KR20160032567A - High pressurized decorative laminate with thermosetting resin and non-flammable property for decoration floor panel - Google Patents

Abstract

The present invention relates to a nonflammable sheet applied in veneer flooring, which comprises: a core layer (10) formed by impregnating a nonflammable phenolic resin; a patterned paper layer (20) formed by impregnating a nonflammable melamine resin and attached to an upper side of the core layer (10); and an overlay layer (30) formed by laminating the nonflammable melamine resin and attached to the upper side of the patterned paper layer (20). Accordingly, it is possible to prevent fire by applying the sheet to the veneer flooring with increased flame retardancy as interior building materials, and the dimensional change can be reduced, as occurs in a production process by thermal bonding or while using the sheet as a flooring sheet.

Description

{High pressurized decorative laminate with thermosetting resin and non-flammable property for decoration floor panel}

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a sheet for stucco flooring, and more particularly, to a high-pressure flame-retardant non-combustible thermosetting resin for a stucco wood flooring that is formed by laminating a plurality of functional layers to a stucco flooring.

Conventional flame retardant (or nonflammable) techniques of general floorboards are carried out by attaching a separate flame-retardant impregnated paper to the top and bottom of the plywood, which is the core material of the floorboard, or by coating a resin layer including flame- However, the improvement of the flame retardant performance of the resin is insufficient to improve the flame retardancy of the whole floorboard. This is because the flame retardancy is basically contained by using a surface material impregnated with resin.

As a prior art document relating to flame retardancy or fire retardancy of a floorboard sheet, Korean Patent Registration No. 0452486 (Prior Art 1) by the present applicant, Korean Patent Registration No. 0824703 (Prior Art 2), etc. can be referred to .

The prior art document 1 includes a flame retardant melamine resin impregnated paper layer formed by laminating a melamine resin impregnated paper obtained by impregnating a flake of a flame retardant melamine resin impregnation paper; And a flame retarded phenolic resin impregnated layer formed by laminating a phenol resin impregnated paper obtained by impregnating a flame retardant phenolic resin impregnated liquid with kraft paper on the lower part of the flame retarded melamine resin impregnated paper layer. Accordingly, it is expected to prevent a major accident caused by a fire.

According to the prior art document 2, the low melting point thermoplastic resin fiber selected from polyethylene, polypropylene, polyvinyl chloride, polyester, and polyethylene-polyester copolymer and a polyester resin, a polyethylene resin, a nylon resin and a thermally fusible fluororesin A high-melting-point thermoplastic resin hollow fiber or a polyester composite air-entangled core yarn is mixed and opened to produce a mat, and then the mat is laminated using a stamperable sheet production apparatus. Accordingly, an excellent flame retardant effect is expected by impregnating an environmentally friendly flame retardant.

However, when the seat of the above-mentioned prior art is applied to the floor, the flame-retardant property is rapidly deteriorated because the surface material is burned before the core material layer when the flame reaches the floorboard when a fire occurs. If the surface material is not burned, the inner core material will not be burnt even if it receives heat, and only the outer shape will be slightly deformed, and it will not develop as a cause of fire. In recent years, it is important to improve the flame retardancy of stained wood flooring in the trend of avoiding PVC flooring.

1. Korean Registered Patent No. 0452486 "Flame Retardant Sheet Using Flame Retardant Resin Composition and Method for Manufacturing the Same" (Open date: March 29, 2003) 2. Korean Patent Registration No. 0824703 entitled "Flame retardant lightweight laminated sound absorbing sheet" (published on Apr. 24, 2008)

It is an object of the present invention to overcome the above-mentioned problems of the prior art by providing a flame-retardant thermosetting resin high pressure-reducing laminate for stucco wood flooring for producing a flocked floorboard having improved flame retardancy as a construction finish material by laminating with a plurality of functional layers .

