KR20070053845A - Natural reinforced wood flooring having natural patterned wood and high density fiberboard and process for preparing the same - Google Patents

Abstract

The present invention relates to a flooring material using veneer and high density fiberboard (HDF) as a base material and a method for manufacturing the same, preferably, the veneer and high density fiberboard are integrated into an adhesive layer, and an ultraviolet or heat curable surface treatment layer and a back surface on the upper and lower surfaces thereof. It is composed of layers, and provides a flooring material characterized in that it has a finished product form that is cut to the appropriate specifications and processed into T & G form.

In this case, by removing the banana shape that occurs in the plywood process in which the veneer and high-density fiber board are integrated, the work time is significantly reduced from at least 1 hour to less than 5 minutes, thereby significantly improving the dimensional stability, productivity and workability. Can be improved.

The flooring material of the present invention provides a natural texture, such as solid wood, using natural veneer on the surface layer, and by using a high-density fiberboard as a base material layer, the durability, such as scratch resistance, impact resistance, etc. is stronger than conventional plywood floor, and existing reinforced floor Contrast It has the advantage of strong dimensional stability and resistance to moisture.

HDF, veneer, flooring, flooring

Description

Natural reinforced wood flooring having natural patterned wood and high density fiberboard and process for preparing the same}

1 is a cross-sectional view of the floor covering according to the present invention.

Figure 2 is a manufacturing process of the floor covering according to the present invention.

Figure 3 is a plan view of the finished product having T & G (Tongue and Groove) form of the flooring according to the invention.

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

10: surface layer 11: surface treatment layer

12: veneer 20: adhesive layer

30: substrate layer 31: high density fiber board (HDF)

32: back layer 40: first step

50: second step 60: third step

70: Tongue 80: Groove

The present invention relates to a flooring material using a veneer and a high density fiber board (HDF) as a base material and a method of manufacturing the same. More specifically, the veneer and high density fiber boards are integrated into an adhesive layer, and an ultraviolet or heat curable surface treatment layer and a back layer on the upper and lower parts thereof. It consists of, and relates to a flooring material and its manufacturing method characterized in that it has a finished product form processed in T & G form after being cut to the appropriate standard.

Conventional natural veneer plywood ondol flooring flooring has the advantage of excellent dimensional stability against heat and moisture by using the plywood plywood layer, but not only the density of veneer itself, but also the plywood plywood (0.6 to 0.8 ㎏ / ㎥) Because of its low density, the surface scratch resistance was measured by diamond needles even when UV-coated on the surface, and the impact resistance was measured by free fall of 225 g metal balls. This value is generally unsatisfactory because users inadvertently drop household items when using flooring or damage the flooring surface when moving heavy objects.

On the other hand, reinforced floor flooring, which laminates the melamine-impregnated overlay sheet on the printing layer based on high-density fiberboard for surface reinforcement, has a stronger surface than water-resistant plywood flooring, but is sensitive to moisture because it uses thermosetting melamine resin as the surface material. The surface has very brittle characteristics, which not only has the disadvantage of partial breakage, such as breaking or stamping of impact parts when a sharp or heavy object falls over a certain load, but also a low texture expressed in a printed form. Compared to domestic plywood flooring flooring, its appearance is artificial and its application is limited.

Korean Patent Laid-Open Publication No. 2003-94934 discloses a sound-proof flooring material characterized in that the surface layer and the base material layer are bonded to the phenol compound resin layer, and the soundproof sheet is bonded to the bottom surface of the base material layer to the phenol compound resin layer. A soundproof flooring material using a perforated base material layer and a soundproof sheet.

Korean Patent Laid-Open No. 2004-95136 discloses a reinforced ondol floorboard in which a high-pressure resin-injected natural veneer layer, an adhesive layer, and a back grooved substrate layer are laminated from above, but this is an amino-based resin that is not processed by conventional methods. It relates to a primer treatment UV coating method to be coated on the surface of the product impregnated with.

