TWI312314B - Caster-resistant surface laminate - Google Patents
Caster-resistant surface laminate Download PDFInfo
- Publication number
- TWI312314B TWI312314B TW94140102A TW94140102A TWI312314B TW I312314 B TWI312314 B TW I312314B TW 94140102 A TW94140102 A TW 94140102A TW 94140102 A TW94140102 A TW 94140102A TW I312314 B TWI312314 B TW I312314B
- Authority
- TW
- Taiwan
- Prior art keywords
- layer
- caster
- surface area
- floor
- area laminate
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
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- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
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Landscapes
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Description
1312314 九、發明說明: 【發明所屬之技術領域】 本發明係關於具有優異耐腳輪性、耐衝擊性及耐水性 之表面積層板以及包含該表面積層板之地 二”、關於耐腳輪天然木製地板,其包含表二層 積f板層合之有溝槽基材(gr°°ved base)(合 南密度強化層、天然薄木片層及合成樹脂層。斤曰口之 【先前技術】 ® ί二:板下加熱系統用之習用地板結構之截面 ^羽,、中天…、溥木片係層合於防水合板上。如第一圖所示, =S用地板具有將天然薄木片層22用uv 成:般uv塗佈層21,,或者將其以== 猎由接者劑層40層合於防水合板層1〇,之結構。 然而,地板下加熱系統用之習用地板之缺點包括在某 ,巧重下耐刮性及耐衝擊性差。特定而言’習用地板之表 性低至0.5至1N(其係使用鑽石針在地板表面刮 ’並且耐衝擊性低至5cm(其係藉由將重量228§之 墜Ϊ至地板而測量)。此等數值顯示習用地板於家用 可;時容易損傷。因Λ ’此等習用地板極 遭致岫費者抱怨,且無法滿足消費者之多樣性需求。 ;疋,具有改良之耐刮性及耐衝擊性之地板為現今所期待。 其他習用地板方面,廣為人知者為藉由將裝飾薄木 &或印刷紙)貼附於合板並將積層板塗伟,或者將合板血 岔度纖維板(MDF)互相層合,再在MDF上接合裝飾薄^ ,,積層板塗佈而製造之地板。此等地板之代表性實例 ^將裝飾片(或印刷紙)貼附於合板,或者將合板與Mdf =層合,再將裝飾片(或印刷紙)接合於中密度纖維板而 取· 〇 然而,前項地板有耐腳輪性不良之問題。再者,當地 5 1312314 板上產生犬出及凹溝之情況,可能發生起毛及邊 而經常將短襪及長襪之紗線抽脫。另一方面,後述地= 渗人水會膨脹之問題(_耐水性差),3 。地板之設計,例如使用木製裝飾薄片(或印刷紙)時。 點’+使:中密度纖維板(物理性質比合板優良)之優 點,所明耐腳輪性,然而卻造成耐水性差之問 入水中時產生剝離。 於他 =,現今需求開發一種為低價㈣築材料之木質地 Ϊ哲f對於溫度變化具有安定尺寸性,並且滿足所需物理 性質(例如耐腳輪性及耐水性)。 