Method for joining stair nose covering member and floor finishing material, and floor finishing material for steps

Abstract

To provide a method for joining a step nose covering member and a floor finishing material that can be implemented at a construction site, and the floor finishing material for steps made by joining the step nose covering member and the floor finishing material.SOLUTION: In a floor finishing material for steps, an edge of a nose covering member and an edge of a floor finishing material on the surface side are butted together, and grooves formed on the back side are filled with bonding material to join the nose covering member and the floor finishing material. Since the edge of the step covering member and the edge of the floor finishing material are butted against each other on the surface side of the floor finishing material for steps, the bonding material filled in the grooves is not exposed. In addition, since a large jointing apparatus is not required, the floor finishing materials for steps can be fabricated at the construction site, and the color pattern and size of the floor finishing materials can be freely selected at the construction site.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for joining a nosing covering member that covers the nosing portion of a stepped portion and a floor finishing material that covers a tread surface, and to a floor finishing material for steps in which the nosing covering member and the floor finishing material are joined and integrated.

Background Art

[0002] In finishing work for stepped portions such as staircases, a nosing covering member that covers the nosing portion of the stepped portion and a floor finishing material that covers the tread surface are installed on a base formed of concrete or the like. In such construction work, a floor finishing material for steps in which the nosing covering member and the floor finishing material are joined and integrated, as proposed in Patent Document 1, may be used.

[0003] For manufacturing the floor finishing material for steps in which the nosing covering member and the floor finishing material are joined and integrated, as described in Patent Document 1, a method is used in which the end portion of the resin nosing covering member and the end portion of the floor finishing material are overlapped, and the overlapped portion is pressed and joined while being heated. Since it is necessary to introduce large-scale joining equipment for pressure bonding while heating, such floor finishing materials for steps have conventionally been mass-produced in factories as standard products, and it has been difficult to freely combine the colors, patterns and sizes of the nosing covering material and the floor finishing material according to the individual requirements of building owners and designers.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of Invention

Problems to be Solved by the Invention

[0005] The present invention has been made in view of such circumstances, and an object thereof is to provide a method for joining a nosing covering member and a floor finishing material, and a floor finishing material for steps, which do not require large-scale joining equipment and can be implemented not only in mass production at factories but also at construction sites. [Means for solving the problem]

[0006] The present invention provides a method for joining a stair nosing covering member and a floor finishing material, characterized by forming a groove on the back side where the front end of the stair nosing covering member and the front end of the floor finishing material abut, and filling the groove with a joining material to join the stair nosing covering member and the floor finishing material.

[0007] The floor finishing material for steps of the present invention is a floor finishing material for steps in which a step nosing covering member and a floor finishing material are joined, characterized in that a joining material is filled into a groove formed on the back side where the surface end of the step nosing covering member and the surface end of the floor finishing material abut. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a method for joining stair nose covering members and floor finishing materials, and a floor finishing material for steps, which does not require large-scale joining equipment and can be implemented not only in mass production at factories but also at construction sites. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view of the front and back surfaces of the floor finishing material for uneven surfaces. [Figure 2] This diagram schematically shows the cross-section of a floor finishing material for uneven surfaces. [Figure 3] This diagram shows how to install floor finishing material for steps into the base of a staircase. [Figure 4] This figure shows an example of the cross-sectional structure of a groove. [Figure 5] This is a diagram illustrating the joining process in Example 1. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described in detail below, but these are provided for illustrative purposes only and do not limit the present invention.

[0011] Figure 1 shows a perspective view of a step-type floor finishing material 1, which is an embodiment of the present invention. The step-type floor finishing material 1 has a back surface that is adhered to the substrate of the step and a front surface that determines the appearance of the step as a decorative surface. Figure 1(a) is a view of the step-type floor finishing material 1 from the front surface, and Figure 1(b) is a view of the step-type floor finishing material 1 from the back surface. The step-type floor finishing material 1 is formed by joining and integrating a step-nosing covering member 2, which has a substantially L-shaped cross-section, and a floor finishing material 3, with a bonding material 6 filled in a groove 8 formed on the back surface. On the back surface, the bonding material 6 is exposed as shown in Figure 1(b), but on the front surface, the bonding material 6 is hidden and not visible as shown in Figure 1(a).

