JP2009074327A - Reinforced floor material and method of manufacturing reinforced floor material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reinforced floor material which maintains excellent moisture-proof properties, exerts sufficient scratch resistance and strength against pressure caused by use etc. of casters, and is proof against interlaminar separation or shear fracture of a decorative veneer. <P>SOLUTION: According to the arrangement of the reinforced floor material, a moisture-proof sheet material 2 which is obtained by laminating upper and lower paper layers on upper and lower surfaces of a resin sheet having imparted thereto heat resistance and moisture proof properties as a core, in one body by an adhesive, is laminated on and bonded to a front surface of a woody fiber plate 1a forming a front layer of a woody substrate 1, via a thermosetting resin adhesive 4b. Then a decorative sliced veneer 3 is laminated on and bonded to a front surface of the moisture-proof sheet material 2 via a thermosetting resin adhesive 4a having elasticity imparted thereto. Thus even if the floor material undergoes application of a load caused by the casters of a wagon or the like, it is free from interlaminar separation or shear fracture in the decorative sliced veneer 3. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、防湿性及び耐傷性に優れた強化床材とその製造方法に関するものである。   The present invention relates to a reinforced flooring material excellent in moisture resistance and scratch resistance and a method for producing the same.

従来から、床材や化粧板等に防湿性を付与するには、例えば、特許文献１に記載されているように、ポリエチレン等の防湿性を有する熱可塑性樹脂フィルムの上下面に紙を一体化してなる「ポリサンド紙」と称される防湿シートを使用し、この防湿シートを介して木質基材の表面に化粧単板を積層、接着することが行われている。   Conventionally, in order to impart moisture resistance to flooring materials and decorative boards, for example, as described in Patent Document 1, paper is integrated on the upper and lower surfaces of a thermoplastic resin film having moisture resistance such as polyethylene. A moisture-proof sheet called “poly sand paper” is used, and a decorative veneer is laminated and bonded to the surface of the wooden substrate through the moisture-proof sheet.

また、特許文献２には、パーティクルボードや合板等の基材の表面に熱硬化性樹脂含浸紙の積層体を一体に接着してなる化粧板において、上記熱硬化性樹脂含浸紙の積層体の任意の層間に水蒸気透過度の低い樹脂フィルムを介在させることにより、防湿機能を発揮させるように構成した防湿性積層体が記載されている。   Further, in Patent Document 2, in a decorative board in which a laminate of thermosetting resin-impregnated paper is integrally bonded to the surface of a substrate such as particle board or plywood, the laminate of the thermosetting resin-impregnated paper is described. A moisture-proof laminate is described that is configured to exert a moisture-proof function by interposing a resin film having a low water vapor permeability between arbitrary layers.

特開平１０−２１１６７４号公報Japanese Patent Application Laid-Open No. 10-2111674 特開昭６１−１６０２４８号公報JP-A 61-160248

しかしながら、上記特許文献１に記載の床材や化粧板によれば、木質基材の表面と化粧単板の裏面とに接着される上側紙層と下側紙層が１０〜２０μｍと薄い場合には問題ないが、２０μｍを超えると、接着剤の浸透していない層が発生する。特に、床材に優れた表面硬度を付与するために木質基材の少なくとも表層部を比重が０．４〜１．０の硬質木質繊維板によって形成し、この硬質木質繊維板の表面に上記防湿シート状物を介して化粧単板を貼着してなる場合において、この床材上でワゴン等のキャスターによる荷重がかかると、接着剤が浸透していない上下紙層で紙間剥離が発生し、化粧単板が剥がれてしまうという問題があった。   However, according to the flooring and decorative board described in Patent Document 1, when the upper paper layer and the lower paper layer adhered to the surface of the wooden substrate and the back surface of the decorative veneer are as thin as 10 to 20 μm, There is no problem, but if it exceeds 20 μm, a layer into which the adhesive does not penetrate is generated. In particular, in order to impart excellent surface hardness to the flooring material, at least the surface layer portion of the wood base material is formed of a hard wood fiber board having a specific gravity of 0.4 to 1.0, and the moisture proofing is formed on the surface of the hard wood fiber board. When a decorative veneer is attached via a sheet-like material, if a load is applied by a caster such as a wagon on this flooring, peeling between paper will occur in the upper and lower paper layers where the adhesive does not penetrate. There was a problem that the veneer was peeled off.

なお、上記防湿シートの上下紙間に介在させている樹脂シートは、一般的に熱可塑性樹脂からなり、熱可塑性樹脂フィルムを溶融させるような高温をかけると、防湿性能が低下するので、通常は、冷圧貼着されるの一般的である。この場合、使用される接着剤中に含まれる水分を飛ばす必要があるため、接着剤の塗布量をできる限り少なくし、また、熱圧プレスを行う場合においても水分によるパンクの発生を防止するために接着剤の塗布量を極力絞るのが一般的である。従って、上述したように、２０μｍ以上の厚みを有する紙を使用すると、接着剤の浸透していない層が発生することになる。   The resin sheet interposed between the upper and lower sheets of the moisture-proof sheet is generally made of a thermoplastic resin, and when subjected to a high temperature that melts the thermoplastic resin film, the moisture-proof performance deteriorates. It is common to be cold-pressed. In this case, the moisture contained in the adhesive to be used needs to be blown off, so that the amount of the adhesive applied is reduced as much as possible, and also when the hot press is performed, the occurrence of puncture due to moisture is prevented. In general, the amount of adhesive applied is generally reduced as much as possible. Therefore, as described above, when paper having a thickness of 20 μm or more is used, a layer into which the adhesive does not permeate is generated.

このような問題点を無くすために、防湿シートの上下面に紙間強化紙といった紙を使用することも検討されている。紙間強化紙とは、紙に予めラテックスやアクリルエマルジョン等の熱可塑性樹脂を含浸させておくことにより、紙間剥離を低減させた紙である。木質基材が比較的軟らかい合板である場合には、この木質基材上に該防湿シートを介して化粧突板を貼着してなる床板として一定の効果を奏する事ができるものの、上述したように木質基材の表層部が硬質木質繊維板等によって形成されている場合には、この木質基材上に上記防湿シートを介して化粧突板を積層接着してなる床材の該化粧突板上にワゴン等のキャスターによる荷重がかかると、防湿シートにせん断破壊力が激しく作用して、紙間強化紙の程度の強度では、紙間剥離を防ぐことが困難である。   In order to eliminate such problems, it has been studied to use paper such as inter-paper reinforced paper on the upper and lower surfaces of the moisture-proof sheet. Paper-to-paper reinforced paper is paper in which separation between papers is reduced by pre-impregnating paper with a thermoplastic resin such as latex or acrylic emulsion. When the wooden base material is a relatively soft plywood, although it can exert a certain effect as a floor board formed by sticking a decorative veneer on the wooden base material via the moisture-proof sheet, as described above When the surface layer portion of the wooden base material is formed of a hard wooden fiber board or the like, a wagon is formed on the decorative veneer of the flooring material obtained by laminating and adhering the decorative veneer on the wooden base material via the moisture-proof sheet. When a load such as a caster is applied, a shear breaking force acts violently on the moisture-proof sheet, and it is difficult to prevent separation between sheets with the strength of the inter-paper reinforced paper.

一方、上記特許文献２によれば、熱硬化性樹脂含浸紙の積層体の任意の層間に水蒸気透過度の低い樹脂フィルムを中間層として介在させているので、この中間層によって防湿効果が期待できると共に、紙間剥離の発生を無くすことができるが、熱硬化性樹脂含浸紙の積層体の任意の層間に上記水蒸気透過度の低い樹脂フィルムを中間層として介在させる際に、中間層にクッション的な機能を発揮する層が全く存在しないため、キャスターによる連続的な荷重が作用すると、化粧突板の内部でせん断破壊が生じるといった問題があった。   On the other hand, according to Patent Document 2, since a resin film having a low water vapor permeability is interposed as an intermediate layer between arbitrary layers of the laminate of thermosetting resin-impregnated paper, a moisture-proof effect can be expected by this intermediate layer. In addition, it is possible to eliminate the occurrence of peeling between papers, but when the resin film having a low water vapor permeability is interposed as an intermediate layer between arbitrary layers of the laminate of the thermosetting resin-impregnated paper, the intermediate layer is cushioned. Since there is no layer that performs such a function, there is a problem that shear failure occurs inside the decorative veneer when a continuous load is applied by a caster.

