JPH07259246A - Floor material - Google Patents

Abstract

PURPOSE:To obtain excellent floor material by integrating a middle layer part, formed of specific wt.% of an inorganic foam body, organic fiber, and the like, in the layered state between an upper and a lower layer parts formed of specific wt.% of mineral fiber, organic fiber, inorganic powder, and the like to form a plate body. CONSTITUTION:A wet inorganic mat formed of an upper layer part l and a lower layer part 2 composed of 30-50wt.% of mineral fiber, 10-30wt.% of organic fiber, 10-30wt.% of inorganic powder, and 7-30wt.% of a binder is formed, and a decorative single plate 5 is attached to a plate body 4 of 0.6-0.7 in specific gravity formed by integrating a middle layer, composed of 55-75wt.% of an inorganic foam body, 5-15wt.% of organic fiber and 10-30wt.% of a binder, in the layered state between the upper and lower layer parts 1, 2. Excellent surface performance can be thereby obtained while preventing the creak of the floor.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to a flooring material having an inorganic material as a base material, which is directly adhered to a flooring base.

[0002]

2. Description of the Related Art Conventionally, there are various types of materials constituting a floor surface of a wooden house, but the simplest method is to directly attach a wooden floorboard to a floor base. The plywood floorboard is used as a typical example.

However, wood for plywood is difficult to obtain from the standpoint of environmental protection and tends to be expensive. Moreover, the plywood has a low surface hardness and is not only susceptible to deformation such as dents due to bruising, but also has poor surface smoothness.
A thin decorative veneer cannot be directly applied, and a thick decorative veneer is required. Further, the plywood made of wood has a high hygroscopic property, and in particular, since the expansion coefficient in the thickness direction is large, a step is likely to occur. Further, plywood has a problem that it is easily affected by termites and decay fungi.

For this reason, it has been considered to use a particle board, a medium specific gravity fiber board or the like as a plate-like body instead of the plywood. However, the density of the particle board is higher than the density of the plywood and the bending strength is plywood. 1/3 to 1/2
Therefore, there is a problem that the coefficient of thermal expansion due to water absorption is twice that of plywood and the coefficient of linear expansion of moisture absorption is about twice that of plywood.

On the other hand, the medium specific gravity fiberboard has a density almost equal to that of plywood, but the bending strength is about 70% of that of plywood, and the coefficient of thickness expansion due to water absorption is about twice that of plywood. However, there is a problem that the coefficient of hygroscopic expansion is 2 to 4 times that of plywood.

Therefore, when the particle board or the medium specific gravity fiber board is used alone, it swells when water is applied to the board, or thrusts up, or
There is a problem that the eyes become transparent due to the subsequent drying.

In order to solve such a problem, there has been considered a method of offsetting the defects of both by combining a plywood and a medium specific gravity fiber board or the like, but this method requires a lot of labor for the bonding work. There is a problem.

In view of the above problems, the present invention provides a flooring material which has substantially the same thickness expansion coefficient and moisture absorption linear expansion coefficient due to water absorption as plywood without using plywood, and which is superior in surface performance to plywood. The purpose is to

[0009]

The flooring material according to the present invention comprises:
In order to achieve the above object, as shown in FIG. 1, 30 to 50% by weight of mineral fiber, 10 to 30% by weight of organic fiber, 10 to 30% by weight of inorganic powder, and 7 to 30% by weight of binder are added. Between the upper and lower layer parts 1 and 2 having the composition, the inorganic foam 55 to 7 is formed.
5% by weight, organic fibers 5-15% by weight, binder 10-3
A decorative veneer 5 is attached and integrated on the surface of a plate-like body 4 having a specific gravity of 0.6 to 0.7 in which a middle layer portion 3 having a component composition of 0% by weight is formed and integrated.

