JPH08112804A - Manufacture of floor material - Google Patents

Abstract

PURPOSE: To provide a method for manufacturing a floor material consisting of an inorg. base material with which generation of warpage can be suppressed within a specified limitation in any cases in the manufacture and applications. CONSTITUTION: A sheet-like body 4 is obtd. by forming lamellarly an intermediate layer part 3 between an upper layer part 1 contg. a mineral fiber, an org. fiber, an inorg. powdery body and a binder as its ingredients and a lower layer part 2 having a compsn. in the same ranges as each ingredient of the upper layer part 1 and having a thickness of 105% to 115% of the thickness of the upper layer part 1 and integrating them to obtain a sheet-like body. Then, a veneer 5 is adhered on the surface of the upper layer part 1 of this sheet-like body 4 with an adhesive and they are integrated to obtain a floor material 6.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material, and more particularly to a method of manufacturing a flooring material which is mainly composed of an inorganic material and has a small warpage during any of manufacturing, processing and construction.

[0002]

2. Description of the Related Art Conventionally, the simplest construction of the floor surface of a wooden house is one in which a wooden floorboard is directly attached to a floor base, and its typical example is Although floor boards made of plywood are used, it is difficult to obtain wood for plywood from the standpoint of environmental protection, and the price tends to increase. Moreover, the plywood made of wood has high water absorption and hygroscopicity, and in particular, the expansion coefficient in the thickness direction is large,
Steps are likely to occur.

For this reason, it has been considered to use a particle board, a medium specific gravity fiber board or the like as a plate-shaped body instead of the plywood. However, the particle board and the medium specific gravity fiber board have a thickness expansion coefficient and a moisture absorption linear expansion due to water absorption. The rate is about twice that of plywood. As a result, when the particle board or the medium specific gravity fiber board is used alone, when water is applied to them, there is a problem that the particles swell and push up, or the eye drops due to subsequent drying.

In order to solve such problems, water absorption,
A flooring material made of an inorganic plate-like material that has little expansion and contraction due to moisture absorption has been considered. Such a flooring material generally has a decorative veneer placed on the surface of an inorganic plate-like body coated with an adhesive,
Then, after being integrated by a hot press, it is cut into a desired size, subjected to actual processing, and the surface of the decorative veneer is polished and painted.

However, in the above-mentioned manufacturing method, if the inorganic plate-like body has a large concave warp in which the central portion is lowered at the stage of the base material, the adhesive cannot be uniformly applied, and the decorative veneer can be adhered beautifully. I can't. Therefore, a method of vertically arranging the inorganic plate-shaped body is also considered, but according to this method, the inorganic plate-shaped body itself does not warp, but a simple water-containing cosmetic product with a subsequent treatment. When a board is attached and the decorative veneer is dried, a large warp is likely to occur. In particular, recently, in order to rationalize production, a veneer with a high water content is often attached, and this tendency is becoming stronger. For this reason,
When the decorative veneer is integrated with a hot press, the adhesive and the decorative veneer shrink when it dries, so that the surface of the decorative veneer tends to be a concave surface, and warping easily occurs. Not only is it difficult to carry out straight actual processing, but it is also difficult to evenly polish it, and uneven coating occurs, so that a beautiful appearance cannot be obtained. Further, when the above-mentioned warped floor material is applied on site, there is a problem that the end portion such as the joint portion is pushed up due to the direction of the warp and actual fitting becomes difficult.
In addition, the range of the warp allowable at the construction site is, for example, 20 mm or less in the length direction and 2 mm or less in the width direction for a floor material having a width of 303 mm and a length of 1818 mm. Generally, it is easier to deal with the convex warp in which the central portion becomes higher.

In view of the above-mentioned problems, the present invention provides a method for manufacturing a flooring material which can suppress the occurrence of warpage to a certain extent during production, processing and construction, and can suppress it toward convex warpage. To provide.

