JPH09317144A - Flooring and flooring ground material and manufacturing thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress the elapsed deterioration of a flooring over a long period of time and, at the same time, to improve a feeling of walking, thermal insulating efficiency and sound insulating efficiency against the lightweight impulsive sound. SOLUTION: In a flooring, at least one intermediate layer (flooring buffer layer) 3 is placed between a face 1 such as a wooden plate material, etc., and a backboard 2 such as a styrene resin foam. The intermediate layer 3 is formed of a buffer 4 such as nonwoven fabric, etc., and an elastic or soft polymer, and it is combined with a net-like body 5 alternately overlapping warp and weft at a neighboring intersecting point and is constituted. A ground material is constituted of the backboard 2 and intermediate layer 3, a sheet is placed on the rear side thereof, and they are sewed up to make it possible to form together as a unit.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor material, a cushioning layer for a floor material, a base material for a floor material, and a method for producing the base material, which are useful for reducing the impact noise of the floor.

[0002]

2. Description of the Related Art Noise absorption of floor materials is noise reduction for downstairs noise (lightweight impact sound) caused by walking of a person or dropping of a spoon, and noise downstairs caused by children jumping or dropping heavy objects. It is roughly divided into the sound deadening property against (heavy impact sound). Of these impact sounds, the heavy impact sound greatly depends on the thickness of the concrete floor slab, and it is effective to increase the concrete thickness to increase the floor rigidity. On the other hand, not only in collective housing but also in single-family homes, a Japanese-style room has a tatami mat laid on a tatami floor, and a Western-style room has a construction method in which a wooden floor material is directly attached to the slab surface. In the construction method of directly bonding the wooden floor material to the slab surface, in order to improve the light impact sound to the downstairs, a floor material in which a wooden board and a cushioning material such as a non-woven fabric are combined in various modes is used. There is.

However, cushioning materials such as non-woven fabric are soft,
Immediately after construction, lightweight impact sound can be attenuated, but if cushioning is enhanced, the floor surface will sink due to walking, giving a fluffy walking feeling. On the other hand, when the thickness of the cushioning material decreases with time, the cushioning property is reduced and the walking feeling is improved, but the sound insulation effect is also reduced. Therefore, it is difficult to improve the sound insulation while enhancing the walking feeling. further,
In a Western-style room where the wooden floor material is directly attached to the slab surface, the heat insulation is also small.

In Japanese Patent Laid-Open No. 2-136467, in order to reduce floor impact noise, a resin or rubber foam sheet formed by sandwiching a mesh body made of polymer or rubber is adhered to the lower part of the surface layer. An installed soundproof floor is disclosed.
This document also discloses disposing the soundproof floor on an elastic layer made of foamed rubber and a base layer made of wood plywood. In this flooring material, floor impact noise can be reduced by viscoelasticity of the foam sheet, and since the net-like body is embedded in the foam sheet, the flooring material also has high rigidity. However, since the net-like body is entirely restrained by being embedded in the foam sheet, and the sound deadening property depends on the foam sheet, the effect of mitigating impact sound and the sound insulation effect are small. In particular, in order to enhance the sound insulation, if a wooden floor material (surface material) having a groove processed on the back surface is arranged on the soundproof floor, since the groove is sealed by the soundproof floor, impact sound is muffled in the groove, Sound insulation is likely to deteriorate.

On the other hand, since the thickness of the tatami mat is about 55 mm and the thickness of the directly attached wood flooring is about 15 mm, there is a difference of about 40 mm between the Japanese-style room and the Western-style room. Such steps create barriers for the elderly,
There is a high possibility that the person will stumble and fall and cause a fracture.

[0006]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a flooring material which is excellent not only in walking feeling and sound insulation but also in heat insulation.
An object is to provide a base material for flooring and a laminate for flooring.
Another object of the present invention is to suppress deterioration over time (sagging) over a long period of time, maintain a high walking feeling, sound insulation and heat insulating properties, and have a highly durable floor material, a flooring base material, and To provide a laminate for flooring. Still another object of the present invention is a flooring material, a flooring material for a flooring material and a flooring material which can be easily adjusted to have substantially the same surface height as a Japanese-style room with a tatami mat floor, and which is useful as a flooring material for a Western-style room without a step difference from the Japanese-style room. It is to provide a laminate for materials. Another object of the present invention is to provide a floor material, a floor material for a floor material, and a laminate for a floor material, which can effectively reduce a lightweight impact sound over a long period of time. Still another object of the present invention is a flooring material which has a good walking feeling, sound insulation and heat insulating properties, and is effective in producing a flooring material with high durability that can effectively reduce lightweight impact sound over a long period of time. It is to provide a method of manufacturing a base material for use.

[0007]

