WO2005123380A1 - Flooring having surface layer of synthetic resin and wood-based board - Google Patents
Flooring having surface layer of synthetic resin and wood-based board Download PDFInfo
- Publication number
- WO2005123380A1 WO2005123380A1 PCT/KR2005/000939 KR2005000939W WO2005123380A1 WO 2005123380 A1 WO2005123380 A1 WO 2005123380A1 KR 2005000939 W KR2005000939 W KR 2005000939W WO 2005123380 A1 WO2005123380 A1 WO 2005123380A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- styrene
- layer
- block copolymer
- flooring
- synthetic resin
- Prior art date
Links
- 238000009408 flooring Methods 0.000 title claims abstract description 74
- 239000002344 surface layer Substances 0.000 title claims abstract description 42
- 229920003002 synthetic resin Polymers 0.000 title claims abstract description 35
- 239000000057 synthetic resin Substances 0.000 title claims abstract description 35
- 239000002023 wood Substances 0.000 title claims abstract description 22
- 239000010410 layer Substances 0.000 claims abstract description 77
- 239000011120 plywood Substances 0.000 claims abstract description 17
- 239000002335 surface treatment layer Substances 0.000 claims abstract description 13
- 239000011094 fiberboard Substances 0.000 claims abstract description 8
- 239000002131 composite material Substances 0.000 claims abstract description 5
- 235000013312 flour Nutrition 0.000 claims abstract description 5
- 239000002245 particle Substances 0.000 claims abstract description 5
- -1 polyethylene Polymers 0.000 claims description 46
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 25
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 25
- 229920001400 block copolymer Polymers 0.000 claims description 21
- 239000000123 paper Substances 0.000 claims description 19
- 239000004698 Polyethylene Substances 0.000 claims description 18
- 239000004743 Polypropylene Substances 0.000 claims description 18
- 229920010524 Syndiotactic polystyrene Polymers 0.000 claims description 18
- FACXGONDLDSNOE-UHFFFAOYSA-N buta-1,3-diene;styrene Chemical compound C=CC=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 FACXGONDLDSNOE-UHFFFAOYSA-N 0.000 claims description 18
- 229920005669 high impact polystyrene Polymers 0.000 claims description 18
- 239000004797 high-impact polystyrene Substances 0.000 claims description 18
- 229920000573 polyethylene Polymers 0.000 claims description 18
- 229920001155 polypropylene Polymers 0.000 claims description 18
- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 claims description 18
- 239000011241 protective layer Substances 0.000 claims description 17
- 239000004814 polyurethane Substances 0.000 claims description 12
- 239000004800 polyvinyl chloride Substances 0.000 claims description 12
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 11
- 239000003365 glass fiber Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 6
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 5
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 5
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 5
- 239000004014 plasticizer Substances 0.000 claims description 4
- 229920001296 polysiloxane Polymers 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 2
- 239000005871 repellent Substances 0.000 claims description 2
- 230000002940 repellent Effects 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- 238000004078 waterproofing Methods 0.000 claims description 2
- 230000001681 protective effect Effects 0.000 abstract description 2
- 238000000859 sublimation Methods 0.000 abstract description 2
- 229920000877 Melamine resin Polymers 0.000 description 10
- 239000004640 Melamine resin Substances 0.000 description 8
- 238000007373 indentation Methods 0.000 description 7
- 230000000704 physical effect Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229920005644 polyethylene terephthalate glycol copolymer Polymers 0.000 description 6
- 239000011248 coating agent Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 229920002635 polyurethane Polymers 0.000 description 5
- 229920000915 polyvinyl chloride Polymers 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 3
- 210000002105 tongue Anatomy 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000002346 layers by function Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011088 parchment paper Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000008022 sublimation Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000012756 surface treatment agent Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
-
- 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
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
-
- 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
-
- 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
- B32B21/06—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 paper or cardboard
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
-
- 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
-
- 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
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
-
- 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
- B32B2317/00—Animal or vegetable based
- B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
-
- 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
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- 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
- B32B2331/00—Polyvinylesters
- B32B2331/04—Polymers of vinyl acetate, e.g. PVA
-
- 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
- B32B2419/00—Buildings or parts thereof
- B32B2419/04—Tiles for floors or walls
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/19—Sheets or webs edge spliced or joined
- Y10T428/192—Sheets or webs coplanar
- Y10T428/195—Beveled, stepped, or skived in thickness
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24934—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including paper layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31975—Of cellulosic next to another carbohydrate
- Y10T428/31978—Cellulosic next to another cellulosic
- Y10T428/31982—Wood or paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31989—Of wood
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31993—Of paper
Definitions
- the present invention relates to a flooring comprising a surface layer made of a synthetic resin, and a wood-based board selected from plywood, medium-density fiberboard (MDF), high-density fiberboard (HDF), particle board and resin- wood flour composite board as a base layer.
