KR200218821Y1 - Melamine laminating sheet having superior dimensional stability and warp stability property - Google Patents

Abstract

The present invention relates to a melamine cosmetic plate for floor decoration, and more particularly to a melamine decorative plate having excellent dimensional stability and flexural stability.

The present invention for this purpose, the present invention in order to achieve the above object, from the melamine decorative plate comprising a surface protective layer 153, shape layer 152 and core layer 151 from above, the core layer 151 The glass fiber layer 162 is a glass fiber woven fabric having a Tex of 11.2 to 136 and a density of 6 to 30 (inclined) x 10 to 36 (weft), or a glass fiber nonwoven fabric having a basis weight of 40 to 120 g / m 2. It provides a melamine decorative plate comprising a).

Melamine decorative plate including the glass fiber layer of the present invention in the core layer shows excellent dimensional stability and flexural stability, and the flooring material produced by laminating it has excellent curling and dimensional stability, so when it is applied to the floor, the gap or seam of the seam is raised. There is almost no phenomenon, and the walls, table surface materials and partitions manufactured by laminating them have very high dimensional stability during use, so that there are almost no problems such as deformation and warping due to heat or moisture.

Description

MELAMINE LAMINATING SHEET HAVING SUPERIOR DIMENSIONAL STABILITY AND WARP STABILITY PROPERTY}

[Industrial use]

The present invention relates to a melamine decorative plate, and more particularly to a melamine decorative plate having excellent dimensional stability and flexural stability. More specifically, the present invention relates to a decorative plate that can be used for flooring, test top, furniture, interior walls of ships, etc. by adhering to a base layer such as vinyl chloride sheet, a water-resistant plywood, particle board, MDF, or HDF.

[Prior art]

In general, decorative laminates are decorative laminates having a shape such as wood grain, the surface of which is usually a thermosetting resin, melamine (resin) cosmetics, diallyl phthalate (resin) decorative plates, polyester (resin) There is an example of a makeup plate. In particular, melamine boards have very good surface strength, which makes them difficult to scratch, and thus have high practical value as interior materials for table tops, furniture surfaces, building materials, and vehicles.

As shown in Fig. 1, a normal melamine decorative plate has a surface protective layer (1) of melamine resin impregnated overlay paper, a shape layer (2) of melamine resin impregnated paper, and a core layer (3) of phenol resin impregnated paper from above. It is manufactured by high pressure laminate with a multi-stage press superimposed in layers. In this case, the core layer (or core material layer) 3 is used to impregnate the kraft paper with phenolic resin, and the shape layer (2) is used to impregnate the printed paper with melamine resin, the surface protective layer (1) The impregnated melamine resin in the overlay paper is often used. The decorative plate thus obtained has a thickness of 0.3 to 3 mm (thickness is determined by the number of core layer-impregnated papers), and other substrates (for example, veneer or particle board, etc.) with the back surface roughened to facilitate adhesion. Synthetic wood).

However, these decorative plates lack flexibility and impact resistance, have a large shrinkage expansion due to environmental changes, and lack of cushioning and sound absorption, so it is very difficult to apply them as flooring materials as they are attached to a floor such as cement.

In general, floor finishing materials of commercial buildings have been used to polish stone or vinyl chloride tile. However, the stone is excellent in durability, but high in price, heavy, difficult to process, and ordinary vinyl chloride tiles are processed by coloring, etc., and are lightweight, flexible, and have excellent cushioning and sound absorption properties. It was difficult to show a beautiful surface, and there was a problem of lack of wear resistance required for flooring.

In order to improve the vinyl chloride tile, a flooring material having the melamine decorative plate attached to the vinyl chloride tile has been used. Vinyl chloride-based flooring materials using a common melamine resin are disclosed in Japanese Patent Application Laid-Open No. Hei 4-101846 and U.S. Patent No. 5,780,147. As shown in Figs. 5 and 6, these are transparent protective layers (overlay layers) 5, 9, shape layers 6, 10, adhesive layers 7, 11, and base layers (vinyl chloride sheet) from above. Layer) (8) (12) has the advantages of the wear resistance of the melamine resin of the surface layer and the vinyl chloride sheet of the base layer, but the dimensional stability and the warpage stability is not good, and if there is a surface defect in the vinyl chloride sheet There was a problem that the defect is transferred to the melamine resin impregnated paper layer on the surface.

Complementing such a conventional vinyl chloride flooring material, Korean Laid-Open Patent Publication No. 99-30751 discloses a melamine sheet laminated vinyl chloride floor decoration material as shown in FIG. Using the balance layer 140 sheeting a glass fiber, pulp, paper, etc. into a woven fabric, a nonwoven fabric, or wodding, complements the dimensional stability and the bending stability, and provides the core layer 151 under the shape layer 152. This solves the problem that the surface defects of the vinyl chloride sheet base material 100 are transferred to the melamine resin impregnated paper layer 150. However, the melamine sheet laminated vinyl chloride flooring material was not satisfactory in dimensional stability and flexural stability.

In addition, to supplement the melamine sheet laminated vinyl chloride flooring material, Korean Patent Application No. 99-12854 discloses a sheet, a woven fabric, between the melamine resin impregnated paper layer 150 and the substrate layer 100 of the vinyl chloride sheet, as shown in FIG. Disclosed is a vinyl chloride resin floor decorative material having a non-woven fabric or a balance layer 140 made of a material selected from the group consisting of melamine or phenol resin impregnated paper. This floor decoration material greatly complements the bending stability by adhering through the balance layer 140, but specifically presents a method of completely controlling the degree of contraction and expansion with respect to temperature and humidity of various layers generated by using a plurality of layers. Considering that the basic matrix of the flooring material is a resin, there is still a big problem in the gap between the seam and the lifting phenomenon before and after construction because the change in dimensions due to moisture and temperature coming from the floor to be constructed is not considered.

Accordingly, an object of the present invention is to provide a melamine decorative plate having greatly improved dimensional change due to flexural stability and shrinkage expansion.

Another object of the present invention is to provide a melamine decorative plate with little gap between the seam and the lifting phenomenon before and after construction.

1 is a cross-sectional view (comparative example 1) of a general melamine decorative plate.

2 is a cross-sectional view (comparative example 2) of a conventional melamine decorative plate.

Figure 3 is a cross-sectional view of the melamine decorative plate for the floor decoration of Examples 1, 2, 3, 4, 5, 9, 10, 11, 12, 13 of the present invention.

Figure 4 is a cross-sectional view of the melamine decorative plate for the floor decorative material of Example 8 of the present invention.

5 is a cross-sectional view of a conventional melamine decorative plate laminated flooring material.

6 is a cross-sectional view of a conventional melamine decorative plate laminated flooring material.

7 is a cross-sectional view of a conventional melamine decorative plate laminated flooring material.

8 is a cross-sectional view of a conventional melamine decorative plate laminated flooring material.

Figure 9 is a cross-sectional view of Examples 14, 15, 16, 17, 18 of the flooring material prepared using the melamine decorative plate of the present invention.

10 is a cross-sectional view of Example 19 of the flooring manufactured using the melamine decorative plate of the present invention.

