JPH07217174A - Flooring material and production thereof - Google Patents

Abstract

PURPOSE:To heighten the soundproof property of a flooring material which uses a cushioning material consisting of a continuously porous type foam body, and especially having recesses and projections alternately on the surface thereof. CONSTITUTION:A sheet-like member 2 is stuck on a cushioning material 3, which has recesses and projections 3b, 3a for forming a soundproof space on at least the surface side of the material, in order to be in bridge shape at the recesses 3b on the surface of the cushioning material, and thus a cushioning member 4 is formed. After that, an adhesive 5 is applied to the rear surface of a floor base board 1, and the floor base board 1 is placed on the sheet-like member 2 of the cushioning member, in order to be in contact with the sheet- like member, and they are stuck to each other by pressing.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a flooring material and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, there has been known a direct-adhesive floor material in which a cushioning material such as a synthetic resin-based or rubber-based foam is adhered to the back surface of a floor substrate to impart a soundproofing performance and a non-absorption property of a construction base surface. There is.

Foams used as cushioning materials are roughly classified into closed-cell foams and open-cell foams. When the closed-cell foams are used as cushioning materials, the floor substrate on the surface is used. The shock absorbing material absorbs this shock when it is contracted and deformed, but there is no place for the air in the closed bubbles to escape during this contraction, causing an air spring phenomenon and reducing the soundproofing performance. When an open-cell foam is used as the cushioning material, the air in the bubbles can move freely because the bubbles are in communication, the air spring phenomenon does not occur, and excellent soundproofing performance can be obtained. It is possible.

[0004]

The floor substrate and the cushioning material are generally adhered to each other by applying an adhesive to the entire back surface of the flooring material, placing the cushioning material and pressing the cushioning material. When a foam is used as the cushioning material, the adhesive penetrates into the bubbles of the foam and cures while the cushioning material shrinks and deforms due to this compression. Even after releasing, it will remain in a contracted state,
There is a problem that the thickness of the cushioning material at the time of designing the floor material becomes thinner and the soundproofing performance is deteriorated.

In particular, this phenomenon has been a problem that tends to occur when an open-cell type foam body in which cells are in communication is used. Furthermore, even if it is attempted to use a cushioning material that has irregularities formed on the adhesive surface to the floor substrate, the concave portion of the cushioning material will be grounded and adhered to the back surface of the floor substrate during compression, and there will be no irregularities on the cushioning material. The situation is the same as when the cushioning material is adhered, resulting in a problem that the designed soundproofing performance cannot be obtained.

Further, even if the pressing conditions are adjusted so that the recesses on the surface of the cushioning material and the back surface of the floor substrate do not come into contact with each other, the pressing is completed and the obtained flooring materials are stacked and stored. In doing so, the cushioning material expands and contracts due to the weight of the flooring material and the recessed portion of the cushioning material comes into contact with the back surface of the flooring material, and the recessed portion is bonded by the adhesive on the back surface of the substrate that has not been completely cured. There were also problems.

[0007]

The inventors of the present invention have reached the present invention as a result of intensive studies to solve such problems.

That is, according to the present invention, the cushioning member 4 is formed by sticking the sheet-like material 2 on at least the surface of the cushioning material 3 having irregularities so as to form a bridge shape in the recess 3b.
A floor material in which the sheet-like material 2 is attached to the back surface of the floor substrate 1 so that the sheet material 2 is in contact with the floor substrate 1, and unevenness 3 at least on the front surface side.
The cushioning material 3 having b and 3a and the sheet-like material 2 are attached so that the sheet-like material 2 has a bridge shape in the concave portion 3b on the surface of the cushioning material 3 to form the cushioning body 4, and then the floor substrate 1 The present invention relates to a floor material manufacturing method in which an adhesive 5 is applied to the back surface, the sheet-like material 2 of the buffer 4 is placed so as to be in contact with the floor substrate 1, and pressure bonding is performed.

The details will be described below. Figure 1
[Fig. 3] is a cross-sectional view of the flooring material of the present invention. The flooring material of the present invention is one in which a cushioning body 4 composed of a sheet-like material 2 and a cushioning material 3 is attached to the back surface side of a flooring substrate 1 having a decorative layer 1a formed on the surface if necessary. In addition, the bumps 3 are provided with irregularities 3b and 3a on the surface side, and the sheet-like material 2 is attached to the recess 3b of the bumper 3 so as to form a bridge shape.

