JP6755104B2 - Floor material - Google Patents

Description

The present invention relates to a flooring material.

For flooring used in detached houses, condominiums and other buildings, in addition to solid flooring made of solid wood, the surface of wood base material made of plywood, MDF, particle board, etc., or these wood base materials There is a decorative flooring material in which a decorative material of a famous wood is attached to the surface of a laminated wood base material (hereinafter, the laminated wood base material is also simply referred to as a "wood base material").

The decorative flooring material uses a base material that expands and contracts less due to moisture than solid wood, and various coatings are applied to the surface to prevent moisture from entering the interior, so after construction. It has come to be used at many construction sites because of its low warpage and easy handling in the usage environment.

The wooden decorative material used for the decorative flooring material is roughly classified into a thin plate having a thickness of about 0.2 to 0.6 mm and a thick plate having a thickness of about 0.7 to 3.0 mm. A thin plate is manufactured by combining and adhering a plurality of wood blocks and cutting them with a slicer. A plate manufactured by such a manufacturing method is called a veneer. On the other hand, the thick plate may be a veneer, but a relatively thick plate of 1.0 mm or more is often manufactured by cutting out wood with a band saw or the like. A board manufactured by such a manufacturing method is called a sawn board.

Among the above-mentioned wood base materials, particle board is a kind of wood board obtained by mixing small pieces of wood with an adhesive and hot-press molding. Since building scraps and demolition waste are used as raw materials, they are used for various purposes because they are inexpensive and can be stably supplied. However, as compared with plywood, the dimensional variation during moisture absorption or release is large.

In Japanese Patent Application Laid-Open No. 2009-190311 (Patent Document 1), a single plate is attached to the front and back surfaces of a particle board, and the thickness of the single plate to be attached to the back surface is larger than the thickness of the single plate to be attached to the front surface. An enlarged wood composite flooring material is disclosed. According to the present invention, a wood composite flooring material having excellent dimensional stability can be obtained.

Japanese Unexamined Patent Publication No. 2009-190311

In the embodiment of Patent Document 1, a veneer as a decorative material is applied to the surface of a wood base material having a particle board having a thickness of 9 mm and a veneer having a thickness of 0.8 mm attached to the front surface and a veneer having a thickness of 2.2 mm attached to the back surface. Is illustrated by pasting. Here, Patent Document 1 does not describe the thickness of the decorative material, but since the decorative material is a veneer, it is considered that the thickness is a thin plate of 0.6 mm or less. Further, since there is no particular explanation about the direction of the grain of the single plate to be attached to the front and back surfaces of the particle board, it is considered that the direction of the grain of the single plate is the same as that of the decorative material.

As described in Patent Document 1, if the decorative material is a thin plate, the influence of expansion and contraction of the decorative material on the wood substrate is small, but in the case of a decorative material using a thick plate of 1.0 mm or more, Due to the expansion and contraction, the dimensional change in the width direction of the wood base material becomes large. However, even if a single plate whose grain direction is the same as that of the decorative material is interposed between the decorative material and the particle board, the width direction due to expansion and contraction of the decorative material using a thick plate of 1.0 mm or more It is difficult to suppress dimensional changes.

The present invention has been made to solve the problems of the prior art, and is caused by a dimensional change in the width direction of a decorative material using a thick plate of 1.0 mm or more and a floor material provided with a wood board base material. The purpose is to prevent the occurrence of gaps, warpage and twisting.

The gist of the present invention is as follows.

(1) A single cloth having a thickness of 1.0 mm or more and a wood grain perpendicular to the grain direction of the decorative material attached to the back surface of the decorative layer and having a thickness of 1.0 mm or more. A flooring material comprising a layer and a wood board layer attached to the back surface of the cloth single plate layer.

(2) Further, the floor material according to (1) above, further comprising a moisture-proof sheet layer attached to the back surface of the wood board layer.

(3) When the thickness of the decorative layer is t ₀ (mm), the thickness t ₁ of the cloth single plate layer is t ₀ −0.3 to t ₀ + 0.3 (mm). Flooring material of 1) or (2).