11 is a cross-sectional view of Comparative Example 3 of the flooring material prepared using a typical melamine decorative plate.

12 is a cross-sectional view of the floor decorative material of Comparative Example 4 prepared using a conventional melamine decorative plate.

Fig. 13 is a cross-sectional view of the table or wall surface material of Example 22 prepared using the melamine decorative plate of the present invention.

It is sectional drawing of the table or wall surface material of the comparative example 5 manufactured using the conventional melamine decorative plate.

15 is a cross-sectional view of the partition of Example 23 prepared using the melamine decorative plate of the present invention.

16 is a cross-sectional view of the partition of Comparative Example 6 manufactured using a melamine decorative plate of the present invention.

Reference numeral 1 is a surface protective layer of the melamine resin impregnated overlay paper, 2 is a shape layer of melamine resin impregnated paper, 3 is a core layer (core material layer) of phenol resin impregnated paper, 5 is an overlay layer, and 6 is a resin impregnated layer. Shape layer, 7 is adhesive layer, 8 is base material layer, 9 is resin impregnated overlay layer, 10 is resin impregnated overlay layer, 11 is hot melt resin adhesive layer, 12 is rubber or thermoplastic resin layer, 100 is Base layer, 110 is easy layer, 130 is adhesive layer, 140 is balance layer, 150 is resin impregnated paper layer, 151 is core layer, 152 is shape layer, 153 is surface protective layer, 161 is melamine A core layer using a resin impregnated paper, 162 is a glass fiber layer, 163 is a core layer using a phenol resin impregnated paper, and 170 is an HPL sheet.

[Means for solving the problem]

The present invention, in order to achieve the above object, in the melamine decorative plate comprising a resin impregnated paper layer comprising a surface protective layer, shape layer, core layer from above,

The core layer has a Tex of 11.2 to 136, a warp number of 6 to 30, a weft number of 10 to 36 glass fiber woven layer, or a basis weight of 40 to 120 g / m 2 glass fiber nonwoven layer. It provides a melamine vanity board comprising.

Hereinafter, the present invention will be described in detail.

[Action]

The present invention greatly improves the dimensional stability and the bending stability of the melamine decorative plate by including a specific glass fiber layer 162 in the core layer 151 of the melamine decorative plate. In particular, the vinyl chloride flooring material attached to the melamine decorative plate of the present invention is stable by the core layer 151 including the glass fiber layer 162 without the balance layer 140 (or the bending stop layer) at the bottom of the flooring material. It has been shown to show excellent dimensional stability and bending stability. In addition, the wall, the table surface material and the partition and the like attached to the melamine decorative plate of the present invention is very excellent in the dimensional stability in use, so that there are almost no problems such as deformation, distortion by heat or moisture.

To this end, the melamine decorative plate of the present invention includes a woven or nonwoven fabric as a glass fiber layer 162 in the core layer 151, and the glass fiber layer 162 is impregnated with a phenolic resin. It is more preferable to use.

The woven fabric of the glass fiber layer uses a glass fiber of E-glass composition manufactured by a loom. Such glass fiber woven fabrics are first warped (warp) process for manufacturing warp, sizing for starch coating on warp, beaming for winding manufactured yarn, and warp tying for spreading the yarn for weaving ( warp tying, weaving weaving, heating, heating, winding, and the like.

The glass fiber woven fabric is preferably a tex (tex) of 11.2 to 136. Fiber yarns are generally not circular in shape, so rather than measuring thickness or thickness directly, the concept of tex is used to check the thickness or thickness indirectly. Tex (tex) is a term indicating the thickness of the glass fiber, which means the number of grams of glass fiber required to produce a fiber chamber of 1,000 m, the larger the tex means to use a thicker glass fiber. Another expression is the internationally standardized concept of the yarn count, which indicates the thickness of a glass fiber in how many yards a pound of fiber is.

If the tex of the fiberglass woven fabric used is less than 11.2, the thickness of the thread is so thin that it is difficult to meet the dimensional stability required after the melamine decorative plate is produced, and the sheet of the fiberglass woven fabric is so flexible that the workability (lamination) ) Becomes very bad.

In addition, when the texture of the glass fiber woven fabric is larger than 136, the thickness of the yarn increases, so that the traces of the glass fiber layer may appear on the surface when the melamine decorative plate is manufactured, and the layer is separated by the weak adhesion between the glass fiber layer and the upper and lower layers. May appear.

Therefore, in order to include the woven fabric made from the glass fiber in the core layer of the melamine decorative plate, it is preferable to select according to the tex and the density criteria shown in Table 1.

TABLE 1

Tex (tex; g number / 1000M fiber) Yarn count (yard count / fiber 1 lb) Fiberglass woven density (number of slopes x number of wefts) 136 37 x 100 6-14 x 10-16 68 75 x 100 8-16 x 12-20 34 150 x 100 10-20 x 15-25 22.5 225 x 100 12 to 24 x 18 to 30 11.2 450 x 100 16-30 x 22-36

The density of a glass fiber woven fabric shows the number of glass fiber oar which enters 1 inch of width | variety, length, and is shown by the diagonal (vertical) x weft (horizontal). When the glass fiber woven fabric having a density lower than the density shown in Table 1 is used, it is difficult to match the required dimensional stability, and because the density is low, the fiber is sparse, so the flexibility of lamination is poor, and the lamination workability is also reduced. If a glass fiber woven fabric of higher density is used, traces of the glass fiber layer may appear on the surface of the melamine decorative plate, and the adhesion between the upper and lower glass fibers may be weakened due to the high density, resulting in interlayer separation.

In general, melamine decorative boards are used by impregnating a resin in paper, and since the dimensional stability and the warpage stability in the width direction (W direction) of the paper are worse than in the longitudinal direction (L direction), the glass fiber woven fabric is the weft side rather than the inclined side. It is preferable to use the reinforcement.

The glass fiber woven fabric used in the present invention is particularly preferably woven with plain weave, and more preferably, low density, loose plain. The more dense fiberglass woven fabric is used, the better the dimensional stability of melamine board, but on the contrary, adhesion with phenol resin impregnated paper (163) or melamine resin impregnated paper (161), which is another layer of core layer, becomes poor. It is better to use fiberglass woven cloth.

The glass fiber woven fabric may be woven with satin, mock leno, twill, etc., but may have problems when applied to the core layer with the glass fiber layer of the present invention. That is, in the case of runners and twills, the tissue is loose and does not have a great effect on the stability of the dimensional, while the woolen yarns and twills have an effect on the dimensional stability, but the traces of the glass fiber layer remain on the surface.

The nonwoven fabric of the glass fiber layer has an E-glass composition, and cuts a glass fiber having a fiber diameter of 6 to 30 μm into a length of 10 to 50 mm, and then mixes and mixes pulp and binder (needle). It is preferred to be made of sheets in a machine. As for the basis weight of the glass fiber nonwoven fabric used for the core layer of a melamine decorative board, 40-120 g / m <2> is preferable.

