JP3084620B2 - Floor material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to flooring.

[0002]

2. Description of the Related Art Conventionally, there has been known a directly adhered flooring material in which a cushioning material such as a synthetic resin or rubber foam is adhered to the back surface of a flooring material substrate to provide soundproofing performance and non-absorbent absorption performance of a construction base surface. Have been.

[0003] Foams used as cushioning materials are roughly classified into closed-cell foams and open-cell foams. When a closed-cell foam is used as a cushioning material, a floor material on the surface is used. Although the shock is applied to the substrate and the shock absorbing material is contracted and deformed, the shock is absorbed.However, there is no place for the air in the closed cells to escape at the time of this contraction. However, when the open-cell type foam is used as the cushioning material, the air in the air bubbles can move freely because the air bubbles are communicated, and the air spring phenomenon does not occur, and excellent soundproof performance is obtained. Is what you can do.

[0004]

When these flooring materials are applied, an adhesive is applied to the base surface and then the floor material is fixed while being fitted thereto. When the adhesive is cured while penetrating into the cushioning material, the cushioning function of the cushioning material is reduced.

[0005] Alternatively, after the floor material is fitted, an operator rides on the surface of the floor material instead of a weight in order to obtain a sufficient adhesive force, so that the cushioning material is compressed and the concave and convex portions formed on the back surface are lowered. The adhesive hardens while in contact with the adhesive applied to the ground.

There has been a problem that flooring materials constructed in such a state cannot exhibit sufficient soundproofing performance. In particular, this problem tends to occur when an open-cell foam is used as a cushioning material to be adhered to the back surface of the flooring material.

[0007] Further, when a floor material is applied to a floor base such as a concrete slab or the like, the hardening reaction of the concrete slab may not be sufficiently completed. In such a place, the floor board absorbs the moisture of the concrete slab after the floor board is installed, causing the floor board to expand, causing warpage or pushing up at the joint of the floor boards. Was.

[0008]

Means for Solving the Problems In order to solve such problems, the present inventor has conducted intensive studies for the purpose of preventing the deterioration of the soundproofing performance and the expansion of the floor material substrate by the method of applying the floor material. As a result, the present invention has been achieved.

That is, according to the present invention, a two-layer cushion material is adhered to the back surface of the floor material substrate 1, and a moisture-proof layer 4 is used as a core layer on the back surface of the two cushion materials, and the paper layers 3, 5 And a floor material having a peel strength of 0.05 to 2.00 kg / cm ² in a peel strength test specified in JIS A 5905. Material. "

[0010]

According to the floor material of the present invention, a moisture-proof sheet having a moisture-proof layer as a core layer and a paper layer formed on the front and back surfaces of the cushion material layer is adhered to the back surface of the cushion material layer. The adhesive applied to the floor does not penetrate into the cushioning material, so that the soundproofing function of the flooring material can be fully exhibited regardless of the construction method, and the flooring material warps due to the absorption of moisture from the floor base surface Thus, it is possible to provide flooring materials that do not cause problems such as the above.

[0011]

FIG. 1 shows an example of a sectional view of a flooring material according to the present invention. A cushioning material 2 is adhered to the back surface of a flooring material substrate 1, and a moisture-proof layer 4 is provided on the back surface of the cushioning material 2. Is a core layer, and a moisture-proof sheet A having paper layers 3 and 5 formed on the front and back thereof is adhered.

As the floor substrate 1 forming the floor of the present invention, for example, a plywood, a wood chipboard, a wood fiber board, a veneer laminated board alone or in any combination, or a board and a board Synthetic resin sheet with excellent buffer effect between
It is possible to use a laminated sheet of foamed synthetic resin or a sound insulation sheet so as to sandwich the sheet.

An optional decorative layer can be formed on the surface of the floor substrate. This decorative layer is made of veneer obtained by cutting natural wood, artificial veneer, and nonwoven fabric, paper, veneer sheet backed with synthetic resin sheet, or decorative paper, resin impregnated paper, nonwoven fabric, paper, synthetic resin sheet, etc. The decorative sheet is formed by bonding or by directly painting or printing on the surface. Also,
An overcoat layer may be provided on the surface of the decorative layer.

