CN101006234A - 用高压单板和浸渍的轻质印刷纸层压的木地板 - Google Patents
用高压单板和浸渍的轻质印刷纸层压的木地板 Download PDFInfo
- Publication number
- CN101006234A CN101006234A CNA2005800280181A CN200580028018A CN101006234A CN 101006234 A CN101006234 A CN 101006234A CN A2005800280181 A CNA2005800280181 A CN A2005800280181A CN 200580028018 A CN200580028018 A CN 200580028018A CN 101006234 A CN101006234 A CN 101006234A
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- Prior art keywords
- resin
- layer
- coating
- wooden floor
- printing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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- Laminated Bodies (AREA)
Abstract
本发明所公开的为一种用于地板采暖系统的UV表面涂覆的层压木地板,其包括具有背槽的基层、粘合层和印刷的木单板层,其中,所述印刷的木单板层通过用热塑性或热固性树脂浸渍和涂敷低定量印刷纸、在高压下加压整体地形成具有低价格增强层的纸层、用基于丙烯酰基的底漆处理纸层的表面和用无溶剂型UV涂料涂敷底漆处理的纸层来制备,且通过粘合层将具有背槽的基层与印刷的木单板层粘合。
Description
技术领域
本发明涉及一种用于地板采暖系统的具有背槽的(back-grooved)层压木地板,其包括选自聚氯乙烯树脂层、定向刨花板(OSB)和高密度纤维板(HDF)和防水胶合板层的基层和层压于基层上面的印刷的木单板层。更具体地说,本发明涉及一种用于地板采暖系统的UV表面涂覆的层压木地板,其包括具有背槽的基层、粘合层和印刷的木单板层,其中所述印刷的木单板层包括从底部依次层压的单板层、树脂浸渍的低定量纸层和底漆处理的UV涂层,且具有背槽的基层与印刷的木单板层通过粘合层而彼此粘合。
背景技术
图1为未处理的天然单板层层压于防水胶合板层上面的用于地板采暖系统的常规木地板的剖面图。如图1所示,常规木地板具有结构:天然单板层24用UV涂料进行表面涂覆以形成常规UV涂层21’或用树脂浸渍,然后通过粘合层40将其层压于防水胶合板层10’上面。
参照图1,下面简要地说明构成用于地板采暖系统的常规木地板的各层。
使用苯酚或三聚氰胺树脂粘合剂,以单板的纹理方向彼此呈直角的方式将5~7个单板层压在一起,且用压机挤压叠层板,以此制备防水胶合板层10’。
通过用浸渍树脂浸渍或不浸渍天然单板,或者在减压或高压下将树脂浸渍到天然单板来制备上部天然单板层24。通过常规技术,使用聚氨酯丙烯酸酯涂料将上部天然单板进行6~10次的顶部、中间或底部涂敷以制备表面UV涂层21’。
因为用于地板采暖系统的常规木地板包括防水胶合板层10’和层压于其上面的防水胶合板层24,所以其呈现优良的耐热和潮湿的尺寸稳定性。
然而,尽管在未处理的上部天然单板上存在表面UV涂层21’,但是由于防水胶合板层10’的低密度,包括防水胶合板层10’和层压于其上面的未处理的上部天然单板的常规地板呈现低至0.5~1N的表面耐划痕性和低至10~20cm的抗冲击强度。使用金刚石针,通过刻划表面UV涂层21’来测定其耐划痕性,且通过将重225g的金属球落到天然单板的表面来测定其抗冲击强度。在将重的家用电器放到木地板上和使用它们时,常规木地板很可能被容易地破坏。因此,常规木地板引起消费者抱怨且不能满足消费者的不同需求。因而需要具有改进的耐划痕性和抗冲击强度的木地板。
