KR100392338B1 - Cork mat and the manufacture method - Google Patents

Abstract

The present invention relates to a cork nonwoven mat and a method of manufacturing the same, and relates to a cork nonwoven mat in which a cork is adhered to a mat or a bottom nonwoven fabric of a mat placed on a floor installation surface of various mats or mats. Cork's excellent insulation, insulation, and waterproofing by attaching members (small unit materials that process wood, bamboo, fibre-reinforced hardwood, ores, metals, etc.) to the nonwoven fabric of matting, and finishing them with a cork nonwoven fabric In the manufacturing method and method of cork non-woven fabric mat, which can produce a cozy indoor atmosphere by applying the functional aspect such as sound insulation effect and excellent elasticity and resilience, and natural beauty and luxury exudes from the cork pattern itself. It relates to a cork nonwoven mat manufactured by.

Description

Cork nonwoven mat and its manufacturing method {Cork mat and the manufacture method}

The present invention relates to a cork non-woven mat and a method of manufacturing the same. To avoid heat in summer and to cool and comfortable, there are many examples of using a mat made of royal, bamboo, solid wood, and pattern wood adhesive plate material indoors or on the floor. The known mat is made of hard and hard wood (wood, board, bamboo, royal etc.), and the wood is cut or made into a unit of a certain size and weaved with thread or bonded to a fabric or leather nonwoven fabric. There is a public utility model No. 1997-008013 (application number Utility Model No. 1995-020081) previously filed and published by the Korean Intellectual Property Office, and published number Utility Model No. 195-000440 (Application number 1995-022609) Ho).

In addition, natural veneer or bamboo is adhered to the plate, and there is a publication number Utility Model No. 2000-0002147 (Application No. 1998-12026) previously filed and published by the Korean Intellectual Property Office. It characterized in that it is configured by adhering the veneer having the same shrinkage to the material, characterized in that the material of the wood board is characterized in that the medium-density fiber plywood or high-density fiber plywood, there is a patent application No. 1998-0017837 In wood seats, the use of wood chips for mats by adhering the pattern wood to MDF or HDF is increasing.

However, in the prior art, when the mat is made of a hard material, the mat is laid on the floor, and the fatigue is felt due to the hardness while the mat is laid on the floor.

Moreover, it was only used in summer, because of the low thermal insulation and heat conduction of wood.

On the other hand, the use of cork is partly used as a shoe, flooring or wallpaper using the effects of the sound absorbing plate, its resilience, anti-decomposition and deodorizing effect, but the cork is a sound absorbing material, insulation, shoe, flooring, wallpaper It is used in part, etc., because it is thick due to the characteristics of the cork, it has a low density and strength, and the surface has a high risk of scratches or breakage. It is difficult to manage, complicated to construct, time-consuming and expensive, so its use is limited despite its excellent utility.

Therefore, the present invention solves the above problems at one time by adhering the unit member of the mat made of a hard material to the cork nonwoven fabric to take full advantage of the natural cushioning function of the comfortable cushion and cork during use, cool in the summer and warm in the winter The purpose is to provide.

In order to achieve the above object, the cork nonwoven mat of the present invention is a cork nonwoven mat made by contacting the unit member of the mat made of wood, bamboo, wood synthetic resin or metal, ore, with the cork nonwoven fabric, A cork sheet obtained by cutting a cork aggregate into a predetermined size, and a nonwoven fabric sheet attached to an adhesive having an application layer on one side of the sectioned cork sheet, the open pore or semi-open pore paint and transparent film on the surface Cork nonwoven fabric having any one of the waterproof coating layer, containing the fragrance, treated with a mat unit member attached to the adhesive having a coating layer on the cork nonwoven fabric, the cork sheet, the nonwoven sheet and The seat unit member is characterized in that it is finished with a border member on the edge of the thickness layer attached including the adhesive.

In addition, the present invention is characterized by consisting of a step of manufacturing a cork, a step of adhering the cork to a nonwoven fabric, and a step of adhering the unit member to the cork nonwoven fabric in a state where the cork is adhered by the adhering process.

