JP7670528B2 - Construction material and manufacturing method thereof - Google Patents

Description

The present invention relates to construction materials and manufacturing methods for construction materials.

In buildings such as houses, a frame is installed where there is a step. A frame is a decorative material installed at the end of the higher part of the step. For example, in an entrance hall, there is a step between the floor of the entrance hall (hereinafter referred to as the "entrance floor") and the floor of the corridor (hereinafter referred to as the "floor"). A construction material called an entrance frame is attached to the higher end of the part where there is a step. Also, in a staircase, there is a step between the floor of the upper floor and the step board one step below. A construction material called an upper step frame is attached to the higher end of the part where there is a step. Some frames have a base material made of laminated wood with decorative material attached to the front and top. This base material is highly water-absorbent, and moisture absorbed by the base material can cause mold to grow on the decorative material, causing discoloration and rotting. In particular, during construction, mortar is applied to the entrance floor, and the entrance frame is installed on top of the mortar. In such cases, the base material of the entrance frame absorbs moisture from the mortar, causing mold and mildew to appear on the decorative material, which causes problems with the design of the entrance frame.

Patent Document 1 discloses a hallway construction material that is installed at the entrance of a house. The hallway construction material described in Patent Document 1 has a moisture-proof layer formed on the bottom surface of the wooden base material. This prevents the wooden base material from absorbing moisture from under the floor.

Patent No. 5486775

The entrance construction material described in Patent Document 1 has a front decorative material provided on the front of a wooden base material. The front decorative material protrudes from the bottom surface of the wooden base material. When this entrance construction material is installed at the entrance, it is placed on mortar, and at this time, the wooden base material is prevented from absorbing moisture by a moisture-proof layer formed on its bottom surface. However, since the front decorative material protrudes from the bottom surface of the wooden base material and is not protected by a moisture-proof layer, there is a risk that the front decorative material will absorb moisture from the mortar by coming into direct contact with the mortar. This poses the problem that the front decorative material will discolor due to mold growth, etc., and there is concern that the design will be impaired.

Therefore, one example of the object of the present invention is to provide a construction material for use in frames that makes the base material less susceptible to decay without compromising the design, and that can prevent discoloration due to mold growth, and a method for manufacturing the construction material.

In order to achieve the above object, a construction material according to one aspect of the present invention comprises:
A construction material used for a frame,
A wood base material,
A top surface decorative material provided on a top surface of the wood base material;
A front decorative material provided on the front surface of the wood base material;
A moisture-proof sheet provided on the bottom surface of the wood base material;
Equipped with
The bottom surface of the wood base material and the bottom surface of the front decorative material are flush with each other,
The moisture-proof sheet covers a bottom surface of the front decorative material,
The moisture-proof sheet has an end portion formed with a chamfer that is inclined relative to the bottom surface of the front decorative material.

In order to achieve the above object, a manufacturing method of a construction material according to one aspect of the present invention includes:
A manufacturing method for a construction material used for a frame, comprising the steps of:
(A) attaching the front decorative material to the front surface of the wood base material so that the bottom surface of the wood base material and the bottom surface of the front decorative material are flush with each other;
(B) attaching a moisture-proof sheet to the bottom surface of the wood base material and the bottom surface of the front decorative material;
(C) a top surface decorative material to be attached to the top surface of the wood base material;
The present invention is characterized by comprising:

The present invention makes it possible to create a construction material for use in frames that is resistant to decay and prevents discoloration due to mold growth without compromising design.

FIG. 1 is a diagram showing the state in which construction materials have been installed. FIG. 2 is a diagram showing a construction material according to the embodiment. FIG. 3 is a diagram showing a construction material in which a wood sheet is provided on the surface of a moisture-proof sheet. FIG. 4 shows a case where a chamfer is formed only on a wood sheet. FIG. 5 is a diagram showing the steps of a manufacturing method for a construction material in sequence.

One embodiment of the present invention will be described below with reference to the drawings.

The construction material of this embodiment is used, for example, as a frame, more specifically, as a step frame for an entrance hall or an upper step frame for a staircase. In the following, the construction material will be described as being used for a frame for an entrance hall.

Figure 1 shows the construction material 1 after installation.

The fixture 1 is installed in the corner that rises from the entrance 100 to the floor 101 inside the room. The entrance 100 is constructed with a finishing material such as tiles or cement. In the section that rises from the entrance 100 to the floor 101, a base 103 is constructed on a foundation 102. A joist 104 is provided on the base 103, and a floor base 105 and a floor dressing material 106 are constructed on the joist 104.

