施形態に係る床材
図1に示すように、本実施形態に係る床材10は、化粧材層1および木質基材層2を備える、総厚さが7.0mm以下の床材である。床材10の巾、長さは特に制約はない。通常、巾は、150、300、303mm、長さは900、1800、1818mmである。厚さは、施工性の観点(切断が容易であり、廃材が少ないなどの理由)からは薄いことが好ましいが、剛性の観点からは、5.0mm以上が好ましい。6.0mm以上がより好ましい。
1. As shown in FIG. 1, a flooring 10 according to this embodiment is a flooring having a decorative material layer 1 and a wood base material layer 2 and having a total thickness of 7.0 mm or less. . The width and length of the flooring 10 are not particularly limited. Usually, the width is 150, 300, 303 mm, and the length is 900, 1800, 1818 mm. The thickness is preferably thin from the viewpoint of workability (for reasons such as easy cutting and little waste material), but from the viewpoint of rigidity, it is preferably 5.0 mm or more. 6.0 mm or more is more preferable.

本実施形態に係る化粧材層1は、突板、挽板等の天然木を加工した化粧材を用いることができる。特に、挽板の天然木が好ましい。化粧材層1が薄すぎると、意匠性が悪くなり、また、木質基材層2の映出が懸念されるので、化粧材層1の厚さは1.0mm以上のものを用いる。より好ましくは、1.2mm以上である。しかし、化粧材層1が厚いほど、コストを上昇させ、また、反りなどの寸法変化が大きくなり扱いにくくなるため、化粧材層1の厚さは2.0mm以下とするのが好ましい。   As the decorative material layer 1 according to the present embodiment, a decorative material obtained by processing natural wood such as a veneer or a ground board can be used. In particular, natural wood of a ground board is preferable. If the decorative material layer 1 is too thin, the design property is deteriorated, and there is a concern about the projection of the wood base material layer 2, so that the thickness of the decorative material layer 1 is 1.0 mm or more. More preferably, it is 1.2 mm or more. However, the thicker the decorative material layer 1 is, the higher the cost is, and the larger the dimensional change such as warpage becomes, so that it is difficult to handle. Therefore, the thickness of the decorative material layer 1 is preferably 2.0 mm or less.

本実施形態に係る木質基材層2は、第1単板層2a、第2単板層2b、第3単板層2c、第4単板層2dおよび第5単板層2eを順に備える。第1単板層2aの表面に化粧材層1が接着されている。そして、第1単板層2a、第3単板層2cおよび第5単板層2eが、その繊維方向が前記床材の長手方向(図1中の左右方向)と直交するクロス単板層である。また、第2単板層2bおよび第4単板層2dが、その繊維方向が前記床材の長手方向と平行である平行単板層である。そして、本実施形態に係る床材10においては、第1単板層2aの厚さは、第5単板層2eの厚さよりも大きいことを最大の特徴とする。   The wood base layer 2 according to the present embodiment includes a first single plate layer 2a, a second single plate layer 2b, a third single plate layer 2c, a fourth single plate layer 2d, and a fifth single plate layer 2e in this order. The decorative material layer 1 is bonded to the surface of the first veneer layer 2a. The first veneer layer 2a, the third veneer layer 2c, and the fifth veneer layer 2e are cross veneer layers whose fiber directions are orthogonal to the longitudinal direction of the flooring (left and right direction in FIG. 1). is there. The second single plate layer 2b and the fourth single plate layer 2d are parallel single plate layers whose fiber directions are parallel to the longitudinal direction of the flooring. And in the flooring 10 which concerns on this embodiment, it is the biggest characteristic that the thickness of the 1st single board layer 2a is larger than the thickness of the 5th single board layer 2e.