提出了将两个三聚氰胺浸渍的覆盖薄片层压到天然单板的上面部分和下面部分的具有表面增强结构的木地板。现有技术的木地板具有比任何其它常规UV涂覆的木地板高的表面强度,但是其具有天然纹理差、可能发生卷曲的问题,这对最终产品的质量具有消极影响。另外,浸渍的覆盖层与单板具有差的粘合力。
此外,使用其包含二氧化钛(TiO2)并具有70~80g/cm2的定量的纸用三聚氰胺树脂浸渍的三聚氰胺单板层压木地板(LPM地板)的层压木地板呈现较好的表面物理性能,例如约3N的耐划痕性和约40cm的抗冲击强度。然而,尽管与低定量棉纸相比具有优良的浸渍性能,但是为使树脂浸渍最大化而使用包含二氧化钛的纸导致差的印刷适性。另外,由于三聚氰胺的浸渍而不能使用丙烯酸酯型的UV涂料。而且,浸渍的三聚氰胺触摸上去是冰冷的,且由于其本性,可能产生静电。
由使用包括甲醛的有机溶剂产生的挥发性有机化合物(VOC)引起病屋综合征,近来已成为健康问题。在这种环境下,需要环境有利的装修材料。
发明内容
技术问题
因此,鉴于上述问题已完成本发明,本发明的一个目的是提供一种用于地板采暖系统的层压木地板,其由于低定量印刷纸的浸渍以及印刷纸与增强层的整合技术而具有显著提高的粘合力和表面强度。
本发明的另一个目的是提供一种具有优良的印刷适性、改进的触感和确实的天然纹理的用于地板采暖系统的层压木地板。
本发明的又一个目的是提供一种具有额外的隔音性能、以低成本由环境有利的材料制成的用于地板采暖系统的具有背槽的层压木地板。
技术方案
为完成本发明的上述目的,本发明提供一种用于地板采暖系统的层压木地板,其包括从底部依次层压的具有背槽的基层、粘合层和印刷的木单板层,其中所述印刷的木单板层包括从底部依次层压的增强层、树脂浸渍的低定量纸层和底漆处理的UV涂层。
根据本发明,在UV表面涂敷的层压木地板中使用低定量棉纸(25~50g/m2)改进差的逼真性,差的逼真性是使用含有二氧化钛(TiO2)的高定量纸(70~80g/m2)的常规层压木地板的一个问题。一系列基于丙烯酰基的底漆处理和UV涂敷解决了浸渍三聚氰胺的低压三聚氰胺地板(LPM)的困难的UV涂敷、触感冰冷、产生静电等问题。额外的树脂涂敷和使用高压压机的挤压操作解决增强层与树脂浸渍的低定量纸层之间的较差粘合力以完成表面强化。由于上述优点,所以与天然单板相比,所述层压木地板呈现UV涂敷的高清晰度印刷适性和天然接触纹理(natural touch texture),且其进一步改进用于地板采暖系统的常规木地板的缺点,例如差的耐划痕性和抗冲击强度。另外,与用于地板采暖系统的常规木地板相比,在基层的背面形成凹槽改进表面强度,且加入一个或多个隔音层可以赋予层压木地板改进的隔音性能。无溶剂型UV涂料的使用是环境有利的。
通过印刷具有25~50g/m2的定量的棉纸并用选自尿素、尿素-三聚氰胺、三聚氰胺、苯酚、丙烯酰基、聚酯、不饱和聚酯、环氧化合物、聚乙酸乙烯酯、聚乙烯醇和聚氨酯树脂的树脂浸渍印刷的棉纸来制备树脂浸渍的低定量纸层。低定量棉纸的使用改进差的逼真性,其为常规产品的一个问题,从而实现优良的印刷适性,例如高清晰度印刷适性。
本发明的层压木地板特征在于:通过涂敷选自尿素、尿素-三聚氰胺、三聚氰胺、苯酚、丙烯酰基、聚酯、不饱和聚酯、环氧化合物、聚乙酸乙烯酯、聚乙烯醇和聚氨酯树脂的树脂并在高压压机中挤压涂层而使增强层与树脂浸渍的低定量纸层形成整体。这种挤压改进差的粘合力并压紧表面完成表面强化。
通过在树脂浸渍的低定量纸层上涂敷基于丙烯酰基的底漆,接着UV涂敷来制备底漆处理的UV涂层。本发明中采用的底漆处理和UV涂敷是一种新技术,通过该技术可以涂敷不能用常规涂敷方法处理的基于氨基的树脂(例如尿素、三聚氰胺或尿素-三聚氰胺树脂)浸渍的产品。
