JP3739583B2 - Manufacturing method for flooring - Google Patents
Manufacturing method for flooring Download PDFInfo
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- JP3739583B2 JP3739583B2 JP37760798A JP37760798A JP3739583B2 JP 3739583 B2 JP3739583 B2 JP 3739583B2 JP 37760798 A JP37760798 A JP 37760798A JP 37760798 A JP37760798 A JP 37760798A JP 3739583 B2 JP3739583 B2 JP 3739583B2
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- Prior art keywords
- cork
- sheet
- rubber
- flooring
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Description
【０００１】
【発明の属する技術分野】
本発明は歩行感と遮音性に優れ歪のない強度と強い耐久性を有した床材の製造方法に関しており、具体的にはコルク材とゴム材とを用いた寸法精度の高い複合床材の製造方法に関するものである。
【０００２】
【従来の技術】
従来、住宅の床に用いるコルク材を主体とする床材としては、コルク粒を所望の厚みにシート化して形成したコルク板を合板あるいはゴム板等の芯板に貼合せ積層一体化した複合材が一般に知られており、昨今では前記したような板材を張り合わせる代りに、特開昭６２−３０８５９号公報に示されたように、所望の粒度を有するコルク粒と加硫済みのゴム材料を適度の大きさの粒度に粉砕したゴム粒とに接着剤を付着せしめて混合し、これらを振動分離または粉散分離せしめて比重の異なる層となさしめた後、シート状に一体成形して積層構造とする床材も提案されている。
【０００３】
【発明が解決しようとする課題】
しかしながら、前者のシート化したコルク板をゴム板等の芯板に貼合せた複合材は、予め形成したコルク材の表面を平滑に造形加工し、これを芯板へ貼り合わせる等の複数の煩雑な工程を経なければならないのでどうしてもコスト高となる大きな欠点を有している。
また、後者の加硫済みゴム材とコルク材のそれぞれを適度の大きさの粒度に粉砕しこれらを接着剤によって一体成形する複合構造では、前記した貼り付け一体化構造に増して手間が掛かり、成形工程も複雑でおよそ低価格で提供できるものでなく、その仕上がりも構造物全体を粉砕物から直接硬化形成せしめるものであるから寸法不良とか表面荒れが発生するなど床材としてはなはだ不都合な欠点を多く残している。
本発明はこのような欠点を除去し、成形性に優れ、軽量・低価格にて寸法精度の高い床材を製造する製造方法を提供するものである。
以下、図面を参照しつつ詳述する。
【０００４】
【課題を解決しようとする手段】
本発明を図面によって詳述すると、図１に示すように板状のコルク材とゴム材よりなる層状をなした床材の製造方法であって、適度の粒度に粉砕したコルク粒に接着剤を混合して所望厚みのコルクシート（１）を圧縮形成せしめ、加硫剤を含むゴム薬品を混合しシート状に仮形成した未加硫状態のゴムシート（２ａ）を前記予め形成したコルクシート（１）と重ね合せ、これを成形プレスで加圧・加熱せしめてコルクシート（１）のコルク粒間の僅かな間隙に未加硫ゴム材の浸透性によってゴム材を入り込ませて硬化させコルクシー ト（１）とゴムシート（２ａ）とを層状に成型一体化せしめた床材の製造方法を特徴としている。
【０００５】
また、前記コルク材とゴム材からなる床材の製造方法であって、図２に示す如く前記コルクシート（１）のシート状未加硫状態のゴムシート（２ａ）が重ね合せられない面へ表面剤（３ａ）を配し、これを成形プレスで加圧せしめて塗装面（３）を形成し表面仕上げのなされた層状の床材を得る製造方法も特徴としている。
【０００６】
【発明の実施の形態】
本発明は前記のようにコルク材とゴム材の二つの弾性が異なる材料を用いて床材を形成し下記に示す大きな作用を得た。
まず、天然材であるコルク材は微細な細胞と該細胞が抱く空気からなっており、その特性は軽量で強い弾力性と高い圧縮回復力を有して、熱絶縁性及び振動吸収性さらには遮音性などに優れる大きな特徴を持っている。
次に、天然材あるいは合成材からなるゴム材料は高い弾力性、伸び性、及び密度を持っており、振動・衝撃等の吸収材として極めて優れた緩衝材料となっている。
【０００７】
本発明では、前記したコルク材を適度の粒度に粉砕してコルク粒を形成し、該コルク粒に接着剤を混合しこれを圧縮してコルクシート（１）を形成する。
次にシート状の未加硫生地のゴムシート（２ａ）を前記コルクシート（１）と重ね合せ、これを加熱圧縮せしめてコルクシート（１）と成形されたゴムシート（２）からなる床材を得たものであり、このように異材質の弾性板材を接着剤を用いることなく一体化せしめた製造方法によってコルクシート（１）の持つ良好な遮音性・圧縮回復性・装飾性さらには軽量性が、ゴムシート（２）の高い弾力性・伸び性あるいは粘着性に結合しここで良好な歩行感を持ち高い寸法精度と耐久性のある床材を得たものである。
