JP2020033780A - Floor material - Google Patents

Abstract

To provide a floor material which can suppress degradation of a veneer by moisture even when the veneer is provided on a surface of a base material.SOLUTION: Floor materials 100 and 100A include a base material 10, a veneer 20 which is provided on one surface of the base material, contains a dimensional stabilization resin, and has a thickness of 1-3 mm, a moisture-proof layer 30 provided between the base material and the veneer, and a coated film layer 40 provided on a surface of the veneer opposite to the moisture-proof layer. Moisture permeability of the coated film layer is larger than moisture permeability of the moisture-proof layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to flooring.

  BACKGROUND ART Floor materials in which a decorative sheet or veneer is attached to a surface of a base material such as a wood fiber board have been conventionally known. By providing a decorative sheet or the like on the surface of the base material, it becomes possible to ensure surface performance such as scratch resistance and stain resistance, and to enhance design.

In Patent Literature 1, even when a plywood substrate and a wood fiber board having different moisture contents are used, there is no influence of the transfer of moisture from the plywood substrate to the wood fiber board, and the flat and the floor heating is used. Disclosed is a floor heating floor material that is less thermally deformed by heat. Specifically, Patent Document 1, on the plywood substrate, 30 g ^/ m and a moisture barrier layer having a 2 · 24h or less of moisture barrier properties, and moisture content of 7% or less of wood fiber board, ^30g / m 2 · 24h Disclosed is a floor heating floor material obtained by sequentially laminating and integrating the following surface decorative layers having moisture-proof performance. With such a configuration, the moisture of the plywood substrate is prevented from migrating to the wood fiber board by the moisture-proof layer, and the migration (infiltration) of moisture from the floor material surface to the wood fiber board is blocked by the surface decorative layer. I have.

JP 2010-236263 A

  As described in Patent Document 1, the surface of a wood fiber board is covered with a moisture-proof surface decorative layer, and a moisture-proof layer is interposed between the wood fiber board and a plywood substrate, thereby allowing moisture to enter the wood fiber board. Can be suppressed. However, in the case where the wood fiber board originally contains moisture, the water is not released from the wood fiber board due to the effect of the surface decorative layer and the moisture-proof layer, so that there is a problem that the wood fiber board is deteriorated by the moisture.

  The present invention has been made in view of such problems of the related art. An object of the present invention is to provide a flooring material capable of suppressing deterioration of a veneer due to moisture even when a veneer is provided on the surface of a base material.

  In order to solve the above problems, a flooring material according to an aspect of the present invention includes a base material, a veneer provided on one surface of the base material, including a dimensional stabilizing resin, and further having a thickness of 1 mm to 3 mm, It has a moisture-proof layer provided between the base material and the veneer, and a coating layer provided on a surface of the veneer opposite to the surface on the moisture-proof layer side. And the moisture permeability of the coating layer is greater than the moisture permeability of the moisture-proof layer.

  According to the present disclosure, even when a veneer is provided on the surface of a base material, it is possible to obtain a flooring material capable of suppressing deterioration of the veneer due to moisture.

It is a perspective view showing a flooring concerning an embodiment of the present invention. It is the schematic which shows the cross section of the flooring material along the II-II line of FIG. It is the schematic which shows the cross section which followed the II-II line | wire of FIG. 1 regarding the flooring concerning other embodiment of this invention. It is a perspective view showing the flooring concerning another embodiment of the present invention.

  Hereinafter, the flooring material according to the present embodiment will be described in detail. Note that the dimensional ratios in the drawings are exaggerated for the sake of explanation, and may differ from the actual ratios.

[Floor material]
As shown in FIG. 1, the flooring material 100 of the present embodiment includes a base material 10, a veneer plate 20 provided on an upper surface 11 which is one surface of the base material 10, and And a provided moisture-proof layer 30. The flooring material 100 further includes a coating layer 40 provided on the surface 21 of the veneer 20 opposite to the surface on the moisture-proof layer 30 side. That is, the flooring material 100 has a configuration in which the coating film layer 40, the veneer plate 20, the moisture-proof layer 30, and the base material 10 are laminated in this order.

  As shown in FIGS. 1 and 2, the entire upper surface 11 of the base material 10 is covered with a veneer plate 20, and a moisture-proof layer 30 is interposed between the base material 10 and the veneer plate 20. . The base material 10 and the moisture-proof layer 30 are laminated so as to contact each other, and the moisture-proof layer 30 and the veneer plate 20 are also laminated so as to contact each other. However, in the flooring material 100, the base material 10 and the veneer plate 20 are configured not to contact each other. The coating layer 40 is provided so as to directly contact the surface 21 of the veneer 20 opposite to the surface on the moisture-proof layer 30 side, and covers the entire surface 21 of the veneer 20.