The mineral fibers forming the upper and lower layers 1 and 2 are
Along with obtaining the desired bending strength, the coefficient of expansion of the thickness when absorbing water,
It is added in order to suppress the coefficient of hygroscopic expansion. For example, rock wool, slag wool, mineral wool,
Glass fiber etc. can be mentioned, these are alone,
Alternatively, two or more kinds can be used in combination. And
The composition ratio of the mineral fibers in the upper and lower layers 1 and 2 is 30 to 5
It is preferably 0% by weight. If it is less than 30% by weight, the desired bending strength cannot be obtained, and the thickness expansion coefficient and moisture absorption linear expansion coefficient due to water absorption cannot be suppressed. On the other hand, when the content of the mineral fiber exceeds 50% by weight, the amount of the organic fiber, the inorganic powder and the binder to be described later becomes relatively low, and the surface hardness and the screwing performance cannot be improved. This is because the drainage during papermaking deteriorates and a good wet mat cannot be obtained.

The organic fibers forming the upper and lower layers 1 and 2 are
Natural fibers and synthetic fibers, which are added in order to improve the bending strength, have high strength of single fiber and small decrease in strength when wet, are preferable. Examples of the natural fibers include pulp, cotton, bast fibers such as flax, hemp, jute, and leaf fibers such as sisal hemp, Manila hemp, and New Zealand hemp. Synthetic fibers include polyester,
Nylon, acrylic fiber and the like can be mentioned, and these can be used alone or in combination of two or more kinds. However, since synthetic fibers are expensive, it is preferable to use them in combination with natural fibers such as cotton and hemp. Further, the natural fiber and the synthetic fiber may be recycled products used for cloth or the like. The composition ratio of the organic fibers in the upper and lower layers 1 and 2 is 1
It is preferably from 0 to 30% by weight. If it is less than 10% by weight, the proportion of brittle mineral fibers relatively increases, so that the plate-like body as a whole is fragile and the strength does not increase. If it exceeds 30% by weight, the coefficient of hygroscopic expansion is high. Because it becomes too big.

The inorganic powder is added to enhance hardness and screwing performance, and examples thereof include calcium carbonate, silica sand, microsilica, magnesium hydroxide and aluminum hydroxide. The composition ratio of the inorganic powder in the upper and lower layer parts 1 and 2 is preferably 10 to 30% by weight. This is because if the content is less than 10% by weight, the desired hardness cannot be obtained, and if a heavy object is placed, the surface will have dents. If it exceeds 30% by weight, the addition amount of the mineral fiber, the organic fiber and the binder will be relatively large. This is because the desired strength cannot be obtained.

The binder forming the upper and lower layer portions 1 and 2 is added to bond the mineral fibers, the organic fibers and the inorganic powder to give desired hardness and strength. For example, polyvinyl alcohol resin is used. , Synthetic resin such as phenol resin and acrylic resin, starch and the like, and these can be used alone or in combination of two or more kinds. However, although a small amount of starch can increase the bending strength, the adhesive strength decreases when it is wet by itself, so it is preferable to use a phenol resin, an acrylic resin or the like together. The composition ratio of the binder in the upper and lower layer portions 1 and 2 is preferably 7 to 30% by weight. This is because if it is less than 7% by weight, sufficient strength cannot be obtained, and if it exceeds 30% by weight, the hardness becomes too high and various problems occur during processing. By setting the composition ratio of the binder in the upper layer portion 1 to 15 to 30% by weight and the binder in the lower layer portion 2 to 7 to 15% by weight, the hardness of the upper layer portion 1 becomes high and the desired surface is obtained. Performance is obtained,
There is an advantage that the hardness of the lower layer portion 2 becomes low and the lower layer portion 2 easily fits into the floor base.

The inorganic foam forming the middle layer 3 is for reducing the weight while maintaining the compressive strength.
Examples include perlite, shirasu foam, silica flour, and glass foam, which may be used alone or in combination of two or more. The composition ratio of the inorganic foam in the middle layer 3 is preferably 55 to 75% by weight. If it is less than 55% by weight, the ratio of the organic fibers and the binder added to form the middle layer part 3 relatively increases, so the strength is improved, but the nail holding power is reduced and the specific gravity is also increased. This is because the effect of reduction cannot be obtained.
This is because if it exceeds 5% by weight, the proportion of the organic fibers or the binder decreases, and it becomes difficult to improve the strength of the intermediate layer portion 3 and thus the plate-shaped body 4 as a whole.