[0007]

[Means for Solving the Problems] In order to achieve the above-mentioned object, the present inventors have conducted intensive studies and as a result, the thickness of the upper and lower layers of an inorganic plate-like body having a three-layer structure, and / or By changing the addition amount of the binder added to them, a large warp is less likely to occur during manufacturing, processing and construction, and even if warpage occurs, a convex warp is more suitable for manufacturing. Therefore, the present invention was completed based on this finding.

In order to achieve the above object, the method for producing a flooring material according to the present invention is, as shown in FIG. 1, an upper layer portion 1 containing mineral fiber, organic fiber, inorganic powder and binder as components.
And a composition in the same range as each component of the upper layer portion 1, and
Between the lower layer portion 2 having a thickness of 105% to 115% of the thickness of the upper layer portion, an intermediate layer portion 3 containing an inorganic foam, an organic fiber and a binder as a component is formed into a layer and integrated into a plate. The sheet 4 is obtained, and the decorative veneer 5 is attached to the surface of the upper layer portion 1 of the sheet 4.
And the step of adhering and integrating.

Mineral fibers, organic fibers, inorganic powders, and a binder of 7.5 to 45% by weight based on these
And the thickness of the upper layer portion having the same composition as each component of the upper layer portion and having the binder added in an amount of 105% to 120% of the amount of the binder added in the upper layer portion. A middle layer 3 containing inorganic foam, organic fibers and a binder as a component is formed between the lower layer and the lower layer to form a plate, which is integrated to obtain a veneer on the surface of the upper layer of the plate. May be a step of adhering and integrating.

Further, the mineral fiber, the organic fiber, the inorganic powder, and the upper layer part having a component composition of 7.5 to 45% by weight of the binder relative to these, the same range as each component of the upper layer part. And having a thickness of 105% to 115% of the thickness of the upper layer portion and having a binder added to the upper layer portion in an amount of 105% to 120% of the amount of the binder added. In addition, a plate-shaped body is obtained by forming and integrating an intermediate layer portion containing inorganic foam, organic fibers and a binder in a layered manner, and adhering a decorative veneer to the surface of the upper layer portion of the plate-shaped body. It may be a process. The adhesive for adhering and integrating the decorative veneer on the surface of the upper layer portion of the plate-like body may be a foaming adhesive that emits gas by heating to reduce shrinkage.

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 and the like can be mentioned, and these alone,
Alternatively, two or more kinds can be used in combination.

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 inorganic powder is added to enhance the hardness and the screwing performance, and examples thereof include calcium carbonate, silica sand, microsilica, magnesium hydroxide and aluminum hydroxide.

The binder forming the upper and lower layer portions 1 and 2 is added to bind the mineral fibers, the organic fibers and the inorganic powder to give desired hardness and strength. Examples thereof include polyvinyl alcohol resins, phenol resins, acrylic resins, and other synthetic resins, starch, and the like, and these can be used alone or in combination of two or more kinds.

The amount of the binder added to the lower layer is preferably 105% to 120% of the amount of the binder added to the upper layer. This is because when the binder hardens and shrinks, the shrinkage of the lower layer increases and a convex warp occurs, but when the amount of the binder added is less than 105%, a decorative veneer is adhered to manufacture. This is because the warp of the flooring material is likely to be concave, troubles are likely to occur in the subsequent steps, and it takes time and effort for on-site construction. If it exceeds 120%, the plate-shaped body before the decorative veneer is attached. This is because the warp of the product becomes too large and it takes a lot of time to attach the decorative veneer.

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 organic fibers forming the middle layer 3 are added to connect the inorganic foams to each other to improve the strength, and the organic fibers forming the middle layer 3 include the upper and lower layers 1. In addition to the organic fibers forming 2, 2, heat-bonding fibers can be cited.