すなわち、厚さ1.0mm以上の天然木化粧材を用いつつ、床材の総厚さを7.0mm以下に抑える場合には、木質基材層2を相対的に薄くせざるを得ず、その製造過程において反りを発生させ、また、その使用時の寸法変化が大きくなる。本発明者らは、木質基材層2としては、表層の単板層(第1単板層2aおよび第5単板層2e)としてクロス単板を用いた合板を用いることを前提として研究を行ったが、単にクロス単板を用いるというだけでは、床材の反りおよび寸法変化を十分に押さえることができなかった。そこで、化粧材層1を貼り付ける前の状態において、巾方向(床材10の短手方向)に凸反りをしている木質基材2を用意し、その凸面側に化粧材層1を貼り付けたところ、床材の反りおよび寸法変化を十分に小さくすることが可能となった。   That is, when using a natural wood decorative material having a thickness of 1.0 mm or more and suppressing the total thickness of the flooring to 7.0 mm or less, the wooden substrate layer 2 must be relatively thin, Warpage occurs in the manufacturing process, and the dimensional change during use increases. The present inventors conducted research on the premise that the wood base material layer 2 is a plywood using a cross veneer as a surface single plate layer (first single plate layer 2a and fifth single plate layer 2e). However, it was not possible to sufficiently suppress the warpage and dimensional change of the flooring simply by using a single cloth plate. Therefore, in the state before applying the decorative material layer 1, a wooden base material 2 having a convex warp in the width direction (short direction of the flooring 10) is prepared, and the decorative material layer 1 is applied to the convex surface side. As a result, the warpage and dimensional change of the flooring can be made sufficiently small.

そして、第1単板層2aの厚さを第5単板層2eの厚さよりも大きくすることにより、化粧材層1を貼り付ける前の木質基材2に巾方向の凸反りを付与できる。特に、第1単板層2aの厚さを第5単板層2eの厚さの1.5倍以上とすることにより、安定的に化粧材層1を貼り付ける前の木質基材2に巾方向の凸反りを付与できる。第1単板層2aの厚さが第5単板層2eの厚さの2.0倍以上とするのが好ましい。   Then, by making the thickness of the first veneer layer 2a larger than the thickness of the fifth veneer layer 2e, it is possible to impart a convex warpage in the width direction to the wooden substrate 2 before the decorative material layer 1 is attached. In particular, by setting the thickness of the first veneer layer 2a to be 1.5 times or more the thickness of the fifth veneer layer 2e, the width of the first veneer layer 2a before the veneering material layer 1 is stably applied is reduced. A convex warp in the direction can be imparted. The thickness of the first single plate layer 2a is preferably 2.0 times or more the thickness of the fifth single plate layer 2e.

本実施形態に係る木質基材層2において、第1単板層1aの厚さは、1.0〜2.0mmとするのが好ましい。第1単板層1aの厚さが1.0mm未満では、床材の巾方向が凹反りになり、2.0mmを超えると、床材の巾方向の凸反りが過大になる。好ましい下限は1.2mmである。第5単板層1eの厚さは、0.3〜1.0mmとするのが好ましい。第5単板層1eの厚さが0.3mm未満では、床材の巾方向の凸反りが過大になり、1.0mmを超えると、床材の巾方向が凹反りになる。好ましい下限は0.4mmであり、好ましい上限は0.8mmである。   In the wood substrate layer 2 according to the present embodiment, the thickness of the first veneer layer 1a is preferably 1.0 to 2.0 mm. If the thickness of the 1st single board layer 1a is less than 1.0 mm, the width direction of a flooring will become a concave curvature, and if it exceeds 2.0 mm, the convex curvature of the width direction of a flooring will become excessive. A preferred lower limit is 1.2 mm. The thickness of the fifth single plate layer 1e is preferably 0.3 to 1.0 mm. If the thickness of the fifth veneer layer 1e is less than 0.3 mm, the convex warpage in the width direction of the flooring becomes excessive, and if it exceeds 1.0 mm, the width direction of the flooring becomes concave. A preferred lower limit is 0.4 mm and a preferred upper limit is 0.8 mm.