本発明は、このような問題点に鑑みてなされたもので、その目的は、優れた防湿性を維持しつつ、キャスターの使用等に対しても充分な耐傷性と強度を発揮することが出来るとともに、紙間剥離や化粧単板のせん断破壊が生じ難い強化床材とこの強化床材の製造方法を提供することにある。   The present invention has been made in view of such problems, and the object thereof is to exhibit sufficient scratch resistance and strength against the use of casters while maintaining excellent moisture resistance. Another object is to provide a reinforced flooring material that is less susceptible to peeling between papers and shearing of a decorative veneer and a method for producing the reinforced flooring material.

上記目的を達成するために、本発明の強化床材は、請求項１に記載したように、少なくとも、表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材と、熱硬化性樹脂接着剤を含浸硬化させている下側紙層と、耐熱性及び防湿性を有する熱可塑性樹脂シートと、熱硬化性樹脂接着剤を含浸硬化させている上側紙層と、化粧突板とを順次、積層一体化してなる構造を有している。   In order to achieve the above object, the reinforced flooring of the present invention, as described in claim 1, includes at least a wood substrate made of a hard wood fiberboard having a surface layer portion having a specific gravity of 0.4 to 1.0, Lower paper layer impregnated and cured with thermosetting resin adhesive, thermoplastic resin sheet having heat resistance and moisture resistance, upper paper layer impregnated and cured with thermosetting resin adhesive, and decorative veneer Are sequentially laminated and integrated.

このように構成した強化床材において、請求項２に係る発明は、上側紙層は３０〜５０μｍの厚みを有していると共に、この上側紙層に含浸硬化されている熱硬化性樹脂接着剤は弾性を有する接着剤であって、この接着剤を該上側紙層の全体に亘って含浸硬化させていることを特徴とする。   In the reinforced flooring material thus configured, the invention according to claim 2 is the thermosetting resin adhesive in which the upper paper layer has a thickness of 30 to 50 μm and is impregnated and cured in the upper paper layer. Is an elastic adhesive, characterized in that this adhesive is impregnated and cured over the entire upper paper layer.

請求項３に係る発明は、上記強化床材の製造方法であって、少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に耐熱性及び防湿性を有する熱可塑性樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置し、さらに、この防湿シート状物上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して防湿シート状物の表面に化粧突板を載置することによって、木質基材と防湿シート状物と化粧突板とからなる積層体を形成し、この積層体を熱圧することによって、上記上側紙層及び上記下側紙層それぞれに上記熱硬化性樹脂接着剤を含浸硬化させると共に、これらの熱硬化性樹脂接着剤によって、木質基材の表面に、防湿シート状物を介して化粧突板を積層一体化させることを特徴とする。   The invention according to claim 3 is a method for producing the above-mentioned reinforced flooring material, wherein at least the surface layer portion has a thermosetting resin adhesive on the surface of a wood base material comprising a hard wood fiber board having a specific gravity of 0.4 to 1.0. After coating the upper and lower paper layers on the upper and lower surfaces of the thermoplastic resin sheet with heat resistance and moisture resistance on the surface of the wooden substrate via this thermosetting resin adhesive The moisture-proof sheet material is placed on the moisture-proof sheet material, and a thermosetting resin adhesive is applied to the moisture-proof sheet material. Then, a makeup is applied to the surface of the moisture-proof sheet material through the thermosetting resin adhesive. By placing a veneer, a laminated body composed of a wooden substrate, a moisture-proof sheet, and a decorative veneer is formed, and by heat-pressing the laminated body, the upper paper layer and the lower paper layer are respectively Impregnating and curing thermosetting resin adhesive, and these The thermosetting resin adhesive, the surface of the wood substrate, and characterized in that integrally laminating a decorative sliced veneer through the moistureproof sheet.

請求項４の発明に係る発明は、少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に、耐熱性及び防湿性を有する熱可塑性樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置することにより、木質基材と防湿シート状物とからなる中間積層体を形成し、この中間積層体を熱圧することによって防湿シート状物の下側紙層に上記熱硬化性樹脂接着剤を全体に亘って含浸硬化させると共に木質基材表面に防湿シート状物を一体に接着させる第一熱圧工程と、熱圧された中間積層体を冷却する冷却工程と、冷却された中間積層体上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して中間積層体に化粧突板を載置することにより最終積層体を形成し、この最終積層体を熱圧することによって防湿シート状物の上側紙層に中間積層体上に塗布した上記熱硬化性樹脂接着剤を含浸硬化させると共に防湿シート状物上に化粧突板を一体に接着させる第二熱圧工程とからなることを特徴とする。   In the invention according to claim 4, the thermosetting resin adhesive is applied to the surface of a wood substrate made of a hard wood fiber board having a specific gravity of 0.4 to 1.0 at least in the surface layer portion, and then the thermosetting. A moisture-proof sheet-like material in which an upper paper layer and a lower paper layer are laminated and integrated with an adhesive on the upper and lower surfaces of a thermoplastic resin sheet having heat resistance and moisture resistance on the surface of a wooden substrate via a resin adhesive. An intermediate laminate composed of a wooden base material and a moisture-proof sheet is formed by placing, and the thermosetting resin adhesive is applied to the lower paper layer of the moisture-proof sheet by hot pressing the intermediate laminate. A first hot-pressing step in which the moisture-proof sheet is integrally bonded to the surface of the wooden substrate, a cooling step for cooling the hot-pressed intermediate laminate, and a cooled intermediate laminate After applying a thermosetting resin adhesive on top, this thermosetting A final laminate was formed by placing a decorative veneer on the intermediate laminate via a resin adhesive, and this final laminate was applied to the upper paper layer of the moisture-proof sheet by hot pressing the intermediate laminate. The thermosetting resin adhesive is impregnated and cured, and further comprises a second hot-pressing step in which the decorative veneer is integrally bonded onto the moisture-proof sheet.

さらに、請求項５に係る発明は、請求項３及び請求項４の強化床材の製造方法の発明において、上側紙層は３０〜５０μｍの厚みを有していると共に、この上側紙層に含浸硬化される熱硬化性樹脂接着剤は弾性を有する接着剤であって、この接着剤を上側紙層の全体に亘って含浸硬化させることを特徴とする。   Further, the invention according to claim 5 is the invention of the method for producing a reinforced flooring material according to claim 3 and claim 4, wherein the upper paper layer has a thickness of 30 to 50 μm, and the upper paper layer is impregnated. The cured thermosetting resin adhesive is an elastic adhesive, and is characterized in that the adhesive is impregnated and cured over the entire upper paper layer.

請求項１の発明によれば、木質基材の少なくとも表層部を比重が０．４〜１．０の硬質木質繊維板により形成しているので、この木質基材上に防湿シート状物を介して化粧突板を一体に積層してなる床材に落下物や家具の移動等による凹み等の発生を防止するための強度を付与しておくことができるばかりでなく、木質基材と化粧突板との間に介在する上記防湿シート状物における樹脂シートによって表面から木質基材内に湿気が侵入するのを防止できて寸法安定性を保持し得るものである。さらに、これらの樹脂シートと共に防湿シート状物を形成している上側紙層及び下側紙層には、全体に亘って熱硬化性樹脂を含浸硬化させているので、上記木質基材の表層部に硬質木質繊維板を使用したことによって防湿シート状物にせん断破壊力が集中的に作用した場合も、上下紙層の紙間剥離を防ぐことができる。   According to the invention of claim 1, since at least the surface layer portion of the wood base material is formed of the hard wood fiber board having a specific gravity of 0.4 to 1.0, the moisture-proof sheet-like material is interposed on the wood base material. In addition to being able to give strength to prevent the occurrence of dents due to falling objects, furniture movement, etc., on the flooring made of laminated decorative veneer integrally, the wooden substrate and decorative veneer It is possible to prevent moisture from entering the wood substrate from the surface by the resin sheet in the moisture-proof sheet-like material interposed between them, and to maintain dimensional stability. Furthermore, since the upper paper layer and the lower paper layer that form a moisture-proof sheet-like material together with these resin sheets are impregnated and cured throughout, the surface layer portion of the wood base material. Even when shear breaking force acts on the moisture-proof sheet-like material intensively by using a hard wood fiberboard, it is possible to prevent peeling between the upper and lower paper layers.

