JP4486121B2 - Manufacturing method for flooring - Google Patents

Description

  The present invention provides a flooring material in which a surface material is molded and hardened on the upper surface of a substantially square synthetic resin seat plate, and a large number of anchors protruding from the upper surface of the seat plate are embedded in the surface material. Regarding the law.

  A large number of the flooring materials are placed on a floor base surface such as a veranda, a balcony, a rooftop, an indoor floor, and an outdoor floor with a seat plate to form a wide area floor.

  Conventionally, as shown in Patent Document 1, a surface material made of cement kneading material or the like is layered on the upper surface of a rectangular synthetic resin seat plate, and a number of anchors projecting from the upper surface of the seat plate in the surface material The flooring in which is embedded is known.

  As the floor material manufacturing means, a surface material mold in which a molding cavity opened on the upper surface is defined by a bottom wall and four side walls raised from four sides of the bottom wall is used, and a molding cavity of the surface material molding die is used. The pre-curing surface material is filled in, the upper surface of the pre-curing surface material and the upper surface from which the anchor of the seat plate protrudes are opposed to each other, and the anchor is embedded in the pre-curing surface material. In this method, the surface material before curing is fixed, and the mold is removed after demolding.

Japanese Patent No. 3746051

  In the floor material manufacturing method typified by Patent Document 1, when the anchor is embedded in the pre-curing surface material, a variation occurs in the anchor embedding depth, and the anchor embedding depth is shallow. If the anchoring depth of the anchor plate is too deep, the uncured surface material wraps around the back surface of the seat plate and hardens on the lower surface. Introducing product defects and how to solve them is an issue.

  The present invention uses the surface material molding die shown in Patent Document 1, and embeds anchors protruding from the upper surface of a synthetic resin seat plate in the surface material before curing filled in the same mold while seating on the surface material before curing. The present invention provides a method for manufacturing a flooring material in which the anchor embedding depth is set appropriately when fixing the anchor, and the fixing failure of the seat plate is effectively prevented.

  As the means, an anchor embedment depth setting means protrudes from the edge of the seat plate, and the anchor embedment depth setting means is brought into contact with the opening edge of the surface material molding die to the surface material before curing. A method is adopted in which the embedding depth of the anchor is set and the surface material before curing is fixed on the upper surface of the seat plate.

  The seat plate is provided with a plurality of coupling windows that can be opened on the upper and lower surfaces of the seat plate, and the surface material before curing enters into each coupling window of the seat plate by contact with the anchor embedding depth setting means. In addition, the amount of penetration is set, and the adhesion and bonding between the surface material and the seat plate are strengthened.

  A flange is provided at the opening edge of the surface material molding die, and the anchor embedding depth setting means is stably brought into contact with the upper surface of the flange. For example, the anchor embedding depth setting means is formed by short pins, and the short pins are brought into contact with the upper surface (opening edge portion) of the buttock to set the anchor embedding depth.

  Further, the anchor embedment depth setting means remains after demolding of the pre-curing surface material or is removed from the seat plate after demolding.

In addition , a flange that protrudes outward at a substantially right angle is formed on the opening edge of the surface material mold, and a rib-like ruler is intermittently provided along the upper surface of the base end of the flange. The anchor embedment depth setting means is abutted and supported at the cut of the ruler part, and the relative positions of the seat plate and the anchor embedment depth setting means, the surface material molding die and the surface material before curing are set by the ruler part. The anchor is embedded at an appropriate depth in the pre-curing surface material at an appropriate position while effectively preventing displacement of the plate and the anchor embedding depth setting means.

  As a concrete example of the anchor embedment depth setting means, a connecting piece for connecting with another flooring is projected from two adjacent sides of the seat plate, and a short pin is formed from the other two adjacent sides of the seat plate. At the same time that the connecting piece is in contact with two adjacent opening edges of the surface material molding die, and at the same time, the short pin is in contact with another adjacent opening edge of the surface material molding die. Set the burial depth and fix the seat plate. In this case, the connecting piece after molding is used as a connecting joint with the adjacent floor material, and the short pin is removed after molding.

  When the connecting piece is not provided, the anchor embedding depth setting means, the short pin exemplified thereof, protrudes from the four sides or three sides of the seat plate, and the short pin is opened on the four or three sides of the surface material molding die. Abutment depth of the anchor is set by coming into contact with the portion (saddle), and the seat plate is fixed.

