JP2021045428A - Floor material and construction method of the same - Google Patents

Abstract

To provide a floor material that achieves "improvement of design property" in a fabric constituting an outer fabric layer by a vinyl chloride resin being weaved in a vaginal core sheath structure mono-filament, and provide a construction method.SOLUTION: A floor material 1 is provided by laminating an outer fabric layer 2 of a fabric 2', a cushion layer 3, a core material layer 4 and a base layer 5 in this order. The fabric 2' is provided with a vinyl chloride resin weaved in a vaginal core sheath structure mono-filament. Also, the fabric is preferable that an intersection with warp and weft of the fabric 2' may be welded, the outer fabric layer 2 may cover end faces of the cushion layer 3 and the core material layer 4, the core material layer 4 may have durometer hardness of 76 or more, a cut amount when the number of operation times is 20 times or more may be 0.1 mm or more in a cutter edge sharpness testing machine, and water repellency of the cushion layer 3 may be 3-grade or more. A construction method of the floor material 1 has a peeling step of peeling the outer fabric layer 2 out of the cushion layer 3, a cutting step of cutting the core material layer 4 peeling the outer fabric layer 2, and a cover step of covering the cut surface of the core material layer 4 with the outer fabric layer 2.SELECTED DRAWING: Figure 1

Description

The present invention relates to a floor material in which a surface material layer composed of a woven fabric, a cushion layer, a core material layer, and a base layer are laminated in this order, and a method of constructing the floor material.

Conventionally, a buffer floor material is known (Patent Document 1).
In this buffer floor material, a skin material, a reinforcing material, a foam material, and a stretchable mold release material are laminated in this order.
Such a buffer floor material uses a plastic skin such as a plastic film as the skin material, and paragraph 0014 of Patent Document 1 describes that it is preferable because the cleaning efficiency when it becomes dirty is high. There is.

Japanese Unexamined Patent Publication No. 2004-116558

However, the skin material of the buffer floor material described in Patent Document 1 has problems such as monotonous design, a risk of the handle disappearing due to wear, and slipperiness due to low frictional resistance.

Therefore, the present invention is a flooring material capable of realizing "improvement of design" by weaving a woven fabric constituting the outer layer of the flooring material with a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath. And the purpose is to provide a method of constructing flooring materials.

The floor material 1 according to the present invention is a floor material in which a surface material layer composed of a woven fabric, a cushion layer, a core material layer, and a base material layer are laminated in this order, and constitutes the surface material layer. The first feature of the woven fabric is that it is woven with a monofilament having a core-sheath structure with a polyvinyl chloride resin as a sheath.
In the present invention, "the outer layer, the cushion layer, the core material layer, and the base layer are laminated in this order" means that all the portions of each layer are laminated in this order, as will be described later. In addition to the case where the outer material layer is covered, the peripheral end portion "only" of the outer material wraps around from the end surface of the floor material to the peripheral end portion of the back surface (covering the end surfaces of the cushion layer and the core material layer, and further, the core material. It also includes the case of covering the back surface of the layer and the back surface of the base layer.

The second feature of the flooring material 1 according to the present invention is that, in addition to the first feature, at least a part of the intersection of the warp and the weft of the woven fabric constituting the outer layer is fused. At the point.

The third feature of the floor material 1 according to the present invention is that, in addition to the above-mentioned first or second feature, the outer material layer also covers at least the end faces of the cushion layer and the core material layer.

The fourth feature of the floor material 1 according to the present invention is that, in addition to the above-mentioned first to third features, the core material constituting the core material layer has a type C durometer hardness of 76 or more.

The fifth feature of the floor material 1 according to the present invention is, in addition to the above-mentioned first to fourth features, the core material constituting the core material layer is a blade sharpness test according to the Honda method for cutting the core material. The point is that the depth of cut is 0.1 mm or more when the number of operations of the machine is 20 times.
The "cutlery sharpness tester according to the Honda type" in the present invention includes not only the Honda type blade sharpness tester itself but also a tester improved according to the Honda type blade sharpness tester and ISO. Includes a testing machine used in the blade wear resistance test of −8442-5 and a testing machine improved according to this blade wear resistance test.

The sixth feature of the floor material 1 according to the present invention is that, in addition to the above-mentioned features 1 to 5, the cushion material constituting the cushion layer is subjected to a water repellency test (spray) of JIS-L-1092: 2009. The point is that the water repellency measured in the test according to the test) is grade 3 or higher.

Due to these characteristics, the woven fabric 2'constituting the outer material layer 2 of the floor material 1 is woven with a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath, so that the woven fabric 2'is different from Patent Document 1. Various designs can be constructed by the patterns and irregularities generated by the structure of the PVC (“improvement of design”), and the polyvinyl chloride resin creates patterns and irregularities by the core-sheath structure monofilament of the sheath. Therefore, the handle is hard to disappear due to wear (“improvement of handle durability”), and it is hard to slip due to high frictional resistance (“improvement of anti-slip property”).

Further, by fusing at least a part of the intersecting portion between the warp threads 2a'and the weft threads 2b' of the woven fabric 2'constituting the outer material layer 2, the pattern or unevenness generated by the structure of the woven fabric 2'is formed. It becomes easier to hold the floor material 1 in the intended state at the time of weaving (“maintenance of design”), and the durability of the outer layer 2 on the most exposed side of the floor material 1 is also improved (“improvement of durability”).

