WO2007097497A1 - Manufacturing method for floors including wood powder - Google Patents

Manufacturing method for floors including wood powder Download PDF

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Publication number
WO2007097497A1
WO2007097497A1 PCT/KR2006/001919 KR2006001919W WO2007097497A1 WO 2007097497 A1 WO2007097497 A1 WO 2007097497A1 KR 2006001919 W KR2006001919 W KR 2006001919W WO 2007097497 A1 WO2007097497 A1 WO 2007097497A1
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WO
WIPO (PCT)
Prior art keywords
wood powder
flooring material
sheet
forming
manufacturing
Prior art date
Application number
PCT/KR2006/001919
Other languages
French (fr)
Inventor
Hyun-Dae Sun
Original Assignee
Dooil Co., Ltd
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.)
Filing date
Publication date
Application filed by Dooil Co., Ltd filed Critical Dooil Co., Ltd
Publication of WO2007097497A1 publication Critical patent/WO2007097497A1/en

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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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • 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
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B37/15—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 being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/08—Coating on the layer surface on wood layer
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/026—Wood layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B32B2264/067—Wood particles
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/71—Resistive to light or to UV
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • 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
    • B32B2471/00—Floor coverings
    • 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
    • B32B38/06—Embossing
    • 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
    • B32B38/145—Printing

