JP2003041755A - Floor material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material having superior damage resistance and high bending strength, showing a small dimension change caused by temperature and humidity changes, and suppressing abnormalities such as warpage, thrust, and crack of a surface finishing material as much as possible. SOLUTION: This floor material is formed by sticking the surface finishing material 2 to the surface of a base material 1. At least, a surface layer of the base material 1 is formed of a fiber plate layer 3 formed by thermoforming a long fiber mat, which is formed by orienting and gathering long fibers obtained from, at least, one of kenaf, oil palm, and coconut and dispersing adhesives thereto; and a powder layer 4 formed by thermoforming powder formed by sticking adhesive on its particle surface. The powder layer 4 is disposed on the surface side to be stuck to the surface finishing material 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flooring material used for a flooring finished floor, a step board of stairs, or the like.

[0002]

2. Description of the Related Art In the field of housing, flooring-finished wooden flooring materials have the advantages that they are easy to clean and maintain, and that they suppress the occurrence of mites, which is one of the causes of sick house syndrome. Therefore, the use is expanding rapidly mainly in multi-family houses.

[0003] In the case of wooden floor materials, the one in which a surface finishing material such as a veneer or a decorative sheet is adhered to the surface of a plate-shaped material serving as a substrate such as plywood has hitherto been the mainstream. The material does not have sufficient surface smoothness or surface hardness, and when the chair or furniture with casters is moved, the surface is scratched when a load that reciprocates against the floor material is applied, and the material has long-term damage. However, there is a drawback that the surface finishing material may peel off without being able to withstand the full use.

For this reason, in recent years, MDF (medium fiberboard) having a relatively high surface smoothness and surface hardness is formed as a surface reinforcing material between the surface finishing material and the plate-shaped material, so that scratch resistance is improved. A lot of flooring materials that are designed to improve

[0005]

However, the fiberboard such as MDF used for the flooring material having improved scratch resistance as described above generally has a small strength against a load such as bending and impact, and is used as a flooring material. There is a problem that it is necessary to thicken a plate-like material, which is a substrate such as plywood, to some extent in order to secure the strength. Further, since a fiberboard such as MDF generally has a larger change in length due to temperature change and humidity change in the room than plywood, a flooring material obtained by adhering a fiberboard such as MDF to a plate-like material serving as a substrate such as plywood is There is a problem that abnormalities may occur such as deformation such as warping or thrusting, and cracking of the surface finish material.

The present invention has been made in view of the above points and has excellent scratch resistance, high bending strength, small dimensional change due to temperature change and humidity change, and warpage, push-up, and cracks in surface finish materials. It is an object of the present invention to provide a flooring material that can suppress the occurrence of abnormalities such as the above.

[0007]

The flooring material according to claim 1 of the present invention is a flooring material formed by adhering a surface finishing material 2 to the surface of a base material 1, and at least a surface layer of the base material 1. To
Fiberboard layer 3 formed by orienting and assembling long fibers obtained from at least one of kenaf, oil palm, and coconut and thermocompressing a long fiber mat in which an adhesive is dispersed
And a powder layer 4 formed by thermocompressing a powder 5 having an adhesive attached to the particle surface, and the powder layer 4 is arranged on the surface side to which the surface finishing material 2 is bonded. It is characterized by being formed.

The invention of claim 2 is characterized in that, in claim 1, the base material 1 is formed by providing a fiber board layer 3 and a powder layer 5 on the surface of a plate-like substrate 6. It is what

According to a third aspect of the present invention, in the first aspect, the base material 1 is provided with the fiber board layers 3 on both surfaces of the plate-like substrate 6, and at least the surface finish material 2 is bonded to the fiber board. It is characterized in that it is formed by providing the powder layer 4 on the surface of the layer 3.

The invention according to claim 4 is the powder 5 for forming the powder layer 4 according to any one of claims 1 to 3,
It is characterized by being formed by using a powder containing cellulose as a main component.

Further, the invention of claim 5 is the powder 5 for forming the powder layer 4 according to any one of claims 1 to 3,
It is characterized by using a powder obtained by crushing at least one of kenaf, oil palm and coconut.

The invention of claim 6 is the powder 5 for forming the powder layer 4 according to any one of claims 1 to 5,
It is characterized by using powder having an average particle diameter of 500 μm or less.

According to a seventh aspect of the present invention, in any one of the first to sixth aspects, the powder layer 4 is formed by laminating a plurality of layers formed of powders 5 having different average particle sizes, It is characterized in that a layer made of powder having a small average particle size is arranged on the surface side to which the finishing material is adhered.

The invention of claim 8 is characterized in that, in any one of claims 1 to 7, the powder layer 4 has a layer thickness in the range of 0.1 to 1 mm.

According to a ninth aspect of the present invention, in any one of the first to eighth aspects, a melamine resin adhesive is used as an adhesive to be attached to the particle surface of the powder 5 forming the powder layer 4. It is a feature.

Further, the invention of claim 10 is based on claims 1 to 8.
In any one of the above, a synthetic rubber adhesive is used as the adhesive to be attached to the particle surface of the powder 5 forming the powder layer 4.

The invention of claim 11 relates to claims 1 to 1.
In any of 0, a synthetic rubber adhesive is used as an adhesive for adhering the surface finishing material 2 to the surface of the powder layer 4.

According to a twelfth aspect of the present invention, there is provided a method for producing a floor material, wherein in producing the floor material according to any one of the first to eleventh aspects, a length obtained from at least one of kenaf, oil palm and coconut palm is used. Characteristically characterized in that powder 5 having an adhesive attached to the particle surface is laminated on the surface of a long fiber mat in which the fibers are oriented and aggregated and the adhesive is dispersed, and the particles are thermocompressed to be integrated. It is what

The invention of claim 13 is characterized in that, in claim 12, the powder 5 is rubbed and laminated on the surface of the long fiber mat.

The invention according to claim 14 is the method according to claim 12 or 13, wherein the water content of the powder 5 having the adhesive adhered to the particle surface is adjusted to 30% by mass or less, and then the powder is formed on the surface of the long fiber mat. It is characterized in that a laminated body 5 is formed by thermocompression molding. .

According to the invention of claim 15, in any one of claims 12 to 14, the water content of the long fiber mat in which the adhesive is dispersed is adjusted to 30% by mass or less, and then the surface of the long fiber mat is powdered. It is characterized in that a laminated body 5 is formed by thermocompression molding.

According to a sixteenth aspect of the present invention, in any one of the twelfth to fifteenth aspects, the powder 5 is moved in the rotary container 7 while the powder 5 is sprayed with an adhesive.
An adhesive is attached to the surface of the particles of the powder 5.

The invention of claim 17 is characterized in that, in claim 16, the inside of the rotary container 7 is set to a high temperature atmosphere of 40 ° C. or higher.

According to the invention of claim 18, in any one of claims 12 to 15, the powder 5 is made to flow while the powder 5 is being flowed in the flow tank 8 set to a high temperature atmosphere of 40 ° C. or higher.
It is characterized in that an adhesive is sprayed on.

[0025]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below.