巧㈣理 【發明内容】 笛一i發明係針對上述先前技術之問題而產生,本發明之 水性=的為提供一種具有優異耐腳輪性、财衝擊性及耐 it表層板,其包含強化層、合成樹脂層及天然木 加且倉:维牲體接合,因而該表面積層板之表面強度增 質地^ 紋路;以及提供包含該表面積層板之木 裝飾ϋΓΐ另—個目的為提供—種能藉由著色實現室内 it面積層板,以及包含該表面積層板之地板。 明達到上述目的之—形態,係提供—種由具 成樹脂層之木f薄木片層組成之耐腳輪表面 及線it^表面積層其特徵為將呈現基本機械性質 外來if化層與呈現優異機械性質並具有足以吸收 声板呈#性之合成樹脂層加以層合,因而該表面積 之耐腳輪性及耐衝擊性。該強化層與該合成 2層對該表面積層板之耐腳輪性之貢獻比率為約4〇%: 仆μ本之耐腳輪表面積層板包含從底層依序層合之強 曰、溥木片層及合成樹脂層,或者從底層依序層合之強 1312314 化層、合成樹脂層及薄木片層。 上述耐腳輪表面積層板中之前者,當藉由壓塑機的壓 力而將木質薄木片層一體接合時,可防止對薄木片之損害 及有效吸收衝擊。 本文中使用之術語「耐腳輪性」意指家中一般使用之 椅子之腳輪所造成之凹陷之程度。 本發明之耐腳輪表面積層板,其特徵為具有改良之表 面物理性質,以致可保護地板表面以防損傷,例如重物或 尖銳物體造成之凹陷及破裂。就此方面而言,合成樹脂層 以由呈現優異機械性質並具有足以吸收外來衝擊之延伸性 # 之合成樹脂製成為較佳。可使用之合成樹脂例如聚氣乙烯 (PVC)、聚環己烯二亞甲基(PC)、聚乙烯(PE)、聚丙烯(PP)、 聚對苯二曱酸乙二酯(PET)、經乙二醇改質之PET(PETG)、 經環己烷二甲醇改質之PETG(PCTG)、經間苯二曱酸改質 之PCTG(PCT-A)、高衝擊性聚苯乙烯(HIPS)、丙烯腈-丁二 烯-苯乙烯共聚合物(ABS)、聚胺基曱酸酯(PU)、苯乙烯-丁 二烯-苯乙烯嵌段共聚合物(SBS)、苯乙烯-乙烯-丁二烯-苯 乙烯嵌段共聚合物(SEBS)、間規聚苯乙烯(SPS)、苯乙烯-乙烯-丙烯-苯乙烯嵌段共聚合物(SEPS)或丙烯酸酯類等。 當然,其中以PVC、PETG及PCTG為較佳,而以PCTG 為特佳。 PVC為非環境友善性材料並在焚燒時產生毒氣,例如 氣化氫氣體(HC1)。相反地,PCTG及PETG為環境友善性 材料,在焚燒時產生二氧化碳(C02)及水蒸氣(H20),使用 時無限制。再者,PCTG及PETG具有所謂「優異光學性質 及無需使用少量添加劑而仍容易加工」之優點;尤其,PCTG 具有優於PETG之耐熱性及耐衝擊性,因此呈現優良之物 理性質,例如對於切剁及衝擊造成之損傷具有改良之耐性。 合成樹脂層之較佳組成包含10至50重量份之增塑劑 或醋酸乙烯酯(EVA),1至5重量份之加工潤滑劑,及100 1312314 重量份之至少一種選自P VC、PC、PE、PP、PET、PETG、 PCTG、PCT-A、HIPS、ABS、PU、SBS、SEBS、SPS、SEPS 及丙烯酸酯類之合成樹脂。該樹脂層可由單層或複合層組 成,且可由一種或多種摻合之樹脂組成。 為實現室内裝飾效果,可於合成樹脂層中添加著色劑 (例如顏料)以對合成樹脂層賦予透明顏色,而使表面積層 板具有著色效果。更且,亦可於合成樹脂層中添加感溫性 顏料,以實現「顏色隨溫度改變而改變」。 使用於製備著色合成樹脂之著色劑為有機及無機染料 及顏料。有機顏料之實例包括偶氮(azo)及雙偶氮(disazo) • 顏料、色澱(laked)之偶氮及雙偶氮顏料、多環式 (polycyclic)顏料、醜菁(phthalocyanine)顏料、奎寧克力 酮(quinicridone)、二萘嵌苯(perylene)顏料、二· °惡嗓 (dioxazine)顏料、蒽醌(anthraquinone)顏料、硫敢(thioindigo) 顏料、二芳基蒽酿(diary anthraquinone )顏料及啥歐酮 (quinophthalone)彥頁料。 無機顏料包括可染色之金屬氧化物、混合氧化物、硫 酸鋁、鉻酸鹽類、金屬粉類、珍珠顏料、螢光物質 (phosphors)、氧化鈦、氧化鐵、碳黑、石夕酸鹽、鈦酸鎳、 鲁鈷顏料及氧化鉻。