In Korean Patent Publication No. 2000-71992, a glass fiber layer, an adhesive layer, a veneer layer, and a surface coating layer are sequentially stacked on a vinyl chloride resin layer, and the veneer layer is impregnated with a water-resistant impregnation resin. Although a veneer laminated vinyl chloride resin flooring is disclosed, it relates to preventing discoloration, curling, and cracking of veneer by water-impregnating the veneer.

The present invention has been made in order to solve the problems of the above-mentioned conventional flooring material, it is possible to obtain a natural texture, such as solid wood using natural veneer, to prevent surface damage such as clipping, cracking by heavy or sharp objects It is to provide a flooring material with improved surface properties.

It is another object of the present invention to provide a method of manufacturing a floor covering comprising a method of removing a banana shape, which is apt to occur in the bonding process in the manufacture of laminated wood flooring, and integrating a veneer and a high density fiberboard having improved workability and productivity. It is.

Still another object of the present invention is to provide a flooring material having a stable rate of dimensional change due to humidity and temperature of a use environment.

In order to achieve the above object, the present invention provides a flooring material comprising a veneer and a high-density fiber board (HDF) integrated with an adhesive layer, and having a surface treatment layer and a backing layer at the top and bottom, respectively.

In the present invention, the back layer is formed of at least one selected from ultraviolet curable paint, thermosetting paint, wax, paper, silicone water repellent, silicone waterproof agent, and synthetic resin, and preferably UV curable as the top surface treatment layer. Or it is formed by coating a thermosetting paint.

In the present invention, the adhesive used in the adhesive layer is preferably a solvent-free adhesive to consider environmental pollution and improve productivity and workability. Specifically, an epoxy-based, polyurethane-based, polyisocyanate-based, polyester-based, acrylate-based, ethylene -At least 1 sort (s) chosen from vinyl acetate copolymer, polyamide type, and synthetic rubber type resin is used.

In the present invention, the adhesive layer may be added 0.1 to 50 parts by weight based on 100 parts by weight of the adhesive, at least one selected from wheat flour, starch and soy flour, for the purpose of improving workability and adhesion in addition to the adhesive. 1 type selected from isothiazolin compounds and derivatives thereof, sodium bisulfite, peroxides, periodic acid and derivatives thereof, and halogen compounds The above can be added in 0.01-10 weight part with respect to 100 weight part of adhesive agents.

In the present invention, the surface treatment layer is formed of one or more resins selected from epoxy resins, polyamide resins, urea resins, and acrylate resins, and includes silica, clay minerals, ceramics, At least one inorganic material selected from glass chops may be added in an amount of 0.1 to 20 parts by weight based on 100 parts by weight of the resin.

The veneer used in the present invention is a wet veneer having a thickness of 0.15 to 0.35 mm or a dry veneer having a thickness of 0.35 to 1.0 mm.

The flooring material of the present invention finally has a connection structure by means of T & G (Tongue and Groove), click system, or connector to be mutually coupled.

In addition, the present invention comprises the steps of forming a back layer under the high-density fiber plate; Adhering veneer on top of the high density fiberboard; Forming a surface coating layer on the veneer; It provides a method for producing a floor covering comprising the step of cutting and shape processing.

In the step of bonding the high-density fiber board and veneer, in the case of room temperature-curable adhesive, pressurizing at a pressure of 10 to 120 kg / cm2 at a temperature of 5 to 40 ° C, and in the case of thermosetting adhesive, 10 to 120 at a temperature of 100 to 200 ° C. It is preferable to integrate by heating and pressing for 15 to 5 minutes at a pressure of kg / cm 2.

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

Figure 1 illustrates the overall configuration of the floor covering according to an embodiment of the present invention, the floor covering is largely composed of a base layer 30 and the surface layer 10 and an adhesive layer 20 for integrating them, The surface layer 10 has a structure in which the veneer 12 and the surface treatment layer 11 are laminated from below, and the base layer 30 is composed of the back layer 32 and the high-density fiber board 31 from below. .