The glass fiber woven or nonwoven fabric may be impregnated with the glass fiber by pretreatment with a coupling agent (coupling agent) or by mixing the coupling agent in the phenolic resin to increase the bonding strength of the phenolic resin and the glass fiber during or before the impregnation of the phenolic resin. Coupling agents include silanes and titanates, and are selected and used according to the properties of the phenol resin. The method of use is preferably 0.1 to 0.5% by weight of the phenolic resin. In case of pretreatment, it is mixed with water or a solvent to impregnate and dry the fiberglass woven or nonwoven fabric in advance. Or after mixing with a solvent, this mixture is mixed with a phenol resin and used. The glass fiber layer 162 itself is very excellent in the dimensional stability, and when positioned in the core layer 151 can provide excellent dimensional stability to the resin impregnated paper layer 150 forming a melamine decorative plate.

The core layer of the present invention may include a phenol resin impregnated paper 163 or a melamine resin impregnated paper 161 in addition to the glass fiber layer. The core layer 151 provides a thickness while supporting the surface protection layer 153 and the shape layer 152 positioned thereon, and may also serve as a base layer composed of a sheet of melamine decorative plate. In addition, several sheets may be used depending on the thickness.

The phenolic resin impregnated paper 163 is prepared by impregnating 40 to 150% by weight of the phenolic resin in kraft paper having a basis weight of 80 to 300g / ㎡. The phenol resin used in this case is a resol type, 30 to 46% by weight of phenol, 46 to 30% by weight of formaldehyde, 4 to 6% by weight of ethyl alcohol as a solvent, 2 to 5% by weight of water, and a basic catalyst of an amine system which is a modifier 15 It is preferable to mix 5 wt% to 3 wt% ortho-cresol and 3-8 wt%.

The melamine resin impregnated paper 161 is prepared by impregnating melamine resin 40 to 150% by weight relative to the basis weight of kraft paper having a basis weight of 80 to 300g / ㎡. The melamine resin used here is 30 to 45% by weight of melamine, 40 to 20% by weight of formaldehyde, 18 to 27% by weight of water as a solvent, 1 to 5% by weight of modifier diethylene glycol or acetoguanamine, sodium hydroxide as a pH adjuster. It is preferably prepared by mixing 10 to 2% by weight of the basic catalyst of the amine system with about 1% by weight and a curing agent.

For reference, the method of calculating the impregnation amount is obtained by subtracting the weight before impregnation from the weight after impregnation in the same area, dividing it by the weight before impregnation, and multiply by 100.

The melamine resin impregnated paper 161 provides excellent flexural stability to the resin impregnated paper layer when positioned at the lowest layer of the core layer 151. In other words, when the composition of the resin impregnated paper layer is composed of the surface protective layer 153, the shape layer 152 and the core layer 151 from above, it is located at the lowest layer to balance the force acting on each layer in the same manner. can do. In particular, the same resin as that of the melamine resin of the uppermost surface protective layer 153 is balanced. In addition, it helps to maintain the force balance of the vinyl chloride sheet base material layer, which is a general base material adhered to the melamine decorative plate thereunder.

The melamine decorative plate of the resin-impregnated paper layer 150 including the phenol resin-impregnated paper 163, the glass fiber layer 162, and the melamine resin-impregnated paper 161 in the core layer 151 of the present invention has dimension stability and flexural stability. This is an excellent balance of power between layers. Therefore, in the case of a melamine decorative plate laminated vinyl chloride flooring material manufactured by a method of adhering a melamine decorative plate formed at a high pressure with an adhesive such as a vinyl chloride sheet, which is a general substrate, and integrating the core layer of the present invention, When used as the core layer 151, it is very effective and can provide excellent dimensional stability and bending stability without attaching the balance layer 140 to the lower portion of the vinyl chloride sheet as in the prior art, together with the balance layer 140 When used, they provide better dimensional stability and flexural stability. Melamine decorative plate including the core layer 151 of the present invention may be manufactured in various forms and depends on the shape and order of the core layer 151. The type of core layer of the melamine decorative plate to which this is applied is as follows.

The first type of core layer 151 is from above

Glass fiber layer (162)

It includes.

The second type of core layer 151 is from above

) Phenol resin impregnated paper (163)

Ii) glass fiber layer 162

Ⅲ) Melamine resin impregnated paper (161)

It includes.

The third type of core layer 151 is from above

Glass fiber layer (162)

Ii) phenol resin impregnated paper (163)

It includes.

The fourth type of core layer 151 is from above

Iii) glass fiber layer 162 of the present invention

Ii) Melamine resin impregnated paper of the present invention (161)

It includes.

The fifth type of core layer 151 is from above

Ⅰ) Melamine resin impregnated paper (161)

Ii) glass fiber layer 162

Ⅲ) Melamine resin impregnated paper (161)

It includes.

The sixth type of core layer 151 is from above

) Phenol resin impregnated paper (163)

Ii) glass fiber layer 162

) Phenol resin impregnated paper (163)

It includes.

The seventh type of core layer 151 is from above

Ⅰ) Melamine resin impregnated paper (161)

Ii) glass fiber layer 162

) Phenol resin impregnated paper (163)

It includes.

Melamine resin impregnated paper, glass fiber layer, and phenolic resin impregnated paper included in the core layer of the present invention may each use two or more sheets as necessary.

The melamine decorative plate of the present invention is a melamine decorative plate including a surface protective layer 153, a shape layer 152, and a core layer 151 from above, and may be used by laminating one or more layers of the core layer 151. have.

In addition, the melamine decorative plate of the present invention may include a separate balance layer 140 between the core layer and the core layer or be included under the core layer, if necessary. The balance layer 140 is preferably a woven fabric, a nonwoven fabric, or a sheet processed with natural fibers by wadding, and the woven fabric or nonwoven fabric is glass fiber, carbon fiber, polyethylene terephthalate (PET), polypropylene, polyester Or from fibers such as nylon. These woven fabrics, nonwoven fabrics, or natural fiber sheets can also be used by impregnating them with melamine resin, phenol resin, or the like.

The type of melamine decorative plate comprising this balance layer 14 is from above.

I) surface protective layer (153).

Ii) shape layer 152

Iii) core layer 151 of the present invention

I) Balance layer 140

Iii) core layer 151 of the present invention

Can be stacked to

I) surface protective layer (153).

Ii) shape layer 152

Iii) core layer 151 of the present invention

I) Balance layer 140

It can also be placed and stacked.

Hereinafter, layers other than the core layer 151 of the present invention will be described in detail. The surface protective layer 153 positioned on the top layer of the resin impregnated paper layer 150 may be 150 to 20 weight percent of overlay paper on overlay paper in which wear-resistant silica or alumina is evenly distributed on cellulose paper of 20 to 80 g / m 2. Preferred is a resin-impregnated cellulose prepared by impregnating 300% by weight of melamine resin and then drying it in an oven at 100 to 150 ° C. and semi-curing it. At this time, the surface protection layer 153 has abrasion resistance of about 200 to 20,000 times when the surface protection layer 153 is polished by wear paper. The surface protective layer 153 is intended to secure surface properties such as wear resistance, scratch resistance in the flooring material.

