JP2011052511A

JP2011052511A - Floor material

Info

Publication number: JP2011052511A
Application number: JP2009205147A
Authority: JP
Inventors: Takuji Tanaka; 拓児田中; Masaki Fukui; 雅基福井; Sadao Nomura; 貞夫野村
Original assignee: Fukuvi Chemical Industry Co Ltd; Daiken Corp
Current assignee: Fukuvi Chemical Industry Co Ltd; Daiken Corp
Priority date: 2009-09-04
Filing date: 2009-09-04
Publication date: 2011-03-17
Anticipated expiration: 2029-09-04
Also published as: JP5143804B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor material which prevents a resident from feeling cold when touching the material even in winter and manufactured by tongue and groove joints by taking construction performance and ease of use into account. <P>SOLUTION: This floor material A includes a floor finish material 1 constituted by laminating a decorative layer 2, a surface reinforcing layer 3, a hard foaming body layer 4, and a rear surface reinforcing layer 5 sequentially and integrally, forming a female solid part 10 and a male solid part 14 on an end face 1a of a butt end, and applying tongue and groove joints and a heat insulating layer 20 laminated and integrated on/with the rear surface of the floor finish material 1. The decorative layer 2 is formed of a resin-made decorative sheet having minute recessed and projecting parts 2a on its surface or a coated material. The surface and rear surface reinforcing layers 3, 5 are formed of an inorganic fiber sheet filled with a moisture hardening type resin or a reaction type resin, and tongue and groove joints are applied on the end face 1a of the butt end of the floor finish material 1. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、床材に関し、特に接触冷感を感じ難い床材に関する。 The present invention relates to a flooring, and more particularly to a flooring that hardly feels a feeling of contact cooling.

従来、遮音を目的として防音性能に優れるとともに、人が歩行しても「ふかふか」せずに歩行感のよい床材として、特許文献１に示されるものが提案されている。この特許文献１の床材は、硬質板状体を表面層とし、それに硬質発泡体及び軟質発泡体が積層された床材であって、上記硬質発泡体に長軸を略厚み方向に配向した気泡が形成されているものである。 Conventionally, a flooring material disclosed in Patent Document 1 has been proposed as a flooring material that has excellent soundproofing performance for the purpose of sound insulation and has a good walking feeling without being “fluffy” even when a person walks. The flooring of Patent Document 1 is a flooring in which a hard plate-like body is used as a surface layer, and a hard foam and a soft foam are laminated thereon, and the major axis of the hard foam is oriented in a substantially thickness direction. Bubbles are formed.

特開平１０−２６６５４５号公報Japanese Patent Laid-Open No. 10-266545

ところが、この特許文献１に示される床材をマンションのコンクリートスラブに直貼りした場合、表面の厚さ１〜５ｍｍの硬質板状体が単板や合板であると、季節変動による湿気により、床材が変形する可能性がある。 However, when the floor material shown in Patent Document 1 is directly attached to a concrete slab of a condominium, if the hard plate-like body having a surface thickness of 1 to 5 mm is a single plate or plywood, The material may be deformed.

そして、硬質板状体として、樹脂板や繊維強化合成樹脂板を用いた場合は、単板や合板等のように季節変動による湿気により床材の変形は生じないものの、特に冬季に手や足で接触した場合、表面の硬さや冷たさ（いわゆる接触冷感）を感じるという問題があった。 And when a resin plate or a fiber reinforced synthetic resin plate is used as the hard plate, the floor material will not be deformed by moisture due to seasonal fluctuations as in the case of a single plate or plywood, but especially in the winter, When touching, there is a problem that the surface is hard or cold (so-called cold contact feeling).

さらに、図６（ａ）に示すように、この特許文献１の床材Ｂに対し、従来の床材に適用されるのと同様の雌実部１０及び雄実部１４を有する本実加工を施した場合、雌実部１０における雌実凸部１２が発泡体で構成されることとなり、その雌実凸部１２の強度は弱くなる。そのため、雌実部１０に対し、隣接する床材Ｂの雄実部１４を嵌合して両床材Ｂ，Ｂを施工した状態で、図６（ｂ）に示すように、両床材Ｂ，Ｂ同士の接合部（雌実部１０と雄実部１４との嵌合部）付近を踏みつけたとき、雌実部１０の雌実凸部１２によって雄実部１４を支持することが困難で、特に裏側（下側）の雌実凸部１２が変形し易くなり、その結果、接合部に段差が発生するという問題があった。 Further, as shown in FIG. 6 (a), the actual processing having the female real part 10 and the male real part 14 similar to those applied to the conventional flooring is performed on the flooring B of Patent Document 1. When applied, the female real convex part 12 in the female real part 10 is made of foam, and the strength of the female real convex part 12 becomes weak. Therefore, as shown in FIG. 6B, both floor materials B in a state in which the male real portions 14 of the adjacent floor materials B are fitted to the female real portions 10 and both floor materials B and B are constructed. , B, it is difficult to support the male part 14 by the female convex part 12 of the female real part 10 when the vicinity of the joint part (fitting part of the female real part 10 and the male real part 14) is stepped on. In particular, the back side (lower side) female real convex portion 12 is easily deformed, and as a result, there is a problem that a step is generated at the joint portion.

他方、発泡体基材の表面に化粧シートを積層一体化したいわゆるクッションフロアが上市されており、このクッションフロアは、冷たく冷えた状態においても、素手や素足で接触したときに冷感を感じ難いという特長がある。しかし、クッションフロアは床面表面に家具を置いたり、重いものを引きずったりすると、床面が傷付くという問題がある。 On the other hand, a so-called cushion floor in which a decorative sheet is laminated and integrated on the surface of the foam base material is marketed. Even when the cushion floor is cold and cold, it is difficult to feel a cold feeling when touched with bare hands or bare feet. There is a feature. However, the cushion floor has a problem that the floor surface is damaged when furniture is placed on the floor surface or when a heavy object is dragged.

本発明は斯かる点に鑑みてなされたもので、その目的とするところは、冬季でも接触冷感を感じ難く、施工性及び施工後の使用に配慮した本実加工を備えることのできる接触冷感を感じ難い床材が得られるようにすることにある。 The present invention has been made in view of such a point, and the object of the present invention is to make contact cooling that makes it difficult to feel a feeling of contact cooling even in winter, and that can be provided with actual processing in consideration of workability and use after construction. The goal is to obtain a flooring that is difficult to feel.

上記の目的を達成するために、請求項１の発明では、表面側から裏面側に向かって化粧層、表面補強層、硬質発泡体層及び裏面補強層が順に積層一体化されてなり、木口端面に雌実部及び雄実部を有していて該雌実部及び雄実部が他の床材の雄実部及び雌実部に嵌合可能な本実加工が施されている床仕上材と、この床仕上材の裏面に積層一体化された断熱層とを備えた床材が対象である。 In order to achieve the above object, according to the first aspect of the present invention, a decorative layer, a surface reinforcing layer, a hard foam layer, and a back reinforcing layer are laminated and integrated in order from the front side to the back side. The floor finishing material has a female real part and a male real part, and the real real processing is performed so that the female real part and the male real part can be fitted to the male real part and the female real part of other flooring materials. And the flooring provided with the heat insulation layer laminated | stacked and integrated on the back surface of this flooring material is object.

そして、上記化粧層は、表面に微細な凹凸部を有する樹脂化粧シート又は塗膜材からなる。 The decorative layer is made of a resin decorative sheet or a coating material having fine irregularities on the surface.

また、上記表面補強層及び裏面補強層は、湿気硬化性樹脂又は反応性樹脂が充填された無機質繊維シートからなることを特徴とする。 Moreover, the said surface reinforcement layer and back surface reinforcement layer consist of an inorganic fiber sheet with which moisture curable resin or reactive resin was filled.

この請求項１の発明では、床材における床仕上材は、硬質発泡体層の表裏両面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層及び裏面補強層が積層一体化されたものであるので、季節変動による湿気により床材が変形し難い。 In the first aspect of the present invention, the floor finishing material in the flooring is composed of a surface reinforcing layer and a back reinforcing layer made of an inorganic fiber sheet in which a moisture-curing resin or a reactive resin is filled on both front and back sides of the hard foam layer. Since these are laminated and integrated, the flooring is difficult to deform due to moisture due to seasonal fluctuations.

また、床仕上材表面の化粧層が、表面に微細な凹凸部を有する樹脂化粧シート又は塗膜材からなるので、この表面の微細な凹凸部により、素足又は素手の接触面積が減ることなり、同じ基材を用いた床材であっても、特に冬季に手や足で接触したときに、接触冷感（表面の硬さや冷たさ）が感じ難くなる。 In addition, since the decorative layer on the surface of the floor finish material is composed of a resin decorative sheet or a coating film material having fine uneven portions on the surface, the contact area of bare feet or bare hands is reduced by the fine uneven portions on the surface, Even if the flooring material uses the same base material, it is difficult to feel a cold feeling of contact (hardness or coldness of the surface) particularly when contacting with hands or feet in winter.

