JP4225173B2 - Manufacturing method for flooring - Google Patents

Description

  The present invention relates to a flooring using a wood board such as a particle board, MDF, OBS or the like as a core material.

  A conventional flooring material uses plywood as a substrate. However, since plywood is produced from natural wood, the cost is high, and it is also problematic from the viewpoint of the global environment to cut a large amount of natural wood to produce plywood.

  On the other hand, using wood residue waste, small-diameter wood, sawmill / plywood factory waste, low-quality chips not used in papermaking, building demolition materials, etc., these timbers are cut into small pieces or fibers to form wood boards such as particle boards, MDF, OBS, etc. It is used as a building material. These wooden boards are preferable from the viewpoint of not only low cost but also effective use of resources. However, the present situation is that such a wood board is not used as a flooring material because it cannot be actually processed or has poor water resistance.

Therefore, there is conventionally known a method in which a substrate is formed by including a core material made of an insulation board, which is a kind of wood board, in a frame made of plywood. (For example, see Patent Document 1)
In the conventional example shown in the above-mentioned Patent Document 1, a square body made of plywood is framed around the periphery to form a frame body, and a core material made of an insulation board is joined to the frame body in a state of close contact bonding. Since the substrate is formed by being inserted, the frame portion can be subjected to actual processing, and the outer periphery of the insulation board can be surrounded by the frame to improve the water resistance.

However, in the above conventional example, in order to form a substrate of a desired size, a frame made of plywood is framed one by one at a desired size, and a core material is incorporated in the frame to bond and integrate. There is a problem that productivity is poor because it is necessary to manufacture one by one.
JP-A-9-60236

  The present invention was invented in view of the above-mentioned conventional problems, and a plurality of floor materials in which the outer periphery of a wood board core material is surrounded by a plywood frame material at a time are manufactured by a simple method. An object of the present invention is to provide a method for manufacturing a flooring that can improve productivity.

  In order to solve the above-mentioned problem, a flooring manufacturing method according to the present invention includes a pair of front and rear frame members 1 made of plywood and a pair of left and right frame members 2 made of plywood that are rectangularly framed and left and right frames. A frame 4 configured by laying one or a plurality of plywood intermediate frame members 3 in parallel with the left and right frame members 2 between the members 2 and the outer periphery of each frame 4 A large-sized substrate 6 is formed with a core material 5 made of a wooden board having the same thickness as that of the frame materials 1, 2 and 3 made of wooden pieces or wood fibers bonded to the frame materials 1, 2 and 3. A plurality of flooring materials 7 are formed by cutting 6 in a direction parallel to the longitudinal direction of the intermediate frame member 3 at a position 1/2 the width of an arbitrary intermediate frame member 3.

  By adopting such a method, a plurality of flooring materials 7 in which the outer periphery of the core material 5 made of wood board is integrally surrounded by plywood frame materials 1, 2, and 3 having the same thickness as the core material 5 are simultaneously provided. It can be manufactured. And since the flooring 7 obtained in this way uses a wooden board as the core 5, the effective use of resources can be achieved, the cost is low, and even if a large number of flooring 7 is manufactured at the same time, Since the outer periphery of the core material 5 made of wood board is surrounded by plywood frame materials 1, 2, and 3, it is possible to perform actual processing on the frame material portion made of plywood. It can be improved.

  Moreover, it is preferable that the width of the intermediate frame member 3 is twice as wide as that of the left and right frame members 2 positioned at both ends.

  By adopting such a method, a plurality of floors obtained by cutting the large substrate 6 in a direction parallel to the longitudinal direction of the intermediate frame member 3 at a position 1/2 the width of the intermediate frame member 3. The width of the left or right frame member 2 located at both ends in the left-right direction is the same as that of the cut intermediate frame member 3, so that a large number of symmetrical floor members 7 can be obtained. Is.

  Further, it is preferable that the reinforcing sheet 8 is laminated and bonded to one side of the large substrate 6.