本发明中使用的基于丙烯酰基的底漆解决例如难以UV涂敷、触感冰冷和产生静电的常规问题。另外,基于丙烯酰基的底漆和无溶剂型UV涂料的使用可以防止病屋综合征的发生并可以提供环境有利的装饰材料。
因为基于丙烯酰基的树脂通常具有比基于聚氨酯的树脂更好的浸渍性能,所以与使用基于聚氨酯的底漆的涂敷相比,使用基于丙烯酰基的底漆的涂敷产生改进的粘合力。
实际的线试验(line test)显示:由于基于丙烯酰基的树脂优于基于聚氨酯的树脂的浸渍性能,基于丙烯酰基的树脂适于以相当有利的成本大规模生产根据本发明的层压木地板。另外,与基于聚氨酯的底漆相比,基于丙烯酰基的底漆被确认对基于丙烯酰基的树脂具有优良的粘合力。
基本上,已知基于聚氨酯的树脂的物理性能(例如强度和粘合力)优于基于丙烯酰基的树脂。然而,考虑到根据本发明的层压木地板的大规模生产,用基于丙烯酰基的树脂的浸渍和基于丙烯酰基的底漆的涂敷是有利的。
本发明中使用的增强层选自单板、屏蔽纸、高密度纤维板(HDF)和牛皮纸(craft paper)。低价格的增强层和树脂浸渍的层的使用确保以低成本改进表面物理性能。
根据增强层和树脂浸渍的低定量纸层的所需厚度,可以层压几种薄片。
为降低地板间的噪音传输并赋予改进的隔音性能,本发明的层压木地板可以进一步包括在选自(a)基层与印刷的木单板层之间和(b)基层下面的至少一个位置层压的至少一个隔音层。
本发明中使用的基层选自聚氯乙烯树脂层、定向刨花板(OSB)、高密度纤维板(HDF)和防水胶合板层,且优选具有背槽的以确保改进的尺寸稳定性和降低破裂的发生。
根据下面的步骤制备包括防水胶合板层和层压于其上面的印刷的木单板层的本发明的具有背槽的层压木地板。
首先,制备选自聚氯乙烯树脂层、OSB、HDF和防水胶合板层等的基层。在使用防水胶合板层作为基层的情况下,使用苯酚或三聚氰胺树脂粘合剂,以单板的纹理方向彼此呈直角的方式将5~7个单板层压在一起,且然后用压机挤压叠层板,以此制备基层。
其次,用选自尿素、尿素-三聚氰胺、三聚氰胺、苯酚、丙烯酰基、聚酯、不饱和聚酯、环氧化合物、聚乙酸乙烯酯、聚乙烯醇和聚氨酯树脂的树脂浸渍具有50g/m2或更低定量的印刷的低定量棉纸,然后使用例如三聚氰胺的树脂只在浸渍的棉纸的一侧进行额外的涂敷,以确保与增强层的充足的粘合力,以此制备地板的表面层。
其后,将树脂浸渍的低定量印刷纸层层压于例如单板的增强层上,然后将制备的叠层板在高压高温下加压以制备高密度的印刷的木单板层。
最后,将印刷的木单板层的表面进行底漆处理和UV涂敷并将基层的背面刻槽以制备本发明的层压木地板。
优选地,为降低地板间的噪音传输并赋予改进的隔音性能,可以在(a)印刷的木单板层与基层之间和/或(b)基层下面层压至少一个隔音层。
有益效果
通过增强层与树脂浸渍的层的整合技术以及一系列的底漆处理和UV涂敷,本发明的层压木地板呈现优于常规地板产品的耐划痕性和抗冲击强度。另外,低定量棉纸的使用改进差的逼真性以实现优良的印刷适性,例如高清晰度印刷适性。在用选自氨基、丙烯酰基、聚酯、聚氨酯和其它树脂的树脂浸渍的低定量纸层上的基于丙烯酰基的底漆处理以及UV涂敷技术的发展确保表面强度和天然纹理的显著改进。
基于丙烯酰基的底漆处理,接着UV涂敷,解决了例如难以UV涂敷、触感冰冷和产生静电的常规问题。额外的树脂涂敷以及使用高压压机的加压操作解决了增强层与树脂浸渍的低定量纸层之间较差的粘合力并完成表面强化。与用于地板采暖系统的常规地板相比,在基层的背面形成凹槽改进表面强度,且加入一个或多个隔音层可以赋予本发明的层压木地板改进的隔音性能。
而且,为改进根据本发明的层压木地板的表面物理性能,使用低价格的单板作为用于增强层的材料,且使用用热固性树脂(三聚氰胺或苯酚树脂)浸渍的纸代替常规高压三聚氰胺(HPL)叠层板中使用的苯酚浸渍的纸作为用于树脂浸渍的低定量纸层的材料。因此,最终产品的卷曲性能显著改善且最终产品的制造成本显著降低。本发明中使用的无溶剂型UV涂料是环境有利的。
