JP3470552B2 - panel - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the structure of a panel such as a flooring material having a rock wool board impregnated with a thermosetting synthetic resin as a base material.

[0002]

2. Description of the Related Art Generally, a direct-attached soundproof floor is constructed by a method of directly attaching a floor material to the lower ground of a building,
The main purpose is to reduce the impact noise on the floor, to reduce the impact force applied to the floor surface and reduce the impact noise transmitted downstairs.

A conventional wooden soundproof floor material used for construction of a conventional sound-insulating floor of this type is constructed, for example, as shown in FIG . That is, the base material of the floor material is formed of plywood 1 ', a plurality of kerfs 2 are provided in rows on the back surface of the plywood 1', and the surface decorative material 3 is laminated on the front surface of the plywood 1 '. The cushion layer 4 is integrally formed on the back surface of the plywood 1 '. The wood soundproof flooring material with this structure has a groove 2 formed in the plywood 1'to reduce the bending rigidity, and the cushion layer 4 is laminated to reduce the overall spring constant per unit area of the floor. By layering vibrating materials, the vibration generated by impact is damped, and measures such as damping the impact are provided to improve the soundproofing performance.

[0004]

However, since the current wooden soundproof flooring material has improved soundproofing performance by reducing the spring constant and bending rigidity, it tends to cause a problem that the feeling of walking becomes poor. Since ′ is used as the base material, dimensional change due to humidity is likely to occur, and problems such as push-up due to moisture absorption, gaps due to drying, and cracking of the surface decorative material are likely to occur. If the surface hardness of the base material is plywood 1 ', it is likely to cause scratches or dents due to the use of furniture with casters or the impact of dropping objects, and the surface is not so smooth. Stockings in V-grooves 5, socks and socks are likely to occur.

The present invention has been made in view of the above-mentioned points, and a panel capable of improving soundproofing performance, surface hardness and smoothness, and further improving dimensional stability against temperature and humidity can be provided. The challenge is to provide.

[0006]

In order to solve the above-mentioned problems, the panel according to claim 1 of the present invention has rigidity on the surface side of a rock wool board impregnated with a thermosetting synthetic resin and has a smooth surface. The surface decorative material is laminated through the reinforcing layer, and the reinforcing layer
And a cushion layer is laminated between the rock wool board and the rock wool board . By using a reinforcing layer that has rigidity on the surface side and has a smooth surface as described above, when the panel is a flooring material, scratches caused by the use of furniture with casters are compared to those using a conventional plywood base material. It reduces the number of dents caused by falling objects. In addition, by using a reinforcing layer having rigidity on the surface side and having a smooth surface, when the panel is a flooring material, the surface becomes smoother than that using a conventional plywood base material. The stockings and socks do not get caught in the V-shaped groove of the material. In addition, rock wool board is a material that has a small dimensional change rate due to humidity and a small dimensional change rate due to temperature compared to the conventional plywood base material, so the dimensional change of the panel with respect to temperature and humidity is small, and it pushes up,
Gaps are reduced. Furthermore, rock wool board has a smaller spring constant than plywood base material and is a material with excellent shock absorption performance, so when the panel is a flooring material, compared to the same floor construction using plywood base material. The soundproof performance (L value) is improved by one rank with the same walking feeling. Further, since the rock wool board is impregnated with a thermosetting synthetic resin, it has sufficient strength even when used as a base material for a panel such as a floor material. Also rock wool board and reinforcement layer
By providing a cushion layer between the
Shape, damping of vibration due to damping effect, total unit area hit
It is possible to improve the soundproofing performance by reducing the spring constant
it can.

The panel of claim 2 of the present invention is characterized in that, in claim 1, the reinforcing layer is a wood powder-plastic composite material. By using the wood powder-plastic composite material for the reinforcing layer, a smooth panel surface having high hardness can be obtained. In addition, rock wool board and wood powder-plastic composite material have higher dimensional stability against changes in temperature and humidity than plywood. Therefore, the panel made of rock wool board and wood powder-plastic composite material can reduce the temperature of the entire panel. The dimensional change due to humidity change is small, and thrust and gaps are reduced.

