KR20140091277A - Flooring and Manufacturing method thereof - Google Patents

Flooring and Manufacturing method thereof Download PDF

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Publication number
KR20140091277A
KR20140091277A KR1020130003352A KR20130003352A KR20140091277A KR 20140091277 A KR20140091277 A KR 20140091277A KR 1020130003352 A KR1020130003352 A KR 1020130003352A KR 20130003352 A KR20130003352 A KR 20130003352A KR 20140091277 A KR20140091277 A KR 20140091277A
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KR
South Korea
Prior art keywords
layer
surface layer
embossment
ink
resin
Prior art date
Application number
KR1020130003352A
Other languages
Korean (ko)
Inventor
김규열
Original Assignee
(주)엘지하우시스
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by (주)엘지하우시스 filed Critical (주)엘지하우시스
Priority to KR1020130003352A priority Critical patent/KR20140091277A/en
Publication of KR20140091277A publication Critical patent/KR20140091277A/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/16—Drying; Softening; Cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Abstract

The present invention relates to a flooring material capable of realizing a natural surface texture of a flooring material, as well as preventing a pressing, a scratching and discoloration.
To achieve this, the flooring material of the present invention comprises a base layer 110 made of any one of MDF, HDF and plywood; A surface layer 130 laminated on the upper surface of the base layer 110 via an adhesive layer 120 and having an embossment 131 made of any one of a neck pattern and various patterns on the surface; And a printing layer (140) formed by filling the embossment (131).
According to the present invention, a surface layer made of a thermoplastic resin is provided on the upper surface of the base layer, and a pattern of wood patterns or various patterns can be formed on the upper surface of the base layer, thereby realizing a natural surface texture of the flooring, The cost can be lowered, and there is an advantage that it is possible to prevent pressing, scratching and discoloration

Description

[0001] FLOORING AND MANUFACTURING METHOD [0002]

The present invention relates to a flooring material, and more particularly, to a flooring material capable of realizing a natural surface texture of a flooring material and capable of lowering the manufacturing cost, and a method for producing the same.

In general, the flooring material is constructed to cover and decorate the concrete floor which is constructed on the indoor floor of the building, and to have a natural wood texture effect as a whole while producing a luxurious indoor atmosphere.

It is well known that, along with the development of the plywood manufacturing technology, the utilization of the logs is enhanced and a lot of plywood having excellent physical properties are provided. The plywood is produced by laminating a thin sheet of wood thinly cut and rounding the wood by a method in which the chips are arranged in a direction perpendicular to each other without cutting the wood or the wood material directly from the wood, And then molding the plate into a plate having a predetermined thickness.

By doing so, the plywood does not have a certain direction of orientation as compared with the wood plate having the texture, so that there is almost no distortion, and the endurance and the like are improved in all directions. However, the plywood processed by this method has a problem that the decoration property is deteriorated because there is no texture of the wood itself due to its processing characteristics.

Therefore, when such plywood is used for flooring materials such as flooring and other building materials, the surface is decorated with veneer and the surface thereof is coated with a resin paint to impart resistance to water resistance and scratching .

As an example of manufacturing this kind of indoor flooring, there is a method of manufacturing a flooring material by bonding a veneer single plate to the upper surface of a plywood with urea resin. Particularly, in order to improve the appearance effect, the surface of the veneer is ground with a brush or the like, and then the appearance and effect are improved by coloring and surface treatment.

However, such a manufacturing method has a disadvantage in that it is difficult to form the desired thickness of the veneer to a desired thickness, and the resistance to water and heat is very weak.

Particularly, a flooring material using such a veneer has a problem in that discoloration, scratching, and deformation due to moisture occur when used.

It is an object of the present invention to provide a flooring material capable of realizing a natural surface texture of a flooring material, as well as preventing depression, scratching and discoloration.

According to an aspect of the present invention, there is provided a flooring material comprising: a base layer made of any one of MDF, HDF, and plywood; A surface layer laminated on an upper surface of the base layer through an adhesive layer and having an embossment formed of any one of a neck pattern and various patterns on the surface; And a printing layer formed by embossing the emboss.

In this case, the surface layer is formed of at least one of a thermoplastic resin including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene) and PVC (vinyl chloride resin).

