CN1453128A - 使用酚醛复合树脂的地板覆盖材料 - Google Patents

使用酚醛复合树脂的地板覆盖材料 Download PDF

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CN1453128A
CN1453128A CN02132087A CN02132087A CN1453128A CN 1453128 A CN1453128 A CN 1453128A CN 02132087 A CN02132087 A CN 02132087A CN 02132087 A CN02132087 A CN 02132087A CN 1453128 A CN1453128 A CN 1453128A
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CN1289287C (zh
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李昌根
柳炯杰
金成一
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Yu Jixi
WUJIN PRODUCE CO Ltd
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WUJIN PRODUCE CO Ltd
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Abstract

本发明公开一种地面覆盖材料，其中包含间苯二酚－甲醛液的酚醛树脂和聚氨酯树脂的酚醛复合树脂与纸混合并干燥，形成预浸料坯，然后热压在PVC基材或防水胶合板的上面，形成透明的保护层或定形层。在该地板覆盖材料中，透明层和定形层是由酚醛复合树脂制成的，因而热变形和潮湿变形性低，且不发生卷曲。此外，由于该地板覆盖材料的表层几乎不因受热而变形，所以不另外需要抑制这种变形的补偿层。

Description

使用酚醛复合树脂的地板覆盖材料
                          技术领域
一般而言，本发明涉及使用酚醛复合树脂的地板覆盖材料，更具体地，本发明涉及用于地板下加热的系统或地板的地板覆盖材料，其具有几乎不热变形和不卷曲的优点，并且具有优良的表面硬度。
                          背景技术
通常，在韩国用于地板下加热系统的地板材料(其韩国专利登记号为189372)包括依次层压在防水胶合板表面的核心层、定形层和透明的保护层，以及附着在胶合板反面的补偿层。核心层是通过纸板与酚醛树脂结合而得到的薄板，定形层和表面层是纸结合的三聚氰胺树脂薄板。在防水胶合板的底面上，必须层压包括纸结合的三聚氰胺树脂薄板的补偿层，以减轻热变形或表面层的卷曲。
这种常规地板覆盖材料因为表面硬度低而具有表面易于划伤的缺点。另外，即使地板覆盖材料的底面层压了补偿层，也不能防止地板覆盖材料的变形或卷曲，这可归因于受热时大幅度膨胀或收缩的表面层。
                          发明内容
因此，本发明的目的是缓解现有技术中存在的问题并提供一种地板覆盖材料，该地板覆盖材料的优点在于表面强度高，热变形低，可以防止卷曲，以及无需地板覆盖材料底面的补偿层，其是利用酚醛复合树脂代替通常的酚醛树脂或三聚氰胺树脂，并由该酚醛复合树脂形成地板覆盖材料的表面层。
                          附图说明
图1是根据本发明基本实施方案的地板覆盖材料的断面图；
图2是根据本发明另一实施方案的地板覆盖材料的断面图；
图3是根据本发明又一实施方案的地板覆盖材料的断面图；及
图4是根据本发明再一实施方案的地板覆盖材料的断面图。
                        具体实施方式
本发明的特征在于，热压由混入酚醛复合树脂中的纸组成的预浸料坯，得到透明保护层1和定形层2，  它们一起构成本发明地板覆盖材料的表面层。
在本发明中使用的酚醛复合树脂是通过将15～25％重量的聚氨酯树脂添加到酚醛树脂中而形成的，所述酚醛树脂是由间苯二酚与甲醛液反应而生成的，并且具有50％重量的固含量。
这种酚醛复合树脂的玻璃化转变温度(Tg)比三聚氰胺树脂的高，因而具有较强的表面硬度。
该复合树脂具有优异的抗剪强度和较低的抗弯强度以及良好的柔软性，并且还能够抑制热变形，因为其中包含柔韧的聚氨酯树脂。
此外，与含水的三聚氰胺树脂相比，该酚醛复合树脂很少吸水，这可归因于身为油性组分的芳香性间苯二酚。
因此，本发明的地板覆盖材料，其中一起构成表面层的透明保护层1和定形层2混入酚醛复合树脂中，具有低吸附、无潮湿变形、低热收缩和膨胀及不因受热二卷曲的优点。
从图1可以看出，定形层2和透明保护层1依次层压在包括PVC基材或防水胶合板3的基材层的顶面上，在其反面热压了背衬层4。在类似于图1的图2中，玻璃纤维层(G/F层)5可以夹在基材层与定形层2之间。此外，在类似于图1的图3中，在基材层的底面上可以层压饰面层6。在类似于图3的图4中，玻璃纤维层(G/F层)5可以嵌入防水胶合板层3与定形层2之间。
玻璃纤维层(G/F层)5的嵌入导致隔热和隔音作用的提高。