さらに、防湿シート状物は、樹脂シートが接着剤により上側紙層及び下側紙層と一体化されているので、樹脂シートとして様々なシートを必要に応じて選定することができる。さらに、樹脂シートと上側紙層に含浸硬化させる接着剤を組み合わせることにより、様々な効果を期待できる。例えば、樹脂シートとして、硬質な樹脂シートを選定した場合は強化層として作用し、軟質な樹脂シートを選定した場合はクッション層として作用する。さらに、突板を熱圧プレスした場合に劣化しないきわめて高い融点を有する硬質な樹脂シートも使用することが出来るため、効率的に生産できる強化床材を提供できる。   Furthermore, since the resin sheet is integrated with the upper paper layer and the lower paper layer by an adhesive, various sheets can be selected as the resin sheet as needed. Furthermore, various effects can be expected by combining a resin sheet and an adhesive that impregnates and cures the upper paper layer. For example, when a hard resin sheet is selected as the resin sheet, it acts as a reinforcing layer, and when a soft resin sheet is selected, it acts as a cushion layer. Furthermore, since a hard resin sheet having an extremely high melting point that does not deteriorate when the protruding plate is hot-pressed can be used, a reinforced flooring that can be produced efficiently can be provided.

また、請求項２の発明によれば、上記防湿シート状物の上側紙層は３０〜５０μｍの厚みを有していると共に上側紙層と上記化粧単板とを接着させている上記熱硬化性樹脂接着剤は弾性を有する接着剤であって、この接着剤を上側紙層の全体に亘って含浸硬化させているので、ワゴンや椅子等のキャスターにより連続的且つ長期的な荷重がかかった場合も、その荷重を弾性的に吸収して上下紙層、化粧単板その他どの部分においても、紙間剥離や層間破壊等のせん断破壊を生じる恐れがない優れた強化床材を提供することができる。   Further, according to the invention of claim 2, the thermosetting property wherein the upper paper layer of the moisture-proof sheet has a thickness of 30 to 50 μm and the upper paper layer and the decorative veneer are bonded together. Resin adhesive is elastic adhesive, and this adhesive is impregnated and cured over the entire upper paper layer, so that continuous and long-term loads are applied by casters such as wagons and chairs. In addition, it is possible to provide an excellent reinforced floor material that elastically absorbs the load and does not cause shear failure such as separation between papers and delamination in any part of the upper and lower paper layers, the decorative veneer, and the like. .

上記強化床材の製造方法としては、請求項３に記載したように、少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に耐熱性及び防湿性を有する樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置し、さらに、この防湿シート状物上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して防湿シート状物の表面に化粧突板を重ねることによって、木質基材と防湿シート状物と化粧突板とからなる積層体を形成し、この積層体を熱圧するものであるから、上側紙層及び下側紙層それぞれに熱硬化性樹脂接着剤を含浸硬化させることができるので、上下紙層の紙間剥離が生じ難い紙層に形成することが出来ると同時に、これらの熱硬化性樹脂接着剤を介して、木質基材、防湿シート状物、化粧突板を強固に積層一体化してなる防湿性及び耐傷性に優れた強化床材を効率よく製造することが出来る。   As a manufacturing method of the said reinforced flooring, as described in Claim 3, at least the surface layer part is a thermosetting resin adhesive on the surface of the wood base material which consists of a hard wood fiber board with specific gravity of 0.4-1.0. After this, the upper paper layer and lower paper layer are laminated and integrated with the adhesive on the upper and lower surfaces of the resin sheet having heat resistance and moisture resistance on the surface of the wooden substrate through this thermosetting resin adhesive. Then, after applying a thermosetting resin adhesive on the moisture-proof sheet, a decorative veneer is placed on the surface of the moisture-proof sheet via the thermosetting resin adhesive. By laminating, a laminated body composed of a wooden substrate, a moisture-proof sheet and a decorative veneer is formed, and this laminated body is heat-pressed, so thermosetting resin adhesion to each of the upper paper layer and the lower paper layer Since the agent can be impregnated and cured, the upper and lower paper layers of paper It can be formed into a paper layer that does not easily peel off, and at the same time, moisture-proof and scratch-resistant by firmly laminating and integrating wood substrates, moisture-proof sheets, and decorative veneers with these thermosetting resin adhesives It is possible to efficiently produce a reinforced flooring material having excellent properties.

なお、このように、木質基材と防湿シート状物と化粧突板との積層体を熱圧プレスによって同時に一体に固着する方法によることなく、請求項４に記載したように、まず、少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に耐熱性及び防湿性を有する樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置することにより木質基材と防湿シート状物とからなる中間積層体を形成し、この中間積層体を熱圧することによって防湿シート状物の下側紙層に上記熱硬化性樹脂接着剤を全体に亘って含浸硬化させると共に木質基材表面に防湿シート状物を一体に接着させる第一熱圧工程と、熱圧された中間積層体を冷却する冷却工程と、冷却された中間積層体上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して中間積層体に化粧突板を載置することにより最終積層体を形成し、この最終積層体を熱圧することによって防湿シート状物の上側紙層に中間積層体上に塗布した上記熱硬化性樹脂接着剤を含浸硬化させると共に防湿シート状物上に化粧突板を一体に接着させる第二熱圧工程によって、この強化床材を製造してもよい。   In addition, as described in claim 4, first, at least the surface layer portion is not based on the method in which the laminated body of the wooden base material, the moisture-proof sheet-like material, and the decorative veneer is fixed integrally at the same time by hot pressing. After applying a thermosetting resin adhesive to the surface of a wood substrate made of hard wood fiber board having a specific gravity of 0.4 to 1.0, the surface of the wood substrate is heat-resistant through this thermosetting resin adhesive. The moisture-proof sheet-like material in which the upper paper layer and the lower paper layer are laminated and integrated with an adhesive is placed on the upper and lower surfaces of the resin sheet having heat resistance and moisture-proof properties, thereby comprising a wood substrate and a moisture-proof sheet material An intermediate laminate is formed, and the intermediate laminate is hot-pressed to impregnate and cure the thermosetting resin adhesive throughout the lower paper layer of the moisture-proof sheet, and the moisture-proof sheet on the surface of the wooden substrate. First hot-pressing process for bonding objects together A cooling step of cooling the hot-pressed intermediate laminate, and after applying a thermosetting resin adhesive on the cooled intermediate laminate, the decorative veneer is applied to the intermediate laminate via the thermosetting resin adhesive The final laminated body is formed by mounting and the above-mentioned thermosetting resin adhesive applied on the intermediate laminated body is impregnated and cured on the upper paper layer of the moisture-proof sheet by hot pressing the final laminated body. You may manufacture this reinforcement | strengthening flooring material by the 2nd hot-pressing process which adhere | attaches a decorative veneer on a moisture-proof sheet-like thing integrally.

これらの強化床材の製造方法においては、上側紙層を３０〜５０μｍの厚みとし、この上側紙層に含浸硬化される熱硬化性樹脂接着剤を弾性を有する接着剤とし、この接着剤を上側紙層の全体に亘って含浸硬化させることにより、効率的に耐キャスター性に優れた床材を製造することが出来る。   In these reinforced flooring manufacturing methods, the upper paper layer has a thickness of 30 to 50 μm, and the thermosetting resin adhesive that is impregnated and cured in the upper paper layer is used as an elastic adhesive. By impregnating and curing the entire paper layer, it is possible to efficiently produce a flooring material having excellent caster resistance.

次に、本発明の具体的な実施の形態を図面に基づいて説明すると、図１は強化床材Ａの簡略断面図で、強化床材Ａは、一定厚みを有する木質基材１の表面（上面）に防湿シート状物を介して化粧突板３を積層一体化してなる構造を有する。   Next, a specific embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a simplified cross-sectional view of a reinforced floor material A. The reinforced floor material A is a surface of a wooden substrate 1 having a certain thickness ( It has a structure in which the decorative veneer 3 is laminated and integrated on the upper surface) via a moisture-proof sheet.