また、床仕上材は、上記硬質発泡体からなる硬質発泡体層の表裏面側に、樹脂が充填された無機質繊維シートからなる表面補強層及び裏面補強層が積層一体化され、その床仕上材の木口端面に雌実部及び雄実部が設けられているので、その雌実部は雌実凸部の強度が増大したものとなる。そのため、隣接する床材同士を床仕上材の木口端面の雌雄実部で実接合して施工したとき、両床材同士の接合部（雌実部と雄実部との嵌合部）付近を踏みつけて断熱層が圧縮変形したとしても、雌実部における表裏両側の雌実凸部が雄実部を確実に支持し、その雌実部の両雌実凸部が変形することなく、両床材の床仕上材が同じ高さで沈むようになり、両床材の接合部に段差が発生することはなく、施工性及び施工後の使用性が向上する。 Further, the floor finishing material has a surface reinforcing layer and a back reinforcing layer made of an inorganic fiber sheet filled with resin laminated and integrated on the front and back sides of the hard foam layer made of the hard foam, and the floor finishing material Since the female real part and the male real part are provided on the end face of the wood, the female real part has an increased strength of the female real convex part. Therefore, when adjacent flooring is actually joined at the male and female real part of the end of the floor finishing material, the vicinity of the joint part (fitting part between the female real part and male real part) between both flooring materials Even if the heat insulating layer is compressed and deformed by trampling, the female real projections on both sides of the female real part surely support the male real part, and both female real convex parts of the female real part are not deformed. The floor finishing material of the material sinks at the same height, and no step is generated at the joint between both floor materials, so that the workability and the usability after construction are improved.

また、上記床仕上材は、硬質発泡体層の表裏面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層及び裏面補強層とが積層一体化されたものであるので、床材の寸法安定性が向上する。 In addition, the floor finishing material is obtained by laminating and integrating a surface reinforcing layer and a back reinforcing layer made of an inorganic fiber sheet filled with a moisture curable resin or a reactive resin on the front and back sides of the hard foam layer. Therefore, the dimensional stability of the flooring is improved.

請求項２の発明では、請求項１の床材において、上記硬質発泡体層の表裏部分には、厚さ０．２〜０．５ｍｍ、比重０．７〜１．１の高比重層が形成され、これら高比重層が木口端面における雌実部の雌実凸部の一部を構成している一方、雄実部は高比重層以外の部分で構成されていることを特徴とする。 In the invention of claim 2, in the flooring material of claim 1, a high specific gravity layer having a thickness of 0.2 to 0.5 mm and a specific gravity of 0.7 to 1.1 is formed on the front and back portions of the hard foam layer. The high specific gravity layer constitutes a part of the female real convex part of the female real part on the end face of the mouth end, while the male real part is constituted by a part other than the high specific gravity layer.

この請求項２の発明では、床仕上材における硬質発泡体層の表裏部分に高比重層が形成され、これら高比重層で雌実部の雌実凸部の一部が構成されているので、その雌実部の雌実凸部の強度が高比重層によってさらに増大し、上記雌実部の雌実凸部の変形を確実に抑制して、施工性及び施工後の使用性の向上をより一層確実に図ることができる。 In the invention of this second aspect, a high specific gravity layer is formed on the front and back portions of the hard foam layer in the floor finish material, and a portion of the female real convex portion of the female real part is constituted by these high specific gravity layers. The strength of the female real part of the female real part is further increased by the high specific gravity layer, and the deformation of the female real convex part of the female real part is surely suppressed, thereby improving the workability and usability after construction. This can be achieved more reliably.

以上のように、請求項１の発明の床材によると、床仕上材の裏面に断熱層が積層一体化され、床仕上材は、硬質発泡体層の表裏面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層及び裏面補強層が積層一体化されたものとし、その床仕上材の木口端面に雌実部及び雄実部が設けられ、床仕上材表面には、表面に微細な凹凸部を有する樹脂化粧シートからなる表面層を設けたことにより、その化粧層表面の微細な凹凸部により、素足又は素手の接触面積が減ることなり、冬季に手や足で接触したときの接触冷感を感じ難くすることができる。また、床仕上材の木口端面における雌実部の表裏の雌実凸部の強度を表面補強層及び裏面補強層によって増大確保することができ、隣接する床材同士を床仕上材の木口端面の雌雄実部で実接合して施工し、両床材同士の接合部付近を踏みつけても、両床材の接合部に段差の発生を防止し、施工性及び施工後の使用性の向上を図ることができる。 As described above, according to the flooring material of the first aspect of the present invention, the heat insulating layer is laminated and integrated on the back surface of the floor finishing material, and the floor finishing material is formed with moisture curable resin or It is assumed that a surface reinforcing layer and a back reinforcing layer made of an inorganic fiber sheet filled with a reactive resin are laminated and integrated, and the floor finishing material is provided with a female real part and a male real part on the end face of the floor finishing material. By providing a surface layer made of a resin decorative sheet having fine irregularities on the surface, the fine irregularities on the surface of the decorative layer reduce the contact area of bare feet or bare hands. It is possible to make it difficult to feel a cold feeling when touching with a foot. In addition, the strength of the female convex part on the front and back of the female real part at the end face of the floor finish can be secured by the surface reinforcing layer and the back reinforcing layer, and the adjacent floor materials can be Even if it is constructed by actual joining at the male and female real parts and steps near the joint part between both flooring materials, it prevents the occurrence of a step at the jointing part of both flooring materials, and improves workability and usability after construction. be able to.

請求項２の発明によると、床仕上材における硬質発泡体層の表裏部分に高比重層を形成し、これら高比重層で雌実部の雌実凸部の一部を構成したことにより、その雌実部の雌実凸部の強度が高比重層によってより一層増大し、施工性及び施工後の使用性の向上を確実に図ることができる。 According to the invention of claim 2, the high specific gravity layer is formed on the front and back portions of the hard foam layer in the floor finish material, and the high specific gravity layer constitutes a part of the female real convex portion of the female real portion. The strength of the female real convex part of the female real part is further increased by the high specific gravity layer, and it is possible to reliably improve the workability and the usability after construction.

図１は本発明の実施形態に係る床材の拡大断面図である。FIG. 1 is an enlarged cross-sectional view of a flooring according to an embodiment of the present invention. 図２は床材の変形例を示す図１相当図である。FIG. 2 is a view corresponding to FIG. 図３は表面化粧層の拡大断面図である。FIG. 3 is an enlarged cross-sectional view of the surface decorative layer. 図４は床材同士を実接合して施工した状態を示す断面図である。FIG. 4 is a cross-sectional view showing a state where floor materials are actually joined to each other. 図５は実施例及び比較例に対する各種試験の結果を示す図である。FIG. 5 is a diagram showing the results of various tests for the examples and comparative examples. 図６は従来の床材示す図４相当図である。FIG. 6 is a view corresponding to FIG. 4 showing a conventional flooring.

以下、本発明の実施形態を図面に基づいて詳細に説明する。以下の好ましい実施形態の説明は、本質的に例示に過ぎず、本発明、その適用物或いはその用途を制限することを意図するものでは全くない。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

図１は本発明の実施形態に係る床材Ａを示し、この床材Ａは床仕上材１と、この床仕上材１の裏面に積層一体化された断熱層２０とを備えた、総厚３ｍｍ〜１２ｍｍのものとされている。 FIG. 1 shows a flooring A according to an embodiment of the present invention. The flooring A comprises a floor finishing material 1 and a total thickness comprising a heat insulating layer 20 laminated and integrated on the back surface of the floor finishing material 1. It shall be 3 mm-12 mm.

上記床仕上材１は、表面側から裏面側に向かって化粧層２、表面補強層３、硬質発泡体層４及び裏面補強層５が順に積層一体化されてなる総厚２ｍｍ〜６ｍｍのもので、その裏面は平面又は略平面とされていて、従来のような溝（裏溝）が形成されていない。また、床仕上材１の四周の木口端面１ａには、雌実部１０及び雄実部１４を有する本実加工が施され、この雌実部１０（又は雄実部１４）は他の床材Ａにおける床仕上材１の同様の雄実部１４（又は雌実部１０）に嵌合可能とされ、両者を嵌合して実結合することで、多数枚の床材Ａ，Ａ，…が施工されるようになっている。 The floor finish 1 has a total thickness of 2 mm to 6 mm in which a decorative layer 2, a surface reinforcing layer 3, a hard foam layer 4 and a back reinforcing layer 5 are laminated and integrated in order from the front side to the back side. The back surface is flat or substantially flat, and a conventional groove (back groove) is not formed. Moreover, the actual processing which has the female real part 10 and the male real part 14 is given to the end edge 1a of the four rounds of the floor finishing material 1, and this female real part 10 (or male real part 14) is another floor material. A plurality of flooring materials A, A,... Can be fitted to the same male part 14 (or female part 10) of the floor finishing material 1 in A, and both are fitted and actually joined. It is to be constructed.