(4) The above (1) to the above (1), wherein the adhesive layer between the decorative layer and the cloth single plate layer and the adhesive layer between the cloth single plate layer and the wood board layer are composed of a modified vinyl acetate adhesive. Any flooring material of (3).

(5) The floor material according to any one of (1) to (4) above, wherein the wood board layer is made of particle board.

According to the present invention, it is possible to prevent the occurrence of gaps, width warpage and twisting due to dimensional changes in the width direction of a floor material provided with a decorative material using a thick plate of 1.0 mm or more.

The figure which illustrated the floor material which concerns on this embodiment

The floor material and the manufacturing method thereof according to this embodiment will be described with reference to FIG.

1. 1. Floor material according to the present embodiment As shown in FIG. 1, the floor material 10 according to the present embodiment has a decorative layer 1 having a thickness of 1.0 mm or more and a decorative layer 1 attached to the back surface of the decorative layer 1. A cloth single plate layer 2 having a grain direction perpendicular to the wood grain direction (floor material longitudinal direction) and having a thickness of 1.0 mm or more, and a wood board layer 3 attached to the back surface of the cloth single plate layer 2. It is a flooring material provided with. The floor material 10 according to the present embodiment may further include a moisture-proof sheet layer 4 attached to the back surface of the wooden base material 3.

As the decorative layer 1 according to the present embodiment, a processed wood such as a veneer or a sawn board can be used. If the decorative layer 1 is too thin, the design is deteriorated, and there is a concern that the cloth single plate layer 2 is projected. Therefore, a decorative layer 1 having a thickness of 1.0 mm or more is used. However, the thicker the decorative layer 1, the higher the cost, and the larger the dimensional change such as warpage, which makes it difficult to handle. Therefore, the thickness of the decorative layer 1 is preferably 8.0 mm or less. More preferably, it is 5.0 mm or less, and even more preferably 3.0 mm or less.

As the cloth single plate layer 2 according to the present embodiment, for example, single plates such as rawang, falkata, eucalyptus, chamelele, rubber, cedar, and larch can be used. If the single plate layer 2 is too thin, it becomes difficult to prevent the dimensional change in the floor material width direction due to the decorative layer 1, so the thickness thereof is set to 1.0 mm or more. On the other hand, if it is too thick, it may be difficult to prevent the dimensional change in the floor material length direction due to the cloth single plate layer 2 itself. Therefore, the thickness of the cloth single plate layer 2 is 8.0 mm or less. It is preferable to do so. More preferably, it is 5.0 mm or less, and even more preferably 3.0 mm or less.

The thickness of the cloth single plate layer 2 is preferably determined in relation to the thickness of the decorative layer 1. In particular, when the thickness of the decorative layer 1 is t ₀ (mm), the thickness of the cloth single plate layer 2 is determined. t _{1 is} preferably to _{t 0 -0.3~t 0 +0.3 (mm)} . If the thickness t ₁ of the cloth single plate layer 2 is less than t ₀ −0.3 (mm), the dimensional change in the floor material width direction due to the decorative layer 1 cannot be prevented, and the thickness of the cloth single plate layer 2 If t ₁ exceeds t ₀ + 0.3 (mm), it may not be possible to prevent the dimensional change in the floor material length direction due to the cloth single plate layer 2. The thickness _{t 1} of the cross veneer layer _2, more preferably, to _{t 0 -0.2~t 0 +0.2 (mm)} , t 0 -0.1~t 0 +0.1 and (mm) It is more preferable to do so.

As the wood board layer 3 according to the present embodiment, for example, a wood fiber board such as MDF, a hard board, or an insulation board, a particle board, or a wood board such as OSB can be used. The thickness of the wood board layer is preferably 2.5 to 15.0 mm. The preferred lower limit is 8.0 mm and the preferred upper limit is 10.0 mm.