上記木質基材１としては、合板やパーティクルボード、ＯＳＢ等の木質板状体１ｂの表面に比重が０．４〜１．０の硬質な木質繊維板１ａを貼着してなる板材が使用されるが、木質基材１の全体を木質繊維板によって形成しておいてもよく、要するに、少なくとも表層部が比重０．４〜１．０の硬質木質繊維板１ａからなる木質基材１であればよい。   As the above-mentioned wood base material 1, a plate material is used in which a hard wood fiber board 1 a having a specific gravity of 0.4 to 1.0 is attached to the surface of a wood board 1 b such as plywood, particle board, or OSB. However, the whole of the wood base material 1 may be formed of a wood fiber board. In short, the wood base material 1 composed of the hard wood fiber board 1a having at least a surface layer portion having a specific gravity of 0.4 to 1.0. That's fine.

上記のような硬質木質繊維板１ａとしては、一般的な比重０．４〜０．８の中比重木質繊維板（以下、ＭＤＦという）や比重０．８〜１．０のハードボード（以下、ＨＤＦという）のうち、上述したように比重が０．４〜１．０の木質繊維板を使用する。なお、比重が０．４以下の木質繊維板は、化粧突板３の表面から衝撃を受けた場合には、凹みや傷が生じやすくなって表面からの衝撃を受けた場合には、凹みや傷が生じやすくなって表面の耐傷性の高い床材を得ることができなく、また、比重が１．０を超えるＨＤＦを使用した場合には、湿気によって厚さ方向の膨潤が大きくなるため好ましくない。また、これらのＭＤＦやＨＤＦへの樹脂含浸により、木質繊維板１ａの少なくとも表面及び全層が硬質化されている木質基材１を使用してもよい。   As the hard wood fiber board 1a as described above, a medium specific gravity wood fiber board (hereinafter referred to as MDF) or a hard board (hereinafter referred to as MDF) having a specific gravity of 0.4 to 0.8. As described above, a wood fiber board having a specific gravity of 0.4 to 1.0 is used. A wood fiber board having a specific gravity of 0.4 or less is likely to be dented or scratched when subjected to an impact from the surface of the decorative veneer 3, and is not easily damaged when subjected to an impact from the surface. It is difficult to obtain a flooring material having a high scratch resistance on the surface, and when HDF having a specific gravity exceeding 1.0 is used, the swelling in the thickness direction is increased by moisture, which is not preferable. . Further, the wood substrate 1 in which at least the surface and the entire layer of the wood fiber board 1a are hardened by resin impregnation into these MDF and HDF may be used.

また、木質繊維板１ａは、使用している結合剤の種類により。例えば該結合剤としてユリアメラミン樹脂を使用したものをＵタイプ、メラミン樹脂を使用したものをＭタイプ、フェノール樹脂を使用したものがＰタイプといわれるが、どのようなタイプであっても使用することが出来る。しかしながら、特に、床材の用途に使用する場合には、上記タイプのうち、のうちＵタイプのものは湿気に対して膨れやすいため、避けるべきである。さらに、上記以外に結合剤としては、イソシアネート系化合物や、ポリオール系化合物等の結合剤を使用した硬質木質繊維板も採用できる。なお、好適にはワックス等の撥水剤が内添されている硬質木質繊維板が使用される。   The wood fiber board 1a depends on the type of binder used. For example, U-type is used as the binder and U-type is used as the binder, M-type is used as the melamine resin, and P-type is used as the phenolic resin. I can do it. However, in particular, when used for flooring applications, among the above types, the U type should be avoided because it tends to swell against moisture. In addition to the above, a hard wood fiber board using a binder such as an isocyanate compound or a polyol compound can also be employed as a binder. Preferably, a hard wood fiber board in which a water repellent such as wax is internally added is used.

また、上記ＭＤＦやＨＤＦは、使用している木質繊維の種類により、針葉樹系と広葉樹系とに分けられるが、一般的には針葉樹系の木質繊維に比べて広葉樹系の木質繊維は、水分に対する寸法安定性に優れているため、広葉樹系の木質繊維からなるＭＤＦやＨＤＦを使用することが望ましい。   The MDF and HDF are classified into softwood and hardwood depending on the type of wood fiber used. In general, hardwood wood fiber is more resistant to moisture than softwood wood fiber. Because of excellent dimensional stability, it is desirable to use MDF or HDF made of hardwood wood fibers.

木質基材１の表面に防湿シート状物２を介して積層一体化してなる上記化粧突板３としては、天然木質材からなる厚さ０．１５〜１．０ｍｍ程度の薄い木質突板を使用するが、その樹種は限定されることなく、また、乾燥単板でもよいし、いわゆる濡れ単板であってもよい。ただし、後述するように、本発明の強化床材Ａを製造するには、木質基材１上に防湿シート状物２を介して化粧突板３を接着するための熱硬化性樹脂接着剤４ａの塗布量を多く必要とするため、好適には０．３５〜０．６ｍｍ厚程度の化粧突板３が使用される。なお、この化粧突板３の表面に溝加工や浮造り加工、或いは着色や塗装を施してもよい。   As the decorative veneer 3 which is laminated and integrated on the surface of the wooden substrate 1 through the moisture-proof sheet-like material 2, a thin wooden veneer having a thickness of about 0.15 to 1.0 mm made of a natural wooden material is used. The tree species is not limited and may be a dry veneer or a so-called wet veneer. However, as will be described later, in order to produce the reinforced flooring A of the present invention, a thermosetting resin adhesive 4a for adhering the decorative veneer 3 via the moisture-proof sheet 2 on the wooden substrate 1 is used. Since a large amount of coating is required, a decorative veneer 3 having a thickness of about 0.35 to 0.6 mm is preferably used. Note that the surface of the decorative veneer 3 may be grooved, floated, colored, or painted.

化粧突板３を木質基材１の硬質木質繊維１ａの表面に一体に積層接着させる上記防湿シート状物２としては、表面処理した樹脂シート２ｃの上下面に上側紙層２ａと下側紙層２ｂとをサンドイッチ状に接合一体化した３層構造の構造を有する。この貼り合わせには、一般的なドライラミネーターが好適に使用される。上下に接着力改善表面処理された樹脂シート２ｃに溶剤系の接着剤を塗布し、樹脂シート２ｃの表面にビニル系接着剤やウレタン系接着剤等の接着剤を塗布し、乾燥させ、溶媒を蒸発させた後に加熱した後に上側紙層２ａを積層させ、ニップロールで圧着一体化を行う。さらに、樹脂シート２ｃの裏面側にも同じ工程で下側紙層２ｂを積層一体化させる。この場合、接着力改善表面処理とは、樹脂シート２ｃの接着力改善表面処理として一般的に行われるコロナ放電処理やプラズマ放電処理である。さらに、これらの接着力改善表面処理を行うため、樹脂シートの選択の幅が広くなり、一般的な熱融着で３層構造になっているポリサンド紙に比べると安定的な生産が可能になる。   As the moisture-proof sheet-like material 2 in which the decorative veneer 3 is integrally laminated and bonded to the surface of the hard wood fiber 1a of the wood substrate 1, the upper paper layer 2a and the lower paper layer 2b are formed on the upper and lower surfaces of the surface-treated resin sheet 2c. Are laminated and integrated in a sandwich shape. For this bonding, a general dry laminator is preferably used. Apply a solvent-based adhesive on the resin sheet 2c that has been surface-treated to improve the adhesive strength, and then apply an adhesive such as a vinyl-based adhesive or a urethane-based adhesive to the surface of the resin sheet 2c. After evaporating and heating, the upper paper layer 2a is laminated, and pressure-bonding integration is performed with a nip roll. Further, the lower paper layer 2b is laminated and integrated on the back side of the resin sheet 2c in the same process. In this case, the adhesion improving surface treatment is a corona discharge treatment or plasma discharge treatment generally performed as an adhesion improving surface treatment of the resin sheet 2c. Furthermore, since these surface treatments with improved adhesive strength are performed, the choice of resin sheets is widened, and stable production is possible compared to poly sand paper having a three-layer structure by general heat fusion. .