A panel according to a third aspect of the present invention is characterized in that, in the first aspect, the reinforcing layer is a resin-impregnated layer obtained by impregnating the surface layer of the rock wool board with a resin. The reinforcing layer can be formed only by impregnating the surface layer of the rock wool board with a resin, and it is not necessary to separately provide the reinforcing layer with the rock wool board, and strength and surface strength can be easily obtained. A urethane resin, a phenol resin, a melamine resin or the like can be used as the impregnating resin forming the resin impregnated layer of the surface layer.

A panel according to a fourth aspect of the present invention is characterized in that, in the first aspect, the reinforcing layer is a medium density fiberboard (MDF board). By using a medium density fiberboard for the reinforcing layer, a smooth and smooth panel surface can be obtained. In addition, rock wool board and medium density fiberboard are materials that have higher dimensional stability against changes in temperature and humidity than plywood.Therefore, a panel consisting of rockwool board and medium density fiberboard allows the dimensions of the entire panel to change due to temperature and humidity changes. The change is small, and the thrust and the gap are reduced.

A panel according to a fifth aspect of the present invention is characterized in that, in any one of the first to fourth aspects, a cushion layer is laminated on the back surface side of the rock wool board. Rock wool board is a material that has a smaller spring constant and bending rigidity than the base material of plywood and is excellent in shock absorption performance, so in the case of flooring with a cushion layer on the back surface of rock wool board, plywood It is not necessary to use a cushion layer having a low spring constant as in the case of the same floor structure using the above base material, and it is possible to improve the soundproof performance without impairing the walking feeling.

[0011] panel according to claim 6 of the present invention, claim
1 is characterized in that the cushion layer is a resin having adhesiveness and elasticity after the adhesive is cured. Has the effect of bonding to the material of the cushion layer and the rock wool board and a reinforcing layer, according to claim 1 by and after bonding also has elasticity
It is possible to further improve the soundproofing performance than the above. As the material of the cushion layer, urethane foam resin or the like can be used.

[0012] panel according to claim 7 of the present invention, claim
1 is characterized in that a concave portion is formed on the front surface side of the rock wool board or the rear surface side of the reinforcing layer, and a cushion material is provided in the concave portion to form the cushion layer. By forming a recess on the front side of the rock wool board or on the back side of the reinforcing layer and providing a cushion layer in this recess, the overall spring constant per unit area can be reduced without increasing the thickness of the entire panel. Is possible. When the panel is a flooring material, walking feeling and load resistance can be ensured by the presence of the convex portion on the surface side of the rock wool board or the rear surface side of the reinforcing layer other than the concave portion.

[0013] panel according to claim 8 of the present invention, claim
In No. 7 , the cushion material of the concave portion is a resin having adhesiveness and elasticity after the adhesive is cured. The material of the cushion layer has the effect of adhering the rock wool board and the reinforcing layer, and has elasticity even after the adhesive is cured.
The soundproofing performance can be improved as compared with the seventh aspect . Further, it is possible to easily obtain the required thickness at the time of adhesive molding of the cushion layer having adhesiveness by the concave portion provided on the front surface side of the rock wool board or the rear surface side of the reinforcing layer. As the material of the cushion layer, urethane foam resin or the like can be used.

The panel according to claim 9 of the present invention is the panel according to any one of claims 1 to 4, wherein both end surfaces of the rock wool board are covered with a reinforcing layer and a real part is provided on the reinforcing layer. Characterize. The reinforcing layer covers both end portions of the rock wool board, and the real portion is provided at that portion, so that the strength of the real portion can be improved. Further, it is also possible to facilitate the required thickness increase at the time of adhesive molding of the cushion layer having adhesiveness as in claim 6 at the portion of the reinforcing layer covering both ends of the rock wool board. For a material such as a wood flour-plastic composite material that can easily secure an arbitrary shape, the shape including the actual part can be formed by extrusion molding or the like.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION In the case of the embodiment of the present invention, a floor material A will be described as an example of a panel.