  As shown in FIG. 2, actual processing is performed on one end surface of the base material 10 to form a convex portion 12. Further, a groove is formed on an end surface of the base material 10 opposite to the one end surface to form a concave portion 13. When joining a plurality of flooring materials 100, the protrusions 12 of one flooring material 100 are inserted into the recesses 13 of the adjacent flooring material 100 and engaged with each other.

  As the base material 10, a material formed from a woody material having good surface smoothness can be used. Examples of such a wood-based material include wood fiber boards such as MDF (medium density fiber board) and HDF (high density fiber board), and wood boards such as particle board and OSB (oriented strand board). Can be The base material 10 is formed from a wood flour / plastic composite material (WPC) in which wood flour, an inorganic filler, a compatibilizer, a colorant, and the like are contained in a predetermined content in a synthetic resin material. You may. However, plywood is preferable as the base material 10, and plywood such as lauan, eucalyptus, falkata, chamelere, drill, rubberwood, poplar, cedar, larch, and hinoki can be suitably used. The thickness of the base material 10 is not particularly limited, and is preferably, for example, 1.0 mm to 10.0 mm, more preferably 1.0 mm to 5.0 mm, and more preferably 1.5 mm to 3.0 mm. More preferred.

  The veneer plate 20 is formed by thinly cutting a veneer, and is used as a decorative surface decorative material. In the floor material 100, the thickness of the veneer plate 20 is not particularly limited, but is preferably 1 mm to 3 mm. When the thickness of the veneer plate 20 is in this range, it is possible to obtain high scratch resistance and dent resistance by increasing hardness while having high designability.

  The wood that constitutes the veneer plate 20 is not particularly limited, and is selected from the group consisting of cedar, larch, pine, rubber tree, hippo, beech, oak, beach, oak, teak, hard maple, cherry, walnut, white ash, and mahogany. At least one of them can be used. Since these woods have a high-class appearance and a high design property, the veneer 20 using these woods can be suitably used as a surface decorative material of the flooring material 100.

  In addition, as the timber constituting the veneer 20, a fast-growing tree which becomes a large-diameter tree in a short period of time mainly in Southeast Asia, such as Japan, can also be used. Specifically, as the wood, at least one selected from the group consisting of neem, chanchinmodoki, alder, lilybean, eucalyptus, poplar, acacia mangium, and falcata can be used. The fast-growing trees are fast growing and relatively inexpensive, and can be sufficiently supplied in plantations. Here, in the fast-growing tree, the anisotropy occurs in the dimensional change due to the wide part of the wide annual ring and the large curvature of the annual ring. Therefore, when drying a fast-growing tree, a large contraction stress is locally generated, and dry cracking is likely to occur. However, by infiltrating the dimensional stabilizing resin into the inside of the fast-growing tree, the swelling state can be maintained and the shrinkage can be suppressed. Therefore, in the present embodiment, the fast-growing tree can be suitably used as wood.

  Wood repeatedly swells and shrinks as it absorbs and desorbs moisture, so that cracks, warpage, and deformation occur due to changes in the amount of moisture. Therefore, the slab 20 is subjected to a dimensional stabilization process in order to suppress cracks, warpage, and deformation.

Here, the dimensional stabilization treatment of wood typically includes the following three types of methods.
(1) Method of impregnating dimensional stabilizing resin into the wood cell wall The dimensional change of wood is caused by the expansion of water molecules between the hydroxyl groups of cellulose, which is a constituent component, and the shrinkage of water molecules by drying, whereby the water molecules are discharged. It happens by doing. Therefore, as the dimensional stabilizing resin, a resin that can enter and be filled in the micro voids in the cell wall of wood instead of water molecules and that can remain in the micro voids without being evaporated even during drying is used. By using such a dimensional stabilizing resin, the cell wall can be maintained in a swollen state by the dimensional stabilizing resin. Therefore, shrinkage of the veneer can be suppressed by a so-called “bulk effect”.
(2) Method of Filling Cell Lumen of Wood By filling the cell lumens of wood with resin, it is possible to prevent water, which is a cause of dimensional change, from entering the cell wall, and develop dimensional stability. At the time of impregnation, the inside of the cell is impregnated in a monomer state, and then cured and polymerized by heat or the like to fix the resin in the wood. In this method, since the fine unevenness of the wood is filled with the resin, there is a characteristic that the texture of the wood is easily lost.
(3) Heat treatment This is a method of heat-treating wood to destroy hydroxyl groups, which are water adsorption points, and to suppress water adsorption itself. Heat steaming is a typical method.
And in this embodiment, it is preferable to apply the dimensional stabilization processing classified into (1).

