JP5859222B2 - Production method of wooden flooring - Google Patents

Description

The present invention relates to a method for producing a decorative material is thermally pressed wear surface of the wood substrate tare by a tree in quality flooring.

  The moisture content of the wooden base material fluctuates due to the entry and exit of moisture and moisture from the floor and the floor surface, or heat when using floor heating, and accordingly, the wooden base material expands and contracts and swells. Conventionally, in order to suppress these dimensional changes, a moisture-proof sheet is interposed between the surface of the wooden substrate and the wooden decorative veneer (decorative material), and hot-pressure bonding (hot press) using an aqueous adhesive In addition, a wooden flooring is known in which moisture entry / exit from the wooden veneer side to the wooden base material is blocked (see Patent Document 1). In addition, in order to prevent moisture from being mixed into the wooden substrate, the moisture-proof sheet or moisture-proof layer is coated with an adhesive on both the front and back surfaces and the four side surfaces of the wooden substrate, and the moisture-proof sheet on the surface side of the wooden substrate is further coated. A wooden flooring is known in which a wood veneer veneer is hot-pressure bonded (see Patent Document 2).

JP-A-8-226221 JP 2000-274054 A

  In the conventional wooden flooring materials described in Patent Documents 1 and 2, when heat-pressure bonding the wooden base material and the decorative material, water vapor generated from the decorative material and the water-based adhesive is blocked by the moisture-proof layer (moisture-proof sheet). In rare cases, since it cannot move to the wooden floor, the high-pressure water vapor stays between the moisture-proof layer and the decorative material, and there is a problem that the decorative material is likely to swell, peel off, rupture, etc.

The present invention was made in view of the circumstances as described above, while blocking moisture from entering and leaving the decorative material side with respect to the wooden base material by a moisture-proof layer to prevent expansion and contraction of the wooden base material, It aims at providing the manufacturing method of the wooden flooring which prevented the swelling of the decorative material, peeling, etc.

The method for producing a wooden flooring according to the present invention includes a moisture-proof layer interposed between the surface of the wooden base material and the decorative material, and the surface of the wooden base material and the decorative material are hot-pressure bonded with an aqueous adhesive. In the method for manufacturing a wooden floor material, a moisture-proof layer forming step of forming a moisture-proof layer provided with a plurality of ventilation holes on the surface of the wooden base material, and the decorative material on the surface of the wooden base material as an aqueous adhesive And heat-pressure bonding, moving water vapor generated from the adhesive through the ventilation holes to the wooden substrate side, and closing the plurality of ventilation holes with the adhesive cured by the heat-pressure bonding. It is characterized by that.

In the present invention, a moisture-proof layer provided with a plurality of ventilation holes is formed on the surface of the wooden substrate, and the decorative material is attached to the surface of the wooden substrate with a water-based adhesive through the moisture-proof layer provided with the plurality of ventilation holes. Since the adhesive is heat-pressure bonded, the water vapor generated from the decorative material and the adhesive during the heat-pressure bonding passes through the plurality of ventilation holes of the moisture-proof layer and moves to the wooden substrate side, and between the moisture-proof layer and the decorative material. Thus, a wooden floor material is produced in which high-pressure water vapor does not stay and the swelling and peeling of the decorative material are suppressed.
After heat pressure bonding, the moisture-proof layer vents are closed by the cured adhesive, and a state close to a moisture-proof layer without vents is realized, so moisture can enter and exit from the decorative material side to the wooden substrate. A wooden base material that is suppressed and prevents expansion and contraction of the wooden base material is produced.

In the method for producing a wooden flooring according to the present invention, in the moisture-proof layer forming step, after forming a plurality of air holes in the moisture-proof sheet, the moisture-proof sheet is bonded to the surface of the wooden substrate with a water-based adhesive. It is characterized by that.
In the present invention, after forming a plurality of ventilation holes in the moisture-proof sheet, the moisture-proof sheet is bonded to the surface of the wooden substrate with a water-based adhesive, thereby providing a plurality of ventilation holes on the surface of the wooden substrate. For example, a long moisture-proof sheet material is continuously transferred to a rotating roll with projections while being pressed to form a plurality of vent holes in advance, and then cut to a desired size for moisture-proofing. A sheet | seat can be produced and the moisture-proof sheet | seat in which the several ventilation hole was formed can be produced efficiently.