The construction material 1 is installed in the corner portion. A wooden base 107 is provided on the foundation 102. Mortar 108 is provided on the front side of the foundation 102 (the entrance 100 side). The construction material 1 is placed on the wooden base 107 and mortar 108, and is fixed to the wooden base 107 and base 103 with a urethane adhesive.

When the construction material 1 of this embodiment is installed as shown in Figure 1, it is configured to suppress the occurrence of mold and discoloration caused by absorbing moisture from the mortar 108.

Figure 2 shows the construction material of this embodiment. In Figure 2, a portion of construction material 1 is shown enlarged.

The construction material 1 includes a wooden base material 10. The wooden base material 10 is columnar. The wooden base material 10 may be made of, for example, solid wood, laminated lumber, plywood, LVL (Laminated Veneer Lumber), MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard) or other wood fiberboard, or may be made of particle board, OSB (Oriented Strand Board) or a laminate of these.

In the following description, the surface of the wooden base material 10 that is the top surface when the fitting material 1 is installed and that will become part of the floor 101 is referred to as the top surface. The surface opposite the top surface and that will be on the mortar 108 and foundation 102 side when the fitting material 1 is installed is referred to as the bottom surface. Furthermore, the surface of the wooden base material 10 that is adjacent to the top surface and bottom surface, faces the entrance 100 side when the fitting material 1 is installed, and is approximately perpendicular to the floor of the entrance 100 is referred to as the front surface.

A top surface decorative material 11 is provided on the top surface of the wooden base material 10. The top surface decorative material 11 forms part of the floor 101 when the fitting 1 is installed. The top surface decorative material 11 has a thickness of, for example, about 0.1 mm to 5.0 mm. The material of the top surface decorative material 11 is not particularly limited, but it may be formed, for example, from wood veneer such as veneer or sawn board, a resin sheet such as an olefin sheet or polyvinyl chloride sheet, or a paper sheet with a printed pattern.

A front decorative material 12 is attached to the front of the wooden substrate 10. The front decorative material 12 has a thickness of, for example, about 0.1 mm to 5.0 mm. The material of the front decorative material 12 is not particularly limited, but it may be formed, for example, from a wood veneer such as veneer or sawn board, a resin sheet such as an olefin sheet or polyvinyl chloride sheet, or a paper sheet with a printed pattern. As shown in the enlarged portion of Figure 2, the side of the front decorative material 12 that forms the bottom side of the wooden substrate 10 (hereinafter referred to as the bottom surface of the front decorative material 12) is approximately flush with the bottom surface of the wooden substrate 10.

A moisture-proof sheet 13 is attached to the bottom surface of the wooden substrate 10. As described above, the bottom surface of the wooden substrate 10 and the bottom surface of the front decorative material 12 are flush with each other. The moisture-proof sheet 13 is attached so as to cover the flush bottom surface of the wooden substrate 10 and the bottom surface of the front decorative material 12. As will be described later, the moisture-proof sheet 13 is a member that prevents the wooden substrate 10 and the front decorative material 12 from absorbing moisture from the mortar 108 when the fitting material 1 is placed on the mortar 108. For this reason, the moisture-proof sheet 13 is formed from a material that is moisture-proof and water-resistant. The moisture-proof and waterproof performance of the moisture-proof sheet 13 is preferably such that the moisture permeability measured in accordance with JIS Z0208 is 30 g/(m ² ·24h) or less, more preferably 20 g/(m ² ·24h) or less, and even more preferably 10 g/(m ² ·24h) or less. The smaller the moisture permeability value, the greater the effect of preventing discoloration, decay, or mold growth due to moisture movement.

Examples of the moisture-proof sheet 13 include polyethylene resin, polypropylene resin, polyethylene terephthalate resin, polystyrene resin, polyvinyl chloride resin, and acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin) molded into a sheet or plate shape. The moisture-proof sheet 13 may be a laminate of multiple layers of these resins integrated together, or a metal layer (metal in a sheet shape) such as aluminum foil. It may also be laminated paper made by laminating resin and paper, or polysand paper. From the viewpoint of moisture prevention, it is not limited to sheets, and it is also possible to apply a resin paint, but there is a problem that the moisture-proof effect of resin paint is low and the moisture-proof performance varies depending on the coating thickness or coating unevenness during manufacturing. Furthermore, since the paint turns yellow due to ultraviolet rays or aging, there is a concern that the design will deteriorate over time, and there is also a problem that the moisture-proof performance may deteriorate if the coating cracks.

The thickness of the moisture-proof sheet 13 is about 0.1 mm to 1.0 mm, more preferably 0.1 mm to 0.5 mm, and even more preferably 0.1 mm to 0.3 mm. There are no particular limitations on the method for adhering the moisture-proof sheet 13, but for example, a water-based adhesive, a resin-based adhesive, a hot melt adhesive, or a pressure sensitive adhesive may be used.

