Flooring and floor structure

Abstract

To provide a floor material having excellent impact relaxation performance and a floor structure.SOLUTION: A floor material 10 of the present disclosure has a first plate 11, a cushioning material 12 laminated on a rear face side of the first plate 11, and a second plate 13 laminated on an opposite side of the first plate 11 in relation to the cushioning material 12. Thickness of the second plate 13 is 0.5 times or more and 5 times or less of the thickness of the first plate 11.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to flooring and floor construction. [Background technology]

[0002] There have been many reported cases of elderly people falling in their homes or facilities, breaking bones, and then being hospitalized. Therefore, there is an increasing need for flooring materials to have excellent shock mitigation performance. In response to this, for example, Patent Documents 1 to 4 disclose flooring materials that have been improved to enhance shock mitigation performance. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-190673 A [Patent Document 2] JP 2011-190674 A [Patent Document 3] JP 2016-199994 A [Patent Document 4] JP 2016-216928 A Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a floor material and a floor structure having excellent shock absorbing performance. [Means for solving the problem]

[0005] The flooring material of the present disclosure comprises a first plate, a cushioning material laminated on the back side of the first plate, and a second plate laminated on the opposite side of the cushioning material to the first plate. The thickness of the second plate is 0.5 to 5 times the thickness of the first plate.

[0006] The floor structure of the present disclosure includes a first plate, a cushioning material laminated on the underside of the first plate, and a second plate laminated on the underside of the cushioning material. The thickness of the second plate is 0.5 to 5 times the thickness of the first plate. Effect of the Invention

[0007] The flooring material and floor structure of the present disclosure can provide excellent shock absorbing performance. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram showing a schematic diagram of an example of a flooring material according to the present disclosure. [Diagram 2] FIG. 2 is a diagram showing a schematic diagram of another example of the flooring material of the present disclosure. [Diagram 3] FIG. 3 is a diagram showing a schematic diagram of an example of a floor structure according to the present disclosure. [Figure 4] FIG. 4 is a diagram illustrating a schematic diagram of another example of the floor structure of the present disclosure. [Diagram 5] FIG. 5 is a diagram illustrating a schematic diagram of still another example of the floor structure of the present disclosure. [Figure 6] FIG. 6 is a diagram illustrating a construction method for obtaining the floor structure of the present disclosure. [Figure 7] FIG. 7 is a diagram showing a floor structure formed by the construction method of FIG. [Figure 8] FIG. 8 is a diagram for explaining another construction method for obtaining the floor structure of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment will be described with reference to the drawings.

[0010] (First embodiment) Fig. 1 shows an exemplary flooring 10 of the first embodiment. The flooring 10 comprises a first plate 11, a cushioning material 12 laminated on the back side of the first plate 11, and a second plate 13 laminated on the opposite side of the cushioning material 12 from the first plate 11. In other words, the cushioning material 12 is sandwiched between the first plate 11 and the second plate 13. This configuration allows the flooring 10 to exhibit excellent shock absorbing performance.

[0011] The thickness of the second plate material 13 is preferably 0.5 times or more, more preferably 0.8 times or more, and even more preferably 1 time or more, the thickness of the first plate material 11. The thickness of the second plate material 13 is preferably 5 times or less, more preferably 3 times or less, and even more preferably 2 times or less, the thickness of the first plate material 11. When the thicknesses of the first plate material 11 and the second plate material 13 satisfy such conditions, excellent shock absorbing performance is more reliably exhibited.

[0012] Furthermore, the thickness of the cushioning material 12 is preferably 0.5 times or more, and more preferably 1 time or more, the thickness of the first plate material 11. Furthermore, the thickness of the cushioning material 12 is preferably 3 times or less, and more preferably 2 times or less, the thickness of the first plate material 11. If these conditions are satisfied, the excellent shock absorbing performance is more reliably exhibited.

[0013] The first plate material 11 preferably has a flexural modulus of 500 MPa or more, more preferably 1000 MPa or more, and even more preferably 2000 MPa or more. The first plate material 11 preferably has a flexural modulus of 4000 MPa or less, more preferably 3500 MPa or more, and even more preferably 3000 MPa or less. From the viewpoint of preventing energy from being locally transmitted to the cushion material 12 and allowing the cushion material 12 to efficiently absorb energy and thereby obtain excellent shock mitigation performance, if such conditions are satisfied, excellent shock mitigation performance is more reliably exhibited.