  According to the present invention, a floor material is molded and hardened on the upper surface of a substantially square synthetic resin seat plate, and a plurality of anchors protruding from the upper surface of the seat plate are embedded in the surface material. When the material is manufactured, the embedment depth of the anchor can be appropriately set without excess or deficiency, and the seat plate and the surface material can be firmly fixed, and the target floor material can be manufactured soundly.

  The best mode for carrying out the present invention will be described below with reference to FIGS.

  The floor material targeted in the present invention is a floor material in which the surface material 2 is layered on the upper surface of the substantially square synthetic resin seat plate 1 shown in FIGS. 1 to 4, and protrudes from the lower surface of the seat plate 1 described later. A plurality of support legs 6 are used to construct a floor by placing a large number on the floor base surface 17, and a continuous gap 18 is formed between the floor and the floor base surface 17.

  As the surface material 2 formed on the surface of the seat plate 1, a molding material obtained by kneading various aggregates such as sand, glass, wood pieces, minerals, etc., with cement or synthetic resin as a binder is applied.

  Alternatively, in addition to the cement and the synthetic resin, a molding material in which various aggregates are blended with what is dried and hardened, such as slag, incinerated ash, and gypsum can be applied. Alternatively, a kneaded material of various sludges such as papermaking sludge and cement or synthetic resin can be applied as a molding material.

  As shown in FIGS. 5 to 11 and the like, the surface material 2 has a structure in which the surface material 2 is molded and hardened on the upper surface of the synthetic resin seat plate 1 and is layered. 1 has a structure in which an anchor 3 that protrudes integrally and vertically from the upper surface of 1 is embedded in an uncured surface material 2 and the uncured surface material 2 and the seat plate 1 are coupled. A large number of the anchors 3 are arranged on the upper surface of the seat plate 1 with a substantially uniform distribution.

  As a molding means for the surface material 2, a surface material mold 10 is prepared in which a bottom wall 10d and four side walls 10e raised from the four sides of the bottom wall 10d define a molding cavity opened on the upper surface. Prepare the one where the anchor embedding depth setting means 29 of the anchor 3 protrudes from the edge 1 a of the other seat plate 1.

  As shown in FIG. 6A, the surface material 2 before curing is filled into the molding cavity of the surface material mold 10. The pre-curing surface material 2 is filled so as to be substantially flush with the opening surface of the mold 10.

  The upper surface of the uncured surface material 2 filled in the surface material mold 10 and the upper surface of the seat plate 1 from which the anchor 3 protrudes are opposed to each other, and as shown in FIG. 6B, the anchor 3 is uncured. Embedded in the surface material 2.

  In the embedding, the anchor embedding depth setting means 29 is brought into contact with the opening edge portion 10a of the surface material molding die 10 to set the embedding depth of the anchor 3 with respect to the surface material 2 before curing, and the surface material before curing. The upper surface of the seat plate 1 is fixed to the upper surface of the plate 2.

  That is, the anchor 3 of the seat plate 1 is embedded in the pre-curing surface material 2 at the opening surface (opening surface corresponding to the lower surface of the surface material 2) of the surface material molding die 10, and the embedded depth is set to the anchor embedding depth. In addition to setting by the setting means 29, the setting means 29 causes the upper surface of the seat plate 1 to be in close contact with the upper surface of the pre-curing surface material 2, so that the seat plate 1 and the upper surface of the seat plate 1 are molded and layered. The floor material having the surface material 2 is obtained. Curing is promoted by natural drying or hot air drying before or after demolding the flooring.

The surface material mold 10 using synthetic resin film type. The outer shape (contour) and the surface pattern of the surface material 2 are formed by the mold 10, and as shown in FIGS. 10 and 11, lateral and / or vertical joint grooves are formed on the upper surface of the surface material 2 as necessary. 11 is formed, and the surface material 2 is partitioned into a plurality of sections in appearance by the joint grooves 11.

  The pre-curing surface material 2 is filled into the surface material mold 10 or after filling and the seat plate 1 is placed oppositely, or the anchor 3 of the seat plate 1 is pushed into the pre-curing surface material 2. Thereafter, the same mold 10 is vibrated to close the filling of the pre-curing surface material 2 and improve the adhesion to the bottom wall 10d of the mold 10, and the surface pattern or / and the eyes of the surface material 2 at the bottom wall 10d. The ground groove 11 is formed well, and the outer shape of the surface material 2 is formed by the bottom wall 10d and the side wall 10e. Moreover, the adhesion between the anchor 3 and the uncured surface material 2 is improved by vibration, and the adhesion (fixing property) of the seat plate 1 to the uncured surface material 2 is improved.