In the method for producing a wooden floor material according to the present invention, the moisture-proof layer forming step includes forming a plurality of ventilation holes in the moisture-proof agent layer after forming a moisture-proof layer on the surface of the wooden substrate. Features.
In the present invention, after forming a moisture-proof agent layer on the surface of the wooden substrate, a plurality of ventilation holes are formed in the moisture-proof agent layer, thereby providing a moisture-proof material having a plurality of ventilation holes on the surface of the wooden substrate. For example, after applying a moisture-proof synthetic resin as a moisture-proofing agent to the surface of the wooden base material, the layer is rotated while pressing a rotating roll with a projection against the synthetic resin coating layer. The pores can be formed, and the step of adhering the moisture-proof sheet having the vent holes formed beforehand to the surface of the wooden substrate is not necessary.
The method for producing a wooden floor according to the present invention is characterized in that the moisture-proof layer is composed of a synthetic resin film, a metal sheet, or a poly sand sheet.
The method for producing a wooden flooring according to the present invention includes the step of forming the wood before the moisture-proof layer forming step or after the moisture-proof layer forming step and before heat-bonding the decorative material to the surface of the wooden substrate. It further has the process of adhere | attaching a moisture-proof layer on the back surface of a base material with a water-based adhesive.

  According to the wooden flooring of the present invention, the decorative material is hot-pressure bonded to the surface of the wooden base material with a water-based adhesive through the moisture-proof layer provided with a plurality of ventilation holes, and the moisture-proof layer and the decorative material Since high-pressure water vapor does not stay between them, moisture from the decorative material side to the wooden base material is blocked by a moisture-proof layer to prevent the wooden base material from expanding and contracting, and the decorative material swells and peels off. A wooden flooring that prevents the above is provided.

  According to the method for producing a wooden floor material according to the present invention, since high-pressure water vapor does not stay between the moisture-proof layer and the decorative material during hot-pressure bonding, moisture entry and exit from the decorative material side to the wooden substrate is prevented. Thus, there is provided a suitable manufacturing method for manufacturing a wooden floor material that prevents expansion and peeling of the decorative material while preventing the expansion and contraction of the wooden base material by blocking.

It is sectional drawing which shows typically the structure of the wooden flooring which concerns on this invention. It is process drawing which shows 1st Embodiment of the manufacturing method of the wooden flooring which concerns on this invention. It is process drawing which shows 2nd Embodiment of the manufacturing method of the wooden flooring which concerns on this invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a wooden flooring and a method for manufacturing a wooden flooring according to the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view schematically showing the configuration of a wooden flooring according to the present invention. In the wooden flooring according to the present invention, the decorative material 2 is hot-pressure bonded with a water-based adhesive through a moisture-proof layer 3 provided with a plurality of fine ventilation holes 3a on the surface of the wooden substrate 1, The air holes 3a are filled with a cured water-based adhesive. A moisture-proof layer 4 is heat-pressure bonded with a water-based adhesive to the back surface of the wooden substrate 1. The surface of the decorative material 2 is painted with a UV curable resin paint 9.

  The wooden substrate 1 is made of particle board, plywood, MDF (medium density fiberboard), laminated material, and the like. The decorative material 2 includes a decorative veneer (for example, oak wet cosmetic veneer) obtained by slicing natural wood having a thickness of about 0.2 mm to 0.3 mm, a laminate of natural wood veneers, and the like.

  The moisture-proof layers 3 and 4 are composed of a synthetic resin film, a metal sheet, a moisture-proof sheet obtained by combining these and a paper layer, or a synthetic resin layer having moisture resistance. In particular, as the moisture-proof layers 3 and 4, the outer two layers of paper (reinforced paper, printed paper, building material base paper, etc.) layer are also used for the purpose of relaxing the expansion / contraction behavior of the decorative material 2 on the surface by heating at the time of hot-pressure bonding It is desirable to use a poly sand sheet having a three-layer structure with a central layer of a non-breathable thermoplastic synthetic resin film (thickness of about 20 to 40 μm) such as PE, PET, and EVA.

