KR20060005011A - Paper laminated wooden floor and it's manufacturing methods - Google Patents

Abstract

The present invention is to provide a reinforcement floor board having a Hanji layer and a method for manufacturing the same, an adhesive layer 20, the impregnated Hanji layer 30 and a transfer paper printed with a pattern of natural patterned wood on the water-resistant plywood (10) The present invention proposes a floorboard and a method of manufacturing the laminated paper layer impregnated with a melamine resin, and a urethane UV coating layer 50 having a laminated structure in this order.

Floorboard, Hanji, Korean paper floorboard

Description

Paper Laminated Wooden Floor and it's Manufacturing Methods}             

Figure 1a, 1b is a structural diagram of a conventional reinforced floorboard

2 is a structural diagram of a floorboard according to the present invention

Figure 3 is a cross-sectional view in the width direction of the finished floorboard

* Description of the major symbols

10. Waterproof plywood 20. Adhesive layer

30.Hanji Formation 40.Shape Formation

50.UV coating layer 60.Custom part

The present invention relates to a hanji floorboard and a method for manufacturing the same, and in detail, a paper sheet impregnated on a water-resistant plywood, a pattern paper layer impregnated with a melamine resin with a transfer paper or titanium paper printed with a pattern of natural patterned wood, and a urethane UV coating layer. It relates to a hanji floorboard having a laminated structure and a manufacturing method thereof.

In general, the floorboard using the water-resistant plywood improves the performance of heat resistance, abrasion resistance, water resistance, fire resistance, etc. on the surface, expresses the texture of natural veneer pattern, and the rate of dimensional change due to the characteristics applied to the length curling, ondol structure, etc. The surface of the plywood is laminated with finishing materials such as PB (Particle Board), MDF (Medium Density fiberboard), HPL (High Pressure Melamine Laminate), and shape paper such as sheets printed on veneer or paper. Is made in a way.

Fig. 1A shows a core layer 2 made of sheet impregnated with phenolic resin on paper, a shape layer 3 made of sheet impregnated with melamine resin, and a sheet of melamine resin impregnated with paper. The transparent protective layer 4 made of the sheet is laminated in order, and the conventional reinforcement in which the balance layer 5 made of the sheet impregnated with the melamine resin in the paper is laminated on the lower part of the water-resistant plywood and integrally compressed by heat and pressure. It is a floorboard structure.

  Compared to solid wood flooring, the structure can economically reinforce the flooring, and provides the advantage that it can be easily manufactured by a process by heat press press operation after manufacturing each layered structure in advance. Due to the large difference in the dimensional change rate of the upper layer, the dimensional stability is low, and when used in the ondol structure, gaps and curling phenomena are severe and the practicality is poor. In addition, the paper constituting the core layer, the shape layer and the transparent protective layer has a disadvantage that heat resistance is not sufficient due to the use of paper made of general pulp as a main raw material, and thus the surface is torn during local pressure action. There is a disadvantage in that the plywood itself does not effectively prevent cracking when constructed in consideration of shrinkage expansion due to moisture. In addition, the transparent protective layer is a simple structure impregnated with the melamine resin paper has a disadvantage that can not secure sufficient surface strength can not effectively prevent scratches, such as by life.

1B is a high pressure melamine laminate having a structure in which a core layer 2 (2 '), a glass fiber layer 7, a core layer 1 (2 "), a shape paper layer 3' and a surface protective paper layer 4 'are stacked from below. (HPL) is laminated with the water-resistant plywood layer 1 'with the adhesive layer 8 interposed therebetween, which has the advantage of improving dimensional stability and curling property by laminating a glass fiber layer between the core layer and the core layer. It is advantageous to improve adhesion to the floor by omitting the lower HPL of the lower part of the plywood, but using glass fiber orthogonal in the form of fabric and impregnating it with a mixture of a coupling agent and a resol type phenolic resin. By forming the fiber layer, the uniformity of the thickness is not perfect, and the phenomenon of the upper shape paper layer and the surface protection paper layer is partially distorted due to shrinkage and expansion during the hot pressing process. There is a limit. In addition, the transparent protective layer has a weakness because of a simple structure in which the paper impregnated with melamine resin to problems such as fading side not as strong a surface inferior function as a floor.

In addition, these floorboards have a limit in terms of commerciality as flooring materials, even though the first-class waterproofing plywood is used, compared to solid wood, where humidity control is inferior, and shape layers are deteriorated when water is infiltrated.

Particularly, these floorboards are made of water-resistant plywood of approximately 1000mm x 900mm size, and after the surface hardening layer is formed, the floorboards are cut into 75 ~ 100mm x 900mm, which is the unit floorboard standard, and the side fitting process is performed to penetrate moisture through the sides. There is a problem that is very vulnerable to moisture because the adhesive portion is peeled off or the discoloration of the printed pattern occurs.