The binder forming the middle layer 3 is added to connect the inorganic foam and the organic fiber, and the binder is the same as that forming the upper and lower layers 1, 2. Therefore, the description is omitted. Others are the same as those for forming the upper and lower layer portions, so description thereof will be omitted. However, it is not always necessary to add the same material in the same amount.
An appropriate amount of different materials can be used as needed. It should be noted that the effect is large even if the heat-fusible fiber is used as a material that also serves as a fiber and a 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. The upper and lower layer portions 1 and 2 may have the same thickness, but the thickness of the lower layer portion may be reduced in order to prevent the occurrence of a large warp when a decorative veneer is attached. Is 105% to 1 of the thickness of the upper layer
It is preferably set to 15%. This is because the total amount of organic components in the lower layer portion is made larger than that in the upper layer portion, and the shrinkage due to drying is increased, so that a convex warp is generated. If the thickness of the lower layer part is less than 105%, the warp of the floor material produced by sticking the decorative veneer becomes concave, and troubles are likely to occur in the subsequent steps, and further, the on-site construction is troublesome. This is because, if it exceeds 115%, the warp of the plate-shaped body becomes too large before the decorative veneer is adhered, and it takes time and effort to adhere the decorative veneer. Further, when the specific gravity of the whole plate-like body is set to 0.6 to 0.7 which is equal to the specific gravity of plywood or the like, it is preferable that the specific gravity of the upper and lower layer portions 1 and 2 is 0.9 or more after clamping. . If the specific gravity of the upper and lower layer portions 1 and 2 is less than 0.9, a dense surface cannot be obtained, the amount of water absorption is large, and the same strength as particle board cannot be secured. Further, if the upper and lower layer parts 1 and 2 are formed by wet papermaking, there is an advantage that the mineral fiber and the organic fiber 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 to obtain a mixture for the middle layer. Then, the mixture for the middle layer portion is wet-paper-formed, and the wet inorganic mat, which is the lower layer portion 2, is evenly scattered and deposited on the surface of the middle layer portion 3.
Is formed, and the wet inorganic mat to be the upper layer 1 is laminated thereon to obtain a laminated body to be the plate-like 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.

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, 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 can be obtained. However, heating and clamping are performed until the overall specific gravity reaches 0.6 to 0.7.

Further, in the above-mentioned 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 or the dry method.

The decorative veneer 5 adhered to the surface of the upper layer portion 1 of the plate-like body 4 with an adhesive enhances the design of the flooring material and prevents the surface of the flooring material from being scratched. Examples include hardwood veneers such as oak, hippo, and teak, or synthetic resin-injected veneers, and those having a thickness of 0.2 mm or more are 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 a large thickness results in a high price, and therefore the thickness should be appropriately selected depending on the application.

The adhesive for adhering the decorative veneer 5 is not particularly limited, and examples thereof include a vinyl acetate-urea adhesive used for general decorative plywood. In particular, there is a difference in shrinkage depending on the type and thickness of the plate and the decorative veneer. To alleviate this, there is also added one that contains a pyrolytic foaming agent with a small shrinkage ratio that discharges and fixes the gas. It is effective in preventing warpage.

Further, the floor material 6 which is the plate-like body 4 to which the decorative veneer 5 is adhered is divided into an appropriate size after the decorative veneer is adhered in a large format for the sake of production efficiency. Is manufactured by
In order to prevent the occurrence of unevenness between adjacent floor materials 6,
Usually, the side end surface is actually processed. As actual processing,
For example, the actual processing equivalent to the wooden floor material such as the actual fruit including the male fruit 7a and the female fruit 7b as shown in FIG.

[0026]

EXAMPLES Next, examples according to the present invention will be described. (Example 1a) 45 parts by weight of rock wool as a mineral fiber, 10 parts by weight of pulp as an organic fiber, 25 parts by weight of calcium carbonate as an inorganic powder, 10 parts by weight of starch as a binder and 10 parts by weight of powdered phenol, and
A small amount of a fixing agent is put into fresh water and stirred to obtain an aqueous slurry having a concentration of 2%, which is introduced into a Fourdrinier paper making machine to make paper.
A wet inorganic mat having a thickness of 5.0 mm serving as an upper layer portion and a wet inorganic mat having a thickness of 5.3 mm serving as a lower layer portion were respectively 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 sprinkled 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 and laminated thereon. Got the body Then, after heating and pressing this laminated body with a hot press, the width is 910 mm and the length is 1
A plate-shaped body having a thickness of 820 mm and a thickness of 9 mm was obtained. The thickness of the upper, lower and middle layers of this plate is 1.5m.
m, 1.6 mm, and 5.9 mm, and the warp of the convex surface having a height of 2.0 mm was generated in the length direction, but the warp was not generated in the width direction. The warp in the width direction means the warp in the width direction measured at the end face of the wood mouth. The same applies thereafter.