Further, by covering at least the end faces 3c and 4c of the cushion layer 3 and the core material layer 4 with the outer material layer 2, the cushion has poor design unlike Patent Document 1 in which the end face (side surface) of the cushioning floor material is not mentioned. Since the layer 3 and the core material layer 4 are exposed, "improvement of design" can be realized.
If the outer material layer 2 covers the end faces 3c, 4c, etc. of the cushion layer 3 and the core material layer 4, the plan-view area of the outer material layer 2 is the same as that of the other cushion layer 3, the core material layer 4, and the base layer 5. It can be said that it is wider than the plan view area. Therefore, when the floor material 1 is cut according to the shape, size, etc. of the construction site when the floor material 1 is constructed, the cut surface (cut end surface) of the cushion layer 3 or the core material layer 4 generated by the cutting. ) Etc. can be easily covered with the outer material layer 2 that is wider and is not cut, further "improvement of design" can be achieved, and a part (peripheral end portion) of the back surface 1b from the end surface 1c of the floor material 1 can be further improved. By covering up to (etc.) with the outer material layer 2 and adhering, the outer material layer 2 and the other cushion layer 3, the core material layer 4 and the base layer 5 can be more strongly fixed, and the durability of the floor material 1 as a whole can be improved. It can be said that it will improve.

In addition, by setting the type C durometer hardness of the core material 4'constituting the core material layer 4 to 76 or more, it is difficult for the user to step on the floor material 1 to make a dent (“dent suppression”), and the floor material 1 It can be said that even if a chair with casters is ridden on the floor, it is difficult for caster marks to be left (“improvement of caster resistance”).

Furthermore, by setting the depth of cut to 0.1 mm or more when the number of operations is 20 with a Honda type blade sharpness tester or the like that cuts the core material 4'that constitutes the core material layer 4, the floor material When constructing 1, the floor material 1 can be easily cut according to the shape and size of the construction site (“easy cutting”). If the same core material 4'has a depth of cut of 0.1 mm or more when the number of operations is 20 times and at the same time has a hardness of 76 or more of the above-mentioned type C durometer, it is easy to cut and has dents and the like. It can be said that it becomes a flooring material 1 that has both difficulty.

Then, by setting the water repellency of JIS-L-1092: 2009 in the cushion material 3'constituting the cushion layer 3 to the third grade or higher, the woven fabric 2'is tentatively composed. Even if the liquid passes through the outer material layer 2 to be formed, the liquid is stopped by the cushion layer 3, it becomes difficult to reach the core material layer 4, and the wetting of the core material layer 4 can be suppressed (“the core material layer 4”. Wetting control ").

The method of constructing the floor material 1 according to the present invention is a method of constructing a floor material in which a surface material layer composed of a woven fabric, a cushion layer, a core material layer, and a base material layer are laminated in this order. The woven fabric constituting the outer material layer contains a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath, and at least a part of the outer material layer is peeled off from the cushion layer, or the outer material layer and the cushion layer are peeled off. A peeling step of collectively peeling at least a part of the core material layer from the core material layer, a cutting step of at least cutting the core material layer in the range where the outer material layer was peeled off in this peeling step, and at least cutting in this cutting step. The first feature is that it has a covering step of covering the cut surface of the core material layer generated by the coating with the outer material layer.

Due to these characteristics, in the construction method of the floor material 1 in which the woven fabric 2'of the outer material layer 2 is woven with the core-sheath structure monofilament of the polyvinyl chloride resin, the peeling step S1 such as peeling the outer material layer 2 from the cushion layer 3 By having a cutting step S2 for cutting the core material layer 4 and the like in the range where the outer material layer 3 and the like are peeled off, and a covering step S3 for covering the cut surface (cut end surface) of the core material layer 4 and the like with the outer material layer 2. By covering the cut surface (cut end surface) of the core material layer 4 or the like generated as a result with the outer material layer 2 remaining without being cut, the cut surface or the like of the floor material 1 is not exposed, and further "designability" is achieved. By covering the floor material 1 from the end surface 1c to a part of the back surface 1b (peripheral end portion, etc.) with the outer material layer 2 which is wider than the cushion layer 3 and the like, the floor material 1 can be improved. The outer material layer 2, the other cushion layer 3, the core material layer 4, and the base layer 5 can be fixed more strongly, and "improvement of durability of the floor material 1" is also realized.

According to the floor material and the method for constructing the floor material according to the present invention, "improvement of design" is achieved by including a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath in the woven fabric constituting the outer layer of the floor material. , Etc. can be realized.

It is a side sectional view which shows the floor material which concerns on this invention. It is a drawing substitute photograph which illustrates the surface and end face of a flooring material. It is a drawing substitute photograph which illustrates the back surface and the end surface of a flooring material. It is a flowchart which shows the construction method of the floor material which concerns on this invention, and shows the case which has a peeling process, a cutting process and a covering process. It is a flowchart which shows the construction method of the floor material which concerns on this invention, and shows the case which has a measuring process, a peeling process, a cutting process, a fixing process, a covering process and a laying process.

<Overall configuration of floor material 1>
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIGS. 1 to 3 show the floor material 1 according to the present invention.
In the floor material 1, the outer material layer 2, the cushion layer 3, the core material layer 4, and the base layer 5, which will be described later, are laminated in this order.

That is, the surface 1a of the floor material 1 is covered with the outer layer 2, and the back surface 1b thereof is covered with at least the base layer 5.
Here, the "front surface 1a" of the floor material 1 is the surface on the side exposed when the floor material 1 is applied (laid) on the floor surface, and conversely, the "back surface 1b" of the floor material 1 is used. Can be said to be the surface on the side that is not exposed when the floor material 1 is installed (laid) on the floor surface.

On the end surface 1c side of the floor material 1, the outer material layer 2 may also cover at least the end surfaces 3c and 4c of the cushion layer 3 and the core material layer 4.
Here, the "end surface 1c" of the floor material 1 is a surface at the end of the floor material 1 and can be said to be a side surface of the floor material 1, and any of the above-mentioned front surface 1a and back surface 1b of the floor material 1 There is no side.
It should be noted that the end surface 1c of the floor material 1 can be exposed when one or more floor materials 1 are installed (laid) not on the entire floor surface but only on a part of the floor surface. I can say.