The melamine resin is 30 to 45% by weight of melamine, 40 to 20% by weight of formaldehyde, 18 to 27% by weight of water as a solvent, 1 to 5% by weight of diethylene glycol or acetoguanamine as a modifier. It is prepared by mixing about 10 wt% to about 1 wt% of sodium hydroxide as a pH adjusting agent and a basic catalyst of an amine system with a curing agent.

The shape layer 152 positioned below the surface protection layer 153 is 60 to 150% by weight based on the weight of the shape paper on the paper of 60 to 150 g / m 2 of titanium oxide-containing cellulose on which a predetermined pattern is printed by a method such as gravure. The impregnated melamine resin and then dried in an oven at 80 to 150 ℃ and at the same time semi-cured resin impregnated titanium paper (titan paper) is prepared. The shape layer 152 gives a shape that represents the decorative beauty of the melamine decorative board (and finally the flooring material) by the printing pattern effect created. The melamine resin impregnated in the shape layer 152 may use the same melamine resin as the surface protection layer 153, and may be a diallyl phthalate resin, a polyester resin, or a phenol resin in addition to the melamine resin.

In the melamine decorative plate of the present invention, the surface protection layer 153, the shape layer 152, and the core layer 151 described above are laminated from above, and then the temperature is 130 to 160 DEG C and 50 to 100 kgf / 2 cm, the compression time is preferably prepared, including the step of pressing for 30 to 90 minutes to produce a decorative plate. The crimping conditions in the hot press can be appropriately changed depending on the use of the decorative plate of the present invention.

There are two ways to apply the melamine vanity of the present invention. One method is to laminate each layer of the melamine decorative plate as in the manufacturing method and press-molded by a separate heat press to prepare a melamine decorative plate first, and then laminate it on the substrate 100 to attach the adhesive layer 130 (HPL; high pressure laminates method). The other is a method of separately manufacturing each layer of the melamine decorative plate on the base layer 100 and then laminating them by press molding using a hot press (LPL; low pressure laminates method).

This application method may vary depending on the substrate to which the decorative plate is attached, but specific examples of the method of manufacturing a melamine decorative plate laminated flooring material are as follows.

One application method is a melamine decorative sheet laminated flooring material comprising a resin impregnating layer 150 and a substrate layer 100 including a surface protective layer 153, a shape layer 152 and a core layer 151 from above. In the manufacturing method,

a) After stacking the surface protective layer 153, the shaping layer 152, and the core layer 151 from above, the temperature is 130 ~ 160 ℃, pressure 50 ~ 100 kgf / ㎠, compression time 30 ~ 90 in a hot press Compacting for minutes to produce HPL; And

b) preparing an adhesive layer 130 by applying 80 to 300 g / m 2 of an adhesive on the base layer 100 or laminating an adhesive film; And

c) laminating the HPL sheet of step a) on the base layer 100 on which the adhesive layer 130 of step b) is formed, and in a hot press, a temperature of 60 to 140 ° C., a pressure of 5 to 30 kgf / cm 2, and a pressing time of 40 to Pressing for 90 minutes.

Another method of application is a melamine decorative sheet laminated flooring material comprising a resin impregnating layer 150 and a base layer 100 including a surface protective layer 153, a shape layer 152 and a core layer 151 from above. In the manufacturing method of

a) laminating the surface protective layer 153, the shape layer 152, and the core layer 151 on the base layer 100 from above; And

b) pressurizing and heating the laminated sheets of step a) at a pressure of 3 to 30 kgf / cm 2 and a temperature of 130 to 160 ° C. in a thermopress press for 40 to 80 minutes.

In the above manufacturing method, the resin impregnated paper layer 150 and the base material layer 100 may be laminated by interposing an adhesive layer 130.

In the manufacturing method of the two floor decorative materials, the base material layer may be used a variety of materials, such as water-resistant plywood, particle board, medium density fiber board (MDF), in particular polyvinyl chloride sheet for light and excellent cushioning Is preferred.

In the above manufacturing methods, the easy layer 110 can be further laminated on the bottom of the flooring material, and this type of lamination follows a method suitable for the various types of structures described above.

Application of the melamine decorative plate of the present invention is a partition of a wall, a table (table top), an office, a toilet by selecting various materials such as a water-resistant plywood, a particle board, a medium density fiber board (MDF), a backlite as a base material in addition to the flooring material. It can be used as a surface material (partition) and the like, because the dimension stability is very excellent compared to the conventional melamine decorative plate, there is an advantage that can be used for a long time because there is very little warping, deformation before and after construction.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the embodiment is intended to illustrate the present invention, but not limited to these.

EXAMPLE

Example 1

Preparation of melamine decorative plate containing glass fiber woven fabric in core layer 1 (FIG. 3)

(Manufacture of the surface protective layer 153)

Melamine resin made of liquid by mixing 37 wt% melamine, 33 wt% formaldehyde, 25 wt% water, 1 wt% diethylene glycol, 0.3 wt% sodium hydroxide, and 3.7 wt% amine basic catalyst An overlay paper of 49 g / m 2 was impregnated with 250% of the weight of the overlay paper, dried in an oven having a temperature of 120 to 140 ° C. for 2 to 3 minutes, and semi-cured to prepare a surface protective layer 153.

(Production of Shape Layer 152)

Melamine resin made in liquid form by mixing 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% by weight of amine-based basic catalyst The shape layer 152 was prepared by impregnating 100% of the weight of the shape paper to 80 g / m 2 and drying it for 2 to 3 minutes in an oven having a temperature of 120 to 140 ° C.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

Phenol prepared by mixing 43% by weight of phenol, 33% by weight of formaldehyde, 5% by weight of ethyl alcohol, 3% by weight of water, 10% by weight of amine basic catalyst, and 6% by weight of ortho-cresol. Phenol resin impregnated paper was prepared by impregnating the resin to 200 g / m 2 of kraft paper 60% of the weight of the kraft paper and then drying it for 2 to 3 minutes in an oven having a temperature of 100 to 140 ° C.

(Manufacture of glass fiber layer woven fabric 162 of core layer 151)

43% by weight of phenol, 33% by weight of formaldehyde, 5% by weight of ethyl alcohol, 3% by weight of glass fiber (E glass composition) woven fabric having a basis weight of 60 g / m 2, Tex of 136 and glass fiber density of 8 × 14 per inch , Glass fiber woven fabric in a resin solution prepared by mixing 10% by weight of an amine-based basic catalyst and 10% by weight of an aqueous solution of 10% by weight of an aminosilane coupling agent prepared by mixing 10% by weight of an amine-based basic catalyst and 6% by weight of ortho-cresol. Was impregnated with 50% by weight and dried in an oven having a temperature of 100 to 120 ° C. for 2 to 3 minutes and semi-cured to prepare a phenolic resin impregnated glass fiber woven fabric.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

200 g / l of a resin made in a liquid state by mixing 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% by weight of an amine-based basic catalyst. Melamine resin impregnated paper was prepared by impregnating 100 wt% of kraft paper in m 2 and drying it for 2 to 3 minutes in an oven having a temperature of 120 to 140 ° C.

