KR101243489B1 - Structure of composite core for wood flooring - Google Patents

Abstract

The present invention relates to a structure of a composite base material for flooring flooring, and more specifically, to develop an intermediate product between plywood and HDF, which is used as a base material of plywood flooring and reinforcement flooring, to secure price competitiveness and supply and demand stability of plywood, The present invention relates to a composite substrate having characteristics that ensure superior quality compared to HDF.

According to the present invention, by using a composite substrate structure in which two or more different kinds of wood materials are laminated in a variety of wood materials, raw materials that depend on imports due to the raw material wave of plywood used as the base of the existing plywood floor Even if prices soar, choosing a suitable floor substrate structure can ensure price competitiveness. In addition, HDF, which is a base material of reinforced floor, has a high absorption thickness expansion ratio with respect to moisture, and when the composite substrate is applied, this disadvantage can be overcome.

Flooring materials, composite materials

Description

Structure of composite core for wood flooring}

1 is a cross-sectional view of a composite substrate according to a first embodiment of the present invention.

2 is a cross-sectional view of a composite substrate according to a second embodiment of the present invention.

3 is a cross-sectional view of a composite substrate according to a third embodiment of the present invention.

4 is a cross-sectional view of the composite substrate according to the fourth embodiment of the present invention.

5 is a cross-sectional view of the composite substrate according to the fifth embodiment of the present invention.

6 is a cross-sectional view of a composite substrate according to a sixth embodiment of the present invention.

7 is a manufacturing process diagram of plywood.

8 is a manufacturing process diagram of a fiber board by the dry method.

9 is a manufacturing process diagram of a fiber board by a wet method.

<Description of the symbols for the main parts of the drawings>

10: veneer

20: Fibreboard (MDF / HDF)

30: Plywood

40: kenaf board

The present invention relates to the structure of the flooring composite material, and more specifically, to develop the intermediate products of plywood and HDF, which is used as a base material of plywood floor and reinforced floor, to secure price competitiveness and supply and demand stability of plywood, The present invention relates to a composite substrate having characteristics that ensure superior quality compared to HDF.

Generally, wood materials can be classified into six types: solid wood, modified wood, laminated composites, particle composites, fiber composites, and wood powder composites.

Modified wood includes preservatives, flame retardant, resin impregnated wood, chemically modified wood and gamma ray irradiated wood.

Laminates include parallel laminates such as aggregates and single plate laminates (LVL, PLV), orthogonal laminates such as plywood, oriented particle boards (OSB, OWB), sandwich composites, and mechanically bonded composites.

Particle composites include Chipboard, Flakeboard, Waferboard, Particle Board such as OSB (Oriented Strandboard), Insulation Board, Medium Density Fiberboard, There is a fiber board such as HDF (High Density Fiberboard).

Fiber composites include paper and fiber reinforced plastics.

Among the various wood materials mentioned above, plywood and HDF are used as the main materials of flooring.However, plywood, which is the base of plywood floor, is unstable in supply and demand, and there is concern about cost increase and resource depletion. It has a disadvantage of high absorption thickness expansion rate against moisture.

In particular, in the case of plywood, Indonesia, a major importer of domestic plywood, has strong restrictions on illegal logging, and the price has soared recently due to a sharp increase in demand for raw materials ahead of the Beijing Olympics in China.

Accordingly, there is a need for a substrate to replace the plywood, the requirement of the replacement substrate is that the price should be cheaper than the plywood, the physical properties should be equivalent to the plywood.

Japanese Patent No. 3753473 discloses a stucco plate, but the substrate has a single layer structure.

Japanese Patent No. 2925384 discloses a composite cosmetic flooring material, but uses plywood composed only of a single plate as a base material.

Japanese Patent Laid-Open No. 2006-7713 discloses a wooden composite stucco plate, but uses a synthetic rubber sheet in which impregnated paper is laminated on both sides as a substrate.

Japanese Laid-Open Patent Publication No. 1998-121706 discloses a composite floor having a heavy fiber plate as a surface layer, but uses a plywood composed of only a single plate as a base material.

Korean Utility Model Registration No. 250209 and No. 250210 disclose composite floorboards, but plywood is used as a base material.