本実施形態に係る木質基材層2において、相対的にクロス比率を大きくすることが重要になる。クロス比率とは、前記木質基材層の総厚さtに対する、前記第1単板層、前記第3単板層および前記第5単板層の合計厚さtの比(t/t)を意味する。そして、クロス比率(t/t)を0.60以上とすれば、安定的に化粧材層1を貼り付ける前の木質基材2に巾方向の凸反りを付与できる。一方、クロス比率(t/t)が0.75を超えると、凸反りが大きくなりすぎるおそれがある。よって、クロス比率(t/t)を0.60〜0.75とするのがよい。クロス比率(t/t)の好ましい下限は0.65であり、好ましい上限は0.70である。 In the wood substrate layer 2 according to the present embodiment, it is important to relatively increase the cross ratio. The cross ratio is the ratio of the total thickness t c of the first veneer layer, the third veneer layer and the fifth veneer layer to the total thickness t t of the wood substrate layer (t c / t t ). Then, if the cross ratio (t c / t t) of 0.60 or more can impart a convex warp of the width direction in front of the wood substrate 2 to give stable bond the facing layers 1. On the other hand, if the cross ratio (t c / t t ) exceeds 0.75, the convex warpage may be too large. Therefore, the cross ratio (t c / t t ) is preferably 0.60 to 0.75. The preferable lower limit of the cross ratio (t c / t t ) is 0.65, and the preferable upper limit is 0.70.

木質基材層2を構成する各層の材質には制約がないが、例えば、ラワン、ファルカータ、ユーカリ、カメレレ、ゴム、スギ、カラマツなどの単板を用いることができる。   Although there is no restriction | limiting in the material of each layer which comprises the woody base material layer 2, For example, single plates, such as a lauan, a falcata, eucalyptus, a chamelet, rubber | gum, a cedar, and a larch, can be used.

2.本実施形態に係る床材の製造方法
本実施形態に係る床材は、下記の(A1)〜(A4)の工程により製造することができる。
(A1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、厚さが異なる2枚のクロス単板と、前記化粧材とを準備する工程、
(A2)前記3プライ合板の一方の面に、接着剤を塗布し、相対的に薄いクロス単板を接着して、前記第5単板層とする工程、
(A3)前記3プライ合板の他方の面に、接着剤を塗布し、相対的に厚いクロス単板を接着して、前記第1単板層とする工程、および、
(A4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
2. Manufacturing method of flooring according to this embodiment The flooring according to this embodiment can be manufactured by the following steps (A1) to (A4).
(A1) a step of preparing a three-ply plywood, two cross veneers in which the fiber direction is orthogonal to the longitudinal direction of the flooring and having different thicknesses, and the decorative material,
(A2) a step of applying an adhesive to one surface of the three-ply plywood and bonding a relatively thin cross veneer to form the fifth veneer layer;
(A3) applying an adhesive to the other surface of the three-ply plywood to bond a relatively thick cross veneer to form the first veneer layer; and
(A4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