Means for Solving the Problems As a result of intensive studies for achieving the above-mentioned object, the present inventors have found that a combination of a non-restraining cushioning material and a mesh material between a surface material and a base material is an intermediate material. By interposing a layer (buffer layer), the impact sound can be propagated and attenuated not only in the impact direction but also in other directions, and the resilience to load and durability are high, and the amount of sinking can be reduced over a long period of time. The inventors have found that it can be made smaller and completed the present invention. That is, (1) the flooring material of the present invention is a flooring material in which at least one intermediate layer is disposed between a surface material and a back surface material, and the intermediate layers are at least non-restraining buffers. It is composed of a combination of wood and mesh. In this floor material, at least the surface layer of the surface material is often composed of a wood-based board material or a resin-based board material, and the surface material is a wood-based board material or a resin-based board material and a fiber board and / or closed cells. You may comprise by the laminated body with a foam. The backing material often contains at least one of a fiber board (such as Tatami board) and a closed cell foam (such as styrene resin foam). The backing material is a laminated body of the fiber board and the closed cell foam. You may comprise. The intermediate layer may be a buffer layer having a sandwich structure composed of a mesh body and a cushioning material provided on both surfaces of the mesh body. The cushioning material can be formed of a porous soft material having a sound deadening property, and the mesh can be configured by a net in which warp thread elements and weft thread elements are alternately (alternately) overlapped at adjacent intersections. In a flooring material having a plurality of intermediate layers, at least one of the fiber board and the closed cell foam may be interposed between the plurality of intermediate layers. Further, by selecting the thickness of the back material, the thickness of the floor material is 15 to 200 mm.
For example, when adjusting the same height as the tatami using a surface material with a thickness of 15 mm, the thickness of the base material is about 40
You may adjust to mm. The present invention comprises (2) a combination of at least a substantially non-restraining cushioning material and a mesh, and can be arranged between a surface material and a back surface material that constitute a floor material. It also provides a cushioning layer for floor materials (soundproofing material for floor materials).

(3) The base material of the present invention is a base material for a floor material on which a surface material can be laminated, and at least a back surface material composed of at least one of a fiber board and a closed cell foam. An intermediate layer composed of a combination of the cushioning material and the mesh body that are substantially unconstrained from each other is laminated. In this base material, the back surface material and the intermediate layer may be sewn and integrated. (4) This base material is sewn with a backing material composed of at least one of the fiber board and the closed-cell foam, and an intermediate layer composed of at least the combination of the cushioning material and the mesh. It can be manufactured by stacking layers. In addition, in this manufacturing method, when the back surface layer is made of foam, the constituent members may be arranged on a sheet and stitched. The present invention is (5) a laminate for flooring, wherein a backing material can be laminated,
At least a wooden board or a resin board with a surface layer (for example,
There is also provided a laminate for flooring in which a surface material composed of a soft resin tile material) and an intermediate layer composed of a combination of at least a substantially non-restraining cushioning material and a mesh material are laminated. To do.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below in detail with reference to the accompanying drawings as needed. The flooring material of the present invention has a structure in which at least one intermediate layer composed of a combination of a cushioning material and a net-like material is disposed between the front surface material and the back surface material. [Surface material] The surface material can be composed of various materials constituting the surface layer of the floor material, for example, wood-based board materials or resin-based board materials, cloth materials such as woven cloth and non-woven cloth.

Examples of the wood-based board material include plywood, particle board, and LVL (parallel plywood).
On the surface of these wood board materials, a veneer wood veneer, a resin sheet made by embossing, etc. [eg vinyl chloride resin, styrene resin, olefin resin (propylene resin, ethylene resin, etc.), ester Synthetic resin such as a system resin] may be attached, or a decorative layer may be formed by applying a coating layer or painting. The resin sheet may be either a non-foamed sheet or a foamed sheet. The foamed sheet is useful for imparting cushioning properties. The cells of the foamed sheet may be either open cells or closed cells, but are preferably closed cells in order to maintain the cushioning property for a long period of time. The resin-based plate material includes a tile material formed of the same synthetic resin as described above (particularly soft resin such as soft vinyl chloride-based resin and olefin-based resin). A preferable surface material often includes a wood-based board material or a resin-based board material (for example, a soft resin tile material for kitchen), and may be a composite material of a wood-based board material and a resin-based board material. Particularly, in many cases, a surface material whose surface layer is made of a wood-based board material or a resin-based board material (soft resin tile material or the like) is used in many cases.

The thickness of the surface material is not particularly limited, and for example,
You may select from the range of 0.1-20 mm, preferably 0.2-15 mm (for example, 0.5-10 mm). When the surface material is made of a wooden board, the thickness of the surface material is, for example, 1 to 20 mm, preferably 2.5 to 15 m.
It is often about m.

Grooves may be formed on the back surface of the surface material (particularly a wooden board material) in order to enhance sound deadening.
The depth of the groove formed by this groove processing is 15 times the total thickness of the surface material.
˜75%, preferably 25-75%, more preferably 40-75%. When the depth of the groove is less than 15% of the total thickness of the surface material, the contribution to the sound insulation is small, and when it exceeds 75%, the strength of the surface material tends to decrease. The width of the groove is, for example, 0.5 to 5 mm, preferably 0.7 to 3.
It can be selected from a range of about 5 mm (1 to 3 mm). If the width of the groove is less than 0.5 mm, the work efficiency of the groove processing tends to decrease, and if it exceeds 3 mm, the strength of the surface material tends to decrease. The pitch of the grooves is, for example, about 1 to 30 cm, preferably about 2 to 20 cm (5 to 20 cm). If the groove pitch is less than 1 cm, the strength tends to decrease, and if it exceeds 30 cm, the contribution to the sound insulation is reduced. The grooves may be formed substantially parallel to the back surface of the surface material, or may be formed to intersect each other like a lattice.

In order to improve the workability and make the floor surfaces of the adjacent surface materials have the same height, the end surfaces of the surface materials (particularly wood board materials) are machined so that they can be actually spliced or jointed to each other. Is advantageous.

Further, the surface material is the wood-based board material,
You may comprise by the laminated body of a resin-type board material and the fiber board and / or closed cell foam laminated | stacked on the back surface of these surface materials. For the fiber board and the closed cell foam, the fiber board and the closed cell foam described in the section of the backing material can be used.

[Backside Material] The backside material contains at least one of the fiberboard and the closed-cell foam in order to enhance the heat insulating property as well as the walking feeling. That is, the backing material can be composed of a fiber board alone, a closed cell foam alone, or a combination (laminate) of a fiber board and a closed cell foam.