An object of the present invention is to provide a composite substrate structure that is excellent in supply and demand stability and price competitiveness than plywood which is the main substrate of the floorboard material, and can secure an excellent absorption thickness expansion ratio than HDF.

In order to achieve the above object, the present invention provides a flooring material composite material, characterized in that two or more kinds of wood materials are laminated.

Wood materials used in the present invention is solid wood, veneer, plywood, particleboard, MDF (Medium Density Fiberboard), HDF (High Density Fiberboard), HPL (High Pressure Laminate), LPL (Low Pressure Laminate), OSB (Oriented Strand Board) ), Flake board (Flake board), Kenaf Board (Kenaf Board), corrugated cardboard, paper, and the like are two or more selected from wood materials.

The composite substrate according to the first embodiment of the present invention is composed of a single plate, a fiber plate, and a single plate from above. As the most preferable composite substrate structure of the present invention, the structure of this embodiment is particularly preferably composed of a single plate, an HDF, or a single plate.

The composite substrate according to the second embodiment of the present invention is composed of a fiber board, a end plate, and a fiber board from above. Moreover, the structure of a fiber board, a plywood, and a fiber board is also possible.

The composite substrate according to the third embodiment of the present invention is composed of a horse board, a fiber board, and a horse board from above.

Composite substrate according to a fourth embodiment of the present invention is composed of a single plate, plywood, single plate from above.

The composite substrate according to the fifth embodiment of the present invention is composed of a single plate, a fiber plate, a single plate, a fiber plate, and a single plate from above.

The composite substrate according to the sixth embodiment of the present invention is composed of a fiber board, a end plate, a fiber plate, a end plate, and a fiber board from above.

In the present invention, at least one layer of the composite substrate preferably includes at least one cured resin selected from epoxy, phenol, acrylic, melamine, polyurethane, unsaturated polyester, and diallyl phthalate.

The present invention relates to a composite substrate in which two or more kinds of wood materials are laminated in two or more layers in various wood materials to form a new structure.

Specifically, the composite substrate of the present invention, two or more wood materials of two or more wood materials, such as solid wood, veneer, plywood, particleboard, MDF, HDF, HPL, LPL, OSB, flake board, yam board, corrugated cardboard, paper, etc. The composite material is composed of a laminated structure, and in the case of a material having anisotropy, the physical properties of fiber orientation are considered, and examples of some of the laminated structures are the same as those of FIGS. 1 to 6.

When stacking two or more different wood materials in combination, the physical properties of each wood material inherent in density, moisture content, fiber anisotropy, etc., and the interactions between these different physical properties Consideration should be given.

As such, by analyzing factors that may affect product properties such as density, thickness, and water content, various products can be configured by selectively applying them according to the purpose of the product, raw material price, and supply and demand.

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

1 is a cross-sectional view of a composite substrate according to a first embodiment of the present invention. The composite substrate of this embodiment is composed of a single plate 10, a fiber plate 20, and a single plate 10 from above.

The veneer 10 is a veneer veneer used for plywood. The plywood veneer is usually cut to a thickness of 1.2 to 4.8 mm, but the appropriate thickness can be adjusted according to the structure of the specific flooring material.

The fiber board 20 has no orientation and is very inexpensive compared to plywood. MDF or HDF is used as the fiber board, and HDF is particularly preferable.

Among the configuration of Figure 1, the configuration of the veneer veneer, HDF, veneer veneer is the most preferable, because the price is cheaper than plywood, but the physical properties are close to the plywood level.

2 is a cross-sectional view of a composite substrate according to a second embodiment of the present invention, wherein the composite substrate is composed of a fiber board 20, a end plate 10, and a fiber board 20 from above. Moreover, the structure of the fiber board 20, the plywood 30, and the fiber board 20 is also possible.

Figure 3 is a cross-sectional view of a composite substrate according to a third embodiment of the present invention, the composite substrate of this embodiment consists of a horse board 40, a fiber board 20, a horse board 40 from above. The horse board 40 is a board made of Kenaf fibers, and has excellent heat resistance and strength.

4 is a cross-sectional view of the composite substrate according to the fourth embodiment of the present invention. The composite substrate of this embodiment is composed of a single plate 10, a plywood 30, and a single plate 10 from above.