The present invention prevents cracks and splitting, which is a weak point of floorboards using water-resistant plywood, improves resistance to moisture, and solves problems such as discoloration of the surface or shape layers, and makes the surface sufficiently strong in everyday life. It is designed to have a function as a high quality flooring material by solving problems such as scratches.

To this end, the present invention is a Hanji floorboard impregnated on a water-resistant plywood, a pattern paper layer impregnated with a melamine resin on a transfer paper or titanium paper printed with a pattern of natural patterned texture, and a Hanji floorboard having a structure laminated with a urethane UV coating layer and its manufacture Give a way.

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

Figure 2 is for showing the basic configuration of the present invention, Figure 3 is a cross-sectional view of the finished floorboard in the width direction, the present invention is an adhesive layer 20, the impregnated Hanji layer on the water-resistant plywood ( 30), a pattern paper layer 40 impregnated with a melamine resin with a transfer paper or titanium paper printed with a pattern of natural patterned wood texture, and a urethane UV coating layer 50 are laminated in this order.

The water-resistant plywood 10 uses a first-class water-resistant plywood having a structure in which a single plate is impregnated with a melamine resin and the like so that adjacent single plates are orthogonal to each other in order to improve water resistance.

The Hanji layer 30 is impregnated with a method of drying the dryer in the dryer after wetted with melamine resin, the impregnation amount is about 300-400% by weight compared to the weighing of the Hanji. The Hanji layer can be composed of one sheet of impregnated Hanji, and can be composed of 2 to 5 sheets of impregnated Hanji, in this case, impregnated in the overlapping state of two sheets by laminating the impregnated Hanji unit layered.

Hanji is made of natural materials such as long fiber and long breadth and low lignin (Lignin) content of mulberry and mulberry fiber, so it is durable, long life, and does not pulp easily even if it absorbs moisture. Hanji impregnated with the melamine resin strongly binds the tough fibrous tissue to the melamine resin, resulting in approximately 2-4 times the tear strength improvement compared to the case of impregnating the common sun with melamine resin.

Hanji is applied to the front and rear direction (MD) twice, and the left and right directions (CD) two times, such as cross-stitching and cross-stitching during the forming of the paper fabric is made in the x-y direction The fibers are entangled in a lattice form and thus have a uniform strength regardless of the direction. Hanji produced by the above method maintains the performance of about 86 ~ 88 gf tear strength, 8 ~ 9 kgf, the number of cutouts 2900 ~ 3000 times for the basis weight 50g / ㎡ both horizontally and vertically.

The impregnated hanji bonded to the upper layer of plywood significantly mitigates the cleavage to shear, which is a disadvantage of plywood, and serves to keep the shape layer stable.

The shape paper layer 40 is formed by printing a wooden pattern on titanium paper coated with titanium dioxide on woodfree paper, and then impregnating it with melamine resin, or laying a transfer paper pre-printed on the paper on a sheet of paper and applying an overlay film thereon. It is formed by the method of thermal bonding. Titanium paper is suitable for gravure printing that can express the shape and texture of solid wood. Transfer paper is a vinyl sheet used with overlay film after printing wood pattern in advance. The printed pattern expressed on the titanium paper can be alleviated by the melamine resin to reduce discoloration, color bleeding, or sulfidation, and the pattern by the transfer paper is prevented from being discolored by being adhered together with the overlay film.

The Hanji layer and the shape paper layer is coated with a melamine resin-based adhesive 20 on the water-resistant plywood, then laminated in the order of the Hanji layer, shape paper layer using a high temperature flat plate press temperature of 140 ~ 160 ℃, 80-100kg / ㎠ pressure Preferably, it is formed by heating and pressing at 150 ° C. and 90 kg / cm 2 pressure.

The UV coating layer 50 is formed by roller coating the urethane resin-based UV coating agent and then irradiating with a UV lamp. The UV coating layer is formed repeatedly on the shape paper layer 2 to 4 times to form a primary coating layer, and the second coating layer is formed by the method of repeating 2-3 times on the surface after the surface is smoothly sent with sand paper.

The UV coating layer is transparent, so that the solid wood pattern formed in the inner shape layer is transparent, and by repeatedly forming a thin coating layer several times, the surface strength is high and the scratch resistance is improved.

The secondary UV coating layer formed after the sending is preferably formed in the final step made of the unit floorboard. That is, a Hanji layer and a shape paper layer are formed on a water-resistant plywood having a certain size, and cut to a size of 75 to 100 mm x 900 mm, which is the standard of the unit floorboard, in the state of forming a primary UV coating layer thereon, and side bite irregularities By forming in a state of forming a flattened state by sending a UV coating agent so that the side cross-section of the Hanji layer and the shape layer in a smoothly trimmed state can be reduced by moisture drying through the side of the floorboard.

