JP3865683B2 - Manufacturing method of flooring using natural materials - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a flooring material provided with a floor surface member formed from a natural material.
[0002]
[Prior art]
Conventionally, floor materials using natural materials have been proposed as floor surface members of floor materials (see, for example, Patent Document 1). This floor material is comprised from the base member formed from the foaming synthetic resin, and the floor surface member provided in the surface side of the base member, and the floor surface member is formed from rattan. In this floor material, the floor surface member is made of rattan, so it is easy to absorb moisture, and when used on the floor surface of a dressing room, the moisture of wet feet is absorbed and the feeling of comfort after bathing can get. Also, since the surface of the flooring is rattan, it feels calm and matches the space of Japanese-style architecture.
[0003]
[Patent Document 1]
Japanese Patent Laid-Open No. 9-25705 [0004]
[Problems to be solved by the invention]
However, this type of conventional flooring has the following problems. First, rattan has the property of absorbing and releasing moisture, and has the property of expanding when absorbing moisture and contracting when releasing moisture. When such rattan is used for the floor surface member, the lower base member is maintained at a substantially constant size regardless of moisture, whereas the surface side floor surface member absorbs when moisture is high. It expands somewhat, and when there is little water, it releases water and shrinks somewhat. Therefore, when used on the floor surface of a dressing room, the floor surface member repeatedly expands and contracts, and when used for a certain period of time, the floor surface member expands and contracts to cause the peripheral edge of the floor material to bend and the floor material to the floor surface. There is a problem that it partially floats from the floor or peels off from the floor.
[0005]
Second, since the floor surface member is simply fixed to the base member, moisture absorbed by the floor surface member penetrates into the base member, and the base member comes to contain moisture. When the base member contains moisture as described above, a part of the moisture is released little by little through the floor surface member, but the floor surface is also easily moistened by the moisture of the base member, which is an unfavorable environment for the floor surface.
[0006]
An object of the present invention is to provide a method for producing a flooring material in which bending hardly occurs even when a floor surface member absorbs moisture.
Another object of the present invention is to provide a method for producing a flooring that can eliminate moisture permeation from the floor surface member to the base member.
[0007]
[Means for Solving the Problems]
The present invention relates to a manufacturing method for manufacturing a flooring material by fixing a floor surface member formed from a natural material and a base member installed on the floor surface,
A hydrolyzing step for expanding the floor surface member with moisture, a laminating step for stacking the floor surface member expanded by interposing an intermediate water-impermeable sheet on the base member, the base member, and the intermediate water-impermeable surface And a thermocompression bonding step in which the adhesive sheet and the floor surface member are subjected to thermocompression bonding in a laminated state.
[0008]
According to the present invention, since the floor surface member is made of natural material, when the moisture is high, the moisture is absorbed, and when the moisture is low, the absorbed moisture is released, and thus the humidity is adjusted. , Can keep the room in a comfortable environment. In addition, since the floor surface member is laminated on the base member via the intermediate water-impermeable synthetic resin sheet and is thermocompression bonded in this laminated state, the intermediate synthetic resinous sheet is melted by heat, and the floor is passed through this sheet. The surface member and the base member can be securely fixed while ensuring water impermeability. Further, since the floor surface member is thermocompression-bonded in a state where it contains moisture and expands, the floor surface member is fixed to the base member in an expanded state, and as described above, it almost expands even when it contains moisture. There is nothing. Therefore, it should be used conveniently as a flooring material that does not swell even when it contains moisture in use, does not bend even when used for a long time in a humid environment, and that gets wet with water, such as a flooring material for a dressing room. Can do.
[0009]
Moreover, in this invention, in the said thermocompression bonding step, it thermocompression-bonds in the state which covered the surface of the said floor surface member with the sheet | seat for evaporation prevention.
[0010]
According to the present invention, since the floor surface member is covered with the evaporation preventing sheet during thermocompression bonding, evaporation during processing of moisture absorbed by the floor surface member can be suppressed, and the floor surface member is in an expanded state in the middle. It can be fixed to the base member via a water-impermeable synthetic resin sheet.