  By adopting such a method, a plurality of high-strength flooring materials 7 each having a reinforcing sheet 8 laminated and bonded on one side can be manufactured simultaneously, thereby improving productivity.

  According to the present invention, a plurality of flooring materials in which the outer periphery of a wood board core material is integrally surrounded by a plywood frame material having the same thickness as the core material can be simultaneously manufactured in a simple method, thereby improving productivity. In addition, because the manufactured flooring material uses a core made of wood board, it is possible to effectively use resources, the cost is low, and even if many pieces are manufactured at the same time, the manufactured flooring material is made of wood. Since the outer periphery of the board core material is surrounded by a plywood frame material, it is also possible to perform actual processing on this frame material part, and the wooden board is not directly exposed to the outer periphery, and the outer peripheral waterproof performance Can be improved.

  Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.

  The large-sized substrate 6 has a pair of front and rear frame members 1 made of plywood and a pair of left and right frame members 2 made of plywood framed in a rectangular shape and parallel to the left and right frame members 2 between the left and right frame members 2. A frame 4 constituted by laying one or a plurality of plywood intermediate frame members 3, and a small wooden piece that is contained in the frame body 4 and whose outer periphery is bonded to the frame members 1, 2, 3 Or it is comprised with the core material 5 made from a wood board made from a wood fiber.

  In forming the large substrate 6, a pair of front and rear frame members 1, a pair of left and right frame members 2, and an intermediate frame member 3 parallel to the left and right frame members 2 are preliminarily formed to form a frame body 4. (If one intermediate frame 3 is used, it is framed in a “day” shape. If two intermediate frames 3 are used, it is framed in a “eye” shape. Three or more frame members 3 may be used), and then a wooden board having the same size as the voids in a plurality of rectangular voids surrounded by the frame members 1, 2 and 3 in the frame body 4 A large-sized substrate 6 is formed by fitting a core material 5 made of wood and adhering the outer periphery of the core material 5 made of wood board to the frame materials 1, 2, and 3 with vinyl acetate, urethane, and epoxy adhesives. Alternatively, a plurality of wood board cores 5 are arranged in a horizontal direction with a certain gap, and an intermediate frame member 3 is placed between adjacent cores 5. The left and right frame members 2 are disposed and bonded to the outer ends in the left and right direction of the core member 5 positioned at both left and right ends, and the front end portion of each core member 5 and the left and right frame members are bonded. 2. Arrange the front frame member 1 along the front end of the intermediate frame member 3 and bond them together. The rear end of each core member 5, the left and right frame members 2, and the rear end of the intermediate frame member 3 The large frame substrate 6 may be formed by performing the arrangement of the core material 5 and the framework of the frame body 4 at the same time, such as arranging and bonding the subsequent frame material 1 along the part, or The large substrate 6 may be formed by other methods. In the present invention, the manufacturing method of the large substrate 6 is not particularly limited.

  The wood board used as the core material 5 is, for example, a particle board, MDF, OSB (phenolic or melamine urea) having a thickness of 9 to 11 mm.

  The plywood frame materials 1, 2, and 3 are all of the same thickness as the core material 5 (that is, those having a thickness of 9 to 11 mm are used). Here, as the intermediate frame member 3, one having a width twice that of the left and right frame members 2 is used. For example, when the width of the left and right frame members 2 is 25 mm, the width of the intermediate frame member 3 is 50 mm.

  A reinforcing sheet 8 made of MDF, kenaf, and waste paper impregnated paper having a thickness of 1 to 3 mm is laminated and integrated with a urethane-based, epoxy-based, or acrylic-based adhesive on one side (the surface in the embodiment) of the large-sized substrate 6. The surface of the large-sized substrate 6 is strengthened, in particular, the caster resistance is improved, and the surface is not uneven.