1 is an exploded perspective view of the cork nonwoven fabric according to the present invention,

Figure 2 is an enlarged cross-sectional view of the cork nonwoven mat produced by the present invention,

Figure 3 is a process diagram for producing a cork nonwoven mat of the present invention,

4 is a partially exploded perspective view of the cork nonwoven mat according to the present invention;

5 is a perspective view of a unit member of the cork nonwoven mat,

6 is a partial cross-sectional view of the cork nonwoven fabric mat of FIG.

-Brief description of the major symbols in the drawings-

20: Cork 22: Cork aggregate

30: adhesive 30a: melamine resin 30c: hot melt adhesive

50: cork nonwoven fabric 50a: nonwoven fabric 51: nonwoven fabric sheet 200: unit member

Hereinafter, a manufacturing process of a known mat unit member will be omitted, and a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 is an exploded perspective view of a cork nonwoven fabric according to the present invention, Figure 2 is an enlarged cross-sectional view of the cork nonwoven mat produced by the present invention, Figure 3 is a process drawing for producing a cork nonwoven mat of the present invention 4 is a partially exploded perspective view of the cork nonwoven fabric mat according to the present invention, FIG. 5 is a perspective view of the cork nonwoven fabric mat member, and FIG. 6 is a partial cross-sectional view of the cork nonwoven fabric mat of FIG. 4.

First Embodiment

(Process for manufacturing cork-S1)

As a step (S1) for producing the cork 20 required to produce the cork nonwoven fabric 50 of the present embodiment, the cork 20 of the cork nonwoven fabric 50 is made of bark of the cork oak or of oak for the cork. The outer shell is boiled in boiling water to remove the hard outer layer and dried in the shade for several months.Then, it is placed in a metal mold and compressed into hot-baked plastics with hot or superheated steam. 22) or by crushing the cork (20) to make particles that can pass through 1 ~ 2mm of the sieve and put into a metal mold and compressed to hot-molded hot or superheated steam to produce a cork aggregate (22) do.

When the cork 20 is put into a metal mold and compressed to be heated and plasticized by heat or superheated steam, the cork 20 is stacked horizontally and pressed vertically to press the laminate to narrow the grain of the cork 20. It is possible to form a wide, it is important to determine the width of the cork 20 obtained by cutting from the cork aggregate 22 to the size of the mold, and determine the shape of the outer shape of the cork 20 according to the shape and shape of the mold To be an element.

That is, when the inside of the mold is circular, the cork 20 having a circular shape may be obtained, and the groove may be formed to form a prefabricated arrangement structure in order to facilitate the arrangement.

And, by changing the type of additives it is possible to obtain a cork 20 having a variety of patterns and colors.

For example, during molding, it is impregnated into the Meraman resin 30b, put into a metal mold, and compressed and heated and molded by hot or superheated steam to create a water-resistant water resistant coke, and resins such as urea and phenol It can also be made by adjusting the density, intensity | strength, or degree of elasticity of the cork 20 by adding.

Alternatively, it is possible to pursue additional functions by adding functional materials such as bio-ceramic or ocher or jade, magnet, germanium and charcoal, or to continuously express the fragrance by adding a fragrance material which can continuously smell, Any color may be obtained by adding colorants or dyes to express the color.

In order to obtain the cork 20 having an arbitrary thickness by cutting the cork aggregate 22 produced by the above process into a slicing machine or a rotary machine of the same principle as the planer, the thickness may be obtained differently depending on the use. will be.

In addition, it is put into a metal mold and compressed and heated and molded by hot or superheated steam to make a cork unit member 200 having a natural pattern and color of cork, or by grinding the cork 20 to obtain a 1-2 mm shaft. The unit member is formed during molding by heating and plasticizing the cork 20 by inserting it into a metal mold and compressing it by heating and molding the hot or superheated steam by compression into a metal mold. It is to be produced by the powder cork unit member 200 to be similar in shape to the same standard and 200).

In addition, the cork 20 was impregnated with a resin composed of the Meraman resin 30a and urea resin at about 35 ° C for about 24 hours to sufficiently impregnate the resin in the particles of the cork and then remove the resin by using a dehydrator. The water-resistant cork 20 can be made strong by heat and plastic molding by compression into a mold and hot or superheated steam, and the density, strength or elasticity of the cork 20 by adding a resin such as urea or phenol. To adjust.