The present invention described above is manufactured and completed in the same manner as in the following examples.

Example

The ready-made grade 1 waterproof plywood is cut into the size of 1000 x 900mm, the standard of Korean paper.

Hanji was immersed in the melamine resin stock solution, which was placed in 5 minutes at a temperature of 100-120 ° C. and dried for 2 to 3 minutes.

At the same time, the titanium paper printed with the solid wood pattern is immersed in the melamine resin stock solution, which is placed in 5 minutes of maintaining a temperature of 100-120 ℃ and dried for 1 to 2 minutes.

Next, after applying the melamine resin-based adhesive on the water-resistant plywood, put the impregnated Hanji and impregnated titanium paper in order in a heated flat press of approximately 1100 X 1000mm standard and pressurized for 1 to 2 minutes at 150 ℃, 90kg / ㎠ pressure .

The urethane-based UV coating agent is applied to the shape paper layer of the water-resistant plywood on which the Hanji layer and the shape paper layer are laminated with a roller, and a coating process and a drying process are performed four times to form a primary coating layer.

Next, it is cut to a size of 75 ~ 100mm x 900 mm to prepare a unit floorboard.

Next, the fitting portion 60 is formed so that yaw and iron are alternately formed on the side of the unit floorboard.

Next, the surface of the primary coating layer, the side alignment portion is sent to smooth and evenly trimmed.

Next, the urethane-based UV coating agent is applied with a roller so as to include the surface and side alignment portions of the primary coating layer, and a second coating layer is formed by applying a coating agent and a drying process twice by irradiating a UV lamp.

In the above embodiment, the pattern paper layer may use a printed wooden pattern on titanium paper, a transfer paper printed on a wooden pattern, and in this case, a method of thermal welding using an overlay film is used.

The present invention according to the above configuration can be resolved the cleavage of the disadvantages of the plywood by strengthening and reinforcing the surface of the water-resistant plywood the Hanji layer impregnated with melamine. In addition, the Hanji layer has a relatively uniform thickness and pressure resistance, so that shrinkage and expansion are significantly reduced during the hot pressing process, so that there is almost no deformation of the upper shape paper layer, thereby preventing distortion of the print pattern.

In addition, the surface of the UV coating layer is a layered structure is very strong and strong to prevent the penetration of moisture, has excellent effects against resistance to various scratches, fire resistance and the like. In particular, the secondary UV coating layer formed in the final step prevents water penetration into the side cross-section, thereby preventing discoloration of the morphology layer due to moisture, which is a fatal weakness of the reinforced floorboard, and peeling of the adhesive part. And quality can be maintained.

Claims (4)

The adhesive layer 20, the impregnated Hanji layer 30 on the water-resistant plywood 10, the pattern paper layer 40 formed by impregnating a titanium paper printed with a pattern of natural patterned wood with melamine resin, and a urethane UV coating layer Hanji floorboards characterized by a structure in which 50 are laminated in this order. The method of claim 1, wherein the impregnated Hanji layer is formed by a method of alternating the movement of the front-rear direction (MD) and the left-right direction (CD) in the form of papermaking, respectively, so that the fibers are entangled in a lattice form in the x-y direction. Hanji floorboards, characterized in that formed in a 1-4 layer structure. The paperboard floorboard according to claim 1, wherein the pattern paper layer is formed by attaching an overlay film to a transfer paper on the paper layer to heat-bond. Immerse the Korean paper in the melamine resin stock solution, and put it in 5 minutes at a temperature of 100-120 ° C. and dry it for 2 to 3 minutes to prepare the impregnated paper. Titanium paper printed with solid wood pattern is immersed in the stock solution of melamine resin. It is put in 5 minutes of maintaining the temperature of ℃ and dried for 1 to 2 minutes to prepare the impregnated paper, apply a melamine resin-based adhesive on the water-resistant plywood, put the impregnated Hanji and impregnated titanium paper in the order of the heated flat press By laminating the shape paper layer, the Hanji layer, and the water-resistant plywood, and applying a urethane-based UV coating agent to the shape paper layer of the water-resistant plywood on which the Hanji layer and the shape paper layer were laminated with a roller and irradiating the UV lamp. Four times to form a primary coating layer, cut this to the unit floorboard size of 75 ~ 100mm x 900 mm size and form the uneven part on the side The coating and drying process is performed by applying a urethane-based UV coating agent with a roller and irradiating the UV lamp so as to combine the surface and side-alignment of the primary coating layer of the unit floorboard. 2 to 3 times to form a secondary coating layer, a method for manufacturing a Hanji floorboard.

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