Figure 5 is a cross-sectional view of a composite substrate according to a fifth embodiment of the present invention, the composite substrate of this embodiment is a top plate 10, a fiber board 20, a end plate 10, a fiber plate 20, the end plate 10 from above Is done.

6 is a cross-sectional view of a composite substrate according to a sixth embodiment of the present invention, in which the composite substrate is a fibrous plate 20, a single plate 10, a fibrous plate 20, a single plate 10, and a fibrous plate 20 from above. Is done.

In order to impart various functionalities in the composite substrate structure of the present invention, charcoal, loess, silver, elvan, germanium, at least one layer among the end plate 10, the fiber board 20, the plywood 30, the yam board 40, By adding functional materials such as magnetite, jade, antibacterial agent and insect repellent, it is possible to impart functions beneficial to health such as far infrared radiation function, anion divergence function, antibacterial function and insect repellent function. In addition, curing resins such as epoxy, phenol, acrylic, melamine, polyurethane, unsaturated polyester, and diallyl phthalate can be added to improve physical properties such as durability, abrasion resistance, water resistance, and the like, and calcium carbonate, talc and titanium oxide. , Fillers such as silica, glass powder, silicon dioxide, etc. can be added to provide functions such as good ball field effect and thermal conductivity improvement, including phosphoric ester, halogenated hydrocarbon, antimony oxide, aluminum hydroxy, phosphate compound, dicyandiamide, etc. Flame retardant can be added to provide flame retardant function.

Example 1

The end plate 10, the HDF 20, and the end plate 10 were integrated by pressing from above, thereby manufacturing a flooring composite material as shown in FIG.

At this time, as the end plate 10 applied to the upper layer and the lower layer, a thickness of about 1.2 mm and a water content of 12% were used. As the HDF 20, a specific gravity of 0.87, a water content of 7.6%, and a thickness of about 4.5 mm were used. It was. Melamine resin was used as an adhesive agent.

The basic manufacturing process is similar to the manufacturing process of the plywood described in Comparative Example 1, and the HDF substrate was applied instead of the middle plate of the plywood. Looking at the manufacturing process in detail, after laminating each layer was integrated into a press, the pressure was 8 kgf / ㎠, the pressurization time 6 minutes, the hot plate temperature was carried out at 125 ℃.

[Example 2]

The composite substrate as shown in Figure 3 made of a horse board 40, HDF 20, the horse board 40 from the above.

At this time, as the yam board 40 applied to the upper layer and the lower layer, the specific gravity was 0.71, the thickness was about 1.5 mm, and the moisture content was 7.1%. As the HDF 20, the specific gravity was 0.87, the moisture content was 7.6%, and the thickness was about 4.5. The thing of mm was used.

The manufacturing process is the same as in Example 1.

[Example 3]

From the above, a composite substrate as shown in Figure 2 made of HDF 20, plywood 30, HDF 20 was prepared.

At this time, as the HDF 20 applied to the upper layer and the lower layer, a thickness of about 1.0 mm and a water content of 7.6% were used. As the plywood 30, a 3 ply, a water content of 7.6%, and a thickness of about 5.0 mm were used. Melamine resin was used as an adhesive agent.

The manufacturing process is the same as in Example 1.

Example 4

The HDF 20, the end plate 10, the HDF 20, the end plate 10, and the HDF 20 were integrally formed by pressing from above to prepare a flooring composite material as shown in FIG.

At this time, as the HDF 20 to be applied, a thickness of about 1.0 mm and a water content of 7.6% were used, and as the end plate 10, a thickness of about 2.0 mm and a water content of 12% were used.

The manufacturing process is the same as in Example 1.

Comparative Example 1

Plywood is a plate-like product manufactured by stacking veneers, which are thin plates cut from solid wood, in an odd number of sheets so that the fiber directions are perpendicular to each other. In general, the single plate is made of 3, 5, 7, 9, etc., and is usually manufactured up to about 1 to 30 mm thick and 3 * 6 (91 * 182 mm), 4 * 8 (122 * 243 mm) There is a standard size of the back.

As shown in Figure 7, in general, the manufacturing process of the plywood goes through a series of steps as follows.