Then, an adhesive agent is applied to the surface of the plate-like body.
Applying at a rate of 5 g / m ² , placing a veneer veneer having a thickness of 0.2 mm, heating and pressing with a hot press, and then naturally cooling it to make a decorative veneer pasting plate (hereinafter, referred to as " Intermediate material "). The adhesive is obtained by kneading vinyl acetate resin, urea resin, wheat flour, and water. And
The warp of the intermediate member formed a concave surface having a depth of 1 mm in the length direction and a concave surface having a depth of 1 mm in the width direction. Further, the warp during the construction of the floor material obtained by actually dividing the intermediate material into three parts in the width direction forms a concave surface with a depth of 1.0 mm in the length direction, and has a depth in the width direction. A concave surface of 0.5 mm was formed. It should be noted that about 10 days had passed since the decorative veneer was attached at the time of construction.

(Example 1b) An intermediate material obtained by treating in the same manner as in Example 1a except that a foam veneer is used instead of the above-mentioned adhesive to attach a decorative veneer. Warpage was measured. The foamed adhesive in this example is the above-mentioned adhesive,
It was obtained by adding a thermal decomposition type foaming agent corresponding to 1% of the resin weight. Then, the intermediate material to which the decorative veneer is attached forms a convex surface with a height of 1.0 mm in the length direction,
No warpage occurred in the width direction. The floor material obtained by dividing the intermediate material into three parts in the width direction had a convex surface with a height of 1.0 mm in the length direction, but no warpage occurred in the width direction.

(Example 2a) A wet inorganic mat having thicknesses of 5.0 mm and 5.7 mm, which are the upper layer and the lower layer, were obtained by making a paper from a slurry having the same composition as in Example 1a, while the mixture for the intermediate layer was used. A laminated body was obtained by spraying and stacking so as to have a thickness of 29 mm, and the laminated body was heated and pressed under the same conditions as in Example 1a to obtain the plate-shaped body of Example 1a and the width and length dimensions. Was obtained, and a plate-like body having a thickness of 8.9 mm was obtained, and the warp of the plate-like body was measured. In addition, the thickness of each of the upper layer portion, the lower layer portion and the middle layer portion of the plate-shaped body is 1.5 m.
m, 1.7 mm and 5.7 mm. This plate-like body forms a convex surface with a height of 3.0 mm in the length direction,
A convex surface of 0.5 mm was formed in the width direction. Next, the warp of the intermediate material obtained by sticking a decorative veneer under the same conditions as in Example 1a was measured. As a result, a concave surface having a depth of 0.5 mm was formed in the length direction and a depth in the width direction. 0.5
It formed a concave surface of mm. In the floor material in which the intermediate material was divided into three parts in the width direction and actually processed, a concave surface having a depth of 0.5 mm was formed in the length direction, but the warp in the width direction was too small to be measured. It was

Example 2b Obtained by treating in the same manner as in Example 2a, except that a decorative veneer was attached using the foamed adhesive of Example 1b in Example 2a. The warp of the intermediate material was measured. The intermediate material to which the decorative veneer was pasted had a convex surface with a height of 1 mm in the length direction, but no warpage occurred in the width direction. Similar results were also obtained in a floor material obtained by subjecting this intermediate material to three divisions in the width direction and subjected to actual processing or the like.