The fiber board is a molded board containing plant fibers such as wood as a main component, and is a pulp-like plant fiber material (containing wood as a main component and containing bamboo, bamboo shoots, straw, pulp dregs, waste wood, etc.). Good) and a binder, the slurry is made into a paper, dehydrated and dried, and optionally heated and pressed to obtain a slurry. The fiber board is a fiber board defined in JIS A 5905, for example, a hard fiber board (hard fiber board, HB) having a density of 0.8 g / cm ³ or more, a density of 0.
A semi-hard fiber board (medium density fiber board, BDF) of 35 to 0.8 g / cm ³ may be used, but a density of 0.35 g / cm from the viewpoint of density and cost.
A soft fiber board (insulation fiber board, IB) of ³ or less (for example, 0.2 to 0.35 g / cm ³ ) is preferable. The soft fiber board (IB) may be a class A insulation board (A-IB) or a seeding board (S-IB), but especially a class T fiber board (tatami board) (T-
IB) is preferred. The fiber board may contain a small amount of a synthetic polymer having a cushioning property (such as rubber) and a synthetic resin foam, if necessary. The thickness of the fiber board can be selected from the range of, for example, 2.5 to 30 mm (for example, 3 to 25 mm), preferably about 7 to 20 mm. In addition,
The thickness of the fiber board is specified in JIS A 5905. For example, the thickness of the T-class fiber board (Tatami board) (T-IB) is 10 mm, 15 mm, and 20 mm. If a thickness exceeding 30 mm is required, the thickness can be adjusted by combining two or more fiber boards. For adjusting the thickness, fiber boards having the same thickness or fiber boards having different thicknesses can be combined. Also, in the combination of fiberboard,
It is also possible to combine a plurality of fiberboards having different densities (for example, the three types of fiberboards).

The closed cell foam includes various foams having closed cells, such as polyurethane foam, polyvinyl chloride foam, polypropylene foam, styrene resin foam and the like. Preferred foams include styrenic resin foams, which are advantageous in terms of heat insulation and mechanical strength. As this styrene resin foam, JIS
It is possible to use a styrene-based resin foam (a heat-insulating plate of type A) by the bead foaming method specified in A 9511 or a styrene-based resin foam (a heat-insulating plate of type B) by the extrusion foaming method.

The thickness of the foam is, for example, 10 to 90 m.
m, preferably 20 to 50 mm. The thickness of the styrene resin foam is specified in JIS A 9511. For example, the thickness of the type B heat insulating plate in the above range is 20 mm, 25 mm, 30 mm,
35 mm, 38 mm, 40 mm, 50 mm and 75 mm. The density of the foam is, for example, 15 to 40 kg.
/ M ³ , preferably about 25 to 35 kg / m ³ .
When the density is less than 15 kg / m ³ , the compressive strength as a floor material is small and gives a fluffy walking feeling, and when the density exceeds 40 kg / m ³ , the heat insulating property and the sound insulating property are easily deteriorated, which is also disadvantageous from the economical aspect. The backing material may be a laminated body of a fiber board and a foam as described above. Further, in the backing material constituted by the laminated body, between the fiber board and the foam,
The cushioning material and the net-like body may be interposed. The thickness of such a laminate can also be selected from the thicknesses of the fiber board and the foam. Grooves may be formed on the back surface of the back surface material in the same manner as the surface material in order to improve sound insulation. Also in the groove processing of the back surface material, the groove depth, the groove width, and the groove pitch can be selected from the same range as that of the surface material groove.

[Intermediate Layer, Floor Material Buffer Layer] A feature of the present invention is that, between the front material and the back material constituting the floor material, at least substantially non-restraining buffer material and net material are provided. The intermediate layer (buffer layer for flooring material) composed of a combination of is interposed. By interposing an intermediate layer (buffer layer) that can be arranged between the surface material and the back surface material, the cushioning material can improve the sound deadening property, and the net-like body can improve the walking sensation and the restoration property over a long period of time. Durability can be maintained.
In addition, since they are substantially unconstrained with each other, the impact sound can be propagated to the space formed between the cushioning material and the mesh body (for example, the space corresponding to the mesh portion of the mesh body), and the sound can be effectively silenced. That is, even if an impact, especially a light impact, acts,
Since the impact sound is propagated not only in the impact direction but also laterally by the net-like material and can be silenced by the cushioning material, the sound deadening property can be greatly improved. In particular, when a mesh body in which warp thread elements and weft thread elements are overlapped and intersected at an intersection point is used, flexibility and resilience against a load are high, and deterioration with time can be prevented and the amount of sinking can be reduced. Moreover, even when an impact is applied, the net-like body can secure a propagation space in which the impact sound can be laterally propagated, so that the sound deadening property can be remarkably improved, and the walking feeling and durability can be improved.

Cushioning Material The cushioning material is a porous soft material having a sound deadening property, for example,
Often made of cloth (woven or non-woven) or soft resin foam. A preferred cushioning material is composed of non-woven fabric or soft resin foam, especially non-woven fabric. In order to improve walking feeling and sound insulation, the cushioning material has, for example, a strength of 0.01 to 0.20 kg / cm ² , preferably 0.0 at 25% compression.
It is about 5 to 0.1 kg / cm ² . If the strength at 25% compression is less than 0.01 kg / cm ² , the walking sensation tends to deteriorate, and if it exceeds 0.20 kg / cm ² , the sound insulation tends to deteriorate.