Peeling of solid wood → Cutting of solid wood → Cutting of single plate → Drying of single plate → Applying adhesive → Deposition → Pressed body → Final finishing

1) Peeling of solid wood: It removes foreign materials such as bark attached to the surface of wood and small stones attached to the bark during felling and transportation to protect the cutting edge when cutting single plate.

2) Cutting of wood: Generally, for the purpose of facilitating cutting and obtaining a good quality sheet, boiling or steaming in a closed chamber is performed. The wood is cut by margining the required plate dimensions.

3) Cutting of single plate: For cutting single plate, the method of cutting concentrically by rotating or circularly rotating solid wood or flitch (cut material prepared for cutting single plate), and cutting from flat plane to flat surface There is a way.

In the former, a rotary lathe or half-round rotary lathe is used, and in the latter a slicer or saw is used. These veneers are usually cut to a thickness of 1.6 to 4.8 mm (1/16 to 3/16 inch) and used to manufacture plywood, but in the case of cosmetic single plates, they are cut very thin to less than 0.8 mm (1/32 inch). Used for surface decoration of other materials. The wood chips to be cut are loaded in a single sheet cutter to cut to the required thickness.

4) Drying of Single Plate: Dry with hot air at 120 to 180 ° C and dry at a temperature of about 15 minutes to 3 hours. Dry with a roller dryer or net dryer. At this time, a continuous dryer for drying the continuous end plate as it is without cutting is also used. Moisture is removed from the veneer to adjust the adhesion or the quality of the final product to a suitable moisture content, which is generally dried to a water content of 5 to 10%.

5) Glue application: Glue is applied by using phenolic resin, lysosinol resin, melamine resin, urea resin, etc. In the case of adhesive with low viscosity and high fluidity, extender or filler is added to compensate for the defect. do. Wheat flour is usually added as an extender to urea resin adhesives and fine wood powder is usually added as fillers to phenolic resin adhesives. In addition, the urea resin adhesive is usually hot-pressed by adding 1 to 2% of ammonium chloride powder as a curing agent to the resin solids in order to promote hardening and complete curing.

A roller spreader is usually used to apply an adhesive blended with various additives to a single plate, which is 200 to 300 g / m 2 for a thin plate of 1.5 mm or less in thickness and 280 to 350 g for a thick plate of 3.0 mm or more in thickness. It is common to apply an adhesive with a coating amount of about / m2.

6) Deposition: The adhesive-coated veneers are constructed according to the specifications of the desired plywood and then stacked on top of each other until a certain quantity is reached. Bonding is completed by compressing the deposited material to reach a certain amount so that the adhesive hardens.

7) Compression body: Urea resin or phenol resin adhesive is bonded by thermo-pressure method. Currently, the method of hot pressing after cold pressing is widely used. For the purpose of easily putting in or taking out the thermopressor or minimizing damage during handling of the single plate, it is pressed at a pressure of 2 kg / cm 2 or more for 10 to 30 minutes in advance at room temperature or at a temperature of 30 to 40 ° C., and then between the hot plates of the thermocompressor. It is a method to harden an adhesive completely by putting into a set and heating and pressing.

The compaction temperature and the compaction time are generally applied at 100 to 130 ° C. for urea resin and 30 seconds per mm of plate thickness, and 130 to 150 ° C. for phenolic resin and 60 seconds per mm of plate thickness. The compaction pressure is differently applied depending on the specific gravity of wood from 5 to 7 kg / cm 2 for light timber such as paulownia to 15 kg / cm 2 or more for heavy timber such as thick wood.

8) Final Finishing: Plywood with adhesion by pressing body is cut into saws according to predetermined dimensions, and surface smoothing treatment is performed to remove unevenness of surface of plywood and to improve surface smoothness. Plywood cut to a certain size is smoothed by a belt scraper or drum sander with a scraper or abrasive cloth, usually by blades. It is shaved to a thickness of about 0.1 to 0.2 mm.

Comparative Example 2

Fiber board is a wood board material manufactured by using vegetable raw material as the main raw material and pulping it and then artificially frying it. Fibreboard is a soft fiber board (0.40 or less), Medium Density Fiberboard (MDF) (0.40 to 0.80), High Density Fiberboard (HDF) (hard fiber board: 0.80 to 1.20), depending on specific gravity, Superhard fiberboard (1.20 to 1.45). Among them, MDF and HDF are mainly used for furniture and interior materials, and among them, HDF is used as a base material of reinforced floor.