The fine ventilation holes 3a provided in the moisture-proof layer 3 are constituted by, for example, mechanically formed scars. The scar can be formed by pressing, rubbing, striking or the like using a mechanical tool, and may be any scratch such as a stab wound, a cut, or an abrasion. Further, the air holes 3a may be formed by chemical means other than mechanical. The number of vent holes 3a is 5 to 50 / cm ² , the hole diameter is 10 to 200 μm, and the hole area ratio is 0.2 to 1.5%.

  The water-based adhesive that bonds the wood base material 1, the decorative material 2, and the moisture-proof layers 3 and 4 is a urea / melamine resin adhesive, an aqueous vinyl urethane adhesive, an SBR (styrene-butadiene rubber) adhesive, and acetic acid. A vinyl resin or EVA (ethylene vinyl acetate) resin adhesive is used.

Next, a first embodiment of a method for producing a wooden floor material will be described. FIG. 2 is a process diagram showing a first embodiment of a method for producing a wooden floor material according to the present invention.
The method for producing a wooden flooring according to the present invention includes a moisture-proof layer forming step of forming a moisture-proof layer 3 provided with a plurality of ventilation holes 3a on the surface of the wooden substrate 1, and a wooden substrate 1 having the moisture-proof layer 3 formed thereon. And a step of heat-pressure bonding the decorative material 2 with a water-based adhesive 7 ((3)-(4) in FIG. 2) on the surface. In the first embodiment, the moisture-proof layer forming step After a plurality of air holes 3a are formed in the sheet 3, the moisture-proof sheet 3 having the air holes 3a is adhered to the surface of the wooden substrate 1 with an aqueous adhesive 6 ((2) in FIG. 2). Prior to the moisture-proof layer forming step, the moisture-proof layer 4 is adhered to the back surface of the wooden substrate 1 with a water-based adhesive 5 ((1) in FIG. 2). The bonding may be performed after the moisture-proof layer forming step and before the step of heat-pressure bonding the decorative material 2. Finally, the surface of the decorative material 2 is coated with the UV curable resin paint 9 ( (5) of 2. A synthetic resin film, a metal sheet, a poly sand sheet, etc. are used for the moisture proof sheet 3. A synthetic resin film, a metal sheet, a poly sand sheet, etc. are used for the moisture proof layer 4. It is composed of a synthetic resin coating layer having moisture resistance.

  According to the manufacturing method of the first embodiment, a large number of air holes 3a are provided in the moisture-proof layer 3, and the amount of water vapor that passes through the moisture-proof layer 3 can be adjusted. Therefore, water vapor generated in the water-based adhesive and in the decorative material Swells between the moisture-proof layer 3 and the decorative material 2, and it is difficult for the decorative material 2 to swell and peel off (puncture), making it easy to apply wet decorative veneer (hot-pressure bonding) using an aqueous adhesive. It becomes. After the hot-pressure bonding, the water-based adhesive is cured and closes the vent hole 3a of the moisture-proof layer 3, so that moisture resistance close to the state where the vent hole 3a does not exist is realized. As a result, moisture entry / exit from the surface side of the wooden substrate 1 is suppressed by the moisture-proof layer 3, and moisture entry / exit from the back side of the wooden substrate 1 is also suppressed by the moisture-proof layer 4. Generation | occurrence | production of 1 expansion-contraction, a swelling, etc. is prevented.