First, the embodiments shown in FIGS . 1 and 2 will be described. The base material of the floor material A is a cushion for surface layer on the surface side of the rock wool board 1 which is hardened by impregnating it with a thermosetting synthetic resin.
The reinforcement layer 6 is integrally formed with the support layer 9 interposed therebetween , and the flooring material A is formed by laminating and integrating the surface decorative material 3 on the reinforcement layer 6 of the base material. One of the two end faces of the rock wool board 1 is provided with a male nut 7 and the other is provided with a male nut 8 that fits into the female nut 7. Examples of the thermosetting synthetic resin with which the rock wool board 1 is impregnated include urethane resin, phenol resin, and melamine resin. The reinforcing layer 6 provided on the surface side of the rock wool board 1 is a wood powder-plastic composite material or a medium density fiberboard (MDF board). The surface decorative material 3 is a thin wood veneer, and V grooves 5 are provided on the surface as needed. The rock wool board 1 impregnated with the thermosetting synthetic resin has a thickness a of, for example, 9 mm, and the reinforcing layer 6 has a thickness b of, for example, 3 mm .

Further reinforcing layer 6 provided on the surface of the rock wool board 1 impregnated with thermosetting synthetic resin may be formed of a resin-impregnated layer. In other words, it is form form the resin containing immersion layer impregnated with rock wool board 1 sufficiently large amount of resin than the impregnation amount of the thermosetting synthetic resin impregnated throughout. The resin that form such a resin containing immersion layer is urethane resins, phenol resins, melamine resins and the like. Such resins including immersion
Resins that form the layers same is desirable as a resin for impregnating the entire rock wool board 1.

[0018] Although Ru Thea integrally laminated cushion layer 9 for the surface layer between the rock wool board 1 and the reinforcing layer 6 impregnated with thermosetting synthetic resin, cushioning layer 9 of this soft foamed urethane sheet, It is made of polyester nonwoven fabric, urethane foam layer that also serves as adhesive. Further, the material of the cushion layer 9 for the surface layer is preferably a material having adhesiveness such as urethane foam also serving as an adhesive and having elasticity after the adhesive is cured.

Further, FIG . 2 shows a roller impregnated with a thermosetting synthetic resin.
The cushion layer for the back side of the back side of the cook wool board 1
4 are laminated and integrated. This cushion layer 4 is soft
It consists of Awau Retanshito or polyester non-woven fabric
It In this case, the cushion on the back of the rock wool board 1
Since the ply layer 4 is provided, it is provided on the back surface of the conventional plywood.
Use a material having a higher spring constant than that of the cushion layer 4.
You can The material of the cushion layer 4 is soft foam urethane.
A material that has adhesive properties like
Materials are preferred.

Table 1 shows the soundproofing performance of the cushion layer 4 for the back surface and the cushion layer 9 for the surface layer.

[0021]

[Table 1]

[0022] Next we explain the embodiment shown in FIG. This example is also basically the same as the above example, but in the case of this example, the rock wool board 1 impregnated with the thermosetting synthetic resin is used.
A concave portion 10 is provided on the surface side of the concave portion 10, and a cushion material is filled in the concave portion 10 to form a cushion layer 9. That is,
As shown in FIG. 3B, the convex portions 1 are formed by arranging rectangular convex portions 11 on the surface side of the rock wool board 1 at substantially equal intervals.
A recess 10 is formed in a portion other than 1, and a cushion material is filled in the recess 10 to form a cushion layer 9. Figure
3 (b), for example, the code c is 50 mm, the d is 50 mm,
e is 10 mm, f is 65 mm, and the height of the convex portion 11 is, for example, 2 mm. Further, in the embodiment shown in FIG.
The cushion layer 9 provided in the recess 10 is made of a material having adhesiveness such as urethane foam that also serves as an adhesive and having elasticity after the adhesive is cured. A cushion layer 4 for the back side is provided on the back side of the rock wool board 1. In the above example, the rock wool board 1 is provided with the concave portion 10 and the cushion layer 9 is provided in the concave portion 10. However, as shown in FIG.
0 may be provided and the cushion layer 9 may be provided in the recess 10.

