KR100361893B1 - Waterproof Plywood Flooring Laminated with High Pressure Melamine Laminate Reinforced with Glass Fiber Layer and the Method for the Manufacturing thereof - Google Patents

Abstract

The present invention relates to a reinforced floorboard laminated with a high pressure melamine laminate (referred to as "HPL") reinforced with a glass fiber layer on a water-resistant laminate layer, and a method of manufacturing the same. The upper high-pressure melamine laminate 20 formed by laminating layer 2 (25), glass fiber layer (24), core layer (1) (23), shape paper layer (22), and surface protective paper layer (21) is interposed between the adhesive layer (40). The present invention relates to a laminated plywood-reinforced floorboard and a method for manufacturing the laminated plywood reinforced with a glass fiber layer.

The water-resistant plywood reinforced floorboard laminated with the HPL reinforced with the glass fiber layer of the present invention has a glass fiber layer 24 and a core layer 1 (23) on the upper HPL 20 'instead of omitting the lower HPL 30 of the conventional invention. By stacking the core HPL 20 of the new structure on the water-resistant plywood layer 10 by laminating it between the core layers 2 (25), the dimensional stability and curling properties are significantly improved, and the water-resistant plywood layer 10 is directly The adhesion was also excellent with the bottom.

Description

Waterproof Plywood Flooring Laminated with High Pressure Melamine Laminate Reinforced with Glass Fiber Layer and the Method for the Manufacturing

The present invention relates to a reinforced floorboard laminated with a high pressure melamine laminate (High Pressure Melamine Laminate: hereinafter referred to as "HPL") reinforced with a glass fiber layer, and a method of manufacturing the same. 2, the high-pressure melamine laminate in which the glass fiber layer, the core layer 1, the shape paper layer and the surface protective paper layer are laminated is laminated with the water-resistant plywood layer with the adhesive layer interposed therebetween, It relates to a reinforced floorboard and a method of manufacturing the same.

As shown in the cross-sectional view of FIG. 1, the conventional HPL laminated laminate is reinforced with an upper HPL 20 'at an upper portion with an adhesive layer 40 interposed therebetween. The lower layer had a structure in which a lower layer HPL 30, which was a balance layer, was stacked with the adhesive layer 40 interposed therebetween.

At this time, the upper HPL (20 ') is composed of a core layer 1 (23), core layer 1 (23), shape paper layer 22 and the surface protective layer 21 in order from the bottom, the lower HPL (30) from below In turn, it consists of core layer 2 (25), core layer 2 (25) and core layer 1 (23), which will be briefly described as follows.

The water-resistant plywood layer 10 was pressed and manufactured by pressing a 5-7 layer single plate using a phenol resin or melamine resin adhesive so that the grain direction was orthogonal.

The core layer 1 (23) forming the upper HPL (20 ') was prepared by impregnating phenolic resin in kraft paper, and the shape paper layer (22) was prepared by impregnating melamine resin in a shape paper printed with a predetermined pattern on a titanium oxide-containing cellulose paper. The surface protective paper layer 21 was prepared by impregnating melamine resin on overlay paper containing wear-resistant silica or alumina evenly distributed on cellulose paper.

In addition, core layer 1 (23) forming the lower HPL (30) was prepared by impregnating phenolic resin in kraft paper, core layer 2 (25) was prepared by impregnating melamine resin in kraft paper.

This conventional HPL laminated laminated plywood laminate is not only excellent in dimensional stability against heat and moisture by using the plywood layer 10 in place of medium density fiberboard (MDF), but also in melamine resin on the surface. Since the impregnated surface protective paper layer 21 and the shape paper layer 22 were laminated, there was an advantage of excellent surface properties.

However, the dimensional change rate of the upper HPL 20 'itself was -0.5 to -0.7%, which was significantly lower than that of the water-resistant plywood layer 10, which was -0.05 to -0.2%, and the curling property was 50 to 60 mm. As a result, cracking and curling phenomena occurred severely during use, and there was a problem that the practicality was lowered.

At this time, the dimensional change rate is a value calculated by dividing the size of the upper HPL (20 ') for 24 hours at a temperature of 80 ℃ for 24 hours, the curling property is heating the top HPL (20') for 24 hours at a temperature of 80 ℃ This is a measure of the size of the curl.