Of the four layers (outer material layer 2, cushion layer 3, core material layer 4, and base layer 5) in the floor material 1, at least two adjacent layers may be fixed to each other, or the outer material layer may be fixed. When 2 also covers at least the end faces 3c and 4c of the cushion layer 3 and the core material layer 4, the outer material layer 2 and the cushion layer 3 are in contact with each other among the outer material layer 2 and the core material layer 4 which are not normally adjacent to each other. At least a part of the range (between the back surface 2b of the peripheral end portion of the outer material layer 2 and the end surface 4c of the cushion layer 3) may be fixed.
Further, the outer layer 2 extends from the end surface 1c of the floor material 1 to a part of the back surface 1b (peripheral end portion and the like) (that is, from the end surfaces 3c and 4c of the cushion layer 3 and the core material layer 4 to the core material layer 4 When covering a part of the back surface 4b (up to the peripheral end, etc.), <1> the range in which the outer layer 2 and the cushion layer 3 are in contact (the back surface 2b and the cushion at the peripheral end of the outer layer 2). It is fixed between the end faces 4c of the layer 3 or at least a part of the back surface 2b of the peripheral end portion of the outer material layer 2 and a part of the back surface 4b of the cushion layer 3 (such as the peripheral end portion). Or <2> Of the outer layer 2 and the base layer 5 that are not normally adjacent to each other, the range in which the outer layer 2 and the base layer 5 are in contact (the back surface 2b and the base layer 5 at the peripheral end of the outer layer 2). Between the back surface 5b of the peripheral end portion (the case where the outer material layer 2 covers up to the peripheral end portion of the base layer 5) and between the end surface 2c of the outer material layer 2 and the end surface 5c of the base layer 5 (outer material layer 2). Does not cover the base layer 5 and the end surface 2c of the outer layer 2 and the end surface 5c of the base layer 5 face each other or are in contact with each other), the surface 2a of the peripheral end of the outer layer 2 and the peripheral end of the base layer 5. At least a part of the surface 5a (the case where the peripheral end of the outer layer 2 is sandwiched between the peripheral end of the base layer 5 and the back surface 4b of the core layer 4) is fixed. You may be.
Here, the above-mentioned fixation may be any of bonding by an adhesive such as synthetic rubber, fusion by applying heat or the like, or a combination of these.

The thickness of the floor material 1 (thickness of the outer material layer 2, the cushion layer 3, the core material layer 4, and the base layer 5 combined) may be any value, and is, for example, 1 mm or more and 100 mm or less, preferably 1 mm or more. It may be 50 mm or less, more preferably 1 mm or more and 20 mm or less (10 mm or the like).
The plan view shape of the floor material 1 is not particularly limited, but is, for example, a substantially square, a substantially rectangular shape, a substantially polygonal shape, or a shape in which irregularities (steps, wavy lines, etc.) are provided on each side of the square, etc. A rhombus, a substantially parallelogram, a substantially rhombus, or the like may have a shape in which irregularities (steps, waveforms, etc.) are provided on each side.

Hereinafter, the case where the floor material 1 has a substantially square shape in a plan view will be described in detail.
The actual size of the floor material 1 is also not particularly limited, but may be, for example, one side of 200 mm or more and 2000 mm or less, preferably 150 mm or more and 1000 mm or less, and more preferably 200 mm or more and 900 mm or less (500 mm, 850 mm, etc.).

<Outer layer 2>
As shown in FIGS. 1 to 3, the outer layer 2 is composed of the woven fabric 2'described later, and is located on the most surface side (upper side, exposed side) of the floor material 1 described above.
Here, the "surface 2a" of the outer layer 2 is a surface located on the exposed side when the floor material 1 is applied (laid) on the floor surface, and conversely, the "back surface 2b" of the outer layer 2 It can be said that is a surface located on the side that is not exposed when the floor material 1 is installed (laid) on the floor surface.

The outer material layer 2 may cover not only the surface 3a of the cushion layer 3 but also at least the end faces 3c and 4c of the cushion layer 3 and the core material layer 4 as described above.
The end surface 2c of the outer layer 2 itself is a surface at the end of the outer layer 2 and can be said to be a side surface of the outer layer 2, which is neither the surface 2a nor the back surface 2b described above in the outer layer 2. It can be said that it is composed of the cross sections of the warp threads 2a'and the weft threads 2b'that weave the woven fabric 2'described later.

Further, when one or more floor materials 1 are applied (laid) not only on the entire floor surface but only on a part of the floor surface, the outer layer 2 is used as the end surface 1c of the floor material 1. Can be said to be exposed.
Further, when the outer layer 2 covers from the end surface 1c of the floor material 1 to a part (peripheral end portion or the like) of the back surface 1b, the floor material 1 is before the floor material 1 is installed (laid). It can be said that the outer layer 2 may be exposed as a part of the back surface (peripheral end portion, etc.) of the above.

The thickness of the outer layer 2 may be any value, and is, for example, 0.01 mm or more and 10.00 mm or less, preferably 0.05 mm or more and 5.00 mm or less, and more preferably 0.10 mm or more and 3.00 mm or less (1 mm or the like). It may be.
The plan view shape of the outer material layer 2 may be a shape similar to the plan view shape of the floor material 1 described above, and is, for example, a substantially square, a substantially rectangular shape, a substantially polygonal shape, or unevenness on each side of the square or the like. It may be a shape provided with (steps, waveforms, etc.), a shape having irregularities (steps, waveforms, etc.) on each side such as a substantially rectangular shape, a substantially parallelogram, and a substantially diamond shape.

Hereinafter, the case where the plan view shape of the outer layer 2 is mainly a substantially square will be described in detail.
In addition, when the outer material layer 2 also covers the end faces 3c, 4c, etc. of the cushion layer 3 and the core material layer 4 (the plan view shape of the outer material layer 2 is wider (larger) than the plan view shape of the floor material 1). If there is, it can be said that any shape is acceptable.