Next, a second embodiment of the method for producing a wooden floor material will be described. FIG. 3 is a process diagram showing a second embodiment of the method for producing a wooden floor according to the present invention.
In the second embodiment of the method for producing a wooden floor material according to the present invention, the moisture-proof layer forming step of forming a moisture-proof layer provided with a plurality of vent holes on the surface of the wooden substrate 1 is moisture-proof on the surface of the wooden substrate 1. After the layer of the agent 8 is formed, a plurality of vent holes 8a are formed in the layer of the moisture-proof agent 8 ((2)-(3) in FIG. 3), which is different from the first embodiment. A process of adhering the moisture-proof layer 4 to the back surface of the wooden substrate 1 with a water-based adhesive 5 ((1) in FIG. 3), and applying a cosmetic material 2 to the surface of the wooden substrate 1 with a water-based adhesive 7 The bonding process ((4)-(5) in FIG. 3) and the coating process ((6) in FIG. 3) with the UV curable resin coating 9 are the same as those in the first embodiment. The layer of the moisture-proofing agent 8 is formed by attaching a synthetic resin film, a metal sheet, or a poly sand sheet, in addition to a method of applying a moisture-proof synthetic resin.

  According to the manufacturing method of the second embodiment, as in the manufacturing method of the first embodiment, a large number of air holes 8a are provided in the layer of the moisture-proofing agent 8, and the amount of water vapor that passes through the layer of the moisture-proofing agent 8 can be adjusted. Therefore, the swelling and peeling (puncture) of the decorative material due to water vapor hardly occur. After the hot-pressure bonding, the adhesive is cured and closes the vent hole 8a, so that a moisture-proof resin layer close to the state where the vent hole 8a does not exist is realized. Moreover, the moisture entry / exit from the surface side of the wooden substrate 1 is suppressed by the layer of the moisture-proof agent 8, and the moisture entry / exit from the back side is also suppressed by the moisture-proof layer 4.

  Next, Examples 1-4 according to the present invention, a conventional example using air-permeable paper instead of the moisture-proof layer, and a comparative example using a moisture-proof layer not provided with air holes will be described.

First, Example 1-3 according to the manufacturing method of the first embodiment will be described.
Example 1
80 g / m ^{2 of} aqueous vinyl urethane adhesive was applied to the back of a particle board having a specific gravity of 0.80, a thickness of 12 mm, a width of about 308 mm, and a length of about 1830 mm, and the outer two paper layers weighed 25 g / m ^2. A poly sand sheet (hereinafter abbreviated as a non-porous poly sand sheet), which is m ² neutral paper and has a center layer made of a polyethylene film having a thickness of 30 μm, was attached. A fine air hole (number 30 / cm ² , diameter hole 100 μm, opening rate 0.2%) is formed on a poly sand sheet with the same structure by pressing a roller with many fine blades formed on the outer periphery. In addition, 80 g / m ² of urea / melamine resin-based adhesive was applied to the surface of the particle board, and the poly sand sheet having the vents was stuck. Further, 80 g / m ² of the same urea / melamine resin adhesive was applied to the upper surface, and an oak wet makeup veneer having a thickness of 0.3 mm was adhered, and the temperature was 110 ° C. and the pressure was 7 kgf / cm ² (6.86 × 10 ⁵ Pa) for 60 seconds and bonded by hot pressing. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

(Example 2)
80 g / m ^{2 of} an aqueous vinyl urethane adhesive was applied to the back surface of a particle board having the same material and dimensions as in Example 1, and the polysand sheet without holes was adhered. Next, a fine air hole (number 25 / cm ² , hole diameter 200 μm, hole area ratio 0.79%) is pressed against the poly-sand sheet without holes by pressing a roller having a large number of fine blades formed on the outer periphery. Then, 80 g / m ² of urea / melamine resin-based adhesive was applied to the surface of the particle board, and the poly sand sheet having the vents was pasted. Furthermore, 80 g / m ² of the same urea / melamine resin adhesive was applied to the upper surface, and a 0.3 mm thick oak wet makeup veneer was attached, and bonded together by hot-pressure bonding under the same conditions as in Example 1. It was. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