In addition, the back layer is made of the lower HPL (30), when the adhesive is applied to the floor when the construction when the bottom HPL (30) when trying to bond the bottom, there was a problem that the adhesiveness with the bottom is not applied, do not apply the adhesive on the floor When the reinforced flooring board and the reinforced flooring board are bonded to each other with an adhesive (injury work: 浮上 施工), there is a problem of severe shrinkage and curling due to non-adhesion with the floor, and significantly suppressing noise generation.

Therefore, in the present invention, instead of omitting the lower HPL 30 of the conventional invention in order to solve the above-mentioned problems, the dimensional stability and curling properties are remarkable by laminating a glass fiber layer between the core layer on the upper HPL 20 '. The present invention is to provide a waterproofing laminate laminate flooring laminate and HPL laminated with excellent adhesion to the floor and excellent manufacturing method.

1 is a cross-sectional view of a conventional HPL laminated plywood reinforced laminate.

Figure 2 is a cross-sectional view of the water-resistant plywood laminate flooring laminated HPL of the present invention.

(Explanation of symbols for the main parts of the drawing)

10: waterproofing plywood layer 20: upper HPL

20 ': top HPL 21: surface protective layer

22: morphology layer 23: core layer 1

24: glass fiber layer 25: core layer 2

30: lower HPL 40: adhesive layer

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

FIG. 2 is a cross-sectional view of a water resistant plywood laminate floor laminated with HPL reinforced with a glass fiber layer of the present invention, in which an upper HPL 20 is laminated on top of the water resistant plywood layer 10 with an adhesive layer 40 interposed therebetween. It shows a water-resistant plywood reinforced floorboard laminated with HPL.

At this time, the upper HPL 20 is composed of a core layer 2 (25), a glass fiber layer 24, a core layer 1 (23), a shape paper layer 22 and a surface protective paper layer 21 in order from the bottom.

After explaining in detail the layers of the HPL reinforced with the glass fiber layer of the present invention laminated plywood laminate flooring in detail, it looks at the process of forming the finished product by laminating each layer.

The water-resistant plywood layer 10 is a layer made of a water-resistant plywood pressed and manufactured by pressing a 5-7 layer single plate using a phenol resin or melamine resin adhesive so that the grain direction is orthogonal to each other. Very small, making it suitable for ondol use.

The water-resistant plywood layer 10 has a dimensional change rate of -0.05 to -0.2% when the dimension shrinkage after heating for 24 hours at a temperature of 80 ℃ is calculated as 100 fractions.

Next, look at one for each layer constituting the upper HPL (20).

First, the surface protective paper layer 21 which gives surface properties, such as abrasion resistance and scratch resistance, is manufactured.

The surface protective paper layer 21 is 150 to 300% by weight of melamine resin compared to the weight of the overlay paper on the overlay paper containing wear-resistant silica or alumina evenly distributed on a cellulose paper having a weight of 20 to 100 g / m 2. After impregnation, it was dried and semi-cured in an oven at 100-150 ° C. for 0.5-4 minutes.

The melamine resin is about 30 to 45% by weight of melamine, 20 to 40% by weight of formaldehyde, 18 to 27% by weight of water as a solvent, diethylene glycol 1 to 5% by weight as a modifier, about 1% by weight of sodium hydroxide as a pH regulator and a curing agent. It is preferable to prepare a liquid phase by reacting a 2-10% by weight of the basic catalyst of the phosphorus amine system.

At this time, the surface protective paper layer 21 is abrasion resistance of 200 to 20,000 times by the abrasive paper by the wear-resistant particles and melamine resin used.

Next, a shape paper layer 22 is disposed below the surface protection paper layer 21 to give a shape of the reinforced floor board by creating a printed pattern effect.

The shape paper layer 22 is impregnated with 60 to 150% by weight of a melamine resin in a shape paper on which a predetermined pattern is printed by a method such as gravure on a titanium oxide-containing cellulose paper having a weight of 80 to 120 g / m 2, and then 80 Dried and semi-cured in an oven at 150 ° C. for 0.5-4 minutes.