これにより、第1単板層2aの厚さは、第5単板層2eの厚さよりも大きい木質基材層2を得ることができる。このとき、上記の工程(A2)および工程(A3)の順は問わず、また、同時に行っても良いが、特に、上記の工程(A2)、工程(A3)の順で木質基材層2を製造した後、工程(A4)を実施する、つまり、工程(A1)、(A2)、(A3)および(A4)をその順で行うことが好ましい。すなわち、相対的に薄いクロス単板(第5単板層2e)を3プライ合板の一方の面に貼り付け、接着した後に、その反対面に相対的に厚いクロス単板(第1単板層2a)を貼り付けるのがよい。これは、比較的厚いクロス単板を先に貼り付けると、材料の反りが大きくなり、その後に比較的薄いクロス単板を貼り付ける作業が困難となるからである。3プライ合板の厚さは、2.5〜3.5mmが好ましく、より好ましい上限は3.0mmである。   Thereby, the wood base material layer 2 whose thickness of the 1st veneer layer 2a is larger than the thickness of the 5th veneer layer 2e can be obtained. At this time, the order of the step (A2) and the step (A3) is not limited and may be performed simultaneously. In particular, the wood base material layer 2 in the order of the step (A2) and the step (A3). After manufacturing, step (A4) is preferably performed, that is, steps (A1), (A2), (A3) and (A4) are preferably performed in that order. That is, after a relatively thin cross veneer (fifth veneer layer 2e) is attached to one surface of a three-ply plywood and bonded, a relatively thick cross veneer (first veneer layer) is formed on the opposite surface. 2a) should be pasted. This is because, when a relatively thick cloth single plate is pasted first, the warp of the material becomes large, and thereafter, the operation of pasting a relatively thin cross single plate becomes difficult. The thickness of the three-ply plywood is preferably 2.5 to 3.5 mm, and a more preferable upper limit is 3.0 mm.

他の本実施形態に係る床材は、下記の(B1)〜(B4)の工程により製造することができる。
(B1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、2枚のクロス単板と、前記化粧材とを準備する工程、
(B2)前記3プライ合板の一方の面に、接着剤を塗布し、一方のクロス単板を接着し、前記3プライ合板の他方の面に、接着剤を塗布し、他方のクロス単板を接着する工程、
(B3)前記2枚のクロス単板のうち、少なくとも一方のクロス単板を研削し、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(B4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
The flooring which concerns on other this embodiment can be manufactured by the process of following (B1)-(B4).
(B1) a step of preparing a three-ply plywood, a fiber direction perpendicular to the longitudinal direction of the flooring, and preparing two cross single plates and the decorative material,
(B2) Adhesive is applied to one surface of the three-ply plywood, one cross veneer is bonded, the adhesive is applied to the other surface of the three-ply plywood, and the other cross veneer is Bonding process,
(B3) At least one of the two cross single plates is ground, the thicker single plate layer is defined as the first single plate layer, and the thin single plate layer is defined as the fifth single plate layer. The process of
(B4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

これにより、第1単板層2aの厚さは、第5単板層2eの厚さよりも大きい木質基材層2を得ることができる。なお、工程(B2)においては、3プライ合板の両方の面に接着剤を塗布し、その両面にクロス単板を貼り付け、同時に接着してもよい。また、工程(B3)は、工程(B2)において、3プライ合板の一方の面に、接着剤を塗布し、一方のクロス単板を接着した後、3プライ合板の他方の面に、接着剤を塗布し、他方のクロス単板を接着する前に行っても良いし、両方のクロス単板を接着した後に行っても良い。   Thereby, the wood base material layer 2 whose thickness of the 1st veneer layer 2a is larger than the thickness of the 5th veneer layer 2e can be obtained. In the step (B2), an adhesive may be applied to both sides of the three-ply plywood, and a cloth single plate may be attached to both sides of the plywood and bonded simultaneously. Further, in the step (B3), in the step (B2), an adhesive is applied to one surface of the three-ply plywood, and one cross single plate is bonded to the other side of the three-ply plywood. May be performed before the other cross single plate is bonded, or after both cross single plates are bonded.

なお、市販の5プライのクロス合板を入手し、一方の面を研削して、第1単板層2aの厚さは、第5単板層2eの厚さよりも大きい木質基材層2を得てもよい。すなわち、下記の(C1)〜(C3)の工程により製造することができる。
(C1)5プライのクロス合板を準備する工程、
(C2)前記5プライのクロス合板の少なくとも一方の表面を研削し、表面の単板層のうち、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(C3)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
A commercially available 5-ply cloth plywood is obtained, and one surface is ground to obtain a wood base layer 2 in which the thickness of the first veneer layer 2a is larger than the thickness of the fifth veneer layer 2e. May be. That is, it can be manufactured by the following steps (C1) to (C3).
(C1) preparing a 5-ply cross plywood,
(C2) At least one surface of the five-ply cross plywood is ground, and among the single plate layers on the surface, the thicker single plate layer is used as the first single plate layer, and the thin single plate layer is used as the fifth single plate layer. A step of making a plate layer,
(C3) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.