(Manufacture of HPL Sheet 170)

Melamine resin impregnated paper 161 of core layer 151, glass fiber layer woven fabric 162 of core layer 151, phenolic resin impregnated paper 163 of core layer 151, shape layer 152 and surface from below The protective layer 153 was sequentially laminated, and then put into a thermopress press, pressurized and heated at a pressure of 100 kgf / cm 2 and a temperature of 135 ° C. for 30 minutes to prepare a high pressure laminates (170) sheet 170.

Comparative Example 1

Preparation of a typical melamine decorative plate (FIG. 1)

(Manufacture of the surface protective layer 1)

Melamine resin made of liquid by mixing 37 wt% melamine, 33 wt% formaldehyde, 25 wt% water, 1 wt% diethylene glycol, 0.3 wt% sodium hydroxide, and 3.7 wt% amine basic catalyst The surface protective layer 1 was prepared by impregnating an overlay paper of 28 g / m 2 with 300% of the weight of the overlay paper and drying it for 2 to 3 minutes in an oven having a temperature of 120 to 140 ° C.

(Production of Shape Layer 2)

The same shape layer 152 as in Example 1 is manufactured.

(Manufacture of core layer 3)

The same phenolic resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of HPL Sheet)

Three core layers (3), shape layer (2) and surface protective layer (1) were stacked in this order from below, and then put into a thermopress press for 20 minutes at a pressure of 55 to 100 kgf / cm 2 and a temperature of 125 to 140 ° C. HPL is prepared by pressing and heating for 40 minutes.

Comparative Example 2

Preparation of melamine decorative plate (FIG. 2) comprising a core layer and a balance layer that do not include a conventional glass fiber layer

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 is prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 is manufactured.

(Production of Phenolic Resin Impregnated Paper 163)

The same phenolic resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of the balance layer 140)

A polypropylene nonwoven fabric having a weight of 50 g / m 2 per unit area was prepared.

(Manufacture of HPL Sheet)

From below, the balance layer 140, two phenol resin impregnated papers 163, the shaping layer 152 and the surface protective layer 153 were laminated in this order, and then put into a thermopress press to give a pressure of 55 to 100 kgf / cm 2 and 125. HPL is manufactured by pressurizing and heating at a temperature of -140 ° C for 20 to 40 minutes.

Example 2

Melamine decorative plate production 2 including a glass fiber woven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same phenolic resin as in Example 1 was used, and a phenolic resin-impregnated glass fiber woven fabric 162 was prepared from a glass fiber woven fabric having a tex of 68 and a density of 12 × 18 per inch.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 3

Melamine decorative plate production 3 including a glass fiber woven fabric in the core layer (FIG. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

A phenolic resin-impregnated glass fiber woven fabric 162 was prepared from a glass fiber woven fabric having the same phenol resin as Example 1 and having a tex of 34 and a density of 14 × 20 per inch.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 4

Melamine decorative plate production 4 containing a glass fiber woven fabric in the core layer (FIG. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

A phenolic resin-impregnated glass fiber woven fabric 162 was prepared from a glass fiber woven fabric having the same phenolic resin as in Example 1 and having a tex of 22.5 and a density of 18 × 26 per inch.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 5

Melamine decorative plate production 5 containing a glass fiber woven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

Using the same phenolic resin as in Example 1 and having a tex of 11.2, a phenolic resin-impregnated glass fiber woven fabric 162 was prepared from a glass fiber woven fabric having a density of 20 × 30 per inch.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 6

Melamine decorative plates of Examples 1 and Comparative Examples 1, 2, and 2, 3, 4, and 5 were prepared at a constant temperature by preparing 3 pieces of 20 mm × 250 mm in the width (W) direction with a large change in shrinkage expansion. It was put in a humidifier for 24 hours and the bending stability was measured.

For measurement, the relative humidity was fixed at 60 ± 5% and the bending stability according to the temperature measured at the temperature of -10, 23, 30, 40, 60 ℃ was shown in Table 2, and the temperature was fixed at 23 ± 3 ℃. The flexural stability according to the humidity is shown in Table 3 by changing the relative humidity to 20, 40, 60, 80, 95%.

The incidence of bending stability is placed on a flat glass surface as soon as it is taken out of the thermo-hygrostat and the average value is determined by measuring the heights of both ends of the edge with a precision ruler. In the case of static bending stability (when the surface is raised), the surface is measured upward and is indicated by a positive value. In case of inverse bending stability (when the surface is flipped down), it is measured with the surface facing down and expressed as a -value.

TABLE 2

Flexural stabilization height with temperature at 60 ± 5% relative humidity

Classification (mm) Comparative Example 1 Comparative Example 2 Example 1 Example 2 Example 3 Example 4 Example 5 Temperature 60 ℃ +25.0 +20.0 +4.5 +4.0 +4.5 +4.5 +4.5 40 ℃ +10.0 +10.0 +2.0 +2.0 +2.5 +2.0 +2.5 30 ℃ 0 -7.0 0 +1.0 +1.7 +0.5 +1.5 23 ℃ -2.0 -10.0 -1.5 -0.5 0 -0.3 +0.5 -10 ℃ -8.0 -15.0 -3.5 -3.0 -3.0 -3.5 -3.0

TABLE 3

Flexural stabilization height with humidity at temperature 23 ± 2%

Classification (mm) Comparative Example 1 Comparative Example 2 Example 1 Example 2 Example 3 Example 4 Example 5 Relative humidity 20% +16.0 +8.0 +2.5 +2.0 +2.5 +2.2 +2.8 40% +9.0 0 0 +0.5 +1.0 +0.5 +1.3 60% -2.0 -10.0 -1.5 -0.5 0 -0.3 +0.5 80% -10.0 -23.0 -2.5 -1.5 -1.2 -1.7 -0.5 95% -18.0 -30.0 -4.0 -3.5 -3.0 -3.5 -3.8

Example 7

Melamine decorative plates of Examples 1 and Comparative Examples 1, 2, and 2, 3, 4, and 5 were prepared at a constant temperature by preparing 3 pieces of 20 mm × 250 mm in the width (W) direction with a large change in shrinkage expansion. It was put in a humidifier for 24 hours and the dimensional stability was measured. The measurement shows the dimension stability A according to the following equation (1) as a percentage of the shrinkage of the shrinkage by heating for 6 hours at a temperature of 80 ℃, the percentage of increase in the dimension after 24 hours at a temperature of 25 ℃ and 95% relative humidity According to Equation 2 below, the dimensional stability B is shown. Each result is shown in Table 4.

[Equation 1]

[Equation 2]

TABLE 4

Dimensional stability test results

division(%) Comparative Example 1 Comparative Example 2 Example 1 Example 2 Example 3 Example 4 Example 5 Dimensional Stability A -0.55 -0.50 -0.20 -0.22 -0.22 -0.25 -0.26 Dimensional Stability B +0.45 +0.37 +0.15 +0.15 +0.16 +0.16 +0.18

As can be seen from the results, it can be seen that the melamine vanity plate of the present invention is very excellent in curling and dimensional stability compared to the general melamine vanity plate and the conventional melamine vanity plate.