The Mooney 12 is used to create a natural texture effect of the wood, according to the needs of the consumer Oak, Birch, Birch, Cherry, Maple, Walnut All species used as veneer can be applied.

Typically, a veneer sliced solid wood is used. Specifically, a solid veneer with a thickness of 0.15 to 0.35 mm or a dry veneer with a thickness of 0.35 to 1.0 mm may be used by cutting the solid wood with a rotary lace or a slicer.

In order to improve the water resistance and hardness as necessary, urea resin, urea melamine resin, melamine resin, phenol resin, acrylic resin, polyester resin, unsaturated polyester resin, epoxy resin, One kind of resin is selected from polyvinyl acetate resin and urethane resin, and impregnated with 30 to 150 parts by weight relative to the weight of natural veneer, followed by drying and semi-cured veneer for 20 seconds to 4 minutes in an oven at 80 to 150 ° C. have.

It is preferable that the high density fiber board 31 has a specific gravity of 0.85 to 1.1 g / cm 3. High Density Fiberboard (HDF) is considerably harder than Medium Density Fiberboard (MDF) or Particleboard (PB), has excellent water resistance, dimensional stability, and high mechanical strength. Therefore, dimensional stability, impact strength and moisture resistance are used when used as a base layer of flooring material. Can be greatly improved.

This high density fiberboard is cheaper than water-resistant plywood, has improved wear resistance and impact resistance, and is used after defects such as cracks and knots are removed, so that wood raw materials can be effectively used, and fibers are uniformly arranged in each direction. Physical property is uniform. In addition, HDF can be easily processed, and after processing, a very smooth and smooth surface can be obtained, so that the flooring material produced using the same gives the surface a smooth and soft feeling. And it is possible to realize the integrated mechanical fixing system, for example, the click construction structure, the connection structure by the connector to form the floor floor material in the vertical or horizontal direction, and the coupling between the floor materials is released by elastically accommodating the expansion force and the contraction force. It can avoid being lost or damaged.

Based on the above-mentioned advantages of HDF, the advantages that can be expressed by combining natural veneer that can give natural texture are compared with the existing wood floor, plywood floor and reinforced floor flooring, respectively.

Compared to the floor of wood, the price is low and the moisture resistance is strong. The surface strength is strong due to the high density fiber board base material. The disadvantages of plywood flooring, durability, scratch resistance and impact resistance are significantly improved, and sound insulation and walkability are excellent. Due to the use of the printed layer, the wood texture is natural wood, compared to the reinforced floor falling compared to plywood flooring, the present invention using natural veneer is the most significant point that can represent a natural texture.

In general, laminated wood flooring may be curved laterally due to non-uniform humidity ratios in the substrate layer at the time of manufacture, and such banana shapes may cause bond gaps.

Therefore, the flooring material of the present invention has a structure in which the back surface layer 31 is added to the back surface to maintain the balance in order to impart the dimensional stability of the high density fiber board 31.

The back layer 32 is a paper material or a melamine resin impregnated paper, UV or thermosetting paint, polyolefin-based synthetic resins, silicone-based water repellents, silicone-based, such as a parchment paper mainly used as a base layer of a general reinforced floor It is composed of a general resin coating layer such as a waterproofing agent, wax, etc. At this time, the back layer 32 must be provided to the entire process of bonding the veneer 12 to the high density fiber board 31, which is hardened by the adhesive and the high density fiber board 31. Shrinkage or curling is formed by shrinking the adhesive coating surface of the), in order to maintain the balance of the high-density fiber board 31 to prevent this.

The adhesive layer 20 is for integrating the high density fiber board 31 and the veneer 12, wherein the adhesive may be epoxy, polyurethane, polyisocyanate, polyester, acrylate, ethylene-vinyl acetate It is a compound, such as a copolymer, polyamide type, and synthetic rubber type resin, Especially ethylene vinyl acetate is preferable.