クロス単板の接着および化粧材の接着に用いる接着剤には特に制約がないが、少なくとも何れか一つの接着工程において、ホットメルト接着剤を用い、冷間プレスにより接着することが好ましい。水系の接着剤を使うと基材の含水率が上がり基材が伸びるので、非水系のホットメルト接着剤が好ましい。ホットメルト接着剤としては、例えば、ポリウレタン(PUR)系接着剤が好ましい。   There are no particular restrictions on the adhesive used for bonding the cross veneer and the decorative material, but it is preferable to use a hot-melt adhesive in at least one of the bonding steps and perform cold bonding. When a water-based adhesive is used, the water content of the substrate is increased and the substrate is elongated, and therefore a non-aqueous hot-melt adhesive is preferable. As the hot melt adhesive, for example, a polyurethane (PUR) adhesive is preferable.

3プライ合板と第1単板層2aとの接着を熱間プレスで行い、3プライ合板と第5単板層2eとの接着を冷間プレスで行うのがよい。熱間プレスの場合には含水率が下がり、基材が収縮するからである。   The three-ply plywood and the first single plate layer 2a may be bonded by hot pressing, and the three-ply plywood and the fifth single plate layer 2e may be bonded by cold pressing. This is because in the case of hot pressing, the moisture content decreases and the base material shrinks.

本発明の効果を確認するために、市販の3プライ合板(0.8mm平行単板、1.2mmクロス単板、0.8mm平行単板)に各種の単板または挽板を貼り付け、表1に示す三種類の床材を用意した。いずれの例においても、化粧材層と木質基材層の接着は、SBR系エチレン酢酸ビニル樹脂接着剤を用いた熱間プレスによって行い、第5単板層と第4単板層との接着は、水性ビニルウレタン樹脂接着剤を用いた冷間プレスによって行った。実施例1および比較例2において、第1単板層と第2単板層との接着は、SBR系エチレン酢酸ビニル樹脂接着剤を用いた熱間プレスによって行った。   In order to confirm the effect of the present invention, various single plates or ground plates are attached to a commercially available three-ply plywood (0.8 mm parallel single plate, 1.2 mm cross single plate, 0.8 mm parallel single plate). Three types of flooring materials shown in 1 were prepared. In any example, the decorative material layer and the wood base material layer are bonded by hot pressing using an SBR-based ethylene vinyl acetate resin adhesive, and the fifth single plate layer and the fourth single plate layer are bonded to each other. It was performed by cold pressing using an aqueous vinyl urethane resin adhesive. In Example 1 and Comparative Example 2, the first single plate layer and the second single plate layer were bonded by hot pressing using an SBR-based ethylene vinyl acetate resin adhesive.

得られた各床材について、下記の方法により各方向における寸法変化率を測定し、その結果を表1に示す。   About each obtained flooring, the dimensional change rate in each direction was measured with the following method, and the result is shown in Table 1.

<寸法変化率測定方法>
(1)各床材から300mm×50mmにカットした試験片を用意する。このとき、測定する方向(長さ方向の反りを測定する場合には長さ方向、巾方向の反りを測定する場合には巾方向)を300mmとする。
(2)次に、各試験片を温度20℃、湿度65%の環境に質量が一定になるまで放置し、調質する(含水率8〜12%程度)。
(3)調質直後の試験片の寸法Sと質量Mを測定する。
(4)各試験片を乾燥試験(温度40℃、湿度30%の環境に1週間放置する試験)および吸湿試験(温度30℃、湿度90%の環境に1週間放置する試験)に供して、乾燥試験後の試験片の寸法Sと質量M、および、吸湿試験後の試験片の寸法Sと質量Mを測定する。
(5)乾燥試験後の試験片について、寸法Sと質量Mを測定した後の試験片を105℃に維持したオーブンに24時間放置し、全乾状態の試験片の質量Mを測定する。また、湿潤試験後の試験片について、寸法Sと質量Mを測定した後の試験片を105℃に維持したオーブンに24時間放置し、全乾状態の試験片の質量Mを測定する。
(6)下記の計算式に基づいて、各方向における乾燥試験での寸法変化率MCおよび湿潤試験での寸法変化率MCを求める。