In this case, the portion obtained by subtracting the plan view shape of the floor material 1 from the plan view shape of the outer material layer 2 covers the end surface 1c of the floor material 1 (at least the end faces 3c and 4c of the cushion layer 3 and the core material layer 4). It becomes.
The actual size of the outer layer 2 is not particularly limited, but is substantially the same as or slightly larger than the actual size of the floor material 1 described above, for example, one side is 200 mm or more and 2200 mm or less, preferably 250 mm or more and 1500 mm or less, more preferably. May be 300 mm or more and 1000 mm or less (600 mm or the like).

<Woven fabric 2'>
As shown in FIGS. 1 to 3, the woven fabric 2'consists of the above-mentioned outer material layer 2.
The woven fabric 2'is woven with a monofilament having a core-sheath structure having a polyvinyl chloride resin (PVC) as a sheath.

That is, the woven fabric 2'means that the threads constituting the warp threads 2a'and the weft threads 2b' are both monofilaments having a core-sheath structure having a polyvinyl chloride resin as a sheath.
At least a part of the intersection of the warp 2a'and the weft 2b' may be fused to the woven fabric 2'. In this case, the woven fabric 2'itself is fused by applying a heat set or the like. Can be said to occur.

The core-sheath monofilament constituting the warp 2a'and the weft 2b' of the woven fabric 2'has a polypropylene resin sheath, but the core material is not particularly limited, but polyethylene terephthalate (PET), which is a thermoplastic material. ), Polyester fibers such as polytrimethylene terephthalate (PTT) and polybutylene terephthalate (PBT), polyolefin fibers such as nylon (polyethylene) fibers, polyethylene (PE) and polypropylene (PP), rayon fibers, cupra fibers, acetate. Synthetic fibers such as fibers, acrylic fibers containing polyacrylonitrile (PAN) as a main component, polyvinyl alcohol (PVA) fibers (vinylone fibers), polyurethane (PU) fibers, and glass fibers, wool, silk, etc. may be used. These may be used alone or in combination.
Further, the fineness of the entire monofilament of the core-sheath structure constituting the warp 2a'and the weft 2b' of the woven fabric 2'may be any value, but for example, the total fineness is 20 dtex or more and 4000 dtex or less, preferably 100 dtex or more and 4000 dtex or less. More preferably, it may be 300 dtex or more and 3600 dtex or less.

On the other hand, among the monofilaments having a core-sheath structure constituting the warp threads 2a'and the weft threads 2b' of the woven fabric 2', the fineness of only the core may be any value, but for example, the total fineness is 0.1 dtex or more and 10.0 dtex. It may be as follows.
If desired, extender pigments such as titanium oxide and calcium carbonate and fillers (fillers) may be arbitrarily added to the warp threads 2a'and weft threads 2b' of the woven fabric 2', and deodorants, antibacterial agents, fungicides, etc. A material to which a flame retardant, a water repellent, an antifouling agent, a colorant, a fragrance, a foaming agent, an ultraviolet absorber, an infrared absorber, or the like is added may be used.

The colors of the warp threads 2a'and the weft threads 2b'of the woven fabric 2'may be any color such as black, green, red, orange, yellow, blue, purple, and white, and one flooring material. In 1, it may have a plurality of color tones, and any value may be used for saturation and lightness.
Further, the cross-sectional shape of the warp 2a'and the weft 2b' of the woven fabric 2'is not particularly limited, and at least one of the core and the sheath is substantially circular or substantially elliptical, or irregularly shaped (for example, approximately triangular or abbreviated). It may be a rectangle, a substantially polygon such as a substantially pentagon or a substantially hexagon, or a substantially star shape).

The woven fabric 2'is a plain weave structure, a satin weave structure, a twill weave structure, a twill weave structure, a pseudo-sheath structure, etc., which are woven, changed, or combined with the above-mentioned warp threads 2a'and weft threads 2b'. May be woven.
The specific value of the density (warp density) of the warp threads 2a'in the woven fabric 2'is also not particularly limited, but may be, for example, 10 threads / 10 cm or more and 1000 threads / 10 cm or less.

The specific value of the density (weft density) of the weft 2b'in the woven fabric 2'is also not particularly limited, but may be, for example, 10 threads / 10 cm or more and 1000 threads / 10 cm or less.
It can be said that the flooring material 1 whose surface 1a or the like is covered with such a woven fabric 2'is like a tatami mat (in particular, see FIGS. 2 and 3).

<Cushion layer 3>
As shown in FIGS. 1 to 3, the cushion layer 3 is composed of the cushion material 3'described later, and is located on the second surface 3a side (upper side, exposed side) of the floor material 1 described above.
Here, the "surface 3a" of the cushion layer 3 is a surface located closer to the exposed side when the floor material 1 is applied (laid) on the floor surface, and the surface 3a is covered with the outer material layer 2. It can be said that it has been damaged. On the contrary, it can be said that the "back surface 3b" of the cushion layer 3 is a surface located on the side that is not exposed when the floor material 1 is applied (laid) on the floor surface.

As described above, not only the surface 3a of the cushion layer 3 but also its end surface 3c may be covered with the outer material layer 2.
The end surface 3c of the cushion layer 3 is a surface at the end of the cushion layer 3, and can be said to be a side surface of the cushion layer 3, which is neither the front surface 3a nor the back surface 3b described above in the cushion layer 3. It can be said that.

The thickness of the cushion layer 3 may be any value, and is, for example, 0.1 mm or more and 20.0 mm or less, preferably 0.5 mm or more and 10.0 mm or less, and more preferably 1.0 mm or more and 5.00 mm or less (2.0 mm). Etc.).
The plan view shape of the cushion layer 3 may be a shape similar to the plan view shape of the floor material 1 described above, and is, for example, a substantially square, a substantially rectangular shape, a substantially polygonal shape, or unevenness on each side of the square or the like. It may be a shape provided with (steps, waveforms, etc.), a shape having irregularities (steps, waveforms, etc.) on each side such as a substantially rectangular shape, a substantially parallelogram, and a substantially diamond shape.