The organic fibers forming the middle layer portion 3 are added to connect the inorganic foams to each other to improve the strength, and the organic fibers forming the middle layer portion 3 include the upper and lower layer portions 1. In addition to the organic fibers forming 2, 2, heat-bonding fibers can be cited. The composition ratio of the organic fibers in the middle layer 3 is preferably 5 to 15% by weight. This is because if the addition amount is less than 5% by weight, the inorganic foam is mainly connected only by the binder, and it is brittle and easily broken. If the addition amount is more than 15% by weight, the effect of lowering the specific gravity becomes small.

The binder forming the middle layer 3 is added to connect the inorganic foam and the organic fiber, and the material and the amount of the binder are the same as those for forming the upper and lower layers. Therefore, although the description is omitted, it is not always necessary to add the same material in the same amount, and an appropriate amount of different material can be used as necessary. In addition,
The effect is large even if the heat-fusible fiber is used as a substitute for the fiber and the binder.

Next, a method of manufacturing the plate-shaped body will be described. For example, a mineral fiber, an organic fiber, an inorganic powder and a binder are suspended in water to obtain an aqueous slurry, which is wet-paper-formed to obtain a wet inorganic mat to be the lower layer 2 and the upper layer 1. In addition, the specific gravity of the whole plate-shaped body is 0.6 to 0.
In the case of 7, the specific gravity of the upper layer portion 1 is preferably 0.9 or more after pressing. When the specific gravity of the upper layer portion 1 is less than 0.9, a dense surface cannot be obtained, the water absorption amount is large, and the surface hardness and bending strength comparable to those of particle board cannot be secured. Further, by forming the upper and lower layer portions 1 and 2 by wet papermaking, the mineral fiber,
There is an advantage that the organic fibers are entangled with each other and the bending strength is improved.

On the other hand, the inorganic foam, the organic fibers and the binder are mixed, for example, under a spray ratio of water 30 to solid content 100 to obtain a mixture for the middle layer. Then, the wet inorganic mat which becomes the upper layer 1 is formed by uniformly spraying and depositing on the surface of the wet inorganic mat which becomes the lower layer 2 obtained by wet papermaking of this mixture. Are laminated to obtain a laminated body which becomes the plate-shaped body 4. When the specific gravity of the whole plate-like body is set to 0.6 to 0.7, the specific gravity of the intermediate layer portion 3 is preferably 0.4 to 0.5 after pressing. This is because if the specific gravity of the middle layer part 3 is less than 0.4, the middle layer part 3 may be sparsely formed and may be destroyed during loading, and if it exceeds 0.5, the thickness is 9 mm, which is equivalent to a general floorboard. This is because the specific gravity of the wood material exceeds 0.6 to 0.7 and becomes heavy. Further, by forming the middle layer portion 3 by a dry method, there is an advantage that the thickness of the middle layer portion 3 can be freely set and the entire thickness can be adjusted.

Then, when the laminate is heated and pressed by a press, air in the middle layer portion 3 is pushed out to reach a certain density, and then the densities of the upper and lower layer portions 1 and 2 increase. Further, when heated and pressed, a part of the inorganic foam of the middle layer 3 bites into the upper and lower layers 1 and 2, and the thin portion of the inorganic foam is destroyed to increase the density of the middle layer 3 and The plate-like body 4 in which the specific gravity of the lower layer portions 1 and 2 is increased is obtained. However, heating and clamping are performed until the overall specific gravity reaches 0.6 to 0.7.

From the standpoint of productivity, it is preferable to use a continuous press for heating and pressing. However, it is not a good idea to complete the drying of the plate-like body 4 by a continuous press, and after the integration, the separate pressing is performed separately. Drying with a dryer is preferable. Further, in the above-described manufacturing method, the manufacturing method in which the dry method and the wet method are combined has been described, but all of them may be manufactured by the wet method. Further, in the above-described manufacturing method, since the laminated body made of a wet mat or the like is heated and pressed by a press, there is an advantage that a flat plate-like body 4 having a high surface hardness can be obtained.