Example 8

Melamine decorative plate manufacturing comprising a glass fiber nonwoven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber nonwoven fabric of the following core layer, the same surface protective layer 153, shape layer 152, phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of the glass fiber layer nonwoven fabric 162 of the core layer 151)

The glass fiber of E glass composition with an average fiber diameter of 15 μm is cut by the length of the long (50 mm) and the short (12 mm), and then mixed by 50% by weight, and the pulp of 1% by weight of this glass fiber and 1 After mixing the wt% binder, a glass fiber nonwoven fabric having a basis weight of 100 g / m 2 was produced in a needling machine.

This glass fiber nonwoven fabric was prepared by mixing 43% by weight of phenol, 33% by weight of formaldehyde, 5% by weight of ethyl alcohol, 3% by weight of water, 10% by weight of amine basic catalyst and 6% by weight of ortho-cresol. The glass fiber layer nonwoven fabric was impregnated with 50% by weight of the glass fiber layer nonwoven fabric, dried in an oven at a temperature of 100 to 120 ° C. for 4 to 5 minutes, and semi-cured to prepare a glass fiber layer nonwoven fabric 162.

(Manufacture of HPL Sheet)

Using the glass fiber nonwoven fabric HPL 170 in the same manner as in Example 1.

Example 9

Melamine decorative plate manufacturing 6 containing a glass fiber woven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

A phenolic resin-impregnated glass fiber woven fabric 162 is used from a glass fiber woven fabric having the same phenolic resin as in Example 1 and having a tex of 68 × 136 (tilt × weft) and a density of 8 × 14 per inch. Prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 10

Melamine decorative plate production comprising glass fiber woven fabric in the core layer 7 (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

Using the same phenolic resin as in Example 1 and having a tex of 34 x 68 (inclined x weft), a phenolic resin impregnated glass fiber woven fabric 162 was formed from a glass fiber woven fabric having a density of 14 x 18 per inch. Prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 11

Melamine decorative plate manufacturing 8 containing a glass fiber woven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same phenolic resin as in Example 1, the tex of the glass fiber woven fabric is 22.5 x 34 (inclined x weft), and the phenolic resin impregnated glass fiber woven fabric from a glass fiber woven fabric having a density of 16 x 20 per inch (162) was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 12

Melamine decorative plate production 9 containing a glass fiber woven fabric in the core layer (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

Using the same phenolic resin as in Example 1 and having a tex of 11.2 × 22.5 (tilt × weft), a phenolic resin-impregnated glass fiber woven fabric 162 was formed from a glass fiber woven fabric having a density of 18 × 24 per inch. Prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 13

Melamine decorative plate production comprising a fiberglass woven fabric in the core layer 10 (Fig. 3)

Except for manufacturing the glass fiber woven fabric of the following core layer, the same surface protective layer 153 as in Example 1, the shape layer 152, the phenol resin impregnated paper 163 of the core layer 151, and core layer 151 Melamine resin impregnated paper 161 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

Using the same phenolic resin as in Example 1 and having a tex of 22.5 × 136 (tilt × weft), a phenolic resin-impregnated glass fiber woven fabric 162 was formed from a glass fiber woven fabric having a density of 20 × 10 per inch. Prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1 using the phenol resin impregnated glass fiber cloth.

Example 14

Preparation of flooring materials using HPL method 1

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same woven glass fiber layer 162 was prepared as in Example 1.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

100 parts by weight of vinyl chloride resin having a degree of polymerization of 1000. 36 parts by weight of dioctylphthalate, 3 parts by weight of a barium-zinc compound and 500 parts by weight of calcium carbonate were mixed in a mixing mixer, and then the vinyl chloride resin compound kneaded in a half-barrier mixer was rolled with a calendar having a temperature of 130 to 160 ° C. to 2.3. The base layer 100 was manufactured in the thickness of mm.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1.

(Manufacture of adhesive layer 130)

The adhesive layer 130 was prepared by coating a polyurethane adhesive having a solid content of 40% by weight using a coating roll on the substrate layer 100 prepared above.

(Manufacture of Flooring Materials (FIG. 9))

After laminating the HPL sheet 170 prepared above on the substrate layer 100 coated with the adhesive layer 130, these were pressurized and heated for 60 minutes at a pressure of 15 kg / cm 2 and a temperature of 80 ° C. in a thermopress press. By pressing, the floor covering of FIG. 9 having a thickness of 3.0 mm was prepared.

Comparative Example 3

Using a general melamine cosmetic plate (Fig. 1) to prepare a floor decoration (Fig. 11) as follows.

(Manufacture of the surface protective layer 1)

The same surface protective layer (1) as in Comparative Example 1 was prepared.

(Production of Shape Layer 2)

The same shape layer 152 as in Example 1 was prepared.

(Manufacture of core layer 3)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of HPL Sheet)

The same HPL sheet as in Comparative Example 1 was prepared (FIG. 1).

(Production of Adhesive Layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Production of Easy Layer 110)

60% by weight of a vinyl chloride resin having a degree of polymerization of 1000, 10% by weight of dioctylphthalate as a plasticizer, 10% by weight of barium-zinc compound as a stabilizer and 20% by weight of calcium carbonate in a mixing mixer and then kneaded in a half-barrier mixer. The resin layer was rolled with a calendar having a temperature of 130 to 160 ° C. to prepare an easy layer 110 having a thickness of 0.5 mm.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of Flooring Materials (FIG. 11))

First, the easy layer 110 under the base layer 100 is thermally bonded with a calendar of 130 to 160 ° C., and then the HPL sheet prepared above is laminated on the base layer 100 coated with the adhesive layer 130. These were pressurized for 50 minutes at a pressure of 10 kg / cm &lt; 2 &gt;

Comparative Example 4

Using a conventional melamine cosmetic plate (Fig. 2) for the floor decoration material was prepared as a floor decoration material (Fig. 12) as follows.

(Manufacture of the surface protective layer 153)

The same surface protective layer (1) as in Comparative Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Manufacture of the core layer 151)

The same phenol resin impregnated paper 163 as in Comparative Example 2 was prepared.

(Manufacture of the balance layer 140)

The same balance layer 140 as in Comparative Example 2 was prepared.

(Manufacture of HPL Sheet)

The same HPL sheet as in Comparative Example 2 was prepared.

(Production of Adhesive Layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Production of Easy Layer 110)

The same easy layer 110 as in Comparative Example 3 was prepared.

(Manufacture of Flooring Materials (FIG. 12))

First, the easy layer 110 under the substrate layer 100 is thermally bonded with a calendar of 130 to 160 ℃ and then laminated the HPL sheet prepared above on the substrate layer 100 coated with the adhesive layer 130, These were pressurized for 60 minutes at a pressure of 15 kg / cm &lt; 2 &gt;

Example 15

Preparation of Flooring Materials Using HPL Method 2

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same glass fiber layer woven fabric 162 as in Example 2 was prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 2.