FIG. 1 shows an example of an embodiment of the invention of claim 1, in which long fibers obtained from at least one of kenaf, oil palm and coconut are oriented and aggregated, and an adhesive is dispersed. The fibrous plate layer 3 formed by thermocompression molding of the long fiber mat produced as described above and the powder layer 4 formed by thermocompression molding of powder having an adhesive on the particle surface are integrally bonded. By doing so, the base material 1 is produced, and the surface finishing material 2 is further adhered to the surface of the powder layer 4 of the base material 1 to form the floor material. Both ends of the floor material shown in FIG.

Here, kenaf is an annual herb,
It is cultivated mainly in China, Southeast Asia, etc., and long fibers can be easily obtained from the bast portion of kenaf by immersing it in water. Oil palm and coconut are cultivated in Malaysia, Indonesia, Philippines, etc.,
Fruit bodies called empty fruit clusters other than fruits used for oil extraction of palm oil, and petioles of oil palm are composed of long fibers. A long fiber can be easily obtained by adding a physical shearing treatment. Conventionally, these long fibers have been used as materials for grain bags and ropes, but recently they are being replaced by synthetic fibers, and the amount of waste is increasing at present. Therefore, by utilizing the long fibers obtained from these kenaf, oil palm and coconut, it is possible to reduce waste and at the same time save wood resources.

Then, a long fiber mat can be produced by assembling the long fibers obtained from these kenaf, oil palm and coconut in an oriented state and dispersing an adhesive therein. The fiberboard layer 3 can be formed by heating and pressurizing the long fiber mat to perform thermocompression molding.

The type of powder forming the powder layer 4 is not particularly limited, and inorganic powder or organic powder may be used as long as the surface smoothness and hardness of the floor material can be improved. It can be used regardless. The powder is mixed with an adhesive to adhere the adhesive to the particle surface of the powder, and the fiber board layer 3
The powder with the adhesive attached is laminated on the surface of, and heated and pressed to form a powder layer 4, thereby forming a powder layer 4 and adhering the powder layer 4 to the fiberboard layer 3 to form an integral body. It can be transformed into.

The type of adhesive used for molding the fiber board layer 3 and the powder layer 4 and the method of dispersing the adhesive in the long fiber mat or the powder are not particularly limited, but the type of adhesive is not limited. , For example, urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin,
Thermosetting resins such as urethane-based resins, furfural-based resins, and isocyanate-based resins that are heat-curable can be used. Further, as a pressing method at the time of thermocompression molding, there are a batch type flat plate press and a continuous press, but the pressing method is not particularly limited, and the pressing temperature, pressing time, pressing pressure, long fiber fine mat and powder The mass ratio of the adhesive and the like is appropriately set according to the type of adhesive used, the thickness of the fiberboard layer 3, the thickness of the powder layer 4, and the like.

In this way, the base material 1 in which the fiberboard layer 3 and the powder layer 4 are integrated is prepared, and the surface finishing material 2 made of a veneer or the like is formed on the surface of the powder layer 4 of the base material 1. A floor material can be obtained by bonding.

Here, the long fibers obtained from kenaf, oil palm, and coconut are approximately 2 to 14 as compared with the softwood fibers obtained from conifers and the hardwood fibers obtained from hardwoods.
Has twice the tensile strength. The fiber board layer 3 oriented so that the fiber length direction of the long fibers is oriented in a certain direction effectively utilizes the high tensile strength of the fiber itself by the orientation, and the bending strength and temperature change and It is extremely excellent against dimensional change due to humidity change, and therefore, it is possible to obtain a flooring material having excellent bending strength and excellent performance against dimensional change due to temperature change and humidity change.

That is, FIG. 4 schematically shows the structure of the fiberboard layer 3, in which the long fibers 10 are entwined in a state of being oriented in a fixed direction and are joined by an adhesive 11. Further, the rigidity against bending load such as the arrow, that is, the mechanical strength against bending deformation can be received by the tensile strength in the direction of arrow B, which is the orientation direction of the long fiber 10, and compared with other general plate-shaped materials. Therefore, high strength can be easily obtained. The strength of the fiberboard layer 3 is
Not only the strength of the long fibers 10 themselves, but also the entanglement of the long fibers 10 and the strength of the bonding portion between the long fibers 10 affect the long fibers 10. Since there are a lot of them, it is possible to further increase the strength by this entanglement, and since the number of bonded portions of the long fibers 10 per one fiber increases, it is possible to further increase the strength by this bonding. .

The cause of the length change, that is, the dimensional change of the floor material due to the temperature change and the humidity change is that the adsorption or desorption of water inside the constituent materials of the floor material and the voids is accompanied by the temperature change and the humidity change. This is because swelling or contraction occurs at that portion. However, the long fibers obtained from kenaf, oil palm, and coconut which compose the fiber board layer 3 of the present invention have extremely high crystallinity in the fiber direction and water infiltration. Is hardly generated, the change in length in the orientation direction is very small in the fiberboard layer 3 in which the long fibers are oriented. Further, in the fiberboard layer 3 formed of oriented long fibers, as described above, a large number of long fibers are entangled in the inside, so that the action of the entanglement causes the long fibers to extend in the direction orthogonal to the orientation direction of the long fibers. It is possible to reduce the change in length, and since there are many bonded parts with adhesive per long fiber, the effect of this bonding also changes the length in the direction orthogonal to the orientation direction of the long fiber. Can be made smaller. Therefore, in the fiberboard layer 3, the length change due to temperature change and humidity change becomes small in both the orientation direction of the long fibers and the direction orthogonal to the orientation direction, and the dimensional change due to temperature change and humidity change of the floor material is reduced. In addition, it is possible to obtain a flooring material in which deformation such as warping or thrusting up and occurrence of abnormalities such as cracks in the surface finish material 2 are suppressed as much as possible.

The length of the long fibers of the fiber board layer 3 is not particularly limited, but is preferably in the range of 100 to 4000 mm. By setting the fiber length of the long fibers within this range, there are many entanglements of the long fibers inside the fiberboard layer 3, and the number of long fibers to be bonded by the adhesive increases. It is possible to reduce the joint portion in the longitudinal direction of the
The effect of improving the strength against bending and suppressing the dimensional change due to temperature change and humidity change can be effectively obtained.

Here, as the fiberboard layer 3, it is possible to use a fiberboard layer 3 made of only long fibers oriented in substantially the same direction. Kenaf, oil palm, long fibers obtained from coconut, as described above, has a characteristic that it is excellent in tensile strength in the fiber direction, by aligning the long fibers in substantially the same direction, the orientation It is possible to take advantage of the excellent tensile strength of long fibers in the direction,
It is possible to obtain a high flexural rigidity of the flooring material, and in addition to such strength, it is possible to obtain a high level of excellent performance with respect to surface hardness and dimensional changes due to temperature changes and humidity changes.

The fiberboard layer 3 is formed by laminating layers in which long fibers are oriented in substantially the same direction so that the orientation directions of the long fibers are orthogonal to each other, and is formed from a plurality of fiber layers. It can also be used. By forming the fiberboard layer 3 in a multi-layer structure in which long fibers are oriented in two directions that are substantially orthogonal to each other, the tensile strength in the two directions in which the long fibers are oriented is high, and the bending rigidity is high in the two directions. Small fiberboard layer 3
Can be obtained. Therefore, the flooring material formed by using such a fiberboard layer 3 can have small anisotropy while maintaining excellent performance with respect to strength, surface hardness, dimensional change due to temperature change and humidity change. It is a thing.
The number of layers of long fibers constituting the fiberboard layer 3 and the thickness of each layer are not particularly limited, but in consideration of reduction of warpage of the fiberboard layer 3, the thickness direction of the fiberboard layer 3 is considered. It is preferable to have a laminated structure that is symmetrical with respect to the center of
It is also preferable to set the number of stacked layers to an odd number.