附图说明
结合附图,通过下面详细的描述更清楚地理解本发明的上述和其它目的、特征以及其它优点。
图1为其天然单板层层压于防水胶合板层上面的用于地板采暖系统的常规木地板的剖面图;
图2为根据本发明的一种实施方式的其印刷的木单板层层压于具有背槽的基层上面的用于地板采暖系统的UV表面涂敷的层压木地板的剖面图;以及
图3为根据本发明的一种实施方式的向图2中所示的层压木地板增加两个隔音层的用于地板采暖系统的UV表面涂敷的层压木地板的剖面图。
具体实施方式
参照下面的实施例和附图更详细地描述本发明。然而,这些实施例和附图不构成对本发明的范围的限制。
根据本发明的一种实施方式的用于地板采暖系统的UV表面涂敷的层压木地板示于图2,其中印刷的木单板层20层压于具有背槽的基层10上面。该层压木地板具有其印刷的木单板层20与基层10通过粘合层40彼此粘合的结构。
印刷的木单板层20层包括从底部依次层压的单板(或至少一种选自屏蔽纸、HDF和牛皮纸的材料)增强层23、树脂浸渍的低定量纸层22和基于丙烯酰基的底漆处理的特别UV涂层21。
将树脂浸渍的低定量纸层22置于增强层23上面,在压机中在20~200kg/cm2压力下挤压叠层板,同时在110~180℃的温度加热15~60分钟,在相同的压力下冷却加压的叠层板15~30分钟,在所述叠层板的表面形成基于丙烯酰基的底漆处理的UV涂层21,以此来制备印刷的木单板层20。
上述制备的印刷的木单板层20与基层10通过粘合层40彼此粘合。
用于制备粘合层40的粘合剂的例子包括热固性三聚氰胺和热固性或室温固性聚氨酯和环氧树脂。
使用热固性三聚氰胺树脂作为粘合剂时,以80~300kg/m2的量将其涂敷到基层10以形成粘合层40。另一方面,使用热固性或室温固性的聚氨酯或环氧树脂作为粘合剂时,以80~250kg/m2的量将其涂敷到基层10以形成粘合层40。其后,将印刷的木单板层20置于粘合层40上面。使用热固性三聚氰胺树脂作为粘合剂时,挤压叠层板并在10~15kgf/cm2压力下固化1~5分钟。同时,使用室温固性的聚氨酯或环氧树脂作为粘合剂时,在10~15kgf/cm2的压力下将叠层板加压2~4小时然后80℃固化2小时。
在室温挤压基层10与印刷的木单板层20可以使由于热的变形最小化。
根据本发明的另一种实施方式的用于地板采暖系统的UV表面涂敷的层压木地板示于图2,其中将两个隔音层加入图2所示的层压木地板。如图3所示,将第一个隔音层30置于基层10与粘合层40之间,且将第二个隔音层31置于基层10下面。然而,隔音层的位置和数目没有特别限制。
可以使用例如聚氯乙烯(PVC)、聚乙烯(PE)、乙烯-醋酸乙烯共聚物(EVA)、聚丙烯(PP)、聚氨酯(PU)、聚酯非纺布、氯丁橡胶(CR)、丙烯腈-丁二烯橡胶(NBR)等作为隔音层的材料。另外,隔音层的表面可以通过化学交联和发泡过程或高压发泡过程处理,其包括浮雕和凹雕技术。
[实施例1]
1.基层10的制备
具有1.0~5.0mm厚度的聚氯乙烯树脂层由包括PVC树脂、增塑剂、填料、稳定剂等的组合物形成。
将三聚氰胺树脂中的通过切割或纤维化木材获得的刨花或纤维加压,接着成形,以此制备刨花板和高密度纤维板。
使用三聚氰胺树脂以单板的纹理方向彼此呈直角的方式将5~7个单板层压在一起,且用压机挤压叠层板,以此制备防水胶合板层。
2.印刷的木单板层20的制备
1)底漆处理的UV涂层21的制备
进行6~10分钟的UV涂敷以赋予表面保护和高质量外观。用基于丙烯酰基的底漆处理氨基树脂浸渍的低定量纸层22,接着UV涂敷。对于该处理,使用无溶剂型基于丙烯酰基的底漆和UV涂料。
2)树脂浸渍的低定量纸层22的制备