Hereinafter, the case where the cushion layer 3 has a substantially square shape in a plan view will be described in detail.
The actual size of the cushion layer 3 is not particularly limited, but is substantially the same as the actual size of the floor material 1 described above. For example, one side is 100 mm or more and 2000 mm or less, preferably 150 mm or more and 1000 mm or less, and more preferably 200 mm. It may be 900 mm or more (500 mm, 850 mm, etc.).

<Cushion material 3'>
As shown in FIGS. 1 to 3, the cushion material 3'consists of the cushion layer 3 described above.
The material of the cushion material 3'is not particularly limited, but may be, for example, a non-woven fabric, a foam, a film, or the like.

When the cushion material 3'is a non-woven fabric, the material of the fibers constituting this non-woven fabric is not particularly limited, but is a thermoplastic material such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or polybutylene terephthalate. Polyester fiber such as (PBT), nylon (polyethylene) fiber, polyolefin fiber such as polyethylene (PE) and polypropylene (PP), rayon fiber, cupra fiber, acetate fiber, acrylic fiber containing polyacrylonitrile (PAN) as a main component. , Polyvinyl alcohol (PVA) fiber (vinylone fiber), polyurethane (PU) fiber and other synthetic fibers, and other fibers such as glass fiber, wool and silk, which may be used alone or in combination.
Further, the fineness of the fibers constituting the non-woven fabric of the cushion material 3'may be any value, and for example, the total fineness may be 20 dtex or more and 3000 dtex or less.

If desired, an extender pigment such as titanium oxide or calcium carbonate or a filler (filler) may be arbitrarily added to the fibers constituting the non-woven fabric of the cushion material 3', or a deodorant, an antibacterial agent, an antifungal agent, or a difficult material may be added. A material to which a fuel agent, a water repellent, an antifouling agent, a colorant, a fragrance, a foaming agent, an ultraviolet absorber, an infrared absorber, or the like is added may be used.
Further, the cross-sectional shape of the fibers constituting the non-woven fabric of the cushion material 3'is not particularly limited, and at least one of the core and the sheath is substantially circular, substantially elliptical, or irregular (for example, substantially triangular or approximately rectangular). It may be a substantially polygon such as a substantially pentagon or a substantially hexagon, or a substantially star shape).

In addition, when the cushion material 3'is a foam or a film, the material of the fibers constituting the foam or the film is not particularly limited, but is a thermoplastic material such as polyethylene terephthalate (PET) or polytrimethylene. Polyester fibers such as terephthalate (PTT) and polybutylene terephthalate (PBT), polyolefin fibers such as nylon (polyethylene) fibers, polyethylene (PE) and polypropylene (PP), rayon fibers, cupra fibers, acetate fibers, polyacrylonitrile (PAN). ) As a main component, synthetic fibers such as acrylic fiber, polyvinyl alcohol (PVA) fiber (vinylone fiber), and polyurethane (PU) fiber may be used, and these may be used alone or in combination.
If desired, a constitutional pigment such as titanium oxide or calcium carbonate or a filler (filler) may be arbitrarily added to the material constituting the foam or film of the cushion material 3', or a deodorant, an antibacterial agent, or an antifungal agent may be added. A material to which an agent, a flame retardant, a water repellent, an antifouling agent, a colorant, a fragrance, a foaming agent, an ultraviolet absorber, an infrared absorber, or the like is added may be used.

<Water repellency, etc.>
As a parameter indicating the waterproofness of the cushion layer 3 (or the cushion material 3'), for example, the water repellency measured in a test according to the water repellency test (spray test) of JIS-L-1092: 2009 is used. It may be used, or other parameters may be used.
The water repellency measured in the test according to the water repellency test (spray test) of JIS-L-1092: 2009 in the cushion material 3'is not particularly limited, but for example, it may be grade 3 or higher. It may be preferably grade 4 or higher, and more preferably grade 5.
The numerical value of "water repellency measured in a test according to the water repellency test (spray test) of JIS-L-1092: 2009" in the present invention includes the repellency of JIS-L-1092: 2009. Of course, the water repellency measured in the test as specified in the water repellency test (spray test) is included, and the water repellency test (spray test) of JIS-L-1092: 2009 is applied mutatis mutandis. It also includes the water repellency measured in the test.

<Core material layer 4>
As shown in FIGS. 1 to 3, the core material layer 4 is composed of the core material 4'described later, and is located on the third surface side (upper side, exposed side) of the floor material 1 described above (in other words, on the exposed side). Secondly located on the back side).
Here, the "surface 4a" of the core material layer 4 is a surface located closer to the exposed side when the floor material 1 is applied (laid) on the floor surface, and conversely, the "surface 4a" of the core material layer 4 is "surface 4a". It can be said that the “back surface 4b” is a surface located on the side that is not exposed when the floor material 1 is installed (laid) on the floor surface.

As described above, the end surface 4c of the core material layer 4 may be covered with the outer material layer 2.
The end surface 4c of the core material layer 4 is a surface at the end of the core material layer 4, and can be said to be a side surface of the core material layer 4, and any of the above-mentioned front surface 4a and back surface 4b in the core material layer 4 It can be said that there is no aspect.

The thickness of the core material layer 4 may be any value, and may be, for example, 1 mm or more and 70 mm or less, preferably 1 mm or more and 40 mm or less, and more preferably 1 mm or more and 15 mm or less (5 mm or the like).
The plan view shape of the core material layer 4 may be similar to the plan view shape of the floor material 1 described above, and may be, for example, a substantially square, a substantially rectangular shape, a substantially polygonal shape, or a square shape on each side. A shape having irregularities (steps, waveforms, etc.), a shape having irregularities (steps, waveforms, etc.) on each side such as a substantially diamond shape, a substantially parallelogram, and a substantially diamond shape may be used.

Hereinafter, the case where the plan view shape of the core material layer 4 is mainly substantially square will be described in detail.
The actual size of the core material layer 4 is not particularly limited, but is substantially the same as the actual size of the floor material 1 described above. For example, one side is 100 mm or more and 2000 mm or less, preferably 150 mm or more and 1000 mm or less, and more preferably. It may be 200 mm or more and 900 mm or less (500 mm, 850 mm, etc.).