  The dimension stabilizing resin is preferably at least one of a glycol-based resin and a glyoxal resin. The glycol-based resin and the glyoxal resin are likely to be filled into the minute voids in the cell wall of the wood constituting the veneer 20 and filled. In addition, since these resins have low volatility even when dried, they remain in the minute voids of the wood and easily exert the bulk effect.

  The glycol-based resin is preferably at least one of a polyalkylene glycol and a polyalkylene glycol derivative. As the polyalkylene glycol, those having a weight average molecular weight of 200 to 20,000 can be used. As the polyalkylene glycol, for example, polyethylene glycol, polypropylene glycol, and polybutylene glycol can be used alone or in combination. Alternatively, the polyalkylene glycol may be a copolymer of alkylene glycols having different alkylene groups, such as a copolymer of ethylene glycol and propylene glycol.

  As the polyalkylene glycol derivative, for example, polyalkylene glycol mono (meth) acrylate can be used. Examples of the polyalkylene glycol mono (meth) acrylate include polyethylene glycol monomethacrylate (PEGMA).

  Glyoxal resin is a cyclic urea resin composed of urea, formaldehyde and glyoxal. When the glyoxal resin enters and fills the micropores in the cell wall of wood, it is insolubilized by a self-polycondensation reaction, and is also insolubilized by an ether bond with a hydroxyl group such as cellulose of wood.

  The dimension stabilizing resin is preferably a mixture of a glycol resin and a glyoxal resin. The glycol-based resin enters and fills the micro voids in the cell wall of wood, and can stay in the micro voids. Thereby, since the cell wall of the wood can be maintained in a swollen state, shrinkage of the wood can be suppressed by the bulk effect, and cracks, warpage, and deformation can be prevented. However, since the impregnated glycol-based resin is still easily soluble in water even after drying the wood, there is a possibility that the glycol-based resin is eluted on the surface of the wood when the wood absorbs water or moisture. . The glyoxal resin is less likely to be eluted from the veneer plate 20 than the glycol resin, but has a smaller bulking effect than the glycol resin.

  However, by using a mixture of a glycol-based resin and a glyoxal resin as the dimension stabilizing resin, the glycol-based resin and the glyoxal resin are dehydrated and condensed, and are insoluble in water inside the cell wall. Furthermore, a mixture of a glycol-based resin and a glyoxal resin is insolubilized by forming an ether bond with a hydroxyl group such as cellulose of wood. Therefore, a mixture of a glycol-based resin and a glyoxal resin can be suitably used as a dimensional stabilizing resin because of its excellent dimensional stability and elution resistance to wood.

  The dimension stabilizing resin is not limited to the glycol-based resin and the glyoxal resin, and a resin capable of providing a bulk effect to wood can be used. Therefore, as the dimension stabilizing resin, at least one selected from the group consisting of glycol resins, glyoxal resins, melamine resins, urea resins, and phenol resins can be used.

  The veneer 20 may be a veneer veneer obtained by increasing the hardness of a veneer veneer by consolidating the veneer veneer and improving the scratch resistance and dent resistance.

  Here, when the veneer 20 impregnated with the dimensional stabilizing resin is directly adhered to the surface of the substrate 10, moisture may migrate from the substrate 10 to the veneer 20. In particular, when the thickness of the veneer plate 20 is large, moisture may migrate from the base material 10 and stay inside the veneer plate 20. When a large amount of water migrates to the veneer 20, the dimensional stabilizing resin is eluted on the surface of the veneer 20, or the dimensional stabilizing resin is hydrolyzed to reduce the dimensional stabilizing effect on the veneer 20. There is.

  Therefore, in the flooring material 100 of the present embodiment, the moisture-proof layer 30 is interposed between the base material 10 and the veneer plate 20, and the base material 10 and the veneer plate 20 are not in contact with each other. The moisture-proof layer 30 is a layer made of a material having low moisture permeability, and can suppress the transfer of moisture from the base material 10 to the veneer 20. As a result, the amount of water remaining in the veneer 20 is reduced, so that the dimensional stabilizing resin is prevented from being eluted on the surface of the veneer 20 and the dimensional stabilizing resin is prevented from being hydrolyzed, and the dimensional stabilizing effect on the veneer 20 is extended. It can be maintained over a period.

  The flooring 100 further includes a coating layer 40 that covers the entire surface 21 of the veneer 20 opposite to the surface on the moisture-proof layer 30 side. Therefore, it is possible to prevent the dimensional stabilizing resin from being eluted on the surface of the veneer 20 and the dimensional stabilizing resin from being hydrolyzed by the transfer of moisture from the atmosphere to the veneer 20.

