JPH112019A - Backing material of floor and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a backing material of a floor as a directly laid raising material of low floor type and a manufacturing method of such backing material, with which it is possible to make uneveness pursuit for the surface of a floor base board having a comparatively small uneveness and to equip a good material characteristic and good processing and working characteristics as a floor backing material. SOLUTION: A mixture of inorganic powder and granular material and a thermosetting resin is applied on a flexible felt or sheet 11 to form a layer having an arbitrary thickness, or otherwise, the flexible felt or sheet 11 is placed on mixture formed by applying into a layer followed by a hot press molding, and thereby a plate is yielded in which the felt or sheet 11 is consolidated with inorganic material molded layer 12. A slit 13 is provided in this layer of the plate so that a backing material 1 of floor is completed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a base material for adjusting a floor height used when finishing a floor after raising a floor on an already constructed floor base.

[0002]

2. Description of the Related Art As a method of raising a floor on an already constructed floor base and then finishing the floor, a method of constructing a floor base again by forming a joist, a plate material such as a particle board, a steel plate or an aluminum plate A method of constructing a floor base with a double floor supporting the floor with legs, a method of applying mortar to a foamed resin plate, and the like are known. These are methods for constructing a floor by raising the horizontal level again on the floor base. Therefore, these methods are effective when the horizontal level of the floor base does not come out. When it is desired to raise the floor base or when the floor base itself has less unevenness and the horizontal level of the floor base itself is maintained, it is an excessive means and a simpler method is required. In such a case, a method of laying a board of an appropriate thickness on the floor base is conceivable, but even a floor base that seems to be relatively smooth often has a slight unevenness and can be used as a floor base When a plate having a high compression rigidity is placed, the disadvantage of rattling is inevitable. In addition, even if an attempt is made to use a flexible plate to suppress the rattling defect, the floor is naturally finished with a soft finish and walking feeling becomes a problem.

[0003]

SUMMARY OF THE INVENTION Accordingly, the present invention has an ability to follow a floor base having a relatively low level of unevenness in accordance with a floor base having a relatively low level of unevenness.
It is an object of the present invention to provide a low-floor-type floor base material having a construction characteristic, which is a material for directly placing and raising a floor, and a method of manufacturing the same.

[0004]

According to the present invention, there is provided (1) a mixture comprising an inorganic powdery material and a thermosetting resin on a flexible felt or sheet, which is sprayed or laminated to an arbitrary thickness. A flexible felt or sheet is placed on the mixture and hot-pressed to form a plate-like material in which the felt or sheet and the inorganic forming layer are integrated, and then a slit is formed in the inorganic forming layer of the plate-like material. (2) The floor base material according to the above (1), wherein:
Underfloor mixture of an inorganic powder and granular material and a thermosetting resin is from the specific surface area 2000cm ² / g~4000cm ² / g fly ash 95 to 80 parts by weight of the powdery phenolic resin 5 parts by weight to 20 parts by weight Ground material, (3) in the flooring material according to (1), the mixture comprising the inorganic powder and the thermosetting resin has a specific surface area of 2000 cm ² / g or more.
80 cm ^{2 to} 4000 cm ² / g fly ash
Parts by weight, particle size 0.5 mm to 5 mm, particle density 0.4 g /
cm ³ 50 to 20 parts by weight pumice ~0.7g / cm ^3, the underfloor member made of powdery phenolic resin 3 to 20 parts by weight, (4) inorganic powder flexible felt or sheet Spraying and laminating a mixture comprising granules and a thermosetting resin to an arbitrary thickness, or placing a flexible felt or sheet on the sprayed and laminating mixture and hot-press molding, and forming the felt or sheet and inorganic molding The present invention provides a method of manufacturing a floor base material, wherein a slit is formed in an inorganic molding layer of the plate-shaped material after the plate-shaped material is integrated with the layer.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. FIG. 1 is a schematic conceptual view of a floor base material 1 of the present invention. In the figure, reference numeral 11 denotes a flexible felt or sheet;
Is an inorganic molding layer obtained by solidifying the inorganic powder and thermosetting resin under heat and pressure. The inorganic molding layer is divided into small pieces by lattice-like slits 13, and each piece is held together by the flexible felt or sheet. The surface shape and size of each piece are not limited, and the slit may be a simple straight line or the like, but the shape surrounded by the slit is preferably a shape that is easy to process, such as a square, a rectangle, or a triangle. In this case, the size of each piece is preferably about 50 to 200 mm on one side. Slit width is 1
mm to 10 mm are preferred.