  Alternatively, as shown in FIGS. 8 and 9, the surface material 2 that is entirely flat without the joint groove 11 can be formed.

  The pre-curing surface material 2 is molded and layered on the seat plate 1 and then demolded. After demolding, the anchor embedding depth setting means 29 remains as it is or is removed.

  As shown in FIGS. 1 and 5, the anchor embedding depth setting means 29 is provided so as to protrude outward from the edge portions 1a of the three sides or the four sides of the seat plate 1, and is provided integrally therewith. 10 three side walls 10e or four side walls 10e abut against the opening edge 10a.

  One or more anchor embedding depth setting means 29 are provided along the edge portion 1a of the seat plate 1, and when provided, a plurality of anchor embedding depth setting means 29 are disposed at intervals on the edge portion 1a.

  As a preferred example, the abutment surface 29b of the anchor embedding depth setting means 29 protrudes from the seat plate edge 1a so as to be flush with the lower surface of the seat plate 1.

  On the other hand, a large number of coupling windows 8 that penetrate the upper and lower surfaces and allow the surface material 2 before being hardened to enter the seat plate 1 are disposed between the anchors 3, and the contact surface of the anchor embedding depth setting means 29. 29b is brought into contact with the opening edge portion 10a of the surface material molding die 10 to allow the intrusion of the uncured surface material 2 into the coupling window 8 and set the amount of infiltration. The uncured surface material 2 penetrates into the coupling window 8 and binds to the inner peripheral surface of the coupling window 8 to reinforce the integral bonding of the seat plate 1, and the uncured surface material 2 wraps around the lower surface of the seat plate 1. To prevent.

  The coupling window 8 includes an outer frame portion 1 ′ that forms the edge portion 1 a of the seat plate 1, and a flat plate beam 13 that is disposed in the inner area of the outer frame portion 1 ′ in the vertical direction, the horizontal direction, the oblique direction, and the like. It is defined by. The anchor 3 is disposed on the beam 13.

  As shown in FIGS. 5 to 7, the flange portion 10b is projected outward from the upper end of the four side walls 10e of the surface material molding die 10 at a substantially right angle, and the anchor embedding depth setting means 29 is applied to the flange portion 10b. Support and show the above setting function.

  As a specific example of the anchor embedding depth setting means 29, a short pin 29 a is projected from the edge 1 a of the seat plate 1. The short pins 29a project outward from the edge portions 1a of the three sides or the four sides of the seat plate 1. The short pin 29a is formed by a round pin or a square pin.

  Preferably, as shown in the enlarged view of FIG. 7, a flat contact surface 29b is formed on the short pin 29a, and the opening edge portion 10a (the flange portion 10b) of the surface material molding die 10 is formed with the corresponding contact surface 29b. ), The short pin 29a is stably supported, and the seat plate 1 is stably supported, and the anchor embedding and the seat plate fixing are performed. In the case of the short and small pins 29a, excision after molding is easy. As described above, the contact surface 29 b of the short pin 29 a is set at the same level as the lower surface of the seat plate 1.

  Although illustration is omitted, as another example of the anchor embedding depth setting means 29, a plate piece is projected substantially horizontally from the edge 1a of the seat plate 1. When the plate piece and the short pin 29a are not provided with connecting pieces 20 and 20 'to be described later, the plate piece and the short pin 29a protrude outward from the edge portions 1a of the three sides or the four sides of the seat plate 1, and the upper plate surface of the plate piece Similarly, the contact surface 29b of the short pin 29a is abutted and supported on the opening edge portion 10a (the flange portion 10b) by contact.

  In addition to the anchor embedment depth setting means 29, as shown in FIGS. 5A and 5B, a ruler portion for restricting the movement of the anchor embedment depth setting means 29 in the planar direction to the opening edge portion 10a of the surface material molding die 10. 10c is provided, and the relative positions of the seat plate 1 and the anchor embedding depth setting means 29, the surface material molding die 10 and the pre-curing surface material 2 are set by the ruler portion 10c.

  The relative position between the anchor embedding depth setting means 29 and the surface material molding die 10 can be easily determined by the ruler portion 10c, and the anchor embedding depth of the anchor 3 by the anchor embedding depth setting means 29 is appropriately set at the relative position. Set.