Further, as the fiber board layer 3, a knitted fabric in which long fiber threads are knitted, a woven fabric in which long fiber threads are knitted, or a long fiber assembly is subjected to needle punching or the like to entangle the long fibers with each other. It is possible to use the one formed from the combination. In this product, the entanglement of the long fibers becomes strong, and at the same time, the strength of the bonded portion of the long fibers is increased, the handleability becomes good, and the tensile strength of the long fibers can be further utilized, so that the fiber board The bending strength of the layer 3 can be further increased, and the change in length of the fiberboard layer 3 in the in-plane direction can be further suppressed. Therefore, the flooring material formed by using such a fiberboard layer 3 can have a small anisotropy while maintaining excellent performance with respect to strength, surface hardness, dimensional change due to temperature change and humidity change. It is a thing.

Further, in the flooring material of the present invention, the powder layer 4 is formed on the surface to be adhered to the surface finishing material 2, and the powder layer 4 makes it possible to increase the reciprocal load of the caster. It is possible to impart scratch resistance.

That is, when the reciprocating load of the casters is applied, the cause of the floor material being scratched or the surface finishing material 2 peeling off is that the material forming the surface portion of the floor material There are variations in the void structure of the plywood), the surface smoothness is low, the adhesive strength with the surface finish material locally decreases, and the strength and hardness of the constituent materials themselves are low. The powder layer 4 formed by thermocompression molding of the body has a dense structure with a small size of voids and a small variation, and has very good surface smoothness and high strength and hardness. Therefore, the surface finishing material 2
By forming the powder layer 4 on the surface to be adhered to, it is possible to enhance the scratch resistance of the floor material, and it is also possible to prevent peeling of the surface finish material 2.

Here, the density of the substrate 1 formed by the fiber board layer 3 and the powder layer 4 is not particularly limited, but is preferably set to 0.4 g / cm ³ or more,
It is more preferably 0.5 g / cm ³ or more. If the density of the base material 1 is less than 0.4 g / cm ³ , a large number of voids will be present on the surface and inside of the base material 1, and the adhesive strength with the surface finish material 2 may decrease. In addition, in the fiber board layer 3, the bonded portions and the entangled portions of the long fibers are reduced, which makes it difficult to sufficiently exhibit the high tensile strength characteristics originally possessed by the long fibers, and the bending strength may be reduced. .

FIG. 2 shows another example of the embodiment of the present invention. The fiberboard layer 3 and the powder layer 4 are adhered to one surface of the plate-like substrate 6 to prepare the base material 1. The floor material is formed by adhering the surface finishing material 2 to the surface of the powder layer 4 arranged on the surface side. A male seed 13 is provided on one end surface of the plate-like substrate 6, and a female seed 14 is provided on the other end surface thereof. In the flooring material thus formed, the surface of the plate-shaped substrate 6 has an increased surface hardness to improve scratch resistance, and a dimensional change due to a temperature change or a humidity change is reduced to suppress the occurrence of an abnormality. A fiberboard layer 3 and a powder layer 4 are provided. Therefore, it is possible to design a flooring material having excellent performance in scratch resistance, bending strength, and dimensional stability, even if a material having a lower strength and a lower cost than the fiber board layer 3 is used as the plate-shaped substrate 6. It is a thing.

FIG. 3 shows still another example of the embodiment of the present invention, in which fiber board layers 3 are adhered to both surfaces of the plate-like substrate 6, respectively, and at least one of both fiber board layers 3 is bonded. The base material 1 is produced by adhering the powder layer 4 and the flooring material is formed by adhering the surface finishing material 2 to the surface of the powder layer 4. In the flooring material thus formed in the sandwich structure, its mechanical strength depends more on the mechanical strength of the surface layers on both sides than on the inner layer, and the bending strength is determined by the fiberboard layer 3 of the surface layer. It is possible to obtain high dimensional stability against temperature changes and humidity changes. Moreover, since the structure of the floor material in the thickness direction is formed substantially symmetrically, it is possible to further suppress changes in the thickness direction such as warpage and push-up of the entire floor material, and a high surface as a floor material. While maintaining hardness in the powder layer 4, the fiberboard layer 3 exhibits high strength and dimensional stability against temperature changes and humidity changes, and the plate-shaped substrate 6 has a lower strength than the fiberboard layer 3 and is an inexpensive material. Even if you use, scratch resistance, bending strength,
It is possible to design a flooring material having excellent dimensional stability. In the flooring material having this sandwich structure, the weight ratio of the fiberboard layer 3 is 5 to 50.
It is preferably in the range of mass%, more preferably 10 to 4
The range of 0 mass% is desirable. Within this range, good mechanical strength characteristics can be easily obtained.

Here, as the plate-like substrate 6, a single plate made of softwood or hardwood, plywood, laminated boards such as LVL, wood boards such as wafer boards, OSB or particle boards, fiber boards such as MDF, rock wool boards. And the like, or fiber-reinforced plates in which these materials are combined with short fiber plates such as whiskers, and chemical-treated plates obtained by treating these materials with a resin or an inorganic material can be used.

In each of the above embodiments of the present invention, as the powder forming the powder layer 4, a powder containing cellulose as a main component can be used. Cellulose is the most major constituent of the stems and stems of plants such as woody plants, and when powders containing such cellulose as the main component are used, kenaf, oil palm, and coconut long The adhesiveness to the fiberboard layer 3 made of fibers is improved, and while the fiberboard layer 3 maintains high strength as a flooring material, it is possible to easily obtain a flooring material having a woody texture such as flooring. Is something that can be done. In addition, powder containing cellulose as the main component, compared to proteins and starch,
It is an excellent material for the flooring material because it is not rotted, has little damage by insects and microorganisms, and has little deterioration over time. Examples of such a powder containing cellulose as a main component include wood powder obtained by crushing the woody part of a woody plant. Woody plants include hardwoods and conifers,
It is not particularly limited. A large amount of wood powder is discharged during the lumbering process, and most of it is discarded, but this can be effectively utilized.

As the powder containing cellulose as a main component, a powder obtained by crushing at least one of kenaf, oil palm and coconut can be used. This powder is
For example, it can be obtained by crushing the end material of the fiberboard layer 3 produced using long fibers obtained from kenaf, oil palm, or coconut, or the core portion obtained by removing the bast portion from the kenaf stem. Most of these are discarded, but they can be effectively used. This powder has good adhesiveness to the fiberboard layer 3, and while maintaining high strength as a flooring material in the fiberboard layer 3, the powder layer 4 made of kenaf, oil palm, or coconut powder ,
It is possible to obtain a flooring material having extremely excellent performance against changes in length due to changes in temperature and humidity.

The powder constituting the powder layer 4 preferably has a particle size of 500 μm or less. In this way, the particle size is 50
By forming the powder layer 4 on the surface of the fiberboard layer 3 using a small powder of 0 μm or less, it is possible to obtain the powder layer 4 having a dense structure with small size and variation of voids,
It has a high surface smoothness and can give a floor material high scratch resistance against reciprocating load of casters.
The lower limit of the particle size of the powder is not particularly set, but about 20 μm is the lower limit of the particle size because of easy availability.