[0012] Figure 2 schematically shows a cross-section of the joint between the step-edge floor finishing material 1, specifically the step-edge covering member 2 and the floor finishing material 3. The end of the floor finishing material 3 is cut approximately perpendicular to the surface 31 and back surface 32 of the floor finishing material. On the other hand, the end of the step-edge covering member 2 opposite the end of the floor finishing material 3 is formed at an angle such that the surface 21 of the step-edge covering member protrudes relative to the back surface 22 of the step-edge covering member. When the surface end of the step-edge covering member 2 and the surface end of the floor finishing material 3 are brought together so that the surface 21 of the step-edge covering member and the surface 31 of the floor finishing material are flush, a groove 8 is formed on the back side of the boundary between the step-edge covering member 2 and the floor finishing material 3.

[0013] The nosing member 2 and the floor finishing material 3 are joined by the joining material 6 filled in the groove 8. The groove 8 has an opening on the back side of the step floor finishing material 1 into which the joining material 6 can be filled, but on the front side of the step floor finishing material 1 the end is butted together and closed, so the joining material 6 filled in the groove 8 is hardly exposed on the front side of the step floor finishing material 1.

[0014] On the surface side of the step-type floor finishing material 1, the surface 21 of the stair nose covering member and the surface 31 of the floor finishing material are butted together so that they are flush, and no step is created at the boundary between the stair nose covering member 2 and the floor finishing material 3. However, the butting of the surface end of the stair nose covering member 2 and the surface end of the floor finishing material 3 is not strictly required, and a small gap may be left between the butted ends as long as the joining material 6 is not noticeable when viewed from the surface side.

[0015] The stair nose covering member 2 is a resin member that covers the stair nose of the stepped section, and its cross-section is formed into a roughly L-shape. The stair nose covering member 2 can be manufactured by known molding methods, for example, by bending a sheet of resin to form a roughly L-shape, or by extrusion molding or injection molding. As the stair nose covering member 2, for example, a vinyl chloride resin molded into a roughly L-shape can be used. Considering slip resistance and durability, the hardness of the resin is preferably 75 to 95 degrees durometer hardness as defined in JIS K6253.

[0016] The stair nose covering member 2 may be colored to enhance its aesthetic appeal, and may be molded in two colors to improve the visibility of the step. In addition, if the surface 21 of the stair nose covering member has a flat portion at its end that is flush with the surface 31 of the floor finishing material, protrusions or recesses may be provided on other parts of the surface for slip resistance.

[0017] The floor finishing material 3 is a resin component that covers the tread of the step, or the tread and riser. The floor finishing material 3 can be any known interior flooring material that is attached to the substrate for finishing purposes, such as a vinyl chloride resin sheet, vinyl chloride resin tiles, or a tile carpet made of tufted carpet composed of nylon fibers or polypropylene fibers fixed to a vinyl chloride resin base material. The floor finishing material 3 may have a protective layer or decorative layer on its surface.

[0018] The floor finishing material 1 for level differences can be installed at a level difference portion by a known method. As an example, FIG. 3 shows a state in which the floor finishing material 1 for level differences is attached to the base 4 of a staircase. The attachment is carried out by applying an adhesive to the tread surface of the base 4 and the riser portion rising therefrom, aligning the internal corner of the nosing covering member 2 of the floor finishing material 1 for level differences with the external corner of the base 4, and pressing and adhering the back surface from the tread surface side toward the riser direction. The joint material 6 filled in the groove portion 8 of the floor finishing material 1 for level differences does not appear on the surface of the staircase after installation, and does not impair the appearance.

[0019] FIG. 4 shows the cross-sectional structure of the groove portion 8 formed on the back surface side where the surface-side end of the nosing covering member 2 and the surface-side end of the floor finishing material 3 are butted against each other. In the embodiment shown in FIG. 2, as shown in FIG. 4(a), the groove portion 8 is formed by butting an end portion formed with a linear inclination relative to the surface 21 of the nosing covering member against an end portion cut substantially perpendicularly to the surface 31 of the floor finishing material. However, the groove portion 8 is not limited to this, and by providing at least at the end of the nosing covering member 2 a structure in which the surface 21 of the nosing covering member protrudes relative to the back surface 22 of the nosing covering member, or at the end of the floor finishing material 3 a structure in which the surface 31 of the floor finishing material protrudes relative to the back surface 32 of the floor finishing material, the groove portion 8 can be formed on the back surface side where the surface-side ends are butted against each other.