[0011]
Moreover, in this invention, after the said thermocompression bonding step, the cold pressurization step which cold-presses the said base member of the laminated state, the said intermediate | middle water-impermeable synthetic resin sheet, and the said floor surface member further is included.
[0012]
According to the present invention, since the base member, the intermediate water-impermeable synthetic resin sheet, and the floor surface member are hot-pressed and then cold-pressed, the floor member can be formed into a very flat state.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, with reference to an accompanying drawing, the manufacturing method of the flooring according to the present invention is explained. Figure 1 is a partially enlarged cross-sectional view showing a part of an embodiment of a flooring material fabricated by the manufacturing method according to the present invention, FIG. 2 saw flooring 1 from the back side 3 is a perspective view, FIG. 3 is a simplified explanatory view for explaining a hydrolytic expansion step in the floor material manufacturing method of FIG. 1, and FIG. 4 is a thermocompression bonding step in the floor material manufacturing method of FIG. FIG. 5 is a simplified explanatory diagram for explaining a cold pressurizing step in the flooring manufacturing method of FIG. 1.
[0016]
In FIG. 1, the illustrated flooring 2 includes a base member 4 installed on the floor surface, a floor surface member 6 provided on the surface side of the base member 4, and between the base member 4 and the floor surface member 6. The intermediate water-impermeable sheet 8 interposed between the two. The floor surface member 6 is formed from a natural material. By forming the floor surface member 6 from a natural material, the floor surface member 6 absorbs moisture when moisture is high, and releases moisture when moisture is low. It can be carried out. The natural material is preferably made of rattan, bamboo, or natural wood. By forming from these materials, moisture absorption and release performance can be improved and matching with Japanese-style building is enhanced. be able to. In the case of using rattan, the floor surface member 6 is formed by connecting the rattan members with connecting members such as threads and strings. When bamboo or natural wood is used, the floor surface member 6 is formed of a plurality of bamboo members and natural wood.
[0017]
The illustrated base member 4 is composed of a pair of plate-like members 10a and 10b, and each plate-like member 10a and 10b has substantially the same structure, and one side portions 12a and 12b thereof are felt, urethane foam, rubber. The other side portions 14a and 14b are made of a synthetic rubber such as styrene butadiene rubber (SBR). Since such synthetic rubber has a relatively high strength, the strength of the plate-like members 10a and 10b is maintained and water-impermeable, and the other side portions 14a and 14b function as a water-impermeable sheet of the base member 4. To do. As shown in FIG. 1, the pair of plate-like members 10 a and 10 b are preferably configured such that their other side portions 14 a and 14 b are on the outer side. The other side portions 14a and 14b of the plate-like members 10a and 10b are located on the both sides of the base member 4, so that both surfaces of the base member 4 can be impermeable. The pair of plate-like members 10a and 10b are fixed by, for example, an adhesive. In this embodiment, the base member 4 is formed of two plate-like members 10a and 10b, but for example, one (in this case, the other side is preferably the back side) or three or more It may be formed from a plate-like member, or a non-water-permeable sheet (which constitutes a back-side non-permeable sheet) by an adhesive or the like on the back side of the plate-like member formed of felt, foamed urethane, or the like. You may make it stick.
[0018]
The intermediate water-impermeable sheet 8 is preferably formed from a synthetic resin such as a urethane-based resin, for example. By forming the intermediate water-impermeable sheet 8 from such a material, the water impermeable sheet can be maintained and the base member 4 can be heated. The floor surface member 6 can be welded through the sheet 8.