【０００８】
【実施例】
以下に実施例を示す。
本発明において使用するコルク粒は、粒径を０．５ｍｍ〜５．０ｍｍ程度に粉砕形成せしめることが床材としての弾力性にも接着剤の混合にも成形後の平滑表面を得るにも容易であるので好ましいものとなる。
このコルク粒に混合する接着剤としては、ユリア樹脂、メラミン樹脂、またはフェノール樹脂等の加熱により硬化する合成樹脂液あるいはこれらの合成樹脂液のエマルジョン等が使用される。
一方、ゴム材としては、天然ゴム、スチレンブタジエンラバー、あるいはニトリルブタジエンラバー等が基材として用いられ、求められる物性により加硫剤を含む種々のゴム薬品が添加される。
【０００９】
成形においては、所望寸法のキャビティを持つ型枠中へ前記予め形成されたコルクシート（１）と未加硫のゴムシート（２ａ）を投入し、１４０℃〜１７０℃の加熱をもって６〜１０ｋｇ／ｃｍ２で８分〜２０分程度圧締して硬化形成せしめる。
上記のようにして成形されたコルクシート（１）とゴムシート（２）は、コルクシート（１）のコルク粒間の僅かな間隙にゴム材が入り込んで硬化されそのそれぞれが木の根状態を形成ししっかり該コルクシート（１）の内部にまで食い込んで絡み合い強い結合を見せる。
このように圧縮時に見せる未加硫ゴム材の高い浸透性を利用したことにより接着力による固着でない物理的な結合が実現する。
【００１０】
また、シート状の未加硫生地のゴムシート（２ａ）を予め形成したコルクシート（１）と重ね合せて加熱圧縮せしめるとき、図２に示すように前記ゴムシート（２ａ）が重ね合せられない反対面へワックス、バニッシュ等の表面剤（３ａ）を塗布せしめて、これを加熱圧締せしめ成型一体化せしめると、歩行面である表面に平滑な塗装面（３）が形成されるのでより商品性の高い床材を提供できる。
【００１１】
【発明の効果】
上記のような構成によって、以下に示す優れた効果が得られる。
本発明は接着剤を用いて予め形成したコルク板とゴム板とを貼合せた複合構造と異なり、コルクシート（１）と未加硫のゴムシート（２ａ）とを直接熱間プレスして床材を得るものであり、このようなゴム材の高い浸透性を利用した一体化によってコルクシート（１）の持つ良好な遮音性・圧縮回復性・装飾性さらには軽量性が、ゴムシート（２）の高い弾力性・伸び性あるいは粘着性と結合しここで良好な歩行感を持ち高い寸法精度と耐久性のある床材を得たものである。
【図面の簡単な説明】
【図１】 本発明の製造方法による実施例を示す断面図である。
【図２】 本発明の製造方法による他の実施例を示す断面図である。
【符号の説明】
１ コルクシート
２ 加硫状態のゴムシート
２ａ 未加硫状態のゴムシート
３ 塗装面
３ａ 表面剤[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a flooring material having excellent walking feeling and sound insulation and having no distortion and strong durability, and specifically, a composite flooring material having high dimensional accuracy using a cork material and a rubber material. It relates to a manufacturing method .
[0002]
[Prior art]
Conventionally, as a flooring mainly composed of cork used for a floor of a house, a cork board formed by forming cork grains into a desired thickness is laminated and integrated on a core board such as a plywood or a rubber board and integrated. In general, instead of laminating the above plate materials, as shown in JP-A-62-30859, cork grains having a desired grain size and vulcanized rubber material are used. Adhesive is attached to and mixed with rubber particles that have been pulverized to an appropriate particle size, and these are separated by vibration or dust separation to form layers with different specific gravity, and then integrally molded into a sheet and laminated A flooring structure is also proposed.
