CN102080441A - 饰面薄板强化原木地板及制作方法 - Google Patents

饰面薄板强化原木地板及制作方法 Download PDF

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CN102080441A
CN102080441A CN2010105673601A CN201010567360A CN102080441A CN 102080441 A CN102080441 A CN 102080441A CN 2010105673601 A CN2010105673601 A CN 2010105673601A CN 201010567360 A CN201010567360 A CN 201010567360A CN 102080441 A CN102080441 A CN 102080441A
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wood veneer
decorative wood
decorative
surface course
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金智雄
张汉喆
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LG Corp
LX Hausys Ltd
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LG Chemical Co Ltd
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Abstract

本发明一实施例饰面薄板强化原木地板包括表面层、粘合层和复合板；该表面层包括给定厚度且呈板状形态的若干个饰面薄板和形成于所述饰面薄板之间的树脂浸渍纸，并通过热压处理相互接合所述饰面薄板和所述树脂浸渍纸而形成一体型结构；该粘合层形成于所述表面层的下部并起到粘合剂作用；该复合板分布在所述粘合层的下部，且通过所述粘合层接合于所述表面层的下部。

Description

饰面薄板强化原木地板及制作方法
技术领域
本发明涉及一种饰面薄板强化原木地板以及其的制作方法，具体涉及一种表面被强化处理但仍保持原木地板的外观并且长期处于地暖的温度下不会出现开裂的地板和其制作方法。
背景技术
通常情况下，公寓或者住宅等的客厅的地面主要使用木地板进行装修。
目前正在广泛使用的木地板中，大部分是为了防止木地板的扭曲变形，用粘合剂以之字形接合木材单板然后在单板上面接合饰面薄板的复合板。
原木地板表面的饰面薄板达到1.5mm以上，它虽然外观秀丽，可是用于地暖时，由于反复收缩和膨胀，表面很容易开裂。
而且，饰面薄板本身强度低，耐划伤性和耐压性弱。
发明内容
为了解决上述问题，本发明提供一种以如下内容为特征的饰面薄板强化原木地板及其制造方法，在多层饰面薄板之间分布苯酚或者三聚氰胺树脂浸渍纸之后实施热压接合，从而保持与现有原木地板相同的厚度。与此同时，由于每层饰面薄板厚度薄，收缩及膨胀力量较小，可以最大限度减少饰面薄板表面的开裂现象。
本发明还提供一种在饰面薄板之间被压轧的树脂浸渍纸(苯酚或者三聚氰胺树脂浸渍纸)，起到增强层作用，从而进一步提高饰面薄板强化原木地板的耐划伤性和耐压性。
本发明要解决的技术问题并不局限于上述内容。以下内容将帮助本发明所属领域技术人员更准确地理解上述内容里没有阐述的其它技术问题。
本发明的技术方案在于：