Further, the embossment is characterized in that it is formed between the rotating embossing roller and the surface layer so as to be engraved.

And a UV coating layer is laminated on the surface layer provided with the print layer.

The printing layer may include a UV curable resin including a dye or a pigment, and a thermoplastic or thermosetting resin.

A method for manufacturing a flooring material, comprising: forming a surface layer using a thermoplastic resin; Pressing the upper surface of the surface layer repeatedly to form an emboss having any one of a neck pattern and various patterns; Filling the emboss with ink to form a print layer; Forming a base layer made of any one of MDF, HDF, or plywood; Forming an adhesive layer on the base layer; And stacking a surface layer integrally on the adhesive layer so that the print layer faces upward.

In this case, the surface layer is formed of at least one of a thermoplastic resin including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene) and PVC (vinyl chloride resin).

The embossment is formed at an engraved surface through a process of passing the surface layer between a pair of rotating embossing rollers to press the upper surface of the surface layer.

The embossment is formed after softening the surface layer at a temperature of 130 to 190 캜.

The printing layer forming step may include: applying the ink onto the top surface of the surface layer to be transferred; And scraping the upper surface of the surface layer so that the applied ink is filled in the embossment.

The printing layer may be formed by filling a UV curable resin, a thermoplastic resin or a thermosetting resin including a dye or a pigment into the embossment and then curing the same.

The step of filling the ink in the embossment is characterized by comprising a doctor blade which is installed in a horizontal direction perpendicular to the conveying direction of the surface layer and at least one end thereof is brought into contact with the surface of the surface layer to scrape the upper surface thereof do.

Further, the doctor blade is characterized by being made of any one of soft rubber, urethane or synthetic resin.

According to the present invention, a surface layer made of a thermoplastic resin is provided on a top surface of a base layer, and a neck pattern or various pattern patterns are formed on the top surface of the base layer, thereby reducing the manufacturing process and the unit cost. Surface texture can be realized, and there is an advantage that pressing, scratching and discoloration can be prevented.

1 is a perspective view showing a flooring according to the present invention,
2 is a side cross-sectional view showing a laminated structure of a flooring according to the present invention,
3 shows another embodiment of the flooring according to the present invention,
FIG. 4 is a view showing an apparatus for manufacturing a flooring material according to the present invention,
5 is a flowchart illustrating a process for manufacturing a flooring according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In the drawings, the same reference numerals as in the drawings denote the same elements in the drawings, unless they are indicated on other drawings.

FIG. 1 is a perspective view showing a flooring according to the present invention, and FIG. 2 is a side sectional view showing a laminated structure of a flooring according to the present invention.

1 and 2, a flooring 100 according to a preferred embodiment of the present invention includes a base layer 110 made of any one of MDF, HDF, and plywood, A surface layer 130 which is laminated via an adhesive layer 120 and has an embossment 131 made of any one of wood patterns and various patterns on its surface and a UV curable resin containing a dye or pigment in the emboss 131, And a printing layer 140 formed by filling an ink containing a thermoplastic or thermosetting resin (hereinafter collectively referred to as ink).

The configuration of the present invention will be described in detail as follows.

The base layer 110 may be formed of any one of MDF (Medium Density Fiberboard), HDF (High Density Fiberboard), and Plywood. have. As already known, MDF and HDF are made by mixing wood flour with glues, compressing them flatly and making them like plywood.

More specifically, the MDF can perform complicated machining operations with uniform fiber distribution over the entire thickness and with a dense structure, without rupture of the side or side. It is also very suitable for overlaying or painting decorative films, veneers, etc., because the surface is solid and smooth. In addition, because of its excellent stability, machinability and high strength, the drawer side, cabinet rail, mirror frame and molding are of course used as flooring as in the present invention.

HDF is a high-density fiberboard with a density of 900 kg / ㎥ or higher, which is much higher than MDF in terms of strength and is widely used as a substitute for plywood, and is widely used as furniture and reinforced flooring.

In this case, the present invention will be described with reference to an example in which the base layer 110 is formed of a plywood.