The melamine resin is about 30 to 45% by weight of melamine, 20 to 40% by weight of formaldehyde, 18 to 27% by weight of solvent water, 1 to 5% by weight of diethylene glycol as a modifier, 1% by weight of sodium hydroxide as a pH regulator and a curing agent. 2-10 wt% of the basic catalyst of the phosphorus amine system is preferably prepared in a liquid phase, and in addition to the melamine resin, a polyester resin, a diaryl phthalate resin or a phenol resin may also be used.

Next, a core layer 1 (23) is prepared to support the surface protective paper layer 21 and the shape paper layer 22 so as to be sheeted with HPL, and to provide a thickness thereof.

The core layer 1 (23) was impregnated with 30 to 60% by weight of a resol type phenolic resin in a kraft paper having a weight of 80 to 300 g / m 2, and then dried and semi-cured in an oven at 150 to 200 ° C. for 10 to 60 seconds. It is.

The phenol resin reacts 33 to 54% by weight of phenol, 30 to 46% by weight of formaldehyde, 4 to 6% by weight of solvent ethyl alcohol and 2 to 5% by weight of water, and 5 to 15% by weight of basic catalyst of the amine system as a modifier. It is a resol type made into a liquid.

This core layer 1 (23) can also use several sheets by thickness.

Next, a glass fiber layer 24 is placed between the core layer 1 (23) and the core layer 2 (25) to impart excellent dimensional stability to the HPL.

The glass fiber layer 24 is in the form of a woven fabric like a regular fiber using long fibers of glass, and has a weight of 50-200 g / m 2 and impregnates with a phenolic resin because it cannot be combined with other layers by itself. Use it.

The phenolic resin is 33-54% by weight of phenol, 30-46% by weight of formaldehyde, 2-5% by weight of water, and 5-15% by weight of a basic catalyst of the amine-based modifier as a resol type made into a liquid phase, and impregnated amount. Depends on the weighing but is usually impregnated up to 30-80% by weight relative to the glass fiber layer weighing.

In addition, the glass fiber layer 24 is pretreated with a coupling agent (coupling agent) in order to increase the bonding strength between the phenol resin and the glass fiber before impregnation or mixing in the phenolic resin, or by mixing the coupling agent together with the phenol resin glass fiber layer (24) Can be impregnated with

In this case, the coupling agent may be a silane-based and titanate-based coupling agents described in SOURCE 10-1998-056608, and may be selected and used according to the characteristics of the phenol resin. The method of use is preferably 0.1 to 0.5% by weight of the phenol resin. In the case of pretreatment, the mixture is mixed with a solvent such as water and coated in advance on the glass fiber layer 24. When the mixture is used with a phenol resin, the phenol resin is mixed with a solvent such as water and then mixed with the phenol resin. Use it.

Next, to prepare a core layer 2 (25) to ensure the curling properties of the HPL itself.

The core layer 2 (25) is impregnated with 40 to 150% by weight of melamine resin compared to the weight of kraft paper, and dried and semi-cured for 0.5 to 2 minutes in an oven at 80 to 150 ° C. .

The melamine resin used at this time is about 30 to 45% by weight of melamine, 20 to 40% by weight of formaldehyde, 18 to 27% by weight of solvent water, 1 to 5% by weight of diethylene glycol as a modifier, and 1% by weight of sodium hydroxide as a pH regulator. And it is preferable to prepare a liquid phase by reacting a 2-10% by weight of the amine-based basic catalyst as a curing agent.

Each layer constituting the upper HPL 20 manufactured as described above in the order of core layer 2 (25), glass fiber layer 24, core layer 1 (23), shape paper layer 22 and surface protective paper layer 21 in order After heating, pressurize, pressurize, heat and pressurize at a pressure of 60-100kg / cm2 for 15-60 minutes at a temperature of 125-155 ° C in a press, and then simultaneously cool down for 15-30 minutes under the same pressure and press the upper HPL ( Complete 20).

The upper HPL 20 has a dimensional change rate of -0.05 to -0.3% when the shrinkage is calculated at 100% after heating for 24 hours at a temperature of 80 ° C, and curls after heating for 24 hours at a temperature of 80 ° C. Curling property at the time of measuring the degree to which it becomes is 0.5-5.0 mm.

That is, it is almost similar to the dimensional change rate of -0.1 to -0.2% of the water-resistant plywood layer 10 to have excellent dimensional stability, and the curling property is also remarkably improved.