The non-woven fabric is produced by olefin fibers such as polypropylene fibers, polyester fibers, polyamide fibers, polyurethane fibers, fibers such as cellulose acetate fibers by a dry method such as a needle punch method or a wet method such as a papermaking method. It is possible and can be used as a sheet or mat. The thickness of the non-woven fabric is, for example,
It is 0.5 to 8 mm, preferably 1 to 5 mm, more preferably about 2 to 3 mm. If the thickness is less than 0.5 mm, the sound insulation is deteriorated, and if it exceeds 8 mm, a fluffy walking feeling is likely to be given. The basis weight of the non-woven fabric is, for example, 50 to 50.
0 g / m ^2, preferably 100 to 300 g / m ² (e.g., 180~250g / m ²⁾ approximately. The basis weight is 5
If it is less than 0 g / m ² , the sound insulation is poor, and if it exceeds 500 g / m ² , the walking feeling may be deteriorated.

The buffer material made of a resin foam is, for example, a soft resin (for example, urethane resin, soft vinyl chloride foam, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer). (For example, an olefin resin).
The cushioning material made of resin foam is often in the form of a sheet (sheet-like foam). In order to improve the cushioning property and the sound deadening property, the open cell ratio of the resin foam is advantageously 25% or more (for example, 25 to 100%, preferably 50 to 100%). When the open cell ratio is less than 25%, the buffering property and the sound deadening property are likely to deteriorate. The thickness of the resin foam is 0.5 to 8 mm, preferably 1 to 5 as in the case of the non-woven fabric.
mm, and more preferably in the range of about 2 to 3 mm. Further, the basis weight of the resin foam is, for example, 50 to
It can be selected from the range of about 500 g / m ² .

The meshwork meshwork is disposed substantially unrestrained state with respect to the cushioning material. That is, the reticulate body and the cushioning material are locally integrated by physical bonding (suture, etc.) or chemical bonding (adhesion, fusion bonding, etc.), and may be locally constrained or separated from each other. It may be in physical contact. The net may be a perforated sheet net having substantially the same thickness at the intersection and the non-intersection part, but the warp element and the weft thread element are overlapped at the intersection part, and the intersection part is more than the non-intersection part. A net having a large thickness is preferable. Alternatively, the overlapping form of the warp thread element and the weft thread element at the intersection may be such that the warp thread element and the weft thread element uniformly (uniformly) vertically overlap, and at least at any intersection, the upper and lower parts overlap each other. May be. Further, the warp thread elements and the weft thread elements may be alternately (alternately) overlapped at a crossing portion adjacent to or adjacent to each other. The reticulate body (net) can be formed of a metal such as stainless steel, but an elastic polymer (for example, isoprene rubber, polybutadiene, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, butyl rubber, ethylene-propylene rubber). , Urethane rubber, silicone rubber, acrylic rubber, ethylene-acrylic rubber,
Fluorine rubber, rubber component such as thermoplastic elastomer),
Flexible or soft polymer [eg, polyethylene (ultra-low density polyethylene, low density, medium density, high density polyethylene, linear polyethylene, etc.), ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene- (meth ) Acrylic acid copolymer, olefin-based polymer such as ethylene- (meth) acrylic acid ester copolymer), and the like. A preferable network is a polymer network having elasticity or flexibility (for example, an elastic or flexible net). For example, the rubber or olefin resin (especially polyethylene, ethylene copolymer or other ethylene-based polymer) is used. Are formed). The mesh may be a foam. The reticulated foam has a closed cell rate of 25% or more (20 to 100%, from the viewpoint of prevention of deterioration of walking feeling and sound insulation over time).
It is preferably 50 to 100% closed cell foam.

The compressive strength of the reticulated body can be selected within a range that can improve the sound insulation without impairing the feeling of walking, and the strength at 25% compression is
For example, 0.05 to 10 kg / cm ² , preferably 0.
1 to 7 kg / cm ² , more preferably 0.2 to 5 kg
/ Cm ² , and may be about 0.25 to 3.5 kg / cm ² . 25% compressive strength is 0.05kg / c
If it is less than m ² , the walking feeling is deteriorated, and if it exceeds 10 kg / cm ² , the sound insulation is likely to be deteriorated.

The thickness of the reticulate body can be selected within a range capable of improving walking and sound insulation properties, and can be selected, for example, from 0.5 to 6 mm (eg 1 to 6 mm), preferably from 1 to 4 mm. The thickness of the mesh means the thickness at the intersection. The basis weight is, for example, 100 to 1000 g /
It can be selected from the range of m ² , preferably about 200 to 800 g / m ² .

The sizes (diameters) of the warp thread elements and the weft thread elements constituting the reticulated body can be selected according to the thickness of the reticulated body, and are, for example, 0.2 to 3 mm, preferably 0.5 to 3 m.
m, and more preferably about 0.5 to 2 mm. If the thickness of the warp thread element and the weft thread element is less than 0.2 mm, the walking feeling is not improved so much, and if it exceeds 3 mm, the sound insulation may be deteriorated. The warp thread element and the weft thread element may be integrated or may be intertwined at the intersection point by fusion, adhesion, or the like.

The shape of the mesh of the mesh is not particularly limited as long as the propagation space for the impact sound can be formed.
Any shape such as a rectangular shape such as a rectangular shape, a rhombus shape, a hexagonal shape, and a circular shape can be adopted. The size of the mesh may not be uniform throughout, but from the viewpoint of walking feeling and sound insulation, the average inner diameter is 2 to 50 mm (for example, 2 to 30 m).
m), preferably about 5 to 30 mm (5 to 15 mm).