The floor board substrate 1 forming the flooring material of the present invention includes, for example, plywood, wood shaving board, wood fiber board, veneer laminated board, cement board, slag gypsum board, alone or in any combination. Alternatively, a laminate in which a synthetic resin sheet having an excellent cushioning effect, a foamed synthetic resin sheet, a sound insulating sheet, or the like is sandwiched between the plate materials can be used.

An optional decorative layer 1a can be formed on the surface of the substrate. This decorative layer is a natural veneer obtained by cutting natural wood, an artificial veneer, and a nonwoven sheet, paper, a veneer sheet lined with a synthetic resin sheet, or a decorative paper,
It is formed by adhering a decorative sheet such as resin-impregnated paper, non-woven fabric, paper, or a synthetic resin sheet with an adhesive, or by directly painting or printing the surface of the decorative plate.

An overcoat layer may be provided on the surface of the decorative layer. By providing such a decorative layer,
The penetration of water from the surface side was also prevented, and problems such as warpage, dew condensation and corrosion due to changes in humidity could be solved.

Further, by forming the groove 1b from the rear surface side of the floor substrate 1, the rigidity of the floor substrate 1 is lowered, and when an impact is applied to the surface of the floor material, the impact is absorbed by the deformation of the floor substrate itself. It is possible to improve the soundproofing performance.

The cushioning material 3 of the present invention has a cushioning function of absorbing a shock applied to the surface of the floor substrate 1 by shrinking and deforming it, and for example, a polyethylene resin, a polypropylene resin, a polyurethane resin. It is possible to use synthetic resin foam such as polystyrene resin and vinyl chloride resin or rubber foam. It is preferable to use an open-cell foam type foam without causing an air spring phenomenon and to exhibit excellent soundproofing performance as a floor material.

Further, by forming the cells as continuous cells, excellent performance can be obtained in the restoring force when the contracted state is released by the long-term load. Further, by forming the concavities and convexities 3b and 3a on at least the surface of the cushioning material 3, when the convex portion 3a of the cushioning material 3 contracts, the space of the concave portion 3b is secured as a moving place of air in the convex portion 3a bubbles. As a result, a flooring material having more excellent soundproofing performance can be obtained. The cushioning material 3 of the floor material shown in FIG. 1 is shown to have back irregularities 3c and 3d formed not only on the front surface side but also on the back surface side, and the same function is exhibited on the back surface side as well, and the sound insulation performance is further improved. Is shown.

As the sheet-like material 2, woven or non-woven fabric made of synthetic fiber or natural fiber, and paper can be used. It is preferable that the sheet-like material 2 is attached to the back surface of the floor substrate so as not to increase the Young's modulus of bending of the floor substrate and has excellent stretchability in the plane direction. For example, synthetic fiber or natural fiber is used. The non-woven fabric is preferably used.

Further, this sheet material has a sufficient adhesive absorbing ability to prevent the adhesive from penetrating more than necessary when it is bonded to the cushioning material using the adhesive. When the cushioning material 3 and the sheet-like material 2 are adhered to each other in advance to obtain a cushioning material, and then the adhesive 5 is applied to the back surface of the floor substrate 1 to bond the cushioning material 4, the sheet-like material from the back surface of the floor substrate 1 It is preferable to use an adhesive having an adhesive impregnating and holding ability in which the adhesive 5 that has penetrated into 2 does not penetrate to the buffer material 3 side on the back surface side. Specifically, when a synthetic fiber or natural fiber non-woven fabric is used, the adhesive having a basis weight of 25 g / m ² or more is used to sufficiently absorb the adhesive 5 and prevent it from permeating to the opposite side.

FIG. 2 is an enlarged view of a state in which the cushioning material 3, the sheet-like material 2 and the floor substrate 1 of the present invention are laminated and integrated, and each state is shown in which they are laminated and integrated with an adhesive. There is. In the figure, 6 indicates a bonding adhesive layer, and 6a indicates a bonding adhesive impregnated portion which is impregnated into the sheet-shaped material 2 when the sheet-shaped material 2 and the cushioning material 3 are bonded. As shown in the figure, when the cushioning material 3 and the sheet-like material 2 of the present invention are bonded, most of the adhesive is impregnated in the sheet-like material 2 and the cushioning material 3 is simply impregnated near the surface thereof. 3 is adhered in a state of being hardly impregnated. Further, the cushioning material 3 and the sheet-like material 2 are adhered to each other without using an adhesive.
It can also be attached by heat-sealing the surface.