As shown in Figs. 8 and 9, the manufacturing method of the fibreboard includes a dry method (Fig. 8) of wetting and shaping the dried fibers using air as a dispersion medium, and a wet method of wetting and molding the pulp suspension using water as the dispersion medium. (FIG. 9).

In general, the fiber board manufacturing process is a series of steps as follows.

Peeling Wood → Crude Wood → Pulping → Sizing → Forming → Drying → Drying → Heat Pressure → Post Treatment

1) Raw material: Wood is most commonly used as a raw material for fiber board, and low specific weight wood is more preferable, because the cell wall is thin when pressed, so that the fiber is easily crushed. It is possible to combine.

2) Timber: Since pulp for fiberboard is usually produced from wood chips, the wood should be cut into chips using a chip cutter, a chip cutter. In the case of the purpose of a specific product, such as the manufacture of light-colored fiberboard, it is preferable to completely peel and then manufacture the chip because the bark may appear as spots of spots. Chips are shredded until larger than the standard dimension reaches a constant size, and screened off smaller than the standard dimension. The water content of the chip is most preferably at a level of 40 to 60% suitable for resolution.

3) Seapulps (pulping): For pulp for fiberboard, the higher yield pulp is better considering the price. High yield pulp contains a large amount of hemicellulose and lignin effective as adhesive components. In addition, the pulp for fibreboard should be pulp that is excellent in water drainage, that is, freeness because it is irritated onto a thick sheet. Chemical pretreated pulp (CGP, chemi-ground pulp) or semi-chemical pulp (SCP) may be used after the chip is treated with chemicals, but chemicals may be used to obtain high yield pulp. It is common to dissolve without using. Disc refiners are most often used for sea islands, but wood mills and aerators are sometimes used.

4) Sizing (sizing): In the fiber board, the sizing agent is used for improving water resistance and strength. Rosin, paraffin, tall oil and the like are used as the water-resistant sizing agent of the fiberboard, and the sizing agent is usually added in an amount of 1 to 2% based on the dry pulp. In order to effectively attach the sizing agent to the fiber surface, it should be added to the pulp (pulp slurry) suspended in water with a deposition agent such as aluminum sulfate. As the reinforcing size agent, synthetic resin adhesives such as phenol resin and urea resin, starch and the like are used.

In the case of a wet hard fiber plate, the main bonding source is due to the flow of lignin, which is a thermoplastic material, and some hydrogen bonding. However, a phenolic resin adhesive may be added to the total dry weight of the mat to improve binding strength. On the other hand, dry hard fiberboard is generally prepared by adding 2 to 3% of phenolic resin adhesive and 8 to 12% of urea resin adhesive to the total dry weight of the mat.

5) Forming: The method of forming a thick sheet-like mat from pulp is made of a wet method in which a pulp suspension having a concentration of 0.5 to 2% is made using a large amount of water, and then dehydrated and formed into a foam. The pulp may be divided into wet forming or air felting, in which the pulp is dried at a moisture content of 6 to 12% in a drier and then molded into an evaporation using the force of air.

6) Drying and hot pressure: The wet mat prepared by the agitator and then cut to a certain size is used for the purpose of producing a soft fiber board, or by pre-drying the wet mat by the wet method and then pressing to produce S-2-S fiber board. It is dried as a pretreatment for the purpose of doing so.

In order to quickly discharge moisture from the formed mat and to form interfiber bonds, a thermocompressor is used to heat pressure. A general method of wet heat pressure is a three-stage thermopressure method. A gold screen is attached to the bottom to remove the water contained at the time of hot press, leaving a mark on the board. In the case of a hard fiber board, the thermal pressure temperature is 180 to 200 ° C., and the time taken for one cycle is 5 to 8 minutes in the case of a hard fiber board having a thickness of 3.2 mm.

In the case of dry-formed mats, a two-stage thermopress method is generally used because the process of removing moisture is unnecessary. One-stage pressurization is performed for 5 to 12 seconds at a pressure of 60 to 80 kg / cm 2, and two-stage pressurization is performed for 1 to 3 minutes at a pressure of 20 to 40 kg / cm 2. At this time, the temperature of the hot plate is 180 to 200 ° C.