  In the present invention, the large substrate 6 having the above configuration is cut to obtain a plurality of flooring materials 7 at the same time. In this case, in the present invention, the large substrate 6 is replaced with any intermediate frame member 3. A plurality of flooring materials 7 are formed by cutting in a direction parallel to the longitudinal direction of the intermediate frame material 3 at a position of 1/2 of the width of the intermediate frame material 3. For example, as shown in FIG. 1A, in the large substrate 6 provided with two intermediate frame members 3, three floor members 7 can be formed from one large substrate 6. In this case, By cutting along the AA line and the BB line in FIG. 1A, a plurality of (three in the illustrated embodiment) flooring materials 7 having the same size as shown in FIG. 1B are manufactured. (Three floor materials 7 of 1 × 6 size can be manufactured from the large substrate 6 of 3 × 6 size in this way).

  The flooring 7 obtained as described above is as shown in FIG. 3, and the outer periphery of the core material 5 made of wood board is surrounded by frame materials 1, 2 and 3, and the reinforcing sheet 8 is integrally laminated on the surface. It is a thing.

  And as shown in FIG. 4, the back sheet 9 which consists of a veneer or a moisture-proof sheet | seat is adhere | attached on the back surface of the flooring material 7 for the water-proof performance improvement of a back surface, and the curvature correction of a product, and natural wood veneer on the surface after that Or the surface decorative material 10 which consists of a decorative resin sheet is adhere | attached, and the subsequent process is the same as the manufacturing process of a general flooring, and performs surface sanding-coloring-drying-undercoat-intermediate coating-top coating-inspection and packing. .

  By the way, as shown in FIG. 5 at any stage of the above-described process, the floor material 7 is subjected to actual processing for forming the male fruit 11 and the female fruit 12 at the side ends. Although the main part of the material 7 is made of wood board, the plywood frame materials 1, 2, and 3 exist on the outer periphery of the core material 5 made of wood board. Alternatively, actual machining can be performed in the same manner as in the past in the three portions.

  In addition, when constructing the flooring 7 obtained according to the present invention, when the flooring 7 is cut, an adhesive (urethane or vinyl acetate) is bonded to the mouth, so that the core material 5 made of wood board is Even if it is exposed to the butt end, the water resistance of this part can be ensured.

  Moreover, since the flooring material 7 obtained by the present invention is weaker in all than the plywood flooring material in terms of flexural strength, it is basically abandoned construction. However, when the joist pitch is narrowed, the joisting work is also possible.

The manufacturing order of the flooring of this invention is shown, (a) is a top view which shows a large format board | substrate, (b) was obtained by cutting a large format board | substrate by the AA line and BB line of (a). It is a top view which shows a some flooring. It is sectional drawing of CC line of Fig.1 (a) same as the above. It is sectional drawing of the DD line of FIG.1 (b) same as the above. It is sectional drawing which laminated | stacked the surface cosmetics and back sheet same as the above. It is sectional drawing of the state which gave actual processing same as the above.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Frame material 2 Frame material 3 Frame material 4 Frame body 5 Core material 6 Large format board 7 Floor material 8 Reinforcement sheet

Claims (3)

  A pair of front and rear frame members made of plywood and a pair of left and right frame members made of plywood are framed in a rectangular shape, and one or a plurality of plywood intermediates between the left and right frame members in parallel with the left and right frame members A frame made of a wooden board having the same thickness as a frame made of a wooden frame or a fiber made of wood fiber, which is formed by laying a frame material, and a small piece of wood or wood fiber that is embedded in the frame and bonded to each frame material. A large-sized substrate is formed with the material, and the large-sized substrate is cut in a direction parallel to the longitudinal direction of the intermediate frame material at a position half the width of an arbitrary intermediate frame material to form a plurality of floor materials. A method for producing a flooring characterized in that:   2. The method for manufacturing a flooring according to claim 1, wherein the width of the intermediate frame member is set to be twice as wide as that of the left and right frame members positioned at both ends.   The method for manufacturing a flooring according to claim 1 or 2, wherein a reinforcing sheet is laminated and bonded to one side of the large-sized substrate.

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