（硬質発泡体層）
上記床仕上材１の硬質発泡体層４となる硬質発泡体としては、熱可塑性樹脂と、粉末状充填剤と、化学発泡剤とが混合されて１．８〜３．０倍に発泡した、全体比重０．３〜０．７の発泡体が使用される。 (Rigid foam layer)
As the hard foam to be the hard foam layer 4 of the floor finishing material 1, a thermoplastic resin, a powder filler, and a chemical foaming agent are mixed and foamed 1.8 to 3.0 times. A foam having an overall specific gravity of 0.3 to 0.7 is used.

一般に、熱可塑性樹脂及び粉末状充填剤のみでは、切削加工による熱で軟化するので、木口端面１ａに対する本実加工は難しいが、この実施形態による配合により均一に分散された樹脂が均一に発泡されるとともに、切削加工による熱軟化が発生し難くなる。さらに、硬質発泡体層４の表裏面に表面補強層３及び裏面補強層５が積層され、これらが後述の如く湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなるため、熱による軟化が生じた場合においても、本実加工を行うことができる。 Generally, the thermoplastic resin and the powdery filler alone are softened by the heat generated by the cutting process, so that the actual processing on the end face 1a is difficult. However, the uniformly dispersed resin is uniformly foamed by the blending according to this embodiment. In addition, thermal softening due to cutting is less likely to occur. Furthermore, since the surface reinforcing layer 3 and the back reinforcing layer 5 are laminated on the front and back surfaces of the hard foam layer 4 and these are made of an inorganic fiber sheet filled with a moisture curable resin or a reactive resin as described later, Even when softening occurs, the actual processing can be performed.

具体的に、上記熱可塑性樹脂としては、発泡可能な熱可塑性樹脂、例えば低密度ポリエチレン、高密度ポリエチレン、直鎖状低密度ポリエチレン、ランダムポリプロピレン、ホモポリプロピレン、ブロック状ポリプロピレン等のオレフィン系樹脂、塩化ビニル系樹脂、ＡＢＳ樹脂、ポリスチレン系樹脂、ポリカーボネート系樹脂、ポリアミド系樹脂、ポリフッ化ビニリデン系樹脂、ポリフェニレンサルファイド系樹脂、ポリスルホン系樹脂、ポリエーテルエーテルケトン系樹脂、ポリエチレンテレフタレート系樹脂、エラストマー系樹脂やラテックス系樹脂、及び、これらの共重合体等が挙げられ、単独で用いられいても併用されてもよい。 Specifically, the thermoplastic resin includes foamable thermoplastic resins such as low density polyethylene, high density polyethylene, linear low density polyethylene, random polypropylene, homopolypropylene, block polypropylene, and other olefinic resins, chloride Vinyl resin, ABS resin, polystyrene resin, polycarbonate resin, polyamide resin, polyvinylidene fluoride resin, polyphenylene sulfide resin, polysulfone resin, polyether ether ketone resin, polyethylene terephthalate resin, elastomer resin, etc. Latex resins, copolymers thereof, and the like can be mentioned, and they may be used alone or in combination.

さらに好ましくは、特にオレフィン系樹脂、塩化ビニル系樹脂、ポリスチレン系樹脂やポリエチレンテレフタレート系樹脂を用いる場合は、再生された樹脂を使用するのが好ましい。従って、カーボン等の顔料を適量添加することで着色してもよい。 More preferably, particularly when using an olefin resin, a vinyl chloride resin, a polystyrene resin or a polyethylene terephthalate resin, it is preferable to use a regenerated resin. Therefore, it may be colored by adding an appropriate amount of a pigment such as carbon.

熱に対する寸法安定性と強度とを考慮すると、特にポリスチレン系樹脂が好適に用いられる。しかし、ポリスチレン系樹脂のみでは柔軟性に劣るため、ポリエチレン系樹脂やポリプロピレン系等の樹脂が添加される。後述するエラストマー系樹脂やゴム系樹脂等により柔軟性を付与させることができるため、必須ではないが、３０重量部を超えると、熱軟化し易くなるため切削加工性に劣り、好ましくない。 In view of dimensional stability and strength against heat, a polystyrene resin is particularly preferably used. However, since a polystyrene resin alone is inferior in flexibility, a resin such as a polyethylene resin or a polypropylene resin is added. Flexibility can be imparted by an elastomeric resin or a rubber-based resin, which will be described later, but it is not essential. However, if it exceeds 30 parts by weight, it tends to be softened by heat, which is not preferable because of poor cutting workability.

さらに、発泡体に適度な靭性を付与するために、エラストマー系樹脂、ゴム系樹脂やラテックス系樹脂が適宜混合されて使用される。これらの樹脂が５重量部に満たないと、靭性に劣り、衝撃で基材表面が凹んだ場合に戻り難くなる。つまり、破壊され易くなる。また、２５重量部を超えると、熱軟化し易くなるため、切削加工性に劣り好ましくない。 Furthermore, in order to impart appropriate toughness to the foam, an elastomer resin, a rubber resin, or a latex resin is appropriately mixed and used. When these resins are less than 5 parts by weight, the toughness is inferior, and it becomes difficult to return when the surface of the base material is recessed by impact. That is, it becomes easy to be destroyed. Moreover, since it will become easy to heat soften when it exceeds 25 weight part, it is inferior to cutting workability, and is not preferable.

上記粉末状充填剤としては、無機微粉末、各種クレイ、珪酸カルシウム、珪酸マグネシウム（タルク）、炭酸カルシウム、硫酸バリウム等を配合することができる。粉末状充填剤の添加量が５重量部に満たないと、切削加工が行い難くなる一方、添加量が１５重量部を超えて多くなり過ぎると、均一に発泡するのが難しくなるだけでなく、切削抵抗が大きくなるため、いずれも好ましくない。樹脂の硬度に応じて切削適正が良好となるよう粉末状充填剤の添加量を適宜調整する。 As said powdery filler, inorganic fine powder, various clays, calcium silicate, magnesium silicate (talc), calcium carbonate, barium sulfate and the like can be blended. If the addition amount of the powdery filler is less than 5 parts by weight, it becomes difficult to perform the cutting process, while if the addition amount exceeds 15 parts by weight, it is difficult not only to foam uniformly, Since cutting resistance becomes large, neither is preferable. Depending on the hardness of the resin, the addition amount of the powder filler is appropriately adjusted so that the cutting suitability is good.

その他、成形体である発泡体の剛性や遮音性能を失わない程度に公知の各種添加剤を添加してもよい。例えば、発泡剤の分解温度を下げるための発泡助剤、成形性を高めるための脂肪酸金属石鹸やオレフィン系ワックス等の滑剤、軽量化のための木粉、耐熱安定剤、耐候安定剤、酸化防止剤、老化防止剤、光安定剤、帯電防止剤等を必要に応じて添加してもよい。 In addition, various known additives may be added to the extent that the rigidity and sound insulation performance of the foamed body are not lost. For example, foaming aids to lower the decomposition temperature of foaming agents, lubricants such as fatty acid metal soaps and olefin waxes to improve moldability, wood powder for weight reduction, heat stabilizers, weathering stabilizers, antioxidants Agents, anti-aging agents, light stabilizers, antistatic agents and the like may be added as necessary.

最も好適な例としては、ポリスチレン樹脂を１００重量部と、ポリエチレン又はポリプロピレン樹脂を０〜３０重量部と、粉末状充填剤を５〜１５重量部と、スチレン系ゴムを５〜２５重量部と、化学発泡剤を０．１〜３重量部とを混合し、１．８〜３．０倍に発泡させ、厚さ１．７５〜５．７５ｍｍ、全体比重０．３〜０．７の硬質発泡体を押し出し成形する。この押し出し成形により、図１に示すように、硬質発泡体層４の表裏部分に厚さ０．２〜０．５ｍｍ、比重０．７〜１．１の高比重層７，７が形成されるように成形される。 Most preferred examples include 100 parts by weight of polystyrene resin, 0 to 30 parts by weight of polyethylene or polypropylene resin, 5 to 15 parts by weight of powdered filler, 5 to 25 parts by weight of styrene rubber, 0.1 to 3 parts by weight of a chemical foaming agent is mixed and foamed 1.8 to 3.0 times, and the thickness is 1.75 to 5.75 mm, and the overall specific gravity is 0.3 to 0.7. Extrude the body. By this extrusion molding, as shown in FIG. 1, high specific gravity layers 7 and 7 having a thickness of 0.2 to 0.5 mm and a specific gravity of 0.7 to 1.1 are formed on the front and back portions of the hard foam layer 4. It is formed as follows.

（表面補強層及び裏面補強層）
上記表面補強層３及び裏面補強層５として、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートが用いられている。 (Surface reinforcing layer and back reinforcing layer)
As the surface reinforcing layer 3 and the back reinforcing layer 5, an inorganic fiber sheet filled with a moisture curable resin or a reactive resin is used.