[0019]
As understood from FIG. 1, the floor material 2 has the following characteristics because the base member 4 is installed on the floor surface and the floor surface member 6 is on the surface side and has the above-described configuration. First, since the intermediate water-impermeable sheet 8 is interposed between the base member 4 and the floor surface member 6, even if the floor surface member 6 absorbs moisture, the moisture does not penetrate into the base member 4. The base member 4 can be prevented from absorbing moisture from the surface side. Second, since the back surface of the base member 4 is covered with the water-impermeable member 14a (functioning as a back-side water-impermeable sheet), moisture from the floor surface does not enter the base member 4 and the base member 4 Absorption of moisture from the back side can also be prevented. Third, since the surface of the base member 4 is also covered with the water-impermeable member 14b (functioning as a front-side water-impermeable sheet), the penetration of moisture from the surface side of the base member 4 is prevented, and the intermediate water-impermeable water is prevented. The moisture sheet 8 and the water-impermeable member 14b can more reliably prevent moisture from penetrating from the floor surface member 6 side.
[0020]
When this flooring 2 is installed on the floor of a room such as a dressing room, for example, it can be configured as shown in FIG. Referring mainly to FIG. 2, a double-sided adhesive tape 16 is adhered to an appropriate portion of the back surface of the base member 4 of the flooring 2, for example, the four corners and a portion between them. Can be attached to the surface. Alternatively, instead of the double-sided adhesive tape 16, a well-known suction tape (not shown) may be used. The suction tape 16 is provided with a large number of suction recesses on the suction surface, and is attached to the floor using the suction action of these suction recesses. When the double-sided adhesive tape 16 (or adsorbing tape) is used, it can be easily removed from the floor surface, the flooring 2 can be dried or replaced, and its maintenance becomes easy. In order to make the removal of the flooring 2 even easier, the base member 4 of the flooring 2 may be provided with a removal piece (for example, formed from a string, a piece of cloth, etc.).
[0021]
Such a flooring 2 can be manufactured as follows, for example. First, as shown in FIG. 3, the floor surface member 6 is formed by spraying water substantially uniformly onto the front surface side (or the back surface side) of the floor surface member 6 formed from a natural material (for example, rattan). Is kept in an expanded state (hydrolysis expansion step). In order to expand the floor surface member 6 with moisture, the moisture may be sprayed and left for about 2 to 10 minutes, for example. Steam may be sprayed instead of water, and such spraying of water is performed using, for example, a sprayer 18.
[0022]
Next, as understood from FIG. 4, an intermediate water-impermeable sheet 8 is placed on the surface side of the base member 4 (a pair of plate-like members 10a and 10b fixed as described above). The floor surface member 6 expanded with moisture is placed on the surface side of the water permeable sheet 8, and these are laminated (lamination step).
[0023]
Thereafter, the laminated base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are subjected to thermocompression bonding (thermocompression bonding step). The thermocompression bonding can be performed using, for example, a heating and pressing apparatus 20 as shown in FIG. The illustrated heating and pressing apparatus 20 includes a lower stationary member 22 and an upper movable member 24, and the upper movable member 24 is moved up and down with respect to the lower stationary member 22 as indicated by a double arrow. The lower stationary member 22 and the upper movable member 24 incorporate heating means 26 and 28 such as heaters, respectively, and the lower stationary member 22 and the upper movable member 24 are heated by heat from the heating means 26 and 28. In such a heating state, the heating and pressing process is performed.
[0024]
In the heating and pressing process, the laminated base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are placed on the upper surface (processed surface) of the lower stationary member 22, and the upper movable member is placed in this state. 24 descends and presses these in the laminated state. At the time of pressing, the heating means 26 and 28 are energized, and the heat is applied to these in the laminated state via the lower stationary member 22 and the upper movable member 24. Heating by the heating means 26 and 28 is performed at about 85 to 100 ° C., for example. If the heating temperature is 85 ° C. or lower, the intermediate water-impermeable sheet 8 is not sufficiently melted, and the base member 4 and the floor surface member 6 may not be firmly fixed. If it exceeds, natural materials such as rattan fibers will not be stable, and the floor surface member 6 may be distorted after processing and the flooring 2 may be distorted. Instead of placing the laminated state on the lower stationary member 22, the base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 are placed on the upper surface of the lower stationary member 22 in the laminated state. You may do it.