<Core material 4'>
As shown in FIGS. 1 to 3, the core material 4'consists of the core material layer 4 described above.
The material of the core material 4'is not particularly limited, but may be, for example, medium density fiberboard (MDF (Medium Density Fiberboard), medium density fiberboard specified in JIS-A-5905: 2014) or synthetic. Boards (waste paper such as art paper, laminated paper, heat-sensitive paper, magazines, synthetic fibers such as polyethylene terephthalate (PET) fiber, polypropylene (PP) fiber, polyethylene (PE) fiber, and non-woven cloth composed of these synthetic fibers. It may be a board made of waste plastic such as polypropylene (excluding polyvinyl chloride resin (PVC)), and other insulation boards (insulation boards specified in JIS-A-5905: 2014). Alternatively, it may be plywood (a wood material in which thinly sliced boards are alternately stacked at right angles to each other and hot-press bonded).

<Hardness, etc.>
As a parameter indicating the hardness of the core material layer 4 (or the core material 4'), for example, type C durometer hardness may be used, or other parameters may be used.
The type C durometer hardness of the core material 4'may be 76 or more, preferably 85 or more, and more preferably 95 or more (76.3, 95.9, 97.3, 98.6, etc.).
The "type C durometer hardness" in the present invention is the hardness measured using the Asker rubber hardness tester C type manufactured by Polymer Meter Co., Ltd. described in JIS-K-7312: 1996 Annex 2.

<Amount of cut when the number of operations is 20>
As a parameter indicating the ease of cutting the core material layer 4 (or core material 4'), for example, cutting when the number of operations is 20 with a cutting tool sharpness tester according to the Honda formula for cutting the core material 4'. The inclusion amount may be used, or other parameters may be used.
The cutting amount when the number of operations is 20 with a cutting tool sharpness tester according to the Honda method for cutting the core material 4'is not particularly limited, but for example, if it is 0.1 mm (0.10 mm) or more. It can be said that it is easy to cut, and it may be preferably 0.15 mm or more, more preferably 0.20 mm or more (0.24 mm, 0.85 mm, etc.).
In the present invention, the "cutting amount when the number of operations is 20 times with a cutting tool sharpness tester according to the Honda method for cutting the core material 4'" means, for example, "LBB10K manufactured by Olfa Co., Ltd." as the cutting tool. You may use it.
In addition, as a "cutlery sharpness tester conforming to the Honda formula", even if it is a tester jointly developed by Gifu Prefectural Industrial Technology Research Institute and Marutomi Seiko Co., Ltd. and / or installed at Gifu Prefectural Industrial Technology Center. good.

<Underground layer 5>
As shown in FIGS. 1 to 3, the base layer 5 is located on the fourth front surface side (upper side, exposed side) of the floor material 1 described above (in other words, is located on the back surface side most). The floor material 1 does not necessarily have to have the base layer 5.
Here, the "front surface 5a" of the base layer 5 is a surface located closer to the exposed side when the floor material 1 is applied (laid) on the floor surface, and conversely, the "back surface 5b" of the base layer 5 It can be said that the floor material 1 is a surface located on the side that is not exposed when the floor material 1 is installed (laid) on the floor surface.

As for the base layer 5, as described above, the base layer 5 is covered with the outer layer 2 up to the peripheral end thereof, and the base layer 5 is not covered with the outer layer 2 and the end face of the outer layer 2 is not covered. Even if 2c and the end surface 5c of the base layer 5 face each other or are in contact with each other, or the base layer 5 sandwiches the peripheral end portion of the outer material layer 2 between the peripheral end portion thereof and the back surface 4b of the core material layer 4. good.
The end surface 5c of the base layer 5 is a surface at the end of the base layer 5, and can be said to be a side surface of the base layer 5, which is neither the front surface 5a nor the back surface 5b described above in the base layer 5. It can be said that.

The thickness of the base layer 5 may be any value, and is, for example, 0.1 mm or more and 30.0 mm or less, preferably 0.5 mm or more and 10.0 mm or less, and more preferably 1.0 mm or more and 3.0 mm or less (1.5 mm). Or 9.0 mm, etc.).
The plan view shape of the base layer 5 may also be a shape similar to the plan view shape of the floor material 1 described above, and is, for example, a substantially square, a substantially rectangular shape, a substantially polygonal shape, or unevenness on each side of the square or the like. It may be a shape provided with (steps, waveforms, etc.), a shape having irregularities (steps, waveforms, etc.) on each side such as a substantially rectangular shape, a substantially parallelogram, and a substantially diamond shape.

Hereinafter, the case where the plan view shape of the base layer 5 is mainly a substantially square will be described in detail.
The actual size of the base layer 5 is not particularly limited, but is substantially the same as or slightly smaller than the actual size of the floor material 1 described above, for example, one side is 100 mm or more and 2000 mm or less, preferably 150 mm or more and 1000 mm or less, more preferably. May be 200 mm or more and 900 mm or less (495 mm or the like).

The material constituting such a base layer 5 is not particularly limited, but may be, for example, a non-woven fabric, a foam, a film, or the like.
When the material of the base layer 5 is a non-woven fabric, the material of the fibers constituting the non-woven fabric is not particularly limited, but is a thermoplastic material such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or polybutylene. Polyester fiber such as terephthalate (PBT), nylon (polyethylene) fiber, polyolefin fiber such as polyethylene (PE) and polypropylene (PP), rayon fiber, cupra fiber, acetate fiber, acrylic containing polyacrylonitrile (PAN) as the main component. Synthetic fibers such as fibers, polyvinyl alcohol (PVA) fibers (vinylone fibers), and polyurethane (PU) fibers may be used, and other fibers such as glass fibers, wool, and silk may be used alone or in combination. In addition, it may have waterproof property and moisture-proof property.
Further, the fineness of the fibers constituting the non-woven fabric of the base layer 5 may be any value, and for example, the total fineness may be 20 dtex or more and 3000 dtex or less.