Mode of Intermediate Layer The structure of the intermediate layer composed of the cushioning material and the mesh is not particularly limited. For example, a structure in which the mesh is arranged on the cushioning material, or the cushioning material is arranged on the mesh. Examples thereof include a structure provided, a structure in which a cushioning material is provided on both surfaces of the mesh body, and a structure in which these structures are combined. Preferred structures for improving cushioning and sound deadening include sandwich structures in which cushioning material is disposed on both sides of the mesh.

The cushioning material and the net-like body can be made unconstrained in various ways. For example, the cushioning material and the net-like body are joined at least at one place (regularly or irregularly spot-like (dotted) joining, regular or irregular linear joining) Aspects), an aspect in which the cushioning material and the mesh body are separated without being bonded and physically laminated, and the like. In the above aspect, the bonding density between the cushioning material and the mesh body can be selected within a range that does not impair the flexibility and the restoring property of the mesh body.
% Or less (for example, 0.001 to 30%), preferably 2
It is 5% or less (for example, 0.001 to 20%), and more preferably 10% or less (for example, 0.001 to 10%). In the case of joining by suturing or the like, depending on the suture density, the stitching interval, etc., the mesh-like or net-like structure has a small area that can be joined, and the mesh-like material and the cushioning material may be locally joined together. Since the amount is large, it can be considered that the bonding density of the cushioning material and the mesh is substantially 0%.
It may be about 0 to 5%. As will be described later,
The back material and the intermediate layer may be integrated by stitching or the like.

Further, a plurality of intermediate layers may be interposed between the surface material and the back surface material. In such a flooring having a plurality of intermediate layers, at least one of the fiberboard and the closed-cell foam is provided between the plurality of intermediate layers (ie, for example, the fiberboard alone, the foam alone, the fiberboard alone). And the foam).

The thickness of the floor material may be adjusted to 15 to 200 mm by selecting the thickness of the back material. For example, if there is a step difference of about 40 mm between the Japanese-style room and the Western-style room, the thickness of the floor material is adjusted by the backing material together with the intermediate layer to adjust the difference between the Japanese-style room where the tatami mat is laid and the Western-style room. It is preferably adjustable. In addition,
In the Western room adjacent to the Japanese-style room, a wood-based board material subjected to flooring is often used, and the thickness of the board material is, for example, about 1 to 20 mm (preferably 2.5 to 15 mm). Therefore, when adjusting the thickness of the floor material to about 55 mm (tatami thickness) by combining the intermediate layer and the back surface material,
Floor material components (intermediate layer and back material) excluding surface materials
Should be adjustable to a thickness of about 54 to 35 mm. The total thickness of the floor material is, for example, 15 to 200 mm.
(For example, 15 to 100 mm), preferably 20 to 15
The floor material is about 0 mm (for example, 20 to 60 mm), and in order to match the surface height of the Western-style room with the Western-style room adjacent to the Japanese-style room, the thickness of the floor material is about 55 mm (tatami thickness).
Is useful.

A typical structure of the flooring material will be described below with reference to the accompanying drawings. FIG. 1 is a schematic sectional view showing an example of the flooring material of the present invention. The common members will be described with the same reference numerals. In the flooring material shown in FIG. 1, an intermediate layer (buffer layer) 3 is interposed between a surface material (wooden board material or resin board material) 1 and a back material (fiber board or styrene resin foam material) 2. The intermediate layer 3 has a structure, and is composed of a combination of a cushioning material (nonwoven fabric or the like) 4 and a mesh body (net or the like in which warp yarn elements and weft yarn elements overlap each other at intersections) 5. In the example shown in FIG. 1, the intermediate layer 3 has a sandwich structure in which the cushioning materials 4 and 4 are arranged on both surfaces of the mesh body 5.

FIG. 2 is a schematic sectional view showing another example of the flooring material of the present invention. This floor material has the same basic structure as the floor material shown in FIG. 1 except that the back surface material 2 shown in FIG. 1 is composed of a plurality of members 2a and 2b. The plurality of members 2a and 2b forming the backing material 2 may be the same common member (for example, a heat insulating material such as fiber board or styrene resin foam), but different members (for example, one Is a fiber board and the other is a styrene resin foam). In this example, the back material 2 is composed of a laminate of a fiberboard 2a on the intermediate layer side and a styrene resin foam 2b on the back surface side.

FIG. 3 is a schematic sectional view showing still another example of the flooring material of the present invention. This floor material is composed of a cushioning material 4 and a mesh material 5 between a surface material 1 (wood board material or resin board material) and back material 2 (fiber board or styrene resin foam material). A plurality of intermediate layers 3 are formed, and
Between these intermediate layers 3 and 3, a member (fiber plate, styrene resin foam or the like) 2a similar to the backing material 2 is interposed. In this example as well, the member 2a interposed between the backing material 2 and the intermediate layers 3 and 3 may be a common member (for example, a fiber board or a styrene resin foam),
In many cases, different members (for example, fiberboard on one side and styrene resin foam on the other side) are used. In this example, the backing material 2 is made of styrene resin foam, and the fiberboard 2a is interposed between the intermediate layers 3 and 3.

Further, FIG. 4 is a schematic sectional view showing another example of the flooring material of the present invention. This floor material has the same basic structure as the floor material shown in FIG. 1 except that the surface material 1 is composed of a plurality of members 1a and 1b. That is, in this example, the surface material 1 is composed of a wood board material or a resin board material 1a and a heat insulating member (for example, a fiber board or a styrene resin foam) 1b.

2 to 4, the cushioning material (nonwoven fabric or the like) 4 and the mesh body (net or the like in which the warp thread element and the weft thread element overlap each other at the intersection) can be combined in various ways. , A combination of the cushioning material 4 arranged on the surface material 1 side and the mesh body 5 arranged on the back surface material 2 side, and a combination of the mesh body 5 arranged on the surface material 1 side and the back surface material 2 side. In combination with the cushioning material 4 provided, cushioning materials 4, 4 are provided on both sides of the mesh body 5.
It may be a sandwich structure in which is provided.