[0014] The flexural modulus is measured based on JIS K7171:2016 when the constituent material of the first plate material 11 is resin, and is the flexural Young's modulus measured based on JIS Z2101:2009 when the constituent material of the first plate material 11 is wood.

[0015] The thickness of the first plate material 11 is preferably 4.0 mm or more, more preferably 3.0 mm or more, and is preferably 15.0 mm or less, more preferably 7.0 mm or less. If these conditions are satisfied, excellent shock absorbing performance is more reliably exhibited.

[0016] The compressive elastic modulus of the cushioning material 12 is preferably 1.0 MPa or more, and more preferably 1.5 MPa or more. The compressive elastic modulus of the cushioning material is preferably 2.5 MPa or less, and more preferably 2.3 MPa or less. If these conditions are satisfied, the cushioning material will more reliably exhibit excellent shock mitigation performance. This compressive elastic modulus was measured based on JIS K7181:2011, using a test specimen cut to 300 mm x 300 mm, and compressed with an indenter of 50 mm diameter at a test speed of 10 mm / min.

[0017] The weight of the cushioning material 12 is, for example, 400 g / m 2 More than 800g / m 2 The apparent density of the cushioning material 12 is, for example, 0.030 g / cm 3 More than 0.070g / cm 3 The following is the result.

[0018] From the viewpoint of obtaining excellent shock absorbing performance, the thickness of the cushioning material 12 is preferably 6.0 mm or more, more preferably 8 mm or more, and is preferably 20 mm or less, more preferably 15 mm or less.

[0019] The second plate material 13 preferably has a flexural modulus of 300 MPa or more, more preferably 1000 MPa or more, and even more preferably 3000 MPa or more. The second plate material 13 preferably has a flexural modulus of 10000 MPa or less, more preferably 6000 MPa or less, and even more preferably 4000 MPa or less. If these conditions are satisfied, excellent shock mitigation performance is more reliably exhibited.

[0020] The bending stress of the second plate 13 is 0.5 N / mm 2 It is preferable that the resistance is 10N / mm or more. 2 More preferably, it is 30N / mm 2 It is more preferable that the bending stress of the second plate member 13 is 80 N / mm 2 It is preferable that the resistance is less than 60N / mm 2 More preferably, it is 50N / mm 2 It is more preferable that the thickness is equal to or less than 100 mm. If such conditions are satisfied, excellent shock absorbing performance can be more reliably exhibited.

[0021] Moreover, it is preferable that the surface hardness of the flooring material 10 is 33 G or less as measured in accordance with the floor hardness test of JIS standard A5917:2018. Such a flooring material will more reliably exhibit excellent shock mitigation performance.

[0022] (Examples of materials for each component) Examples of materials constituting the first board material 11 include medium density fiberboard (hereinafter referred to as "MDF"), insulation board (soft fiberboard), hardboard (hard fiberboard), plywood, sorghum board, resin foam board, etc. The first board material 11 is preferably made of any one of these single materials or a composite of multiple materials, and from the viewpoint of obtaining excellent shock mitigation performance, it is preferable that the first board material 11 is made of MDF among these materials.

[0023] The second plate 13 may be made of the same material as the first plate 11 .

[0024] Examples of materials constituting the cushioning material 12 include fiber structures such as nonwoven fabric, synthetic fiber felt, and natural fiber felt; and foam materials such as synthetic resin foam and rubber foam. The cushioning material 12 is preferably composed of any one of these single materials or a composite of multiple materials, and from the viewpoint of obtaining excellent shock mitigation performance, it is preferable that the cushioning material 12 is composed of a nonwoven fabric among these materials, and more preferably that the cushioning material 12 is composed of a board-type nonwoven fabric.

[0025] The board-type nonwoven fabric can be produced, for example, by spraying heated steam onto a staple fiber web of conjugate fibers formed of a first material with a high melting point such as polyester and a second material with a low melting point such as an ethylene-vinyl alcohol copolymer to fuse the second material. The conjugate fiber may be a sheath-core type having an inner layer of the first material and an outer layer of the second material, or a side-by-side type in which the first material and the second material are bonded together. An example of a commercially available board-type nonwoven fabric is "Felibendy" (registered trademark) manufactured by Kuraray Kuraflex Co., Ltd.