  Here, in the flooring 100, the moisture permeability of the coating layer 40 is preferably larger than the moisture permeability of the moisture-proof layer 30. Moisture permeability refers to the amount of water vapor that passes through a unit area of a film-like substance for a certain period of time, and can be measured according to Japanese Industrial Standard JIS Z0208 (Testing method for moisture permeability of moisture-proof packaging material (cup method)). . That is, it is preferable that the amount of water passing through the coating layer 40 is larger than the amount of water passing through the moisture-proof layer 30.

  As described above, the moisture can be suppressed from being transferred from the base material 10 to the veneer plate 20 by interposing the moisture-proof layer 30. In addition, by covering the surface 21 of the veneer 20 with the coating layer 40, it is possible to suppress the transfer of moisture from the atmosphere to the veneer 20. However, as in Patent Document 1, when the moisture permeability of the moisture-proof layer and the coating layer is the same and the moisture permeability is low, and when moisture remains in the veneer, the influence of the moisture-proof layer and the coating layer. This makes it difficult for moisture to be released from the veneer. Therefore, the dimension stabilizing resin may be hydrolyzed by moisture, and the veneer may be deteriorated.

  Therefore, in the present embodiment, the moisture permeability of the coating layer 40 is made larger than that of the moisture-proof layer 30. Thus, even if moisture remains in the veneer 20, moisture is released from the veneer 20 to the outside of the flooring 100 through the coating layer 40. As a result, it is possible to suppress elution of the dimension stabilizing resin from the veneer 20 and hydrolysis of the dimension stabilizing resin due to moisture.

The flooring 100, the moisture permeability of the moisture-proof layer 30 is not particularly limited, is preferably not more than 50g ^/ m 2 · 24h, more preferably at most ^{30g / m 2 · 24h, 10g} / m 2 · 24h It is more preferred that: The moisture permeability of the coating layer 40 is not particularly limited as long as it is greater than that of the moisture-proof layer 30. However, the moisture permeability of the coating layer 40 is preferably at least twice the moisture permeability of the moisture-proof layer 30, more preferably at least 5 times, even more preferably at least 10 times. The upper limit of the moisture permeability of the coating layer 40 is not particularly limited, but may be, for example, 300 g / m ² · 24 h or less.

  The moisture-proof layer 30 can be made of a material having good surface smoothness. As the moisture-proof layer 30, for example, a resin sheet made of a resin can be used. As the resin, a polyolefin containing at least one of polyethylene and polypropylene can be used. In addition, as the moisture-proof layer 30, a sheet in which a nonwoven fabric is attached to both sides of a polyethylene film can be used, and the nonwoven fabric is preferably made of a material having adhesiveness. By using a sheet provided with a nonwoven fabric having such an adhesive property, it becomes possible to easily bond the veneer plate 20, the moisture-proof layer 30, and the base material 10.

  When bonding the veneer plate 20, the moisture-proof layer 30, and the substrate 10, the adhesive between the base material 10 and the moisture-proof layer 30 and / or between the moisture-proof layer 30 and the veneer plate 20 is used to bond them. May be interposed. Such an adhesive is not particularly limited as long as it can firmly bond them. Examples of the adhesive include an aqueous adhesive such as an aqueous vinyl urethane resin adhesive, a vinyl acetate resin adhesive, and an aqueous isocyanate resin adhesive.

  The moisture-proof layer 30 is not limited to a resin sheet having a low moisture permeability. For example, the moisture-proof layer 30 may be formed by interposing an adhesive between the veneer plate 20 and the base material 10 and further increasing the thickness of the adhesive. Can be. That is, an adhesive layer obtained by curing an adhesive can be used as the moisture-proof layer 30 without using a resin sheet for forming the moisture-proof layer 30. Since the moisture permeability decreases as the thickness of the adhesive layer increases, it is possible to form the moisture-proof layer 30 having a desired moisture permeability by adjusting the thickness of the adhesive layer between the veneer 20 and the substrate 10. it can. As an adhesive capable of forming such a moisture-proof layer 30, for example, a polyurethane-based adhesive can be used.

  The coating layer 40 may be made of a material that can increase the moisture permeability of the moisture-proof layer 30. Specifically, the coating layer 40 is preferably a cured film formed by applying a paint to the surface 21 of the veneer 20 and then curing the coating. By using such a cured film as the coating layer 40, the coating amount can be obtained by adjusting the amount of coating applied and changing the thickness of the cured film. That is, the moisture permeability of the coating layer 40 can be increased by reducing the amount of the applied coating material and the thickness of the cured film. Conversely, the moisture permeability of the coating layer 40 can be reduced by increasing the amount of the applied paint to increase the thickness of the cured film. Therefore, the coating layer 40 having a desired moisture permeability can be obtained by adjusting the application amount of the paint so that the moisture permeability is higher than that of the moisture-proof layer 30.