关于本发明的透明保护层1，用液态的酚醛复合树脂浸渍纸并干燥之，得到预浸料坯，然后热压该预浸料坯。该层使表面的物理性能得到加强，如抗污染性、抗划伤性、抗冲击性和耐化学品性，以及尺寸变形性，同时保护了定形层2。
特别地，当使用与高耐磨性颗粒混合的纸时，透明保护层1的硬度进一步提高。
上述定形层2是按与制备透明保护层1相同的方式得到的，即把印刷了图形的纸与液态的酚醛复合树脂混合并干燥之，得到预浸料坯，然后热压该预浸料坯。该层在外观上提供具有各种天然织构的图案形状。
在本发明中，当高度耐磨的陶瓷添加到酚醛复合树脂中时，透明保护层1的表面硬度可以得到进一步提高。
同时，由透明保护层1和定形层2组成的上层的厚度0.05～040毫米，而PVC基材或防水胶合板层3的厚度为5～12毫米。背衬层4或饰面层6的厚度约为0.10～0.60毫米。因此，优选形成总厚度6～13毫米的层压结构。
PVC基材层3包含选自淡英斑岩、翡翠和黄土中的至少一种(10～20％重量)，制得具有优异保健性能的能够辐射远红外线的地板材料。该基材层是利用氯乙烯总重量60～70％的至少一种选自比重高达2.7～4.5的碳酸钙、滑石和硫酸钡的填料而制备的，因而具有高的隔热性和传热速度。
PVC背衬层4(0.01-0.60mm)包含50～80％的填料，增加了结构的附着力，并且不产生热变形。
饰面层6由单层的薄木板组成。该木板的作用是吸附气体，该气体是从地板下加热系统上面的地板裂缝中释放出来的。所以，该层可以防止地板表面因释放出来的气体而凸起。
至于透明保护层1和定形层2，将纸重量100～300％的透明酚醛复合树脂与纸混合，并在150℃的烘箱中干燥10分钟，得到预浸料坯，然后对其进行热压。
在本发明的地板覆盖材料中，利用压机依次热压透明保护层1、定形层2、基材层(PVC基材或防水胶合板)3以及背衬层4或饰面层6。
压制过程如此进行，即把各层压板以及防水胶合板或PVC基材3引入开式压机进行热压，并在温度为150～170℃的平面式压机上以40～70kg/cm2的压力压制20～30分钟。
将加热层冷却20～30分钟，以使热变形最小化。
从加强产品的外观来看，将压制物的上表面硬化部分制成不平的图案，从而可以得到具有各种图案和光泽的地面覆盖材料。
本发明的以及常规的地面覆盖材料的物理性质见下面的表1。
表1
单位   本发明的地板覆盖材料(地板)   本发明的地板覆盖材料(地板下) 增强的地板材料 PVC地面覆盖材料
卷曲(W) ％   +0.05   -0.15   -0.18  -0.75
热收缩(W) ％   -0.07   -0.06   -0.11  -0.41
 热收缩(L)   ％     -0.10     -0.12     -0.13     -0.50
 耐磨性   mg     0.143     0.137     0.1565     0.556
注：W-宽度，L-长度
耐磨性试验
基于KSF-3111(耐磨性试验)
磨蚀周期的大小：H-22(总载荷：500g)
试验的次数：500次
磨蚀前的重量-磨蚀后的重量＝耐磨性(mg)
卷曲和收缩
制备9cm(宽)×90cm(长)尺寸的试验片。
使该试验片在干燥烘箱中于80℃下放置6小时，然后对试验片进行测量。
在干燥之前和干燥之后，按百分比计算变化的宽度和变化的长度之间的差异(％)。
如上所述，包括透明保护层1和定形层2的表面层是由酚醛复合树脂制备的，因而由受热或受潮而导致的变形低，并且还具有防止卷曲的优点，以及优异的抗划性和表面强度。
以PVC基材作为底层的本发明的地面覆盖材料传热速度高并且隔音作用良好，所以适用于地板下加热系统。
根据优选实施方案，本发明的地面覆盖材料的底面无需附着补偿层，这不同于其底面可能附着不同层常规地面覆盖材料。
此外，在本发明的地面覆盖材料中可能因为表面层的高强度和柔韧性而不包含核心层，因而本发明的地板覆盖材料的优点在于结构简单和制备成本低。
已经以说明的方式对本发明进行了描述，但是应当理解，所使用的术语实际上是用于说明的而不是用于限制的。根据上述教导，可以对本发明做出多种修饰和变更。因此，应当理解，本发明在所附权利要求书的范围内是可以实施的，并不只限于上述的具体说明中。

Claims (5)

1.一种使用酚醛复合树脂的地板覆盖材料，包括位于PVC基材或防水胶合板层上面的定形层和透明保护层，该定形层和透明保护层是如此形成的，即将15～25％重量的聚氨酯树脂添加至通过间苯二酚与甲醛液的反应而得到的酚醛树脂中，形成液相的酚醛复合树脂，之后将该酚醛复合树脂与纸混合形成预浸料坯，然后对该预浸料坯进行热压。
2.权利要求1的地板覆盖材料，其中该PVC基材包含10～20％重量的选自淡英斑岩、翡翠和黄土中的任一种，并且是利用60～70％重量的选自碳酸钙、滑石和硫酸钡的填料制成的，按聚氯乙烯树脂的总重量计。
3.权利要求1的地板覆盖材料，其中在该PVC基材或防水胶合板层的底面附着了背衬板层或饰面板层。
4.权利要求3的地板覆盖材料，其中该背衬板层为含有50～80％重量填料的PVC板。
5.权利要求1～4中任一项的地板覆盖材料，其中在该定形层的底面上层压了玻璃纤维层(G/F层)。
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