[Base Material] The base material of the present invention is capable of laminating the above-mentioned surface material and is composed of a laminated body of a back surface material and an intermediate layer. That is, the base material for the floor material is at least one of a fiberboard (for example, a T-class fiberboard) and a closed cell foam (for example, a styrene resin foam), and a backing material that is at least one of the backboard materials. An intermediate layer composed of a combination of a cushioning material (for example, the non-woven fabric) and the reticulated body (for example, a reticulated body composed of an elastic or soft polymer and having a warp element and a weft element overlapping at an intersection) Are stacked. Similar to the above, the backing material may be either a fiber board alone, a closed cell foam alone, or a laminate of a fiber board and a closed cell foam. If necessary,
As described above, it may be a laminated body in which a cushioning material or a mesh body is interposed between the fiber board and the closed cell foam. A preferable intermediate layer is composed of a mesh body and a cushioning material provided on both surfaces of the mesh body, as described above.

In the above-mentioned base material, the back surface material and the intermediate layer do not necessarily have to be integrated, but it is preferable that they are integrated in view of handling property. The method for integrating the backing material and the intermediate layer is not particularly limited. For example, a method of adhering with an adhesive (rubber-based, acrylic-based adhesive, etc.) or a suturing machine such as a tatami mat making machine is used. (Sewn) method can be adopted. A preferable method includes a method of laminating and integrating the backing material and the intermediate layer by sewing. The use of the suturing means by the suturing machine does not require curing of the adhesive and is capable of partially fixing a plurality of layers at one time, which is also advantageous in terms of productivity. Especially,
When the suturing means is used, the cushioning material and the mesh body are locally restrained, but the cushioning material and the mesh body are unconstrained in most regions of the intermediate layer. Therefore, even if the impact acts on the floor material, the impact sound can be attenuated while propagating not only in the impact direction but also in the lateral direction due to the space and voids formed in the intermediate layer.
In addition, a dent is generated in the stitched portion by stitching, and this dent also greatly contributes to the muffling. Therefore, the flooring material having the base material prepared by stitching can remarkably improve the sound deadening property.

When the back surface material and the intermediate layer are integrated with each other by suturing, if the lowermost layer of the back material is made of foam, the suture thread may not stop on the bottom surface of the foam and may break the foam. . Therefore, when the lowermost layer of the back material is made of foam, it is preferable that the back material made of foam and the intermediate layer are sequentially arranged and sewn on the sheet forming the back layer. As the sheet for fixing the suture thread, for example, cloth (woven cloth, non-woven cloth), synthetic resin sheet (sheet of polypropylene resin, polyester resin, polyamide resin, etc.) can be used. When stitching the laminate of the back surface material and the intermediate layer, the stitching pitch (spacing) can be selected within a range that does not impair the cushioning property, sound deadening property and durability of the intermediate layer.
2 to 25 cm (for example, 2 to 20 cm), preferably 3
It can be selected from a range of about 15 cm (for example, 3 to 10 cm).

Base material and surface material (wooden board etc.)
A flooring material can be manufactured by laminating and. For the lamination, a conventional method, for example, an adhesive (rubber type, acrylic type, vinyl acetate type, ethylene-vinyl acetate copolymer type,
A method of adhering a surface material on a base material with a urethane adhesive or the like, a method of adhering and fixing a surface material on a base material with a double-sided adhesive tape, etc. can be adopted. In the latter method, a double-sided pressure-sensitive adhesive tape is provided so as to straddle the connecting parts of the surface materials (for example, the actual joint or the joint part).
By joining the base material and the surface material, the liquid can be prevented from entering the base material from the joining portion (butting portion) of the surface material by the double-sided adhesive tape, and the waterproof property can be improved. In addition, in order to improve the waterproof property, a waterproof film or sheet may be used instead of the double-sided adhesive tape.

[Floor material laminate] The floor material laminate of the present invention is a laminate of the surface material and the intermediate layer (floor material buffer layer), and the back material can be laminated. . That is, the flooring laminate is a surface material having a surface layer of at least a wood-based board material or a resin-based board material (such as a soft resin tile material), at least a cushioning material (such as a non-woven fabric), and a mesh body (for example, It is composed of an elastic or soft polymer, and is composed of a laminate with an intermediate layer composed of a combination of a mesh body in which warp thread elements and weft thread elements overlap each other at an intersection point.

By combining such a flooring laminate with a backing material, it is useful for producing a flooring material having high sound insulation, walking feeling, heat insulation and little deterioration over time and high durability. Is. That is, as described above, the intermediate layer (buffer layer)
Has a flexibility due to the net-like body, has a good walking feeling, has high durability due to the restoring property of the net-like body, and exhibits a high sound deadening property by the combination of the cushioning material and the net-like body.
Further, the laminate for flooring material can be greatly improved in heat insulating property by forming the flooring material in combination with the backing material such as the fiber board or the closed cell foam. The flooring laminate is not necessarily integrated, but the surface material and the intermediate layer (buffer layer) may be integrated by means such as adhesion.

In the construction of the flooring material, the laminate for flooring material is laminated on the back surface material (fiber board, closed cell foam or the like) arranged at the construction site. At the time of stacking, an adhesive or the like may be used.