- MDF medium-density fiberboard
- HDF high-density fiberboard
- a variety of flooring products are widely used.
- a plywood flooring for an under- floor heating system having small dimensional deformation is known, which is produced by laminating one or more natural wood veneers to each other to form a waterproof plywood as a base, integrally forming a natural veneer on the base by using an adhesive, and coating a surface treatment agent, such as urethane acrylate, on the natural veneer to form a surface treatment layer.
- a surface treatment agent such as urethane acrylate
- the conventional plywood flooring for an under-floor heating system is produced simply by laminating a veneer on a plywood and coating the surface of the veneer in order to maximize the natural texture of the plywood flooring.
- damage to the surface is observed due to limited physical properties of the natural veneer.
- a laminate flooring product comprising an MDF or HDF layer as a base, a printed layer impregnated with a melamine resin formed on the base, and a surface treatment layer made of melamine formed on the printed layer.
- the conventional laminate flooring uses a thermosetting melamine resin as a surface material, the surface is likely to be brittle. Accordingly, when a sharp or heavy object having above specified load drops onto the laminate flooring, the impact site is partly damaged, e.g., broken or indented.
- the present invention has been made in view of the above problems of the prior art floorings, and it is an object of the present invention to provide a flooring having improved surface physical properties such that the surface of the flooring is protected against damage, e.g., indentation and breakage, caused by a heavy or sharp object.
- a flooring comprising a wood-based board as a base and a surface layer laminated thereon wherein the surface layer includes a protective layer made of a synthetic resin.
- the flooring of the present invention is characterized in that it has improved surface physical properties such that its surface is protected against damage, e.g., indentation and breakage, caused by a heavy or sharp object.
- the surface layer is preferably made of a synthetic resin showing superior mechanical properties and having an elongation sufficient to absorb an external impact.
- poly vinyl chloride PVC
- PE polyethylene
- PP polypropylene
- PET polyethylene terephthalate
- PETG gly col-modified polyethylene terephthalate
- HPIPS high-impact polystyrene
- ABS polyurethane
- PU acrylonitrile-butadiene-styrene
- SEBS syndiotactic polystyrene
- SEPS syndiotactic polystyrene
- SEPS syndiotactic polystyrene
- the surface layer includes a printed layer, a protective layer, and a surface treatment layer.
- the synthetic resin is preferably used to form the printed layer and/or the protective layer, particularly, the protective layer.
- a preferred composition of the protective layer comprises 10-50 parts by weight of a plasticizer for controlling the hardness of the protective layer or ethylene vinyl acetate (EVA), and 1-5 parts by weight of a processing lubricant, and 100 parts by weight of at least one synthetic resin selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS and SEPS.
- a plasticizer for controlling the hardness of the protective layer or ethylene vinyl acetate (EVA) ethylene vinyl acetate (EVA)
- EVA ethylene vinyl acetate
- a processing lubricant 100 parts by weight of at least one synthetic resin selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS and SEPS.
- the printed layer is formed to impart printing effects, e.g., printed wood, marble and other patterns, to the flooring of the present invention. Since the printed layer provides a natural texture without the use of natural veneer, natural resources can be advantageously preserved.
- the printed layer consists of a base layer for printing made of a synthetic resin and a printed surface formed on the base layer.
- the printed layer is formed of a printed paper or a resin-impregnated printed paper obtained by printing a paper and impregnating the printed paper with a synthetic resin.
- the printed layer consists of a glass fiber layer formed by impregnating a glass fiber sheet with a synthetic resin, a base layer for printing made of a synthetic resin laminated on the glass fiber layer, and a printed surface formed on the base layer.
- the wood-based board used as a base of the flooring according to the present invention is at least one board selected from waterproof plywood, medium-density fiberboard (MDF), high-density fiberboard (HDF), particle board, and resin-wood flour composite board.