この防湿シート状物２は、上記木質基材１の木質繊維板１ａ上に重ね合わせる下側紙層２ｂを熱硬化性樹脂接着剤によって一体に接着させていると共に、上側紙層２ａの上面を化粧突板３の下面に熱硬化性樹脂接着剤４ａによって、一体に接着させることにより、木質基材１の木質繊維板１ａ上に防湿シート状物２を介して化粧突板３が一体に積層接着していると共に、防湿シート状物２の上下紙層２ａ、２ｂには、上記熱硬化性樹脂接着剤４ａ、４ｂがそれぞれ全体（全層）に亘って含浸硬化されている強化床材Ａを構成している。   The moisture-proof sheet-like material 2 is formed by integrally bonding a lower paper layer 2b to be superimposed on the wood fiber board 1a of the wood base material 1 with a thermosetting resin adhesive, and the upper surface of the upper paper layer 2a. The veneer veneer 3 is integrally bonded to the lower surface of the veneer veneer 3 with a thermosetting resin adhesive 4a, so that the veneer veneer 3 is integrally laminated and bonded onto the wood fiber board 1a of the wood substrate 1 via the moisture-proof sheet-like material 2. In addition, the upper and lower paper layers 2a and 2b of the moisture-proof sheet-like material 2 constitute a reinforced floor material A in which the thermosetting resin adhesives 4a and 4b are impregnated and cured over the whole (all layers), respectively. is doing.

上記樹脂シート２ｃとしては、ドライラミネート法により上下紙層２ａ、２ｂと積層一体化されるため、高密度ポリエチレン、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエステル、ポリアミド等の１５０〜２００度以上の耐熱温度を有する、耐熱性に優れた樹脂シートの選定が可能である。なお、樹脂シート２ｃはこれらに限定されるものでなく、化粧突板３を貼着する熱圧プレスの温度（１００〜１３０℃）と圧力（０．８〜１．５ＭＰａ）に耐え、接着力改善表面処理により強接着が可能な樹脂シートであれば、どのようなものでも使用できる。   Since the resin sheet 2c is laminated and integrated with the upper and lower paper layers 2a and 2b by a dry laminating method, the resin sheet 2c has a heat-resistant temperature of 150 to 200 ° C. or higher such as high-density polyethylene, polyethylene terephthalate, polybutylene terephthalate, polyester, and polyamide. It is possible to select a resin sheet having excellent heat resistance. In addition, the resin sheet 2c is not limited to these, and can withstand the temperature (100 to 130 ° C.) and pressure (0.8 to 1.5 MPa) of a hot-press press for attaching the decorative veneer 3 to improve the adhesive strength. Any resin sheet that can be strongly bonded by surface treatment can be used.

この樹脂シート２ｃの上下に層着されている上下紙層２ａ、２ｂとしては、２０〜５０μｍ程度のクラフト紙、薄葉紙、チタン紙等が用いられる。さらに好適には、ラテックスや合成樹脂等を含浸硬化させた紙間強化シート状物が使用される。ただし、この紙間強化シート状物は、上記熱硬化性樹脂接着剤４ａ、４ｂの含浸を阻害しない程度に紙間強化されている必要がある。   As the upper and lower paper layers 2a and 2b layered on the upper and lower sides of the resin sheet 2c, kraft paper, thin paper, titanium paper or the like of about 20 to 50 μm is used. More preferably, a paper-reinforced sheet-like material impregnated and cured with latex or synthetic resin is used. However, this inter-paper reinforcing sheet-like material needs to be inter-paper strengthened to such an extent as not impeding the impregnation of the thermosetting resin adhesives 4a, 4b.

防湿シート状物２の上下紙層２ａ、２ｂに含浸硬化すると共に、この防湿シート状物２を介して木質基材１の木質繊維板１ａ上に化粧突板３を一体に積層、接着させている上記熱硬化性樹脂接着剤４ａ、４ｂとしては、熱硬化特性を有していればどのような接着剤でも使用可能であり、例えば、尿素メラミン系樹脂、ポリエステル系樹脂、酢酸ビニル系樹脂、メラミン系樹脂やイソシアネート系樹脂及びこれらの変性物を単独又は混合した接着剤等が好適に使用できる。   The upper and lower paper layers 2a and 2b of the moisture-proof sheet 2 are impregnated and cured, and the decorative veneer 3 is integrally laminated and adhered to the wood fiber board 1a of the wood substrate 1 through the moisture-proof sheet 2. As the thermosetting resin adhesives 4a and 4b, any adhesive having thermosetting properties can be used. For example, urea melamine resin, polyester resin, vinyl acetate resin, melamine Adhesives or the like in which a single resin, an isocyanate resin, or a modified product thereof is used alone or in combination can be preferably used.

木質基材１の表層部を形成している木質繊維板１ａ上に防湿シート状物２の下側紙層２ｂを接着させる熱硬化性樹脂接着剤４ｂとしては、耐傷性を向上させるために比較的固めの尿素メラミン系樹脂を接着することができ、耐キャスター性を向上させるためには、弾性を有する酢酸ビニル系樹脂やラテックス系樹脂及びこれらの変性物を単独又はメラミン樹脂等と適宜混同した弾性を有する熱硬化性樹脂接着剤を使用することが望ましい。   The thermosetting resin adhesive 4b for adhering the lower paper layer 2b of the moisture-proof sheet 2 to the wood fiber board 1a forming the surface layer portion of the wood substrate 1 is compared in order to improve scratch resistance. In order to improve the caster resistance, it is possible to adhere a hard urea melamine resin, and to mix the elastic vinyl acetate resin and latex resin and their modified products alone or with melamine resin as appropriate It is desirable to use a thermosetting resin adhesive having elasticity.

さらに、防湿シート状物２の上側紙層２ａと化粧突板３とを接着させる熱硬化性樹脂接着剤４ａとしては、強化床材Ａの耐クラック性能と耐キャスター性能を向上させるために、弾性を有する熱硬化性樹脂接着剤を使用することが好ましく、特に、酢酸ビニル系樹脂やラテックス系樹脂に、アクリル系樹脂、メラミン系樹脂やイソシアネート系樹脂及びこれらの変性物を単独又は混合した熱硬化性樹脂を添加した上記接着剤が好適に使用される。この場合、熱硬化性樹脂接着剤４ａと熱硬化性樹脂接着剤４ｂは、同じ組成の接着剤でもよく、別な組成の接着剤でもよい。   Further, as the thermosetting resin adhesive 4a for adhering the upper paper layer 2a of the moisture-proof sheet 2 and the decorative veneer 3 in order to improve the crack resistance performance and caster performance of the reinforced floor material A, elasticity is used. It is preferable to use a thermosetting resin adhesive having, in particular, a thermosetting material in which an acrylic resin, a melamine resin, an isocyanate resin, and a modified product thereof are used alone or in combination with a vinyl acetate resin or a latex resin. The above-mentioned adhesive added with a resin is preferably used. In this case, the thermosetting resin adhesive 4a and the thermosetting resin adhesive 4b may be an adhesive having the same composition or an adhesive having a different composition.

次に、上記のように構成した強化床材Ａの製造方法について述べる。図２は、その一つの実施例であり、同図（イ）に示すように、表層部に、比重０．４〜１．０の木質繊維板１ａを一体に設けている木質基材１の表面にロールコーターによって、熱硬化性樹脂接着剤４ｂを全面に亘って塗布したのち、耐熱性及び防湿性を有する樹脂シート２ｃの上下面に上側紙層２ａと下側紙層２ｂを接着剤により積層一体化させた防湿シート状物２を載置する。さらに、この防湿シート状物２の上側紙層２ａに熱硬化性樹脂接着剤４ａを塗布したのち、この熱硬化性樹脂接着剤４ａを介して防湿シート状物２上に化粧突板３を積み重ねることによって、木質基材１と防湿シート状物２と化粧突板３とからなる積層体Ａ'を得る。   Next, the manufacturing method of the reinforced flooring A comprised as mentioned above is described. FIG. 2 shows one embodiment of the wood substrate 1 in which a wood fiber board 1a having a specific gravity of 0.4 to 1.0 is integrally provided on the surface layer portion as shown in FIG. After the thermosetting resin adhesive 4b is applied over the entire surface by a roll coater, the upper paper layer 2a and the lower paper layer 2b are bonded to the upper and lower surfaces of the resin sheet 2c having heat resistance and moisture resistance with an adhesive. The moisture-proof sheet-like material 2 laminated and integrated is placed. Further, after applying the thermosetting resin adhesive 4a to the upper paper layer 2a of the moisture-proof sheet-like material 2, the decorative veneer 3 is stacked on the moisture-proof sheet-like material 2 via the thermosetting resin adhesive 4a. Thus, a laminate A ′ composed of the wooden substrate 1, the moisture-proof sheet-like material 2 and the decorative veneer 3 is obtained.