In order to achieve the above object, the present invention provides a non-combustible sheet for a floorboard, comprising: a core layer formed by impregnating a non-combustible phenolic resin; A shape layer formed by impregnating a nonflammable melamine resin and bonded to the upper side of the core layer; And an overlay layer formed by impregnation with a nonflammable melamine resin and bonded to the upper side of the shape layer.

According to the detailed configuration of the present invention, the impregnation of the core layer contains an inorganic material selected from glass fiber, silicon dioxide, alumina and calcium carbonate, and the impregnation area of the overlay layer contains aluminum oxide.

As a modification of the present invention, a fire extinguishing agent layer is further provided between the core layer and the shape layer.

In this case, the extinguishing agent layer may be a powdery form selected from ammonium dihydrogenphosphate, sodium bicarbonate, silicon dioxide, aluminum hydroxide, and magnesium hydroxide.

As described above, according to the present invention, it is possible to prevent fire by applying the flame retardant as a building finishing material to a flouzing board having an increased flame retardancy, and at the same time, there is an effect of reducing the dimensional change during the manufacturing process by thermal bonding or during use as a floor board.

Fig. 1 is a constitutional view showing the incombustible sheet according to the present invention in a separated state
2 is a schematic view showing a lamination process of a non-combustible sheet according to the present invention
3 is a schematic view showing the completed state of the incombustible sheet according to the present invention

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

The present invention relates to a non-combustible sheet applied to a floor board. In particular, it can be applied to all kinds of architectural finishing materials including ceilings, walls, and the like in addition to the flooring, but is not necessarily limited thereto.

According to the present invention, the core layer 10 produced by impregnating a non-combustible phenolic resin is used as a base material. The core layer 10 is a material selected from paper (kraft paper), resin, and fiber (fabric), and maintains the mechanical strength corresponding to the tensile, compression, and shear loads of the finished product sheet. As an example of a phenol resin impregnating solution, a mixture prepared by mixing 2 to 3 parts by weight of ammonia and 45 to 55 parts by weight of methanol with respect to 100 parts by weight of a mixture of phenol and formalin in a molar ratio of 0.9 to 0.95 is used.

At this time, the core layer 10 may include a water-resistant material such as glass fiber, polypropylene, polyester, and carbon fiber. In addition, carbon black may be included to enhance the electromagnetic wave absorbing function, and a metal thin plate, a wire mesh, or the like may be included as a reinforcing material in accordance with the use of the sheet to increase the mechanical strength.

In addition, according to the present invention, the shape layer 20 is formed by impregnating a non-combustible melamine resin and is bonded to the upper side of the core layer 10. With respect to the optimum conditions and drying conditions of the melamine resin impregnating solution, reference can be made to the registered patent publication No. 0368329 and the registered patent publication No. 0329502 filed by the present inventor. 5 to 10 parts by weight of gypsum may be added to the melamine resin impregnation solution based on 100 parts by weight of the total composition. The shape layer 20 is formed by impregnating the melamine resin impregnation solution with a resin having a desired pattern so that the impregnation amount of the resin is 55 to 65% and drying. The titanium oxide-containing cellulose paper is preferable as the material of the shape layer 20, but is not necessarily limited thereto.

In addition, according to the present invention, the overlay layer 30 is formed by impregnation with incombustible melamine resin, and is bonded to the upper side of the shape layer 20. The overlay layer 30 is a material selected from paper, resin, and fiber, and maintains the flame retardancy, heat resistance, and abrasion resistance of the finished product sheet. The amount of melamine resin impregnation solution and the amount of impregnation are comparable to those of the above-mentioned type layer 20, but the content of melamine is relatively increased.

According to the detailed configuration of the present invention, the impregnation of the core layer 10 contains an inorganic material selected from glass fiber, silicon dioxide, alumina and calcium carbonate, and the impregnation area of the overlay layer 30 contains aluminum oxide . When inorganic powder (glass fiber, silicon dioxide, alumina, calcium carbonate) powder is mixed in the range of 5 to 20 mu m in particle size in the phenol resin impregnation solution of the core layer 10, the incombustibility and flame retardancy of the finished product sheet can be improved. The melamine impregnation solution of the overlay layer 30 is mixed with aluminum oxide powder in the range of 5 to 20 mu m in particle size to improve the incombustibility and flame retardancy.