  As a specific example of the ruler portion 10c, the ruler portion 10c is formed along an opening edge portion 10a of the surface material molding die 10, that is, a base end upper surface of the flange portion 10b joined to the upper ends of the four side walls 10e of the molding die 10. The ribs are provided intermittently over the length, and the anchor embedding depth setting means 29 (short pin 29a or plate piece) is brought into contact with and supported by the cut 10f of the ruler portion 10c. The anchor 3 is embedded in the pre-curing surface material 2 at an appropriate depth at an appropriate position while the ruler portion 10c effectively prevents the seat plate 1 and the anchor embedding depth setting means 29 from being displaced in the plane direction. Like that.

  As another specific example of the anchor embedding depth setting means 29, as shown in FIG. 5B, a connecting piece (connecting joint) 20 for connecting to another flooring from two adjacent sides of the seat plate 1 is provided. Then, the setting means 29 (short pin 29a or plate piece) is projected from the other two adjacent sides of the seat plate 1, and the connecting piece 20 is opened at the two adjacent edges of the surface material molding die 10. 10a (the flange portion 10b) and at the same time, the short pin 29a or the plate piece is brought into contact with the other adjacent opening edge portion 10a of the surface material molding die 10 to set the embedding depth of the anchor 3, and the seat plate To fix.

  Since the connecting piece 20 that also serves as the anchor embedding depth setting means 29 is used for connecting the flooring materials, it remains without being removed after molding.

  When the connecting piece 20 is not provided, as shown in FIG. 5A, the anchor embedding depth setting means 29, its exemplified short pin 29a or plate piece is projected from four or three sides of the seat plate 1, and the short The pin 29a is brought into contact with the four or three side opening edge portions 10a of the surface material molding die 10 to set the embedment depth of the anchor 3 to fix the seat plate.

  Each of the floor materials is connected to adjacent floor materials at four sides. As shown in FIG. 3, FIG. 5B, and FIG. 12, as the connecting means, a connecting piece that protrudes substantially horizontally outwardly from the outer frame portion 1 'constituting the outer peripheral edge portion 1a of two adjacent sides of the seat plate 1 A plurality of 20 are arranged at intervals along each side, and an engagement hole 19 penetrating vertically is provided in each connecting piece 20.

  Similarly, a plurality of connecting pieces 20 ′ protruding substantially horizontally outward from the outer frame portion 1 ′ constituting the outer peripheral edge portion 1 a of the other two adjacent sides of the seat plate 1 are arranged at intervals along each side. The engaging projections 21 project downward from the lower surface 24 ′ of each connecting piece 20 ′. The engaging protrusion 21 is a split protrusion or a protrusion that is not split.

  The engaging protrusion 21 is inserted into the engaging hole 19 of the connecting piece 20 with a forcible force, and the engaging protrusion 21 is inserted into an annular locked step portion 22 b formed on the inner peripheral surface of the engaging hole 19. The engaging step 23b of the engaging claw 23a formed on the outer surface of the floor is engaged to connect the flooring. The engagement means an engagement state and an engageable state, and includes a case where a gap is formed between the engagement claw 23a and the engagement step portion 23b to enable the engagement.

  As another example of the connecting means between the flooring materials, the supporting legs 6 of the adjacent flooring materials can be connected using a connecting ring or the like without providing the connecting pieces 20 and 20 '. In this case, anchor embedding depth setting means 29 exemplified by the short pin 29a is provided on the three or four sides of the seat plate 1.

  As a means for strengthening the coupling between the seat plate 1 and the surface material 2, the anchor 3 is provided with an anchor coupling hole 5 that penetrates between the rising side surfaces, and the pre-curing surface material 2 flows into the anchor coupling hole. The good habituation to the anchor 3 is promoted, and the anchor effect by the anchor 3 is improved.

  Further, as shown in FIGS. 3 to 4, a support leg 6 is provided directly below the anchor 3 or at a position different from the anchor 3, and the seat leg is connected to the support leg 6 so as to pass through the seat board 1 and open on the upper and lower surfaces. Hole 4 is provided.

  The uncured surface material 2 is allowed to flow into the seat plate coupling hole 4 and the coupling holes 4 and 5 cooperate to improve the anchor effect of the anchor 3.