木質基材１の木質繊維板１ａの表面と、防湿シート状物２の上側紙層２ａにそれぞれ塗布する上記熱硬化性樹脂接着剤４ａ、４ｂの塗布量は、防湿シート状物２ａ、２ｂの紙厚によって異なるが、上下紙層２ａ、２ｂ内に、全体にわたって含浸させ、かつ、木質基材１の木質繊維板１ａとの接着及び化粧突板３との接着を全面的に確実に行わせるため、上下紙層２ａ、２ｂが、３０μｍ程度の薄葉紙であれば、７５ｇ／ｍ２程度、５０μｍ程度のクラフト紙からなる場合は、１３０ｇ／ｍ２程度の接着剤を塗布する必要がある。   The amount of the thermosetting resin adhesive 4a, 4b applied to the surface of the wood fiber board 1a of the wood substrate 1 and the upper paper layer 2a of the moisture-proof sheet-like material 2 is the same as that of the moisture-proof sheet-like materials 2a, 2b. Although depending on the paper thickness, the upper and lower paper layers 2a and 2b are entirely impregnated, and the adhesion to the wood fiber board 1a of the wood substrate 1 and the adhesion to the decorative projecting board 3 are ensured over the entire surface. If the upper and lower paper layers 2a and 2b are thin papers of about 30 μm, it is necessary to apply an adhesive of about 130 g / m 2 if they are made of kraft paper of about 75 g / m 2 or about 50 μm.

次いで、この積層体Ａ'を熱圧プレス機の上下プレス盤内に挿入して、温度１００〜１３０℃、圧力０．３〜１．５ＭＰａの熱圧条件でもって３０〜９０秒間、熱圧プレスする。この際、木質基材１の木質繊維板１ａの表面、及び、防湿シート状物２の上側紙層２ａ上に塗布している熱硬化性樹脂接着剤４ａの塗布量が多いため、含まれている水分によって、パンクが発生することがある。このパンクを防止するために、熱圧プレスを２段階に分けて行うことも行うことが望ましい。すなわち、最初に温度１００〜１３０℃、圧力０．２〜０．５ＭＰａの熱圧条件でもって１０〜３０秒程度のプレススケジュールでもってＡ’を熱圧プレスすることにより、熱硬化性樹脂接着剤４ａ、４ｂの接着剤中の水分を水蒸気として飛ばした後、続いて温度１００〜１３０℃、圧力０．８〜１．５ＭＰａの熱圧条件でもって３０〜６０秒程度のプレススケジュールでもって、Ａ’を熱圧プレスする。   Next, this laminate A ′ is inserted into the upper and lower press panels of a hot press machine, and hot press is performed for 30 to 90 seconds under hot press conditions of a temperature of 100 to 130 ° C. and a pressure of 0.3 to 1.5 MPa. To do. At this time, since the amount of the thermosetting resin adhesive 4a applied on the surface of the wood fiber board 1a of the wood substrate 1 and the upper paper layer 2a of the moisture-proof sheet-like material 2 is large, it is included. Puncturing may occur depending on the water content. In order to prevent this puncture, it is desirable to perform the hot-pressing in two stages. That is, a thermosetting resin adhesive is first obtained by hot-pressing A ′ with a press schedule of about 10 to 30 seconds under conditions of hot pressure of a temperature of 100 to 130 ° C. and a pressure of 0.2 to 0.5 MPa. After the moisture in the adhesives 4a and 4b was blown off as water vapor, the press schedule was about 30 to 60 seconds under the hot pressure conditions of temperature 100 to 130 ° C. and pressure 0.8 to 1.5 MPa. 'Hot press.

この熱圧プレスによって、熱硬化性樹脂接着剤４ａ、４ｂが防湿シート状物２の上下紙層２ａ、２ｂに全体（全層）に亘って含浸したのち硬化するとともに、これらの熱硬化性樹脂接着剤４ａ、４ｂによって木質基材１の木質繊維板１ａの表面に防湿シート状物２を介して化粧突板３が積層接着して図２（ロ）に示すように強化床材を得る。この強化床材Ａはこのまま床材として使用してよいが、その表面に浮造り加工や塗装を施すことが好適に行われる。   By this hot-pressing, the thermosetting resin adhesives 4a and 4b are impregnated over the whole (all layers) of the upper and lower paper layers 2a and 2b of the moisture-proof sheet-like material 2 and then cured, and these thermosetting resins The decorative veneer 3 is laminated and adhered to the surface of the wood fiber board 1a of the wood substrate 1 with the moisture-proof sheet-like material 2 by the adhesives 4a and 4b to obtain a reinforced flooring as shown in FIG. Although this reinforced flooring A may be used as it is as a flooring, it is preferable to float or paint on the surface.

このような化粧加工において、着色を施す場合に、その着色剤としては特に限定されないが、有機顔料や無機顔料等の顔料系着色剤や、染料系着色剤が好適に使用される。また、塗装による化粧加工の場合においても、その塗装材料は特に限定されないが、熱硬化性樹脂や紫外線硬化型樹脂、電子線硬化型樹脂等の様々な塗料を使用することが出来る。特に、床用の塗装用塗料としては、好適にはＶＯＣの問題が少ない無溶剤系の紫外線硬化型アクリレート樹脂が好適に使用することが出来る。   In such cosmetic processing, when coloring is performed, the colorant is not particularly limited, but pigment-based colorants such as organic pigments and inorganic pigments, and dye-based colorants are preferably used. Also, in the case of cosmetic processing by painting, the coating material is not particularly limited, but various paints such as a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin can be used. In particular, a solvent-free ultraviolet curable acrylate resin with few VOC problems can be suitably used as a floor coating.

図３は、本発明の強化床材Ａの別な製造方法を示すもので、まず、同図（イ）に示すように、表層部に比重０．４〜１．０の木質繊維板１ａを一体に設けている木質基材１の表面にロールコーターによって、熱硬化性樹脂接着剤４ｂを全面に亘って塗布した後、防湿シート状物２を重ねることにより、木質基材１と防湿シート状物２からなる中間積層体Ａ１を得る。   FIG. 3 shows another method for producing the reinforced flooring A of the present invention. First, as shown in FIG. 3 (a), a wood fiber board 1a having a specific gravity of 0.4 to 1.0 is applied to the surface layer portion. After the thermosetting resin adhesive 4b is applied over the entire surface by a roll coater on the surface of the wood base material 1 provided integrally, the wood base material 1 and the moisture-proof sheet shape are overlapped with the moisture-proof sheet material 2 An intermediate laminate A1 made of the product 2 is obtained.

次いで、この中間積層体Ａ１を熱圧プレス機の上下プレス盤間に挿入して上記実施例における強化床材Ａの製造時と同じプレススケジュールでもって熱圧プレスすることにより、熱硬化性樹脂接着剤４ｂを防湿シート状物２の下側紙層２ｂの全体（全層）に亘って含浸させるとともに硬化させると共に、この熱硬化性樹脂接着剤４ｂによって、木質基材１の木質繊維板１ａの表面に防湿シート状物２を一体に積層接着する。この熱圧プレスによる木質基材１と防湿シート状物２との接着処理を第一熱圧工程とする。第一熱圧工程後は、熱圧された中間積層体を冷却する冷却工程により、３５℃以下、好ましくは３０℃以下に中間積層体を冷却養生する。   Next, the intermediate laminate A1 is inserted between the upper and lower presses of the hot press machine and hot press is performed using the same press schedule as that for manufacturing the reinforced flooring A in the above embodiment, thereby bonding the thermosetting resin. The agent 4b is impregnated over the entire lower paper layer 2b (all layers) of the moisture-proof sheet-like material 2 and cured, and the thermosetting resin adhesive 4b allows the wood fiber board 1a of the wood substrate 1 to be cured. A moisture-proof sheet-like material 2 is integrally laminated and adhered to the surface. The adhesion treatment between the wooden substrate 1 and the moisture-proof sheet-like material 2 by this hot-pressing is defined as a first hot-pressing step. After the first hot pressing step, the intermediate laminated body is cooled and cured at 35 ° C. or lower, preferably 30 ° C. or lower, by a cooling step of cooling the hot-pressed intermediate laminated body.