(Manufacture of adhesive layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Manufacture of Flooring Materials (FIG. 9))

Floor decoration material (FIG. 9) was prepared using the respective layers in the same manner as in Example 14.

Example 16

Preparation of Flooring Materials Using HPL Method 3

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same glass fiber layer woven fabric 162 as in Example 3 was prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 3.

(Manufacture of adhesive layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Manufacture of Flooring Materials (FIG. 9))

Floor decoration material (FIG. 9) was prepared using the respective layers in the same manner as in Example 14.

Example 17

Preparation of Flooring Materials Using HPL Method 4

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Fiberglass Layer Woven Type 162 of Core Layer 151)

The same glass fiber layer woven fabric 162 as in Example 4 was prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 4.

(Manufacture of adhesive layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Manufacture of Flooring Materials (FIG. 9))

Floor decoration material (FIG. 9) was prepared using the respective layers in the same manner as in Example 14.

Example 18

Manufacturing of Flooring Materials Using HPL Method 5

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same glass fiber layer woven fabric 162 as in Example 5 was prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 5.

(Manufacture of adhesive layer 130)

The same adhesive layer 130 as in Example 14 was prepared.

(Manufacture of Flooring Materials (FIG. 9))

Floor decoration material (FIG. 9) was prepared using the respective layers in the same manner as in Example 14.

Example 19

Preparation of flooring material using the LPL method (Fig. 10)

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same glass fiber layer woven fabric 162 as in Example 1 was prepared.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base layer 100 as in Example 14 was prepared.

(Manufacture of the balance layer 140)

The same balance layer 140 as in Comparative Example 2 was prepared.

(Manufacture of floor decoration material (FIG. 10))

The balance layer 140, the core layer 151 which is the resin impregnated paper layer 150, the shape layer 152, and the surface protective layer 153 are sequentially stacked on the substrate layer 100 prepared above, and then a hot press ( hot pressing) was pressurized and heated at a pressure of 40 kg / cm &lt; 2 &gt; and a temperature of 130 to 140 [deg.] C. for 20 to 30 minutes to simultaneously compress the layers to prepare a floor decoration material of FIG. 10 having a thickness of 3.0 mm. At this time, the core layer 151 is laminated in the order of melamine resin impregnated paper 161, glass fiber woven mat 162, phenol resin impregnated paper 163 from the bottom.

Example 20

Prepare flooring materials of Example 14 and Comparative Examples 3, 4, 15, 16, 17, 18, and 19, each of which was prepared at a constant temperature of 20 mm × 250 mm in the width (W) direction with a large change in shrinkage expansion. It was put in a humidifier for 24 hours and the curling degree was measured. The measurement shows the curling degree according to the temperature measured at a temperature of -10, 23, 30, 40, and 60 ° C. at a relative humidity of 60 ± 5%, and the temperature is fixed at 23 ± 3 ° C. The relative humidity was changed to 20, 40, 60, 80, 95%, and the degree of curling according to humidity is shown in Table 6 below.

The incidence of curling is placed on a flat glass surface as soon as it is taken out of the thermo-hygrostat and the average value is determined by measuring the height of both ends of the edge with a precision ruler. In the case of the normal curling (upper surface), the surface is measured upwards and displayed as a positive value. In the case of reverse curling (when the surface is flipped down), it is measured with the surface facing down and displayed as a negative value.

TABLE 5

Curling height with temperature at 60 ± 5% relative humidity

Classification (mm) Comparative Example 3 Comparative Example 4 Example 14 Example 15 Example 16 Example 17 Example 18 Example 19 Temperature 60 ℃ +8.0 +6.0 +2.5 +2.0 +2.3 +2.3 +2.5 +2.3 40 ℃ +4.0 +3.5 +1.5 +1.3 +1.5 +1.7 +1.0 +1.2 30 ℃ +2.3 +1.5 +0.7 +0.5 +0.8 +1.0 +0.5 +0.7 23 ℃ -0.9 -1.1 -0.1 -0.2 0 -0.3 -0.3 -0.2 -10 ℃ -4.0 -5.0 -2.3 -2.0 -1.8 -2.0 -1.5 -1.7

TABLE 6

Curling height according to humidity at temperature 23 ± 2%

Classification (mm) Comparative Example 3 Comparative Example 4 Example 14 Example 15 Example 16 Example 17 Example 18 Example 19 Relative humidity 20% +3.5 +3.0 +1.0 +0.7 +1.2 +1.0 +1.5 +1.0 40% +1.0 +1.3 +0.5 +0.3 +0.4 +0.5 +0.5 +0.5 60% -0.9 -1.1 -0.1 -0.2 0 -0.3 -0.3 -0.2 80% -3.2 -4.0 -1.2 -1.0 -0.8 -1.0 -1.2 -1.1 95% -4.8 -5.8 -2.0 -1.8 -1.5 -2.0 -2.5 -2.2

Example 21

Prepare three floor decoration materials of Example 14 and Comparative Examples 3, 4, 14, 15, 16, and 17, each 20 mm × 250 mm in the width (W) direction with a large change in shrinkage expansion. It was added for 24 hours and the dimensional stability was measured. The measurement is shown in the dimensional stability A according to Equation 1 as a percentage of the shrinkage of the shrinkage by heating for 6 hours at a temperature of 80 ℃ and the percentage of stretching after 24 hr at a temperature of 25 ℃ and 95% relative humidity According to Equation 2, the dimension stability B is represented. Each result is shown in Table 7.

TABLE 7

Dimensional stability test results

division(%) Comparative Example 3 Comparative Example 4 Example 14 Example 15 Example 16 Example 17 Example 18 Example 19 Dimensional Stability A -0.35 -0.32 -0.10 -0.12 -0.12 -0.13 -0.14 -0.12 Dimensional Stability B -0.35 -0.30 +0.09 +0.10 +0.10 +0.12 +0.13 +0.10

As can be seen from the above results, the flooring material using the melamine cosmetic plate of the present invention can be seen that the curling and dimensional stability is very excellent. There is almost no problem.

Example 22

Fabrication of Wall and Table Surfaces Using HPL Method

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same woven glass fiber layer 162 was prepared as in Example 1.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

A 7.0 mm thick plywood was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1.

(Production of Adhesive Layer 130)

The adhesive layer 130 was prepared by coating a polyvinyl alcohol adhesive having a solid content of 40 wt% on the substrate layer 100 prepared above using 300 to 400 g / m 2.

(Manufacture of Walls, Table Surface Materials)

After laminating the HPL sheet 170 prepared above on the substrate layer 100 coated with the adhesive layer 130, and pressing them under a pressure of 5 to 30 kgf / cm 2 at room temperature in a cold press for 90 minutes and at room temperature for 48 hours. Aging produced the wall and table surface materials of FIG. 13 with a thickness of 7.5-8.0 mm.

Example 23

Preparation of Partitions Using HPL Method

(Manufacture of the surface protective layer 153)

The same surface protective layer 153 as in Example 1 was prepared.

(Production of Shape Layer 152)

The same shape layer 152 as in Example 1 was prepared.