再者,除此等顏料之外,可視需要選擇 並使用其他顏料以產生適當之顏色。 在感溫顏料中,造色(color-creating)成分包括2,2-二丁 基胺基-6-甲基-7-苯胺基螢烷、2,2-二丁基異戊基-6-甲基-7-苯胺基螢烷及3,3-二甲基胺基-6-曱基-7-苯胺基螢烷等,顯 色劑(color developer)包括可與盼性化合物(phenol-based compound)混合之化合物,例如雙盼-A及雙紛-S、Ϋ酸對 羥基苄酯、對苯基酚及酸性石膏粉(terra alba),以藉由電 子之供給-接受機構產生或除去顏色。 需了解本發明所使用之上述感溫著色劑只係用於說 明,並非以任何方式對本發明設限。各種感溫著色劑可與 8 1312314 用無:=。量該有機及無機顏料可根據所 ⑶板藉成 體接合。依照此種方式,本發明之:f壓塑巧而-耐腳輪性及耐衝擊性。 表面積層板可同時維持
塗怖耐=表面積層板以在最上面部分包含uV 無溶劑之類型為更佳。使用蛊滚#丨 塗佈漆乂 m ^ ί 使用無办劑υν塗佈漆可防止出現 屋况劣化現象,並可提供對環境友善之最終產品。 環产苯、甲苯及二甲苯之UV塗佈漆可滿足 =匕f 材料在品質等級上之最低需求,而無溶劑 欲伟漆可滿足其最高等級之需求。因此,無溶劑uv塗 佈漆為對環境最友善型漆類。 1 對,境友善性建材之品質等級可分為T列五組:最高 級(五化標,)、優良級(四花標誌)、良好級(三花標誌)、普 通I級(二花標誌)及普通π級(一花標誌)。建議使用最高等 級之材料以將室内空氣環境維持在最佳水準。 製造本發明之表面積層板所用之強化層係選自薄木 片:遮蔽紙、咼密度纖維板(HDF)及牛皮紙。低價位強化層 及樹脂含浸層之使用可以低成本改善耐腳輪性及耐衝^ 性0 根據所需要之厚度以及強化層及合成樹脂層之價格, 可將一層或多層低基重層或高基重層進行層合。 本發明之耐腳輪表面積層板可使用於製造地板、壁 櫥、天花板及傢俱,其中以製造地板最佳。 本發明再提供一種耐腳輪地板,其包含具有強化層及 合成樹脂層之耐腳輪表面積層板。 ^ 本發明之耐腳輪地板包含從底層依序層合之基材、接 著劑層及耐腳輪表面積層板。 9 1312314 為降低地板間之聲音傳遞並賦予改盖之 發明之耐腳輪地板復可包含至少一層層°合於 與耐腳輪表面積層板之間及&丨美# ^ n $、 音層。 n^(b)基材下方之至少一處之隔 製造本發明之地板所用之基材匕 中較佳於背面渺# ii b〇ard)及防水合板層,其 裂成溝槽以確保尺寸安定性之改善及減少龜 【實施方式】 此等實施例非為本發明之範圍設限月邊地了解,然而’ 第一圖表示地板下加熱系統用之習用地柘夕番品l 第一圖所示,該地板且有 用地板之截面。如 21,、天然薄木片22、;1層將-般UV塗佈層 之結構。 A層4〇及防水合板層10,層合 第二圖表示根據本發明— 板之截面。如第二圖所示,,較佳實施例之耐腳輪地 板經接著劑層40層合於基材板,有將耐腳輪表面積層 本發明之-較佳實施例如第2 -層板20包含從底層起依 ^~圖=不二耐腳輪表面積 蔽紙、聊及牛皮紙中°之^木^或至少-種從遮 合成樹脂層23、天然薄木// = )=密度強化層24、 根據本發明之另一個較▲:,、广劑UV塗佈層21。 輪表面積層板20包含從底芦以圖不),耐腳 一種從遮蔽紙、HDF及牛由序層a之薄木片(或至少 層24、天然薄木片層22、二中選出之材料)、高密度強化 佈層21。 σ成樹脂層23及無溶劑UV塗 耐腳輪表面積層板2〇 # 24、合成樹脂層23 =成疋猎由將高密度強化層 、4木片層22從底層起依序排疊; 1312314 或者將面密度強化層24、天然薄木片層22人 · 2?ί 垒力加壓,同時加熱至110至^ ς 30 ^ Π ί .積層板^基材Ια由互接相著^層40將所製造之耐腳輪表面 I用於形成接著劑層40之接著劑包括埶固性三 ^树月曰,熱固性或室溫可硬化性胺基甲酸酯或環 聚乙,醇或聚醋酸乙烯酯等。 / ί月曰, 80至當二用气固Ϊ三聚氰胺樹脂做為接著劑時,係將1以 另一方佈在基材1G上以形成接著劑層40。 為接著劑時’硬基2甲酸醋或環氧樹脂做 7 = ΐ丄ϋ 至250g/m之量塗佈在基材10 上以形成接者劑層40。然後,將耐腳輪表面 5著=二ΐ。當使用熱固性三聚氰胺樹脂“接S ^積層板係在10至15kgf/cm2之壓力下經!至5分鐘 硬ib ° ί者’當使用室溫可硬化性胺基甲酸醋或環氧 為接著劑時,積層板係在至15kgf/cm2之壓力下 /翌裂 日。 形。將基材10及耐腳輪積層板在室溫下壓製可消減熱變 板之i = 個較佳實施例之耐腳輪地 =截面圖,其中將二隔音層加在第二圖所示之地板上。 二圖所示,第一個隔音層3〇係嵌於基材1〇與接著 曰一 〇之間,而第二個隔音層31則置於基材10之下;然而, 隔音層之位置與數量並無特別限定。 可使用之隔音層材料例如聚氯乙烯(pvc)、聚乙烯 (PE)、乙烯-醋酸乙烯酯(EVA)、聚丙烯(pp)、聚胺基甲酸 酯(pu)、聚酯不織布、氣丁二烯橡膠(c及丙 橡膠⑽R)等。再者,隔音層之表面可藉由壓紋= 11 1312314 (intaglio)技術、化學交聯及發泡技術及高壓發泡方法進行 加工。 [實施例] 1.基材10之製造 將包含PV c樹脂、增塑劑、填充劑、安定劑及其他成 分之組合物形成具有1.0至5.0mm厚度之聚氯乙烯樹脂 層。該基材可由至少一種選自熱固性樹脂及熱塑性樹脂之 樹脂形成。 ^ 粒片板及高密度纖維板係藉由將木材裁切或纖維化所 得到之粒片或纖維在三聚氰胺樹脂中加壓而成型。 > ~防水合板層係藉由將三至七層薄木片排疊,使用三聚 氰胺樹脂以各層薄木片之木紋方向互相呈直角之方式,在 壓塑機中壓合形成積層板。 2·耐腳輪表面積層板20 1) 無溶劑UV塗佈層21之製造 彳ί到保護表面及高品質效果,UV塗佈可使用無溶劑 塗佈漆進行六至十次。 ⑴ 2) 天然薄木片層22之製造 鱼ίΐ ft片層22的製造,係藉由將天然原木使用迴轉 式車床或切片機裁切成厚度0.12至5mm。 3) 合成樹脂層23之製造 30重U招SI 23的製造’係從包含100重量份之咖、 壓延 4) 高密度強化層24之製造 切片2=以;=天以木使用迴轉式車床或 為改善紋方向發生龜裂。 至其含水量為H)%或更木片之彎曲’將該薄木片乾燥 12 1312314 遮蔽的製造,係藉由將基重為5〇至15〇g/m2之紙 奸酚或二聚氰胺樹脂浸潰;繼而在80至15(TC之烘箱中 =二^至3分鐘乾燥及半硬化。根據厚度需要,可 張或多張此種遮蔽紙。 输紐的製造,係藉由將得自針葉木或落葉木之樹種的 纖維用酚樹脂處理,再成形、高溫加壓及硬化。 ^皮紙的製造,係藉由將基重為80至300g/m2之紙張 吏用三聚氰胺或酚樹脂浸潰,繼而在8〇至15〇。〇之烘^ 及半硬化。根據厚度需要,可使用兩 • 23之1 高合密度強化層24、天然薄木片層22及合成樹脂層 將合成樹脂層23置於高密度強化層24與天然薄木片 間。或者,將高密度強化層24、天然薄木片層22 ,層23依序從底層起進行層合。將得到之結構物 在壓塑機中於110至17(TC ’以遞升之壓力2〇、4〇、、 80、100、120 及 150kg/cm2 分別加壓 15、2〇、25 及 3〇 鐘,並在相同壓力下冷卻25分鐘以將各層一體接合。 3.基材10與耐腳輪表面積層板2〇之層合 層系藉由们5〇咖2之熱固性三聚氰胺樹脂 二熱固性或室溫可硬化性胺基f酸酯或環2樹脂 = 然後,將耐腳輪表面積層板20放置 ίϊtV Λ尤。“吏用熱固性三聚氰胺樹脂時,將積層 板於12 kgf/cm之壓力下進行2至5分鐘加壓及硬化。、另 二丄盈可硬化性樹脂時,將積層板於15 m上 日,㈣㈣㈣表面積層板黏層 於是將依照本發明製造之高度耐腳輪 例-)之表面物理性質與第一圖所示之地板下加熱板系(:用 13 1312314 s用地板(比較例一)比較。