FIG. 2 is a cross-sectional view showing the construction of the floor base material according to the present invention. As shown in FIG. 2, for example, the floor base material 1 is placed on the floor base 4 with the inorganic molding layer 12 side being the floor base 4 side. The carpet base material 5 is laid on the floor base material 1 and the carpet 6 is laid thereon to form a floor. Since the floor base material 1 is provided with slits 13 in the inorganic molding layer 12 and cut into small pieces, irregularities of the floor base are absorbed as shown in the figure, so that there is play between the floor base and the floor base material. Does not occur. FIG. 2 shows a case where the surface of the flexible felt or the sheet 11 is directed upward, but the flexible felt or the sheet 11 may be arranged so as to be in contact with the floor base 4. On the other hand, as shown in FIG. 3, in the case of a conventional floor substrate using a simple
Cannot follow the uneven floor base 4, and a gap 8 occurs between the plate 7 and the floor base 4. In such a case, when walking just above the gap 8, a phenomenon such as sinking of the board occurs, so that not only the walking feeling becomes very unstable, but also it is not preferable in terms of safety. The flooring material of the present invention does not have such a problem.

The flexible felt or sheet 11 includes:
Sheets made of nonwoven fabric made of polyester, polypropylene, nylon, etc., glass cloth, paper, natural rubber, butyl rubber, foamed polyethylene, foamed polyurethane, vinyl chloride, coconut fiber and the like can be used. By using a flexible felt or sheet, in addition to the function of fastening the small pieces described above, there is a function of giving the brittle inorganic molding layer 12 the impact resistance required as the floor substrate 1. For this reason, it is not necessary to frequently use fiber reinforcement or resin which is commonly used, and a product can be obtained with a simple composition using a small amount of resin.

The inorganic powder particles used for the inorganic molding layer 12 include a particle size of 1 μm to 600 μm generally used as resin concrete or a thermosetting resin filler.
Natural sand such as river sand, sea sand, mountain sand, etc. Although it is possible to use them alone or in combination, a fly ash having a specific surface area in the range of 2000 to 4000 cm ² / g is particularly desirable. Fly ash is collected from the flue of coal-fired furnaces such as thermal power plants and has a bulk density of 0.8.
of ^{g / cm 3 ~1.3g / cm 3} , a powder comprising expanded particles in a part, even when used alone, a good cutting the underfloor member, even when used in combination with hard silica sand, etc. Give aptitude.

Further, as the coarse aggregate, it is also possible to use a lightweight aggregate such as a pumice, an anti-firestone, and a sintered expanded shale in combination with the above-mentioned filler. 0.5-5m particle size as lightweight aggregate
Yes m, particle density 0.4g / cm ³ ~0.7g / cm ³ of pumice (e.g. the Hokkaido Usu, Tarumai volcanic production, etc.) satisfies the compressive strength required as underfloor, substantially lower weight of It is particularly suitable when lightness is required. Furthermore, fly ash and pumice stone are mixed in a weight ratio of 80:20 to 5: 5.
By using the resin in the range of 0:50, the lightness and processability can be satisfied with a smaller amount of the resin, which is particularly desirable.

As the thermosetting resin, a phenol resin, an epoxy resin, and an unsaturated polyester resin can be used. However, from the viewpoint of reducing the odor of an organic solvent and formaldehyde remaining after molding, excellent cutting workability is required. From the viewpoint of giving, it is particularly desirable to use a powdery phenol resin. When a powdery phenolic resin is used, the resin fills the gaps of the inorganic particles in a foamed manner and forms a structure in which the inorganic particles are bonded by a foamed resin layer. In addition, the amount of the inorganic particles in the resin layer is reduced, and the cutting process is facilitated.

The mixing ratio of the thermosetting resin is in the range of 3 parts by weight to 20 parts by weight based on 100 parts by weight of the inorganic powder. If the amount of the resin is less than this range, the required strength properties will not be exhibited, and if the amount of the resin exceeds this range, it will be overspecified. In particular, when a powdery phenol resin is used, if the amount of the resin is too large with respect to the gap between the inorganic particles, the expansion ratio of the resin is reduced, and good cutting properties cannot be expected.