使用2~5色凹版印刷机印刷具有25~50g/m2的定量的棉纸来制备树脂浸渍的低定量纸层22,用选自尿素-三聚氰胺、三聚氰胺、丙烯酰基、丙烯酰基、聚氨酯和聚酯树脂的树脂浸渍印刷的棉纸,并接着在90~150℃的烘箱干燥或半固化10~60分钟。
3)增强层23的制备
使用旋切机或切割机将天然原木材切割成0.3~8mm的厚度来制备单板。如果需要,用胶布把单板的两层粘住来贮藏以防止处理时在纹理方向发生破裂。为提高尺寸稳定性和使单板的弯曲最小化,将单板干燥到具有10%或更低的含水量。
通过用苯酚或三聚氰胺树脂浸渍具有50~150g/m2的定量的无纤维素(cellulose wood-free)的纸,接着在80~150℃的烘箱干燥和半固化0.5~3分钟来制备屏蔽纸。根据所需厚度,可以使用两片或多片屏蔽纸。
通过用苯酚树脂处理由针叶树或阔叶树获得的纤维,接着成形,在高温下加压并固化来制备HDF。
通过用三聚氰胺或苯酚树脂浸渍具有80~300g/m2的定量的未漂白牛皮纸,接着在80~150℃的烘箱干燥和半固化0.5~3分钟来制备牛皮纸。根据所需厚度,可以使用两片或多片牛皮纸。
4)增强层23与树脂浸渍的低定量纸层22的整合
首先,将例如三聚氰胺的树脂涂敷于树脂浸渍的棉纸22的底面,然后将增强层23置于树脂上。将制得的叠层板在压机中在20、40、60、80和100kg/cm2的升压下在110~170℃分别加压15、20、25和30分钟,并在相同的压力下冷却25分钟以使两层整合。
3.基层10和印刷的木单板层20的层压
以150kg/m2的量将热固性三聚氰胺树脂涂敷到基层10以形成粘合层40。选择性地,以200kg/m2的量将室温固性的聚氨酯或环氧树脂涂敷到基层10以形成粘合层40。其后,将印刷的木单板层20放到粘合层40上面。使用热固性三聚氰胺树脂时,挤压叠层板并在12kgf/cm2压力下固化2~5分钟。另一方面,使用室温固性型聚氨酯或环氧树脂时,在10kgf/cm2压力下将叠层板加压2小时并然后在80℃干燥2小时以将印刷的木单板层20粘附于基层10。
将上述制备的层压木地板(实施例1)的表面物理性能与图1中所示的用于地板采暖系统的常规天然单板装饰的木地板(比较例1)的相比较。结果示于下表1中。
按照下面的常规步骤测定木地板的表面强度。首先,将木地板切割成具有预定尺寸的试样。使用金刚石针,通过刻划试样的表面来测定耐划痕性,并以0.5N单位表示。通过将重物(225g)从升高的高度(增量10cm)落到试样的表面并直观观察对试样破坏的存在来测定抗冲击强度。
表1
实施例1 | 比较例1 | |
耐划痕性(N) | 3~4 | 0.5~1 |
抗冲击强度 | 30~40 | 10~20 |
(cm) |
从表1中所示的数据明显看出,与常规木地板的表面物理性能相比,根据本发明的层压木地板的表面物理性能显著提高。具体地说,耐划痕性提高到最大值为4N,且抗冲击强度提高到最大值为40cm。这些结果显示整体形成的印刷的木单板层可以有效提高表面强度,从而消除消费者的抱怨,并满足消费者的不同需求。另外,与天然单板相比,本发明的层压木地板呈现UV涂敷的高清晰度印刷适性和天然接触纹理。
虽然为说明性目的已公开本发明的优选实施方式,本领域的技术人员应该理解,不偏离所附权利要求所公开的本发明的范围和实质,各种修改、添加和替换是可行的。
Claims (9)
1、一种用于地板采暖系统的层压木地板,其包括从底部依次层压的具有背槽的基层、粘合层和印刷的木单板层,其中所述印刷的木单板层包括从底部依次层压的增强层、树脂浸渍的低定量纸层和底漆处理的UV涂层。
2、根据权利要求1所述的层压木地板,其中,所述树脂浸渍的低定量纸层通过印刷具有25~50g/m2的定量的棉纸并用选自尿素树脂、尿素-三聚氰胺树脂、三聚氰胺树脂、苯酚树脂、丙烯酰基树脂、聚酯树脂、不饱和聚酯树脂、环氧树脂、聚乙酸乙烯酯树脂、聚乙烯醇树脂和聚氨酯树脂的树脂浸渍印刷的棉纸来制备。