The floor material or the base material of the present invention is applied to the slab surface by applying an adhesive (for example, rubber-based, acrylic-based, vinyl acetate-based adhesive, etc.) to the slab surface, if necessary. This can be done by adhesively fixing the material to the slab surface. When the slab surface has irregularities or uneven parts, for example, plastering the slab surface or making it 1 to 3
After the slab surface is flattened by using a foamed sheet having a size of about mm, the work can be performed in the same manner as above. Alternatively, mortar dango may be placed on the slab surface at appropriate intervals (for example, at intervals of about 30 cm), and the floor materials may be arranged at the same height. Further, when the distance between the slab surface and the desired floor surface is large, it is also possible to raise by using a styrene resin foam or a fiber board, etc., depending on the thickness of the floor material of the present invention,
It may be raised by bundling, joists, hauling, and scraping.

The size of the flooring material, the base material and the laminate of the present invention is not particularly limited, but is usually the size of a tatami mat (that is, 910 mm × 1820 mm).
0 x 910 mm, 606 mm x 910 mm, 303 mm
Any size such as × 910 mm can be selected.

The flooring material, base material and laminate of the present invention can be applied not only to a house (for example, a Western-style room or living room floor) but also to various indoors such as an office building. It is useful as a flooring material that eliminates the step between the Japanese-style room and the Western-style room and adjusts the Japanese-style room and the Western-style room to almost the same surface height. The flooring material, base material, and laminate of the present invention can be used not only in a Western-style room or living room, but also in a board-attached place (for example, a hallway, stairs landing, etc.) or a tile-attached place (for example, a kitchen). Can be used.

[0047]

According to the present invention, since the intermediate layer or the cushioning layer is composed of a combination of the cushioning material and the mesh body, not only the walking feeling and the sound insulation but also the heat insulation is high. In particular, deterioration over time (sagging) can be suppressed, the amount of sinking is small even when a load is applied, high walking feeling, sound insulation and heat insulation can be maintained for a long period of time, and durability is high. Further, by adjusting the thickness of the back material, the surface height can be easily adjusted to be almost the same as that of a tatami-mat room, and it is useful as a floor material for a Western-style room without a step. Furthermore, the lightweight impact sound can be effectively reduced for a long period of time.

[0048]

EXAMPLES The present invention will be described below in more detail with reference to Examples, but the present invention is not limited to these Examples.

Examples 1 to 6 As shown in the table, the following non-woven fabrics, a reticulate body composed of an ethylene-based polymer, a T-class fiberboard, a polystyrene foam board, and a cloth are arranged in this order from the top to the bottom. Then, using a tatami mat production machine, polypropylene sewn threads were sewn to fabricate a flooring base material. An ethylene-vinyl acetate emulsion adhesive was used on the non-woven fabric of this base material, and a kerf (groove width; 2
mm, groove depth: 6 mm, groove pitch: 15 mm) and a wood-based board material having a thickness of 9 mm was laminated to produce a floor material.

The following members were used to prepare the flooring material. Further, the arrangement order of the floor member components is the order described in the table. Nonwoven fabric (A): basis weight 210 g / m ² , thickness 2.8 mm, polyester fiber non-woven fabric Non-woven fabric (B): basis weight 140 g / m ² , thickness 2.0 mm, polyester fiber non-woven fabric reticulate body (A): Dainippon Plastic Co., Ltd., Netron DN-13 rhombic mesh, maximum diameter of warp and weft of 1.5 mm, mesh size: maximum inner dimension 8.1 mm, minimum inner dimension 2.5 mm, thickness 2.0 mm, basis weight 380 g / m ² , 25% compressive strength according to JIS-K-6767: 3.11 kg / cm ² Reticulate body (B): Dainippon Plastics Co., Ltd., Netron DN square mesh, maximum diameter of warp and weft 1. 6 mm, mesh size: inner size 9 mm, thickness 1.9 mm, basis weight 410 g / m ² , 25% compressive strength 0.3 kg / cm ² according to JIS-K-6767 T class fiber board: J Tatami board specified in IS A 5905 (thickness 10 mm, 15 mm) Polystyrene foam board: manufactured by Daicel Chemical Industries, Ltd., polystyrene board "Daicel foam" B1 (foaming ratio 35 times, density 30 kg / m ³ , thickness 25 mm, 40 mm ) Cloth: basis weight: 95 g / m ² , thickness: about 0.2 mm Comparative Example 1 As shown in the table, two non-woven fabrics (B) were bonded with an ethylene-vinyl acetate emulsion adhesive, and then ethylene- The vinyl acetate emulsion adhesive was used and laminated with the same wood board as in Example 1 to prepare a floor material.

Comparative Examples 2-3 As shown in Table 1, Example 1 was used without using a mesh.
A flooring material was prepared in the same manner as in.

The floor materials obtained in the examples and comparative examples were fixed to a 150 mm concrete slab on the surface of the polystyrene foam board with a rubber adhesive, and the lightweight impact sound and sink amount were measured, and the walking feeling was evaluated. did. In the floor material of Comparative Example 1, the non-woven fabric surface was fixed to the concrete slab using a rubber adhesive. Light Impact Sound: Light impact sound level (LL value) was measured according to JIS A-1418. Sinking amount: A sinking amount (mm) when a load of 80 kg was applied to a loading plate having a diameter of 50 mm for 30 seconds was measured. Walking sensation: The walking sensation on the floor surface by five panelists was rated according to the following criteria, and indicated as an average score.・ No sinking 4 points ・ Slightly fluffy 3 points ・ Fluffy 2 points ・ Very fluffy 1 point Thermal resistance: Calculate thermal resistance as reciprocal of thermal conductivity at 25 ℃ did.