Example 3a From the slurry having the same composition as in Example 1a, a wet inorganic mat having a thickness of 5.0 mm as an upper layer portion was obtained. On the other hand, a wet inorganic mat having a thickness of 5.0 mm, which is a lower layer, was obtained from the slurry having a binder content of 21 parts by weight in Example 1a. Then, the mixture for the middle layer used in Example 1a was uniformly sprayed and deposited on the wet inorganic mat to be the lower layer so as to have a thickness of 30 mm, and the wet inorganic mat to be the upper layer was placed thereon. All the laminated bodies were obtained. Others are the same as those in Example 1a
A plate-like body was obtained by treating in the same manner as above, and the warp of this plate-like body was measured. Next, the warp of the intermediate material obtained by sticking a decorative veneer to this plate-shaped body was measured. The warp of the plate-like body formed a convex surface having a height of 4 mm in the length direction, and no warp occurred in the width direction. Further, the warp of the intermediate material to which the decorative veneer was adhered formed a concave surface having a depth of 1 mm in the length direction and a concave surface having a depth of 0.5 mm in the width direction. Further, the warp during the construction of the flooring 4 obtained by dividing the intermediate member into three pieces in the width direction and subjected to actual processing was a concave surface having a depth of 1 mm in the length direction, and no warp was generated in the width direction. .

(Example 3b) A floor obtained by treating in the same manner as in Example 3a except that a decorative veneer was attached using the foamed adhesive of Example 1b in Example 3a. The warp of the material was measured. The intermediate material to which the decorative veneer was stuck formed a convex surface having a height of 0.5 mm in the length direction, but no warpage occurred in the width direction. The same applies to the flooring material obtained by subjecting the intermediate material to three divisions in the width direction and subjecting it to actual processing.

(Example 4) From the same slurry as in Example 1a, a wet inorganic mat having a thickness of 5.0 mm to be an upper layer portion was obtained. On the other hand, in the slurry of Example 1a, the binder 2
The slurry containing 3 parts by weight was made into a paper to obtain a wet inorganic mat having a thickness of 5.0 mm as a lower layer. Then, the mixture for the middle layer used in Example 1a was uniformly sprayed and deposited on the wet inorganic mat to be the lower layer so as to have a thickness of 30 mm, and the wet inorganic mat to be the upper layer was placed thereon. To obtain a laminate. Others were treated in the same manner as in Example 1a described above to obtain a plate-like body, and the warp of this plate-like body was measured. Next, the warp of the intermediate material obtained by sticking a decorative veneer to this plate-shaped body was measured. The warp of the plate-like body formed a convex surface having a height of 8 mm in the length direction and a convex surface having a height of 1 mm in the width direction. As for the warp of the intermediate material to which the decorative veneer was adhered, a 2 mm convex surface was formed in the length direction, but the warp did not occur in the width direction. Furthermore, the warp during the construction of the flooring material obtained by dividing the intermediate material into three parts in the width direction and subjected to actual processing was a convex surface having a height of 2 mm in the length direction, and no warp occurred in the width direction.

(Embodiment 5) This embodiment is the same as the above embodiment 1a.
And Example 3a. That is,
From the same slurry as in Example 1a, a wet inorganic mat having a thickness of 5.0 mm, which was the upper layer, was obtained. On the other hand, Example 1
In a, slurry containing 21 parts by weight of a binder was made into a paper to obtain wet inorganic mats each having a thickness of 5.3 mm as a lower layer. Then, the mixture for the middle layer portion used in Example 1a was formed on the wet inorganic mat as the lower layer portion to a thickness of 30.
Then, the wet inorganic mat as the upper layer portion was placed thereon to obtain a laminate. This laminate was treated in the same manner as in Example 1a to obtain a plate-like body, and the warp of the plate-like body was measured. Next, the warp of the intermediate material obtained by sticking a decorative veneer to this plate-shaped body was measured. The warp of the plate-like body formed a convex surface having a height of 6 mm in the length direction and a convex surface having a height of 1 mm in the width direction. As for the warp of the intermediate material to which the decorative veneer was adhered, a convex surface having a height of 1 mm was formed in the length direction, but the warp did not occur in the width direction. Further, the warp during the construction of the flooring material obtained by dividing the intermediate material into three parts in the width direction and subjected to actual processing is a convex surface having a height of 0.5 mm in the length direction, and no warp occurs in the width direction. It was