[0023] Next we explain the embodiment shown in FIG. This example is also basically the same as the above example, but in the case of this example, the reinforcing layer 6 made of wood powder-plastic composite material is applied not only to the surface side of the rock wool board 1 but also to both end surfaces of the rock wool board 1. The reinforcing layer 6 on both end faces is provided with a female fruit 7 on one side and a male fruit 8 on the other side.
Is provided .

[0024] Next we explain the embodiment shown in FIG. In the case of this example, the rock wool board 1 impregnated with a thermosetting synthetic resin is formed by arranging a plurality of blocks 1a and integrating adjacent blocks 1a with a cushion layer 9a. In this case, the cushion layer 9 provided on the surface side of the rock wool board 1 is formed of a cushion material having adhesiveness such as urethane foam resin also serving as an adhesive and having elasticity after the adhesive is cured. When the cushion layer 9 is formed, the cushion layer 9a is formed by filling the gap 1b between the adjacent blocks 1a with a cushion material.

[0025]

According to the first aspect of the present invention, the surface decorative material is laminated on the surface side of the rock wool board impregnated with the thermosetting synthetic resin through the reinforcing layer having rigidity and smooth surface. Therefore, when the panel is a flooring material, scratches due to the use of furniture with casters and dents due to dropping of objects are less than those using conventional plywood as a base material.
Further, when the panel is a floor material, the surface becomes smoother than that of the conventional one using plywood as a base material.
Stockings and socks are less likely to get caught in the groove, and rock wool board is a material that has a smaller rate of dimensional change due to humidity and a smaller rate of dimensional change due to temperature than conventional plywood base materials. Since the dimensional change of the panel with respect to humidity is small, pushing up, gaps, etc. are reduced, and the rock wool board is a material with a smaller spring constant than the base material of plywood and excellent impact absorption performance. , If the panel is a floor material, compared to the same floor structure using a plywood base material, the same level of walking feeling and soundproofing performance (L
The value) is improved by one rank, and since the rock wool board is impregnated with a thermosetting synthetic resin, it has sufficient strength even when used as a base material for a panel such as a flooring material. . Moreover, the reinforcing layer and rock wool bow
Since a cushion layer is laminated between the
Shrinkage deformation, vibration damping due to damping effect, total unit area
To improve the soundproofing performance by reducing the spring constant per hit.
It is capable of

The invention of claim 2 of the present invention is the invention of claim 1.
In the above, since the reinforcing layer is a wood powder-plastic composite material, a surface of a panel with high hardness and smoothness can be obtained, and rock wool board and wood powder-plastic composite material have a temperature and humidity change as compared with plywood. Since it is a material with high dimensional stability against, the panel made of rock wool board and wood powder-plastic composite material has a small dimensional change due to temperature and humidity changes of the entire panel, and push up, gap, etc. are reduced. .

The invention of claim 3 of the present invention is the invention of claim 1.
In the above, since the reinforcing layer is a resin-impregnated layer in which the surface layer of the rockwool board is impregnated with resin, the reinforcing layer can be formed simply by impregnating the surface layer of the rockwool board with the resin, and a separate reinforcing layer is bonded to the rockwool board. Therefore, the strength and the surface strength can be easily obtained.

The invention according to claim 4 of the present invention is the invention according to claim 1.
In the above, since the reinforcing layer is a medium-density fiberboard (MDF board), a panel surface having high hardness and smoothness can be obtained, and rock wool board and medium-density fiberboard are different in temperature and humidity from plywood. It is a material with high dimensional stability against, and therefore, the panel made of rock wool board and medium density fiberboard has a small dimensional change due to changes in temperature and humidity of the whole panel, and can reduce thrust and gap.

According to a fifth aspect of the present invention, in any one of the first to fourth aspects, a cushion layer is laminated on the back surface side of the rock wool board, and the rock wool board is a base material for plywood. Compared to the conventional flooring using a plywood base material, when a cushion layer is provided on the back surface of a rock wool board, it has the same spring floor and flexural rigidity as the material with excellent shock absorption performance. It is not necessary to use a cushion layer having a low spring constant, and it is possible to improve the soundproof performance without impairing the feeling of walking .

