JPH0548827B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <<Industrial Application Field>> The present invention relates to a sound-insulating wooden flooring material and a method for producing the same. More specifically, the present invention relates to a sound-insulating wooden flooring material that can be applied directly to a concrete floor and a method for manufacturing the same.

<<Prior Art>> Conventionally, carpets and the like have been directly attached to concrete floors for the floors of mid-to-high-rise residences. However, when carpets are used, there is a drawback that it takes time and effort to replace the carpet.
Furthermore, in recent years, as people have reconsidered the suitability of wood materials for Japan's climate and their familiarity with the texture of wood, there has been a growing tendency to use wood flooring materials.

However, since wood flooring has significantly poorer sound insulation properties than carpets, livability will be significantly impaired if it is directly attached to a concrete floor.

Furthermore, the reality is that concrete floors inevitably have an unevenness of about 5 mm, making it difficult to make concrete floors and wooden flooring materials come into close contact with each other.

≪Problems to be solved by the invention≫ Various improvements have been made to the above-mentioned drawbacks (for example, Utility Model Application No. 56-3945, Utility Model Application Publication No. 61-1998)
No. 22109, Utility Model No. 60-63628, No. 60-121052, and No. 61-47339), in all cases, a buffer material is used entirely at some point between the wooden floor and the concrete floor, so the wooden floor If a thick cushioning material is used with emphasis on sound insulation performance, the floor will sink locally when heavy items such as furniture are placed on it, and the floor will rise and fall each time you walk, making it uncomfortable to walk on. The problem arises that it gets worse.

Therefore, a first object of the present invention is to provide a flooring material with excellent sound insulation performance.

A second object of the present invention is to provide a flooring material that has excellent sound insulation performance and does not cause local subsidence or ups and downs when walking.

A third object of the present invention is to provide a wooden flooring material that is excellent in sound insulation, walkability, and other livability properties.

Furthermore, a fourth object of the present invention is to provide a method suitable for efficiently producing flooring materials with excellent sound insulation properties, walkability, etc.

<<Means for Solving the Problems>> The above-mentioned objects of the present invention are to provide a lower layer made of a planar foam having plywood pieces along at least one longitudinal side, and a foam covering 40% or more of the total area. A flooring material for direct installation consisting of three layers: a middle layer made of a foam-embedded plywood having a buried portion, and an upper layer made of a decorative laminated plywood, wherein the middle layer made of the foam-embedded plywood is located at both ends in the length direction. The present invention has been achieved by a flooring material for direct attachment, which is characterized in that it is fixed to the upper layer and the lower layer so as to form engaging projections and recesses, respectively, and a method for manufacturing the same.

The present invention will be explained in detail below with reference to the drawings.

FIG. 1 is a sectional view showing an example of the flooring material for direct attachment of the present invention. In the figure, reference numeral 1 denotes a decorative material constituting the decorative laminated plywood adhered to the surface of the plywood 3; 10 denotes a foam-embedded plywood consisting of a punched plywood 5 and a foam 7 inserted into the punched area; 9; is a foam body with plywood pieces 11 along its length. 20
and 22 are protrusions and recesses for engaging the flooring materials together.

<<Function>> The foam 9 is a cushioning material that adapts to the unevenness of the concrete floor and adheres closely when the flooring material of the present invention is directly attached to the concrete floor, and has a thickness of 2
It is preferable to set the foaming ratio to 3 mm to 3 mm and the expansion ratio to 5 to 30 times. In this case, it is preferable to add an inorganic filler such as calcium carbonate to improve adhesion to the concrete floor. The plywood piece 11 is
It prevents the foam 9 from being completely compressed and also forms part of the connecting part when connecting the flooring units of the present invention. Therefore, they may be provided piecemeal along the sides as long as they can substantially fulfill their role.