The decorative veneer 5 attached to the surface of the upper layer portion 1 of the plate-like body 4 is attached to improve the design of the floor material and to prevent the surface of the floor material from being scratched. Examples thereof include hardwood veneers such as oak, hippo, and teak, or synthetic resin-injected veneers, and have a thickness of 0.2.
mm or more is used. This is because if it is less than 0.2 mm, the substrate is exposed with a slight scratch. It is to be noted that the decorative veneer 5 preferably has a large thickness, but increasing the thickness results in high cost, and therefore the thickness should be appropriately set depending on the application.

On the back surface of the lower layer portion 2 of the plate-like body 4, a plurality of grooves 6 reaching the middle layer portion 3 may be provided in parallel in order to improve familiarity with the floor base. It should be noted that the higher the hardness of the entire plate-shaped body 4 is, the smaller the pitch of the grooves 6 is desirably made. The pitch of the grooves 6 is 50 mm to 150 m.
It is set in the range of m.

In the same manner as described above, the plate-like member 4 is provided in order to improve the familiarity with the floor substrate and to reduce the impact force applied to the floor substrate.
The cushion material 7 may be appropriately attached and integrated on the back surface of the. Examples of the cushion material 7 include synthetic resin materials such as urethane foam material and polyethylene foam material, non-woven fabric,
Soft rubber or synthetic resin sheet, thickness 1-5
mm mm is used.

Further, the floor material 8 which is the plate-like body 4 to which the decorative veneer 5 is adhered has its side end surfaces actually processed in order to prevent the occurrence of unevenness between adjacent floor materials 8. You may keep it. As the actual processing, for example, a male seed 9 as shown in FIG.
a, actual fruit consisting of female fruit 9b, or actual fruit equivalent to wooden flooring such as employment fruit.

[0025]

EXAMPLES Next, examples according to the present invention will be described. (Example) 45 parts by weight of rock wool as a mineral fiber,
10 parts by weight of pulp as organic fiber, 25 parts by weight of calcium carbonate as inorganic powder, starch 10 as binder
Parts by weight, 10 parts by weight of powdered phenol, and a small amount of a fixing agent in fresh water and stirred to obtain an aqueous slurry having a concentration of 2%, which is introduced into a Fourdrinier paper making machine to form a paper having a thickness of 5 A wet inorganic mat having a lower layer portion and an upper layer portion of 0.0 mm was obtained.

On the other hand, 70 parts by weight of perlite as an inorganic foam, 10 parts by weight of pulp as an organic fiber, 10 parts by weight of starch as a binder, and 10 parts by weight of powdered phenolic resin were added to 100 parts of these solid components and 30 parts of water was added. Were mixed under a spraying ratio of to obtain a mixture for the middle layer.

Then, the mixture for the middle layer is uniformly sprayed and deposited to a thickness of 30 mm on the wet inorganic mat which is the lower layer, and the wet inorganic mat which is the upper layer is arranged on the mixture. A 40 mm laminate was obtained. Then, this laminated body is pressed at a temperature of 180 ° C. and a pressure of 12 kg / cm ^{2 to} a thickness of 9
The sample was obtained by pressing the plate to a thickness of mm to form a plate-like body, drying the plate-like body for 20 minutes in a drying oven at a temperature of 180 ° C., and then cutting the plate-shaped body into an appropriate length and width. Then, a 0.2 mm thick oak veneer is attached to the surface of the sample with a vinyl acetate-acrylic adhesive, while a width of 1.0 is applied to the back surface of the plate.
mm, depth 5.0 mm, pitch 100 mm in width direction
And the sample of Example 2 was obtained.