本发明中饰面薄板强化原木地板包括表面层、粘合层和复合板；所述表面层包括给定厚度且呈板状形态的若干个饰面薄板和形成于所述饰面薄板之间的树脂浸渍纸，并通过热压处理相互接合所述饰面薄板和所述树脂浸渍纸而形成一体型结构；所述粘合层形成于所述表面层的下部并起到粘合剂作用；所述复合板分布在所述粘合层的下部，且通过所述粘合层接合于所述表面层的下部。
优选地，所述饰面薄板的厚度介于0.3～1.0mm之间。
所述树脂浸渍纸为苯酚树脂浸渍纸或者三聚氰胺树脂浸渍纸。
本发明中饰面薄板强化原木地板在所述表面层的上部可以进一步包括UV涂覆层。
本发明中饰面薄板强化原木地板制造方法包括制备具有给定厚度且呈板状的若干个饰面薄板的步骤、在所述饰面薄板之间分布树脂浸渍纸的步骤、通过热压处理接合所述饰面薄板和所述树脂浸渍纸而形成表面层的步骤、在复合板的上部形成起到粘合剂作用的粘合层的步骤以及在所述粘合层的上部分布所述表面层将所述表面层接合在所述复合板的上部的步骤。
本发明中饰面薄板强化原木地板制造方法可以进一步包括在所述表面层的上部形成UV涂覆层的步骤。
说明书及附图详细说明了其它实施例的具体事项。
参考附图和以下实施例，就可以准确地理解本发明的优点及/或者特征和实施方法。可是，以下实施例并不限定本发明，而是以各种形态实现的实施方式。本实施例有助于完整地说明本发明，且帮助本发明所属领域技术人员准确地理解本发明的范围。另外，依据权利要求书的权利范围定义本发明，说明书中相同的参照符号指相同的构成因素。
本发明的技术效果在于：
本发明一实施例中，在多层饰面薄板之间分布苯酚或者三聚氰胺树脂浸渍纸之后实施热压接合，从而保持与现有原木地板相同的厚度。与此同时，由于每层饰面薄板厚度薄，收缩及膨胀力量较小，可以最大限度减少饰面薄板表面的开裂现象。
本发明中，在饰面薄板之间被压轧的树脂浸渍纸(苯酚或者三聚氰胺树脂浸渍纸)起到增强层的作用，从而进一步提高饰面薄板强化原木地板的耐划伤性、耐压性。
本发明中，饰面薄板强化原木地板表面形成UV涂覆层，从而增强饰面薄板强化原木地板表面强度的同时，保护饰面薄板强化原木地板表面花纹，使饰面薄板强化原木地板长期保持整洁的表面。
附图说明
图1为本发明一实施例中饰面薄板强化原木地板的分离侧面图；
图2为本发明一实施例中饰面薄板强化原木地板的结合侧面图；
图3为现有原木地板在80℃的温度下受热6小时后开裂的外观图；
图4为本发明一实施例中饰面薄板强化原木地板在80℃的温度下受热6小时后的外观图；
图5为本发明一实施例中饰面薄板强化原木地板的制造工序图。
附图符号说明
110-表面层；111-饰面薄板；112-树脂浸渍纸；120-粘合层；130-复合板；140-UV涂覆层。
具体实施方式
下面参考附图详细说明本发明的实施例。
图1为本发明一实施例中饰面薄板强化原木地板的分离侧面图，图2为本发明一实施例中饰面薄板强化原木地板的结合侧面图。
如图1及图2所示，本发明一实施例中饰面薄板强化原木地板(100)包括表面层(110)、粘合层(120)和复合板(130)。
所述表面层(110)包括分布在若干个饰面薄板(111)以及所述若干个饰面薄板(111)之间的树脂浸渍纸(112)。
所述若干个饰面薄板(111)分别具备给定厚度并呈板状。例如，优选地，所述各个饰面薄板(111)的厚度介于0.3～1.0mm之间。
所述各个饰面薄板(111)的厚度介于上述范围之内，从而最大限度减少将所述饰面薄板(111)用于地暖而出现收缩或者膨胀时，其表面出现开裂、划伤或者凹陷等现象。
饰面薄板是指将木材加工成像薄薄地纸张一样的木块，可以彰显木材的天然本色和雍容奢华，以上内容仅供参考。