- the flooring of the present invention may further comprise a bottom layer laminated under the wood-based board.
- the bottom layer is formed of at least one material selected from papers, silicone -based water repellents, silicone-based waterproofing agents, and synthetic resins.
- the synthetic resin used as a material for the printed layer of the surface layer and the bottom layer is at least one polymer selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS, SEPS, and acrylates.
- the flooring of the present invention is preferably processed to have a tongue and groove (T & G) shape.
- the surface layer can be embossed such that three-dimensional pattern effects are maximized.
- Fig. 1 is a cross-sectional view showing the overall structure of a flooring according to the preferred embodiment of the present invention
- Fig. 2 is a cross-sectional view showing a surface layer according to one embodiment of the present invention
- Fig. 3 is a cross-sectional view showing a surface layer according to another embodiment of the present invention
- Fig. 4 is a cross-sectional view showing a surface layer according to another embodiment of the present invention
- Fig. 5 is a flow chart showing a process for producing a flooring of the present invention.
- FIG. 6 is a diagram showing a finished product in a tongue and groove (T & G) shape processed from a flooring of the present invention. Best Mode for Carrying Out the Invention
- the flooring largely comprises a surface layer 10, a base layer 30, and an adhesive layer 20 adhering the two layers together.
- the surface layer 10 includes a printed layer 13 on which a pattern, e.g., wood, marble or the like, is printed, a protective layer 12 made of a synthetic resin for protecting the printed surface of the printed layer, and a surface treatment layer 11 laminated in this order from the bottom.
- the base layer 30 includes a bottom layer 32 and a wood-based board 31 laminated thereon.
- the printed layer 13 has the following three structures.
- FIG. 2 there is shown a cross-sectional view of a surface layer 10 according to one embodiment of the present invention.
- the surface layer 10 includes a printed layer 13, a protective layer 12, and a surface treatment layer 11 laminated in this order from the bottom wherein the printed layer 13 consists of a base layer 15 for printing made of a synthetic resin and a printed surface 14 formed on the base layer 15.
- Fig. 3 is a cross-sectional view showing a surface layer according to another embodiment of the present invention.
- the surface layer 10 includes a printed layer 13, a protective layer 12, and a surface treatment layer 11 laminated in this order from the bottom wherein the printed layer 13 is formed of a printed paper or a resin-impregnated printed paper 16 obtained by printing a paper and impregnating the printed paper with a synthetic resin.
- Fig. 4 is a cross-sectional view showing a surface layer according to another embodiment of the present invention.
- the surface layer 10 includes a printed layer 13, a protective layer 12, and a surface treatment layer 11 laminated in this order from the bottom wherein the printed layer 13 consists of a glass fiber layer 17 formed by impregnating a glass fiber sheet with a synthetic resin, a base layer for printing 15, and a printed surface 14 laminated in this order from the bottom.
- Fig. 5 is a flow chart showing a process for producing the flooring of the present invention.
- the flooring of the present invention is produced through the following three steps. First, a printed layer 13 on which a pattern is printed and a protective layer 12 are thermally laminated at 120 ⁇ 150°C or are adhered together using a transparent adhesive, and then a UV-curable or heat-curable surface treatment layer 11 made essentially of urethane acrylate is coated thereon, achieving formation of a surface layer 10 (first step 40). Before or after coating of the surface treatment layer 11, embossing can be carried out in an appropriate manner to impart a predetermined embossed shape to the entire surface or a portion of the surface layer. In the formation of the surface layer 10 in the first step, the coating of the surface treatment layer 11 may be omitted depending on the intended application of the finished product.
- the protective layer 12 is a functional layer for providing improved surface physical properties to the flooring of the present invention while protecting the printed layer 13.
- the protective layer 12 is transparent or semi-transparent so that the printed pattern of the printed layer 13 is visible, and is preferably composed of 10-50 parts by weight of a plasticizer or EVA, 1-5 parts by weight of a processing lubricant, and 100 parts by weight of at least one synthetic resin selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS and SEPS.
- the printed layer 13 may be formed by forming a printed surface 14 on a base layer for printing 15 made of a thermoplastic synthetic resin by gravure, transfer, sublimation, silk screen, or digital printing using a printer (Fig. 2); the printed layer 13 may be formed of a resin-impregnated printed paper 16 obtained by printing a paper via the printing technique and impregnating the printed paper with an acrylate or a thermoplastic resin (Fig. 3); or the printed layer 13 may be formed by forming a base layer for printing 15 on a glass fiber layer 17 impregnated with a PVC resin and forming a printed surface on the base layer by the printing technique (Fig. 4).