If desired, an extender pigment such as titanium oxide or calcium carbonate or a filler (filler) may be arbitrarily added to the fibers constituting the non-woven fabric of the base layer 5, or a deodorant, an antibacterial agent, a fungicide, or a flame retardant. , Water repellent, antifouling agent, colorant, fragrance, foaming agent, ultraviolet absorber, infrared absorber and the like may be added.
Further, the cross-sectional shape of the fibers constituting the non-woven fabric of the base layer 5 is not particularly limited, and at least one of the core and the sheath is substantially circular or substantially elliptical, or irregularly shaped (for example, substantially triangular or substantially rectangular). It may be a substantially polygonal shape such as a substantially pentagon or a substantially hexagon, or a substantially star shape).

In addition, when the base layer 5 is a foam or a film, the material of the fibers constituting the foam or the film is not particularly limited, but is a thermoplastic material such as polyethylene terephthalate (PET) or polytrimethylene terephthalate. Polyester fibers such as (PTT) and polybutylene terephthalate (PBT), polyolefin fibers such as nylon (polyethylene) fibers, polyethylene (PE) and polypropylene (PP), rayon fibers, cupra fibers, acetate fibers, polyacrylonitrile (PAN). Synthetic fibers such as acrylic fibers, polyvinyl alcohol (PVA) fibers (vinylone fibers), and polyurethane (PU) fibers containing the above as a main component may be used, and these may be used alone or in combination.
If desired, an extender pigment such as titanium oxide or calcium carbonate or a filler (filler) may be arbitrarily added to the material constituting the foam or film of the base layer 5, or a deodorant, an antibacterial agent, or an antifungal agent. , A flame retardant, a water repellent, an antifouling agent, a colorant, a fragrance, a foaming agent, an ultraviolet absorber, an infrared absorber, or the like may be added.

The base layer 5 may be only one layer or may be a plurality of layers.
The thickness of the peripheral end portion of the base layer 5 may decrease (thinn) with the passage of time after the construction of the floor material 1, and the base layer 5 may have a substantially convex shape in a side cross-sectional view.
Further, the back surface 5b of the base layer 5 may be anti-slip processed.

<Construction method of floor material 1>
FIGS. 4 and 5 show a method of constructing the floor material 1 according to the present invention.
The method of constructing the floor material 1 is a method of constructing the floor material 1 described so far, and includes at least a peeling step S1, a cutting step S2, and a covering step S3, which will be described later.
Further, the construction method of the floor material 1 includes a measuring step S0 before the peeling step S1, a fixing step S2'between the cutting step S2 and the covering step S3, or the covering step S3. The laying step S4 may be provided later.

<Peeling process S1>
As shown in FIGS. 4 and 5, in the peeling step S1, at least a part of the above-mentioned outer material layer 2 is peeled off from the cushion layer 3, or at least a part of the outer material layer 2 and the cushion layer 3 is peeled off from the core material layer. This is the process of peeling off all together from 4.
In the peeling step S1, the range in which the outer material layer 2 is peeled off from the cushion layer 3 (surface 3a) and the range in which the outer material layer 2 and the cushion layer 3 are collectively peeled off from the core material layer 4 (surface 4a) are actually the cores. It can be said that the material layer 4 and the like are peeled off a little wider than the range to be cut and removed.

Further, when the outer material layer 2 covers the end faces 3c and 4c of the cushion layer 3 and the core material layer 4, and the peripheral end portion of the outer material layer 2 is sandwiched between the core material layer 4 and the base layer 5, the outer material layer 2 is sandwiched between the core material layer 4 and the base layer 5. Before peeling the outer layer 2 from the cushion layer 3 in the peeling step S1, the base layer 5 (peripheral end portion and the like) is first peeled, and then the outer layer 2 is peeled from the back surface 4b of the core material layer 4.
Even when the outer material layer 2 and the cushion layer 3 are not fixed by adhesion or the like, at least the surface 3a of the cushion layer 3 is covered with the outer material layer 2, so that the peeling step S1 is required.

<Cut step S2>
As shown in FIGS. 4 and 5, in the cutting step S2, at least the core material layer 4 in the range where the outer material layer 2 is peeled off in the above-mentioned peeling step S1 is cut at least (in some cases, the core material layer 4 and the cushion). This is a step of cutting the layers 3 together).
In the cutting step S2, the core material layer 4 and the like are cut according to the shape and size of the place where the floor material 1 is to be installed. Therefore, when the cushion layer 3 and the core material layer 4 are cut together, the core material layer 4 and the like are cut. The plan view shape of the cushion layer 3 and the plan view shape of the core material layer 4 after cutting are substantially the same.

Further, in the cutting step S2, the base layer 5 may be cut together with the core layer 4 and the like. In this case, the plan view shape of the base layer 5 after cutting is the core layer 4 after cutting. It may be substantially the same as or slightly smaller than the plan view shape such as.
In addition, in the cutting step S2, the core material layer 4 and the like and the base layer 5 do not have to be combined. In this case, apart from cutting the core material layer 4 and the like, only the base layer 5 is cut (after cutting). The plan view shape of the base layer 5 can be cut so as to be different from the plan view shape of the core material layer 4 and the like after cutting), only the core material layer 4 and the like are cut, and the base layer 5 is not cut at all. It doesn't matter.

<Covering process S3>
As shown in FIGS. 4 and 5, the covering step S3 is a step of covering the cut surface with the core material layer 4 and the like generated by cutting at least in the cutting step S2 described above with the outer material layer 2.
In the covering step S3, as described above, it can be said that the range in which the cushion layer 3 and the core material layer 4 and the like can be covered by the outer material layer 2 is wider than before the cushion layer 3 and the core material layer 4 and the like are cut.