In producing the floor covering material of the present invention, the inorganic powder and the thermosetting resin are respectively weighed and dry-mixed using a powder mixing device such as a Nauta mixer or a ribbon mixer. To spray and stratify this mixture, use a powder feeder such as a belt feeder or vibration feeder,
It is possible to use a method in which the mixture is dropped and spread on a flexible felt or a sheet spread on a self-propelled mold, or a method in which the flexible felt or sheet is disposed on the mixture spread on a mold. In particular, a method is preferred in which the mixture is dropped and sprayed on a flexible felt or sheet previously laid using a belt feeder. The molding conditions for forming the flexible felt or sheet integrally with the inorganic layer formed by spraying and laminating are a pressure of 5 to 30 kg / cm ³ and a temperature of 100 to 100 kg / cm ³ .
It is preferable to perform the heat compression at 200 ° C. in a time zone in which the thermosetting resin is cured. As an effect of this heat molding, the production of a plate-like inorganic molding layer composed of a thermosetting resin and inorganic powder particles and the step of bonding with a flexible felt or sheet can be performed simultaneously, and Stronger adhesion between the two can be obtained by the heat fusion effect and the bonding force of the thermosetting resin. Further, by integrating with a flexible felt or sheet, it is possible to reinforce the bending strength of the inorganic material forming layer, thereby omitting a reinforcing material such as a reinforcing fiber. As a means for forming a slit, a circular saw such as a tip saw and a diamond saw used for woodworking and new building materials, or a cutting tool such as a router can be used. It is preferable to use a method in which the slits are continuously arranged in parallel and a plurality of slits are simultaneously formed.

Further, as a variation of the present invention, it is possible to attach a cushioning material of about 1 mm to several mm on the surface opposite to the plastic felt or the sheet. This has the effect of eliminating the possibility of floor noise occurring between the floor base and the floor base.

[0014]

【Example】

Example 1 As a flexible felt, a regular polyester short fiber (30 denier) having a basis weight of 700 g and a low melting point (11
(0 ° C.) A polyester nonwoven fabric (6 denier) of equal weight mixed cotton nonwoven fabric (manufactured by Dynic) is placed on a release sheet, and a novolak type phenol resin (NK-7001 manufactured by Nippon Steel Chemical Co., Ltd.) is placed thereon. Parts by weight, specific surface area 2500g
/ Cm ³ of the fly ash (manufactured by Tohoku Electric) 90 parts by weight was sprayed stratification at a rate of 13 kg / m ^2, is inserted into the hot press, pressure 20 kg / cm ^2, and pressing the heat for 15 minutes at a temperature 160 ° C.. The obtained molded plate has a thickness of 11 mm (inorganic molded layer 10 mm, felt 1 mm) and a density of 1.25 g / cm.
^3. Bending strength (load on felt) 150kgf / c
m ² . The bonding between the flexible felt and the inorganic molding layer was also sufficient. This molded plate is 50cm x 100
cm, and a grid-like slit was formed in the inorganic molding layer at a pitch of 10 cm from the opposite side of the flexible felt to produce a floor base material. When this floor base material is placed on the floor base with the felt surface facing upward, the small pieces are finished in the floor along the uneven surface of the floor by their own weight, so there is no rattling, and the upper surface is almost smooth by the felt. And wooden floors, carpets, etc. could be erected on it.

Example 2 As a flexible sheet, a plain woven glass cloth (manufactured by Kanebo) with a basis weight of 280 g was placed on a release sheet, and a novolak-type phenol resin (NK-700, manufactured by Nippon Steel Chemical Co., Ltd.) was placed thereon.
1) 90 parts by weight of fly ash (manufactured by Tohoku Electric Power Co., Ltd.) having a specific surface area of 2500 g / cm ^{3 and} a weight of 13 kg / m ² were sprinkled and stratified, inserted into a hot press, and subjected to a pressure of 20 kg.
/ Cm ^{2 at} a temperature of 160 ° C. for 15 minutes. The obtained molded plate has a thickness of 10.2 mm (inorganic molded layer 10 mm,
Glass cloth 0.2 mm), density 1.25 g / cm ³ ,
Flexural strength (load on glass cloth) 150kgf / cm
^2. Bending strength (glass cloth surface tension side) 300kgf
/ Cm ² . Further, the bonding between the glass cloth and the inorganic molding layer was also sufficient. This molded plate is 50cm x 1
It was cut into 00 cm, and a grid-like slit was formed at a pitch of 10 cm in the inorganic molding layer from the opposite side of the glass cloth to produce a floor base material. When this floor base material is placed on the floor base with the felt surface facing up, the small pieces will be finished on the floor along the uneven surface of the floor by their own weight, so there is no rattling,
Further, the upper surface was kept almost smooth by a glass cloth, and it was sufficiently possible to construct a wooden floor, a carpet, and the like thereon.