By providing such a decorative layer, permeation of moisture from the surface side is also prevented, and problems such as warpage, dew condensation, corrosion and the like due to a change in humidity can be solved.

Further, by forming a groove from the back surface side of the floor substrate 1, the rigidity of the floor substrate 1 is reduced, and when an impact is applied to the floor material surface, the impact is caused by deformation of the floor substrate itself. It can be absorbed and the soundproof performance can be improved.

The cushioning material 2 of the present invention has a cushioning function of absorbing shock energy by contracting and deforming the shock applied to the surface of the floor substrate 1.
For example, a synthetic resin foam or a rubber foam such as a polyethylene resin, a polypropylene resin, a polyurethane resin, and a polystyrene resin can be used.

Further, it is preferable to use an open-cell type foam, since an air spring phenomenon does not occur and an excellent cushioning effect can be exhibited.

Further, by using the open-cell type, excellent performance can be obtained with a high restoring force when released from a state of contraction due to a long-term load. The expansion ratio is JIS K
A material adjusted so that the hardness according to −6767 is in the range of 10 to 40 kg is used. Even if the foamed sheet has the same expansion ratio, the hardness is naturally different due to the different resin.

The hardness of the foam has an effect on the cushioning function as a cushioning material and the amount of sink when a load is applied to the floor material surface. When the foaming amount is less than 10 kg, the cushioning function is excellent. If the floor material is too soft, the amount of sinking becomes large when the floor material is used, causing problems such as poor walking feeling. On the other hand, if it is larger than 40 kg, it is not preferable because it is too hard to perform a sufficient buffer function.

Also, as shown in FIG.
By forming projections and depressions on at least the back side, when the projections of the cushioning material 2 shrink, the recessed space is secured as a place for air in the projection bubbles to move, and more excellent soundproofing performance is obtained. The flooring is obtained.

Further, by adhering the moisture-proof sheet A to the surface of the convex portion of the unevenness formed on the back surface side of the cushion material 2, the portion other than the convex portion surface is formed when the convex portion of the cushion material 2 contracts. It is secured as a place for air in and out of the bubbles. Further, as shown in FIG. 3, a cushion material having unevenness formed on the front and back surfaces of the cushion material 2 can be used.

By forming the unevenness on the surface side of the cushioning material 2 as described above, the same effect is exerted on the surface side of the cushioning material 2 and the soundproofing performance is further improved.

The convex shape of the irregularities may be any shape such as a column, a triangle, a square, a polygon, or a truncated cone, a truncated pyramid, a truncated pyramid, or a truncated polygon. Can be.

When the bumps are formed on the front and back surfaces of the cushion material 2, the shapes of the protrusions on the front surface and the back surface, the area ratio of the protrusions to the cushion material surface, and the size of the protrusions are different. Can be formed.

To form the projections with different sizes means, for example, to make the surface area of the projections different or to make the heights of the projections different.

By forming these elements individually or in combination and differently, when an impact is applied to the floor material substrate, the deformation characteristics of the convex portions on the front surface side and the rear surface side of the cushion material 2 are different. It is preferable because excellent soundproofing performance can be exhibited over a wider sound range.

In particular, by forming the convex portions on the front surface side and the rear surface side so as to have different sizes, when a local load is applied to the floor substrate, an impact due to local deformation of the floor substrate 1 is absorbed. Works, and when the local deformation reaches the cushion material 2, the smaller one of the convex portions formed on the front and back of the cushion material 2 starts to deform first, and then the larger one deforms. It exhibits excellent soundproofing performance due to two-stage absorption.

On the other hand, by forming the area ratio of the convex portion to the entire cushion material differently, even when a local impact is applied, the deformation of the floor substrate 1 follows the local deformation of the floor substrate 1. Is reached, the force of the entire floor material substrate as a surface for pushing down the cushion material acts on the entire cushion material 2.

At this time, the projections formed on the front and back sides of the cushion material 2 on the side with the smaller area ratio firstly begin to be deformed, and then the side with the larger area ratio is deformed, resulting in a two-stage deformation, and excellent soundproofing. Demonstrate performance.