Figure 2018087436
<Dimensional change rate measurement method>
(1) A test piece cut to 300 mm × 50 mm from each floor material is prepared. At this time, the measurement direction (the length direction when measuring warpage in the length direction and the width direction when measuring warpage in the width direction) is 300 mm.
(2) Next, each test piece is left in an environment of a temperature of 20 ° C. and a humidity of 65% until the mass becomes constant and tempered (water content of about 8 to 12%).
(3) measuring the size S 0 and mass M 0 temper after specimens.
(4) Each test piece is subjected to a drying test (a test that is left in an environment of a temperature of 40 ° C. and a humidity of 30% for one week) and a moisture absorption test (a test that is left to stand in an environment of a temperature of 30 ° C. and a humidity of 90% for one week) dry test dimension S 1 and the mass M 1 of the specimen after, and to measure the dimension S 2 and the mass M 2 of the test piece after moisture absorption test.
(5) For the test piece after the drying test, the test piece after measuring the dimension S 1 and the mass M 1 is left in an oven maintained at 105 ° C. for 24 hours, and the mass M 3 of the test piece in a completely dry state is measured. To do. Further, the test piece after humidity test, a test piece after the measurement of dimension S 2 and mass M 2 was left for 24 hours in an oven maintained at 105 ° C., measuring the mass M 3 of the dry specimen .
(6) based on the following calculation equation to determine the rate of dimensional change MC 2 in dimensional change MC 1 and wet test in dry test in each direction.
Figure 2018087436

Figure 2018087436
Figure 2018087436

表1に示すように、実施例1では、乾燥、吸湿のいずれの条件においても長さ方向、巾方向のいずれの寸法変化率も小さい。また、長さ方向と巾方向の寸法変化率に差がないので、ねじれが発生しない。一方、3プライ合板の裏面側に化粧材層と同じ厚さの化粧材を貼り付けた比較例1は、乾燥、吸湿のいずれの条件においても寸法変化率が大きい。この床材は、全体としてクロス単板層と平行単板層(挽板含む)のバランスが良いものの、木質基材層が本発明の条件を満足していないため、寸法変化率が大きくなっている。また、比較例2は、実施例1と同じ総厚さを有するが、第5単板層に平行単板を用いており、乾燥条件において巾方向の寸法が大きくなった。   As shown in Table 1, in Example 1, the dimensional change rate in both the length direction and the width direction is small under both conditions of drying and moisture absorption. Moreover, since there is no difference in the dimensional change rate in the length direction and the width direction, no twisting occurs. On the other hand, Comparative Example 1 in which a decorative material having the same thickness as the decorative material layer is attached to the back side of the three-ply plywood has a large dimensional change rate in both dry and moisture absorption conditions. Although this flooring material has a good balance between the cross veneer layer and the parallel veneer layer (including the ground plate) as a whole, the wood base material layer does not satisfy the conditions of the present invention, so the dimensional change rate is increased. Yes. Moreover, although the comparative example 2 has the same total thickness as Example 1, the parallel single plate is used for the 5th single plate layer, and the dimension of the width direction became large on dry conditions.

本発明によれば、反りおよび寸法変化が小さい床材を提供することができる。   ADVANTAGE OF THE INVENTION According to this invention, a flooring with a small curvature and a dimensional change can be provided.