On the other hand, in any of the above cases, it is preferable that the inorganic material is mixed in the range of 5 to 15 parts by weight relative to the impregnation solution. If the content of the inorganic material is less than the appropriate lower limit, the improvement of the flame retardancy is insufficient, and if the content exceeds the upper limit, the bonding force in the laminated state is weakened.

As a modification of the present invention, an extinguishing agent layer (40) is further provided between the core layer (10) and the surface layer (20). The extinguishing agent layer 40 interrupts or delays the transfer of the flame ignited in the overlay layer 30 to the shape layer 20 and the core layer 10. The extinguishing agent layer 40 is installed in a plurality of divided portions so as to prevent the weakening of the bonding strength between the core layer 10 and the shingles layer 20.

In this case, the extinguishing agent layer 40 may be a powdery form selected from ammonium dihydrogenphosphate, sodium bicarbonate, silicon dioxide, aluminum hydroxide, and magnesium hydroxide. Ammonium dihydrogenphosphate is a crystalline powder, which when heated above 190 ° C releases moisture and ammonia and is condensed. Sodium bicarbonate emits moisture and carbon dioxide when heated above 300 ° C to perform the digestion function. Silicon dioxide emits nitrogen and carbon dioxide in the event of a fire, and performs fire-fighting as well as digestion. Aluminum hydroxide and magnesium hydroxide generate moisture by reaction caused by fire, which shows flame retardance and inhibits flame spreading.

On the other hand, the extinguishing agent layer 40 is formed to have a particle size of 15 탆 or less by coating the above-mentioned components in the form of a powder, and applying the powder to a thickness as thin as possible. If the particle size of the powder phase is too large, there is a fear that the bonding force between the core layer 10 and the shape layer 20 is weakened. An adhesive may be added to coat the powder layer of the extinguishing agent layer 40 on the core layer 10.

In the method for producing a sheet according to the present invention, the core layer 10, the fire extinguishing agent layer 40, the shingling layer 20 and the overlay layer 30 are laminated in order and pressed at a temperature of 130 to 180 캜, A pressure of 50 to 80 kg / cm 2, and a pressing time of 20 to 40 minutes.

On the other hand, a sheet having a laminated structure is affected by moisture in an environment where four seasons are distinct, and in particular, when laminated on a floorboard, contraction expansion due to a change in temperature and humidity occurs. Nitrile, acrylic, polyester, epoxy, urethane and the like having waterproofness can be used as an adhesive for reducing this phenomenon.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit and scope of the invention as defined by the appended claims. It is therefore intended that such variations and modifications fall within the scope of the appended claims.

10: core layer 20:
30: overlay layer 40: extinguishing agent layer

Claims (4)

A flame retardant sheet applied to a parquet flooring comprising:
A core layer 10 formed by impregnating a nonflammable phenolic resin;
A shape layer 20 formed by impregnating a non-combustible melamine resin and bonded to the upper side of the core layer 10; And
And an overlay layer (30) formed by impregnation with a nonflammable melamine resin and bonded to the upper side of the flake layer (20). The method according to claim 1,
Characterized in that the impregnation zone of the core layer (10) contains an inorganic material selected from glass fibers, silicon dioxide, alumina and calcium carbonate, and the impregnation zone of the overlay layer (30) contains aluminum oxide. High pressure resin plate. The method according to claim 1,
Wherein a fire extinguishing agent layer (40) is further provided between the core layer (10) and the foil layer (20). The method of claim 3,
Characterized in that the extinguishing agent layer (40) is a powder form mixed with ammonium dihydrogen phosphate, sodium bicarbonate, silicon dioxide, aluminum hydroxide, magnesium hydroxide, and the like, is used as the fire extinguishing agent layer (40).

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