Further, the powder layer 4 can be formed not only in a single layer structure but also in a multi-layer structure in which a plurality of layers are laminated.
In this case, each layer is composed of powders having different particle diameters, and the layers of the powder having a larger particle diameter are laminated on the surface of the fiberboard layer 3 in this order from the layer of the powder having a smaller particle diameter, The powder layer 4 is formed, and the powder layer having the smallest particle size is arranged on the surface to which the surface finishing material 2 is bonded. In this way, by forming the powder layer 4 so that the particle size of the powder on the side to which the surface finishing material 2 is adhered becomes small, the surface of the powder layer 4 is formed with a small size of voids and a small variation. The fiber can be formed into a structure, the surface smoothness can be further enhanced, and the particle size of the powder on the side in contact with the fiberboard layer 3 is large. The powder of the layer 4 is easily entangled, and the fiberboard layer 3
The adhesiveness between the powder layer 4 and the powder layer 4 is improved. As a result, it becomes possible to obtain a floor material having further improved scratch resistance and bending performance. Further, when the powder layer 4 is formed by laminating the powder on the fiber board layer 3 and then thermocompressing it, the powder in contact with the fiber board layer 3 has a large particle size, so that the long fibers of the fiber board layer 3 are It is possible to prevent the powder from dropping excessively in the meantime.

In each of the above-mentioned embodiments, the layer thickness of the powder layer 4 is preferably set in the range of 0.1 to 1 mm.
By setting the layer thickness of the powder layer 4 in this range, it is possible to stably produce a floor material having high surface smoothness and hardness in any portion, and caster can be used in any portion of the floor material. It is possible to stably impart high scratch resistance against the reciprocating load of the above.

As described above, the powder layer 4 is formed by thermocompressing a powder having an adhesive attached to the particle surface. As an adhesive to be attached to the particle surface of the powder,
A melamine resin adhesive can be used. The melamine-based resin adhesive is excellent in adhesiveness and water resistance, and can increase the strength of the powder layer 4 and reduce the dimensional change of the powder layer 4 due to humidity change. is there. Therefore, it becomes possible to obtain a flooring material having further excellent bending performance, scratch resistance, and crack resistance.

Further, a synthetic rubber adhesive may be used as the adhesive to be attached to the surface of the powder particles. As a synthetic rubber adhesive, styrene-butadiene rubber (S
Examples of the adhesive include synthetic rubber components such as BR type), butadiene rubber type, chloroprene rubber type, nitrile rubber type, and silicone rubber type. Since these synthetic rubber adhesives have high viscosity as an adhesive component, they have little penetration into the interior of the material when they are applied and attached.
Further, it has an appropriate elasticity even after adhesion. Therefore, the adhesive component of the adhesive that effectively adheres to the surface of the powder particles can form the powder layer 4 while filling the voids between the powder particles during thermocompression molding. The unevenness due to the voids is extremely small, and the powder layer 4 having very good surface smoothness can be formed, and the powder layer 4 as a whole has appropriate elasticity and is excellent in deformation followability. Becomes Therefore, when a reciprocating load of the casters is applied from above the surface finish material 2, the surface finish material 2 becomes more difficult to peel off, and extremely high scratch resistance can be imparted.

In each of the above embodiments, when the surface finishing material 2 is adhered to the surface of the powder layer 4, a synthetic rubber adhesive is used as an adhesive agent for adhering the powder layer 4 and the surface finishing material 2. Can be used. As the synthetic rubber adhesive, those mentioned above can be exemplified, and this synthetic rubber adhesive has an appropriate elasticity as described above. Therefore, an adhesive layer having elasticity can be present between the powder layer 4 and the surface finishing material 2, and when a reciprocating load of the caster acts on the surface finishing material 2, the adhesive layer can follow the deformation followability. The surface finish 2 becomes more difficult to peel off, and very high scratch resistance can be imparted.

In producing the above flooring material, long fibers obtained from kenaf, oil palm, and coconut are oriented and aggregated, and an adhesive is dispersed to prepare a long fiber mat, and the adhesive is attached to the particle surface. By laminating the powder thus obtained on the surface of the long fiber mat and thermocompressing it, the fiber board layer 3 is formed from the long fiber mat and the powder layer 4 is formed from the powder, and at the same time, the fiber board is formed. The base material 1 may be produced by integrally bonding the layer 3 and the powder layer 4. By molding and integrating the fiber board layer 3 and the powder layer 4 by the same thermocompression molding as described above, the base material 1 is absorbed while absorbing irregularities at the interface between the fiber board layer 3 and the powder layer 4.
It is possible to form a floor material, which has high strength, surface smoothness and hardness, and further has high dimensional stability against temperature and humidity changes, which is obtained by the fiber board layer 3 and the powder layer 4. It can be manufactured.

As described above, when laminating the powder having the particle surface with the adhesive on the surface of the long fiber mat, the powder is rubbed on the surface of the long fiber mat to be laminated, and then thermocompression molding is performed. You may do it. The method of rubbing the powder is not particularly limited, and examples thereof include a method using a brush or a roll. By rubbing the powder on the surface of the long fiber mat in this way, the powder enters the gaps between the long fibers, and the interface between the fiberboard layer 3 and the powder layer 4 obtained by thermocompression molding is further complicated. It is possible to increase the adhesive strength between the fiberboard layer 3 and the powder layer 4, and thus it is possible to easily manufacture a flooring material having further improved performance such as bending strength. It is a thing.

In addition, when the powder with the adhesive attached to the surface of the particles is laminated on the surface of the long fiber mat and thermocompression molding is performed, the water content of the powder with the adhesive attached is 3
After the content is adjusted to 0% by mass or less, the powder may be laminated on the surface of the long fiber mat for thermocompression molding.
By adjusting the water content of the powder to which the adhesive is adhered to 30% by mass or less, it is possible to reduce the generation of moisture vapor during thermocompression molding, and the bubbles generate powder when the vapor is generated. It is possible to suppress generation in the layer 4, and it is possible to further improve the surface smoothness of the powder layer 4. As a result, it becomes possible to obtain a flooring material that has a higher scratch resistance against the reciprocating load of the casters. The method of adjusting the water content is not particularly limited, but it can be performed by heating at a temperature not higher than the curing temperature of the adhesive adhered to the powder. The lower the water content of the powder to which the adhesive is attached, the more preferable. The lower limit is not particularly set, but about 5% by mass is the practical lower limit.

Further, when the powder is laminated on the surface of the long fiber mat in which the adhesive is dispersed as described above and the thermocompression molding is performed, the water content of the long fiber mat in which the adhesive is dispersed is 30% by mass. After making the following adjustments, the powder can be laminated on the surface of the long fiber mat and subjected to thermocompression molding. By adjusting the water content of the long-fiber mat in which the adhesive is dispersed to 30% by mass or less, it is possible to reduce the generation of moisture vapor during thermocompression molding, and to generate bubbles when the vapor is generated. It is possible to suppress the generation in the body layer 4, and it is possible to further improve the surface smoothness of the powder layer 4. As a result, it becomes possible to obtain a flooring material that has a higher scratch resistance against the reciprocating load of the casters. The method of adjusting the water content is not particularly limited, but it can be performed by heating at a temperature not higher than the curing temperature of the adhesive dispersed in the long fiber mat. The lower the water content of the long fiber mat to which the adhesive is attached, the more preferable, and the lower limit is not particularly set,
The practical lower limit is about 5% by mass. Further, the adjustment of the water content of the powder and the adjustment of the water content of the long fiber mat may be performed separately, or may be performed simultaneously after the powder is laminated on the long fiber mat.