(Embodiment 6) This embodiment is a combination of Embodiments 2a and 4. That is, from the same slurry as in Example 1a, the thickness of the upper layer was 5.5 m.
m wet inorganic mat was obtained. On the other hand, in Example 1a, a slurry obtained by adding 23 parts by weight of a binder was paper-made to obtain a wet inorganic mat having a thickness of 6.0 mm as a lower layer part. Then, the mixture for the middle layer used in Example 1a was uniformly sprayed and deposited on the wet inorganic mat as the lower layer so as to have a thickness of 58 mm, and the wet inorganic mat as the upper layer was placed thereon. To obtain a laminate. This laminate was treated as in Example 1a to give a thickness of 1
A 5 mm plate-shaped body was obtained, and the warp of this plate-shaped body was measured. Next, the warp of the intermediate material obtained by sticking a decorative veneer to this plate-shaped body was measured. The warp of the plate-like body forms a convex surface having a height of 12 mm in the length direction and a height of 2 mm in the width direction.
It formed a convex surface of mm. In addition, the warp of the intermediate material to which the decorative veneer is attached forms a convex surface having a height of 2 mm in the length direction and a height of 1 m at the end surface in the width direction.
m convex surface was formed. Further, the warp during the construction of the floor material, which was obtained by actually dividing the intermediate material into three parts in the width direction, was a convex surface having a height of 1 mm in the length direction, but no warpage occurred in the width direction. .

Comparative Example 1a From the slurry having the same composition as in Example 1a, a wet inorganic mat having a thickness of 5 mm to be upper and lower layers was obtained in the same manner as in Example 1a. Then, the mixture for the middle layer used in Example 1a was uniformly sprayed and deposited on the wet inorganic mat to be the lower layer so as to have a thickness of 30 mm, and the wet inorganic mat to be the upper layer was placed thereon. To obtain a laminated body having a thickness of 40 mm. Others are the same as those in Example 1a described above.
A plate-like body was obtained by treating in the same manner as above, and the warp of this plate-like body was measured. Then, the warp of the intermediate material obtained by sticking a decorative veneer to the plate-shaped body with an adhesive was measured. The warp of the plate-like body did not occur in either the length direction or the width direction. The warp of the intermediate material having the decorative veneer attached was a concave surface with a depth of 20 mm in the length direction, and the warp in the width direction was a concave surface with a depth of 3.6 mm. Further, the warp at the time of construction of the floor material obtained by dividing the intermediate material into three in the width direction and performing actual processing is a concave surface with a depth of 18 mm in the length direction and forms a concave surface with a depth of 1 mm in the width direction. Was.

(Comparative Example 1b) Intermediate obtained by the same treatment as in Example 1a except that the foamed adhesive of Example 1b was used in place of the adhesive in Comparative Example 1a. The warp of the material was measured. The warp of the intermediate material to which the decorative veneer was adhered was a concave surface having a depth of 10 mm in the length direction and a concave surface having a depth of 0.5 mm in the width direction.

For convenience of explanation, Table 1 shows the measurement results of the warpage in the above-mentioned Examples and Comparative Examples.

[Table 1]

As is clear from the above measurement results, the maximum warpage in either direction of the intermediate material and the flooring material, to which the decorative veneer of the example is adhered, is extremely smaller than that of the comparative example. The example process floor material more than the comparative example,
In other words, it was found that there is no effort required for actual processing, painting, etc. and on-site construction. On the other hand, the plate-shaped body of the comparative example does not warp in the length direction, whereas the plate-shaped body of the example has a warp of the convex surface.
The warps of 5 and 6 are extremely large. However, since the length of the plate-shaped body is about 1820 mm, the above-mentioned warp is relatively extremely small when viewed from the whole plate-shaped body, and since it is a convex warp, the plate-shaped body according to the embodiment has When applying the adhesive, it can be smoothly inserted into the applicator, and there is no particular problem in manufacturing. Examples 2b and 3b in which the decorative veneer is attached to the plate with a foaming adhesive rather than the intermediate material and floor material of Examples 2a and 3a in which the decorative veneer is attached to the plate with an adhesive Intermediate material,
The floor material has a smaller degree of change in warpage in the length direction. It is considered that this is because the shrinkage force when the foamed adhesive is fixed is small.