1 化粧材層
2 木質基材層
2a 第1単板層
2b 第2単板層
2c 第3単板層
2d 第4単板層
2e 第5単板層
10 本実施形態に係る床材
DESCRIPTION OF SYMBOLS 1 Cosmetic material layer 2 Wood base material layer 2a 1st single board layer 2b 2nd single board layer 2c 3rd single board layer 2d 4th single board layer 2e 5th single board layer 10 The flooring which concerns on this embodiment

Claims (11)

第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、
前記第1単板層の表面に接着された、厚さが1.0〜2.0mmである化粧材層とを備える、総厚さが7.0mm以下である床材であって、
前記第1単板層、前記第3単板層および前記第5単板層が、その繊維方向が前記床材の長手方向と直交するクロス単板層であり、
前記第2単板層および前記第4単板層が、その繊維方向が前記床材の長手方向と平行である平行単板層であり、
前記第1単板層の厚さが前記第5単板層の厚さよりも大きい、
床材。
A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer and a fifth veneer layer in order,
A flooring material having a total thickness of 7.0 mm or less, comprising a decorative material layer having a thickness of 1.0 to 2.0 mm adhered to the surface of the first veneer layer,
The first single plate layer, the third single plate layer and the fifth single plate layer are cross single plate layers whose fiber directions are orthogonal to the longitudinal direction of the flooring,
The second single plate layer and the fourth single plate layer are parallel single plate layers whose fiber directions are parallel to the longitudinal direction of the flooring,
The thickness of the first veneer layer is greater than the thickness of the fifth veneer layer;
Flooring.
前記第1単板層の厚さが前記第5単板層の厚さの1.5倍以上である、
請求項1に記載の床材。
The thickness of the first veneer layer is at least 1.5 times the thickness of the fifth veneer layer;
The flooring according to claim 1.
前記第1単板層の厚さが1.0〜2.0mmであり、
前記第5単板層の厚さの0.3〜1.0mmである、
請求項1または請求項2に記載の床材。
The thickness of the first single plate layer is 1.0 to 2.0 mm,
The thickness of the fifth veneer layer is 0.3 to 1.0 mm.
The flooring according to claim 1 or 2.
前記木質基材層が、厚さが2.5〜3.5mmの3プライ合板に、前記第1単板層および前記第5単板層を接着した、
請求項1から請求項3までのいずれかに記載の床材。
The wood base layer is bonded to the three-ply plywood having a thickness of 2.5 to 3.5 mm, the first single plate layer and the fifth single plate layer,
The flooring material according to any one of claims 1 to 3.
前記木質基材層の総厚さtに対する、前記第1単板層、前記第3単板層および前記第5単板層の合計厚さtの比(t/t)が、0.60〜0.75である、
請求項1から請求項4までのいずれかに記載の床材。
The ratio (t c / t t ) of the total thickness t c of the first veneer layer, the third veneer layer and the fifth veneer layer to the total thickness t t of the wood substrate layer is 0.60 to 0.75,
The flooring material according to any one of claims 1 to 4.
第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(A1)〜(A4)の工程を有する、床材の製造方法。
(A1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、厚さが異なる2枚のクロス単板と、前記化粧材とを準備する工程、
(A2)前記3プライ合板の一方の面に、接着剤を塗布し、相対的に薄いクロス単板を接着して、前記第5単板層とする工程、
(A3)前記3プライ合板の他方の面に、接着剤を塗布し、相対的に厚いクロス単板を接着して、前記第1単板層とする工程、および、
(A4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer, and a fifth veneer layer in order, and affixed to the surface of the first veneer layer A method for producing a flooring comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, comprising the following steps (A1) to (A4).
(A1) a step of preparing a three-ply plywood, two cross veneers in which the fiber direction is orthogonal to the longitudinal direction of the flooring and having different thicknesses, and the decorative material,
(A2) a step of applying an adhesive to one surface of the three-ply plywood and bonding a relatively thin cross veneer to form the fifth veneer layer;