表面補強層３と裏面補強層５とに、種類や厚みの異なる無機質繊維シートや種類の異なる充填樹脂を使用することもできるが、バランスを考慮し、表面補強層３と裏面補強層５とに無機質繊維シートを使用し、さらに同じ樹脂を充填させることが好ましい。 Different types and thicknesses of inorganic fiber sheets and different types of filling resins can be used for the surface reinforcing layer 3 and the back reinforcing layer 5, but in consideration of the balance, the surface reinforcing layer 3 and the back reinforcing layer 5 It is preferable to use an inorganic fiber sheet and further fill the same resin.

具体的には、ガラス繊維、炭素繊維等を用い、これらの繊維がバインダーにより結合されている無機質繊維シートを使用する。バインダーとしては、ポリビニルアルコール、アクリル系樹脂等の熱可塑性樹脂や、エポキシ樹脂、不飽和ポリエステル系樹脂等の熱硬化性樹脂が用いられており、所定の目付け量とシート形状とが保持される程度にシート成形が保持されていればよい。 Specifically, an inorganic fiber sheet in which glass fibers, carbon fibers, etc. are used and these fibers are bonded by a binder is used. As the binder, thermoplastic resins such as polyvinyl alcohol and acrylic resins, and thermosetting resins such as epoxy resins and unsaturated polyester resins are used, and the predetermined weight and sheet shape are maintained. It is sufficient that the sheet molding is held on the surface.

無機質繊維シートを使う効果は、硬質発泡体層４やその他樹脂の温度による寸法変化を抑えるとともに、切削加工による床仕上材１の振動を抑え、高精度な本実加工を可能にする役割がある。従って、ある程度の強度が必要であり、目付け量が８０〜１５０ｇ／ｍ^２、好ましくは１００〜１２０ｇ／ｍ^２程度の無機質繊維シートが使用される。目付け量が８０ｇ／ｍ^２に満たない場合は、寸法変化を抑える効果が弱く、目付け量が１５０ｇ／ｍ^２を超えると、床材Ａとしての剛性が高くなりすぎるために、好ましくない。 The effect of using the inorganic fiber sheet has a role of suppressing the dimensional change due to the temperature of the hard foam layer 4 and other resins and suppressing the vibration of the floor finishing material 1 due to the cutting process and enabling the actual processing with high accuracy. . Therefore, a certain level of strength is required, and an inorganic fiber sheet having a basis weight of 80 to 150 g / m ² , preferably about 100 to 120 g / m ² is used. When the basis weight is less than 80 g / m ² , the effect of suppressing the dimensional change is weak, and when the basis weight exceeds 150 g / m ² , the rigidity as the flooring A becomes too high, which is not preferable.

さらに、床仕上材１に靭性を付与するために、上記無機質シートに加えて、ＰＰ、ＰＥ、ＰＥＴ等の樹脂繊維シートを積層したハイブリッド不織布を使用してもよい。この場合、無機質繊維シートは目付け量が８０〜１５０ｇ／ｍ^２、好ましくは１００〜１２０ｇ／ｍ^２程度であればよく、これら無機質繊維シートに加えて、目付け量が３０〜１５０ｇ／ｍ^２程度の樹脂繊維シートを積層し、これらの積層物全体を充填するように湿気硬化型樹脂又は反応型樹脂を充填すればよい。 Furthermore, in order to impart toughness to the floor covering material 1, in addition to the inorganic sheet, a hybrid nonwoven fabric in which resin fiber sheets such as PP, PE, and PET are laminated may be used. In this case, the inorganic fiber sheet basis weight 80 to 150 g / ^{m 2,} preferably may be about 100 to 120 g / ^{m 2,} in addition to these inorganic fiber sheet, basis weight 30 to 150 g / ^{m 2} of about A resin fiber sheet may be laminated, and a moisture curable resin or a reactive resin may be filled so as to fill the entire laminate.

また、湿気硬化型樹脂又は反応型樹脂としては、ウレタン系接着剤、反応型ＰＵＲホットメルト接着剤、エポキシ系接着剤等の、水分を含まず熱硬化の必要がない接着剤が好適に用いられる。特に、適度な充填性及び靭性を有しているＰＵＲホットメルト接着剤が最も好ましい。上記無機質繊維シートを完全に充填する程度に塗布・充填・固化される。 Further, as the moisture curable resin or the reactive resin, an adhesive that does not contain moisture and does not need to be thermally cured, such as a urethane adhesive, a reactive PUR hot melt adhesive, and an epoxy adhesive, is preferably used. . In particular, a PUR hot melt adhesive having an appropriate filling property and toughness is most preferable. It is applied, filled and solidified to such an extent that the inorganic fiber sheet is completely filled.

具体的には、硬質発泡体の表面をプラズマ処理やコロナ放電等により表面改質処理し、この表面に湿気硬化型樹脂又は反応型樹脂を塗布し、さらにこの表面に無機質シート状物を載置し、さらにロールプレス等で圧締することで表面補強層３及び裏面補強層５が設けられる。 Specifically, the surface of the hard foam is subjected to a surface modification treatment by plasma treatment or corona discharge, a moisture curable resin or a reactive resin is applied to the surface, and an inorganic sheet is placed on the surface. Further, the front surface reinforcing layer 3 and the back surface reinforcing layer 5 are provided by pressing with a roll press or the like.

（化粧層）
上記化粧層２としては、厚さ０．１ｍｍ〜０．６ｍｍの表面に微細な凹凸部２ａを有する樹脂化粧シート又は塗膜材が使用される。 (Makeup layer)
As the decorative layer 2, a resin decorative sheet or a coating material having a fine uneven portion 2a on the surface having a thickness of 0.1 mm to 0.6 mm is used.

具体的には、図３（ａ）に示すように、シート表面に１〜２００μｍ程度の凹凸深さを有するシボ付け加工（エンボス加工）を行ってもよいし（特開２００８−２３８６０１号公報参照）、図３（ｂ）に示すように、塗膜厚みよりも大きな粒径の粒状物（顔料、樹脂ビーズ等）を含む塗膜を設けることにより凹凸部２ａを実現してもよい。表面の微細な凹凸部２ａにより、素足又は素手の接触面積が減るため、同じ基材を用いた床材であっても、接触冷感を感じ難くなる。 Specifically, as shown in FIG. 3A, the sheet surface may be embossed with embossing having an uneven depth of about 1 to 200 μm (see JP 2008-238601 A). ), As shown in FIG. 3B, the uneven portion 2a may be realized by providing a coating film containing granular materials (pigments, resin beads, etc.) having a particle size larger than the coating film thickness. Since the contact area of bare feet or bare hands is reduced by the fine irregularities 2a on the surface, even if it is a flooring material using the same base material, it becomes difficult to feel a cold feeling of contact.

好ましくは、予め表面塗装を施したオレフィン系樹脂、塩ビ系樹脂等の樹脂化粧シートを積層一体化し、化粧層２とするのが望ましい。 Preferably, a decorative layer 2 is formed by laminating and integrating a resin decorative sheet such as an olefin resin or a vinyl chloride resin that has been previously surface-coated.

化粧層２は、湿気硬化型樹脂又は反応型樹脂により硬質発泡体層４の表面に貼着一体化される。特にＰＵＲホットメルト接着剤が最も好適に用いられる。 The decorative layer 2 is bonded and integrated on the surface of the hard foam layer 4 with a moisture curable resin or a reactive resin. In particular, a PUR hot melt adhesive is most preferably used.

このとき、化粧層２は、表面補強層３の表面のみに設けられていてもよいし、図２に示すように、木口端面１ａにおいて、雌実部１０における表面側の雌実凸部１２先端面及び雄実部１４における表面側の雄実切欠き１６底面に至る部分まで化粧層２が設けられていてもよい。 At this time, the decorative layer 2 may be provided only on the surface of the surface reinforcing layer 3, or, as shown in FIG. 2, the front end of the female real convex portion 12 on the front surface of the female real portion 10 on the end face 1a. The decorative layer 2 may be provided up to a part reaching the bottom surface of the male cutout 16 on the surface side and the male solid portion 14.

そして、上記床仕上材１において、表面の化粧層２と表面補強層３と硬質発泡体層４の表側の高比重層７との合計である総厚さが１ｍｍ以内であることが望ましい。この厚さが１ｍｍを越えると、床材Ａに手や足が接触したときに表面の硬さや冷たさを感じ易くなってくる。 In the floor finish 1, the total thickness of the surface decorative layer 2, the surface reinforcing layer 3, and the high specific gravity layer 7 on the front side of the hard foam layer 4 is preferably within 1 mm. When this thickness exceeds 1 mm, it becomes easy to feel the hardness and coldness of the surface when a hand or a foot contacts the flooring A.