所述饰面薄板(111)可以在天然饰面薄板、染色饰面薄板和集成饰面薄板中选择。据参考资料，所述天然饰面薄板是指没有对饰面薄板实施任何物理及化学加工的饰面薄板；所述染色饰面薄板是指对饰面薄板实施化学处理和脱色处理之后进行染色的饰面薄板；所述集成饰面薄板是指对于所述天然饰面薄板实施物理加工而重新形成的饰面薄板。
所述树脂浸渍纸(112)形成于所述若干个饰面薄板(111)之间。所述树脂浸渍纸(112)可以起到增强所述各个饰面薄板(111)的硬度的增强剂的作用，也可以起到相互粘合所述各个饰面薄板(111)的粘合剂的作用。
为此，所述树脂浸渍纸(112)可以选择苯酚树脂浸渍纸或者三聚氰胺树脂浸渍纸中的一种。即，所述苯酚树脂浸渍纸和所述三聚氰胺树脂浸渍纸是用于强化地板的白垩纸的代表性物质，将其用于所述各个饰面薄板(111)之间时，可以增强所述饰面薄板(111)的硬度。
而且，对于所述苯酚树脂浸渍纸或者所述三聚氰胺树脂浸渍纸实施热压处理时，该两种树脂浸渍纸表现出非常优秀的粘合性能。因此，将该两种树脂浸渍纸用于所述各个饰面薄板(111)之间时，可以进一步提高所述饰面薄板(111)的粘结力。
为了提高所述苯酚树脂浸渍纸和所述三聚氰胺树脂浸渍纸的耐磨性，可以将氧化铝陶瓷及纳米陶瓷中的一种以上添加入该两种树脂浸渍纸。
采用所述苯酚树脂浸渍纸作为所述树脂浸渍纸(112)时，所述苯酚树脂浸渍纸可以由薄片形状的苯酚粘合组成。采用所述三聚氰胺树脂浸渍纸作为所述树脂浸渍纸(112)时，所述三聚氰胺树脂浸渍纸可以由薄片形状的三聚氰胺粘合组成。
上述树脂浸渍纸(112)的工序流程大体上可以分成树脂(苯酚或者三聚氰胺)浸渍及干燥两个步骤。
为了进一步提高所述耐磨性，可以在所述浸渍和干燥工序之间增加添加氧化铝的工序流程。
如上所述，本发明实施例中，可以对所述饰面薄板(111)和所述树脂浸渍纸(112)进行热压处理而粘合成一体型结构。然后，对在所述饰面薄板(111)之间的所述树脂浸渍纸(112)进行压轧而增强所述饰面薄板(111)的硬度。
而且，本发明实施例中，例如，使所述各个饰面薄板(111)的厚度达到0.5mm，从而降低了收缩或者膨胀的力量，防止出现所述饰面薄板(111)的表面开裂的现象。
所述粘合层(120)形成于所述复合板(130)的上部。所述粘合层(120)起到作为粘合剂接合所述表面层(110)和所述复合板(130)的作用。
所述粘合层(120)采用的材质可以在PVAC(Poly Vinyl Acetate)、EVA(Ethylene Vinyl Acetate)、EPI(Emulsified Poly Isocyanate)及PU(Poly Urethane)等材料中选择一种材质组成。
而且，所述粘合层(120)采用的粘合剂为用于常温及热硬化的二液型合成树脂粘合剂，该种粘合剂为水溶性粘合剂，不会引起环境污染，且耐水性及耐热性强。
所述复合板(130)分布在所述粘合层(120)的下部。所述复合板(130)通过所述粘合层(120)与所述表面层(110)的下部接合。
据参考资料，复合板是指将木材加工成薄板，即，加工成单板之后，以单数层叠使其纤维方向呈直角交叉的同时，用粘合剂接合而成的板状体。
进一步，本发明一实施例中饰面薄板强化原木地板(100)进一步包括UV涂覆层(140)。
所述UV涂覆层(140)通过UV涂覆处理形成于所述表面层(110)的上部，即，所述若干个饰面薄板(111)中最上部的饰面薄板(111)的上部。
以下详细说明所述UV涂覆层(140)的形成工序。首先，在所述表面层(110)的表面采用辊涂法涂覆UV涂料，并使用UV硬化器实施干燥工序。反复实施上述工序之后，所述表面层(110)的表面形成具有一定厚度的所述UV涂覆层(140)。