When the adhesive 9 is adhered to the particle surface of the powder 5, the powder 5 is put into the rotary container 7 as shown in FIG.
By spraying the adhesive 9 on the surface of the powder 5, the adhesive 9 can be attached to the particle surface of the powder 5. The rotary container 7 is formed of a cylindrical drum, and the rotary shaft is arranged laterally so as to be driven to rotate in the vertical direction as indicated by the arrow. A spray window 16 is opened in the center of the side end surface of the rotary container 7, and a spray device 17 is arranged outside the spray window 16. And the rotating container 7
By pouring the powder 5 into the inside of the rotary container 7 and rotating the rotary container 7 in the vertical direction, the powder 5 is stirred in the rotary container 7, and the adhesive 9 is passed from the spray device 17 through the spray window 16.
When sprayed with, the powder 5 moving evenly in the rotary container 7 and the mist of the adhesive efficiently come into contact with each other, and the adhesive can be evenly attached to the particle surface of the powder 5. is there. By thus uniformly adhering the adhesive to the particle surface of the powder 5, it is possible to easily manufacture the flooring material having the above-mentioned excellent performance.

Here, in spraying the adhesive 9 on the powder 5 while rotating the rotating container 7 as described above, the inside of the rotating container 7 is set to a high temperature atmosphere of 40 ° C. or higher, and the inside of this high temperature atmosphere is set. It is preferable to spray the adhesive 9 on the powder 5 of FIG. By thus setting the inside of the rotary container 7 at a high temperature of 40 ° C. or higher, the adhesive can be uniformly attached to the particle surfaces of the powder 5, and at the same time, the water content of the powder 5 can be adjusted. Can be performed, and the process can be simplified. Therefore, it is possible to easily manufacture a flooring material having excellent performance as described above. The atmosphere temperature in the rotary container 7 is not particularly limited as long as it is 40 ° C. or higher, but it is preferable to adjust the temperature below the curing temperature of the adhesive 9 used.

Further, in the embodiment shown in FIG. 6, the adhesive 5 is sprayed on the powder 5 while flowing the powder 5 in the flow tank 8 set to a high temperature atmosphere of 40 ° C. or higher, The adhesive 9 is made to adhere to the surface of the particles 5. Flow tank 8
Air such as warm air flows from the lower surface as indicated by the arrow, and the powder 5 supplied into the fluid tank 8 flows while floating in the fluid tank 8 as indicated by the arrow. Also fluid tank 8
A spray device 17 is arranged in the upper part of the. Then, when the adhesive 9 is sprayed from the spraying device 17 while the powder 5 is put into the fluid tank 8 to be fluidized, the powder 5 and the adhesive mist that are moving evenly in the fluid tank 8 are efficiently generated. And the adhesive can be evenly attached to the particle surfaces of the powder 5. Further, the powder 5 can be dried at both an ambient temperature of 40 ° C. or higher and the fluidizing air flow in the fluidizing tank 8 to adjust the water content, which can simplify the process. Is. Therefore, it is possible to easily manufacture a flooring material having excellent performance as described above. The atmosphere temperature in the flow tank 8 is not particularly limited as long as it is 40 ° C. or higher, but it is preferable to adjust the temperature below the curing temperature of the adhesive 9 used. The velocity of the air for fluidization is appropriately selected according to the type and particle size of the powder 5 used.

[0060]

EXAMPLES Next, the present invention will be specifically described with reference to examples.

(Example 1) A long fiber mat was prepared by orienting kenaf filaments in one direction and assembling them, and by uniformly dispersing and adhering 15% by mass of a phenolic resin adhesive to the kenaf filament at a temperature of 155. The fiberboard layer 3 having a density of 750 kg / m ³ and a thickness of 1.6 mm was produced by thermocompression molding under the conditions of ° C, pressure 3 MPa, time 2 minutes. This fiberboard layer 3
On top of that, a silica powder having an average particle size of 550 μm, which is obtained by uniformly dispersing and adhering 15% by mass of a phenol resin adhesive, is laminated, and this is hot pressed under the conditions of temperature 155 ° C., pressure 3 MPa, time 1 minute By molding, the powder layer 4 having a thickness of 1.1 mm is laminated and integrated on the surface of the fiberboard layer 3 to have a density of 800.
kg / m ^3, to prepare a substrate 1 having a thickness of 2.7 mm. Then, a phenol resin adhesive is applied to the surface of the powder layer 4 of the base material 1 and the surface finishing material 2 made of a veneer having a thickness of 0.3 mm is adhered to the surface of the powder layer 4 as shown in FIG. I got the floor material. Both ends of this floor material were finished by processing a real part 12 having a cutout shape.

(Example 2) Density 600 as the plate-like substrate 6
Example 1 using a lauan plywood of kg / m ³ and a thickness of 9 mm
In the same manner as described above, a laminated body having a density of 800 kg / m ³ and a thickness of 2.7 mm produced by laminating and integrating the powder layer 4 on the surface of the fiber board layer 3 is formed on the plate-shaped substrate 6 with a phenol resin adhesive. The base material 1 was produced by bonding. Further, by adhering the surface finishing material 2 made of a veneer having a thickness of 0.3 mm to the surface of the powder layer 4 with a phenolic resin adhesive, a thickness of 12 mm is obtained.
A floor material as shown in FIG. 2 was obtained. 1 male on both ends of this flooring
3 and female 14 were processed and finished.

Example 3 A long fiber mat was prepared by orienting and collecting kenaf filaments in one direction and uniformly dispersing and adhering 15% by mass of a phenolic resin adhesive to the kenaf filament at a temperature of 155. The fiberboard layer 3 having a density of 800 kg / m ³ and a thickness of 1.6 mm was produced by thermocompression molding under the conditions of ° C, pressure 3 MPa, time 2 minutes. Next, the plate-shaped substrate 6
As the lauan plywood having a density of 600 kg / m ³ and a thickness of 7.4 mm, the fiberboard layer 3 was bonded to both surfaces of the plate-shaped substrate 6 with a phenolic resin adhesive. Further, a silica powder having an average particle size of 550 μm, in which 15% by mass of a phenol resin adhesive is uniformly dispersed and adhered, is laminated on the surface of one fiber board layer 3, and this is laminated at a temperature of 155 ° C. and a pressure of 3 MPa,
Base material 1 having a density of 670 kg / m ³ and a thickness of 11.7 mm, in which a powder layer 4 having a thickness of 1.1 mm is laminated and integrated on the surface of the fiber board layer 3 by thermocompression molding under the condition of a time of 1 minute. Was formed. Then, a surface finishing material 2 made of a veneer having a thickness of 0.3 mm was adhered to the surface of the powder layer 4 with a phenolic resin adhesive to obtain a floor material having a thickness of 12 mm as shown in FIG. Male and female seeds 13 and 14 were processed and finished on both ends of this floor material.