[0026] The cushioning material 12 may be a laminated body in which a plurality of constituent materials are laminated together, specifically, for example, a laminated body of a plurality of nonwoven fabrics. In this case, the means for joining the plurality of constituent materials may be, for example, a chemical joining means using a hot melt adhesive, a double-sided adhesive tape, an adhesive sheet, a liquid adhesive, or the like; or a mechanical joining means such as sewing together or tacking with a tacker. The plurality of constituent materials may be joined only by a chemical joining means, may be joined only by a mechanical joining means, or may be joined by a combination of a chemical joining means and a mechanical joining means. Also, the plurality of constituent materials may be joined only at the edges or corners, and the center portion may be left unjoined.

[0027] The means for joining the first plate material 11 and the cushioning material 12 include, for example, chemical joining means using a hot melt adhesive, double-sided tape, adhesive sheet, liquid adhesive, etc.; and mechanical joining means such as sewing by stitching and tacking by a tacker. From the viewpoint of obtaining excellent shock mitigation performance, it is preferable that the first plate material 11 and the cushioning material 12 are joined by adhesion of a chemical joining means, including the central portion. On the other hand, from the same viewpoint, it is preferable that the first plate material 11 and the cushioning material 12 are not joined by a mechanical joining means at the central portion. Also, the first plate material 11 and the cushioning material 12 may be joined only at the edges or corners, and the central portion may be left unjoined.

[0028] The above-mentioned joining means can also be used as joining means between the second plate material 13 and the cushioning material.

[0029] The surface hardness (hereinafter referred to as the "first G value") of the flooring material 10 of this embodiment measured in accordance with the floor hardness test of JIS A5917:2018 is preferably 33 G or less, more preferably 30 G or less. The surface hardness measured according to the floor hardness test (hereinafter referred to as the "second G value") is also preferably 33 G or less, more preferably 30 G or less. These first G value and second G value are the acceleration when the head model is allowed to freely fall onto the measurement object and collides with it, and are taken as the hardness of the surface of the measurement object.

[0030] The difference between the first G value and the second G value of the flooring material 10 of this embodiment is preferably as small as possible, preferably 10G or less, more preferably 5G or less, and even more preferably 3G or less. The first G value is the average of the measurements from the third to fifth times of the five drop trials, and the second G value is the average of all the measurements from the five drop trials. Usually, the impact mitigation performance decreases when the drop trial is repeated, so the second G value is smaller than the first G value. Therefore, a small difference between the first G value and the second G value means that the impact mitigation performance is maintained even if the drop trial is repeated.

[0031] As shown in FIG. 2, a decorative material 14 may be further laminated on the front surface side (the side opposite to the cushion material) of the first plate material 11 to form a floor material 10a.

[0032] Examples of materials constituting the decorative material 14 include resin tatami mats, Japanese paper tatami mats, natural rush tatami mats, resin sheets, synthetic fiber or natural fiber fabrics, flooring, carpets, rugs, etc. The decorative material 14 may have a cushioning material such as a resin foam sheet laminated on the back side. From the viewpoint of obtaining floor surface performance such as durability, the thickness of the decorative material 14 is preferably 0.5 mm or more, more preferably 0.5 mm or more, and is preferably 15.0 mm or less, more preferably 4.0 mm or less.

[0033] Second Embodiment Next, a floor structure will be described as a second embodiment. Figures 3, 4, and 5 are diagrams showing an example of a floor structure according to this embodiment.

[0034] Fig. 3 shows the structure of a slab-mounted floor. That is, the floor material 10a having the decorative material 14 shown in Fig. 2 is placed directly on the floor slab 20. In Fig. 3, a plurality of laminates (similar to the floor material 10 in Fig. 1) of a first plate material 11, a cushion material 12 and a second plate material 13 are arranged on the floor slab 20 (two are shown in the example of Fig. 3), and the decorative material 14 is placed on top of them. The decorative material 14 is provided so as to expose a part of the first plate material 11 without covering it. The decorative material 14 may be provided separately after the floor material 10 (Fig. 1) not having the decorative material is placed.

[0035] Next, Fig. 4 shows a double-floor structure. That is, in this structure, a floor panel 21 is provided on a floor slab 20 via joists 22 and supports 23, and a floor material 10a is placed on the floor panel 21.

[0036] 5 shows a floor structure of the joist and floor panel construction method. That is, in this structure, a floor panel 21 is provided on a floor slab 20 via a joist 22, and a floor material 10a is placed on the floor panel 21.

[0037] The floor material 10 and the floor material 10a described in the first embodiment can be used in various floor structures including the above three examples, and exhibit excellent shock absorbing performance.