(Production of Phenolic Resin Impregnated Paper 163 of Core Layer 151)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Glass Fiber Layer Woven Fabric 162 of Core Layer 151)

The same woven glass fiber layer 162 was prepared as in Example 1.

(Manufacture of Melamine Resin Impregnated Paper 161 of the Core Layer 151)

The same melamine resin impregnated paper 161 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

A particleboard having a thickness of 12.0 mm was prepared.

(Manufacture of HPL Sheet)

HPL 170 was prepared in the same manner as in Example 1.

(Production of Adhesive Layer 130)

The adhesive layer 130 was prepared by coating a polyvinyl alcohol adhesive having a solid content of 40 wt% using 300 to 400 g / m 2 using a coating roll below and above the substrate layer 100 prepared above.

(Production of partition)

After stacking the HPL sheet 170 prepared above and below the substrate layer 100 coated with the adhesive layer 130, respectively, these were press-pressed for 90 minutes at a pressure of 5 to 30 kgf / cm2 at room temperature in a cold press. Aging for room temperature (Aging) for a time to prepare a partition of Figure 14 of 8.0 to 8.5 mm thick.

Comparative Example 5

Using a typical melamine decorative plate (Fig. 1) to prepare a wall, table surface material as shown below.

(Manufacture of the surface protective layer 1)

The same surface protective layer (1) as in Comparative Example 1 was prepared.

(Production of Shape Layer 2)

The same shape layer 152 as in Example 1 was prepared.

(Manufacture of core layer 3)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base material as in Example 22 was prepared.

(Manufacture of HPL Sheet)

HPL sheet (Fig. 1) was prepared in the same manner as in Comparative Example 1.

(Production of Adhesive Layer 130)

The same adhesive layer 130 as in Example 22 was prepared.

(Manufacture of Walls, Table Surface Materials)

In the same manner as in Example 22, the wall and the table surface material of FIG. 15 were manufactured.

Comparative Example 6

Using a typical melamine decorative plate (Fig. 1) to prepare a partition as follows.

(Manufacture of the surface protective layer 1)

The same surface protective layer (1) as in Comparative Example 1 was prepared.

(Production of Shape Layer 2)

The same shape layer 152 as in Example 1 was prepared.

(Manufacture of core layer 3)

The same phenol resin impregnated paper 163 as in Example 1 was prepared.

(Manufacture of Base Layer 100)

The same base material as in Example 23 was prepared.

(Manufacture of HPL Sheet)

HPL sheet (Fig. 1) was prepared in the same manner as in Comparative Example 1.

(Production of Adhesive Layer 130)

The same adhesive layer 130 as in Example 23 was prepared.

(Production of partition)

The partition of FIG. 16 was manufactured in the same manner as in Example 23.

Example 24

The walls, the table surface material and the partitions of Examples 22 and 23 and Comparative Examples 5 and 6 were prepared with 3 pieces of 20 mm × 250 mm, respectively, in a width (W) direction with a large change in shrinkage expansion, and placed in a thermo-hygrostat for 24 hours. Dimensional stability was measured. The measurement is shown in the dimensional stability A according to Equation 1 as a percentage of the shrinkage of the shrinkage by heating for 24 hours at a temperature of 80 ℃ and as a percentage of the increase in dimension after 24 hr at a temperature of 25 ℃ and 95% relative humidity According to Equation 2, the dimension stability B is represented. Each result is shown in Table 8.

TABLE 8

Dimensional stability test results

division(%) Example 22 Example 23 Comparative Example 5 Comparative Example 6 Dimensional Stability A -0.14 -0.16 -0.30 -0.36 Dimensional Stability B +0.05 +0.08 +0.14 +0.20

As can be seen from the above results, the wall, the table surface material and the partition manufactured using the melamine cosmetic plate of the present invention have very high dimensional stability during use, so that there are almost no problems such as deformation and warping due to heat or moisture.

Melamine decorative plate including the glass fiber layer of the present invention in the core layer shows excellent dimensional stability and flexural stability, and the flooring material produced by laminating it has excellent curling and dimensional stability, so when it is applied to the floor, the gap or seam of the seam is raised. There is almost no phenomenon, and the walls, table surface materials and partitions manufactured by laminating them have very high dimensional stability during use, so that there are almost no problems such as deformation and warping due to heat or moisture.

Claims (15)

In the melamine decorative plate comprising a resin impregnated paper layer comprising a surface protective layer, a shape layer, a core layer from above, The core layer has a Tex of 11.2 to 136, a warp number of 6 to 30, a weft number of 10 to 36 glass fiber woven layer, or a basis weight of 40 to 120 g / m 2 glass fiber nonwoven layer. Melamine board containing a. The method of claim 1, The core layer from above a) phenol resin impregnated paper layer; b) a glass fiber layer; And c) melamine resin impregnated layer Melamine vanity containing The method of claim 1, The core layer from above Glass fiber layer (162) Ii) phenol resin impregnated paper (163) Melamine board containing a. The method of claim 1, The core layer from above Glass fiber layer (162) Ii) Melamine resin impregnated paper (161) Melamine board containing a. The method of claim 1, The core layer from above Ⅰ) Melamine resin impregnated paper (161) Ii) glass fiber layer 162 Ⅲ) Melamine resin impregnated paper (161) Melamine board containing a. The method of claim 1, The core layer from above ) Phenol resin impregnated paper (163) Ii) glass fiber layer 162 ) Phenol resin impregnated paper (163) Melamine board containing a. The method of claim 1, The core layer from above Ⅰ) Melamine resin impregnated paper (161) Ii) glass fiber layer 162 ) Phenol resin impregnated paper (163) Melamine board containing a. The method of claim 1, The glass fiber woven fabric has a tex of 136, the number of warp yarns 6-14, the number of weft yarns melamine decorative plate 10-16 (weft). The method of claim 1, The glass fiber woven fabric has a melamine decorative plate having a tex of 68, a warp number of 8 to 16, and a weft number of 12 to 20. The method of claim 1, The glass fiber woven fabric has a tex of 34, a number of warp yarns 10 to 20, and a number of weft yarns 15 to 25 melamine decorative plate. The method of claim 1, The glass fiber woven fabric has a melamine decorative plate having a tex of 22.5, a warp number of 12 to 24, and a weft number of 18 to 30. The method of claim 1, The glass fiber woven fabric has a melamine decorative plate having a tex of 11.2, a number of warp yarns 16 to 30, and a number of weft yarns of 22 to 36. The method of claim 1, The glass fiber layer is a melamine decorative plate which is a glass fiber woven fabric or a glass fiber nonwoven fabric impregnated with a phenol resin of 40 to 100% by weight relative to the basis weight. The method of claim 1, The melamine decorative plate is a melamine that is laminated by interposing between the core layer and the core layer or placing the balance layer 140 of a woven fabric, a nonwoven fabric, or a sheet processed with natural fibers by wodding. Floorboard. The method of claim 14, Melamine decorative plate is selected from the group of fibers consisting of glass fibers, carbon fibers, polyethylene terephthalate (PET), polypropylene, polyester, and nylon.