(Example 3)
80 g / m ^{2 of} an aqueous vinyl urethane adhesive was applied to the back surface of a particle board having the same material and dimensions as in Example 1, and the polysand sheet without holes was adhered. Next, fine air holes (number 48 / cm ² , diameter hole 200 μm, open area ratio 1.5%) are pressed against the poly-sand sheet without holes by pressing a roller having a large number of fine blades formed on the outer periphery. Then, 80 g / m ² of urea / melamine resin-based adhesive was applied to the surface of the particle board, and the poly sand sheet having the vents was pasted. Furthermore, 80 g / m ² of the same urea / melamine resin adhesive was applied to the upper surface, and a 0.3 mm thick oak wet makeup veneer was attached, and bonded together by hot-pressure bonding under the same conditions as in Example 1. It was. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

Next, a comparative example and a conventional example will be described.
(Comparative example)
80 g / m ^{2 of} an aqueous vinyl urethane adhesive was applied to the back surface of a particle board having the same material and dimensions as in Example 1, and the polysand sheet without holes was adhered. Furthermore, 80 g / m ² of urea / melamine resin adhesive was applied to the surface of the particle board, and the above-mentioned poly-sand sheet without holes was adhered. Furthermore, 80 g / m ² of the same urea / melamine resin adhesive was applied to the upper surface, and a 0.3 mm thick oak wet makeup veneer was attached, and bonded together by hot-pressure bonding under the same conditions as in Example 1. It was. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

(Conventional example)
80 g / m ^{2 of} an aqueous vinyl urethane adhesive was applied to the back surface of a particle board having the same material and dimensions as in Example 1, and the polysand sheet without holes was adhered. Then urea-melamine resin based adhesive to the surface of the particle board 80 g / m ² coated by sticking a building material base paper weighing 25 g / m ^2, further the same urea-melamine resin adhesive on the top surface 80 g / After applying m ^2, an oak wet veneer veneer having a thickness of 0.3 mm was attached, and bonded by hot-pressure bonding under the same conditions as in Example 1. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

  And the presence or absence of peeling (puncture) of a decorative veneer was confirmed about each test piece of the wooden flooring obtained by the said Example 1-3, the prior art example, and the comparative example. Moreover, the moisture release and moisture absorption test were done on the following conditions, and the change of the moisture content and the dimensional change (length change rate, thickness change rate) accompanying a test were evaluated.

After attaching the test marks to the test piece using an epoxy resin adhesive, etc., so that the length between the test marks in the vertical and horizontal directions is about 100 mm, and removing all moisture in the test piece under high temperature conditions The mass M0 is measured. Next, after standing for 7 days in a thermo-hygrostat set to a temperature of 20 ° C. and a humidity of 65% RH, the length between the gauge points, the thickness of the central portion, and the mass M1 are measured. The moisture content before the test is obtained by the following formula.
Pre-test moisture content (%) = (M1-M0) / M1 × 100

Next, after leaving the test piece in a constant temperature and humidity chamber at a temperature of 40 ± 2 ° C. and a humidity of 90 ± 5% RH for 7 days, the test piece is immediately taken out, the length between the gauge points, the thickness of the center part, and the mass. M2 is measured, and each length change rate, thickness change rate, and water content after the test are obtained (the above, moisture absorption test).
Water content after moisture absorption test (%) = (M2−M0) / M2 × 100

Next, after leaving the test piece again in a thermo-hygrostat set to a temperature of 20 ° C. and a humidity of 65% RH for 7 days, the length between the gauge points, the thickness of the central portion, and the mass M3 are measured. Next, after leaving the test piece in a constant temperature and humidity chamber at a temperature of 40 ± 2 ° C. and a humidity of 30 ± 5% RH for 7 days, the length between the gauge points, the thickness of the central portion, and the mass M4 are measured. Each length change rate, thickness change rate, and moisture content after the test are obtained (the moisture release test).
Moisture content after moisture release test (%) = (M4-M0) / M4 × 100

Based on the following calculation formula, first, the change rate (%) of the dimension (length and thickness) before and after each test of moisture absorption and moisture release is obtained.
Rate of change in length (%) = (length between gauge points before test−length between gauge points after test) / (length between gauge points before test) × 100
Thickness change rate (%) = (thickness before test−thickness after test) / (thickness before test) × 100

Next, the amount of change in moisture content (%) before and after each test was determined, and the above-mentioned length change rate (%) and thickness change rate (%) were divided by the amount of change in moisture content (%). The rate of change in dimensions (length and thickness) per 1% was determined.
Length change rate per 1% moisture content (%) = Length change rate (%) / (moisture content before test-moisture content after test)
Thickness change rate per 1% moisture content (%) = Thickness change rate (%) / (moisture content before test-water content after test)
The test results are shown in Table 1.