3、根据权利要求1所述的层压木地板,其中,通过涂敷选自尿素树脂、尿素-三聚氰胺树脂、三聚氰胺树脂、苯酚树脂、丙烯酰基树脂、聚酯树脂、不饱和聚酯树脂、环氧树脂、聚乙酸乙烯酯树脂、聚乙烯醇树脂和聚氨酯树脂的树脂并在高压压机中给涂层加压来使所述增强层与树脂浸渍的低定量纸层整体地形成。
4、根据权利要求1所述的层压木地板,其中,所述底漆处理的UV涂层通过在所述树脂浸渍的低定量纸层涂敷基于丙烯酰基的底漆、接着UV涂敷来制备。
5、根据权利要求4所述的层压木地板,其中,所述基于丙烯酰基的底漆和UV涂料为无溶剂型。
6、根据权利要求1所述的层压木地板,其中,所述增强层选自单板、屏蔽纸、高密度纤维板(HDF)和牛皮纸。
7、根据权利要求1所述的层压木地板,其中,根据所需厚度,使用数片所述增强层和树脂浸渍的低定量纸层。
8、根据权利要求1所述的层压木地板,其进一步包括在选自(a)基层与印刷的木单板层之间和(b)基层下面的至少一个位置层压的隔音层。
9、根据权利要求1所述的层压木地板,其中,所述底层选自聚氯乙烯树脂层、高密度纤维板(HDF)、定向刨花板(OSB)和防水胶合板层。
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CN104093921A (zh) * | 2012-02-03 | 2014-10-08 | 乐金华奥斯株式会社 | 具有pla层的地板 |
CN111132826A (zh) * | 2018-08-30 | 2020-05-08 | 东兴聚合体株式会社 | 隔音地板材料 |
CN111132826B (zh) * | 2018-08-30 | 2022-04-15 | 东兴聚合体株式会社 | 隔音地板材料 |
CN113882610A (zh) * | 2021-11-15 | 2022-01-04 | 怀化大隆农业科技有限公司 | 一种抗静电的竹木装饰板 |
TWI813497B (zh) * | 2021-12-29 | 2023-08-21 | 啟裕國際股份有限公司 | 曲木家具複合板及其製法 |
CN114905811A (zh) * | 2022-04-19 | 2022-08-16 | 财纳福诺木业(中国)有限公司 | 一种防水复合地板的结构和生产方法 |
CN114905811B (zh) * | 2022-04-19 | 2024-01-12 | 财纳福诺木业(中国)有限公司 | 一种防水复合地板的结构 |
Also Published As
Publication number | Publication date |
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WO2006033510A1 (en) | 2006-03-30 |
JP2008513644A (ja) | 2008-05-01 |
TWI266682B (en) | 2006-11-21 |
KR20060026664A (ko) | 2006-03-24 |
EP1794388A4 (en) | 2010-11-03 |
KR100716404B1 (ko) | 2007-05-11 |
US7449231B2 (en) | 2008-11-11 |
EP1794388B1 (en) | 2013-05-29 |
JP4567060B2 (ja) | 2010-10-20 |
EP1794388A1 (en) | 2007-06-13 |
US20060062966A1 (en) | 2006-03-23 |
CN101006234B (zh) | 2011-06-08 |
TW200610632A (en) | 2006-04-01 |
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