In addition, at the end of the moisture-proof sheet 13, a chamfered portion 13A is formed that is inclined relative to the flush bottom surface of the wood base material 10 and the bottom surface of the front decorative material 12. The chamfered portion 13A is formed at the end of the moisture-proof sheet 13 so that the moisture-proof sheet 13 remains on the bottom surface of the front decorative material 12. By forming the chamfered portion 13A, burrs or fuzz that occur during manufacturing can be removed, and clothing and other items can be prevented from getting caught after the construction material 1 is installed.

The chamfering to form the chamfered portion 13A may be a C-surface (45°) formed only on a flat surface, a chamfered surface, a chamfered angle other than 45°, an R-surface including a curved surface, or a chamfered shape combining a flat surface and a curved surface. The chamfered portion 13A may be formed in advance on the moisture-proof sheet 13, or may be formed when the moisture-proof sheet 13 is attached to the bottom surface of the wood substrate 10.

When the construction material 1 with the moisture-proof sheet 13 attached is placed on the mortar 108, the moisture-proof sheet 13 covers the bottom surface of the wooden base material 10, preventing moisture from the mortar 108 from penetrating into the wooden base material 10. This prevents the occurrence of mold and mildew on the front decorative material 12 due to moisture penetrating from the wooden base material 10 into the front decorative material 12.

In addition, since the moisture-proof sheet 13 covers the bottom surface of the front decorative material 12, even if the front decorative material 12 is installed so that it is located directly above the mortar 108, the moisture in the mortar 108 is prevented from penetrating directly into the front decorative material 12. In addition, there are cases where the mortar 108 is installed after the fitting material 1 is installed. In this case, the mortar 108 is often installed up to just below the front decorative material 12, and the mortar 108 contains more moisture than when the fitting material 1 is placed and installed after the mortar 108 has been installed and dried to a certain extent. For this reason, the moisture-proof sheet 13 covering the bottom surface of the front decorative material 12 is particularly effective in preventing moisture from penetrating directly into the front decorative material. This prevents the occurrence of mold and the like on the front decorative material 12. In other words, the moisture-proof sheet 13 prevents moisture from the mortar 108 from indirectly penetrating into the front decorative material 12 via the wood base material 10, and from directly penetrating into the front decorative material 12.

In addition, a wooden sheet 14 may be provided on the surface of the moisture-proof sheet 13. Figure 3 shows a construction material 1 with a wooden sheet 14 provided on the surface of the moisture-proof sheet 13.

The wood sheet 14 is attached to the surface of the moisture-proof sheet 13. The material of the wood sheet 14 is not particularly limited as long as the strength and durability are ensured, but examples include veneer, single board, sawn board, fiberboard such as MDF and HDF. The thickness of the wood sheet 14 is not particularly limited, but is preferably thin in consideration of material costs and workability during manufacturing. The thickness of the wood sheet 14 is 0.1 mm to 5.0 mm, more preferably 0.1 mm to 3.0 mm, and even more preferably 0.1 mm to 1.0 mm. The method of adhering the wood sheet 14 is not particularly limited, but for example, a water-based adhesive, a resin-based adhesive, a hot melt adhesive, or a pressure-sensitive adhesive may be used.

By providing the wood sheet 14 on the surface of the moisture-proof sheet 13, the design of the bottom side of the construction material 1 can be prevented from being impaired. Furthermore, the wood sheet 14 acts to suppress expansion and contraction of the moisture-proof sheet 13 due to temperature (especially heat during drying in the coloring and painting processes), so it is possible to prevent the moisture-proof sheet 13 from peeling off from the wood base material 10.

When the wood sheet 14 is provided on the surface of the moisture-proof sheet 13, a chamfered portion 14A is formed at the ends of the moisture-proof sheet 13 and the wood sheet 14, which is inclined relative to the bottom surface of the wood base material 10. By forming the chamfered portion 14A, burrs or fuzz that occur during manufacturing can be removed, clothes and other items can be prevented from getting caught after the construction material 1 is installed, and cracks in the wood sheet 14 caused by corners being hit when the construction material is transported can be prevented.

The chamfering process to form the chamfered portion 14A may be C-surface processing (45°) that is formed only on a flat surface, chamfering with a chamfering angle other than 45°, R-surface processing that includes a curved surface, or chamfering with a shape that combines a flat surface and a curved surface.