（本実加工）
上記床仕上材１の木口端面１ａに設けられる本実加工は切削加工によるものである。例えば床仕上材１（床材Ａ）の幅方向（又は長さ方向）に対向する一方の木口端面１ａに雌実部１０が、また他方の木口端面１ａに雄実部１４がそれぞれ形成されている。雌実部１０は、木口端面１ａの厚さ方向の中間部を断面矩形状に切り欠くことにより、雌実凹条１１（凹溝）と、切り欠いた際に残った部分で雌実凹条１１の溝壁部分を構成する１対の雌実凸部１２，１２とからなる。一方、雄実部１４は、木口端面１ａの厚さ方向の表裏隅角部を中間部を残してそれぞれ断面矩形状に切り欠くことにより、切り欠いた際に残った部分からなる雄実凸条１５と、切欠き部により構成される１対の雄実切欠き１６，１６とからなる。雄実凸条１５は断面が先細りテーパ形状のもので、その厚さは雌実凹条１１の溝幅よりも少し小さく形成されており、実結合時には、この雄実凸条１５が雌実凹条１１に嵌合される（図４（ａ）参照）。 (Actual processing)
The actual machining provided on the end edge 1a of the floor finish 1 is based on cutting. For example, a female part 10 is formed on one end face 1a facing the width direction (or length direction) of the floor finish 1 (floor A), and a male part 14 is formed on the other end face 1a. Yes. The female real part 10 includes a female real groove 11 (concave groove) and a female real groove formed by cutting out an intermediate part in the thickness direction of the end face 1a in a rectangular shape. It consists of a pair of female real convex parts 12 and 12 which constitute 11 groove wall parts. On the other hand, the male solid part 14 is formed by cutting away the front and back corners in the thickness direction of the end face 1a into a rectangular cross section, leaving the middle part, thereby forming the male convex ridge composed of the remaining part. 15 and a pair of male notches 16 and 16 constituted by notches. The male ridge 15 has a taper shape with a tapered cross-section, and its thickness is formed slightly smaller than the groove width of the female ridge 11, and when merging, the male ridge 15 is formed into a female ridge. It is fitted to the strip 11 (see FIG. 4A).

そして、上記硬質発泡体層４の表裏部分の高比重層７，７がそれぞれ木口端面１ａにおける雌実部１０の雌実凸部１２，１２の一部を構成しており、換言すれば雌実部１０の各雌実凸部１２に高比重層７が含まれている。一方、雄実部１４は高比重層７，７に雄実切欠きが形成されていて、雄実凸条１５は高比重層７，７以外の表裏中間部分で構成されている。 And the high specific gravity layers 7 and 7 of the front and back part of the said hard foam layer 4 respectively comprise the female real convex parts 12 and 12 of the female real part 10 in the end face 1a, in other words, female real Each female real convex portion 12 of the portion 10 includes a high specific gravity layer 7. On the other hand, the male part 14 is formed with a male notch in the high specific gravity layers 7 and 7, and the male solid ridge 15 is constituted by front and back intermediate parts other than the high specific gravity layers 7 and 7.

総厚２ｍｍ〜６ｍｍの床仕上材１の木口端面１ａに本実加工が施されるには、高精度な切削加工が求められる。そのため、この実施形態では、表面補強層３及び裏面補強層５により雌実部１０（特に雌実凸部１２，１２）を補強し、切削加工する際の切削時の摩擦熱によって床仕上材１が溶融してバリが発生することもなく、高精度な本実加工を可能にしている。 In order to perform the actual machining on the end surface 1a of the floor finishing material 1 having a total thickness of 2 mm to 6 mm, highly accurate cutting is required. Therefore, in this embodiment, the floor finish 1 is reinforced by the frictional heat at the time of cutting when the female real part 10 (particularly the female real convex parts 12 and 12) is reinforced by the front surface reinforcing layer 3 and the back surface reinforcing layer 5. It is possible to perform actual processing with high accuracy without melting and generating burrs.

（断熱層）
一方、上記床仕上材１の裏面に積層一体化された断熱層２０は、比重０．１〜０．４、厚さ１ｍｍ〜６ｍｍの樹脂発泡体又は樹脂不織布からなるものである。これら樹脂発泡体や樹脂不織布は周知のものを使用することができ、樹脂発泡体としては、例えばポリエチレン発泡体等からなる。 (Insulation layer)
On the other hand, the heat insulating layer 20 laminated and integrated on the back surface of the floor covering material 1 is made of a resin foam or a resin nonwoven fabric having a specific gravity of 0.1 to 0.4 and a thickness of 1 mm to 6 mm. As these resin foams and resin nonwoven fabrics, known ones can be used, and the resin foam is made of, for example, polyethylene foam.

また、この樹脂発泡体又は樹脂不織布の、床仕上材１裏面に対する積層一体化は、反応性ＰＵＲホットメルト樹脂等による接着により行われる。 Moreover, lamination | stacking integration of this resin foam or a resin nonwoven fabric with respect to the floor finishing material 1 back surface is performed by adhesion | attachment by reactive PUR hot-melt resin.

（床材の製造方法）
次に、上記床材Ａを製造する２つの製造方法について説明する。尚、この製造方法については、部分的に前述している。 (Method for manufacturing flooring)
Next, two manufacturing methods for manufacturing the flooring A will be described. This manufacturing method has been partially described above.

＜製造方法１＞
まず、ポリスチレン樹脂を１００重量部と、ポリエチレン又はポリプロピレン樹脂を０〜３０重量部と、粉末状充填剤を５〜１５重量部と、スチレン系ゴムを５〜２５重量部と、化学発泡剤を０．１〜３重量部とを混合し、１．８〜３．０倍に発泡させて、厚さ１．７５〜５．７５ｍｍ、全体比重０．３〜０．７の硬質発泡体を形成する。 <Manufacturing method 1>
First, 100 parts by weight of polystyrene resin, 0 to 30 parts by weight of polyethylene or polypropylene resin, 5 to 15 parts by weight of powdered filler, 5 to 25 parts by weight of styrene rubber, and 0 of chemical foaming agent 0.1-3 parts by weight and foamed 1.8-3.0 times to form a rigid foam having a thickness of 1.75-5.75 mm and an overall specific gravity of 0.3-0.7. .

上記硬質発泡体の表裏面にそれぞれプラズマ処理やコロナ処理等の改質処理を施した後、その硬質発泡体の表面に湿気硬化型樹脂又は反応型樹脂を塗布し、無機質繊維シートを載置してロールプレス等で圧締することで、表面に表面補強層３を設けるとともに、硬質発泡体の裏面に湿気硬化型樹脂又は反応型樹脂を塗布し、無機質繊維シートを載置してロールプレス等で圧締することで、裏面に裏面補強層５を設ける。 After applying a modification treatment such as plasma treatment or corona treatment to the front and back surfaces of the hard foam, a moisture curable resin or a reactive resin is applied to the surface of the hard foam, and an inorganic fiber sheet is placed thereon. By pressing with a roll press or the like, the surface reinforcing layer 3 is provided on the surface, a moisture curable resin or a reactive resin is applied to the back surface of the hard foam, and an inorganic fiber sheet is placed on the roll press or the like. The back surface reinforcing layer 5 is provided on the back surface.

そして、上記表面補強層３及び裏面補強層５が設けられた床仕上げの硬質発泡体の四周木口端面１ａに切削加工により雌実部１０及び雄実部１４を有する本実加工を施す。 Then, the actual processing having the female real part 10 and the male real part 14 is performed by cutting on the quadruple end end surface 1a of the floor-finished hard foam provided with the surface reinforcing layer 3 and the back reinforcing layer 5.

次いで、上記表面補強層３の全体及び木口端面１ａの雌雄実部１０，１４の一部に至るまで湿気硬化型樹脂又は反応型樹脂をロール塗布した後、直ちに、その塗装の施された表面に雌雄実部１０，１４の一部に至るまで、表面に微細凹凸部を有する表面化粧シートをラッピングマシン等により貼着一体化する。 Next, a moisture curable resin or a reactive resin is roll-applied to the entire surface reinforcing layer 3 and a part of the male and female real parts 10 and 14 of the end face 1a of the mouth end, and immediately, the coated surface is immediately applied. A surface decorative sheet having fine irregularities on the surface is pasted and integrated with a lapping machine or the like until reaching a part of the male and female real parts 10 and 14.

さらに、裏面補強層５の表面（床仕上材１裏側の下面）に湿気硬化型樹脂又は反応型樹脂を塗布して、比重０．１〜０．４、厚さ１ｍｍ〜６ｍｍの樹脂発泡体からなる断熱層２０を積層一体化することにより、総厚３ｍｍ〜１２ｍｍの床材Ａとする。 Further, a moisture curable resin or a reactive resin is applied to the surface of the back reinforcing layer 5 (the lower surface on the back side of the floor finish 1), and a resin foam having a specific gravity of 0.1 to 0.4 and a thickness of 1 mm to 6 mm. The resulting heat insulating layer 20 is laminated and integrated to obtain a flooring material A having a total thickness of 3 mm to 12 mm.