(Embodiment 4) The plate-shaped substrate 6 has a density of 570.
kg / m ^3, with softwood plywood thickness 9 mm, also other was to use a hemlock powder having an average particle size of 550μm as powder, to obtain a floor material, such as in FIG. 2 in the same manner as in Example 2 It was

(Example 5) Powder having an average particle size of 550 μm
Example 4 except that the kenaf crushed powder of m was used.
A floor material as shown in Fig. 2 was obtained in the same manner as in.

(Example 6) As a powder, the average particle size is 300μ.
A flooring material as shown in FIG. 2 was obtained in the same manner as in Example 4, except that the mung beetle powder of m was used.

Example 7 As a powder, the average particle size is 300 μ
m powder and powdered hemlock powder having an average particle size of 550 μm at a mass ratio of 2: 3, and the latter is laminated on the fiberboard layer 3 so that the latter is on the lower side and the former is on the upper side. A flooring material as shown in FIG. 2 was obtained in the same manner as in Example 4 except that molding was performed.

(Embodiment 8) The thickness of the powder layer 4 is 0.6 mm.
2A and 2B in the same manner as in Example 6 except that it is formed in FIG.
Got the flooring like.

(Example 9) A floor material as shown in Fig. 2 was obtained in the same manner as in Example 8 except that a melamine resin adhesive was used as the adhesive to be attached to the powder.

Example 10 Example 8 was repeated except that an SBR adhesive was used as the adhesive to be attached to the powder.
A floor material as shown in Fig. 2 was obtained in the same manner as in.

(Embodiment 11) Surface finishing material 2 on powder layer 4
A floor material as shown in FIG. 2 was obtained in the same manner as in Example 9 except that the SBR adhesive was used as the adhesive for adhering.

(Example 12) The kenaf filaments were oriented in one direction to be aggregated, and the phenol resin adhesive was used in 15 parts.
A long fiber mat was prepared by uniformly dispersing and adhering the same by mass%. On this long-fiber mat, a melamine resin-based adhesive was uniformly dispersed in an amount of 15% by mass, and a Batsuga powder having an average particle diameter of 300 μm was laminated thereon.
The powder layer 4 having a thickness of 0.6 mm was laminated and integrated on the surface of the fiber board layer 3 having a thickness of 2.1 mm by thermocompression molding under the conditions of 55 ° C., pressure 3 MPa and time 2 minutes. 2.7
The base material 1 of mm was produced. And the powder layer 4 of this base material 1
The surface finishing material 2 made of a veneer having a thickness of 0.3 mm is adhered to the surface of the SBR adhesive with a thickness of 3 m.
A floor material as shown in FIG. Both ends of this floor material were finished by processing a real part 12 having a cutout shape.

(Example 13) A flooring material as shown in Fig. 1 was obtained in the same manner as in Example 12 except that the Betuga powder was laminated on the long fiber mat while rubbing it with a spatula.

(Example 14) The kenaf filaments were oriented in one direction to be aggregated, and the phenol resin adhesive was used in 15 parts.
A long fiber mat was prepared by uniformly dispersing and adhering the same by mass%. On this long-fiber mat, 15% by mass of a melamine resin-based adhesive was uniformly dispersed and adhered, and then a Betuga powder having an average particle diameter of 300 μm, the water content of which was adjusted to 10% by mass, was laminated, and the temperature was adjusted to the temperature. 155 ℃, pressure 3MP
a, a powder layer 4 having a thickness of 0.6 mm is laminated and integrated on the surface of a fiber board layer 3 having a thickness of 2.1 mm by thermocompression molding under a condition of time of 3 minutes, density 800 kg / m ³ , A laminated body having a thickness of 2.7 mm was produced. Next, as the plate-like substrate 6, a coniferous wood plywood having a density of 570 kg / m ³ and a thickness of 9 mm was used, and the above laminated body was adhered thereon with a phenolic resin to prepare the base material 1, and further the powder layer 4 Surface finish 2 consisting of a 0.3 mm thick veneer with SBR adhesive on the surface
Was adhered to obtain a floor material having a thickness of 12 mm as shown in FIG. Fits both male and female 12 and 1 on both ends of this flooring
3 was processed and finished.

(Example 15) Moisture content of a long fiber mat of 10
A flooring material as shown in FIG. 2 was obtained in the same manner as in Example 14 except that the flooring material was adjusted to be used by mass%.

(Example 16) The Batsuga powder 5 having an average particle size of 300 µm was charged into the rotary container 7 shown in Fig. 5, the temperature in the rotary container 7 was set to 30 ° C, and the rotary container 7 was set to 2 ° C.
The melamine-based resin adhesive was sprayed while rotating at 7 rpm so that the powder 5 was evenly attached in an amount of 15% by mass. A floor material as shown in FIG. 2 was obtained in the same manner as in Example 15 except for the above.

(Embodiment 17) The temperature in the rotary container 7 is adjusted to 60
A flooring material as shown in Fig. 2 was obtained in the same manner as in Example 16 except that the temperature was set at ° C.

(Embodiment 18) Betuga powder 5 having an average particle diameter of 300 μm is put into the fluid tank 8 shown in FIG.
4. Set the internal temperature to 60 ° C and fluidize air velocity 5.
While flowing the powder 5 under the condition of 0 m / s, the melamine-based resin adhesive was sprayed so that the powder 5 was uniformly attached in an amount of 15% by mass. A floor material as shown in FIG. 2 was obtained in the same manner as in Example 15 except for the above.

(Comparative Example 1) A 0.3 mm thick veneer is bonded to the surface of an MDF having a density of 750 kg / m ³ and a thickness of 2.7 mm with a phenolic resin adhesive, as shown in FIG. The floor material of the structure was obtained. Both ends of this floor material were processed and finished with mating and chipped real parts 12.

(Comparative Example 2) A 0.3 mm-thick veneer is bonded to the surface of a lauan plywood having a density of 600 kg / m ³ and a thickness of 2.7 mm with a phenolic resin adhesive to produce a resin as shown in FIG. A floor material with a different structure was obtained. Both ends of this floor material were processed and finished with mating and chipped real parts 12.

(Comparative Example 3) By laminating a 0.3 mm thick veneer with a phenolic resin adhesive on the surface of a lauan plywood having a density of 600 kg / m ³ and a thickness of 11.7 mm, as shown in FIG. A floor material with a different structure was obtained. Male and female seeds 13 and 14 were processed and finished on both ends of this floor material.

(Comparative Example 4) By bonding a veneer having a thickness of 0.3 mm to the surface of a softwood plywood having a density of 600 kg / m ³ and a thickness of 11.7 mm with a phenolic resin adhesive, as shown in FIG. A floor material with a different structure was obtained. Male and female seeds 13 and 14 were processed and finished on both ends of this floor material.

(Comparative Example 5) A 2.7 mm thick MDF was adhered to the surface of a lauan plywood having a density of 600 kg / m ³ and a thickness of 9 mm with a phenolic resin adhesive, and a thickness of 0.3 mm was formed on the surface of the MDF. The flooring material having a structure as shown in FIG. 2 was obtained by adhering the veneer plate with a phenol resin adhesive.
Male and female seeds 13 and 14 were processed and finished on both ends of this floor material.