Due to the characteristics of each cork 20, its structure and density or strength is weak, in order to compensate for the cork 20 made of cork non-woven fabric (50a; paper, impregnated paper, vinyl chloride, fabric, mesh, etc.) As a very thin thickness, excellent in tension and no peeling), or by attaching the cork unit member 200 made of each small sheet material to the nonwoven fabric 50a for cork, which is wider and more standardized, and further processed. It makes work easier.

(Process of bonding cork to nonwoven fabric-S2)

As the step (S2) of adhering the cork 20 to the nonwoven fabric sheet 51, the cork 20 to the natural cork 20 manufactured by the first step S1 of manufacturing the cork 20 is bonded to an adhesive ( 30) is applied to the nonwoven fabric sheet 51 to which the coating is applied, and is pressed and bonded by the press (6). The cork 20 is laminated or pulverized, placed in a mold, and heated and plasticized by hot or superheated steam to form the cork aggregate 22, and between the surface of the cork 20 and particles due to an adhesive or stabilizer added. When the adhesive to the adhesive material is impregnated, the residual water may cause the loosening of the cork 20 to the peeling between the corks 20 may occur.

In addition, due to the characteristics of the particles of the cork 20, the structure of the cork particles due to the expansion of the internal air is destroyed, or the swelling phenomenon occurs due to peeling between the cork and the cork, this problem is essentially prevented and the nonwoven fabric sheet 51 In order to minimize deformation caused by heat, they are compressed by cold press.

In order to adhere the cork 20 to the nonwoven fabric sheet 51, the adhesive 30 is applied to the nonwoven fabric sheet 51 by passing the nonwoven fabric sheet 51 through the spreader roller 5 on which the adhesive 30 is pumped. Done.

At this time, the adhesive 30 used is a vinyl acetate-based emulsion bond having a solid content of 48% or more, the compounding ratio of the emulsion bond 8 melamine 2 is suitable and 70 ~ 90ml / m2 in the application amount It is suitable to form.

In addition to the functional material, such as bio-ceramic, ocher or jade, magnets, germanium, charcoal, etc., to the adhesive 30, an additional color may be pursued, or a colorant or dye may be added to express an arbitrary color to obtain an arbitrary color. have.

The cork 20 is placed on the nonwoven fabric sheet 51 to which the adhesive 30 is applied, so as to fill the area of the nonwoven fabric sheet 51 so as to be aligned with each other, and the moisture of the adhesive 30 is evaporated. It is stable, and the reaction of drying or curing of the adhesive 30 starts and adhesive drying (which indicates a state in which the adhesive is dried or cured. When the surface of the applied adhesive is pressed by hand, the adhesive is applied but the adhesive is buried in the hand. In the non-state) is pressed for 40 seconds with a press and then the primary adhesion is completed by pressing the cork nonwoven fabric 50 again for about 3 hours until the adhesive 30 is completely dried.

At this time, if pressure is applied before the adhesive drying of the adhesive 30, the cork 20 overlaps or sags due to self-moisture of the adhesive 30, so that the surface layer is crying and the cork adhered when the water content is high ( 20) when the moisture content is lowered later acts as a cause of deformation due to cracking or peeling of the cork 20 or shrinkage and expansion of the cork nonwoven fabric 50.

As described above, the measurement of the deposition time after the deposition and the pressurization for a predetermined time depends on the working conditions, etc., which can be sufficiently sensed by those skilled in the art.

In addition, in the case where the cork 20 is attached to the nonwoven fabric sheet 51 by the press 6, in the case of the cork 20 manufactured by using an additive (such as a thermosetting resin) that does not react with some heat, Although heat compression may be performed to shorten the adhesion time, the temperature of the heat source directly transmitted to the nonwoven fabric sheet 51 and the cork 20 may be such that the cork particle structure is destroyed or swells due to peeling between the cork and the cork. In order to prevent this, 60 ° is preferable, and due to the nature of the cork 20, due to the thick or large particles, there is some embossing on the surface of the cork 20. By pressing a cushioning material such as a sponge on the cork 20 and pressing, even the recessed portion may be easily bonded.