7) Post-treatment: Heat treatment, oil impregnation, and humidity treatment are performed to improve the strength and water resistance of the fiber board and to prevent distortion caused by uneven moisture absorption.

① Heat treatment: It is mainly treated to thin medium-density fiber board and hard fiber board manufactured by the wet method. When the fiber board is heated at 140 to 180 ° C. for 2 to 5 hours, the bending strength is improved by about 10 to 20%, and the absorption rate is about 10 to 30%. Degrades.

② Oil impregnation treatment: When the oil-impregnated fiberboard is heat treated to harden the oil, the material is improved more than the heat treatment alone. As with heat treatment, it is usually treated on thin medium-density fiber boards and hard fiber boards manufactured by the wet method. The oils used are linseed oil and tall oil, but recently there is no risk of ignition. Alkyd resin and phenol resin are used.

③ Humidity treatment: Since the fiber board after heat pressure or oil impregnation is close to 0% moisture content, when it is used as it is, the length or thickness expansion occurs due to moisture absorption. Moreover, distortion and the like occur due to non-uniform moisture absorption. In order to prevent such defects, the fiber board after the heat pressure or oil impregnation treatment is put into a humidity chamber and subjected to humidity treatment for 6 to 8 hours at 40 to 60 ° C. and a relative humidity of 90 to 95%.

④ Processing: The fiber board may be cut to a certain size or perforated depending on its purpose. In addition, anticorrosion, insect repellent, fireproof treatment, surface coating treatment, printing and the like may be produced in some cases. Medium-density fiberboards produced by the dry process usually provide surface adjustment by grinding.

[Test Example]

Absorption thickness expansion ratio was measured for the composite substrate, the conventional plywood, and the HDF substrate, and the results are shown in Table 1.

As can be seen in Table 1, the absorption thickness expansion ratio of the flooring composite material prepared in Example was superior to Comparative Example 2.

Here, the absorption thickness expansion ratio was measured by comparing the thickness before and after immersion in 20 ℃ water for 24 hours, 70 ℃ water for 2 hours in a constant temperature bath according to KSF 3200 standard.

Test Items Example 1 Example 2 Comparative Example 2 Absorption Thickness Expansion Rate (%) 20 ℃ 24 hours 4.54 7.53 23.02 70 ℃ 2 hours 33.44 25.84 138.04

The composite base material for flooring floorings presented in the present invention may bring cost saving effect of plywood replacement, which is unstable in supply and demand due to current raw material price hikes. In other words, price competitiveness can be secured when raw material supply and demand depend on imports. In addition, by stacking two or more kinds of wood materials in two or more layers, it is possible to secure a stable basic physical properties (absorption thickness expansion ratio) compared to HDF by reducing the cost.

In addition, by stacking two or more kinds of wood materials in two or more layers, it is possible to produce products of various structures, and it is possible to make products of various uses using materials that are easily supplied and have basic physical properties. It can induce differentiation from the product.

Claims (10)

Plywood made of veneer single plate, HDF and MDF, and fiber board are bonded to each other to form a composite substrate, and any one of these bonded substrates is added with far-infrared, anionic or antibacterial substance, and at least one layer of the composite substrate is epoxy, phenol, Composite base material for flooring flooring comprising at least one cured resin selected from acryl, melamine, polyurethane, unsaturated polyester, diallyl phthalate. delete The composite base material according to claim 1, wherein the composite base material comprises a single plate, a fiber board, and a single plate from above. The composite base material for floor flooring according to claim 1, wherein the composite base material is made of a fiber board, a end plate, and a fiber board from above. The composite base material for floor flooring according to claim 1, wherein the composite base material is made of fiberboard, plywood, and fiberboard from above. According to claim 1, wherein the composite substrate is a flooring material composite flooring, characterized in that consisting of a horse board, a fiber board, a sheep board. The composite base material for floor flooring according to claim 1, wherein the composite base material is composed of a single plate, a plywood, and a single plate from above. The flooring composite material according to claim 1, wherein the composite material is composed of a single plate, a fiber plate, a single plate, a fiber plate, and a single plate from above. The flooring composite material according to claim 1, wherein the composite material is composed of a fiber board, a end plate, a fiber board, a end plate, and a fiber board from above. delete

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