[0025]
When heated and pressurized in this manner, the intermediate water-impermeable sheet 8 melts and melts into the base member 4 and the floor surface member 6, and the base member 4 and the floor surface member 6 are fixed via the intermediate water-impermeable sheet 8. In addition, non-permeability between the two is ensured. Further, since the floor surface member 6 is heated and pressurized in an expanded state, that is, in a state where the fiber is extended by absorption of moisture, the floor surface member 6 is fixed to the base member 4 in an expanded state. . Such heating and pressing is performed for about 3 to 5 minutes, for example. The heating and pressurizing device 20 shown in the figure is heated by the heating means 26 and 28 incorporated in the lower stationary member 22 and the upper movable member 24. However, the present invention is not limited to this configuration, and the lower stationary member 22 is not limited thereto. Alternatively, the heating means 26 or the heating means 28 of the upper movable member 24 may be used.
[0026]
At the time of this heating and pressurization, as shown in FIG. 4, it is preferable to cover the floor surface member 6 by placing an evaporation preventing sheet 30 on the surface side of the floor surface member 6. Moisture absorbed by the floor surface member 6 at the time of heating and pressurization is evaporated by heat and diffused to the outside. By configuring in this way, the diffusion of water vapor is prevented and the floor surface is expanded in a state containing moisture. The member 6 can be fixed to the base member 4. As the evaporation preventing sheet 30, for example, a water-impermeable sheet such as wax paper that is difficult to be thermally deformed can be used.
[0027]
Thereafter, as shown in FIG. 5, the floor material 2 (base member 4, intermediate water-impermeable sheet 8 and floor surface member 6) subjected to heat and pressure processing is pressurized at normal temperature (cold pressure step). The cold pressurization can be performed using, for example, a pressurization device 32 as shown in FIG. 5, and the pressurization device 32 shown includes a lower stationary member 34 and an upper movable member 36, and the upper movable member 36. Is moved up and down with respect to the lower stationary member 34 as shown by a double-headed arrow.
[0028]
In the cold pressing process, the base member 4, the intermediate water-impermeable sheet 8 and the floor surface member 6 that have been subjected to the heating and pressing process are mounted on the upper surface (processed surface) of the lower stationary member 34, and are thus mounted. In this state, the upper movable member 36 descends and presses them, for example, for about 3 to 5 minutes. When cold pressing is performed in this manner, the heated and pressurized flooring 2 is in a very flat state and is suitable as the flooring 2. Note that when the flooring 2 is hardly distorted after the heat pressing process, the cold pressing process can be omitted.
[0029]
Since the floor material 2 manufactured in this way is fixed to the base member 4 in a state where the fiber of the floor surface member 6 is extended, the floor material 2 hardly extends even if it contains moisture in the usage state installed on the floor surface. It can be advantageously used as a flooring material that does not bend even when used over a long period of time in a humid environment and is installed on a floor surface that gets wet with water, for example, a floor surface such as a dressing room.
In the manufacturing method described above, moisture is added to the floor surface member 6 and expanded before heating and pressing, but the floor surface member 6 can also be manufactured without being expanded. That is, the intermediate water-impermeable sheet 8 is placed on the surface side of the base member 4, and the floor surface member 6 is placed on the surface side of the intermediate water-impermeable sheet 8 to be in a laminated state (lamination step). The base member 4 in the laminated state, the intermediate water-impermeable sheet 8 and the floor surface member 6 are subjected to heat and pressure processing as described above using the heat and pressure apparatus 20 shown in FIG. 4 (heat pressure bonding step), and then The pressure-processed floor material 2 (the base member 4 in the laminated state, the intermediate water-impermeable sheet 8 and the floor surface member 6) is subjected to pressure processing as described above using the pressure device 32 shown in FIG. (Pressurizing step).
