JP2817572B2 - Floor material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring, and more particularly to a flooring made of wood fiber, wood flakes or the like as a raw material, being lightweight, and having sufficient strength and rigidity.

[0002]

2. Description of the Related Art As a conventional floor material, as shown in FIG. 3, a decorative veneer 3 is generally adhered to one surface of a plywood 31. Plywood as a raw material for such flooring is a plate obtained by bonding and laminating a plurality of veneer veneers or the like so that their grain directions are perpendicular to each other, and has sufficient strength and rigidity to be used as flooring. Have. However, producing such plywood required a lot of raw wood.

[0003] In recent years, the shortage of timber resources and the protection of forests have become a problem, and it is clear that deforestation will become increasingly difficult in the future. Therefore, the supply of plywood manufactured using a large amount of raw wood is unstable or insufficient, and accordingly, the conventional flooring using such plywood has a shortage of materials or a rise in material costs. It is expected that its manufacture will be difficult. Therefore,
There is a strong demand for the application of materials obtained by effectively utilizing wood flakes and wood fibers, which have been conventionally discarded, without requiring a large amount of wood for production, to flooring materials.

[0004] As a plate material using wood flakes, the wood flakes are arranged in a substantially constant direction and bonded with a binder.
2. Description of the Related Art Directional wood laminates that are molded and integrated are known.
In such a directional wood flake assembly, the strength of the wood flakes in the arrangement direction is improved. Further, as a plate material using wood fiber obtained by defibrating wood as a raw material, a wood fiber integrated board obtained by bonding and integrating the wood fiber with a binder is already known. The use of these boards makes it possible to effectively use wood flakes and the like, which were conventionally discarded wood, so that their supply is also stable.However, when each of these materials is used alone, it has insufficient strength as a floor material. There was a problem.

[0005]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a flooring material which is lightweight and has sufficient strength and rigidity by using a material such as a directional lamella laminated board or a wood fiber laminated board. It is in.

[0006]

This object is achieved by laminating a medium-density wood fiber laminated board on both sides of a directional laminated wood slab,
On one surface of the medium-density wood fiber accumulation board, a decorative veneer is formed by joining, and the medium-density wood fiber accumulation board is formed by :
Fiber length 1-30mm, fiber width 0.1-2mm,
Wood with a fiber length of 3 mm or more and 50% or more
The problem can be solved by a floor material which is obtained by adhering porous fibers with a binder and molding and integrating them . The above-mentioned directionality refers to the direction of the grain direction of the thin wood piece, and does not refer to the longitudinal direction of the shape of the thin wood piece.

Hereinafter, the flooring material of the present invention will be described in detail.
FIG. 1 is a view showing a cross section of a flooring material of the present invention. In the figure, reference numeral 1 denotes a core material made of a directional thin wood laminated plate. The core material 1
On both sides, a surface layer material 2 made of a medium-density wood fiber integrated board is laminated. Further, a decorative veneer 3 is adhered to one surface of the surface material 2.

As the core 1 of the flooring material of the present invention, a directional thin wood laminated board is used. FIG. 2 is a view showing the structure of an example of such a directional wood lamella assemblage, in which thin, long and thin wood lamellas 21 are arranged substantially aligned in the left-right direction in the figure, and they are made of a foamable binder. Adhered, molded and integrated. Note that the directionality is not limited to one-way direction parallel to the longitudinal direction, and may be a type of orthogonal direction. The wood flake 21 has a length of 20 to 100.
mm, a width of 3 to 50 mm, and a thickness of 0.2 to 0.8 mm. As these wood flakes 21, flakes such as Japanese red pine, larch, Scots pine, Abies sachalinensis, aspen, lodgepole pine and the like are preferably used, but the tree species is not particularly limited.

These thin wood pieces 21 are adhered by a foaming binder and are integrally formed. The foamable binder used here binds the wood flakes to each other in the directional wood lamella assembly and foams itself, and preferably has a resin component only at the intersection of the wood flakes. By using a foam cell to expand small gaps in the wood flakes, the amount of resin used is reduced and the density of the directional wood flake assembly is reduced. In this specification, a binder having a foaming property is referred to as a “foamable binder”, and a foamed binder that has been foamed is referred to as a “foamable binder”.