[0020] Other examples of the groove portion 8 are shown in FIGS. 4(b) to (e). FIG. 4(b) is provided with a protruding portion on the surface side of the end portion cut substantially perpendicularly to the surface 21 of the nosing covering member. When the surface 21 of the nosing covering member 2 and the surface 31 of the floor finishing material are butted so as to be flush with each other, this protruding portion abuts against the end portion cut substantially perpendicularly to the surface 31 of the floor finishing material, and the groove portion 8 is formed on the back surface side.

[0021] Contrary to FIG. 4(a), FIG. 4(c) forms the groove portion 8 on the back surface side by butting an end portion obliquely molded so that the surface 31 of the floor finishing material protrudes relative to the back surface 32 of the floor finishing material, against an end portion cut substantially perpendicularly to the surface 21 of the nosing covering member, such that the surface 21 of the nosing covering member and the surface 31 of the floor finishing material are flush with each other.

[0022] Figures 4(d) and 4(e) show examples in which the surfaces of both ends of the stair nose covering member 2 and the floor finishing material 3 are processed to protrude from the back surface, and a groove 8 is formed on the back side where they are butted together. In Figures 4(d) and 4(e), after butting both ends of the stair nose covering member 2 and the floor finishing material 3 which are substantially perpendicular to the surface, a grooving blade can be applied to the boundary to cut the back surface 22 of the stair nose covering member 2 and the back surface 32 of the floor finishing material to form the groove 8. The cross-section of the groove 8 may be arc-shaped as in Figure 4(d) or straight as in Figure 4(e).

[0023] The width and depth of the groove 8 can be adjusted depending on the type and amount of adhesive material 6 used for filling. It is preferable to temporarily fix the stair nose covering member 2 and the floor finishing material 3, which are joined at their ends, using tape or jigs to prevent misalignment during the work, at least until the joining with the adhesive material 6 is complete.

[0024] In this invention, instead of overlapping and joining the ends of the stair nose covering member 2 and the ends of the floor finishing material 3 for joining purposes, a groove 8 is formed on the back side where the front end of the stair nose covering member 2 and the front end of the floor finishing material 3 are butted together, and the joining material 6 is filled into the groove 8 to join them. For this reason, there is no need for equipment to heat or pressurize the overlapping portion of the ends.

[0025] The bonding material 6 filled into the groove 8 is not particularly limited as long as it exhibits sufficient adhesive strength. For example, solvent-based adhesives, one-component curing adhesives, two-component curing adhesives, moisture-curing adhesives, thermoplastic resins, hot-melt resins, UV-curing resins, etc., can be used. Furthermore, if a transparent bonding material 6 is used, even if there is a small gap between the surface 21 of the butted stair nose covering material and the surface 31 of the floor finishing material, and the bonding material 6 is exposed on the surface side, it will not be very noticeable because the bonding material 6 is transparent.

[0026] As adhesives, resin-based adhesives such as acrylic, epoxy, and urethane can be used. As hot-melt resins, resins such as olefin resins, polyurethane resins, vinyl chloride resins, and vinyl acetate resins can be used. As UV-curing resins, in addition to acrylates such as 1,4-butanediol, 1,3-butanediol, diacrylate, neopentyl glycol diacrylate, 1,6-hexanediol diacrylate, and diethylene glycol diacrylate, epoxy and urethane UV-curing resins can be used.

[0027] If too much bonding material 6 is filled into the groove 8, it will remain as a protrusion on the back side after hardening. Therefore, it is preferable to smooth out any excess bonding material 6 with a spatula or similar tool before hardening, or to scrape it off with a knife after hardening.

[0028] Examples 1 to 3 show the process of joining a step-nosing covering member 2 and a floor finishing material 3 using different joining materials 6 to produce a step-level floor finishing material 1. [Example 1] In Example 1, a step-mounted floor finishing material 1 was fabricated by joining the step-nosing covering member 2 and the floor finishing material 3 with a bonding material 6. • Stair nose covering member 2: Extruded polyvinyl chloride resin, 2 mm thick, 85 degrees hardness • Floor finishing material 3: Vinyl chloride resin sheet (Permalium Marble EM2 manufactured by Tajima Roofing Co., Ltd.), 2mm thick • Bonding material 6: Acrylic UV-curing resin