Therefore, in this covering step S3, even if the end faces 3c and 4c of the cushion layer 3 and the core material layer 4 are exposed before cutting, these end faces 3c and 4c are also covered with the outer material layer 2 after cutting. It can be said that you will be able to get it.
Similarly, in the covering step S3, even if the back surface 4b of the core material 4 is not covered before cutting, a part (peripheral end, etc.) of the back surface 4b of the core material 4 is also displayed after cutting. Even if it can be covered with the stratum 2 or even if the back surface 4b of the core material 4 is covered before cutting, the outer layer 2 can cover a wider range of the back surface 4b of the core material 4 after cutting. It can be said that

<Other processes>
As shown in FIG. 5, the construction method of the floor material 1 includes at least one of the measuring step S0, the fixing step S2', and the laying step S4, in addition to the peeling step S1 to the covering step S3 described above. You may be.

In the measuring step S0, before the peeling step S1, when the floor material 1 is constructed, the range where the outer material layer 2 is peeled off, the cushion layer 3 and the core material layer 4 are formed according to the shape and size of the construction site. This is the process of measuring (measuring) the area to be cut.
To measure the peeling range and cutting range, apply the floor material 1 to be constructed at the edge of the construction site (near the wall surface, etc.) to the edge of the construction site, measure it with a ruler, etc. It doesn't matter which one you do.

The fixing step S2'is a step of fixing the end faces 3c, 4c and the like of the cushion layer 3 and the core material layer 4 and the outer material layer 2 covering them.
If the fixing in the fixing step S2'is adhesion by an adhesive, it is bonded between the outer material layer 2, the cushion layer 3, the end faces 3c, 4c, etc. of the core material layer 4 between the cutting step S2 and the covering step S3 described above. After applying the agent, the outer material layer 2 covers the end faces 3c, 4c, etc. of the cushion layer 3 and the core material layer 4, and adheres (fixes) between the outer material layer 2, the cushion layer 3 and the core material layer 4. It becomes.
If the fixing in the fixing step S2'is fused by applying heat or the like, the outer material layer 2 covers the end faces 3c, 4c, etc. of the cushion layer 3 and the core material layer 4 after the covering step S3 described above. Heat or the like is applied to the floor material 1 in the state of being in a state of being fused (fixed) between the outer material layer 2, the cushion layer 3, and the core material layer 4.

In the laying step S4, the floor material 1 whose plan view shape is changed according to the shape, size, etc. of the place where the floor material 1 is to be constructed is applied to the construction site by the peeling step S1 to the covering step S3 and the like described so far. This is the process of laying (constructing) on the edge (near the wall surface, etc.).
In this laying step S4, the back surface 1b of the floor material 1 may not be coated with an adhesive, and the floor material 1 may be simply placed on the floor surface. Conversely, the floor material 1 may be adhered to the back surface 1b of the floor material 1. The agent may be applied to adhere (fix) the floor material 1 to the floor surface.

<Others>
The present invention is not limited to the above-described embodiment. Each configuration such as the floor material 1 and the construction method of the floor material 1 or the overall structure, shape, dimensions, etc. can be appropriately changed according to the gist of the present invention.
The floor material 1 does not have to have the base layer 5.
The outer material layer 2 may cover only the surface 3a of the cushion layer 3 and may not cover the end surface 3c of the cushion layer 3, the end surface 4c of the core material layer 4, the back surface 4b of the core material layer 4, and the like.
The woven fabric 2'constituting the outer material layer 2 does not have to be fused at all at the intersection of the warp and the weft.

The cushion material 3'constituting the cushion layer 3 has a water repellency of less than 3rd grade (2nd grade or less) measured in a test according to the water repellency test (spray test) of JIS-L-1092: 2009. There may be.
The core material 4'constituting the core material layer 4 has a cutting edge sharpness tester according to the Honda method for cutting the core material 4', and the number of operations until the depth of cut reaches 2 mm is more than 100 times. Is also good.

The floor material of the present invention can be widely used for construction (laying) on the floor surface of a general house or the floor surface of a hotel, a public facility, or the like.
The method for constructing the floor material of the present invention can also be widely used when constructing (laying) the above-mentioned floor material on the floor surface of a general house, a hotel, a public facility, or the like.

1 Floor material 2 Outer material layer 2'Woven fabric 3 Cushion layer 3'Cushion material 4 Core material layer 4'Core material 5 Base layer S1 Peeling process S2 Cutting process S3 Covering process

Claims (7)

A flooring material in which an outer material layer composed of a woven fabric, a cushion layer, a core material layer, and a base material layer are laminated in this order.
The woven fabric constituting the outer layer is a flooring material woven with a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath. The flooring material according to claim 1, wherein the woven fabric constituting the outer material layer is characterized in that at least a part of the intersection portion between the warp and the weft is fused. The floor material according to claim 1 or 2, wherein the outer material layer also covers at least the end faces of the cushion layer and the core material layer. The floor material according to any one of claims 1 to 3, wherein the core material constituting the core material layer has a type C durometer hardness of 76 or more. The core material constituting the core material layer is characterized in that the depth of cut is 0.1 mm or more when the number of operations is 20 with a cutting tool sharpness tester according to the Honda method for cutting the core material. The floor material according to any one of claims 1 to 4. The cushion material constituting the cushion layer is characterized in that the water repellency measured in a test according to the water repellency test (spray test) of JIS-L-1092: 2009 is grade 3 or higher. Item 5. The floor material according to any one of Items 1 to 5. A method of constructing a floor material in which an outer material layer composed of a woven fabric, a cushion layer, a core material layer, and a base material layer are laminated in this order.
The woven fabric constituting the outer layer is woven with a monofilament having a core-sheath structure having a polyvinyl chloride resin as a sheath, and is also woven.
A peeling step of peeling at least a part of the outer material layer from the cushion layer, or collectively peeling at least a part of the outer material layer and the cushion layer from the core material layer.
A cutting step of cutting at least the core material layer in the range where the outer material layer was peeled off in this peeling step.
A method for constructing a floor material, which comprises a covering step of covering the cut surface of the core material layer generated by cutting at least in this cutting step with the outer material layer.

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