[0003]
[Problems to be solved by the invention]
However, the composite material in which the former cork plate formed into a sheet is bonded to a core plate such as a rubber plate is formed by smooth shaping the surface of a pre-formed cork material and pasting it on the core plate. Therefore, there is a great disadvantage that the cost is inevitably increased.
In addition, in the composite structure in which each of the latter vulcanized rubber material and cork material is pulverized to an appropriate particle size and integrally formed with an adhesive, it takes more time than the pasted integrated structure, The molding process is complicated and can not be provided at a low cost, and the finished structure is also formed by directly curing the entire structure from the pulverized product, resulting in inconvenient disadvantages as a flooring such as defective dimensions and surface roughness. A lot is left.
The present invention eliminates such drawbacks, and provides a production method for producing a flooring material having excellent moldability, light weight, low cost and high dimensional accuracy.
Hereinafter, it will be described in detail with reference to the drawings.
[0004]
[Means to solve the problem]
The present invention will be described in detail with reference to the drawings. As shown in FIG. 1, it is a method for producing a layered floor material composed of a plate-like cork material and a rubber material, and an adhesive is applied to cork particles pulverized to an appropriate particle size. mixed to allowed compressed form cork sheet (1) of the desired thickness, cork sheet mixing the rubber sheet unvulcanized provisionally formed into a sheet (2a) and rubber chemicals said preformed containing vulcanizing agent ( 1) and superimposed, Korukushi DOO which was cured by entering the rubber material by penetration of the unvulcanized rubber material to small gap between the cork granules of cork sheet (1) and allowed to pressurizing and heating the molding press It is characterized by a method for producing a flooring in which (1) and a rubber sheet (2a) are molded and integrated in layers.
[0005]
Moreover, it is a manufacturing method of the floor material which consists of the said cork material and a rubber material, Comprising: As shown in FIG. 2, the sheet-like unvulcanized | cured rubber sheet (2a) of the said cork sheet (1) is to the surface which cannot be overlaid. Another feature is a manufacturing method in which a surface agent (3a) is disposed and pressed with a molding press to form a painted surface (3) to obtain a surface-finished layered flooring.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, the floor material is formed using the two materials having different elasticity, that is, the cork material and the rubber material as described above, and the following great effects are obtained.
First, natural cork is composed of fine cells and the air that the cells hold. Its characteristics are lightweight, strong elasticity and high compression recovery, thermal insulation and vibration absorption, It has major features such as excellent sound insulation.
Next, a rubber material made of a natural material or a synthetic material has high elasticity, stretchability, and density, and is an extremely excellent buffer material as an absorbing material for vibration and impact.
[0007]
In the present invention, the cork material is pulverized to an appropriate particle size to form cork particles, and an adhesive is mixed with the cork particles and compressed to form the cork sheet (1).
Next, the sheet-like unvulcanized fabric rubber sheet (2a) is overlaid with the cork sheet (1), and this is heated and compressed to form a cork sheet (1) and a molded rubber sheet (2). The cork sheet (1) has good sound insulation, compression recovery, decoration, and light weight by the manufacturing method in which different elastic plates are integrated without using an adhesive. The rubber sheet (2) is bonded to the high elasticity, stretchability or adhesiveness of the rubber sheet (2) to obtain a floor material having a good gait and high dimensional accuracy and durability.
[0008]
【Example】
Examples are shown below.
Cork grains used in the present invention can be easily pulverized to a particle size of about 0.5 mm to 5.0 mm for elasticity as a flooring material, mixing of adhesives, and obtaining a smooth surface after molding. Therefore, it is preferable.
As the adhesive to be mixed with the cork grains, a synthetic resin liquid that is cured by heating, such as urea resin, melamine resin, or phenol resin, or an emulsion of these synthetic resin liquids is used.
On the other hand, natural rubber, styrene butadiene rubber, nitrile butadiene rubber or the like is used as a rubber material as a rubber material, and various rubber chemicals including a vulcanizing agent are added depending on required physical properties.