[0042]

As is apparent from the above description, according to the method for manufacturing a flooring material according to claim 1 of the present invention, the thickness of the lower layer portion is made larger than that of the upper layer portion, so that the plate Although a slight warpage occurs in the sheet, the surface of the upper layer portion is convex. Therefore, in the case of a concave warp, the tip of the plate-shaped body is located in the air, which hinders the insertion into the coating machine, but in the case of a convex warp, the tip of the plate-shaped body is located on the reference plane. Therefore, there is no problem in applying the adhesive. When a decorative veneer is attached to the surface of the plate-like body having a convex warp with an adhesive to integrate the veneered veneer, the convex warp of the plate-like body is caused by contraction of the decorative veneer and the adhesive. Since the flat intermediate material which is offset and less warped is obtained, the floor material can be easily processed and constructed in the field.
According to claim 2, since the amount of the binder added to the lower layer portion is larger than that of the upper layer portion, a slight warpage occurs in the plate-shaped body, but the surface of the upper layer portion is a convex surface. Become. Therefore, as in the former case, there is no particular problem when attaching the decorative veneer. When a decorative veneer is attached to the plate-like body with an adhesive so as to be integrated, warpage of the plate-like body is offset by contraction of the decorative veneer and the adhesive, and a flat intermediate material with less warp. As a result, the floor material can be easily processed and constructed on site. According to claim 3, the lower layer portion is thicker than the upper layer portion, and the amount of the binder added to the lower layer portion is larger than that of the upper layer portion. ,
The plate-like body has a considerably large convex warp. Therefore, the first invention and the second invention are effective when the warp cannot be sufficiently absorbed or when a concave warp occurs to cause a hindrance in the production or construction of the floor material. According to claim 4,
Since the decorative veneer is attached to the plate with a foaming adhesive that has a small shrinking force when sticking, the occurrence of concave warpage is small because the shrinkage on the surface side that occurs when the decorative veneer is attached is small, Further, even if it occurs, its value is small, so that it is possible to prevent the occurrence of problems during processing and construction.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a flooring 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 ... Floor material, 7a ... Male fruit, 7b ... Female fruit.

Claims (4)

[Claims] 1. An upper layer part containing mineral fibers, organic fibers, an inorganic powder and a binder, and a composition in the same range as each component of the upper layer part and having a thickness of 105 of the upper layer part.
% To 115% of the lower layer portion, an intermediate layer portion containing an inorganic foam, an organic fiber and a binder as a component is formed into a layer and integrated to obtain a plate-shaped body. A method for manufacturing a floorboard, characterized in that a decorative veneer is attached and integrated on the surface of the upper layer portion. 2. Mineral fiber, organic fiber, inorganic powder,
And an upper layer part having a component composition of 7.5 to 45% by weight relative to these, a composition in the same range as each component of the upper layer part, and 1% of the amount of the binder added in the upper layer part.
Between the lower layer portion added with the binder of 05% to 120%, the intermediate layer portion containing the inorganic foam, the organic fibers and the binder is formed into a layer and integrated to obtain a plate-shaped body. A method for producing a flooring material, characterized in that a decorative veneer is attached integrally to the surface of the upper layer of the body. 3. Mineral fiber, organic fiber, inorganic powder,
And an upper layer part having a composition of 7.5 to 45% by weight of a binder, and a composition in the same range as each component of the upper layer part, and 105% to 1% of the thickness of the upper layer part.
A middle layer having a thickness of 15% and an inorganic foam, an organic fiber, and a binder as a component between the upper layer and the lower layer containing the binder in an amount of 105% to 120% of the binder addition amount. A method for producing a flooring material, characterized in that a part is formed into a layer and integrated to obtain a plate-like body, and a decorative veneer is attached integrally to the surface of the upper layer part of the plate-like body. 4. A decorative veneer is attached and integrated with a foaming adhesive on the surface of the upper layer portion of the plate-like body.
The manufacturing method of the flooring material according to any one of 1 to 3.