If the initial local deformation is too large, the walking feeling when walking is poor, and the cushioning material is used to restrain the local deformation of the flooring substrate even slightly and to spread it over a wide surface and absorb it. It is preferable that the size of the convex portion on the front surface side of No. 2 is larger than the size of the convex portion on the back surface side.

Further, as shown in FIG. 4, the flooring material of the present invention is subjected to a peeling test with the flooring material substrate 1, the cushioning material 2 and the moisture-proof sheet A being laminated, as shown in FIG. Peeling occurs. The peel strength at this time is JIS A
0.05-2.00 in peel strength test according to -5905
A combination of an adhesive and a cushion material is selected so as to be kg / cm ² .

When the peeling test is performed on the flooring material of the present invention, if the peeling strength is less than 0.05 kg / cm ² , the flooring material is easily peeled off by impact to the floor surface after the construction,
Steps are likely to occur at the joints of the floor materials, and the fruits are easily damaged. On the other hand, if it is larger than 2.00 kg / cm ² , although problems such as peeling and steps do not occur, the impact function is low and sufficient soundproof performance cannot be exhibited, which is not preferable.

As a method of forming the unevenness of the cushion material 2, it can be manufactured by hot-pressing a foam by a hot plate press having an uneven shape mold. In addition, the formation of the uneven shape by this hot plate press
A foam having the same thickness as the cushion material having the target uneven shape can be formed by denting only the concave portion by heat and pressure, or a foam material thicker than the cushion material having the target uneven shape can be used. Alternatively, it can be formed by forming a concavo-convex shape while reducing the overall thickness.

Examples of the moisture-proof sheet A of the present invention include synthetic resin sheets such as polyethylene, vinyl chloride, polypropylene, and polyurethane; metal sheets such as aluminum and copper; bituminous sheets such as asphalt felt and roofing;
A foam sheet such as polyurethane foam, polyethylene foam, polystyrene foam, foamed rubber, or a rubber sheet is used as the moisture-proof layer 4 and the paper layers 3 and 5 laminated on the front and back sides thereof
For example, kraft paper, tissue paper, recycled paper, or the like is used.

The three layers are laminated with paper layers 3 and 5 on the front and back of the moisture-proof layer 4 and bonded by heat sealing or using an adhesive. As the adhesive used at this time, urea resin, phenol resin, melamine resin, vinyl acetate resin, vinyl urethane resin and the like are used. The moisture-proof sheet obtained by either method also has a portion in which the adhesive used for bonding to the moisture-proof layer or the resin in which the moisture-proof layer itself has melted has penetrated into the inside of the paper layer adhered to the front and back of the moisture-proof layer. .

The cushioning member 2 and the moisture-proof sheet A can be laminated by using the same adhesive as that used for attaching the moisture-proof layer and the paper layer. The adhesive can be applied and adhered to the entire surface, or can be applied and adhered partially.

Further, when unevenness is formed on the back surface of the cushioning material 2, an adhesive is applied only to the surface of the convex portion of the cushioning material 2, and after laminating both, the pressure is applied from both surfaces, so that the cushioning material 2 is pressed. The cushion member 2 and the moisture-proof sheet A can be bonded without the concave portion and the moisture-proof sheet A being bonded, which is preferable.

Further, the adhesive used for bonding the cushion material 2 and the moisture-proof sheet A penetrates into the inside of the paper layer from the surface of the paper layer 3 on the surface side of the moisture-proof sheet A, and the moisture-proof layer 4 and the paper layer 3 When the adhesive is applied, the adhesive or the moisture-proof layer itself formed inside the paper layer 3 reaches the portion where the melted resin permeates. For this reason, the peel strength in the paper layer 3 on the front surface side is extremely excellent.

In the paper layer 5 on the back side of the moisture-proof sheet A, an adhesive formed inside the paper layer 5 when the moisture-proof layer 4 is adhered to the paper layer 5 or a resin in which the moisture-proof layer itself melts. When the flooring material of the present invention is constructed, the adhesive applied to the floor base surface penetrates from the back side of the paper layer 5 to reach the permeated portion from the moisture-proof layer 4 side, Lumber 2
As in the case of the adhesive surface of the moisture-proof sheet A, the excellent peel strength is exhibited.