When a wooden sheet 14 is provided on the surface of the moisture-proof sheet 13, a chamfered portion 14A may be formed only on the wooden sheet 14 as shown in FIG. 4. FIG. 4 shows a chamfered portion 14A formed only on the wooden sheet 14. In this case, the chamfered portion 14A may be formed on the wooden sheet 14 in advance, or may be formed when the wooden sheet 14 is attached to the surface of the moisture-proof sheet 13. Furthermore, if the chamfered portion 14A is not formed on the moisture-proof sheet 13, it is possible to prevent the moisture-proof sheet 13 covering the bottom surface of the front decorative material 12 from becoming thin.

Next, we will explain the manufacturing method of the construction material 1. Figure 5 is a diagram showing the steps of the manufacturing method of the construction material 1 in order.

First, the front decorative material 12 is attached to the front surface of the wooden substrate 10 (FIG. 5(A)). The bottom surface of the front decorative material 12 is made to be approximately flush with the bottom surface of the wooden substrate 10. The front decorative material 12 may be attached so that the bottom surface of the front decorative material 12 and the bottom surface of the wooden substrate 10 are approximately flush with each other, or the front decorative material 12 may be attached to the front surface of the wooden substrate 10 and then the bottom surface of the front decorative material 12 and the bottom surface of the wooden substrate 10 are made to be flush with each other. The attached front decorative material 12 is then deburred.

Next, the moisture-proof sheet 13 is attached to the bottom surface of the wooden substrate 10 (FIG. 5(B)). There are no particular limitations on the method of attaching the moisture-proof sheet 13, but for example, a water-based adhesive, a resin-based adhesive, a hot melt adhesive, or a pressure-sensitive adhesive is used to attach the wood substrate 10 and the moisture-proof sheet 13. At this time, the moisture-proof sheet 13 is attached so as to cover the bottom surface of the wood substrate 10 and the bottom surface of the front decorative material 12. After that, the moisture-proof sheet 13 is deburred and chamfered. The chamfering may be performed using a blade or sandpaper.

Next, the top surface decorative material 11 is attached to the top surface of the wooden base material 10 (Figure 5 (C)). The attached top surface decorative material 11 is then deburred. The top surface decorative material 11 is also chamfered. After that, the fitting material 1 is colored and dried, and then painted and dried. The top surface decorative material 11 may be attached before the moisture-proof sheet 13 is attached to the bottom surface of the wooden base material 10.

After the step of FIG. 5(B), the wood sheet 14 may be attached to the surface of the moisture-proof sheet 13. The method of adhering the wood sheet 14 is not particularly limited, but for example, the wood sheet 14 and the moisture-proof sheet 13 may be adhered to each other using a water-based adhesive, a resin-based adhesive, a hot melt adhesive, or a pressure-sensitive adhesive. The moisture-proof sheet 13 and the wood sheet 14 may be integrated in advance.

Reference Signs List 1: Construction material 10: Wood base material 11: Top surface decorative material 12: Front surface decorative material 13: Moisture-proof sheet 13A: Chamfered portion 14: Wood sheet 14A: Chamfered portion 100: Entrance 101: Floor 102: Foundation 103: Base 104: Joist 105: Floor base 106: Floor decorative material 107: Wood base 108: Mortar

Claims (4)

A construction material used for a frame,
A wood base material,
A top surface decorative material provided on a top surface of the wood base material;
A front decorative material provided on the front surface of the wood base material;
A moisture-proof sheet provided on the bottom surface of the wood base material;
Equipped with
The bottom surface of the wood base material and the bottom surface of the front decorative material are flush with each other,
The moisture-proof sheet covers a bottom surface of the front decorative material,
The moisture-proof sheet has an end portion formed with a chamfer that is inclined with respect to the bottom surface of the front decorative material.
Construction materials. A manufacturing method for a construction material used for a frame, comprising the steps of:
(A) attaching the front decorative material to the front surface of the wood base material so that the bottom surface of the wood base material and the bottom surface of the front decorative material are flush with each other;
(B) attaching a moisture-proof sheet to the bottom surface of the wood base material and the bottom surface of the front decorative material ;
(C) attaching a top surface decorative material to the top surface of the wood base material;
(D) forming a chamfered portion at an end of the moisture-proof sheet, the chamfered portion being inclined relative to the bottom surface of the front decorative material;
Equipped with
In the step (D), the chamfered portion is formed on the end of the moisture-proof sheet so that the moisture-proof sheet remains on the bottom surface of the front decorative material.
Manufacturing method of construction materials. The step (C) is carried out after the step (B).
A method for manufacturing the construction material according to claim 2. The moisture-proof sheet is made by molding a polyethylene resin, a polypropylene resin, a polyethylene terephthalate resin, a polystyrene resin, a polyvinyl chloride resin, or an acrylonitrile-butadiene-styrene copolymer synthetic resin.
A method for manufacturing a construction material according to claim 2 or 3 .

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