Comparative Example A commercially available plywood (type I plywood having a thickness of 9 mm) was used as a sample of Comparative Example 1. On the other hand, thickness 9
A commercially available plywood floor plate obtained by sticking a 0.3 mm thick oak veneer to a mm plywood in the same manner as in Example 2 was used as a sample of Comparative Example 2. In addition, a 0.2 mm thick oak veneer is attached to the surface of a 6 mm thick plywood (Type I), and the back surface is 3 m thick.
The sample of Comparative Example 3 was obtained by adhering the medium specific gravity fiber plate of m.

Table 1 shows the measurement results concerning the physical properties of the samples of Example 1 and Comparative Example 1.

[Table 1]

The above measurement results are obtained based on the following method. Bending strength: Based on JIS A 5907-1977. Bending Young's modulus: Based on JIS Z 2113-63. Compressive strength: JIS Z-2111 Brinell hardness: JIS Z-2448 Wood screw holding force: Based on JIS A 5908. Water absorption: {(weight after soaking for 24 hours-weight before soaking)
/ Weight before immersion} × 100 Water absorption thickness Expansion coefficient: According to JIS A 5908. Moisture absorption linear expansion coefficient: Performed according to JIS A 5403.

As is clear from the above measurement results, comparing Example 1 and Comparative Example 1, the two are almost equivalent in density, but the bending strength and bending Young's modulus of Example 1 are those of Comparative Example 1. Inferior to, and almost equal to commercially available particle board. Therefore, in order to obtain the same strength as in the case where the floor surface is formed by plywood by forming the floor surface by spanning the joist in Example 1, the thickness in Example 1 is about twice that of the plywood. However, since it can be used with a thickness almost equal to that of plywood when directly attached to a floor base, there is no practical problem when directly attached to a floor base.

In addition, regarding the wood screw holding force, the first embodiment
Is inferior to Comparative Example 1. However, when directly attached to the floor substrate, the external force acting on the wood screw is smaller than when it is laid over the joists, and therefore there is no practical problem when directly attached to the floor substrate as described above.

On the other hand, Example 1 is superior to Comparative Example 1 in compressive strength and Brinell hardness. In particular, the compressive strength of Example 1 is twice or more that of Comparative Example 1. The surface condition of Example 1 is better than that of Comparative Example 1 because it is press-processed. Therefore, in Comparative Example 1, a thick decorative veneer is used, but in Example 1,
There is no problem even if a thin decorative veneer (thickness: 0.2 mm) is used.

Further, the water absorption coefficient and the water absorption thickness expansion coefficient of Example 1 were superior to those of Comparative Example 1, and both of them were substantially equal in the moisture absorption linear expansion coefficient. Therefore, it was found that the floor covering according to Example 1 can also be used in a water area where Comparative Example 1 can be used.

Next, a caster resistance test was conducted on Example 2 and Comparative Examples 2 and 3. What is the caster resistance test?
It is a test for visually observing whether or not a scratch is caused when a caster carrying a weight of 60 kg is reciprocally moved on each sample. In Example 2 and Comparative Example 2, scratches were not made even after reciprocating 50,000 times, but Comparative Example 3
Was scratched about 30,000 times.

As is clear from the above results, according to the flooring materials of Examples 1 and 2, alternatives having the same water resistance and moisture resistance as plywood and having better surface performance than plywood were obtained. I found out that

Next, the sound insulation characteristics of the cushion material lining the plate-like body according to the present invention will be described. That is, a single veneer-clad plywood having a width of 900 mm, a length of 900 mm, and a thickness of 9 mm was used as a sample of Reference Example 1, and the plywood was lined with a 2 mm-thick Calp (trade name) as a cushion material to obtain a reference example. A sample of Reference Example 3 was obtained by lining the plywood with a urethane foam resin having a thickness of 4 mm as a cushion material. Then, each sample was directly attached to a slab having a thickness of 150 mm, and a sound insulation test based on measurement of floor impact sound level according to JIS A 1418 was performed. The measurement results are shown in FIG.