For the moisture-proof sheet layer 4 according to the present embodiment, for example, a PET film or a polyolefin film (polyethylene, polypropylene, etc.) can be used. Further, as a moisture-proof layer other than the above, paper or polysand paper obtained by combining paper and polyethylene can be used. In JIS K 7129B, the moisture-proof sheet layer 4 has, for example, a water vapor permeability of 5 g / m ² · d or less, preferably 4 g / m ² · d or less. The moisture-proof sheet layer 4 can effectively suppress the infiltration of moisture from the back surface side of the wood board layer 3. The moisture-proof sheet layer 4 may be fixed to the wood board layer 3 by a fixing member other than the adhesive. The thickness of the moisture-proof sheet layer 4 is preferably 0.01 to 0.1 mm. If it is less than 0.01 mm, the moisture-proof performance may be insufficient, and if it exceeds 0.1 mm, it only increases the cost.

The adhesive layer between the decorative layer 1 and the cloth single plate layer 2 (not shown) and the adhesive layer between the cloth single plate layer 2 and the wood board layer 3 (not shown) are a modified vinyl acetate adhesive and a urea melamine resin. It is preferably composed of an adhesive. Further, it is more preferable that it is composed of a modified vinyl acetate adhesive that does not emit formaldehyde.

The floor material 10 according to the present embodiment preferably has a thickness of 5.0 to 25.0 mm. The preferred lower limit is 10.0 mm and the preferred upper limit is 15.0 mm.

2. 2. Method for manufacturing floor material according to the present embodiment As the method for manufacturing the floor material 10 of the present invention, a known method can be adopted. For example, it can be manufactured by pasting a cloth single plate on a wooden board and then pasting a decorative material on the cloth single plate. In the case of the floor material provided with the moisture-proof sheet layer 4, a wooden board to which the moisture-proof sheet is attached in advance may be used.

As Example 1, a cloth single plate having a thickness of 1.5 mm was attached onto a particle board having a thickness of 9.0 mm using a modified vinyl acetate adhesive (pressing conditions: 130 ° C., 140 seconds), and then, Under the same conditions, we prepared a flooring material with decorative material pasted on a single cloth plate. As the particle board, a modified vinyl acetate adhesive was used, and a moisture-proof sheet (polyethylene sheet) having a thickness of 0.01 mm was attached as a moisture-proof layer on the back surface thereof.

As Comparative Example 1, a parallel single plate having a thickness of 1.5 mm was attached to the front and back surfaces of a particle board having a thickness of 9.0 mm using a modified vinyl acetate adhesive (pressing conditions: 130 ° C., 140 seconds), and then. Under the same conditions, we prepared a flooring material with a decorative material attached on a parallel single plate. The parallel single plate is a single plate having a grain parallel to the grain direction of the decorative material.

As a conventional example (Comparative Example 2), a decorative material having a thickness of 2.0 mm was attached to the surface of a plywood having a thickness of 10.0 mm using a modified vinyl acetate adhesive (pressing conditions: 130 ° C., 180 seconds). I prepared the floor material.

For each of the obtained floor materials, the dimensional change rate in each direction was measured by the following method, and the results are shown in Table 1.

<Measurement method of dimensional change rate>
(1) Prepare a test piece cut into 300 mm × 50 mm from each floor material. At this time, the measurement direction (the length direction when measuring the warp in the length direction and the width direction when measuring the warp in the width direction) is set to 300 mm.
(2) Next, each test piece is left in an environment with a temperature of 20 ° C. and a humidity of 65% until the mass becomes constant, and the humidity is adjusted (moisture content of about 8 to 12%).
(3) Measure the size S ₀ and the mass M ₀ of the test piece immediately after humidity control.
(4) Each test piece is subjected to a drying test (a test of leaving it in an environment of a temperature of 40 ° C. and a humidity of 30% for one week) and a moisture absorption test (a test of leaving it in an environment of a temperature of 30 ° C. and a humidity of 90% for one week). dry test dimension S ₁ and the mass M ₁ of the specimen _after, and to measure the dimension S ₂ and the mass M ₂ of the test piece after moisture absorption test.
(5) The test piece after drying the test, the test piece was measured dimension S ₁ and the mass M ₁ and left for 24 hours in an oven maintained at 105 ° C., measuring the mass M ₃ of the dry specimen To do. Further, the test piece after moisture absorption test, a test piece after the measurement of dimension S ₂ and mass M ₂ was left for 24 hours in an oven maintained at 105 ° C., measuring the mass M ₃ of the dry specimen ..
(6) based on the following calculation equation to determine the rate of dimensional change MC ₂ in dimensional change MC ₁ and moisture absorption test in a dry test in each direction.