(Comparative Example 6) 2.7 mm thick MDF was adhered to the surface of a softwood plywood having a density of 570 kg / m ³ and a thickness of 9 mm with a phenolic resin adhesive, and the surface of this MDF was 0.3 mm thick. The flooring material having a structure as shown in FIG. 2 was obtained by adhering the veneer plate with a phenol resin adhesive.
Male and female seeds 13 and 14 were processed and finished on both ends of this floor material.

Table 1 shows the construction and manufacturing conditions of the flooring materials in Examples 1 to 18 and Comparative Examples 1 to 6 and the performance evaluation results of the obtained flooring materials.

[0086]

[Table 1]

In Table 1, the equivalent bending Young's modulus (the bending Young's modulus when the entire flooring was assumed to have a homogeneous structure) was used as an index showing the strength of the flooring. As an index showing the surface hardness, the amount of hard ball compression dents (the amount of dents when a load of 300 N is applied to the floor material surface by hard balls having a diameter of 10 mm) is used, and as an index showing the surface smoothness, the caster resistance (diameter 50 mm) The number of times until the surface finish material peeled when the caster was moved on the surface of the floor material at a speed of 20 reciprocations / minute under a load of 250 N) was used. Further, as an index showing length change (dimensional change), a cold B test specified by JAS (special plywood) was performed, and the rate of length change after the test was used.

As can be seen from Table 1, each of the examples has excellent performance with respect to the comparative example having the same thickness.

[0089]

As described above, the flooring material according to claim 1 of the present invention is a flooring material formed by adhering a surface finishing material to the surface of a base material. ,
Adhesive is attached to the fiberboard layer formed by thermocompressing a long fiber mat in which the long fibers obtained from at least one of oil palm and coconut are oriented and aggregated and the adhesive is dispersed, and the particle surface The powder layer is formed by thermo-pressing the powder that has been formed, and the powder layer is placed on the surface side that is bonded to the surface finish material, so the orientation of kenaf, oil palm, and coconut The fiberboard layer formed of the long fibers can provide excellent bending strength and dimensional stability against temperature and humidity changes, and the powder layer with a dense structure provides good surface smoothness. It has excellent scratch resistance, high bending strength, small dimensional change due to temperature change and humidity change, and can suppress abnormal occurrences such as warpage, push-up and cracks of surface finish materials as much as possible. It is capable of providing that flooring.

Further, in the invention of claim 2 according to claim 1, the base material is formed by providing the fiber board layer and the powder layer on the surface of the plate-like substrate, and therefore the fiber board layer is excellent. It is possible to obtain excellent bending stability and dimensional stability against temperature changes and humidity changes, and to obtain good surface smoothness due to the powder layer. It is possible to provide a flooring material having high scratch resistance, bending strength, and dimensional stability even if an inexpensive material smaller than the layer is used.

According to a third aspect of the present invention, in the first aspect, the base material is provided with fibrous board layers on both surfaces of the plate-like substrate, and at least the surface of the fibrous board layer to which the surface finishing material is adhered is provided. Since it is formed by providing a powder layer, the fiberboard layer provides excellent bending strength and excellent dimensional stability against temperature and humidity changes, and the powder layer provides a good surface smoothness. It is possible to provide a flooring material having high scratch resistance, flexural strength, and dimensional stability even if an inexpensive material having a lower strength than the fiber board layer is used as the plate-shaped substrate. Yes, in particular, by providing fiberboard layers on both sides of the plate-like substrate, the structure of the floor material in the thickness direction can be formed substantially symmetrically, further suppressing changes such as warpage and push-up of the entire floor material. Is something that can

According to the invention of claim 4, in any one of claims 1 to 3, the powder containing cellulose as a main component is used as the powder forming the powder layer. It is possible to obtain high adhesion of the powder layer,
Further, it is possible to provide a flooring material having a high wooden texture as a flooring.

The invention according to claim 5 is the powder according to any one of claims 1 to 3, which is obtained by crushing at least one of kenaf, oil palm and coconut as the powder forming the powder layer. Since it was used, while maintaining performance such as strength as a floor material in the fiberboard layer, kenaf, oil palm,
With the powder layer made of coconut powder, it is possible to obtain a flooring material having high dimensional stability against temperature changes and humidity changes.

Further, according to the invention of claim 6, a powder having an average particle diameter of 500 μm or less is used as the powder forming the powder layer, so that the fine powder layer having a small size and variation of voids is obtained. Can be formed, the surface smoothness of the surface of the powder layer can be enhanced, and the scratch resistance against reciprocating load of the caster can be further improved.

According to a seventh aspect of the present invention, in any one of the first to sixth aspects, the powder layer is formed by laminating a plurality of layers made of powder having different average particle diameters, Since a layer made of powder with a small average particle size is arranged on the surface side to which is adhered, it is possible to form the surface of the powder layer into a dense structure with a small size and variation of voids, and to provide a smooth surface. It is possible to further enhance the sex,
The powder having a large particle size on the side in contact with the fiberboard layer facilitates the entanglement of the powdery layer with respect to the fiberboard layer, thereby improving the adhesiveness between the fiberboard layer and the powder layer. Further, when the powder is laminated on the fiberboard layer and then thermocompression-molded to form the powder layer, since the powder contacting the fiberboard layer has a large particle size, the powder is placed between the long fibers of the fiberboard layer. Can be prevented from dropping excessively.

Further, according to the invention of claim 8, in any one of claims 1 to 7, since the layer thickness of the powder layer is in the range of 0.1 to 1 mm, the surface smoothness and hardness are high in any part. The powder layer can be stably formed.

According to the ninth aspect of the invention, in any one of the first to eighth aspects, a melamine resin adhesive is used as the adhesive to be attached to the particle surface of the powder forming the powder layer. The melamine resin adhesive is excellent in adhesiveness and water resistance, and can increase the strength of the powder layer and reduce the dimensional change of the powder layer due to the humidity change. It is possible to obtain a flooring material having further excellent bending performance, scratch resistance, and crack resistance.

Further, the invention of claim 10 is based on claims 1 to 8.
In any of the above, since the synthetic rubber adhesive is used as the adhesive to be attached to the particle surface of the powder forming the powder layer, the synthetic rubber adhesive has a relatively high viscosity of the adhesive component. The powder has less penetration into the inside of the particles and has an appropriate elasticity, and it is possible to form a powder layer having less unevenness due to voids between the powders and good surface smoothness. The layer has moderate elasticity as a whole and is excellent in deformation followability, and when a reciprocating load of casters acts on the surface finish material,
It is possible to prevent the surface finishing material from peeling and to impart high scratch resistance.

The invention of claim 11 relates to claims 1 to 1.
In any of 0, since the synthetic rubber adhesive is used as the adhesive for adhering the surface finishing material to the surface of the powder layer, the synthetic rubber adhesive has appropriate elasticity and An adhesive layer having elasticity can be present between the body layer and the surface finish material, and prevents the surface finish material from peeling off when a reciprocating load of the caster acts on the surface finish material. In addition to being able to provide high scratch resistance.

A method for producing a flooring material according to a twelfth aspect of the present invention is the production of the flooring material according to any one of the first to eleventh aspects, wherein the floor material is obtained from at least one of kenaf, oil palm and coconut. The long fibers are oriented and aggregated, and the surface of the long fiber mat in which the adhesive is dispersed is laminated with the powder with the adhesive attached to the particle surface, which is then thermocompressed and integrated. Therefore, it is possible to form the base material while absorbing the irregularities at the interface between the fiberboard layer and the powder layer, which is obtained by the fiberboard layer and the powder layer,
A flooring material having high strength, surface smoothness and hardness, and high dimensional stability against changes in temperature and humidity can be easily produced.