Example 3 As a flexible felt, a regular type polyester short fiber (30 denier) having a basis weight of 700 g and a low melting point (11
0 ° C) type polyester short fiber (6 denier) of equal weight mixed cotton nonwoven fabric (manufactured by Dynic) is placed on a release sheet, and a novolak type phenol resin (NK-7001 manufactured by Nippon Steel Chemical Co., Ltd.) is placed thereon. Parts by weight, specific surface area 2500 g /
56 parts by weight of fly ash (manufactured by Tohoku Electric Power Co.) of cm ³ , pumice with a particle size of 0.5 mm to 5 mm (from Usu Volcano, Hokkaido) 37
1 part by weight of the inorganic powder / particle / thermosetting resin mixture
Spraying was performed at a rate of 2.6 kg / m ² , inserted into a hot press, and hot-pressed at a pressure of 20 kg / cm ² and a temperature of 160 ° C. for 15 minutes. The obtained molded plate has a thickness of 15 mm (inorganic molded layer 14 mm, felt 1 mm) and a density of 0.88 g / c.
m ³ , bending strength (load on felt surface) 50kgf / cm
^{Was 2} . This molded plate was cut out to 50 cm × 100 cm, and the inorganic molded layer was cut from the opposite side of the flexible felt.
A flooring material was produced by inserting grid-shaped slits at a cm pitch. When this floor base material is placed on the floor base with the felt surface facing upward, the small pieces are finished in the floor along the uneven surface of the floor due to their own weight, so there is no rattling, and the upper surface is almost smooth by the felt. And wooden floors, carpets, etc. could be erected on it.

Comparative Example 1 Example 1 was repeated except that the flexible felt of Example 1 was omitted.
In the same manner as in the above, an inorganic molded plate was prepared. 50c of the board
When cut out to mx 100 cm and placed on the same floor base as in the example, rattling occurred before and after the plate.

[0018]

As described above, the floor base material of the present invention, by adopting the above configuration, can cope with a floor base having a relatively small unevenness, and has a non-following property on the base surface. At the same time, it is possible to provide a low-floor-type flooring material for direct mounting, which has excellent characteristics as a flooring material and has excellent characteristics and processing characteristics. In addition, the method for producing a floor base material of the present invention,
By adopting the above method, it is possible to reliably and easily manufacture the floor base material having the above excellent characteristics.

[Brief description of the drawings]

FIG. 1 is a schematic conceptual view of a floor base material of the present invention.

FIG. 2 is a cross-sectional view showing a construction state of a floor base material of the present invention.

FIG. 3 is a cross-sectional view showing a construction state of a conventional floor substrate.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Floor base material 11 Flexible felt or sheet 12 Inorganic molding layer 13 Slit 4 Floor base

Claims (4)

[Claims] 1. A mixture of an inorganic powdery material and a thermosetting resin is sprayed to a desired thickness on a flexible felt or sheet, or a flexible felt or sheet is spread on the spray-layered mixture. And then press-molded to form a plate-like material in which the felt or sheet and the inorganic molding layer are integrated, and then a slit is formed in the inorganic molding layer of the plate-like material. Flooring material. 2. The flooring material according to claim 1, wherein the mixture comprising the inorganic powder and the thermosetting resin has a specific surface area of 20%.
00cm ² / g~4000cm ² / fly ash 95 to 80 parts by weight of g, the underfloor member made of powdery phenolic resin 5 to 20 parts by weight. 3. The flooring material according to claim 1, wherein the mixture comprising the inorganic powder and the thermosetting resin has a specific surface area of 20%.
00cm ² / g~4000cm ² / fly ash 80 to 20 parts by weight of g, particle size 0.5 mm to 5 mm, pumice 50 particle density 0.4g / cm ³ ~0.7g / cm ³
A floor covering material comprising from 20 parts by weight to 20 parts by weight, and from 3 parts by weight to 20 parts by weight of a powdery phenol resin. 4. A flexible felt or sheet, wherein a mixture of inorganic powder and a thermosetting resin is sprayed and layered to an arbitrary thickness on the flexible felt or sheet, or the flexible felt or sheet is spread on the spray-layered mixture. A floor material, wherein the felt or sheet and the inorganic material layer are integrated into a plate-like material, and a slit is formed in the inorganic material layer of the plate-like material. Manufacturing method.