結果如以下 地板之表面強度係根據以下 / 從地板裁切成具有預定尺寸之彳步驟篁測。百先, 表面使用鑽石針刮痕而量測並以〇 5N工:^係藉片 ί^Γί(22内5g)從遞升之高度(每次間隔二ϊίϊ 舌式片在何重0kg下以12m/min之速率加壓, 覆加壓100次,並以肉眼或在光學^ ^ ^ ^ 凹陷或斷裂之發生。 子”貝微鏡下觀察疋否有 表一 -- 實施例一 比較例一 3至4 〇·5 至 1 耐衝擊性 $80 5至10 $10次(塗佈層破裂) $腳輪性(60kg;) 2100次(無變化)
I i缺ίί一中出現之數據所示,依照本發明之高度耐腳輪 …、木質地板(實施例一)之表面物理性質與第一圖所示之 地板下加熱系統用之習用地板之表面物理性質比較,^得 極大的改善。具體而言,依照本發明之地板之耐到性最大 提高至4Ν’耐衝擊性最大提高至100cm。再者,依照本發 明之地板之耐腳輪性在6〇kg荷重下即使經i 〇〇次後仍未發 現表面凹陷。由於天然薄木片之耐腳輪性明顯地改善 有效的降低了消費者的抱怨程度;並且因本發明的地板之 表面物理性質徹底地改善’而足能令消費者滿意。 藉由將包含高密度強化層及合成樹脂層之木質薄木片 層整合’本發明之地板呈現比習用地板製品優異之财腳輪 性、耐水性、耐刮性及耐衝擊性。尤其,添加著色劑及感 溫顏料於合成樹脂層可提供室内裝飾之效果。 再者,無溶劑UV塗佈處理有助於環境保護。藉由使 用高壓壓塑機的壓力而將強化層、合成樹脂層及天然薄木 14 1312314 片層整合,可達到表面強化效果。當與地板下加熱系統用 之習用地板比較時,在基材背部表面形成溝槽可改善本發 明之地板之表面強度,並且增加一個或二個 ^ ^ 本發明地板改良之隔音效果。 θ』賦于 【圖式簡單說明】 中將習用地板之截面圖,其 之截^圖實施例之耐腳輪地板 互相層合。 輪表面積層板與背面有溝槽之基材
第三圖為根據本發明一 板之戴面圖,其中將二陪立=個較佳實施例之耐腳輪地 【主要元件符號說明】日層加在第二圖所示之地板上。 10基材 防水合板層 20 耐腳輪表面積層板 21無溶劑UV塗佈層 21,一般UV塗佈層 22薄木片 9
23 合成樹脂層 24高密度強化層 30第一個隔音層 31第二個隔音層 40接著劑層 15
Claims (1)
1312314 條正 1公年例口日, 十、申請專利範圍: | 補.¾ 1. 一種耐腳輪表面積層板,係為木質薄木片層,該木 質薄木片層包含從底層依序層合之強化層、薄木片 層及合成樹脂層。 2. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該合成樹脂層係由至少一種選自下列者之合成樹脂 組成:聚氯乙烯(PVC)、聚環己烯二亞曱基(PC)、聚 乙烯(PE)、聚丙烯(PP)、聚對苯二甲酸乙二酯(PET)、 經乙二醇改質之PET(PETG)、經環己基二曱醇改質 之 PETG(PCTG)、經間苯二曱酸酸改質之 PCTG(PCT-A)、高衝擊聚苯乙烯(HIPS)、丙烯腈-丁 二烯-苯乙烯共聚合物(ABS)、聚胺基曱酸酯(PU)、 苯乙烯-丁二烯-苯乙烯嵌段共聚合物(SBS)、苯乙烯-乙烯-丁二烯-苯乙烯嵌段共聚合物(SEBS)、間規聚 苯乙烯(SPS)、苯乙烯-乙烯-丙烯-苯乙烯嵌段共聚合 物(SEPS)及丙烯酸酯類。 3. 如申請專利範圍第2項之对腳輪表面積層板,其中 該合成樹脂為經乙二醇改質之PET(PETG)或經環己 基二曱醇改質之PETG(PCTG)。 4. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該合成樹脂層含有著色劑。 5. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該合成樹脂層含有感溫顏料。 6. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該木質薄木片層藉由使用高壓壓塑機的壓力而一體 接合。 