  As a coating material for forming the coating layer 40, at least one selected from the group consisting of aminoalkyd resin, vinyl resin, acrylic resin, epoxy resin, urethane resin, acrylic urethane resin, unsaturated polyester resin and isocyanate resin Can be used. Further, as a paint for forming the coating film layer 40, it is preferable to use a UV-curable paint in order to enhance work efficiency.

  The coating layer 40 may be added with an inorganic filler made of an inorganic material, for example, an alumina powder as an extender. The coating layer 40 preferably has a higher visible light transmittance so as not to impair the grain and color of the veneer plate 20.

  As shown in FIGS. 1 and 2, the coating layer 40 is provided so as to directly contact the surface 21 of the veneer 20 on the side opposite to the moisture-proof layer 30 side, and covers the entire surface 21 of the veneer 20. Is preferred. Thereby, it is possible to suppress the penetration of moisture into the interior of the veneer 20 through the surface 21 of the veneer 20 from the outside of the flooring 100. However, the present embodiment is not limited to such an aspect, and the coating layer 40 may cover the end surfaces of the veneer 20 and the moisture-proof layer 30.

  Specifically, as shown in FIG. 3, in the flooring material 100 </ b> A, the coating layer 40 includes the entire surface (surface 21) of the veneer 20 on the side opposite to the moisture-proof layer 30 side, and the end surface 22 of the veneer 20. It is preferable that the end face 32 of the moisture-proof layer 30 is entirely covered. Accordingly, it is possible to prevent water from penetrating from the outside of the flooring material 100 through the surface 21 and the end face 22 of the veneer 20 and into the interior of the veneer 20. Therefore, it is possible to further suppress elution of the dimensional stabilizing resin from the veneer 20 and hydrolysis of the dimensional stabilizing resin due to moisture.

  In FIG. 3, the coating layer 40 covers the entire end face 22 of the veneer plate 20 and the end face 32 of the moisture-proof layer 30. However, in order to further suppress infiltration of moisture into the veneer plate 20, the coating layer 40 extends from the boundary between the moisture-proof layer 30 and the base material 10 to the convex portions 12 and the concave portions 13 of the base material 10. The end face of the material 10 may be covered.

  As described above, in the flooring materials 100 and 100A, the moisture-proof layer 30 is interposed between the base material 10 and the veneer plate 20 as a whole. The moisture-proof layer 30 is not provided on the other surface (the lower surface 14) of the substrate 10 opposite to the one surface (the upper surface 11). Therefore, the base material 10 can easily absorb and release moisture through the lower surface 14. However, the present embodiment is not limited to such an aspect, and the moisture-proof layer 30 may be provided on the other surface of the substrate 10 opposite to the one surface. For example, when the substrate 10 is made of a particle board, it is preferable to provide a moisture-proof layer 30 on the lower surface 14 of the substrate 10. Since the particle board is a material that easily generates mold and the like due to moisture absorption, by providing the moisture-proof layer 30 on both the upper surface 11 and the lower surface 14 of the base material 10, the penetration of moisture into the base material 10 is suppressed, It becomes possible to prevent the occurrence of mold and the like.

  As described above, the flooring materials 100 and 100A of the present embodiment include the base material 10 and the veneer plate 20 provided on one surface of the base material 10 and including the dimensional stabilizing resin and having a thickness of 1 mm to 3 mm. A moisture-proof layer 30 is provided between the base material 10 and the veneer plate 20. The flooring materials 100 and 100A further include a coating layer 40 provided on the surface (surface 21) of the veneer 20 opposite to the surface on the moisture-proof layer 30 side. The moisture permeability of the coating layer 40 is larger than the moisture permeability of the moisture-proof layer 30. By interposing the moisture-proof layer 30 between the base material 10 and the veneer plate 20, it is possible to suppress the transfer of moisture from the base material 10 to the veneer plate 20. In addition, by covering the surface 21 of the veneer 20 with the coating layer 40, it is possible to suppress the transfer of moisture from the atmosphere to the veneer 20. By making the moisture permeability of the coating layer 40 larger than that of the moisture-proof layer 30, even if moisture is left on the veneer 20, moisture is released from the veneer 20 to the outside of the flooring 100 through the coating layer 40. Is done. As a result, it is possible to suppress elution of the dimension stabilizing resin from the veneer 20 and hydrolysis of the dimension stabilizing resin due to moisture.