[0038] In the above, it is assumed that at least the first plate material 11, the cushion material 12, and the second plate material 13 are joined together in advance to form the floor material 10, which is then placed on the floor slab 20 or the floor panel 21. However, the floor structure can also be constructed with each layer being separate. This will be explained below.

[0039] Fig. 6 is an example of a joist and floor panel construction method. In this case, a second plate 13a is placed on a floor slab 20, with joists 22 in between, instead of the floor panel 21 in Fig. 5. A laminate in which a first plate 11 and a cushioning material 12 are layered and joined, and further provided with a decorative material 14, is placed on top of that. As a result, the floor structure shown in Fig. 7 is formed, that is, a floor structure including the first plate 11, the cushioning material 12 layered thereunder, and the second plate 13 layered thereunder. The decorative material 14 may or may not be provided.

[0040] As shown in Fig. 8, the decorative material 14, the first plate material 11, and the cushion material 12 may also be laminated and joined separately onto the second plate material 13a. In this case, the floor structure shown in Fig. 7 is also formed. In addition, various methods can be used by laminating and joining any number of layers in advance. Furthermore, it is also possible to form the floor structure shown in Fig. 7 by placing the floor material 10a of Fig. 2 on the floor slab 20 via joists 22. EXAMPLES

[0041] (Flooring) Flooring materials were produced in the following Examples 1 to 5 and Comparative Examples 1 to 3. The configurations of each are also shown in Table 1.

[0042] <Example 1> As the first plate material, MDF having a thickness of 6.4 mm (flexural strength of 30.5 MPa, flexural modulus of 2880 MPa) was prepared.

[0043] As a cushioning material, three sheets of board-type nonwoven fabric (manufactured by Kuraray Kuraflex, product name: Felivendy) were laminated together with a hot melt adhesive to create a nonwoven fabric laminate with a thickness of 12.0 mm. The board-type nonwoven fabric used was manufactured by spraying heated steam onto a staple fiber web of conjugate fiber having an inner layer of polyester and an outer layer of ethylene-vinyl alcohol copolymer. The nonwoven fabric laminate also had a compressive elastic modulus of 1.66 MPa and an apparent density of 0.050 g / cm. 3 It is.

[0044] The second board is 5.5 mm thick MDF (bending stress 35 N / mm 2 , flexural modulus 2944 MPa) was prepared.

[0045] The first plate material 11, the cushion material, and the second plate material were laminated by bonding them together with a hot melt adhesive.

[0046] In this manner, the flooring material of Example 1 was produced.

[0047] <Example 2> The second board is 4.0 mm thick MDF (bending stress 37 N / mm 2 The first plate material, the cushion material, and the lamination method of each layer were the same as in Example 1, and a floor material of Example 2 was produced.

[0048] <Example 3> The second board is a 9.0 mm thick plywood (bending stress 11 N / mm 2 The first plate material, the cushion material, and the lamination method of each layer were the same as in Example 1, and a floor material of Example 3 was produced.

[0049] <Example 4> The first board material, cushion material, and second board material were prepared in the same manner as in Example 3. Furthermore, as a decorative material, a tatami facing (weight: 838 g / m2) with a thickness of 2.0 mm and made of resin imitation rush was used. 2 , apparent density: 0.419g / cm 3 ) was prepared.

[0050] The first plate 11, the cushioning material, and the second plate were laminated by bonding with a hot melt adhesive. Furthermore, a decorative material was laminated on the front side of the first plate 11 without bonding, and the corners were joined with a tacker to produce the flooring material of Example 4.

[0051] <Example 5> A carpet (thickness 6.0 mm, manufactured by Toli Industries, Inc.) was prepared as a decorative material. Except for that, the flooring material of Example 5 was produced in the same manner as in Example 4.

[0052] <Comparative Example 1> A first plate and a cushioning material were prepared similar to those in Examples 1 and 3. The cushioning material was laminated by adhering it to the back side of the first plate using a hot melt adhesive. In this way, the flooring material of Comparative Example 1 was produced. Therefore, the flooring material of Comparative Example 1 has a configuration similar to that of Examples 1 or 3, except that the second plateing material is omitted.