The invention of claim 6 of the present invention is the invention of claim 1.
In the above, since the cushion layer has adhesiveness and is a resin having elasticity after the adhesive is cured, it has the effect of adhering the rock wool board and the reinforcing layer to the material of the cushion layer, and by having elasticity even after adhering. The soundproofing performance can be further improved as compared with the first aspect.

The invention of claim 7 of the present invention is the invention of claim 1.
In the above, since the concave portion was formed on the front surface side of the rock wool board or the rear surface side of the reinforcing layer, and the cushion material was provided in the concave portion to form the cushion layer, it is possible to form a comprehensive unit without increasing the thickness of the entire floor material. It is possible to reduce the spring constant per area, and the presence of protrusions on the surface side of the rock wool board or on the back side of the reinforcing layer other than the above-mentioned recesses makes it possible to improve walking feeling and load resistance. It can be secured.

The invention of claim 8 of the present invention is the invention of claim 7.
In the above, since the cushion material of the concave portion is a resin having adhesiveness and elasticity after adhesive curing, the material of the cushion layer has an effect of adhering the rock wool board and the reinforcing layer, and has elasticity even after adhesive curing. According to the present invention, the soundproofing performance can be improved as compared with that of claim 7 ,
Further, it is possible to easily obtain the required thickness at the time of adhesive molding of the cushion layer having adhesiveness by the concave portion provided on the front surface side of the rock wool board or the rear surface side of the reinforcing layer.

The invention of claim 9 of the present invention is the invention of claim 1.
According to any one of claims 4 to 5, the reinforcing layer covers both end surfaces of the rockwool board and the reinforcing layer is provided with a real portion, so that the strength of the real portion can be improved. also der to facilitate necessary thickness out during adhesive forming the adherent is a cushioning layer such as of claim 6 in the portion of the reinforcing layer covering the opposite ends of the board
It

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a floor material according to an example of an embodiment of the present invention.

FIG. 2 is a sectional view of another example of the above.

FIG. 3 shows another example of the above, (a) is a cross-sectional view of the flooring material,
(B) is a top view of a rock wool board.

FIG. 4 is a sectional view of another example of the above.

FIG. 5 is a cross-sectional view of another example of the above.

FIG. 6 is a sectional view of another example of the above.

FIG. 7 is a sectional view of another example of the above.

FIG. 8 is a sectional view of a conventional example.

[Explanation of symbols]

1 rock wool board 2 kerf 3 surface decorative materials 4 cushion layer 6 Reinforcement layer 7 female 8 male facts 9 cushion layer 10 recess

─────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-9-60276 (JP, A) SAIKAI 52-107019 (JP, U) SUNKOKEI 3-33883 (JP, Y2) SUNKO 52- 57175 (JP, Y1) (58) Fields investigated (Int.Cl. ⁷ , DB name) E04F 15/00-15/22 B32B 1/00-35/00

Claims (9)

(57) [Claims] 1. A and the surface has a stiffness in the surface of the rock wool boards impregnated with a thermosetting synthetic resin is laminated surface decorative material over a smooth reinforcement layer, the reinforcement layer and the rock wool ball
A panel characterized in that a cushion layer is laminated between the panel and the board. 2. The panel according to claim 1, wherein the reinforcing layer is a wood flour-plastic composite material. 3. The panel according to claim 1, wherein the reinforcing layer is a resin-impregnated layer obtained by impregnating a surface layer of rock wool board with a resin. 4. A medium density fiberboard (MDF board) having a reinforcing layer.
The panel according to claim 1, wherein 5. The cushion layer is laminated on the back surface side of the rock wool board, according to any one of claims 1 to 4.
Panel according to any one of. 6. The cushion layer has adhesiveness and is adhesively cured.
2. A resin having elasticity afterwards.
The panel described. 7. The surface side or supplement of a rock wool board
A recess is formed on the back side of the strong layer, and a cushion material is installed in the recess.
2. A cushion layer is formed by using
The panel described. 8. The cushion material of the recess has adhesiveness and
A contract characterized by being a resin having elasticity after curing and hardening
The panel according to claim 7 . 9. Both sides of the rock wool board with reinforcing layers
It is characterized by covering the surface and providing a real part in the reinforcing layer.
The panel according to any one of claims 1 to 4 .