[0010] Such a foamable binder may be composed of a self-foaming resin, or may be composed of a non-foamable resin and a foaming agent. An example of the self-expanding resin is an expandable polyurethane resin. Examples of non-foamable resin foamed by a foaming agent include polyurethane resin, polystyrene resin,
Epoxy resin, polyvinyl chloride resin, phenol resin,
Urea resins or mixtures thereof can be mentioned. As the foaming agent, a volatile foaming agent such as C
Cl ₃ F, CCl ₂ F ₂ or CCl ₂ F-CClF,
₂ , or a thermally decomposable blowing agent such as azodicarbonamide, azohexahydrobenzonitrile, 2,2 ′
-Azoisobutyronitrile, benzenesulfohydrazide, or N, N'-dinitroso-N, N'-dimethylterephthalamide. Further, these foamable binders may include a non-foamable binder such as a urea resin, a melamine resin, and a phenol resin. These mixing ratios can be appropriately adjusted according to the density of the desired directional laminated wood lamella.

The ratio of the foamable binder to the wood flakes in the directional wood flake assembly is determined by the wood fiber 10
It is preferably 10 to 30 parts by weight with respect to 0 parts by weight. Further, the thickness of the directional wood lamella is 5 m.
m to 13 mm, and the density is 0.4
It is preferably 0 to 0.65 g / cm ³ . When the density is less than 0.40 g / cm ³ , the strength of the plate becomes insufficient. On the other hand, when the density is more than 0.65 g / cm ³ , the weight of the whole material increases and it becomes difficult to handle. The bending Young's modulus of this directional wood lamella assembly is 40-80 × 1.
It is preferably 0 ² MPa. Bending Young's modulus is 40
If it is less than × 10 ² MPa, the deflection as a floor material will be larger than a specified value. If it exceeds 80 × 10 ² MPa, the appropriate elasticity required for walking will be insufficient.

The surface layer material 2 used in the flooring material of the present invention is a wood fiber integrated board obtained by using wood fibers obtained by fibrillating wood as a raw material, bonding them with a binder, and forming and integrating them. Particularly, those having a medium density and high rigidity are preferable. The wood fibers forming the medium-density wood fiber integrated board are obtained by defibrating wood chips by a conventional method, and have a fiber length of 1 to 30 mm and a fiber width of 0.1 to 2 mm ,
And the fiber length is more than 3mm and contains more than 50%
is there. These wood fibers are preferably acetylated in advance. When acetylating wood fiber, the wood fiber is dried to a moisture content of 3% or less, preferably 1% or less, and then contacted with a vaporized vapor such as acetic acid, acetic anhydride, chloroacetic acid, etc. in the gas phase. Acetylation (acetylation degree 12
〜20%).

[0013] Such a wood fiber is bonded and integrated with a binder. The binder used for the surface layer material may be the foamable binder as described above, or may be either a non-foamable binder or a mixture thereof, but practically, the releasability from the mold for molding is used. In view of this, those mainly composed of a non-foamable binder are preferred. These mixing ratios can be appropriately set in consideration of the density and releasability of the desired wood fiber integrated board.

[0014] The ratio of the binder to the wood fiber in the medium-density wood fiber integrated board is as follows.
It is preferable that the amount be 5 parts by weight or more based on 00 parts by weight. If the amount of the binder is 5 parts by weight or less based on 100 parts by weight of the wood fiber, the strength of the obtained medium density wood fiber integrated board becomes insufficient. In addition, the thickness of the medium-density fiberboard is 1 to 5 mm, preferably 1 to 2 mm. Furthermore, the density of this medium density wood fiber accumulation board is 0.
It is preferably 40 to 0.65 g / cm ³ . When the density is less than 0.40 g / cm ³ , the strength of the plate becomes insufficient. On the other hand, when the density is more than 0.65 g / cm ³ , the weight of the whole material increases and it becomes difficult to handle. The flexural Young's modulus of this wood fiber integrated board is 20-40 × 10 ² M
It is preferably Pa.