[0029] Figures 5(a) to 5(d) illustrate the process of joining the stair nosing covering member 2 and the floor finishing material 3. First, in the first step, as shown in the example in Figure 4(a), a stair nosing covering member 2 is prepared, which is shaped at an angle so that the surface 21 of the stair nosing covering member protrudes from the back surface 22 of the stair nosing covering member at its end, and a floor finishing material 3 is prepared, which is cut approximately perpendicular to the surface 31 of the floor finishing material. The prepared stair nosing covering member 2 and floor finishing material 3 are placed on a workbench with their ends butted together so that the surface 21 of the stair nosing covering member and the surface 31 of the floor finishing material are flush, and the surface 21 of the stair nosing covering member and the surface 31 of the floor finishing material are temporarily fixed with the first tape 5 to prevent misalignment (Figure 5(a)). At this time, a groove 8 is formed on the back side at the boundary between the stair nosing covering member 2 and the floor finishing material 3.

[0030] The first tape 5 was P-Cut Tape 4140 Transparent (manufactured by Teraoka Seisakusho Co., Ltd.), which can block air, has an ultraviolet transmittance of 6.1% or more, adheres to and fixes to the surface of the stair nose covering member 2 and the floor finishing material 3, and can ultimately be easily removed.

[0031] In the second step, the stair nose covering member 2 and floor finishing material 3, which were temporarily fixed with the first tape 5, are turned upside down and placed on a flat surface with the back side facing up, and the UV-curing resin 7, which is the bonding material 6, is filled into the groove 8 from the back side (Figure 5(b)). If the amount of UV-curing resin 7 filled is too small, the bonding strength between the stair nose covering member 2 and floor finishing material 3 will decrease, so the UV-curing resin 7 was filled to the extent that it bulged out of the groove 8.

[0032] In the third step, a second tape 9 is applied over the filled UV-curing resin 7 to block it from the air (Figure 5(c)). Blocking it from the air prevents the UV-curing resin 7 from coming into contact with oxygen in the air, which would inhibit the curing reaction. Also, force is applied over the second tape 9 to flatten the UV-curing resin 7 that had been filled in a raised manner. At this time, the UV-curing resin 7 spreads around the groove 8, but the back surface of the step floor finishing material 1 is adhered to the substrate 4 and is not exposed, so it does not affect the finished appearance of the step. For the same reasons as the first tape 5, the same P-cut tape 4140 transparent (manufactured by Teraoka Seisakusho Co., Ltd.) was used for the second tape 9.

[0033] In the fourth step, as shown in Figure 5(c), the front and back surfaces of the stair nose covering member 2 and the floor finishing material 3 were temporarily fixed with the first tape 5 and the second tape 9, respectively. The ultraviolet curing resin 7 was then cured by irradiating it with ultraviolet light, and after irradiation from the back side, ultraviolet light was irradiated from the front side through the first tape 5.

[0034] In the fourth stage, the peak illuminance was 700 mW / cm². 2 Using an irradiator capable of emitting ultraviolet light as described above, the ultraviolet light source was moved along the groove 8 to irradiate the same spot for 0.3 seconds or more, thereby joining the wide stair nose covering member 2 and the floor finishing material 3.

[0035] In the fifth step, the first tape 5 and the second tape 9 were peeled off and removed from the stair nose covering member 2 and the floor finishing material 3, which were joined together by the hardened ultraviolet curing resin 7, to obtain the floor finishing material for steps 1 (Figure 5(d)).

[0036] When the joint strength (tensile strength) of the fabricated step-type floor finishing material 1 was measured using a tensile testing machine, a joint strength of 200 N or more per 25 mm was obtained. Furthermore, the fracture was due to material failure of the floor finishing material 3, not at the joint between the step-nosing covering member 2 and the floor finishing material 3. This indicates that the joint method of the step-nosing covering member and the floor finishing material of the present invention provides a joint strength that is practically acceptable for use as a step-type floor finishing material.