Reference numeral 5 indicates an adhesive layer for adhering the floor substrate 1 and the sheet-like material 2, and 5a indicates an adhesive-impregnated portion with which the sheet-like material 2 is impregnated.

Further, in FIG. 2, the adhesive-impregnated portion 5a and the bonding adhesive-impregnated portion 6a are shown separated in the sheet-like article 2 without overlapping, but the adhesive agent of the sheet-like article 2 is shown. By using a material having a slightly small impregnation holding capacity, it is possible to obtain a hardened flooring material in a state where the adhesive impregnated portions 5a and 6a overlap each other. Peeling strength is improved by eliminating problems such as peeling at the center portion in the thickness direction, which is preferable.

When a synthetic resin sheet or the like having a small adhesive impregnation holding capacity is used as the sheet-like material, first,
When the cushioning material 3 and the sheet-like material 2 are adhered to each other by the bonding adhesive 6, the bonding adhesive 6 is not impregnated into the sheet-like material 2 and is absorbed up to a deep portion in the front surface side convex portion 3a of the cushioning material 3 and hardened. Therefore, the cushioning performance of the convex portion on the surface side of the cushioning material is hardly exhibited, which is not preferable.

Further, the adhesive impregnated portion 5 to be impregnated into the sheet-like material 3 when the sheet-like material 2 is adhered to the back surface of the floor substrate 1.
It is not preferable because a spreads to the back surface side of the sheet-like material 2 and adheres to the concave and convex concave portions 3b formed on the front surface side of the cushioning material 3.

Further, even when the cushioning material 3 is directly adhered to the back surface of the floor substrate without using the sheet-like material 2 by the adhesive, the adhesive is hardly impregnated into the back surface of the floor substrate 1, and therefore the deep portion of the bump 3a of the cushioning material is formed. The adhesive is impregnated up to the point where the same problem occurs.

An example of the method for manufacturing a flooring material according to the present invention will be described. First, the convex and concave portions 3a formed on the surface side of the cushioning material 3 are provided.
The bonding adhesive 6 is applied to the surface, the sheet-like material 2 is placed on the surface, and the material is adhered by pressing, so that the surface of the cushioning material 3 having irregularities on the surface becomes a bridge shape in the concave portion 3b. A buffer body 4 having the sheet-like material 2 attached thereto is obtained.

At this time, most of the adhesive 5 is impregnated in the sheet-like material 2, so that the buffer 5 is prevented from being impregnated with the adhesive 5.

Further, the cushioning material 3 and the sheet-like material 2 are adhered by laminating the cushioning material 3 and the sheet-like material 2 and heat-sealing the surface of the convex portion 3a of the cushioning material 3. You can also

If the cushioning material 3 and the sheet-like material 2 are adhered by heat fusion, the joining adhesive 6 is used as the cushioning material when the cushioning material 3 and the sheet-like material 2 are adhered by the bonding adhesive 6. Although the problem of impregnating into 3 does not occur, since the surface of the cushioning material convex portion 3a is melted, the function of the cushioning material 3 at that portion is lost, and the cushioning material 3 and the sheet-like material 2 are separated by the bonding adhesive 6. As a result, a buffer body having almost the same buffering function as that of the case of sticking is obtained.

[0028] Then, placed so that the adhesive 5 of the aqueous emulsion type coating amount 5 to 20 g / scale ² was applied to the floor board 1 the entire back surface is adhered to the back surface of the sheet 2 floor board 1 of the cushion 4 After that, it is adhered by pressing. At this time, when a nonwoven fabric made of synthetic fiber such as polyethylene is used as the sheet-like material 2, by using a nonwoven fabric having a basis weight of 25 g / m ² or more, the adhesive 5 applied to the back surface of the floor substrate 1 penetrates to the back surface side. Without doing so, the flooring material is obtained in which the sheet-like material 2 is attached in a state of forming a bridge shape in the concave and convex concave portions 3b formed on the surface of the cushioning material 3.

In addition, the cushioning material 3 and the sheet-like material 2 are preliminarily adhered to each other in this manner, and then the cushioning material 4 is adhered to the back surface of the floor substrate 1 to obtain the cushioning material 3 and the sheet-like material 2 in FIG. The adhesive impregnated portion 5a for adhering the floor substrate 1 and the sheet-like material 2 has permeated after the bonding adhesive impregnated portion 6a for adhering the Since the sheet-like material 2 that has been attached has the bonding adhesive impregnated portion 6a that has already been cured, the adhesive 5 is impregnated on the back surface side of the bonding adhesive impregnated portion 6a, and the convex portion 3a of the cushioning material 3 is formed. It is preferable because the adhesive 5 can be prevented from penetrating.