  In FIGS. 1 and 2, the protruding plate 20 is formed by cutting a veneer thinly, but the present embodiment is not limited to such an aspect. For example, as in the case of a flooring material 100B shown in FIG. 4, a laminated material formed by gluing and bonding a plurality of wood pieces may be used as the veneer plate 20A. Further, as the veneer plate 20A, a compacted laminated material in which the hardness is increased by subjecting the laminated material to compaction processing to improve the scratch resistance performance and the dent resistance performance may be used.

[Production method of flooring]
Next, a method for manufacturing a flooring material according to the present embodiment will be described. The flooring material 100 is formed by laminating and bonding the above-described veneer 20, the moisture-proof layer 30, and the base material 10 in this order, and then applying and curing a paint for forming the coating layer 40 on the surface 21 of the veneer 20. By doing so, it can be obtained.

  The method of manufacturing the veneer plate 20 is not particularly limited, but can be manufactured, for example, as follows. First, a dimensional stabilization process of impregnating a dimensional stabilizing resin into the wood constituting the veneer 20 is performed. Specifically, the wood can be impregnated with the dimensional stabilizing resin by immersing the wood in an aqueous solution containing the dimensional stabilizing resin and leaving the wood to stand. In order to accelerate the impregnation of the dimensional stabilizing resin into the wood, it is preferable to pressurize the wood while the wood is placed in a pressure-resistant container filled with an aqueous solution. At this time, the pressure to be applied is not particularly limited, but is preferably, for example, 0.3 to 2.0 MPa.

  In order to expedite the impregnation of the wood with the dimensional stabilizing resin, the wood may be immersed in an aqueous solution after the pressure inside the wood has been reduced and the air inside the wood has been removed. This makes it easier for the aqueous solution to penetrate into the interior of the wood vessel, so that the wood can be quickly impregnated with the dimensional stabilizing resin.

  After impregnating the wood with the dimensional stabilizing resin, it is preferable to remove excess aqueous solution adhering to the wood. After impregnating the wood with the dimension stabilizing resin, the wood may be dried to remove water as a solvent.

  Then, the veneer 20 is obtained by slicing the wood impregnated with the dimensional stabilizing resin. The method for slicing wood is not particularly limited, and for example, can be performed using a slicer. As the slicer, any of a vertical collision slicer and a horizontal collision slicer can be used. If necessary, the obtained veneer plate 20 may be pressed to perform a consolidation treatment.

  Next, the obtained veneer plate 20 and the moisture-proof layer 30 are bonded to the base material 10. The bonding method is not particularly limited. For example, after the veneer 20 and the moisture-proof layer 30 are overlaid on the substrate 10, the veneer 20, the moisture-proof layer 30 and the substrate 10 are heated and pressed, so that the veneer 20 and the moisture-proof layer 30 are pressed. Can be adhered to the substrate 10. The apparatus used for such an adhesion step is not particularly limited, and for example, a hot press molding machine or the like can be used.

  An adhesive may be interposed between the veneer plate 20 and the moisture-proof layer 30 and between the moisture-proof layer 30 and the base material 10 to join them. As such an adhesive, those described above can be used. When a sheet in which a nonwoven fabric made of an adhesive material is attached to both surfaces of a resin film is used as the moisture-proof layer 30, the veneer 20 and the moisture-proof layer 30 can be bonded to the base material 10 without using an adhesive. Can be adhered to.

  As described above, the veneer plate 20, the moisture-proof layer 30, and the base material 10 may be bonded together by heating and pressing, but the present embodiment is not limited to this method. For example, first, the moisture-proof layer 30 is superimposed on the base material 10 and heated and pressed, thereby bonding them. After that, the veneer 20 is superimposed on the moisture-proof layer 30 and heated and pressed, thereby bonding them. Is also good. That is, first, the moisture-proof layer 30 may be bonded to the substrate 10, and then the veneer 20 may be bonded to the moisture-proof layer 30.

  Next, a paint for forming the coating layer 40 is applied to the surface 21 of the veneer 20 in the composite material in which the veneer 20 and the moisture-proof layer 30 are bonded to the base material 10. The method of applying the paint is not particularly limited, and for example, a method of applying with a roller such as a sponge roller, a brush or a roll coater, or a method of spraying with a spray device or the like can be used. In the case where the coating layer 40 is formed so as to cover the entire end face 22 of the veneer 20 and the end face 32 of the moisture-proof layer 30, paint is also applied to the end face 22 of the veneer 20 and the end face 32 of the moisture-proof layer 30. .

  After applying the coating material, the coating film layer 40 can be formed by drying and removing the solvent in the coating material. When the paint is an ultraviolet curable paint, the coating layer 40 can be formed by irradiating the paint with ultraviolet rays.