[0030]
The floor material 2 manufactured in this way is fixed to the base member 4 with the floor surface member 6 fixed to the base member 4 at room temperature, in other words, the fiber of the floor surface member 6 hardly extends. The floor does not shrink due to the release of moisture even when it is dried in the usage state installed on the floor, and does not bend even when used for a long time in a normal or easy-to-dry environment, and does not have much moisture It can be conveniently used as a flooring material to be installed on a surface such as a living room floor.
[0031]
As mentioned above, although embodiment of the manufacturing method of the flooring according to this invention was described, this invention is not limited to these embodiment, A various deformation | transformation thru | or correction | amendment are possible without deviating from the scope of the present invention. .
[0032]
【The invention's effect】
According to the method for producing a flooring of claim 1 of the present invention, the floor surface member is laminated on the base member via the intermediate water-impermeable synthetic resin sheet, and is thermocompression bonded in this laminated state. A sheet | seat is fuse | melted with a heat | fever, A floor | surface surface member and a base member can adhere reliably, ensuring non-permeability through this sheet | seat. Further, since the floor surface member is thermocompression-bonded in a state where it contains water and expands, the floor surface member is fixed to the base member in an expanded state, and hardly expands even if it contains water in the use state.
[0033]
Further, according to the method for producing a flooring material of claim 2 of the present invention, since the floor surface member is covered with the evaporation preventing sheet at the time of thermocompression bonding, evaporation of moisture absorbed by the floor surface member can be suppressed, The floor surface member can be fixed to the base member via the intermediate water-impermeable synthetic resin sheet in an expanded state.
[0034]
Further, according to the method for producing a flooring material of claim 3 of the present invention, since it is cold-pressurized after being hot-pressed, it can be formed into a very flat flooring material.
[0036]
Further, according to the method for producing a flooring material of claim 4 of the present invention, since the floor surface member is formed of any of rattan, bamboo, and natural wood, when the moisture is high, the moisture is absorbed and the moisture is low. Sometimes the absorbed moisture is released and the humidity of the chamber can be adjusted in this way.
[Brief description of the drawings]
FIG. 1 is a partially enlarged cross-sectional view showing an enlarged part of an embodiment of a flooring manufactured by a manufacturing method according to the present invention.
FIG. 2 is a perspective view of the flooring of FIG. 1 as viewed from the back side.
FIG. 3 is a simplified explanatory diagram for explaining a hydrolytic expansion step in the floor material manufacturing method of FIG. 1;
FIG. 4 is a simplified explanatory view for explaining a thermocompression bonding step in the floor material manufacturing method of FIG. 1;
FIG. 5 is a simplified explanatory diagram for explaining a cold pressurizing step in the floor material manufacturing method of FIG. 1;
[Explanation of symbols]
2 Floor material 4 Base member 6 Floor surface member 8 Intermediate water-impermeable sheet 10a, 10b Plate-like member 14a, 14b Non-water-permeable member 16 Double-sided adhesive tape 20 Heating and pressing device 22, 34 Stationary lower member 24, 36 Upper movable member 26, 28 Heating means 30 Evaporation prevention sheet 32 Pressure device

Claims (4)

In a manufacturing method for manufacturing a flooring material by fixing a floor surface member formed from a natural material and a base member installed on the floor surface,
A hydrolyzing step for expanding the floor surface member with moisture, a laminating step for stacking the expanded floor surface member with an intermediate water-impermeable synthetic resin sheet interposed between the base member, the base member, and the intermediate member method for producing a flooring, which comprises a heat pressing step of thermocompression bonding while the non-permeable synthetic resin sheet and the floor surface member stacked, the.   The method for producing a flooring material according to claim 1, wherein, in the thermocompression bonding step, thermocompression bonding is performed in a state where the surface of the floor surface member is covered with an evaporation preventing sheet.   The floor according to claim 1 or 2, further comprising a cold pressurizing step of cold pressurizing the base member in the laminated state, the intermediate water-impermeable synthetic resin sheet, and the floor surface member after the thermocompression bonding step. A method of manufacturing the material. The floor surface member, rattan, bamboo, method for producing a flooring material of any claim 1 which is formed from natural wood.

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