- a specific composition of the base layer for printing 15 comprises 100 parts by weight of a thermoplastic synthetic resin selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS and SEPS, 10-50 parts by weight of a plasticizer or EVA , 0-200 parts by weight of calcium carbonate (CaCO ) as a filler, and if necessary 1-5 parts by weight of a processing lubricant.
- a thermoplastic synthetic resin selected from PVC, PE, PP, PET, PETG, HIPS, ABS, PU, SBS, SEBS, SPS and SEPS
- a plasticizer or EVA 0-200 parts by weight of calcium carbonate (CaCO ) as a filler
- CaCO calcium carbonate
- the surface layer 10 formed in the first step is adhered to a base layer 30 using an epoxy- or polyurethane-based adhesive (second step 50).
- a wood-based board 31 of the base layer 30 there is used at least one board selected from waterproof plywood, particle board, MDF, HDF, and resin-wood flour composite board.
- a paper including a parchment paper mainly used as a material for a lower layer of a general laminate flooring, a melamine resin-impregnated paper, or a general resin coating layer is used to form a bottom layer 32.
- the bottom layer 32 can be formed before or after adhesion of the base layer 30 to the surface layer 10. The formation of the bottom layer 32 may be omitted depending on the intended application of the finished product.
- the laminated panel produced in the second step is cut into pieces having a size of a general flooring, and the four sides of the pieces are processed in the length and width directions to have two tongues 70 and two grooves 80, thus achieving the final appearance of the finished flooring product (third step 60).
- a base layer 30 was formed by coating HDF as a wood-based board 31 with a synthetic resin as a bottom layer 32.
- a printed layer 13 and a protective layer 12, each of which was composed of 100 parts by weight of PETG and 30 parts by weight of EVA, and a UV-curable surface treatment layer 10 were sequentially laminated to form a surface layer 10.
- the surface layer 10 was laminated on the base layer 30 to produce a flooring having a structure shown in Fig. 1.
- the flooring of the present invention shows improved surface physical properties. That is, the surface of the flooring is protected against damage, e.g., surface indentation and breakage, caused by a heavy or sharp object, which are main disadvantages of the conventional plywood flooring comprising a natural veneer and a waterproof plywood.
- the conventional plywood flooring using a natural veneer as a main surface material causes damage to forest resources, while the flooring of the present invention provides a natural texture by printing effects, which is advantageous in terms of natural resource preservation.
- the conventional laminate flooring comprises a surface layer made of a melamine resin, it has the problems of bending and distortion due to changes in ambient atmospheric conditions, e.g., moisture and temperature. Accordingly, an additional balance layer must be formed on the bottom surface of the conventional laminate flooring, result in a structural disadvantage.
- the flooring of the present invention exhibits a stabilized dimensional variation despite changes in humidity and temperature when compared to a melamine resin, it avoids the need of an additional balance layer.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE200511001468 DE112005001468T5 (en) | 2004-06-22 | 2005-03-31 | Floor covering having a surface layer of synthetic resin and a wood-based panel |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR20-2004-0017566U KR200370449Y1 (en) | 2004-06-22 | 2004-06-22 | Flooring having surface layer of synthetic resin and wood-based board |
KR20-2004-0017566 | 2004-06-22 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005123380A1 true WO2005123380A1 (en) | 2005-12-29 |
Family
ID=35480930
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/KR2005/000939 WO2005123380A1 (en) | 2004-06-22 | 2005-03-31 | Flooring having surface layer of synthetic resin and wood-based board |
Country Status (5)
Country | Link |
---|---|
US (1) | US7678466B2 (en) |
KR (1) | KR200370449Y1 (en) |
CN (1) | CN100584599C (en) |
DE (1) | DE112005001468T5 (en) |
WO (1) | WO2005123380A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
CN1972799A (en) | 2007-05-30 |
DE112005001468T5 (en) | 2009-04-16 |
CN100584599C (en) | 2010-01-27 |
US7678466B2 (en) | 2010-03-16 |
KR200370449Y1 (en) | 2004-12-17 |
US20050281986A1 (en) | 2005-12-22 |
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