The surface layer 130 may be made of one or more of thermoplastic resins including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene), PVC (vinyl chloride resin). That is, the surface layer 130 is formed by extrusion or various methods, and then the embossment 131 is formed on the upper surface of the surface layer 130. At this time, the surface layer 130 is heated to a predetermined temperature (130 to 190 DEG C) to be softened. Therefore, it is preferable that the surface layer 130 is made of a thermoplastic resin which can be softened by applying heat.

Referring to FIG. 4, the embossment 131 may be embossed through a process of passing and pressing the surface layer 130 between a pair of rotating embossing rollers R. More specifically, the pair of embossing rollers R maintain a predetermined clearance so as to form the embossment 131 with a constant pressing force without damaging the upper surface of the surface layer 130 which is press-fitted in one direction.

At least one of the pair of embossing rollers R has a protruding portion R1 having a predetermined shape for pressing one surface of the surface layer 130 to form the embossment 131. Here, preferably, the protrusion R1 may be formed on a roller provided on the upper side.

The emboss roller R having such a structure receives the power of a motor (not shown) provided at one side and is rotated at a constant speed, So that the emboss 131 is repeatedly formed.

The print layer 140 is filled in the embossment 131 to enhance the appearance of patterns such as a neck pattern or various patterns. Preferably, the printing layer 140 may be made of UV ink or liquid PVC having various colors.

In this case, the printing layer 140 may be formed by filling any one of UV ink or ink of liquid PVC in the embossing 131 and then curing (gelling) the ink.

More specifically, after the ink is applied to the upper surface of the surface layer 130 to be transferred, the ink applied to the printing layer 140 is filled only in the embossment 131, The upper surface of the surface layer 130 may be scratched. The specific formation process of the print layer 140 will be described later.

On the other hand, a UV coating layer 150 may be further formed on the surface layer 130 including the print layer 140 so as to protect the surface (see FIG. 3).

The manufacturing process of the flooring according to the present invention will now be described with reference to FIG.

First, the surface layer 130 is formed using at least one of thermoplastic resins including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene), and PVC (vinyl chloride resin). At this time, the surface layer 130 may be formed by various methods such as extrusion and injection. In the present invention, the method of manufacturing the surface layer 130 is not limited (S1).

The completed surface layer 130 is conveyed in one horizontal direction through a conveyance unit 10 including a conveyor or a plurality of rollers that are rotated by receiving power of a motor (not shown). A heating unit 20 for heating and softening the surface layer 130 at a predetermined temperature (130 to 190 ° C) immediately before a pressing process of forming embossed embosses 131 on the surface of the surface layer 130 to be transferred, .

The softened surface layer 130 is formed on the upper surface of the surface layer 130 while passing through the embossment forming part 30 including a pair of rotating embossing rollers R, The embossment 131 is repeatedly formed (S3).

The surface layer 130 on which the embossment 131 is formed is continuously conveyed in one horizontal direction and the surface layer 130 is passed through the ink spraying part 40 for applying any one of UV ink or ink of liquid PVC on the surface.

The surface layer 130 immediately after the application of the ink is provided in a horizontal direction orthogonal to the transport direction and is provided with a doctor blade 50 for scraping the upper surface of the surface layer 130 so that at least one end of the surface layer 130 is in contact with the surface of the surface layer 130, . In this case, the doctor blade 50 is preferably made of soft rubber, urethane or synthetic resin. The doctor blade 50 having such a structure scatters the upper surface of the surface layer 130 passing therethrough so that the ink applied is filled in the embossment 131 while at the same time the ink applied to the other portions is swept away . In other words, the ink applied on the upper surface of the surface layer 130 is filled only in the emboss 131 formed at a negative angle, and the printed layer 140 is finally completed after the process of curing the filled ink (S5) .

When the surface layer 130 provided with the print layer 140 is provided through the above process, the surface layer 130 is provided with the base layer 110 made of any one of MDF, HDF and plywood (S7).

Then, an upper layer of the base layer 110 is integrally laminated via an adhesive layer 120. In this case, the surface layer 130 is laminated such that the print layer 140 faces upward.

Preferably, the surface layer 130 is stacked on the base layer 110, and the upper surface of the surface layer 130 is pressurized by using a press or a roller, so that a firm bonding state can be achieved (S9).

The flooring material 100 manufactured through the process described above is further provided with protrusions and coupling grooves (not shown) to be coupled thereto so as to facilitate the assembly of the flooring material 100 arranged in succession on the right and left or longitudinally bonded surfaces of the flooring material 100 .