7. 如申請專利範圍第1項之耐腳輪表面積層板,尚包 含位在最上部分的UV塗佈層。 8. 如申請專利範圍第7項之耐腳輪表面積層板,其中 16 1312314 該UV塗佈層係由無溶劑UV塗佈漆形成。 9. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該強化層係選自薄木片、遮蔽紙、高密度纖維板 (HDF)及牛皮紙。 10. 如申請專利範圍第1項之耐腳輪表面積層板,其中 根據所需要之厚度將數片強化層及合成樹脂層進行 層合。 11. 如申請專利範圍第1項之耐腳輪表面積層板,其中 該表面積層板係用於製造地板、壁櫥、天花板及傢 倶。 12. —種财腳輪地板,包含一耐腳輪表面積層板,其中 該耐腳輪表面積層板為木質薄木片層’該木質缚木 片層包含從底層依序層合之強化層、薄木片層及合 成樹脂層。 13. 如申請專利範圍第12項之耐腳輪地板,其中該地 板包含從底層依序層合之基材、接著劑層及耐腳輪 表面積廣板。 14. 如申請專利範圍第13項之耐腳輪地板,其尚包含 至少一層層合於選自(a)基材與财腳輪表面積層板之 間及(b)基材下方之至少一處之隔音層。 15. 如申請專利範圍第13項之耐腳輪地板,其中該基 材係選自合成樹脂層、高密度纖維板(HDF)、中密度 纖維板(MDF)、粒片板(strand board)及防水合板層。 16. 如申請專利範圍第13項之耐腳輪地板,其中該基 材背面形成溝槽。 17
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- 2005-10-18 WO PCT/KR2005/003458 patent/WO2006109914A1/en active Application Filing
- 2005-10-18 CN CNB2005800015218A patent/CN100451269C/zh not_active Expired - Fee Related
- 2005-10-18 EP EP20050809040 patent/EP1869269B1/en not_active Expired - Fee Related
- 2005-10-18 JP JP2007513081A patent/JP2007522980A/ja active Pending
- 2005-10-31 US US11/262,671 patent/US7462400B2/en not_active Expired - Fee Related
- 2005-11-15 TW TW94140102A patent/TWI312314B/zh not_active IP Right Cessation
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EP1869269A4 (en) | 2008-05-21 |
EP1869269B1 (en) | 2012-09-05 |
KR100750479B1 (ko) | 2007-08-22 |
US7462400B2 (en) | 2008-12-09 |
CN100451269C (zh) | 2009-01-14 |
KR20060109242A (ko) | 2006-10-19 |
JP2007522980A (ja) | 2007-08-16 |
US20060234009A1 (en) | 2006-10-19 |
WO2006109914A1 (en) | 2006-10-19 |
CN1922371A (zh) | 2007-02-28 |
EP1869269A1 (en) | 2007-12-26 |
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