如上所述，在所述表面层(110)的上部形成所述UV涂覆层(140)的目的在于，增强所述表面层(110)的表面强度，保护所述饰面薄板(111)的花纹，长期保持整洁的表面。
而且，采用所述UV涂覆剂完全填充在形成于所述表面层(110)的表面的微型槽内，从而保护在使用过程中暴露在外部的表面，并显示出光亮平整的表面。
下表1对比了本发明一实施例中饰面薄板强化原木地板(100)和现有原木地板的物理特性。
如表1所示，据实验结果，本发明一实施例中饰面薄板强化原木地板(100)在80℃高温下经过一定时间(6个小时、24小时)之后，其尺寸稳定性和Warp稳定性(宽度和长度)仍然保持着和未受热之前几乎同等的水平。
据参考资料，冲击强度是指掉下286g的球状锤时表面不出现龟裂、破碎、剥离等现象的高度。
表1
Figure BSA00000368491100071
据实验结果，现有原木地板在200mm以上的高度出现表面龟裂现象。然而，本发明一实施例中饰面薄板强化原木地板(100)在350mm以上的高度才出现表面龟裂现象。这表示冲击强度得到了提高。
图3所示为现有原木地板在80℃的温度下受热6小时后开裂的外观图，图4所示为本发明一实施例中饰面薄板强化原木地板在80℃高温下受热6小时之后也没有出现开裂现象的外观图。
首先，如图3所示，现有原木地板在80℃高温下经过6个小时之后出现了开裂现象，图中椭圆所圈之处即为裂痕。
而图4所示为本发明一实施例中饰面薄板强化原木地板在80℃高温下经过6个小时之后也没有出现开裂现象。
如上所述，在若干层饰面薄板之间分布苯酚或者三聚氰胺树脂浸渍纸之后，对饰面薄板实施热压接合，从而在保持与现有原木地板相同的厚度的同时，由于每层饰面薄板厚度薄且收缩及膨胀的力度不大，所以最大限度降低了饰面薄板表面的开裂的可能性。
而且，本发明中饰面薄板强化原木地板在饰面薄板之间压轧的树脂浸渍纸(苯酚/三聚氰胺)可起到增强层作用，从而进一步提高饰面薄板强化原木地板的耐划伤性和耐压性。
图5是本发明一实施例中饰面薄板强化原木地板的制造工序图。
如图1及图5所示，步骤(510)制备具有给定厚度且呈板状的若干个饰面薄板(111)。
所述若干个饰面薄板(111)具有给定厚度且呈板状。例如，优选地，所述各饰面薄板(111)的厚度介于0.3～1.0mm范围之内。
在上述厚度范围内形成所述各个饰面薄板(111)，从而最大限度地减少了将所述饰面薄板用于地暖而出现表面开裂的现象或者在使用过程中出现划伤、凹陷等现象。
下一步，步骤(520)在所述饰面薄板(111)之间分布树脂浸渍纸(112)。
所述树脂浸渍纸(112)在起到增强所述各个饰面薄板(111)硬度的作用的同时，也起到作为粘结剂相互接合所述各个饰面薄板(111)的作用。
为此，可以采用苯酚树脂浸渍纸或者三聚氰胺树脂浸渍纸形成所述树脂浸渍纸(112)。所述苯酚树脂浸渍纸或者所述三聚氰胺树脂浸渍纸是用于强化地板的白垩纸的代表性树脂浸渍纸。因此，形成于所述各个饰面薄板(111)之间时，可以增强所述饰面薄板(111)的硬度。
而且，所述苯酚树脂浸渍纸或者所述三聚氰胺树脂浸渍纸经过热压处理之后接合性能卓越。因此，形成于所述各个饰面薄板(111)之间时，可以提高所述饰面薄板(111)的接合力。
如上所述，接合所述树脂浸渍纸(112)的工序大体上分成树脂(苯酚或者三聚氰胺)浸渍及干燥两个步骤。为了增强所述耐磨性，可以在所述浸渍和干燥工序之间增加添加氧化铝的工序流程。
下一步，步骤(530)通过热压处理接合所述饰面薄板(111)和所述树脂浸渍纸(112)而形成表面层(110)。