In general, widely used solvent-based adhesives cannot be used in recent years due to strict regulations on volatile organic compounds (VOC) and cause sick house syndrome. In addition, recently, an aqueous adhesive that replaces a solvent type adhesive as an environmentally friendly adhesive cannot be used to accompany the banana phenomenon of high density fiber boards as a result of the drop in moisture content of wood in the thermocompression bonding process for laminating veneer on a high density fiber board. Therefore, solvent-free adhesives are essential, which can reduce the amount of formaldehyde dissipation and prevent the generation of volatile organic solvents, and significantly shorten the plywood process of bonding veneer and dense fiberboard to integrate them for at least one hour or more within five minutes. This significantly improves dimensional stability, productivity and workability.

Wheat flour, starch, extracted soy flour or mixtures thereof may be added to the adhesive, of which wheat flour and starch are preferred, and wheat flour is more preferred. The additive, particularly wheat flour, is added in an amount of 0.1 to 50 parts by weight, preferably 25 parts by weight or less, based on 100 parts by weight of the synthetic resin adhesive, in view of improving workability and adhesion. These additives, in particular wheat flour, improve the water resistance as well as the thickening and filling role of the adhesive, and do not adhere in cold water, but serve to adhere by heat. The wheat flour is finally added at the time of mixing the adhesive, but when it is added 10 parts by weight or more, it is preferable to add it in small portions to prevent agglomeration.

In addition, antimicrobial agents or preservatives which have excellent effects on the microorganisms of the wood and adhesives against microorganisms, in particular against bacteria and fungi, may be added. The antimicrobial agent, preservative, and the like can be added to 0.01 to 10 parts by weight with respect to 100 parts by weight of the adhesive, but in order not to change the adhesive properties is preferably added to 2.0 parts by weight or less. As an antimicrobial agent or an antiseptic agent, an isothiazolin compound and its derivatives, sodium bisulfite, peroxide, periodic acid and its derivatives, halogen-based compounds including chlorine and bromine compounds can be used.

The surface treatment layer 10 is finished by surface coating treatment on the veneer 20, the surface treatment layer is generally composed of a primer (Primer), undercoat, middle and top coat layer from below.

The surface treatment layer 10 is a UV-curable or heat-curable synthetic resin containing urethane acrylate as a main component, in order to impart high-strength surface properties with improved damage due to abrasion or impact, epoxy resin, polyamide resin, and urea. It is preferable to use 1 or more types of resin among resin and an acrylate resin, and especially epoxy resin is preferable.

In addition, it is possible to secure such high-strength surface properties as an additive. In this case, 0.1 to 20 parts by weight based on 100 parts by weight of a resin such as urethane acrylate so as not to affect the transparency of inorganic materials such as silica, clay mineral, ceramic, glass fiber, and the like. It is used by dispersing within the range by weight.

In the flooring material of the present invention, it is preferable that the finished product is processed in a general T & G shape in consideration of the ease of assembly, but in an integrated mechanical fixing system, for example, a click construction structure, a connector, which is combined in a vertical or horizontal direction. It may have a connection structure.

Figure 2 is a manufacturing process of the floor covering according to an embodiment of the present invention, the manufacturing process is largely divided into the following three processes.

The first process 40 is a process of applying the back layer 32 to the lower portion of the high density fiber board 31. At this time, by forming the back layer 32 before the bonding process of the high density fiber board 31 and the veneer 12, it is possible to prevent distortion or curling to maintain the balance of the high density fiber board 31.

The second process 50 is the bonding process of the veneer 12 and the base material layer 30. In the second step 50, the veneer 12 and the base layer 30 may be formed of an adhesive 20 such as a thermosetting melamine resin, a thermosetting or room temperature curing urethane, an epoxy resin, polyvinyl alcohol, polyvinylacetate, and acrylate. To bond.