しかる後、図３（ロ）に示すように、この中間積層体Ａ１における防湿シート状物２の上側紙層２ａ上にロールコーターによって、熱硬化性樹脂接着剤４ａを全面に亘って均一に塗布し、この熱硬化性樹脂接着剤４ａを介して化粧突板３を防湿シート状物２上に重ね合わせることにより、最終積層体Ａ’’を形成する。   Thereafter, as shown in FIG. 3B, the thermosetting resin adhesive 4a is uniformly applied over the entire surface by the roll coater on the upper paper layer 2a of the moisture-proof sheet 2 in the intermediate laminate A1. Then, the final laminate A ″ is formed by superposing the decorative projecting plate 3 on the moisture-proof sheet-like material 2 through the thermosetting resin adhesive 4a.

こうして得られた最終積層体Ａ’’を、上記中間積層体Ａ１に対する熱圧プレス工程として、第二熱圧プレス工程を行うことにより、図３（ハ）に示すように強化床材Ａを得ることができる。この場合、第二熱圧プレス工程も上記と同様に、最終積層体Ａ’’を熱圧プレス機の上下プレス盤間に挿入して、上記実施例における強化床材Ａの製造時と同じプレススケジュールの条件でもって熱圧プレスすることにより、熱硬化性樹脂接着剤４ａを防湿シート状物２の上側紙層２ａの全体（全層）に亘って含浸させるとともに硬化させると共に、この熱硬化性樹脂接着剤４ａによって、防湿シート状物２の表面に化粧突板３を一体に積層接着する。   The final laminate A ″ thus obtained is subjected to a second hot-pressing step as a hot-pressing step for the intermediate laminate A1, thereby obtaining a reinforced flooring A as shown in FIG. be able to. In this case, in the second hot-pressing step as well, the final laminate A ″ is inserted between the upper and lower press panels of the hot-pressing machine, and the same press as in the manufacture of the reinforced flooring A in the above embodiment. The thermosetting resin adhesive 4a is impregnated throughout the entire upper paper layer 2a (all layers) of the moisture-proof sheet-like material 2 and cured by hot pressing under the conditions of the schedule. The decorative veneer 3 is integrally laminated and bonded to the surface of the moisture-proof sheet-like material 2 by the resin adhesive 4a.

得られた強化床材Ａは、前記製造方法によって得られた強化床材Ａと略同一の物性を有し、その化粧突板３の表面に上記同様に任意の化粧加工を施して優れた外観と安定した品質を有する強化床材を得ることができる。次に、本発明の具体的な実施例を示す。   The obtained reinforced flooring A has substantially the same physical properties as the reinforced flooring A obtained by the above-described manufacturing method, and the surface of the decorative veneer 3 is subjected to any cosmetic processing in the same manner as described above and has an excellent appearance. A reinforced flooring material having stable quality can be obtained. Next, specific examples of the present invention will be described.

〔実施例１〕
厚み９ｍｍで５層構成のラワン合板の表面に変性酢酸ビニル系接着剤をロールコーターで６５ｇ／ｍ２塗布した。この表面に厚み２．７ｍｍで比重が０．８の木質繊維板を積層し、冷圧プレスにより積層接着し、木質基材を得た。この木質基材の表面に尿素メラミン系樹脂１００重量部に対してＳＢＲ系樹脂を１５重量部添加してなる樹脂固形分率５０％の熱硬化性樹脂接着剤をロールコーターにより、７５ｇ／ｍ２塗布した。次いで、軟化点１３０℃の高密度ポリエチレン樹脂シートの上下面にコロナ放電処理を行い、この上下面それぞれに厚さ３０μｍで目付量３０ｇ／ｍ２の薄葉紙をウレタン系接着剤でドライラミネートし積層一体化した３層の防湿シート状物を上記熱硬化性樹脂接着剤の層上に重ねた後、この防湿シート状物上に尿素メラミン系樹脂１００重量部に対して、ラテックス系樹脂を５０重量部添加してなる樹脂固形分率５０％の熱硬化性樹脂接着剤をロールコーターによって、７５ｇ／ｍ２塗布した。 [Example 1]
65 g / m 2 of a modified vinyl acetate adhesive was applied to the surface of a lauan plywood having a thickness of 9 mm and a 5-layer structure using a roll coater. A wood fiber board having a thickness of 2.7 mm and a specific gravity of 0.8 was laminated on this surface, and laminated and adhered by a cold press to obtain a wood substrate. Applying 75 g / m2 of thermosetting resin adhesive having a resin solid content of 50% to the surface of this wood base material by adding 15 parts by weight of SBR resin to 100 parts by weight of urea melamine resin by a roll coater did. Next, the upper and lower surfaces of the high-density polyethylene resin sheet having a softening point of 130 ° C. are subjected to corona discharge treatment. After stacking the three layers of moisture-proof sheet on the thermosetting resin adhesive layer, 50 parts by weight of latex resin is added to 100 parts by weight of urea melamine-based resin on the moisture-proof sheet. A thermosetting resin adhesive having a resin solid content of 50% was applied by a roll coater at 75 g / m 2.

しかる後、この熱硬化性樹脂接着剤の層上に化粧突板を載置し、直ちに平板熱圧プレス機により、１２０℃、０．５ＭＰａの熱圧を１５秒間行い、続いて、１２０℃、０．８ＭＰａの熱圧を４５秒間行うプレススケジュールでもって熱圧プレスすることにより、強化床材を得た。こうして得られた強化床材における化粧突板の表面に無機顔料形の水系着色剤で着色した後、ドライヤーで乾燥させ、アクリレート系の紫外線硬化型樹脂で透明塗膜層を化粧突板表面に形成した。   Thereafter, a decorative veneer is placed on the thermosetting resin adhesive layer and immediately subjected to hot pressing at 120 ° C. and 0.5 MPa for 15 seconds by a flat plate hot press machine, followed by 120 ° C., 0 A reinforced flooring was obtained by hot-pressing with a press schedule in which a hot pressure of .8 MPa was applied for 45 seconds. The surface of the decorative veneer in the reinforced floor material thus obtained was colored with an inorganic pigment-type water-based colorant, and then dried with a drier, and a transparent coating layer was formed on the surface of the veneer veneer with an acrylate-based ultraviolet curable resin.

この強化床材に対して、耐キャスター試験を行った。試験の結果、上下紙層での紙間剥離や単板でのせん断破壊等は確認されなかった。また、試験後の試験体の表面観察を行ったが、全く問題なかった。この耐キャスター試験とは、２５ｋｇの重りを載せた単輪の鉄キャスターを強化床材の同一箇所を通過するように３００ｍｍの距離を往復運動させる試験である。移動スピードは、２秒／一往復である。   A caster resistance test was performed on the reinforced flooring. As a result of the test, separation between papers in the upper and lower paper layers, shear fracture in the single plate, and the like were not confirmed. Further, the surface of the test specimen after the test was observed, but there was no problem at all. This caster-resistant test is a test in which a single-wheel iron caster carrying a weight of 25 kg is reciprocated by a distance of 300 mm so as to pass through the same portion of the reinforced flooring. The moving speed is 2 seconds / one round trip.

〔実施例２〕
上記実施例１の木質基材表面に塗布した熱硬化性樹脂接着剤を赤色に着色し、防湿シート状物上に塗布した熱硬化性樹脂接着剤を青色に着色した以外は、実施例１と全く同じ製法で強化床材を得た。この強化床材を断面観察したところ、防湿シート状物の下側紙層は全体（全層）が赤色であり、上側紙層は全体（全層）が青色に着色されているのが確認できた。 [Example 2]
Example 1 except that the thermosetting resin adhesive applied to the surface of the wood substrate of Example 1 was colored red and the thermosetting resin adhesive applied on the moisture-proof sheet was colored blue. Reinforced flooring was obtained using exactly the same manufacturing method. A cross-sectional observation of this reinforced flooring confirmed that the lower paper layer of the moisture-proof sheet was entirely red (all layers) and that the upper paper layer was colored blue (all layers). It was.