In the flooring material of the present invention, it is preferable to stack the same type of medium-density wood fiber laminated board on both sides of the above-mentioned directional wood laminated board. Further, it is preferable that the laminated body of the directional thin wood laminated board and the medium density wood fiber integrated board be simultaneously subjected to hot pressing. The decorative veneer used for the flooring material of the present invention is not particularly limited, and a conventionally used thickness of 0.2 to 0.8 is used.
A decorative veneer having a thickness of about mm can be used. In particular, the surface of the medium-density wood fiber integrated board is smooth and flat, so that a thin veneer veneer can be used.

According to the present invention, the wood fiber for the surface layer material coated with a binder and the wood fiber for the core material coated with an expandable binder are dry-formed and simultaneously hot-pressed. Is preferred. Specifically, first, a material obtained by applying a binder to a wood fiber serving as one surface material 2 on a hot pressing plate is sprayed, and then a material obtained by applying a foaming binder to a thin piece of wood serving as a core material 1 is applied. Then, the pieces of wood are scattered so as to be arranged in substantially the same direction. further,
A material obtained by applying a binder to wood fiber as the other surface material 2 is sprayed to form a three-layer laminate. At this time, the method of applying the binder to the wood fibers for the surface layer material is performed immediately before the step of hot-pressing, and is performed substantially continuously to the step. At a different time, a method in which a so-called prepreg formed by performing a coating process in a different facility at a different time and drying it to form a sheet, and uniting it with a thin wood piece for core material at the time of hot pressing is also suitably used.

Next, the laminate is subjected to hot pressing simultaneously in a hot pressing machine. The heat and pressure conditions are as follows:
Preferably, the pressure is 2 MPa, the temperature is 150 to 200 ° C., and the time is the desired thickness (mm) × 5 to 120 seconds.
Next, a veneer veneer prepared separately is adhered to the surface of the plate material thus formed with an adhesive to obtain the floor material of the present invention. At that time, the surface of the plate material may be polished by a conventional method, and a decorative veneer may be bonded to the polished surface. The floor material of the present invention thus obtained has a density of 0.4 to 0.65 g / cm ³ ,
Japanese Agriculture and Forestry Standard (JAS) for wood composite flooring
3.5mm or less, which is the acceptable level for "brightness and deflection"
Below.

The directional thin wood laminated board used as the core material in the present invention has a high strength in the arrangement direction because the thin wood pieces are arranged in almost the same direction. Also,
In this directional wood laminate assembly, since the molding and integration is performed using a foaming binder, the amount of resin used is small, the density of the obtained flooring material is low, and the foaming binder itself contains microbubbles. It is softened, has a buffering action against external force, and is hard to break. In the flooring material of the present invention, by stacking these directional laminated wood lamellas and the medium-density wood fiber accumulating board, the weight is reduced, the strength and rigidity are improved, and the flooring material can be sufficiently used as a flooring material. . Ma
In addition, as a raw material of the medium density wood fiber integrated board, the fiber length is 1 to
30 mm, fiber width is 0.1 to 2 mm, and fiber length
Uses wood fiber containing 50% or more of 3mm or more
Because the bending strength of the wood fiber itself increases,
The strength as a material is further improved. Furthermore, using a wood fiber stacking plate as the surface layer material were co-molding them situ
In this case , the unevenness on the surface of the directional wood laminate plate of the core material is eliminated, and the surface material surface becomes smooth.

Next, the flooring material of the present invention will be specifically described based on examples. (Example 1) As a material of a cored directional wood laminate assembly, 100 weighs of wood flakes having a length of 20 to 100 mm, a width of 3 to 50 mm, and a thickness of 0.2 to 0.8 mm A mixture of 10 parts by weight of a non-concentrated urea resin and 10 parts by weight of a foamable urethane resin was kneaded together with the wood flakes as a foamable binder, and the foamable binder was applied to the wood flakes. The raw material of the medium-density wood fiber integrated board of the surface layer material is 100 parts by weight of wood fiber (manufactured by Canadian Forest Products, F4-17) containing 50% or more of fibers having a fiber length of 3 mm or more, and urethane as a foaming binder. A mixture of 10 parts by weight of a resin (crude MDI manufactured by Sumitomo Bayer Urethane Co., Ltd.) and 10 parts by weight of a non-concentrated type urea resin as a non-foaming binder is
The mixture was kneaded with the wood fibers, and a binder was applied to the wood fibers.