  As described above, the flooring materials 100 and 100A of the present embodiment are obtained by laminating the veneer 20, the moisture-proof layer 30, and the base material 10 in this order and bonding them, and then apply the paint for forming the coating layer 40 on the veneer 20. It can be obtained by coating and curing. Therefore, it is possible to obtain a floor material capable of suppressing deterioration of the veneer plate 20 due to moisture by a simple method.

  Hereinafter, the present embodiment will be described in more detail with reference to Examples and Comparative Examples, but the present embodiment is not limited to Examples.

The following materials were used in preparing the flooring materials of Examples and Comparative Examples.
Wood for veneer A hard maple material having a thickness of 5/4 inch (3.175 mm) and being a dry material (KD material) was used.
-Dimension stabilizing resin Polyethylene glycol (PEG2000) having a weight average molecular weight of 2000 was used as a water-soluble dimensional stabilizing resin. In the impregnation step, PEG2000 was dissolved in ion-exchanged water to use a dimensional stabilizing resin aqueous solution having a solid content of 30% by mass.
-Base material Falkata plywood having a width of 313 mm, a length of 1845 mm, and a thickness of 10 mm was used.
· Moisture barrier moisture permeability VS sheet is 7 g ^/ m 2 · 24h (manufactured by Toppan Printing Co.), and moisture permeability was used VS sheet (manufactured by Toppan Printing Co., Ltd.) is a 80g ^/ m 2 · 24h.
- The coating layer moisture permeability using a urethane acrylate (manufactured by NATCO Co., Ltd.) which is a 60g ^/ m 2 · 24h.

[Example 1]
First, a hard maple material as veneer wood was impregnated with PEG2000 by a vacuum pressure method. Specifically, first, after the hard maple material was placed in a pressure-resistant container, a decompression treatment was performed at a pressure of -0.95 MPa or less for 10 minutes. Next, the above-mentioned aqueous solution of dimensional stabilization resin was poured into the pressure-resistant container, and the hard maple material was immersed in the aqueous solution. Then, in a state where the hard maple material was immersed in the aqueous solution, a pressure treatment was performed for 3 hours under a pressure atmosphere of 0.8 MPa or more.

  Then, the impregnated hard maple material was sliced using a slicer to obtain a veneer having a thickness of 2 mm.

Next, the obtained veneer and the moisture-proof layer having a moisture permeability of 7 g / m ² · 24 h were bonded to a substrate using a modified vinyl acetate adhesive. Specifically, a modified vinyl acetate adhesive was applied to the surface of the base material such that the application amount was 70 g / sheet, and then the moisture-proof layer was overlaid. Further, a modified vinyl acetate adhesive was applied to the surface of the moisture-proof layer so that the application amount was 70 g / sheet, and then the veneers were overlapped. The laminate of the veneer, the moisture-proof layer and the substrate was pressed at 105 ° C. for 3 minutes to obtain a composite material in which the veneer and the moisture-proof layer were bonded to the substrate.

  Then, the end face of the obtained composite material was subjected to actual floor processing and groove processing using a router.

Next, urethane acrylate coating was applied to the surface of the veneer in the composite material having the grooves and the grooves formed thereon using a roll coater. Specifically, the coating was applied to the entire surface of the veneer and to the portion where the grooved surface of the veneer at the end face of the composite material was in contact with the moisture-proof layer. Thereafter, the urethane acrylate coating film was cured by irradiating the urethane acrylate coating film with ultraviolet rays. Incidentally, urethane acrylate cured film obtained has a moisture permeability was 60g ^/ m 2 · 24h.

  In this way, the veneer impregnated with the dimensional stabilizing resin and the moisture-proof layer are adhered to the base material, and further the entire surface of the veneer, and the coating layer covering the entire end surface of the veneer and the entire end surface of the moisture-proof layer are formed. The provided flooring material of this example was obtained.

[Example 2]
When urethane acrylate was applied, the floor material of this example was obtained in the same manner as in Example 1 except that only the entire surface of the veneer was applied. That is, in the second embodiment, the coating is not applied to a portion where the groove surface of the grooved veneer on the end surface of the composite material and the moisture-proof layer are in contact. Therefore, in the flooring material of Example 2, the veneer impregnated with the dimensional stabilizing resin and the moisture-proof layer are bonded to the base material, and only the entire surface of the veneer is covered with the coating layer.

[Comparative Example 1]
As moisture barrier, except that water vapor permeability using VS sheet is 80g / m 2 · ^24h in the same manner as in Example 1 to obtain a floor material of the present embodiment.