＜製造方法２＞
まず、ポリスチレン樹脂を１００重量部と、ポリエチレン又はポリプロピレン樹脂を０〜３０重量部と、粉末状充填剤を５〜１５重量部と、スチレン系ゴムを５〜２５重量部と、化学発泡剤を０．１〜３重量部とを混合し、１．８〜３．０倍に発泡させて、厚さ１．７５〜５．７５ｍｍ、全体比重０．３〜０．７の硬質発泡体を形成する。 <Manufacturing method 2>
First, 100 parts by weight of polystyrene resin, 0 to 30 parts by weight of polyethylene or polypropylene resin, 5 to 15 parts by weight of powdered filler, 5 to 25 parts by weight of styrene rubber, and 0 of chemical foaming agent 0.1-3 parts by weight and foamed 1.8-3.0 times to form a rigid foam having a thickness of 1.75-5.75 mm and an overall specific gravity of 0.3-0.7. .

また、上記硬質発泡体の表裏面にプラズマ処理やコロナ処理等の改質処理を施した後、その硬質発泡体の表面に湿気硬化型樹脂又は反応型樹脂を塗布し、無機質繊維シートを載置してロールプレス等で圧締することで、表面に表面補強層３を設けるとともに、硬質発泡体の裏面に湿気硬化型樹脂又は反応型樹脂を塗布し、無機質繊維シートを載置してロールプレス等で圧締することで、裏面に裏面補強層５を設ける。 In addition, after applying a modification treatment such as plasma treatment or corona treatment on the front and back surfaces of the hard foam, a moisture curable resin or a reactive resin is applied to the surface of the hard foam, and an inorganic fiber sheet is placed thereon. Then, by pressing with a roll press or the like, the surface reinforcing layer 3 is provided on the surface, a moisture curable resin or a reactive resin is applied to the back surface of the hard foam, and an inorganic fiber sheet is placed on the roll press. The back surface reinforcing layer 5 is provided on the back surface by pressing with, for example.

以上までは上記製造方法１と同じである。その後、上記表面補強層３の表面に湿気硬化型樹脂又は反応型樹脂を塗布した後、直ちに、表面に微細凹凸部を有する表面化粧シートを貼着又は塗膜材を塗布して一体化する。 The above is the same as the manufacturing method 1 described above. Thereafter, after applying a moisture curable resin or a reactive resin to the surface of the surface reinforcing layer 3, a surface decorative sheet having fine irregularities on the surface is immediately applied or a coating material is applied and integrated.

続いて、上記表面補強層３及び裏面補強層５が設けられた硬質発泡体の四周木口端面１ａに切削加工により雌実部１０及び雄実部１４を有する本実加工を施す。 Subsequently, the actual processing including the female real part 10 and the male real part 14 is performed by cutting on the quadrilateral end end surface 1a of the hard foam provided with the front surface reinforcing layer 3 and the back surface reinforcing layer 5.

さらに、製造方法１と同様に、裏面補強層５の表面（床仕上材１裏側の下面）に湿気硬化型樹脂又は反応型樹脂を塗布して、比重０．１〜０．４、厚さ１ｍｍ〜６ｍｍの樹脂発泡体からなる断熱層２０を積層一体化することにより、総厚３ｍｍ〜１２ｍｍの床材Ａとする。 Further, in the same manner as in the production method 1, a moisture curable resin or a reactive resin is applied to the surface of the back reinforcing layer 5 (the bottom surface on the back side of the floor finish 1), and the specific gravity is 0.1 to 0.4 and the thickness is 1 mm. A flooring material A having a total thickness of 3 mm to 12 mm is obtained by laminating and integrating the heat insulating layer 20 made of a resin foam of ˜6 mm.

これら製造方法１，２のいずれにおいても、上記床材Ａを容易に製造することができる。 In any of these production methods 1 and 2, the floor material A can be easily produced.

したがって、この実施形態においては、床材Ａにおける床仕上材１は、熱可塑性樹脂、粉末状充填剤及び化学発泡剤が混合されて発泡した硬質発泡体からなる硬質発泡体層４の表裏面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層３及び裏面補強層５が積層一体化されたものであるので、季節変動による湿気により床材Ａが変形し難くなる。 Therefore, in this embodiment, the floor finishing material 1 in the flooring material A is a front and back side of the hard foam layer 4 made of a hard foam foamed by mixing a thermoplastic resin, a powder filler and a chemical foaming agent. In addition, since the surface reinforcing layer 3 and the back reinforcing layer 5 made of an inorganic fiber sheet filled with a moisture curable resin or a reactive resin are laminated and integrated, the floor material A is deformed by moisture due to seasonal variation. It becomes difficult.

また、床仕上材１表面の化粧層２が、表面に微細な凹凸部２ａを有する厚さ０．１ｍｍ〜０．６ｍｍの樹脂化粧シート又は塗膜材からなるので、この表面の微細な凹凸部２ａにより、素足又は素手の接触面積が減ることなり、同じ基材を用いた床材であっても、特に冬季に手や足で接触したときに、接触冷感（表面の硬さや冷たさ）を感じ難くなる。 Moreover, since the decorative layer 2 on the surface of the floor finish 1 is made of a resin decorative sheet or a coating material having a thickness of 0.1 mm to 0.6 mm having a fine uneven portion 2a on the surface, the fine uneven portion on the surface 2a reduces the contact area of bare feet or bare hands, even if it is a flooring using the same base material, especially when touching with hands and feet in winter, the feeling of cold contact (hardness and cold surface) It becomes difficult to feel.

また、床仕上材１は、熱可塑性樹脂、粉末状充填剤及び化学発泡剤が混合されて発泡された硬質発泡体からなる硬質発泡体層４の表裏面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層３及び裏面補強層５が積層一体化されたものであり、その床仕上材１の木口端面１ａに雌実部１０及び雄実部１４が切削加工により設けられているので、その雌実部１０は表裏両側の雌実凸部１２，１２の強度が増大したものとなっている。そのため、図４（ａ）に示すように、隣接する床材Ａ，Ａ同士を床仕上材１の木口端面１ａの雌雄実部１０，１４で実接合して施工したとき、図４（ｂ）に示すように、両床材Ａ，Ａ同士の接合部（雌実部１０と雄実部１４との嵌合部）付近を踏みつけて断熱層２０が圧縮変形したとしても、雌実部１０の雌実凸部１２，１２が雄実部１４の雄実凸条１５を上下方向に確実に支持し、その雌実部１０の裏側の雌実凸部１２が下側に変形したり（図示の如く雄実部１４側である図で左側の床材Ａに荷重が加わった場合）、上側の雌実凸部１２が上側に変形したり（雌実部１０側である図で右側の床材Ａに荷重が加わった場合）することはなく、両床材Ａの床仕上材１が図で仮想線の位置から同じ高さで沈むようになり、両床材Ａ，Ａの接合部に段差が発生することはない。このことで、床材Ａの施工性が向上するとともに、その施工後の歩行感も優れたものとなって使用性が向上する。 Further, the floor finish 1 is a moisture curable resin or reactive type on the front and back sides of the hard foam layer 4 made of a hard foam obtained by mixing a thermoplastic resin, a powder filler and a chemical foaming agent. A surface reinforcing layer 3 and a back reinforcing layer 5 made of an inorganic fiber sheet filled with a resin are laminated and integrated, and the female part 10 and the male part 14 are cut on the end face 1a of the floor finish 1 of the floor finish. Since it is provided by processing, the female real part 10 has increased strength of the female real convex parts 12 on both sides. Therefore, as shown in FIG. 4 (a), when adjacent flooring materials A and A are actually joined at the male and female real parts 10 and 14 of the end edge 1a of the floor finishing material 1 as shown in FIG. 4 (b). As shown in FIG. 2, even if the heat insulating layer 20 is compressed and deformed by stepping on the vicinity of the joint portion (fitting portion between the female real portion 10 and the male real portion 14) between the two flooring materials A, A, The female real convex portions 12 and 12 securely support the male convex portion 15 of the male real portion 14 in the vertical direction, and the female real convex portion 12 on the back side of the female real portion 10 is deformed downward (shown in the figure). Thus, when the load is applied to the left floor material A in the figure on the male real part 14 side, the upper female real convex part 12 is deformed upward (in the figure on the female real part 10 side, the right floor material) When the load is applied to A), the floor finishing material 1 of both floor materials A sinks at the same height from the position of the phantom line in the figure, and at the joint of both floor materials A and A The difference does not occur. This improves the workability of the flooring A, improves the feeling of walking after the work, and improves the usability.