(Process of bonding unit member and cork nonwoven fabric-S3)

The matting unit member is passed through a spreading roller (5) on which a hot melt adhesive (30c; an adhesive which is dissolved and applied by heat using a thermoplastic resin and then applied for a short time through a cooling process) is pumped. After coating on the back surface of the unit member 200, and then adhered to the cork non-woven fabric 50 and pressurized by the press (6) is made and then pressurized about 24 hours until the hot melt adhesive (30c) is completely reacted By loading, the coating material 200 and the cork nonwoven fabric 50 are completely bonded.

The functional material, such as bio-ceramic or ocher or jade, magnets, germanium, charcoal, etc. may be added to the adhesive 30c to pursue additional functions, and the coated nonwoven fabric impregnated with a thermoplastic adhesive may be coated with the coating material 200 and cork. Adhesion may be made by inserting between the nonwoven fabrics 50 and hot pressing.

In the above, the surface to which the cork 20 of the cork nonwoven fabric 50 is bonded may be located on the bottom surface of the wood carpet 1, and may be bonded to the unit member 200 to be formed inside.

Alternatively, the unit member 200 may be adhered to one surface of the cork nonwoven fabric 50 to which the cork 20 is adhered to both sides, and the other side may be exposed on the bottom surface of the wood carpet 1.

When assembling in the above process by cutting the cutting of the unspecified coating material (200) by using a cutting saw, the cutting foundation, wrapped around the edge of the wood carpet (1) with a rim (60) and then sewing using a sewing machine (70).

Alternatively, the corrugated nonwoven fabric 1 of the present embodiment is provided by forming a sewing groove 80 at an edge along the sewing line and wrapping it with an edge member 60 and then sewing 70 using a sewing machine.

Second Embodiment

Processed in the form of a powder and blended with the powder having a beneficial function to the human body, such as jade, germanium, ceramics, etc.,

A nonwoven fabric sheet 51 (a floor nonwoven fabric containing jade or charcoal, germanium, ceramics, magnets, etc.) is mounted on a conveying part of a known laminating machine and passes through its spreader roll 6 to thereby form a urethane bond 30c. (Bonding consisting of polyols (diols), diasocyanates, chain extenders, solvents, other additives, etc.) is applied and the adhesive drying of the urethane bond 30c proceeds through a drying chamber at 60 degrees Celsius for 5 seconds. The powdered cork 20 is sprayed onto the urethane bond 30c and bonded to it, pressurized by a rubber roller of a primary soft material, and then pressed by a rubber roller of a secondary hard material and subjected to a tertiary steel roller. After pressurized by passing through the drying chamber at room temperature, the remaining cork 20 in addition to the adhered cork 20 is removed with a brush and wind, pressurized with a fourth hard rubber roller and the temperature of the fifth surface is set to 80 degrees. By passing the steel roller is made adhesive.

Alternatively, the cork 20 to the cork unit member 200 may be adhered to the nonwoven fabric 50a for cork and then adhered to the nonwoven fabric sheet 51.

The nonwoven fabric sheet 51 is first cut to the size of the wood carpet (1), and then the adhesive 30 is applied to the cork 20 by the press 6 or the high frequency press 7 to attach the cork nonwoven fabric 50. It may be manufactured.

Then, the cork 20 on the upper part is polished with the paper of the first 220 # particles, and the paper of the second 440 # particles is polished, and the rough and uneven parts of the surface are polished by a grinder or by hand to remove impurities and contamination on the surface. The remaining cork 20 is removed, and additional functions are added to the urethane bond 30c or vinyl chloride used at this time by adding functional materials such as bio ceramics or ocher to jade, magnets, germanium, and charcoal. It is also possible to carry out what is manufactured in pursuit.

The coating layer 40 may be applied as necessary to protect the surface of the cork nonwoven fabric 50 from surface contamination or scratches, and to express the beautiful pattern and color of the cork 20 as it is, such as paint and transparent vinyl. Way.