As shown in Table 1, Example 1 of the present invention provided with a cross single plate layer between the decorative layer and the wood board layer has a small dimensional change rate in the width direction under both drying and moisture absorbing conditions. Further, since there is no difference in the dimensional change rate in the length direction and the width direction, twisting does not occur. As a result, there was a slight difference in dimensional change from the case where plywood was used as the wood board layer (conventional example 2), but the result was comparable in twist. On the other hand, in Comparative Example 1, although the single plate layers were provided on the front and back surfaces, the dimensional change rate in the width direction was large. In addition, the dimensional change rates in the length direction and the width direction are significantly different, and twisting is likely to occur.

According to the present invention, it is possible to prevent the occurrence of gaps, width warpage and twisting due to dimensional changes in the width direction of a floor material provided with a decorative material using a thick plate of 1.0 mm or more.

1 Decorative layer 2 Cloth single board layer 3 Wood board layer 4 Moisture-proof sheet layer 10 Floor material according to this embodiment

Claims (5)

A decorative layer with a thickness of 1.0 to 3.0 mm and
A cloth single plate layer having a grain thickness perpendicular to the grain direction of the decorative layer and having a thickness of 1.0 to 3.0 mm, which is attached to the back surface of the decorative layer.
A wood board layer having a thickness of 8 to 10 mm, which is attached to the back surface of the cloth single plate layer, is provided.
The wood board layer is made of particle board or wood fiber board.
The cloth single plate layer is composed of rawang, falkata, eucalyptus, chamelele, rubber, cedar or larch.
A moisture-proof sheet layer having a thickness of 0.01 to 0.1 mm , which is attached to the back surface of the wood board layer, is provided.
The moisture-proof sheet layer has a water vapor permeability of 5 g / m ² · d or less.
A flooring material in which the dimensional change rates MC ₁ and MC ₂ obtained by the measurement methods (1) to (6) below are both 0.038 or less.
(1) Prepare a test piece cut into 300 mm × 50 mm from each floor material. At this time, the measurement direction (the length direction when measuring the warp in the length direction and the width direction when measuring the warp in the width direction) is set to 300 mm.
(2) Next, each test piece is left in an environment with a temperature of 20 ° C. and a humidity of 65% until the mass becomes constant, and the humidity is adjusted (moisture content of about 8 to 12%).
(3) Measure the size S ₀ and the mass M ₀ of the test piece immediately after humidity control.
(4) Each test piece is subjected to a drying test (a test of leaving it in an environment of a temperature of 40 ° C. and a humidity of 30% for one week) and a moisture absorption test (a test of leaving it in an environment of a temperature of 30 ° C. and a humidity of 90% for one week). dry test dimension S ₁ and the mass M ₁ of the specimen _after, and to measure the dimension S ₂ and the mass M ₂ of the test piece after moisture absorption test.
(5) The test piece after drying the test, the test piece was measured dimension S ₁ and the mass M ₁ and left for 24 hours in an oven maintained at 105 ° C., measuring the mass M ₃ of the dry specimen To do. Further, the test piece after moisture absorption test, a test piece after the measurement of dimension S ₂ and mass M ₂ was left for 24 hours in an oven maintained at 105 ° C., measuring the mass M ₃ of the dry specimen ..
(6) based on the following calculation equation to determine the rate of dimensional change MC ₂ in dimensional change MC ₁ and moisture absorption test in a dry test in each direction.

The flooring material according to claim 1, wherein the decorative layer is made of a sawn board.
Claim 1 or 2 in which the thickness t ₁ of the cloth single plate layer is t ₀ −0.3 to t ₀ + 0.3 (mm), where t ₀ (mm) is the thickness of the decorative layer. Flooring material described in.
Any of claims 1 to 3, wherein the adhesive layer between the decorative layer and the cloth single plate layer and the adhesive layer between the cloth single plate layer and the wood board layer are composed of a modified vinyl acetate adhesive. Flooring material described in Crab.
The flooring material according to any one of claims 1 to 4, wherein the wood board layer is made of particle board.

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