  The anchor embedding depth setting means 29 is brought into contact with the opening edge 10a (the flange portion 10b) to set the embedding depth of the anchor 3 with respect to the surface material 2 before curing, and at the same time, curing into the seat plate coupling hole 4 The amount of penetration of the front surface material 2 is set appropriately. The uncured surface material 2 penetrates into the seat window coupling hole 4 while entering the coupling window 8, thereby strengthening the integral coupling between the seat plate 1 and the surface material 2.

  The seat plate 1 having the anchor embedding depth setting means 29 is integrally formed of a synthetic resin, and a suitable material for the synthetic resin is polyacetal which is less deformed by temperature change and less electrostatic charge.

The top view of a seat board. FIG. 2 is a sectional view taken along line AA in FIG. 1. The top view which shows the other examples of a seat plate. BB sectional drawing in FIG. 1A is a plan view showing an example in which the seat plate in FIG. 1 is fixed to the uncured surface material to form a composite structure using a surface material mold, and B is a composite structure in which the seat plate in FIG. 2 is fixed to the uncured surface material. FIG. A is a cross-sectional view showing a state immediately before fixing to the pre-curing surface material filled in the surface material mold, and B is a cross-sectional view showing a state where the surface material is fixed to the pre-curing surface material filled in the mold and formed into a composite structure. The contact part enlarged view of an anchor embedding depth setting means. A is an enlarged perspective view of a contact portion when the anchor embedding depth setting means is formed of short pins, and B is a cross-sectional view thereof. The top view which shows the flooring which does not have a joint groove. FIG. 9 is a cross-sectional view of the floor material in FIG. 8. The top view which shows the flooring which has a joint groove. FIG. 11 is a cross-sectional view of the floor material in FIG. 10. The principal part sectional drawing which shows the state laid down, connecting flooring materials mutually.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Seat board, 1 '... Outer frame part, 1a ... Edge part, 2 ... Surface material, 3 ... Anchor, 4 ... Seat board joint hole, 5 ... Anchor joint hole, 6 ... Support leg, 8 ... Joint window, DESCRIPTION OF SYMBOLS 10 ... Surface material shaping | molding die, 10a ... Opening edge part, 10b ... Gutter part, 10c ... Ruler part, 10d ... Bottom wall, 10e ... Side wall, 10f ... Cut, 11 ... Joint groove, 13 ... Flat plate beam, 17 ... Floor ground surface , 18 ... gap, 19 ... engagement hole, 20, 20 '... connection piece, 21 ... engagement protrusion, 22b ... annular locked stepped portion, 23a ... locking claw, 23b ... locking stepped portion, 24' ... lower surface of connecting piece, 29 ... anchor embedment depth setting means, 29a ... short pin, 29b ... contact surface.

Claims (4)

In a method for manufacturing a flooring material in which a surface material is layered on the upper surface of a substantially square synthetic resin seat plate and a large number of anchors projecting from the upper surface of the seat plate are embedded in the surface material, the bottom wall and the bottom Using a surface material molding die made of a synthetic resin film that defines a molding cavity opened at the upper surface with four side walls raised from the four sides of the wall, the surface before curing filled in the molding cavity of the surface material molding die When the anchor is embedded in the uncured surface material with the upper surface of the material and the upper surface of the seat plate facing each other, the anchor embedding depth setting means provided at the edge portion of the seat plate is the surface material molding A rib-shaped ruler portion is formed along the upper surface of the base end of the flange portion while forming a flange portion that protrudes outward at a substantially right angle to the opening edge portion of the surface material molding die while being brought into contact with the opening edge portion of the mold. Are provided intermittently over the length, and the anchor embedding depth setting means is abutted and supported at the cut of the ruler portion. To, the preparation of floor coverings, characterized by fixing the upper surface of the seat plate on the upper surface of the front set and cure the buried depth of the anchor surface material for the pre-curing surface material. A plurality of coupling windows that can be opened on the upper and lower surfaces of the seat plate are provided on the seat plate, and the pre-curing surface material is infiltrated into each coupling window of the seat plate by contact with the anchor embedding depth setting means. The method for producing a flooring material according to claim 1. 2. The method for manufacturing a flooring material according to claim 1, wherein the anchor embedding depth setting means is formed by short pins. A connecting piece for connecting to another flooring is projected from two adjacent sides of the seat plate, a short pin is projected from the other two adjacent sides of the seat plate, and the connecting piece and the short pin are connected. 2. The method for manufacturing a flooring material according to claim 1, wherein the anchor embedding depth setting means is used.

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