Finally, an adhesive layer 40 which serves to bond the upper HPL 20 and the water-resistant plywood layer 10 thus manufactured is formed on the water-resistant plywood layer 10.

The adhesive constituting the adhesive layer 40 uses a room temperature-curable urethane resin.

The room temperature-curable urethane resin was applied to the water-resistant plywood layer 10 by coating an amount of 80 to 200 g / m 2 to form an adhesive layer 40, and then mounted on the upper HPL 20 at a pressure of 5 kgf / cm 2 at room temperature. After pressing for 2 hours and drying at 80 ° C. for 2 hours, adhesion is completed.

Thus, by compressing the water-resistant plywood layer 10 and the upper HPL (20) at room temperature conditions it is possible to minimize the deformation due to heat.

When the composition of the product is finished, the product is processed and processed into the existing floorboard manufacturing process.

Example

1. Manufacturing the waterproofing plywood layer 10

The 5-layer single plate was pressed using a phenol resin adhesive so that the grain direction was orthogonal to each other, and pressed into a press to prepare a water-resistant plywood layer 10.

2. Manufacturing of the upper HPL 20

1) Manufacture of Surface Protective Layer 21

The surface protective paper layer 21 has 37% by weight of melamine, 33% by weight of formaldehyde, 25% by weight of water, 1% by weight of diethylene glycol, and 0.3% of sodium hydroxide on the overlay paper containing alumina evenly distributed on a cellulose paper having a weight of 38 g / m 2. % And an amine-based basic catalyst was reacted with 3.7% by weight of a melamine resin prepared in a liquid phase, and then impregnated with 250% by weight of the overlay paper, and then dried in an oven at 130 ° C. for 3 minutes and semi-cured to form a surface protective paper layer ( 21) was prepared.

2) Manufacture of Shape Paper Layer 22

Shape paper layer 22 is 37% by weight of melamine, 33% by weight of formaldehyde, 25% by weight of water, 1% by weight of diethylene glycol, on a shape paper printed with a predetermined pattern by gravure printing on a titanium oxide-containing cellulose paper having a weight of 80 g / m 2, After impregnating the melamine resin prepared in the liquid phase by reacting 0.3 wt% of sodium hydroxide and 3.7 wt% of the basic catalyst of the amine system with 100 wt% of the weight of the paper, it was dried in an oven at 120 ° C. for 2 minutes and semi-cured. Shape paper layer 22 was prepared.

3) Core layer 1 (23) manufacture

The core layer 1 (23) was prepared in a liquid state by reacting a weight of 200 g / m 2 of kraft paper with 49% by weight of phenol, 33% by weight of formaldehyde, 5% by weight of ethyl alcohol, 3% by weight of water, and 10% by weight of a basic catalyst of an amine system. One phenolic resin was impregnated with 60 wt% of the weight of kraft paper, and then dried in an oven at 190 ° C. for 30 seconds and semi-cured to prepare a core layer 1 (23).

4) Glass fiber layer 24 production

49 wt% phenol, 33 wt% formaldehyde, 5 wt% ethyl alcohol, 3 wt% water, basic catalyst based on amine in a glass fiber layer (A glass composition, average fiber diameter 12 μm) 24 weighing 200 g / m 2 After impregnating the resin solution prepared by reacting 100% by weight of the phenol resin prepared in the liquid phase by reacting the weight% with 10 parts by weight of the 10% by weight aminosilane coupling agent aqueous solution, 50% by weight of the glass fiber layer 24 weighed, The glass fiber layer 24 was prepared by drying in an oven for 3 minutes and semi-curing at the same time.

5) Core layer 2 (25) manufacturing

Core layer 2 (25) is kraft paper weighing 200 g / ㎡ 37% by weight of melamine, 33% by weight of formaldehyde, 25% by weight of water, 1% by weight of diethylene glycol, 0.3% by weight of sodium hydroxide and 3.7 basic catalyst of the amine system The core layer 2 (25) was prepared by impregnating the melamine resin prepared in the liquid phase by reacting the weight percent by weight with respect to the weight of the kraft paper, and then drying it for 3 minutes in an oven at 130 ° C.