As is clear from FIG. 2, according to the reference example 3 lined with urethane foam resin, its sound insulation characteristic is L-.
While the sound insulation characteristic of Reference Example 1 including only plywood was L-75, the sound insulation characteristic of Reference Example 2 backed by a culp was L-70, while it was 55. Therefore, it has been found that the sound insulation characteristics are remarkably improved when the urethane foam resin as described above is lined. Further, even with a plywood having a bending strength and a bending Young's modulus larger than those of the floorboard according to the present invention, good sound insulation characteristics were obtained as described above. It has been revealed that a flooring material having even better sound insulation properties can be obtained by backing with urethane foam resin.

[0039]

As is apparent from the above description, according to the flooring material according to claim 1 of the present invention, it is relatively easier to obtain the raw material than the plywood. The price can be avoided. Further, according to the floor material of the present invention, since the surface hardness is high, scratches and the like are unlikely to occur during transportation, which is convenient for transportation. In particular, by heating and pressing to integrate, a plate-shaped body having a smooth surface and high hardness can be obtained, so that a thick decorative veneer is not required. Further, the plate-like body according to the present invention has lower water absorption and hygroscopicity than plywood, and in particular, the expansion coefficient in the thickness direction is small, so that a floor material in which a step is unlikely to occur can be obtained. Moreover, since most of the middle layer portion is composed of the inorganic foam and is further covered with the upper and lower layer portions containing the mineral fiber as the main component, a floor material that is not easily attacked by termites and humus is obtained. Therefore, according to the present invention,
The thickness expansion coefficient and the moisture absorption linear expansion coefficient due to water absorption are almost the same as those of plywood, and there is an effect that a floor material having better surface performance than plywood can be obtained. According to claim 2, since the amount of the binder added to the upper layer is 15 to 30% by weight, the hardness of the upper layer is increased and the surface performance is improved, while the binder is added to the lower layer. Since the amount of the binder is 7 to 15% by weight, the hardness of the lower layer portion becomes low, it is easy to adapt to the floor base, the workability is improved, and floor squeaking can be prevented. According to claim 3, since a plurality of grooves reaching the intermediate layer portion are arranged side by side at a predetermined pitch on the back surface of the plate-like body, the fitting to the floor base is improved and the construction is facilitated, and It can prevent ringing from the floor. According to claim 4, since the cushion material is attached and integrated on the back surface of the plate-like body, the impact force can be absorbed and relaxed,
It is possible to form a floor surface having excellent sound insulation properties. According to the fifth aspect, since the side end surface of the plate-like body is provided with the real portion that can be connected to the adjacent plate-like body by being abutted against it, no inlandness occurs between the adjacent floor materials. effective.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a flooring material according to the present invention.

FIG. 2 is a graph showing the sound insulation characteristics of the cushion material according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Upper layer part, 2 ... Lower layer part, 3 ... Middle layer part, 4 ... Plate-shaped body, 5
... Decorative veneer, 6 ... Groove, 7 ... Cushion material, 8 ... Floor material, 9
a ... male fruit, 9b ... female fruit.

Claims (5)

[Claims] 1. An upper and lower layer portion having a component composition of 30 to 50% by weight of mineral fiber, 10 to 30% by weight of organic fiber, 10 to 30% by weight of inorganic powder, and 7 to 30% by weight of binder, A plate-like body having a specific gravity of 0.6 to 0.7, which is formed by layering and forming an intermediate layer part having an inorganic foam of 55 to 75% by weight, an organic fiber of 5 to 15% by weight, and a binder of 10 to 30% by weight. A floorboard characterized in that a decorative veneer is attached and integrated on the surface of. 2. The amount of the binder added to the upper layer is 15 to 30% by weight, and the amount of the binder added to the lower layer is 7 to 15% by weight. The flooring material according to Item 1. 3. The flooring material according to claim 1, wherein a plurality of grooves reaching the middle layer portion are arranged in parallel at a predetermined pitch on the back surface of the plate-shaped body. 4. The flooring material according to any one of claims 1 to 3, wherein a cushion material is attached and integrated on the back surface of the plate-shaped body. 5. The side portion of the plate-like body is provided with a real part that can be connected to another adjacent plate-like body by being abutted against the adjacent plate-like body. Floor material.