(A3) applying an adhesive to the other surface of the three-ply plywood to bond a relatively thick cross veneer to form the first veneer layer; and
(A4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.
前記工程(A1)、(A2)、(A3)および(A4)を順に行う、
請求項6に記載の床材の製造方法。
The steps (A1), (A2), (A3) and (A4) are sequentially performed.
The manufacturing method of the flooring material of Claim 6.
第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(B1)〜(B4)の工程を有する、床材の製造方法。
(B1)3プライ合板と、繊維方向が前記床材の長手方向と直交し、2枚のクロス単板と、前記化粧材とを準備する工程、
(B2)前記3プライ合板の一方の面に、接着剤を塗布し、一方のクロス単板を接着し、前記3プライ合板の他方の面に、接着剤を塗布し、他方のクロス単板を接着する工程、
(B3)前記2枚のクロス単板のうち、少なくとも一方のクロス単板を研削し、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(B4)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer, and a fifth veneer layer in order, and affixed to the surface of the first veneer layer A method for producing a flooring comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, comprising the following steps (B1) to (B4).
(B1) a step of preparing a three-ply plywood, a fiber direction perpendicular to the longitudinal direction of the flooring, and preparing two cross single plates and the decorative material,
(B2) Adhesive is applied to one surface of the three-ply plywood, one cross veneer is bonded, the adhesive is applied to the other surface of the three-ply plywood, and the other cross veneer is Bonding process,
(B3) At least one of the two cross single plates is ground, the thicker single plate layer is defined as the first single plate layer, and the thin single plate layer is defined as the fifth single plate layer. The process of
(B4) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.
クロス単板の接着および/または化粧材の接着に際し、
ホットメルト接着剤を用い、冷間プレスにより接着する、
請求項6から請求項8までのいずれかに記載の床材の製造方法。
When bonding cross veneers and / or decorative materials,
Use hot melt adhesive and adhere by cold pressing,
The method for manufacturing a flooring material according to any one of claims 6 to 8.
前記3プライ合板と前記第1単板層との接着を熱間プレスで行い、
前記3プライ合板と前記第5単板層との接着を冷間プレスで行う、
請求項6から請求項9までのいずれかに記載の床材の製造方法。
Bonding the three-ply plywood and the first single plate layer with a hot press,
Bonding the three-ply plywood and the fifth single plate layer with a cold press,
A method for manufacturing a flooring material according to any one of claims 6 to 9.
第1単板層、第2単板層、第3単板層、第4単板層および第5単板層を順に備える木質基材層と、前記第1単板層の表面に貼り付けられ、厚さが1.0〜2.0mmである化粧材層とを備える床材を製造する方法であって、下記の(C1)〜(C3)の工程を有する、床材の製造方法。
(C1)5プライのクロス合板を準備する工程、
(C2)前記5プライのクロス合板の少なくとも一方の表面を研削し、表面の単板層のうち、厚い方の単板層を第1単板層とし、薄い方の単板層を第5単板層とする工程、
(C3)前記第1単板層の表面に、接着剤を塗布し、化粧材を接着して、前記化粧材層とする工程。
A wood substrate layer comprising a first veneer layer, a second veneer layer, a third veneer layer, a fourth veneer layer, and a fifth veneer layer in order, and affixed to the surface of the first veneer layer A method for producing a flooring comprising a decorative material layer having a thickness of 1.0 to 2.0 mm, comprising the following steps (C1) to (C3).
(C1) preparing a 5-ply cross plywood,
(C2) At least one surface of the five-ply cross plywood is ground, and among the single plate layers on the surface, the thicker single plate layer is used as the first single plate layer, and the thin single plate layer is used as the fifth single plate layer. A step of making a plate layer,
(C3) The process of apply | coating an adhesive agent to the surface of the said 1st single board layer, adhere | attaching a cosmetic material, and setting it as the said cosmetic material layer.
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