[0009]
In molding, the preformed cork sheet (1) and unvulcanized rubber sheet (2a) are put into a mold having a cavity of a desired size, and heated at 140 ° C. to 170 ° C. to 6-10 kg / Crush for about 8 minutes to 20 minutes at cm 2 to form a cured product.
The cork sheet (1) and the rubber sheet (2) formed as described above are cured by the rubber material entering a slight gap between the cork grains of the cork sheet (1), and each of them forms a tree root state. The cork sheet (1) is firmly entangled and entangled to show a strong bond.
In this way, physical bonding that is not fixed by adhesive force is realized by utilizing the high permeability of the unvulcanized rubber material that is shown during compression.
[0010]
Further, when the sheet-like unvulcanized fabric rubber sheet (2a) is overlapped with a pre-formed cork sheet (1) and heat-compressed, the rubber sheet (2a) cannot be overlapped as shown in FIG. If a surface agent (3a) such as wax or vanish is applied to the opposite surface, and this is heat-pressed and molded and integrated, a smooth painted surface (3) will be formed on the surface that is the walking surface. High-quality flooring can be provided.
[0011]
【The invention's effect】
With the above configuration, the following excellent effects can be obtained.
Unlike the composite structure in which a cork plate and a rubber plate formed in advance using an adhesive are bonded together, the present invention directly presses the cork sheet (1) and the unvulcanized rubber sheet (2a) into a floor. The cork sheet (1) has good sound insulation, compression recovery, decoration, and light weight by integration using the high permeability of such a rubber material. ), Which is combined with high elasticity, stretchability or adhesiveness, and has a good gait and high dimensional accuracy and durability.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment according to the manufacturing method of the present invention.
FIG. 2 is a cross-sectional view showing another embodiment according to the manufacturing method of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1
Claims (2)
適度の粒度に粉砕したコルク粒に接着剤を混合してコルクシートを圧縮形成せしめ、
加硫剤を含むゴム薬品を混合しシート状に仮形成した未加硫状態のゴムシートを前記予め形成したコルクシートと重ね合せ、
これを成形プレスで加熱加圧成形せしめ、コルクシートのコルク粒間の僅かな間隙に未加硫ゴム材の浸透性によってゴム材を入り込ませて硬化させコルクシートとゴムシートの層状に一体化せしめることを特徴とする床材の製造方法。In the manufacturing method of the floor material formed by laminating the cork material and the rubber material,
Adhesive is mixed with cork grains pulverized to an appropriate particle size to compress the cork sheet,
A rubber sheet containing a vulcanizing agent is mixed with an unvulcanized rubber sheet temporarily formed into a sheet shape, and the pre-formed cork sheet is overlaid,
This allowed hot pressing in molding press, allowed to integrate into the cork grains between the small gap in the unvulcanized rubber material of the permeable cork sheet and the rubber sheet was cured by entering the rubber material by a layer of cork sheet A method for producing a flooring characterized by the above.
前記未加硫状態のゴムシートの重ね合わされるコルクシートの反対面へ表面剤を塗布し、
これを成形プレスで加圧せしめ層状に成型一体化せしめたことを特徴とする請求項１の床材の製造方法。In the method for producing the flooring ,
Applying a surface agent to the opposite surface of the cork sheet to be overlaid with the unvulcanized rubber sheet,
2. The method for producing a flooring material according to claim 1, wherein this is press-molded by a molding press and molded and integrated into a layer shape.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP37760798A JP3739583B2 (en) | 1998-12-28 | 1998-12-28 | Manufacturing method for flooring |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP37760798A JP3739583B2 (en) | 1998-12-28 | 1998-12-28 | Manufacturing method for flooring |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2000199329A JP2000199329A (en) | 2000-07-18 |
| JP3739583B2 true JP3739583B2 (en) | 2006-01-25 |
Family
ID=18509002
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP37760798A Expired - Fee Related JP3739583B2 (en) | 1998-12-28 | 1998-12-28 | Manufacturing method for flooring |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3739583B2 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107503493A (en) * | 2017-07-31 | 2017-12-22 | 太仓市金强家具有限公司 | A kind of shockproof floor of environment protection damp-proof anticorrosion |
| JP7429924B2 (en) | 2020-10-16 | 2024-02-09 | 内山工業株式会社 | Decorative sheet and its manufacturing method |
-
1998
- 1998-12-28 JP JP37760798A patent/JP3739583B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP2000199329A (en) | 2000-07-18 |
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