[0030]

【Example】

Example 1 As a floor substrate, a depth of 4 mm was formed on the back surface of a medium specific gravity fiberboard having a thickness of 7 mm.
The sheet-like material made of a non-woven fabric having a basis weight of 50 g / m ² made of polyester fiber as a cushioning material and a polyurethane resin-based open-cell type foam sheet (average expansion ratio of 15 times) are used to form convexes on the front and back surfaces. Part height 1.5 mm
And a 4 mm thick cushioning material on which unevenness is formed are integrally bonded by heat fusion on the convex surface of the cushioning material,
Water-based vinyl urethane adhesive 10 g /
After applying the shaku ² , a floor material was obtained by stacking and cold pressing so that the nonwoven fabric of the buffer adhered to the back surface of the floor material.

Example 2 The cushioning material and the sheet-like material of Example 1 were adhered by applying an adhesive to the surface of the cushioning material on the surface side and then placing the sheet-like material on it and applying cold pressure. A flooring material was obtained in the same manner except that a buffer material was used.

Test Example 1 The same flooring material except that the flooring materials obtained in Examples 1 and 2 and the cushioning material of Comparative Example 1 having no unevenness on the surface side were used. Was used to measure the floor impact sound level. The flooring materials of Examples 1 and 2 are L-45.
However, the comparative example was unsuccessful.

[0033]

According to the flooring material of the present invention, the cushioning member 4 is formed by sticking the sheet-like material 2 on at least the surface of the cushioning material 3 having the irregularities 3b and 3a so as to form the bridge shape in the recessed portion 3b. Has a structure in which the sheet-like material 2 is adhered to the back surface of the floor substrate 1 so as to contact with the floor substrate 1, and therefore a shock is applied to the surface of the floor material, and the convex portion 3a on the surface side of the cushioning material 3 contracts and deforms. At this time, the space of the concave portion 3b is secured as a moving place of the air in the bubbles of the convex portion 3a, so that the floor material having excellent soundproofing performance can be obtained. In particular, the use of an open-cell foam as the cushioning material 3 has a remarkable effect.

Further, the sheet-like material 2 is interposed between the cushioning material 3 and the floor substrate 1, so that the cushioning material 3 is adhered only on the surface of the convex portion 3a, and the bonding adhesive 6 is used. Even when the cushioning material 3 is bonded, the bonding adhesive 6 is prevented from penetrating into the convex portion 3a, and the cushioning function originally possessed by the cushioning material 3 can be sufficiently exerted.

[Brief description of drawings]

1 is a cross-sectional view of the flooring material of the present invention,

2 is a partially enlarged view of FIG. 1,

[Explanation of symbols]

1: floor substrate, 1a: decorative layer, 1b: groove, 2: sheet material, 3: cushioning material, 3a, 3b: convex portion, concave portion, 3c, 3
d: back convex portion, back concave portion, 4: buffer, 5: adhesive or adhesive layer, 5a: adhesive impregnated portion, 6: bonding adhesive or bonding adhesive layer, 6a: bonding adhesive impregnated portion.

Claims (6)

[Claims] 1. A cushioning body comprising a cushioning material having a sheet-like material adhered to the surface of a cushioning material having at least unevenness so as to form a bridge in a recess, wherein the sheet-like material is a floor substrate on the back surface of the flooring substrate. A flooring material characterized by being attached so as to be in contact with each other. 2. The flooring material according to claim 1, wherein a nonwoven fabric is used as the sheet material. 3. The flooring material according to claim 1, wherein an open-cell foam sheet is used as the cushioning material. 4. The sheet-shaped material has a basis weight of 25 g / m ^2.
The flooring material according to claim 1, wherein the non-woven fabric is used. 5. The flooring material according to claim 1, wherein a flooring substrate having grooves formed on its surface is used. 6. A cushioning material and a sheet-like material having at least surface irregularities are attached so that the sheet-like material forms a bridge shape in the recesses on the surface of the cushioning material to form a cushioning body, and then the floor substrate A method for manufacturing a flooring material, characterized in that an adhesive is applied to the back surface, the cushion-like sheet-like material is placed so as to contact the floor substrate, and pressure-bonding is performed.