At this time, in the case of the room temperature-curable adhesive, the veneer layer 12 and the base layer 30 are integrated by pressing at a pressure of 10 to 120 kg / cm 2 at a temperature of less than 40 ° C. In the case of a thermosetting adhesive, the temperature is 100 to 200 ° C. at a temperature of 10 to 120 kg / cm 2 for 15 seconds to 5 minutes for integration and heating.

The reason for the heat pressurization for such a short time is to prevent distortion or curling of the base layer 30. In general, the thermal pressure time of wood is closely related to the moisture content of wood. If the moisture content of the wood is lowered due to the high temperature, the wood may warp, causing product defects.

Therefore, the shortening of the thermal pressure time is recognized as an important problem because it is closely related to not only productivity but also defective rate. As a result of the shortening of the heat pressure time during the plywood process, the productivity of the veneer of the present invention and the substrate layer were greatly improved, and the dimensional stability was improved by removing the banana phenomenon of the final product by maintaining the moisture content of the wood.

The third process 60 is a cutting and processing process of flooring material. In the third step (60), the panel integrated through the second step (50) is usually cut to the size of a general flooring material, and then, on the veneer 12, an ultraviolet curable or thermosetting surface treatment layer containing urethane acrylate as a main component. (11) is coated to complete the surface layer (10).

In the processing process, as shown in Figure 3, the four sides in the longitudinal direction and the width direction, it is preferable to produce the appearance of the flooring flooring by processing into two parts of the tongue (70), Groove (80), It can also be machined into an integrated mechanical fixation system that combines in a vertical or horizontal direction, such as a click system or a system using connectors.

Hereinafter, preferred embodiments of the present invention will be described. However, the following examples are for illustrating the present invention, and the present invention is not limited to the following examples.

EXAMPLE

The high-density fiber board 31 is coated with a backing layer 32 on the base material layer 30 coated with a synthetic resin layer 20 on top of the natural veneer 12 and the UV cured surface treatment layer 11. The laminated surface layer 10 was laminated to manufacture a floor covering having a structure as shown in FIG. 1.

Comparative Example 1

Plywood floor made of water-resistant plywood laminated with natural veneer on top and UV cured surface treatment layer

Comparative Example 2

Reinforced floor laminated with surface layer of melamine resin based on high density fiberboard

[Test Example]

The surface properties of the flooring materials of Examples and Comparative Examples 1 and 2 were compared, and the results are shown in Tables 1 and 2.

test item Comparative Example 1 Comparative Example 2 Example Surface roughness 10 cm 50 cm 55 cm Surface cracking 20 cm 30 cm 100 cm

test item Comparative Example 1 Comparative Example 2 Example Dimensional stability L 80 ℃ -0.26% -0.32% -0.15% L dipping 0.07% 0.11% 0.04% W 80 ℃ -0.32% -0.35% -0.24% W dipping 0.11% 0.15% 0.04%

Surface testability of the test items in Table 1 is a measure of the drop height that damages the surface when free-falling screwdriver weighing 110 g perpendicular to the surface of the flooring material to be measured. According to the measurement results of Table 1, in the case of the reinforced floor using a thermosetting melamine resin as a surface layer (Comparative Example 2), the marks were generated on the surface of the vertical free fall at the height of 50 cm with a flat-blade screwdriver. In Example), the mark was generated at the height of 55 cm, which is higher than the reinforced floor.

The surface cracking property of the test item of Table 1 measured the fall height at which the surface is broken when freely dropping the iron hole of diameter 3cm and weight 228g perpendicular to the surface of the flooring material to be measured. According to the measurement results of Table 1, in the case of the reinforced floor (Comparative Example 2), the surface cracks occurred from the height of 30 cm when freely falling the iron ball, while the flooring material (example) of the present invention is three times higher than this Surface cracking occurred when dropping iron balls at a height of 100 cm.

Inferred from the above two experimental results, the flooring material of the present invention has an excellent improvement effect on the surface of the surface caused by a heavy object or a sharp object, compared to the reinforced floor having the surface layer of the melamine resin material. You can conclude.