First, half of the wood fibers to which the binder has been applied are evenly spread on a hot pressing plate, and the thin wood pieces to which the foamable binder has been applied are placed thereon, and the wood thin pieces are arranged in substantially one direction. Sprayed evenly. Further, the remaining wood fibers were sprayed thereon to form a laminate having a thickness of 280 mm. The laminate was subjected to simultaneous hot and pressure molding at a temperature of 150 ° C. and a pressure of 2 MPa for 15 minutes to a thickness of 12 mm. The surface of the plate thus formed is smooth, its specific gravity is 0.59 g / cm ³ , and its bending strength is 55M.
Pa and the bending Young's modulus were 60 × 10 ² MPa.
Next, a decorative veneer having a thickness of 0.3 mm was bonded to the surface of the plate material. Since the surface of the three-layer laminate was smooth, the decorative veneer was well bonded, and the surface of the obtained 12 mm thick flooring material was also smooth.

(Test Example 1) The bending strength and bending deflection of the flooring material produced in Example 1 were evaluated. First, regarding bending strength, JIS-A5908
Was 50 to 60 MPa. In addition, the size of the bending deflection is 300 m
m (width) x 1800 mm (length) x 12 mm (thickness), supported by a span of 700 mm, and a displacement of 21 kg weight applied on a load rod placed perpendicular to the center of the span ( A) was evaluated by the difference (AB) between the displacement (B) when a load of 9 kg was applied and the displacement (B). As this difference is less represents that rigidity is strong, the bending
Deflection value is based on Japanese Agricultural Standards (JAS) for wood composite flooring
3.5mm or less, which is the acceptable level for "brightness and deflection"
Must be below. For the flooring of Example 1 comprising a veneer veneer 0.3 mm thick and having a thickness of 12 mm,
Was subjected to the above test, the magnitude of the bending deflection,
2.5 mm, and had sufficient rigidity as a floor material.

(Test Example 2) A conventional floor material using plywood, having a thickness similar to that of the floor material of Example 1, was tested in Test Example 1.
The same evaluation was performed. As a result, the bending strength is 40 to 5
It was 0 MPa, and the magnitude of the bending deflection was 2.7 mm. From these results, it can be seen that the flooring material of the present invention has rigidity equal to or higher than that of the conventional plywood product, and has higher rigidity than the conventional product.

(Example 2) As the material of the directional wood thin laminated board of the core material, the length is 20 to 100 mm and the width is 3 to 50.
mm, 100 parts by weight of wood flakes having a thickness in the range of 0.2 to 0.8 mm are prepared, and a mixture of 10 parts by weight of a non-concentrated urea resin and 10 parts by weight of a foamable urethane resin is used as a foaming binder. Was prepared and put into a rotating drum rotating at a low speed, and the foamable binder was applied to the wood flakes by spraying when spontaneously falling in the drum. The raw material for the medium-density wood fiber integrated board of the surface layer material is wood fiber (manufactured by Canadian Forest Products, F.
4-17), a urethane resin (coarse MD manufactured by Sumitomo Bayer Urethane Co., Ltd.) as a foamable binder
I) When a mixture of 10 parts by weight and 10 parts by weight of a non-concentrated type urea resin as a non-foamable binder is prepared, and wood fibers are put in a rotating drum rotating at a low speed, and naturally dropped in the drum. The wood fiber was coated with a binder by spraying the mixture with a spray.

First, half of the wood fibers to which the binder has been applied are evenly spread on a hot pressing plate, and the wood flakes to which the foaming binder has been applied are placed thereon, and the wood flakes are arranged in almost one direction. Sprayed evenly. Furthermore, the remaining wood fibers are sprayed thereon, and these laminates are
A temperature of 150 ° C and a pressure of 2MP so that the thickness becomes 25mm.
a) for 15 minutes. The surface of the plate material thus formed is smooth, and its specific gravity is 0.59 g / c.
m ³ , flexural strength 63.2 MPa, flexural Young's modulus 6
It was 1 × 10 ² MPa.