下一步，步骤(540)在复合板(130)的上部形成起到粘合剂作用的粘合层(120)。
此时，采用在PVAC(Poly Vinyl Acetate)、EVA(Ethylene Vinyl Acetate)、EPI(Emulsified Poly Isocyanate)及PU(Poly Urethane)等中选择的一种作为粘合剂形成所述粘合层(120)。
而且，用于常温及热硬化的二液型合成树脂粘合剂形成所述粘合层(120)，该粘合剂属于水溶性粘合剂，不会引起环境污染，且耐水性及耐热性强，。
下一步，步骤(550)在所述粘合层(120)的上部分布所述表面层(110)。
下一步，步骤(560)对于所述表面层(110)、所述粘合层(120)及复合板(130)实施常温及常压处理，将所述表面层(110)接合在所述复合板(130)的上部。
下一步，步骤(570)在所述表面层(110)的上部形成UV涂覆层(140)。
所述UV涂覆层(140)的形成工序如下：首先，采用辊涂法将UV涂料涂覆在所述表面层(110)的表面之后，使用UV硬化器实施干燥工序。反复实施上述工序之后，所述表面层(110)的表面形成具有一定厚度的所述UV涂覆层(140)。
上述内容详细说明了本发明的具体实施例，当然，在不脱离本发明的范围的前提下，可以对于本发明实施各种变形。因此，本发明的权利要求范围并不是依据上述实施例加以限制，而是依据包括本发明的权利要求范围在内的与该权利要求范围等同的等同物来确定。
以上内容参照有限的实施例和附图详细说明了本发明。以上实施例和附图只用以说明本发明而非限制本发明。本发明所属领域技术人员应当理解，可以对于上述内容实施各种修改和变形。因此，应该依据权利要求书来理解本发明的技术思想，对于本发明实施的等同性或者等价性变形均应涵盖于本发明的技术思想的范畴当中。

Claims (8)

1.一种饰面薄板强化原木地板，其特征在于：包括表面层、粘合层和复合板；该表面层包括给定厚度且呈板状形态的若干个饰面薄板和形成于所述饰面薄板之间的树脂浸渍纸，并通过热压处理相互接合所述饰面薄板和所述树脂浸渍纸而形成一体型结构；该粘合层形成于所述表面层的下部并起到粘合剂作用；该复合板分布在所述粘合层的下部，且通过所述粘合层接合于所述表面层的下部。
2.根据权利要求1所述的饰面薄板强化原木地板，其特征在于：所述饰面薄板的厚度介于0.3～1.0mm之间。
3.根据权利要求1所述的饰面薄板强化原木地板，其特征在于：所述树脂浸渍纸为苯酚树脂浸渍纸或者三聚氰胺树脂浸渍纸。
4.根据权利要求1所述的饰面薄板强化原木地板，其特征在于：进一步包括形成于所述表面层的上部的UV涂覆层。
5.一种饰面薄板强化原木地板制造方法，其特征在于：包括制备具有给定厚度且呈板状的若干个饰面薄板的步骤、在所述饰面薄板之间分布树脂浸渍纸的步骤、通过热压处理接合所述饰面薄板和所述树脂浸渍纸而形成表面层的步骤、在复合板的上部形成起到粘合剂作用的粘合层的步骤以及在所述粘合层的上部分布所述表面层将所述表面层接合在所述复合板的上部的步骤。
6.根据权利要求5所述的饰面薄板强化原木地板制造方法，其特征在于：所述饰面薄板的厚度介于0.3～1.0mm之间。
7.根据权利要求5所述的饰面薄板强化原木地板制造方法，其特征在于：所述树脂浸渍纸为苯酚树脂浸渍纸或者三聚氰胺树脂浸渍纸。
8.根据权利要求5所述的饰面薄板强化原木地板制造方法，其特征在于：进一步包括在所述表面层的上部形成UV涂覆层的步骤。
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