しかも、上記硬質発泡体層４の表裏部分には、厚さ０．２〜０．５ｍｍ、比重０．７〜１．１の高比重層７，７が形成され、これら高比重層７，７が木口端面１ａにおける雌実部１０の雌実凸部１２，１２の一部を構成している一方、雄実部１４は高比重層７，７以外の部分で構成されているので、その雌実部１０の雌実凸部１２，１２の強度が高比重層７，７によってより一層増大し、上記雌実部１０の雌実凸部１２の変形を確実に抑制して、施工性及び施工後の使用性の向上を確実に図ることができる。 In addition, high specific gravity layers 7 and 7 having a thickness of 0.2 to 0.5 mm and a specific gravity of 0.7 to 1.1 are formed on the front and back portions of the hard foam layer 4, and these high specific gravity layers 7 and 7 are formed. Constitute part of the female real convex portions 12 and 12 of the female real part 10 on the end face 1a of the mouth, while the male real part 14 is constituted by a portion other than the high specific gravity layers 7 and 7, so that the female The strength of the female real convex portions 12, 12 of the real part 10 is further increased by the high specific gravity layers 7, 7, and the deformation of the female real convex portion 12 of the female real part 10 is reliably suppressed, so that the workability and construction are improved. It is possible to reliably improve the later usability.

また、上記床仕上材１は、硬質発泡体層４の表裏面側に、湿気硬化型樹脂又は反応型樹脂が充填された無機質繊維シートからなる表面補強層３及び裏面補強層５とが積層一体化されたものであるので、床仕上材１（床材Ａ）の寸法安定性が向上する。また、その床仕上材１の木口端面１ａに上記雌実部１０及び雄実部１４を切削加工する際、切削時の摩擦熱により床仕上材１が溶融してバリが発生することはない。しかも、表面補強層３及び裏面補強層５により雌実部１０（特に雌実凸部１２，１２）が補強されているので、切削加工による床仕上材１の振動が抑えられ、よって、木口端面１ａに対する本実加工を精度よくかつ効率よく切削加工により設けることができる。 In addition, the floor finishing material 1 includes a surface reinforcing layer 3 and a back reinforcing layer 5 made of an inorganic fiber sheet filled with a moisture curable resin or a reactive resin on the front and back sides of the hard foam layer 4 and laminated together. Therefore, the dimensional stability of the floor finishing material 1 (floor material A) is improved. Further, when the female real part 10 and the male real part 14 are cut on the wood end face 1a of the floor finish 1, the floor finish 1 is not melted by frictional heat at the time of cutting, and burrs are not generated. Moreover, since the female real part 10 (particularly the female real convex parts 12 and 12) is reinforced by the front surface reinforcing layer 3 and the back surface reinforcing layer 5, the vibration of the floor covering 1 due to the cutting process is suppressed, and thus the end face of the mouth end. The actual machining for 1a can be provided accurately and efficiently by cutting.

次に、具体的に実施した実施例について説明する。 Next, specific examples will be described.

（実施例１）
ポリスチレン樹脂を１００重量部と、ポリエチレン樹脂を５重量部と、タルクを７重量部と、スチレン系ゴムを５重量部と、化学発泡剤を０．５重量部とを混合して２．０倍に発泡させ、押し出し成形することで、厚さ４．５ｍｍ、全体比重（みかけ比重）０．５５の硬質発泡体を得た。この硬質発泡体では、表裏層にそれぞれ厚さ０．５ｍｍ、比重０．９の高比重層が形成されていた。 Example 1
Mixing 100 parts by weight of polystyrene resin, 5 parts by weight of polyethylene resin, 7 parts by weight of talc, 5 parts by weight of styrene-based rubber, and 0.5 parts by weight of chemical foaming agent, 2.0 times By foaming and extrusion molding, a rigid foam having a thickness of 4.5 mm and an overall specific gravity (apparent specific gravity) of 0.55 was obtained. In this hard foam, high specific gravity layers having a thickness of 0.5 mm and a specific gravity of 0.9 were formed on the front and back layers, respectively.

こうして得られた硬質発泡体の表裏両面にコロナ処理を施した後、その表面に反応性ＰＵＲホットメルト樹脂を５０ｇ／ｍ^２ロール塗布し、直ちに１１０ｇ／ｍ^２のガラスクロスを載置し、ロールプレスすることで、表面に表面補強層を設けた。表面補強層の厚みは０．１ｍｍであった。 After applying corona treatment to the front and back surfaces of the hard foam thus obtained, 50 g / m ² roll of reactive PUR hot melt resin was applied to the surface, and a 110 g / m ² glass cloth was immediately placed on the roll. A surface reinforcing layer was provided on the surface by pressing. The thickness of the surface reinforcing layer was 0.1 mm.

続いて、この硬質発泡体の裏面に、上記表面補強層を設けるのと同様に、反応性ＰＵＲホットメルト樹脂を５０ｇ／ｍ^２ロール塗布し、直ちに１１０ｇ／ｍ^２のガラスクロスを載置し、ロールプレスすることで、裏面に裏面補強層を設けた。裏面補強層の厚みは０．１ｍｍであった。 Subsequently, the reactive PUR hot melt resin was applied in a roll of 50 g / m ^{2 in} the same manner as the surface reinforcing layer was provided on the back surface of the hard foam, and immediately a glass cloth of 110 g / m ² was placed. By roll pressing, a back surface reinforcing layer was provided on the back surface. The thickness of the back reinforcing layer was 0.1 mm.

次に、上記表面補強層の表面に反応性ＰＵＲホットメルト樹脂をロール塗布し、直ちに、表面に塗装の施されかつ１〜２００μｍ程度の深さの凹凸部を有するエンボス加工された厚さ０．２ｍｍのオレフィン系樹脂化粧シートをラッピングマシーンにより貼着一体化して化粧層を得た。 Next, a reactive PUR hot melt resin is roll-applied to the surface of the surface reinforcing layer, and the embossed thickness of 0.1 to 200 [mu] m deep is immediately applied to the surface and embossed. A decorative layer was obtained by sticking and integrating a 2 mm olefin resin decorative sheet with a wrapping machine.

続いて、表面補強層及び裏面補強層の設けられた硬質発泡体の四周木口端面に切削加工により本実加工を施した。 Subsequently, the actual processing was performed by cutting on the end face of the quadruple end of the hard foam provided with the front surface reinforcing layer and the back surface reinforcing layer.

さらに、裏面補強層の表面に反応性ＰＵＲホットメルト樹脂をロール塗布し、この表面に厚さ４．５ｍｍ、比重０．１のポリエチレン発泡体（断熱層）を貼着一体化し、床材を得た。 Furthermore, a reactive PUR hot melt resin is roll-applied to the surface of the back reinforcing layer, and a polyethylene foam (heat insulating layer) having a thickness of 4.5 mm and a specific gravity of 0.1 is adhered and integrated on this surface to obtain a flooring material. It was.

（実施例２）
実施例１において、硬質発泡体の表面に反応性ＰＵＲホットメルト樹脂を１００ｇ／ｍ^２ロール塗布し、直ちに２２０ｇ／ｍ^２のガラスクロスを載置し、ロールプレスすることで、表面に表面補強層を設けた。すなわち、表面補強層におけるガラスクロスの目付量と反応性ＰＵＲホットメルト樹脂の塗布量とを倍増させたものである。その他は実施例１と同じである。 (Example 2)
In Example 1, 100 g / m ² roll of reactive PUR hot melt resin was applied to the surface of the hard foam, and a glass cloth of 220 g / m ^{2 was} immediately placed and roll-pressed. Was provided. That is, the basis weight of the glass cloth in the surface reinforcing layer and the coating amount of the reactive PUR hot melt resin are doubled. Others are the same as in the first embodiment.

（比較例１）
実施例１において、硬質発泡体の表裏面に表面補強層を形成せず、その表面に化粧層を、また裏面に断熱層をそれぞれ積層一体化した。その他は実施例１と同じである。 (Comparative Example 1)
In Example 1, the surface reinforcing layer was not formed on the front and back surfaces of the hard foam, the decorative layer was laminated on the surface, and the heat insulating layer was laminated and integrated on the back surface. Others are the same as in the first embodiment.

（比較例２）
実施例１において、化粧層となるオレフィン系樹脂化粧シート表面の凹凸部を有するエンボス加工をなくしたものである。その他は実施例１と同じである。 (Comparative Example 2)
In Example 1, the embossing which has the uneven | corrugated | grooved part of the olefin resin decorative sheet surface used as a decorative layer is eliminated. Others are the same as in the first embodiment.

（比較例３）
実施例１において、硬質発泡体の表面に反応性ＰＵＲホットメルト樹脂を３０ｇ／ｍ^２ロール塗布し、直ちに５５ｇ／ｍ^２のガラスクロスを載置し、ロールプレスすることで、表面に表面補強層を設けた。すなわち、表面補強層におけるガラスクロスの目付量と反応性ＰＵＲホットメルト樹脂の塗布量とを半減させたものである。その他は実施例１と同じである。 (Comparative Example 3)
In Example 1, 30 g / m ² roll of reactive PUR hot melt resin was applied to the surface of the hard foam, and a glass cloth of 55 g / m ^{2 was} immediately placed and roll-pressed. Was provided. That is, the basis weight of the glass cloth in the surface reinforcing layer and the coating amount of the reactive PUR hot melt resin are halved. Others are the same as in the first embodiment.