[0037] [Example 2] In Example 2, the step-nosing covering member 2 and the floor finishing material 3 were joined together with a bonding material 6 to create a step-level floor finishing material 1. • Stair nose covering member 2: Extruded polyvinyl chloride resin, 2 mm thick, 85 degrees hardness • Floor finishing material 3: Vinyl chloride resin sheet (Permalium Marble EM2 manufactured by Tajima Roofing Co., Ltd.), 2mm thick • Joining material 6: Welding rod (Permalium Marble EM2 welding rod manufactured by Tajima Roofing Co., Ltd., Φ4mm string-shaped, made of polyvinyl chloride resin)

[0038] In Example 2, after butting the ends of the stair nose covering member 2 and the floor finishing material 3, an arc-shaped groove 8 is formed from the back side using a grooving blade. Specifically, the ends of the stair nose covering member 2 and the floor finishing material 3, which are formed substantially perpendicular to the front and back surfaces, are butted together, and the front side is temporarily fixed with tape. The temporarily fixed stair nose covering member 2 and floor finishing material 3 are placed on a workbench with the back side facing up, and a grooving blade is applied to the boundary between the stair nose covering member 2 and the floor finishing material 3 to cut the back surface 22 of the stair nose covering member and the back surface 32 of the floor finishing material, forming an arc-shaped groove 8 on the butted back surface as shown in the example in Figure 4(d).

[0039] Next, the welding rod was heated and melted using a welding heating tool (Leister welding machine) while the resin was filled into the groove 8. After the resin cooled and hardened, the convex parts were cut smoothly with a knife to obtain the step floor finishing material 1.

[0040] [Example 3] In Example 3, the following step-nosing covering member 2 and floor finishing material 3 were joined together with a bonding material 6 to create a step-level floor finishing material 1. • Stair nose covering member 2: Extruded polyvinyl chloride resin, 2 mm thick, 85 degrees hardness • Floor finishing material 3: Vinyl chloride resin sheet (Permalium Marble EM2 manufactured by Tajima Roofing Co., Ltd.), 2mm thick • Bonding material 6: Urethane-based one-component curing adhesive (Cement VG manufactured by Tajima Roofing Co., Ltd.)

[0041] As shown in the example in Figure 4(a), a stair nosing covering member 2 is prepared, which is shaped at an angle so that the surface 21 of the stair nosing covering member protrudes from the back surface 22 of the stair nosing covering member, and a floor finishing material 3 is prepared, which is cut approximately perpendicular to the surface 31 of the floor finishing material. The prepared stair nosing covering member 2 and floor finishing material 3 are placed on a flat workbench with the back side facing upwards and the ends are butted together. After butting together, the stair nosing covering member 2 and floor finishing material 3 are temporarily fixed with a pressing jig, and a urethane-based one-component curing adhesive is injected into the groove 8 formed on the back side so that it rises up. The urethane-based one-component curing adhesive that has risen up from the groove 8 is smoothed out on the surface using a spatula and cured to obtain a step floor finishing material 1.

[0042] According to the present invention's method for joining a stair nose covering member 2 and a floor finishing material 3, a stair nose covering member 2 and a floor finishing material 3 can be joined and a stair-level floor finishing material 1 can be manufactured simply by using a small ultraviolet light source, a welding machine, and common tools. This makes it possible to perform work not only in industrial manufacturing but also at construction sites, and allows clients and designers to freely select colors, patterns, and sizes.

[0043] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and various modifications and changes are possible within the scope of the gist of the present invention as described in the claims. [Explanation of Symbols]

[0044] 1. Floor finishing material for steps 2-stage nose covering member 21 Surface of the stair nose covering member 22 Back surface of the eaves covering member 3. Floor finishing materials 31 Surface of floor finishing material 32. Back side of floor finishing material 4. Primer 5. The first tape 6 Bonding material 7 Ultraviolet curing resin 8 grooves 9. Second Tape

Claims

1. A method for joining a stair nose covering member and a floor finishing material, A groove is formed on the back side where the front end of the stair nose covering member and the front end of the floor finishing material meet. A joining method for joining the step nose covering member and the floor finishing material by filling the groove with a joining material.

2. The bonding method according to claim 1, wherein the bonding material is an ultraviolet-curing resin, and the bonding method is characterized by filling the groove with the ultraviolet-curing resin and then curing the ultraviolet-curing resin by irradiating it with ultraviolet light.

3. The joining method according to claim 1 or 2, characterized in that the surface-side end of the stair nose covering member and the surface-side end of the floor finishing material are butted together so that the surface of the stair nose covering member and the surface of the floor finishing material are flush.

4. A step-level floor finishing material in which a step-nosing covering member and a floor finishing material are joined together, A floor finishing material for steps, characterized in that a jointing material is filled into a groove formed on the back side where the front end of the step nosing covering member and the front end of the floor finishing material abut.

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