First, the coating layer 40 by the paint has a cork nonwoven fabric 50 and the cork 20 of the upper part is polished by using a grinder or manual work to rough the rough and uneven parts of the surface with paper of 200 # ~ 500 # particles. After cutting and smoothing out impurities or deposits on the surface, first coating with isolator paint 40a and spray coating with open poa or semi-open pore coating with paint of known urethane 40d. It is good to use flexible paint with good flexibility.

The above coating is repeated several times when the desired degree of coating or smoothness cannot be obtained.

Alternatively, the transparent vinyl chloride to transparent film 40c is pressed by a press 6 or compressed by a roller to obtain an effect as described above.

This is due to the flexibility and soft texture that the paint cannot keep up with, and the film or vinyl 40c forming the coating film completely shields the penetration of moisture or foreign matter from the surface, and preserves its color or quality for a long time. The simplicity of work is very great.

Alternatively, the transparent vinyl chloride to transparent film 40c may be adhered to the cork nonwoven fabric 50, but the transparent vinyl chloride to transparent film 40c may be placed on the sewing machine 70 by sewing.

The coating 40 may be applied by a paint, or the transparent vinyl chloride or the transparent film 40c may be pressed by a press 6 or compressed by a roller to obtain an effect of the above coating.

If necessary, the above process is repeated to produce a cork nonwoven fabric 50 having the cork 20 adhered to both sides of the nonwoven fabric sheet 51.

The unit member is attached to the cork nonwoven fabric to make a mat, so the natural hygiene of the cork, strong deodorizing power, indoor humidity control, sound absorption and sound insulation, antistatic, heat insulation and insulation, excellent elasticity, antibacterial and anti-corrosive and strong elasticity, etc. In addition, the above-mentioned cork is used for wood carpets, and in one cubic inch of cork, 200 million cells are each packed in a resin film and filled with air, and half of the volume is filled with air. It has the characteristic of returning to its original state even after being pressed, so it is possible to minimize the phenomenon such as scratches and squeezing during use, and it is less fatigue due to the softness and elasticity, which is the characteristic of cork, and especially in accidents such as the elderly and children falling down. Cork's elasticity can reduce its impact and protect against injuries And it can be significantly reduced because of the noise absorbing property of cork can also be called its features.

Thus, it is harmless to the human body, can meet the desire of the user to pursue a healthier and more vigorous life using environmentally friendly materials, and can obtain a cork non-woven fabric mat that can always produce a cozy indoor atmosphere.

Claims (8)

In the cork nonwoven fabric mat made by adhering the unit member of the mat made of wood, bamboo, wood synthetic resin, metals or ores with the cork nonwoven fabric, The non-woven fabric sheet 51 attached to the adhesive sheet 30 having a coating layer on one side of the corrugated sheet, which is obtained by cutting the hot-rolled calcined cork aggregate into a predetermined size, A cork nonwoven fabric 50 having a waterproof coating layer 40 of any one of an open pore or semi-open pore paint and a transparent film on the surface, and containing a fragrance, and on the cork nonwoven fabric 50. The mat unit member 200 attached on the adhesive 30c having the coating layer, the cork sheet 20, the nonwoven sheet 50 and Cork non-woven fabric mat, characterized in that the seat unit member 200 is configured to finish with a border member 60 on the edge of the thick layer attached, including the adhesive (30, 30c). The cork nonwoven fabric mat according to claim 1, wherein the cork nonwoven fabric (50) is made by adhering powdered cork to a nonwoven fabric sheet (51). The cork sheet 20 is bonded to both sides of the cork nonwoven fabric 50, and the mat unit member 200 is adhered to one surface of the cork sheet 20 of the cork sheet 20. Cork nonwoven fabric mat characterized in that it became. delete delete delete Process (S1) for manufacturing the cork 20, Adhering the cork 20 to the nonwoven fabric sheet 51 (S2), Cork nonwoven fabric manufacturing method characterized in that the unit member 200 and the cork non-woven fabric (50) bonding step (S3). The cork non-woven fabric mat of claim 1, wherein the adhesive for adhering the mat unit member 200 and the cork nonwoven fabric 50 is bonded with a thermoplastic hot malt.