  Table 1 summarizes the thickness of the veneer, the moisture permeability of the moisture-proof layer and the coating layer, and the coating location of the coating layer in the flooring materials of Examples 1 and 2 and Comparative Example 1.

[Evaluation]
The wire mesh was placed on a 50 ° C. hot water tank, and the floor material of each example was installed so that steam would hit from the back side of the floor material and that the steam would not leak from the gap between the wire mesh and the back surface of the floor material. . In such a state, steam generated from warm water at 50 ° C. was continuously applied for 100 hours, and the discoloration of the appearance of the flooring material and the presence or absence of resin elution on the surface of the flooring material were evaluated.

(Appearance discoloration)
The chromaticity (L ^* ) and lightness (a ^* , b ^* ) of the coating layer side before and after applying steam to each of the flooring materials in each example were measured using a spectrophotometer. Then, the color difference (ΔE ^* ) of the floor material of each example before and after applying steam was obtained. In the flooring material of each example, the case where ΔE ^* was 5 or less was evaluated as “○”, and the case where ΔE ^* exceeded 5 was evaluated as “x”. The evaluation results are shown in Table 1.

(Elution of resin)
The floor material of each example was visually observed before and after the application of steam to confirm the presence or absence of resin elution. Then, the case where the resin did not elute from the surface and the groove of the flooring material was evaluated as “○”, and the case where the resin eluted from the surface or the groove of the flooring material was evaluated as “×”. The evaluation results are shown in Table 1.

  In the flooring material of Example 1, a moisture-proof layer is provided between the base material and the veneer, and the coating layer covers the entire surface of the veneer and the entire end face of the veneer and the moisture-proof layer. For this reason, even when steam is applied from the back surface of the flooring material, the steam does not easily enter the veneer plate due to the effects of the moisture-proof layer and the coating layer. Furthermore, since the moisture permeability of the coating layer is greater than the moisture permeability of the moisture-proof layer, even if steam invades the veneer, moisture is released to the outside through the coating layer, making it difficult for water to stay in the veneer. Has become. As a result, it can be understood that deterioration of the veneer and color change can be suppressed, and furthermore, elution of the dimensional stabilizing resin impregnated into the veneer can be suppressed.

  In the flooring material of Example 2, a moisture-proof layer is provided between the base material and the veneer, and the coating layer covers the entire surface of the veneer. The moisture permeability of the coating layer is larger than that of the moisture-proof layer. Therefore, the effect of the moisture-proof layer makes it difficult for moisture to penetrate into the veneer, and even when steam invades the veneer, moisture is easily released to the outside through the coating layer. As a result, it can be seen that deterioration of the veneer and color change can be suppressed. However, in the flooring material of Example 2, since the end surfaces of the veneer and the moisture-proof layer were not covered with the coating layer, the vapor came into contact with the end surface of the veneer, and the dimensional stabilizing resin was slightly eluted.

  In the flooring material of Comparative Example 1, a moisture-proof layer is provided between the base material and the veneer, and the coating layer covers the entire surface of the veneer and the entire end face of the veneer and the moisture-proof layer. However, since the moisture permeability of the moisture-proof layer is greater than the moisture permeability of the coating layer, the steam applied to the back surface of the floor material passes through the base material and the moisture-proof layer to reach the veneer, and a large amount of moisture is present inside the veneer. Has stayed. As a result, the veneer deteriorated and the color changed.

  The present embodiment has been described above, but the present embodiment is not limited to these, and various modifications can be made within the scope of the present embodiment.

DESCRIPTION OF SYMBOLS 10 Base material 20, 20A Veneer plate 22 End surface of veneer plate 30 Moisture-proof layer 32 End surface of moisture-proof layer 40 Coating layer 100, 100A, 100B Floor material

Claims (4)

A substrate,
A veneer plate provided on one surface of the base material, including a dimension stabilizing resin, and further having a thickness of 1 mm to 3 mm;
A moisture-proof layer provided between the base material and the veneer,
A coating layer provided on a surface of the veneer opposite to the surface on the moisture-proof layer side,
With
The floor material, wherein the moisture permeability of the coating layer is greater than the moisture permeability of the moisture-proof layer.   The flooring material according to claim 1, wherein the coating layer covers the entire surface of the veneer on the side opposite to the moisture-proof layer side, and the entire end surface of the veneer and the entire end surface of the moisture-proof layer. .   The flooring according to claim 1 or 2, wherein the moisture-proof layer is not provided on the other surface of the substrate opposite to the one surface.   The flooring according to any one of claims 1 to 3, wherein the dimensional stabilizing resin is at least one of a glycol-based resin and a glyoxal resin.

Images