FIG. 4 shows another embodiment of the present invention, in which a woven or non-woven fabric made of synthetic resin or natural fiber, a non-woven fabric, paper or the like is provided between a floor material substrate 1 and a cushion material 2. This shows a configuration in which an adhesive penetration preventing layer 6 having an adhesive absorbing ability is interposed.

When a groove is formed from the back side of the floor substrate 1, the adhesive permeation preventing layer 6 is attached to the floor substrate 1 so that the floor substrate 1 does not have high rigidity. Are preferred.

FIG. 5 shows another embodiment of the present invention, in which a natural veneer, an artificial veneer, a nonwoven fabric, a paper, and a synthetic resin sheet obtained by cutting natural wood on the surface of a floor substrate are lined. Veneer sheet, or decorative paper, resin impregnated paper,
When the optional decorative layer 7 such as a nonwoven fabric, paper, or a synthetic resin sheet is formed, the flooring is likely to warp due to the amount of shrinkage and expansion of the optional decorative layer 7 due to a change in water content.

In order to prevent this, a discarded adhesive layer 8 is formed on the back surface of the floor material substrate 1 to balance the front surface side and the back surface side of the floor material substrate 1 and prevent warpage. The same natural veneer as the optional decorative layer 7 may be used as the discarded layer 8,
An artificial veneer, a veneer sheet, a synthetic resin sheet, or a material similar to the moisture-proof sheet A of the present invention can be used.

Further, in the case of forming a groove on the back surface of the floor substrate 1, after the discarding layer 8 is bonded to the back surface of the floor substrate 1, the groove extends from the surface of the discarding layer 8 into the floor substrate 1. Form a groove. Even if the discarded adhesive layer 8 is divided by the groove in this manner, a balance is obtained between the portion of the discarded adhesive layer 8 that is not divided by the groove and the corresponding decorative layer 7 on the surface side of the corresponding portion, and warpage is generated. Is prevented. Further, if necessary, both the discarded adhesive layer 8 and the adhesive permeation prevention layer 6 shown in FIG. 4 can be formed on the back surface of the floor material substrate 1.

[0045]

According to the flooring material of the present invention, it is possible to perform the construction without lowering the soundproofing performance due to the adhesive applied to the ground surface penetrating into the cushion material 2 during construction. Further, in the paper layer 3 on the front side of the moisture-proof sheet A, the adhesive used for bonding the cushioning material 2 and the moisture-proof sheet A permeates from the surface of the paper layer 3 on the front side of the moisture-proof sheet A into the inside of the paper layer. And
When the moisture-proof layer 4 and the paper layers 3 and 5 are adhered to each other, the adhesive formed on the inside of the paper layers 3 and 5 or the moisture-proof layer 4 itself reaches the permeation portion of the molten resin. The peel strength in 3 is very excellent.

[Brief description of the drawings]

FIG. 1 is a first example of a sectional view of a flooring material of the present invention,

FIG. 2 is a cross-sectional view in the case where irregularities are formed on the back surface side of the cushion material 2,

FIG. 3 is a cross-sectional view in the case where irregularities are formed on the front and back surfaces of the cushion material 2,

FIG. 4 is a cross-sectional view when an adhesive penetration preventing layer 6 is interposed between the floor substrate 1 and the cushion material 2;

FIG. 5 is a cross-sectional view when a decorative layer 7 is formed,

[Explanation of symbols]

1: floor material substrate, 2: cushion material, 3: paper layer on the front side,
4: moisture-proof layer, 5: paper layer on the back side, 6: adhesive permeation prevention layer, 7: decorative layer, 8: discarded layer, A: moisture-proof sheet.

Claims (2)

(57) [Claims] 1. A cushioning material layer is adhered to the back surface of a floor material substrate, and a moisture-proof sheet having a moisture-proof layer as a core layer and paper layers formed on the front and back surfaces thereof is adhered to the back surface of the cushioning material layer. A floor material having a peel strength of 0.05 to 2.00 kg / cm ² in a peel strength test specified in JIS A 5905. 2. The flooring material according to claim 1, wherein an adhesive-impregnated layer is formed on a paper layer on the surface side of the moisture-proof sheet.