In the thirteenth aspect of the present invention, since the powder is rubbed on the surface of the long fiber mat to be laminated in the twelfth aspect, it is possible to allow the powder to enter the gap between the long fibers. The adhesive strength between the fiberboard layer and the powder layer can be increased, and thus, the flooring material having further improved performance such as bending strength can be easily manufactured.

The invention according to claim 14 is the method according to claim 12 or 13, wherein the water content of the powder having the adhesive adhered to the particle surface is adjusted to 30% by mass or less, and then the powder is applied to the surface of the long fiber mat. Since it is designed to be hot-pressed by laminating, it is possible to reduce the generation of steam at the time of hot-pressing, and suppress the generation of bubbles in the powder layer due to the steam generation,
It is possible to improve the surface smoothness of the powder layer, and it is possible to obtain a flooring material that is provided with further high scratch resistance against the reciprocating load of the casters and the like.

The invention according to claim 15 is the method according to any one of claims 12 to 14, wherein the water content of the long fiber mat in which the adhesive is dispersed is adjusted to 30% by mass or less, and then the surface of the long fiber mat is powdered. Since the product obtained by stacking the bodies is subjected to thermocompression molding, it is possible to reduce the generation of steam during thermocompression molding, to suppress the generation of bubbles in the powder layer due to the steam generation, The surface smoothness can be improved, and it becomes possible to obtain a flooring material having higher scratch resistance against the reciprocating load of the caster and the like.

According to the invention of claim 16, in any one of claims 12 to 15, the adhesive is sprayed onto the powder while moving the powder in the rotary container, thereby adhering to the particle surface of the powder. Since the agent is made to adhere, the powder and the adhesive can be evenly contacted in the rotating container to evenly adhere the adhesive to the particle surface of the powder, as described above. It is possible to easily produce a flooring material having excellent performance.

According to the seventeenth aspect of the present invention, in the sixteenth aspect, the inside of the rotary container is set to a high temperature atmosphere of 40 ° C. or higher, so that the adhesive can be uniformly attached to the powder in the rotary container. In addition to being able to adjust the water content of the powder, the process can be simplified.

The invention of claim 18 is the method according to any one of claims 12 to 15, wherein the adhesive is sprayed onto the powder while the powder is made to flow in a flow tank set to a high temperature atmosphere of 40 ° C. or higher. As a result, the powder and the adhesive can be evenly contacted in the fluidized tank to evenly adhere the adhesive to the particle surface of the powder. It is possible to easily produce a flooring material having Moreover, the water content of the powder can be adjusted at the same time, and the process can be simplified.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of an embodiment of the present invention.

FIG. 2 is a perspective view showing another example of the embodiment of the present invention.

FIG. 3 is a perspective view showing still another example of the embodiment of the present invention.

FIG. 4 is a diagram schematically showing the structure of a fiberboard layer.

FIG. 5 is a schematic perspective view showing an example of an embodiment in which an adhesive is applied to powder using a rotating container.

FIG. 6 is a schematic perspective view showing an example of an embodiment in which an adhesive is applied to powder using a fluidized tank.

[Explanation of symbols]

1 base material 2 Surface finish 3 fiberboard layers 4 powder layer 5 powder 6 Plate substrate 7 rotating containers 8 fluid tank

Continued front page    (72) Inventor Kazunori Umeoka             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Kenji Onishi             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Ryo Sugawara             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company F-term (reference) 2E162 CC08 EA08 FC02                 4F055 AA12 BA13 CA15 EA02 EA24                       EA30 FA02 FA04 GA20

Claims (18)

[Claims] 1. A flooring material formed by adhering a surface finishing material to the surface of a base material, wherein at least a surface layer of the base material comprises:
Kenaf, oil palm, a fiberboard layer formed by thermocompressing a long fiber mat in which the long fibers obtained from at least one of coconut palm are oriented and aggregated and the adhesive is dispersed,
It is formed by a powder layer formed by thermocompressing a powder with an adhesive attached to the particle surface, and a powder layer is arranged on the surface side that is bonded to the surface finish material. And floor material. 2. The flooring material according to claim 1, wherein the base material is formed by providing a fiber board layer and a powder layer on the surface of a plate-shaped substrate. 3. The base material is formed by providing a fiber board layer on both surfaces of a plate-like substrate and at least a powder layer on the surface of the fiber board layer on the side to which the surface finishing material is adhered. The flooring material according to claim 1, wherein the flooring material is present. 4. The flooring material according to claim 1, wherein a powder containing cellulose as a main component is used as the powder forming the powder layer. 5. A kenaf as the powder forming the powder layer,
The flooring material according to any one of claims 1 to 3, which is made of a powder obtained by crushing at least one of oil palm and coconut palm. 6. The flooring material according to claim 1, wherein a powder having an average particle diameter of 500 μm or less is used as the powder forming the powder layer. 7. A layer made of a powder having a small average particle diameter, which is formed by laminating a plurality of layers made of powders having different average particle diameters, and which has a small average particle diameter on the surface side to which a surface finishing material is adhered. The flooring material according to any one of claims 1 to 6, wherein the flooring material is arranged. 8. The flooring material according to claim 1, wherein the powder layer has a thickness of 0.1 to 1 mm. 9. The flooring material according to claim 1, wherein a melamine-based resin adhesive is used as an adhesive that adheres to the particle surfaces of the powder forming the powder layer. 10. The flooring material according to claim 1, wherein a synthetic rubber adhesive is used as an adhesive that is attached to the particle surface of the powder that forms the powder layer. 11. The flooring material according to claim 1, wherein a synthetic rubber adhesive is used as an adhesive for adhering the surface finishing material to the surface of the powder layer. 12. In producing the flooring material according to any one of claims 1 to 11, long fibers obtained from at least one of kenaf, oil palm and coconut are oriented and aggregated, and an adhesive is dispersed. On the surface of the long fiber mat
A method for producing a flooring material, characterized by stacking powders having an adhesive attached on the surface of particles, and thermocompressing and laminating the powders. 13. The method for producing a flooring material according to claim 12, wherein powder is rubbed on the surface of the long fiber mat to be laminated. 14. The water content of a powder having an adhesive adhered to the surface of the particles is adjusted to 30% by mass or less, and then, a product obtained by laminating the powder on the surface of a long fiber mat is subjected to thermocompression molding. The method for producing a flooring material according to claim 12 or 13. 15. The long-fiber mat in which the adhesive is dispersed is adjusted to have a water content of 30% by mass or less, and then the long-fiber mat is laminated with powder on the surface thereof and subjected to thermocompression molding. Item 15. A method for producing a flooring material according to any one of Items 12 to 14. 16. While moving the powder in the rotary container,
The method for producing a flooring material according to any one of claims 12 to 15, wherein the adhesive is attached to the particle surface of the powder by spraying the adhesive onto the powder. 17. The method for producing a flooring material according to claim 16, wherein the inside of the rotary container is set to a high temperature atmosphere of 40 ° C. or higher. 18. The adhesive is sprayed onto the powder while flowing the powder in a fluidized tank set to a high temperature atmosphere of 40 ° C. or higher. Floor material manufacturing method.