(Comparative Example 1) In place of the foamable binder of the core material, 10 parts by weight of a non-foamable urea resin was used.
Except for using wood fiber (manufactured by Canadian Forest Products Co., Ltd., F3-5) containing 95% or more of a material having a thickness of at most 95 mm, a plate material having three layers laminated was simultaneously hot-press molded in the same manner as in Example 2. Although the surface of the plate was smooth, its specific gravity was as large as 0.70 g / cm ^3, and its bending strength was 33.3 g / cm ³ .
It was 0 MPa and the bending Young's modulus was 34 × 10 ² MPa, both of which were inferior to the sheet material of Example 2.

The flooring material according to the present invention is obtained by using a directional thin wood laminated board as a core material and laminating a medium density wood fiber laminated board on both sides thereof. Therefore, the strength and rigidity can be greatly improved as compared with the case where they are used alone. Ma
In addition, as a raw material of the medium density wood fiber integrated board, the fiber length is 1 to
30 mm, fiber width is 0.1 to 2 mm, and fiber length
Uses wood fiber containing 50% or more of 3mm or more
Because the bending strength of the wood fiber itself increases,
The strength as a material can be further improved. Furthermore, according to the floor material formed by bonding decorative veneers, the rigidity is equal to or higher than that of the floor material using conventional plywood, and the bending strength, bending deflection, etc. are improved. It has characteristics that it can be used as a flooring material. In particular, by using a foamable resin as the binder, the density of the plate material can be reduced, and a lightweight and high-strength floor material can be obtained. Also, when the core material and the surface layer material are simultaneously formed, the floor material of the present invention is canceled out even if each layer has partial hardness, softness or thickness, and becomes uniform and smooth as a whole plate material. It is difficult to appear and has good smoothness as a base material for applying a decorative veneer. Further, according to the flooring material of the present invention, the raw material conventionally used as waste material can be effectively used, and there is an effect of protecting wood resources. Further, such a raw material is inexpensive, and the cost of the raw material can be reduced.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a structure of a flooring material of the present invention.

FIG. 2 is a front view showing a structure of a directional thin wood laminated board used as a core material of a flooring material of the present invention.

FIG. 3 is a cross-sectional view showing a structure of a conventional flooring material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Core material, 2 ... Surface material, 3 ... Decorative veneer, 31 ... Plywood

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 15/04 E04F 15/04 Z (72) Inventor Kazushi Endo 10-1 Nakazawacho, Hamamatsu City, Shizuoka Prefecture Yamaha Corporation ( 56) References JP-A-4-144705 (JP, A) JP-A-4-25403 (JP, A) JP-A-4-351544 (JP, A) Shokai Sho 57-24031 (JP, U) Ministry of Agriculture and Forestry Test site, “New Edition Woodworking Handbook” published by Maruzen Co., Ltd. January 15, 1973 p. 766 Table 10.16 “Standard Material of Particleboard” Section Takeshi Uemura “Practical Knowledge of Wood” Toyo Keizai Issued on July 20, 1976, p. 206, page 206. Table 10.3 "Standards of wood composite floorboards" (58) Fields investigated (Int. Cl. ⁶ , DB name) B27D 1/04 B27M 3/04 B27N 3/00-3/04

Claims (2)

(57) [Claims] 1. A laminated medium density wood fiber stacking plate on both sides of the directional wooden strands assembled plate, on one surface of the medium density wood fiber stacking plate, is formed by joining a decorative veneer, the Medium-density wood fiber accumulation board, fiber length 1-30mm, fiber
With a width of 0.1 to 2 mm and a fiber length of 3 mm or more
Of wood fiber containing more than 50% by using binder
And a floor material characterized by being molded and integrated . 2. The directional wood lamella assem- bly emits wood flakes.
The flooring material according to claim 1, wherein the flooring material is adhered with a foam binder and molded and integrated .