The foam embedded plywood 10 is a board that blocks floor impact noise, and the punched plywood 5 prevents the foam 7 from compressing and deforming and losing its performance as a sound insulating material, and prevents pressure from above and below. It acts as a supporting bone. Therefore, the plywood 5 can be appropriately designed in terms of the number and shape of holes to be punched, the punched area, etc., taking into consideration the strength during use and the strength during manufacture, and the thickness thereof can also be appropriately selected. The punching area is 20 to 80%, and preferably 40% or more in order to obtain a sufficient sound insulation effect.
Further, the thickness is 2 to 10 mm, preferably 2.5 to 5 mm.

The materials of the foams 7 and 9 may be the same or different, and may be appropriately selected from known foam materials such as polyolefin, styrene, urethane, etc. However, foaming is preferred from the viewpoint of cost and life. Preferably, a foamed olefin such as polyethylene is used.

Foam 7 has a foaming ratio of 10 from the perspective of sound absorption performance.
It is at least 40 times, preferably 40 times or more.

The decorative material 1 may be a wood material such as a veneer, a polymeric material such as a so-called cushion floor, or a carpet, but it may be suitable for adaptability to the climate of Japan, aesthetic point of view, or ease of maintenance. A wood material is preferable from the viewpoint of thickness, and from the viewpoint of the overall strength and life of the decorative board, the thickness of the plywood on which the decorative material is applied is preferably 2 to 5 mm, particularly 2.5 to 3 mm.

In addition, the cross-sectional shapes of the convex portions and concave portions that connect the flooring materials to each other can be arbitrarily selected, but the cross-sectional shapes of the upper layer joints and the lower layer are designed to make it difficult for liquid substances such as water to enter and to simplify the installation with nails, etc. It is preferable to shift the joints between the two, and from this point of view, a synthetic resin waterproof sheet 13 can be provided if necessary.

The shape of the flooring material of the present invention can be designed as appropriate, and two or more shapes can be combined, but from the viewpoint of ease of construction, a parallelogram is preferred, and a rectangle is particularly preferred.

A rectangle is the basic shape when constructing a floor, but especially when the decorative material is wood, a rectangle with a width of 1 shaku (approximately
300 mm) and 6 shaku (approximately 1800 mm) in length. Of course, dimensions that are multiples of this can also be adopted.

Although the flooring material of the present invention can be appropriately manufactured by any known method, it is particularly preferable to use the following method because the product can be manufactured easily and at low cost.

That is, first, a decorative material made of plywood laminated with a veneer or the like is prepared. Next, overlap another plywood with a sheet foam that is slightly thicker than the plywood and has good sound absorption performance, and from the sheet foam side, use a punching machine to cut the plywood at any location and shape into the plywood. Punch out more than 40% of the area. During punching, after punching out the plywood, the plywood pieces remaining in the punching machine are pushed out, and then, while the tip of the punching machine is being pulled out from the plywood, or after being pulled out, the foam remaining in the punching machine is also pushed out. , Prepare a foam-embedded plywood board that is inserted into the punched out part of the plywood board and functions as a sound insulating board.

On top of the prepared foam-embedded plywood, the decorative laminated plywood is shifted in the width direction and fixed using known means such as adhesive or nails. Next, along at least one longitudinal side of the foam embedded plywood,
A piece of plywood is fixed to the back surface of the foam-embedded plywood by shifting the decorative plywood in the direction in which the decorative plywood is shifted by a different amount of shift from the amount of shift between the decorative plywood and the foam-embedded plywood. If the plywood piece is provided along only one side, the foam 9 is glued to the side surface of the plywood piece and the back side of the foam-embedded plywood. In this case, the combined area and shape of the plywood piece and the foam 9, the area and shape of the foam-embedded plywood, and the area and shape of the decorative laminated plywood are the same. A waterproof sheet 13 may be provided under the plywood piece as appropriate.

In addition, when manufacturing the foam-embedded plywood, instead of using the above method, the punched plywood 5 is used when manufacturing the foam.
It can also be produced by putting it in a foaming pot.