〔比較例〕
上記実施例２の木質基材表面に塗布した熱硬化性樹脂接着剤の塗布量を５０ｇ／ｍ２にし、防湿シート状物上に塗布した熱硬化性樹脂接着剤の塗布量を５０ｇ／ｍ２にした以外は実施例２と全く同じ方法で強化床材を得、この強化床材に対して耐キャスター試験を行った。試験の結果、表面観察により、一部で単板の浮きが確認された。単板の浮きの部分を切断し、断面観察を行ったところ、下側紙層の一部で紙間剥離し、単板の浮きが発生していることが確認された。この紙間剥離している部分は、防湿シート状物の下側紙層と樹脂シートの界面で、青色になっていない、つまり熱硬化性樹脂接着剤が含浸硬化されていない部分であった。 [Comparative example]
The application amount of the thermosetting resin adhesive applied to the surface of the wood substrate of Example 2 was set to 50 g / m2, and the application amount of the thermosetting resin adhesive applied to the moisture-proof sheet was set to 50 g / m2. Except for the above, a reinforced flooring was obtained in exactly the same manner as in Example 2, and a caster resistance test was performed on the reinforced flooring. As a result of the test, the single plate was partially lifted by surface observation. When the floating portion of the veneer was cut and the cross section was observed, it was confirmed that the paper was peeled off at a part of the lower paper layer and the veneer was lifted. The part where the paper was peeled off was a part which was not blue at the interface between the lower paper layer of the moisture-proof sheet and the resin sheet, that is, the part where the thermosetting resin adhesive was not impregnated and cured.

優れた防湿性を維持しつつ、キャスターの使用等に対しても充分な耐傷性と強度を発揮することが出来るとともに、紙間剥離や化粧単板のせん断破壊が生じ難い強化床材とこの製造方法を提供する。   Reinforced flooring that can exhibit sufficient scratch resistance and strength even when casters are used while maintaining excellent moisture-proof properties, and that does not easily cause peeling between papers or shear breakage of decorative veneers and its manufacture Provide a method.

強化床材の簡略縦断面図Simplified longitudinal section of reinforced flooring 強化床材の製造方法の一例を示す簡略工程図Simplified process diagram showing an example of manufacturing method for reinforced flooring 強化床材の別の製造方法の一例を示す簡略工程図Simplified process diagram showing an example of another method for manufacturing reinforced flooring

符号の説明Explanation of symbols

Ａ 強化床材
１ 木質基材
１ａ 木質繊維板
２ 防湿シート状物
２ａ 上側紙層
２ｂ 下側紙層
２ｃ 樹脂シート
３ 化粧突板
４ａ、４ｂ 熱硬化性樹脂接着剤 A Reinforced flooring 1 Wood base 1a Wood fiber board 2 Moisture-proof sheet 2a Upper paper layer 2b Lower paper layer 2c Resin sheet 3 Cosmetic veneer 4a, 4b Thermosetting resin adhesive

Claims (5)

少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材と、熱硬化性樹脂接着剤を含浸硬化させている下側紙層と、耐熱性及び防湿性を有する樹脂シートと、熱硬化性樹脂接着剤を含浸硬化させている上側紙層と、化粧突板とを順次、積層一体化してなることを特徴とする強化床材。   A wood base material comprising at least a hard wood fiber board having a specific gravity of 0.4 to 1.0, a lower paper layer impregnated and cured with a thermosetting resin adhesive, and a resin having heat resistance and moisture resistance A reinforced flooring material comprising a sheet, an upper paper layer impregnated and cured with a thermosetting resin adhesive, and a decorative veneer, which are sequentially laminated and integrated. 上側紙層は３０〜５０μｍの厚みを有していると共に、この上側紙層に含浸硬化されている熱硬化性樹脂接着剤は弾性を有する接着剤であって、この接着剤を上側紙層の全体に亘って含浸硬化させていることを特徴とする請求項１に記載の強化床材   The upper paper layer has a thickness of 30 to 50 μm, and the thermosetting resin adhesive impregnated and cured in the upper paper layer is an adhesive having elasticity, and this adhesive is applied to the upper paper layer. The reinforced flooring material according to claim 1, which is impregnated and cured throughout. 少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に、耐熱性及び防湿性を有する樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置し、さらに、この防湿シート状物上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して防湿シート状物の表面に化粧突板を載置することによって、木質基材と防湿シート状物と化粧突板とからなる積層体を形成し、この積層体を熱圧することによって、上記上側紙層及び上記下側紙層それぞれに上記熱硬化性樹脂接着剤を含浸硬化させると共に、これらの熱硬化性樹脂接着剤によって、木質基材の表面に、防湿シート状物を介して化粧突板を積層一体化させることを特徴とする強化床材の製造方法。   After applying a thermosetting resin adhesive to the surface of a wooden base material comprising at least a hard wood fiber board having a specific gravity of 0.4 to 1.0, the surface of the wooden base material is passed through this thermosetting resin adhesive. On the surface, a moisture-proof sheet-like material in which an upper paper layer and a lower paper layer are laminated and integrated with an adhesive is placed on the upper and lower surfaces of a heat-resistant and moisture-proof resin sheet. After applying the thermosetting resin adhesive to the wood base material, the moisture-proof sheet material and the decorative veneer by placing the decorative veneer on the surface of the moisture-proof sheet material through the thermosetting resin adhesive The above-mentioned thermosetting resin adhesive is impregnated and cured in each of the upper paper layer and the lower paper layer by forming a laminate composed of Due to the moisture-proof sheet shape on the surface of the wooden substrate Method for producing a reinforcing flooring for causing integrally laminating a decorative sliced veneer through. 少なくとも表層部が比重０．４〜１．０の硬質木質繊維板からなる木質基材の表面に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して木質基材の表面に、耐熱性及び防湿性を有する樹脂シートの上下面に上側紙層と下側紙層を接着剤により積層一体化させた防湿シート状物を載置することにより、木質基材と防湿シート状物とからなる中間積層体を形成し、この中間積層体を熱圧することによって防湿シート状物の下側紙層に上記熱硬化性樹脂接着剤を全体に亘って含浸硬化させると共に木質基材表面に防湿シート状物を一体に接着させる第一熱圧工程と、熱圧された中間積層体を冷却する冷却工程と、冷却された中間積層体上に熱硬化性樹脂接着剤を塗布したのち、この熱硬化性樹脂接着剤を介して中間積層体に化粧突板を載置することにより最終積層体を形成し、この最終積層体を熱圧することによって防湿シート状物の上側紙層に中間積層体上に塗布した上記熱硬化性樹脂接着剤を含浸硬化させると共に防湿シート状物上に化粧突板を一体に接着させる第二熱圧工程とからなることを特徴とする強化床材の製造方法。   After applying a thermosetting resin adhesive to the surface of a wooden base material comprising at least a hard wood fiber board having a specific gravity of 0.4 to 1.0, the surface of the wooden base material is passed through this thermosetting resin adhesive. On the surface, a wooden substrate and a moisture-proof sheet are placed by placing a moisture-proof sheet-like material in which upper and lower paper layers are laminated and integrated with an adhesive on the upper and lower surfaces of a heat-resistant and moisture-proof resin sheet. An intermediate laminate comprising a sheet is formed, and the intermediate laminate is hot-pressed to impregnate and cure the thermosetting resin adhesive over the entire lower paper layer of the moisture-proof sheet. After applying a thermosetting resin adhesive on the cooled intermediate laminate, a first hot-pressing step in which the moisture-proof sheet-like material is integrally bonded to the surface, a cooling step in which the hot-pressed intermediate laminate is cooled, and Make up on the intermediate laminate through this thermosetting resin adhesive A final laminate is formed by placing a plate, and the final laminate is heated and pressed to impregnate and cure the thermosetting resin adhesive applied on the intermediate laminate on the upper paper layer of the moisture-proof sheet. And a second hot-pressing step in which the decorative veneer is integrally bonded onto the moisture-proof sheet-like material. 請求項３及び請求項４の強化床材の製造方法の発明において、上側紙層は３０〜５０μｍの厚みを有していると共に、この上側紙層に含浸硬化される熱硬化性樹脂接着剤は弾性を有する接着剤であって、この接着剤を上側紙層の全体に亘って含浸硬化させることを特徴とする強化床材の製造方法   In the invention of the method for producing a reinforced flooring according to claim 3 and claim 4, the upper paper layer has a thickness of 30 to 50 μm, and the thermosetting resin adhesive impregnated and cured in the upper paper layer is A method for producing a reinforced flooring, characterized in that the adhesive has elasticity, and the adhesive is impregnated and cured over the entire upper paper layer.

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