[0053]

[Table 1] Example 7 With respect to the flooring material manufactured in Example 1, after applying a load of 80 kg to a loading plate having a diameter of 50 mm for 6 months and then once removing the load, the sinking amount was 2.1 mm,
The change in the amount of sink for 6 months was 0.2 mm. Also,
The lightweight impact sound level (LL value) was 45, and no change was observed with time. Comparative Example 4 The flooring material produced in Comparative Example 3 was subjected to a load of 80 mm on a loading plate having a diameter of 50 mm for 6 months in the same manner as in Example 7, and then the load was once removed to measure. Is 2.2 mm, and the change in the amount of subsidence during 6 months is 1.
4 mm. The light impact sound level (LL value) was 51, and the light impact sound level (LL value) was increased by "5". As is clear from comparison between Example 7 and Comparative Example 4, the flooring material of the present invention can suppress deterioration (settling) with time and maintain high sound insulation performance.

[Brief description of drawings]

FIG. 1 is a schematic sectional view showing an example of a flooring material of the present invention.

FIG. 2 is a schematic cross-sectional view showing another example of the flooring material of the present invention.

FIG. 3 is a schematic sectional view showing still another example of the flooring material of the present invention.

FIG. 4 is a schematic sectional view showing another example of the flooring material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Surface material 2 ... Back surface material 3 ... Intermediate layer (buffer layer) 4 ... Buffer material 5 ... Net body

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location B32B 5/02 B32B 5/02 5/18 5/18 E04F 15/02 0231-2E E04F 15/02 T

Claims (24)

[Claims] 1. A flooring in which at least one intermediate layer is disposed between a surface material and a backing material, said intermediate layer being a cushioning material and a net-like material which are at least substantially unconstrained from each other. A flooring material that is constructed in combination with the body. 2. The flooring material according to claim 1, wherein the intermediate layer is composed of a mesh body and a cushioning material provided on both surfaces of the mesh body. 3. A flooring material having a plurality of intermediate layers interposed between a surface material and a back surface material, wherein at least one of a fiber board and a closed cell foam is interposed between the plurality of intermediate layers. The flooring material according to item 1. 4. The floor according to any one of claims 1 to 3, wherein the cushioning material is a porous soft material having a sound deadening property, and the mesh body is a net in which warp thread elements and weft thread elements overlap each other at intersection points. Material. 5. The cushioning material is a non-woven fabric or a soft resin foam, and the reticulate body is an elastic or flexible net in which warp and weft elements overlap at intersections. Flooring. 6. The flooring material according to claim 1, wherein the reticulate body is formed of a polymer having elasticity or flexibility. 7. The flooring material according to claim 1, wherein the reticulate body is formed of rubber or olefin resin. 8. The flooring material according to any one of claims 1 to 3, wherein at least the surface layer of the surface material is constituted by a wood board material or a resin board material. 9. The floor according to any one of claims 1 to 3, wherein the surface material is composed of a laminate of a wood board material or a resin board material and a fiber board and / or a closed cell foam. Material. 10. The flooring material according to claim 1, wherein the backing material is composed of at least one of a fiber board and a closed cell foam. 11. The flooring material according to claim 1, wherein the backing material is composed of a laminate of a fiber board and a closed cell foam. 12. The flooring material according to claim 9, wherein the fiber board is a fiber board specified in JIS A 5905. 13. The flooring material according to claim 3, wherein the foam is a styrene resin foam. 14. The thickness of the floor material depends on the back surface material and is about 15 to.
The flooring material according to claim 1, which is adjustable to 200 mm. 15. The flooring material according to claim 1, wherein the backing material is grooved. 16. A flooring material in which an intermediate layer is interposed between a surface material containing a wood board material or a resin board material and a back surface material containing at least one of a fiber board and a styrene resin foam. The intermediate layer is composed of a combination of a net and a cushioning material that are substantially unrestrained from each other, and the net is a crossing point between a warp element and a weft element made of an elastic or flexible polymer. A flooring material that is composed of a net that overlaps with, and the cushioning material is composed of a non-woven fabric or a soft resin foam. 17. A flooring material which is composed of at least a substantially non-restraining combination of a cushioning material and a mesh, and which can be arranged between a surface material and a backing material constituting the flooring material. Buffer layer. 18. The cushioning material, wherein the intermediate layer is composed of cushioning materials disposed on both surfaces of the mesh body in a substantially unrestrained state.
7. The buffer layer for flooring according to 7. 19. A base material for a flooring, the surface material of which is stackable, the backing material being composed of at least one of a fiberboard and a closed cell foam, and at least substantially non-restraining cushions from each other. A base material in which an intermediate layer composed of a material and a mesh is laminated. 20. The base material according to claim 19, wherein the back surface material and the intermediate layer are sewn and integrated. 21. The base material according to claim 20, wherein a back surface material made of a foam material disposed on a sheet forming the back surface layer and an intermediate layer are sewn together. 22. An underlayer on which a backing material made of at least one of a fiber board and a closed-cell foam and an intermediate layer made of at least a combination of a cushioning material and a mesh are sewn and laminated. Method of manufacturing wood. 23. A backing material comprising a sheet, a fiber board and a closed cell foam, and at least the foam of the fiber board and the closed cell foam disposed on the sheet.
23. The method of manufacturing a base material according to claim 22, wherein the backing material is sewn with an intermediate layer which is disposed on the back surface material and which is composed of at least a cushioning material and a mesh. 24. A laminate for flooring, in which a backing material can be laminated, wherein the surface layer is composed of at least a wood-based board material or a resin-based board material, and at least a substantially unrestrained cushioning material. A laminate for a flooring material, in which an intermediate layer composed of a combination of a resin and a mesh is laminated.