6) Manufacturing the upper HPL 20 by laminating the layers of 1) -5)

The layers of 1) to 5) manufactured as described above were arranged in the order of core layer 2 (25), glass fiber layer (24), core layer 1 (23), shape paper layer (22) and surface protective layer (21) from below. After mounting, the press was heated and pressurized for 30 minutes at a temperature of 130 ° C. and a pressure of 100 kg / cm 2, and then cooled simultaneously for 25 minutes under the same pressure to prepare an upper HPL 20.

3. After forming the adhesive layer 40 on the water-resistant plywood layer 10, the upper HPL (20) laminated

Applying a room-temperature-curable urethane resin to the coating amount 120g / ㎡ on the water-resistant plywood layer 10 to form an adhesive layer 40, and then mounted the upper HPL (20) and crimped at a pressure of 5kgf / ㎠ at room temperature for 2 hours It dried at 80 degreeC for 2 hours.

Thereafter, it was processed in the same manner as the manufacturing process of the existing floorboard to complete the waterproofing plywood reinforced floorboard laminated HPL reinforced with the glass fiber layer of the present invention.

The water-resistant plywood reinforced floorboard laminated with the HPL reinforced with the glass fiber layer of the present invention has a glass fiber layer 24 and a core layer 1 (23) on the upper HPL 20 'instead of omitting the lower HPL 30 of the conventional invention. By stacking the core HPL 20 of the new structure on the water-resistant plywood layer 10 by laminating it between the core layers 2 (25), the dimensional stability and curling properties are significantly improved, and the water-resistant plywood layer 10 is directly The adhesion was also excellent with the bottom.

Claims (3)

The adhesive layer is an upper high-pressure melamine laminate 20 in which core layer 2 (25), glass fiber layer (24), core layer 1 (23), shape paper layer (22) and surface protective paper layer (21) are laminated in order from the bottom. A water-resistant plywood laminate flooring laminated with a high-pressure melamine laminate reinforced with a glass fiber layer, which is configured to be laminated with the water-resistant plywood layer 10 with a 40 in between. According to claim 1, wherein the upper high-pressure melamine laminate 20 is the surface protective paper layer 21 is impregnated with a melamine resin in the overlay paper containing the evenly distributed wear-resistant silica or alumina in the cellulose paper, the shape paper layer 22 is oxidized Titanium-containing cellulose paper is impregnated with a melamine resin in a pattern paper on which a predetermined pattern is printed, core layer 1 (23) is impregnated with a resol-type phenolic resin in kraft paper, and the glass fiber layer 24 is made of glass filaments Woven in the form, it is impregnated with a resol type phenol resin after pretreatment with a coupling agent, or impregnated with a mixture of a coupling agent and a resol type phenol resin, and core layer 2 (25) is impregnated with melamine resin in kraft paper, The water-resistant plywood layer 10 is a pressurizing agent by pressing the 5-7 layers of the single plate using a phenol resin or melamine resin adhesive so that the grain direction is orthogonal. The water-resistant plywood reinforced floor board laminated with a high-pressure melamine laminated board reinforced with a glass fiber layer. The surface protection paper layer 21 is prepared by impregnating melamine resin in the overlay paper containing wear-resistant silica or alumina evenly distributed in the cellulose paper, and the shape paper layer by impregnating melamine resin in the shape paper on which titanium oxide-containing cellulose paper is printed with a predetermined pattern. (22) was prepared, and a kraft paper was impregnated with a resol-type phenolic resin to prepare a core layer 1 (23). The fabric was woven into glass using fiber filament, pretreated with a coupling agent, and then impregnated with a resol-type phenolic resin. Impregnated with a coupling agent and a resol type phenolic resin to prepare a glass fiber layer 24, and impregnated with melamine resin in kraft paper to prepare a core layer 2 (25). , The glass fiber layer 24, the core layer 1 (23), the shape paper layer 22 and the surface protective paper layer 21 in order, and then heated and pressurized to make the upper high-pressure melamine laminate 20, 5 to The 7-layer single plate was pressed using a phenol resin or melamine resin adhesive so that the grain direction was orthogonal to each other to form a water-resistant plywood layer 10, and then an adhesive made of a room temperature-curable urethane resin on the water-resistant plywood layer 10. After forming the adhesive layer 40 by using, the upper high-pressure melamine laminate 20 is placed on top of the adhesive layer 40 and pressurized at room temperature, the high-pressure melamine laminate reinforced with a glass fiber layer reinforced laminate How to make floorboards.