（比較例４）
実施例１において、硬質発泡体の表面に反応性ＰＵＲホットメルト樹脂をロール塗布し、直ちにガラスクロスを載置し、ロールプレスすることで、表面に表面補強層を設けた。この表面補強層の表面に、両面コロナ放電処理を施した０．５ｍｍのＰＥＴ（ポリエチレンテレフタレート）樹脂シートを積層し、その表面に実施例１と同じ微細エンボス付０．２ｍｍオレフィンシートを積層一体化した。その他は実施例１と同じである。 (Comparative Example 4)
In Example 1, a reactive PUR hot melt resin was roll-applied to the surface of the hard foam, and a glass cloth was immediately placed and roll-pressed to provide a surface reinforcing layer on the surface. A 0.5 mm PET (polyethylene terephthalate) resin sheet subjected to double-sided corona discharge treatment is laminated on the surface of this surface reinforcing layer, and the same 0.2 mm olefin sheet with fine embossing as in Example 1 is laminated on the surface. did. Others are the same as in the first embodiment.

（比較例５）
実施例１において、硬質発泡体層の表面に反応性ＰＵＲホットメルト樹脂をロール塗布し、直ちにガラスクロスを載置し、ロールプレスすることで、表面に表面補強層を設けた。この表面補強層の表面に比重０．７５、厚さ１．０ｍｍのＭＤＦ（中比重木質繊維板）をＰＵＲホットメルト接着剤で積層し、この表面に実施例１と同じ微細エンボス付０．２ｍｍオレフィンシートを積層一体化した。その他は実施例１と同じである。 (Comparative Example 5)
In Example 1, the surface of the hard foam layer was coated with a reactive PUR hot melt resin, a glass cloth was immediately placed, and roll pressing was performed to provide a surface reinforcing layer on the surface. A MDF (medium specific gravity wood fiber board) having a specific gravity of 0.75 and a thickness of 1.0 mm was laminated on the surface of the surface reinforcing layer with a PUR hot melt adhesive, and the same fine embossed 0.2 mm as in Example 1 was applied to this surface. Olefin sheets were laminated and integrated. Others are the same as in the first embodiment.

（比較例６）
実施例１において、表面補強層及び裏面補強層の設けられた硬質発泡体の四周木口端面に切削加工により本実加工ではなく、木口端面の裏側半部を矩形状に切り欠いてなる雌実部と、表側半部を同様に矩形状に切り欠いてなる雄実部とからなる合決り加工を施した。そして、裏面補強層の表面に反応性ＰＵＲホットメルト樹脂を介してポリエチレン発泡体を、硬質発泡体の雌雄実部とによって本実構造となるように貼着一体化し、床材を得た。その他は実施例１と同じである。 (Comparative Example 6)
In Example 1, a female real part in which the back half of the end face of the hard end is not cut into a real shape by cutting the end face of the quadrilateral end of the hard foam provided with the surface reinforcing layer and the back face reinforcing layer. And the concluding processing which consists of the male part which notched the front side half part in the rectangular shape similarly was performed. Then, a polyethylene foam was bonded and integrated on the surface of the back surface reinforcing layer via a reactive PUR hot melt resin so as to form a real structure with the male and female real parts of the hard foam to obtain a flooring. Others are the same as in the first embodiment.

以上の実施例及び比較例に対して施工試験、切削試験、冷感試験及び寸法安定性試験を行った。 A construction test, a cutting test, a cooling sensation test, and a dimensional stability test were performed on the above examples and comparative examples.

（施工試験）
幅１５０ｍｍ×長さ９００ｍｍに切削加工した実施例及び比較例の床材を、雌雄実嵌合させながら施工した。施工後、床面全体を歩行し、歩行感の確認を行った。 (Construction test)
The flooring materials of Examples and Comparative Examples cut into a width of 150 mm and a length of 900 mm were applied while fitting the male and female. After the construction, the entire floor was walked to confirm the feeling of walking.

（切削試験）
生産設備の実切削機械（テノーナー）を使用して、実際に切削加工を行った。回転鋸を使用して雌雄実部を床仕上材の両端面に施し、本実の外観観察及び加工精度の確認を行った。 (Cutting test)
Cutting was actually performed using the actual cutting machine (tenoner) of the production facility. The male and female real parts were applied to both end faces of the floor finish using a rotary saw, and the actual appearance was observed and the processing accuracy was confirmed.

（冷感試験）
各実施例及び各比較例に係る、幅１５０ｍｍ×長さ９００ｍｍに切削加工した４枚の床材を並べて雌雄実部で嵌合させ、６００×９００ｍｍの試験体を得た。この試験体を１０℃に調整した環境室内で２４時間養生し、この表面を素足及び素手で接触し、それぞれの冷感を官能評価した。 (Cool feeling test)
According to each example and each comparative example, four floor materials cut into a width of 150 mm and a length of 900 mm were arranged and fitted in the male and female real parts to obtain a 600 × 900 mm specimen. This test body was cured for 24 hours in an environmental chamber adjusted to 10 ° C., and the surface was contacted with bare feet and bare hands, and each cooling feeling was subjected to sensory evaluation.

（寸法安定性試験）
得られた床仕上材を８０℃ドライヤーに投入し、２４時間経過して取り出した後に直ちに寸法を測定した。投入前の寸法を１としたときの寸法の伸張率で評価した。 (Dimensional stability test)
The obtained floor finish was put into an 80 ° C. dryer, and after 24 hours had been taken out, the dimensions were measured immediately. Evaluation was based on the extension ratio of the dimension when the dimension before the injection was 1.

以上の各試験の結果を図５に示す。 The results of the above tests are shown in FIG.

これらの試験結果をみると、実施例は全ての試験において良好な結果を示しており、本願発明が有効であることが判る。 Looking at these test results, the examples show good results in all tests, and it can be seen that the present invention is effective.

本発明は、床材の接合部で段差が発生せず、接触冷感を感じ難い点で、極めて有用であり、産業上の利用可能性が高い。 The present invention is extremely useful in that a step does not occur at the joint portion of the flooring material, and it is difficult to feel a feeling of contact cooling, and industrial applicability is high.

Ａ床材
１床仕上材
１ａ木口端面
２化粧層
２ａ凹凸部
３表面補強層
４硬質発泡体層
５裏面補強層
７高比重層
１０雌実部
１１雌実凹条
１２雌実凸部
１４雄実部
２０断熱層 A flooring material 1 floor finishing material 1a end face of face 2 decorative layer 2a uneven part 3 surface reinforcing layer 4 rigid foam layer 5 back reinforcing layer 7 high specific gravity layer 10 female real part 11 female real concave line 12 female real convex part 14 male real Part 20 Heat insulation layer

Claims

表面側から裏面側に向かって化粧層、表面補強層、硬質発泡体層及び裏面補強層が順に積層一体化されてなり、木口端面に雌実部及び雄実部を有していて該雌実部及び雄実部が他の床材の雄実部及び雌実部に嵌合可能な本実加工が施されている床仕上材と、
上記床仕上材の裏面に積層一体化された断熱層とを備えた床材であって、
上記化粧層は、表面に微細な凹凸部を有する樹脂化粧シート又は塗膜材からなり、
上記表面補強層及び裏面補強層は、湿気硬化性樹脂又は反応性樹脂が充填された無機質繊維シートからなることを特徴とする床材。 A decorative layer, a surface reinforcing layer, a hard foam layer, and a back reinforcing layer are laminated and integrated in order from the front surface side to the back surface side. Floor finishing material that has been subjected to actual processing that allows the male part and the male part to be fitted to the male part and the female part of other floor materials,
A flooring material comprising a heat insulating layer laminated and integrated on the back surface of the flooring material,
The decorative layer is composed of a resin decorative sheet or a coating material having fine irregularities on the surface,
The floor reinforcing layer and the back reinforcing layer are made of an inorganic fiber sheet filled with a moisture curable resin or a reactive resin.

請求項１において、
硬質発泡体層の表裏部分には、厚さ０．２〜０．５ｍｍ、比重０．７〜１．１の高比重層が形成され、
上記高比重層が木口端面における雌実部の雌実凸部の一部を構成している一方、雄実部は高比重層以外の部分で構成されていることを特徴とする床材。 In claim 1,
A high specific gravity layer having a thickness of 0.2 to 0.5 mm and a specific gravity of 0.7 to 1.1 is formed on the front and back portions of the hard foam layer,
The flooring material according to claim 1, wherein the high specific gravity layer constitutes part of the female real convex portion of the female real part on the end face of the mouth end, while the male real part is constituted by a portion other than the high specific gravity layer.