  From Table 1, in the comparative example in which the moisture-proof layer having no air holes is provided, peeling (puncture) of the decorative veneer occurs, but in Example 1-3 in which the moisture-proof layer having the air holes 3a is provided, It can be confirmed that there is no peeling (puncture) of the decorative veneer. Moreover, compared with the conventional example using the building material base paper which does not have moisture resistance, Example 1-3 and the comparative example which provided the moisture-proof layer have small length change rate (%) and thickness change rate (%). It can be confirmed that the dimensions are difficult to change. In addition, in the range (0.2%, 0,79%, 1.5%) of the aperture ratio of the ventilation hole 3a changed by the present Example 1-3, good results that are almost the same with respect to the dimensional change are obtained. Has been obtained.

Next, Example 4 according to the manufacturing method of the second embodiment will be described.
Example 4
80 g / m ^{2 of} an aqueous vinyl urethane adhesive was applied to the back surface of a particle board having the same material and dimensions as in Example 1, and the polysand sheet without holes was adhered. Next, 20 g / m ² of acrylic urethane UV curable resin paint is applied to the surface of the particle board and dried, and then a roller with a large number of fine projection blades formed on the outer periphery is pressed against the coating layer to pass fine particles. Creates pores. Furthermore, 80 g / m ² of urea / melamine resin adhesive was applied to the upper surface of the coating layer in which the air holes were formed, and an oak wet makeup veneer having a thickness of 0.3 mm was adhered, and under the same conditions as in Example 1. Bonded by hot-pressure bonding. Then, UV coating was performed on the surface of the decorative veneer to produce a wooden flooring.

1 Woody base material 2 Single veneer (decorative material)
3 Moisture-proof sheet (moisture-proof layer)
3a Vent 4 Moisture-proof layer 5 Adhesive 6 Adhesive 7 Adhesive 8 Moisture-proof (moisture-proof layer)
8a Vent

Claims (5)

In the method for producing a wooden flooring, wherein a moisture-proof layer is interposed between the surface of the wooden substrate and the decorative material, and the surface of the wooden substrate and the decorative material are heat-pressure bonded with an aqueous adhesive,
A moisture-proof layer forming step of forming a moisture-proof layer provided with a plurality of ventilation holes on the surface of the wooden substrate;
The cosmetic material is heat-pressure bonded with a water-based adhesive to the surface of the wooden substrate, water vapor generated from the adhesive is moved to the wooden substrate side through the vent hole, and the plurality of vent holes are provided. And a step of closing with the adhesive cured by the hot-pressure bonding. 2. The woody material according to claim 1 , wherein, in the moisture-proof layer forming step, after forming a plurality of air holes in the moisture-proof sheet, the moisture-proof sheet is bonded to the surface of the wooden substrate with an aqueous adhesive. A method for manufacturing flooring. 2. The wooden flooring according to claim 1 , wherein the moisture-proof layer forming step forms a plurality of ventilation holes in the moisture-proof agent layer after forming a moisture-proof agent layer on the surface of the wooden substrate. Manufacturing method. The said moisture-proof layer is comprised with a synthetic resin film, a metal sheet, or a poly sand sheet, The manufacturing method of the wooden flooring of any one of Claim 1 to 3 characterized by the above-mentioned. Before the moisture-proof layer forming step or after the moisture-proof layer forming step, before heat-bonding the decorative material to the surface of the wooden substrate, the moisture-proof layer is attached to the back surface of the wooden substrate. The method for producing a wooden flooring material according to any one of claims 1 to 4, further comprising a step of adhering at a step.

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