[0053] <Comparative Example 2> A first board and cushioning material were prepared similarly to those in Comparative Example 1. A decorative material (tatami facing) similar to that in Example 4 was also prepared. A cushioning material was laminated by bonding to the back side of the first board using a hot melt adhesive. Furthermore, a decorative material was laminated to the front side of the first board 11 without bonding, and the corners were joined with a tacker to produce a flooring material in Comparative Example 2. The flooring material in Comparative Example 2 has a configuration similar to that of the flooring material in Example 4, except that the second board is omitted.

[0054] <Comparative Example 3> A carpet similar to that in Example 5 was prepared as a decorative material. Otherwise, a flooring material in Comparative Example 3 was produced in the same manner as in Comparative Example 2. The flooring material in Comparative Example 3 has a configuration similar to that of the flooring material in Example 5, except that the second board material is omitted.

[0055] [Table 1]

[0056] (Test evaluation results) Table 1 shows the first G value and the second G value (measured according to JISA5917:2018 and JIS A6519:2013, respectively, as described above) for Examples 1 to 5 and Comparative Examples 1 to 3. In all of the Examples, the two G values ​​were the same. Also, in the Comparative Examples, the first G value was either 1 larger or the same.

[0057] The smaller the G value, the better the shock mitigation performance. The G values ​​in Comparative Examples 1 to 3 are about 34 to 36, whereas in the Examples, the maximum G value is 31 in Example 1 or 2, and is even smaller at 24, 28, and 27 in Examples 3 to 5, respectively, all being 30 or less.

[0058] Moreover, the flooring materials of Examples 3 to 5 are configured by adding a second plate material to the flooring materials of Comparative Examples 1 to 3, respectively. The G value is significantly smaller in each case, and the impact mitigation performance is improved by sandwiching the cushioning material between the first plate material and the second plate material. Furthermore, when Example 3 is compared with Examples 4 and 5, the G value is larger when a decorative material is provided. Therefore, simply increasing the number of layers does not improve the impact mitigation performance, and a configuration in which the cushioning material is sandwiched between plates is desirable. [Industrial Applicability]

[0059] The flooring material and floor structure of the present disclosure have excellent impact absorbing performance and are therefore useful for constructing floors in homes and various facilities where people spend time. [Explanation of symbols]

[0060] 10, 10a Flooring 11 First Plank 12 Cushioning material 13, 13a Second plate 14 Cosmetic materials 20 Floor slab 21 Floor Panel 22 Joist 23 Pillar

Claims

1. A first plate material; A cushioning material laminated on the back surface side of the first plate material; a second plate material laminated on the cushion material on the opposite side to the first plate material, The thickness of the second plate is 0.5 to 5 times the thickness of the first plate, A flooring material characterized in that the flexural modulus of the second board material is 300 MPa or more and 10,000 MPa or less.

2. A first plate material; A cushioning material laminated on the back surface side of the first plate material; a second plate material laminated on the cushion material on the opposite side to the first plate material, The thickness of the second plate is 0.5 to 5 times the thickness of the first plate, The bending stress of the second plate is 0.5 N / mm ２ More than 80N / mm ２ A flooring material characterized in that:

3. In claim 1 or 2, A flooring material, characterized in that the thickness of the cushion material is 0.5 to 3 times the thickness of the first board material.

4. In claim 1 or 2, The bending elastic modulus of the first plate material is 500 MPa or more and 4000 MPa or less, The cushioning material has a compressive elastic modulus of 1.0 MPa or more and 2.5 MPa or less.

5. In any one of claims 1 to 4, The surface hardness measured according to JIS A5917:2018 floor hardness test is 33G. A flooring material characterized in that:

6. A first plate material; a cushioning material laminated on the underside of the first plate material; a second plate material laminated under the cushion material, The thickness of the second plate is 0.5 to 5 times the thickness of the first plate, A floor structure characterized in that the bending elastic modulus of the second plate material is 300 MPa or more and 10,000 MPa or less.

7. A first plate material; a cushioning material laminated on the underside of the first plate material; a second plate material laminated under the cushion material, The thickness of the second plate is 0.5 to 5 times the thickness of the first plate, The bending stress of the second plate is 0.5 N / mm ２ More than 80N / mm ２ A floor structure characterized in that:

8. In claim 7, A floor structure, characterized in that the thickness of the cushion material is 0.5 to 3 times the thickness of the first plate material.

9. In claim 7 or 8, The bending elastic modulus of the first plate material is 500 MPa or more and 4000 MPa or less, A floor structure characterized in that the compressive elastic modulus of the cushioning material is 1.0 MPa or more and 2.5 MPa or less.

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