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention.

100: flooring material 110: base layer
120: adhesive layer 130: surface layer
131: Emboss 140: Printed layer
150: UV coating layer

Claims (13)

A base layer 110 made of any one of MDF, HDF, and laminate;
A surface layer 130 laminated on the upper surface of the base layer 110 via an adhesive layer 120 and having an embossment 131 made of any one of a neck pattern and various patterns on the surface; And
And a printing layer (140) formed by filling the embossment (131) in the embossment (131). The method according to claim 1,
The surface layer (130)
Wherein the thermoplastic resin comprises at least one of thermoplastic resin including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene) and PVC (vinyl chloride resin). 3. The method according to claim 1 or 2,
The embossment (131)
And the surface layer (130) is passed between a pair of embossing rollers (R) that are rotated so as to form an engraved surface. The method of claim 3,
In the upper part of the surface layer 130 provided with the print layer 140,
Lt; RTI ID = 0.0 > UV < / RTI > coating layer (150). The method according to claim 1,
The printing layer 140 may be formed,
A UV curable resin comprising a dye or pigment, and a thermoplastic or thermosetting resin. Forming a surface layer (130) using a thermoplastic resin;
Repeatedly forming an embossment 131 of any one of a neck pattern and a variety of patterns by pressing the upper surface of the surface layer 130;
Filling the ink in the embossment (131) to form a printing layer (140);
Forming a base layer (110) made of any one of MDF, HDF or plywood;
Forming an adhesive layer (120) on the base layer (110); And
And stacking the surface layer (130) integrally on the adhesive layer (120) so that the print layer (140) faces upward. The method according to claim 6,
The surface layer (130)
A thermoplastic resin including PLA (Poly Lactic Acid), PE (polyethylene), PP (polypropylene) and PVC (vinyl chloride resin). 8. The method according to claim 6 or 7,
The embossment (131)
Wherein the surface layer (130) is formed between the pair of emboss rollers (R) by rotating the upper surface of the surface layer (130) while pressing the upper surface of the surface layer (130). 9. The method of claim 8,
The embossment (131)
Wherein the surface layer (130) is formed after softening the surface layer (130) at a temperature of 130 to 190 ° C. The method according to claim 6,
The step of forming the print layer (140)
Applying the ink to an upper surface of the surface layer 130 to be transferred; And
And scraping the top surface of the surface layer (130) so that the applied ink is filled in the embossment (131). 11. The method of claim 10,
The printing layer 140 may be formed,
Wherein the embossment (131) is formed through a process of filling any one of a UV curable resin including a dye or a pigment, a thermoplastic resin or a thermosetting resin and curing the same. 11. The method of claim 10,
The step of filling the ink in the embossment (131)
And a doctor blade (50) installed in a horizontal direction orthogonal to a conveying direction of the surface layer (130), at least one end of the doctor blade (120) being arranged to abut the surface of the surface layer (130) Method of manufacturing flooring material. 13. The method of claim 12,
The doctor blade (50)
Characterized in that it is made of one of soft rubber, urethane or synthetic resin.
KR1020130003352A 2013-01-11 2013-01-11 Flooring and Manufacturing method thereof KR20140091277A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
KR1020130003352A KR20140091277A (en) 2013-01-11 2013-01-11 Flooring and Manufacturing method thereof

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104405107A (en) * 2014-11-27 2015-03-11 常熟市金达洁净墙地板有限公司 Wear-resisting floor
KR20180095272A (en) 2017-02-17 2018-08-27 주식회사 케이씨씨 Method for manufacturing floor mateial and floor material manufactured therefrom
KR20220142614A (en) * 2021-04-15 2022-10-24 신동호 Manufacturing method of eco-friendly flooring material using urea resin

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104405107A (en) * 2014-11-27 2015-03-11 常熟市金达洁净墙地板有限公司 Wear-resisting floor
KR20180095272A (en) 2017-02-17 2018-08-27 주식회사 케이씨씨 Method for manufacturing floor mateial and floor material manufactured therefrom
KR20220142614A (en) * 2021-04-15 2022-10-24 신동호 Manufacturing method of eco-friendly flooring material using urea resin

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