≪Effects of the Invention≫ As detailed above, in the floorboard of the present invention, since there is always plywood in each layer to support the load, excessive load is not applied to the foam material, and the performance of the foam material can be maintained over a long period of time. can be maintained. In addition, from the perspective of increasing the sound insulation effect, the foaming ratio and insertion area of the foam material in the foam-embedded plywood can be appropriately selected, so the sound insulation can be achieved while maintaining the original performance of the flooring material, such as walkability. It can be used as a flooring material with good performance. EXAMPLES Hereinafter, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited thereto.

Example 1 300mm x 1800mm thick 2.5mm plywood, foaming ratio 40
Layer double sheet polyethylene foam and use a punching machine to cut the center 200mm from the polyethylene foam side.
An area of ×1600 mm was punched out, and the plywood remaining inside the punching machine was extruded. Next, while pulling out the tip of the punching machine from the plywood, the foamed polyethylene remaining in the punching machine was extruded and inserted into the plywood to produce a foam-embedded plywood.

On the other hand, 0.3mm veneer (oak wood) on plywood of the same size.
A decorative laminated plywood board was produced by laminating the sheets together using a urea-melamine resin adhesive.

Next, the foam-embedded plywood and decorative laminated plywood were
The left side of the decorative laminated plywood was attached along the long side so that it protruded 20 mm from the left side of the foam-embedded plywood.

Furthermore, place a piece of plywood 70 mm x 1800 mm thick and 2.5 mm thick on the bottom left side of the foam-embedded plywood.
2 mm protruding from the plywood, and then the sides of the plywood piece are in contact with the calcium carbonate at a foaming ratio of 20%.
260 with a thickness of about 2.7mm containing weight as filler
A flooring material was manufactured by pasting polyethylene foam measuring mm x 1800 mm.

The flooring material manufactured in this manner was directly attached to a concrete floor using a known method, and its sound performance was measured (by the Japan Building Research Institute), and the lightweight floor impact sound was LL60, which was extremely good. . Furthermore, the heavy floor impact sound was also good at LH55.

Example 2 Instead of the center punching done in Example 1,
5 squares of 20mm x 20mm in the width direction and in the longitudinal direction
A flooring material of the present invention was produced in the same manner as in Example 1, except that 55 pieces, a total of 275 pieces, were punched out to form a lattice-shaped foam-embedded plywood. The sound insulation performance of this flooring material was even better than that of Example 1, and the walkability was also further improved.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an example of the flooring material for direct attachment of the present invention. In the figure, 1 is decorative material, 3 is plywood,
5 is a punched plywood, 7 is a foam, and 10 is a foam-embedded plywood.

Claims (1)

[Scope of Claims] 1. A lower layer consisting of a sheet foam having plywood pieces along at least one longitudinal side, and 40% of the total area.
A flooring material for direct installation consisting of three layers: a middle layer made of foam-embedded plywood having the foam-embedded portion as described above, and an upper layer made of decorative laminated plywood, wherein the middle layer made of the foam-embedded plywood has a length. A flooring material for direct attachment, characterized in that it is fixed to the upper layer and the lower layer so as to form engaging convex portions and concave portions, respectively, at both end portions in the direction. 2. The floor material for direct attachment according to claim 1, wherein the decorative material constituting the upper layer of decorative laminated plywood is a veneer. 3 After plywood and a foam slightly thicker than the thickness of the plywood are overlapped, 40% or more of the total area of the plywood is punched out from the foam side, and the foam-embedded plywood is manufactured by embedding the foam instead. , the upper layer of the foam-embedded plywood is a decorative laminated plywood; the lower layer is a planar foam having plywood pieces along at least one side in the length direction; 1. A method for manufacturing a flooring material for direct attachment, characterized by fixing so as to form engaging convex portions and concave portions at both end portions of the direction.