Table 2 compares the dimensional stability of the flooring materials of Examples and Comparative Examples, and measured the dimensional stability of the length (L) and width (W) direction at 80 ℃ and immersion conditions, respectively, flooring floor according to the present invention It can be seen that the dimensional stability of is superior to the flooring material of the comparative example.

As described above, the flooring material of the present invention uses natural veneer on the surface layer to provide a natural texture, such as solid wood, and by using a high-density fiberboard as the base layer, durability, such as scratch resistance, impact resistance, etc. than conventional plywood floor It is strong and has an excellent improvement effect on dimensional stability and water resistance compared to existing reinforced floor.

In addition, it is possible to provide natural texture and natural gentleness of the natural veneer itself instead of the artificial appearance by the printing layer known as a disadvantage of the existing reinforced floor. In addition, the conventional reinforced floor is composed of a surface layer of the melamine resin as a raw material has a problem that is bent or distorted depending on the humidity and temperature of the use environment has a structural constraint that must be attached to the balance layer on the back of the base layer, In the case of the present invention, the dimensional change rate due to humidity and temperature can produce a stable flooring material as compared to the melamine resin.

In this case, by removing the banana shape that occurs in the plywood process of bonding the veneer and the high density fiber board and integrating it, the dimensional stability, productivity and workability are remarkably improved by drastically reducing the working time from at least 1 hour to less than 5 minutes. You can.

Claims (12)

A flooring material comprising a veneer and a high-density fiber board (HDF) integrated with an adhesive layer, and having a surface treatment layer and a back layer, respectively, at the top and the bottom. The flooring material according to claim 1, wherein the back layer is formed of at least one selected from ultraviolet curable paint, thermosetting paint, wax, paper, silicone water repellent, silicone waterproof, and synthetic resin. The adhesive agent used in the said adhesive layer is a solvent-free adhesive, Epoxy type, polyurethane type, polyisocyanate type, polyester type, acrylate type, ethylene-vinyl acetate copolymer, polyamide type, synthetic rubber type resin Flooring material, characterized in that at least one selected from. 4. The flooring material according to claim 3, wherein at least one selected from wheat flour, starch and soy flour is added to the adhesive in an amount of 0.1 to 50 parts by weight based on 100 parts by weight of the adhesive. According to claim 3, wherein the adhesive isothiazolin-based compound and its derivatives, sodium bisulfite, peroxide, periodic acid and its derivatives, halogen-based compounds Flooring material characterized in that the addition of at least one selected from 0.01 to 2.0 parts by weight based on 100 parts by weight of the adhesive. The floor covering according to claim 1, wherein the surface treatment layer is formed of at least one resin selected from an epoxy resin, a polyamide resin, a urea resin, and an acrylate resin. 8. The floor according to claim 7, wherein at least one inorganic material selected from silica, clay mineral, ceramic, and glass chop is added to the surface treatment layer in an amount of 0.1 to 20 parts by weight based on 100 parts by weight of the resin. Flooring. The flooring material according to claim 1, wherein the veneer is a wet veneer having a thickness of 0.15 to 0.35 mm or a dry veneer having a thickness of 0.35 to 1.0 mm. The floor covering according to claim 1, wherein the floor covering has a connection structure by a Tongue and Groove (T & G), a click system, or a connector. Forming a backing layer under the high density fiberboard; Adhering veneer on top of the high density fiberboard; Forming a surface coating layer on the veneer; Method for producing a floor covering material comprising the step of cutting and shape processing. The method of claim 10, wherein in the bonding step of the high-density fiber board and veneer, the method of manufacturing flooring material, characterized in that the pressure is integrated at a pressure of 10 to 120 kg / ㎠ at a temperature of 5 to 40 ℃. The method of claim 10, wherein in the bonding step of the veneer of the high-density fiber board and veneer, it is integrated by heating and pressing for 15 seconds to 5 minutes at a pressure of 10 to 120 kg / ㎠ at a temperature of 100 to 200 ℃ Method of manufacturing flooring material to be.

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