Definitions

  • the present invention relates to a method of manufacturing a flooring material including wood powder so as to represent a texture like natural wood.
  • the present invention has been made to develop an advanced flooring material showing a texture like wood by introducing a natural ingredient, particularly wood po wder, into the flooring material itself.
  • a method of manufacturing a flooring material comprising: a step of forming a wood powder layer, wherein a main sheet formed of a synthetic resin such as PP, PE, SPS or PET is laminated with a wood powder layer, in particular, a separately formed wood powder sheet, by using wood powder paste including wood powder; and a step of forming a pattern, wherein transfer printing and/or gravure printing is performed on the wood powder layer.
  • a wood powder layer wherein a main sheet formed of a synthetic resin such as PP, PE, SPS or PET is laminated with a wood powder layer, in particular, a separately formed wood powder sheet, by using wood powder paste including wood powder
  • a method of manufacturing a flooring material including wood powder comprising: (a) a step of softening a main sheet, wherein a synthetic resin sheet transferred continuously from a feed roller is heated and softened by using a heater; (b) a step of forming a wood powder layer, wherein a wood powder layer is formed on the softened main sheet to a predetermined thickness by using wood powder paste including 30 ⁇ 80 wt% of wood powder and 20 ⁇ 70 wt% of a synthetic resin containing an adhesive; and (c) a step of forming a pattern, wherein a predetermined pattern is introduced onto the sheet lamintaed with the wood powder layer.
  • flooring material includes all kinds of materials that can be used as flooring materials, for example, tiles, floor covering sheets, and other floor mats (e.g. impact-absorbing mats for children).
  • step (b) i.e. the step of forming a wood powder layer is carried out by laminating the main sheet obtained from step (a) with a wood powder sheet having a predetermined thickness.
  • the wood powder sheet is formed by the process comprising the steps of: introducing wood powder paste, which comprises 30 ⁇ 80 wt% of the wood powder, and 20 ⁇ 70 wt% of the synthetic resin further comprising 15 ⁇ 50 wt% of an adhesive and 5 ⁇ 20 wt% of side materials including a dispersant, based on the total weight of the wood powder paste, into a blender via a hopper; heating and melting the materials to provide wood powder paste; and passing the wood powder paste through a calender having a heating roller assembly and a cooling roller assembly.
  • the side materials may include a foaming agent, a stabilizer, a lubricant, and a softening agent to obtain a product having a lower weight and improved stability.
  • the method of manufacturing a flooring material including wood powder may further comprise additional steps to increase the dimensional stability of the flooring material by preventing the flooring material from being deformed due to the shrinkage and expansion caused by variations in temperature and humidity. More particularly, the method accoriding to the present invention may further comprises step (d) of aging the flooring material by passing it through a water bath filled with water maintained at 90 ⁇ 100°C, after step (c) of forming a pattern.
  • the method further comprises a step of preventing deformation of the flooring material by cooling the laminated sheet to 20 ⁇ 35°C, after step (b) of forming a wood powder layer. More preferably, the method according to the present invention further comprises step (e) of carrying out post-treatment by cooling, drying and cutting the resultant flooring material.
  • step (c) of forming a pattern may be carried out by a transfer printing process, a gravure printing process or a combination thereof.
  • the transfer printing process uses a PET film as a base film of the transfer sheet.
  • the transfer temperature in the transfer printing process is higher than the softening point of the synthetic resin forming the main sheet.
  • the method according to the present invention comprises an additional step of heating the main sheet to a temperature higher than the softening point.
  • the method of manufacturing a flooring material including wood powder further comprises an embossing step, before or after step (c) of forming a pattern, so as to impart a texture like a natrual material, such as wood or rock, to the flooring material.
  • the method of manufacturing a flooring material further includes a step of forming a functional coating layer having at least one effect selected from the group consisting of an anti-bacterial effect, a UV protecting effect and an anti-scratch effect, so as to further increase the reliability of the flooring material.
  • the method of manufacturing a flooring material including wood powder comprises a step of forming a wood powder layer, wherein a main sheet formed of a synthetic resin such as PP, PE or PET is laminated with a wood powder layer, in particular, a separately formed wood powder sheet, by using wood powder paste including wood powder, and a step of forming a pattern, wherein transfer printing and/or gravure printing is performed on the wood powder layer.
  • the flooring material obtained by the method represents a texture like natural wood.
  • the flooring matrial is aged by passing it through a water bath filled with water at 90 ⁇ 100°C.
  • FIG. 1 is a schematic block diagram illustrating the method of manufacturing a flooring material including wood powder according to a preferred embodinent of the present invention.
  • step (a) i.e. the softening step SlO is carried out by heating and softening a main sheet transferred continuously from a feed roller around which the laminated synthetic resin sheet is wound. This facilitates lamination of wood powder paste with a predetermined thickness in the subsequent step (b), i.e. the step S20 of forming a wood powder layer.
  • the softening treatment may be performed by using a heated transfer roller or a separate electric heater.
  • the main sheet may be formed of a material selected from general plastic materials with a high cost efficiency.
  • the main sheet may be formed of a material selected from the group consisting of PVC, PE, PET, PP, SPS and combinations thereof.
  • PVC has been widely used as a material for a floor covering sheet.
  • PVC is problematic in that it has a low heat resistance and a relatively high electrostatic property.
  • the material for the main sheet is preferably selected considering advantages and disadvantages of various general plastic materials.
  • Polypropylene (PP) is particularly preferred, because it is superior in terms of printability, heat resistance (m.p. 160 ⁇ 170°C), gloss, antistatic property, water steam protectability, mechanical strength, light weight and cost efficiency.
  • step (b), i.e. the step S20 of forming a wood powder layer is carried out.
  • a wood powder layer with a predetermined thickness is formed on the softened main sheet by using wood powder paste including 30 ⁇ 80 wt% of wood powder and 20 ⁇ 70 wt% of a synthetic resin containing an adhesive.
  • the wood powder that may be used in the present invention include pure wood materials such as freshly crushed dry wood or waste saw dust, rice hulls, or a mixture of pure wood materials with rice hulls.
  • the wood powder has a water content of 5% or less and an average particle diameter of 20 ⁇ 500D so as to be mixed well with other synthetic resins.
  • the wood powder may be present in an amount of 30 ⁇ 80 wt% based on the total weight of the wood powder paste.
  • the wood powder paste may be applied directly onto the main sheet by using an extruder such as a T-die, and then passed through a roller so that the wood powder paste can be attached onto the main sheet under pressure.
  • the wood powder paste is formed into a separate wood powder sheet, and then laminated with the main sheet, in order to increase the productivity.
  • the wood powder sheet is formed first by the process comprising the steps of: introducing wood powder paste, which comprises 30 ⁇ 80 wt% of the wood powder, and 20 ⁇ 70 wt% of the synthetic resin further comprising 15 ⁇ 50 wt% of an adhesive and 5 ⁇ 20 wt% of side ingredients including a dispersant, based on the total weight of the wood powder paste, into a blender via a hopper; heating, mixing and melting the materials at a temperature higher than the softening point of the synthetic resin to provide wood powder paste; extruding the wood powder paste via an extrusion device such as a T-die, and forming a sheet while passing the wood powder paste directly through a calender; and laminating the wood powder sheet with the main sheet obtained from step (a), i.e.
  • the calender includes a series of heating rollers warmed to a temperature higher than the melting point of the synthetic resin, at the begining part thereof, in order to prevent the molten materials from being cooled upon the contact with the ambient atmosphere.
  • the heating rollers are followed by a series of cooling rollers in order to cure the wood powder sheet stably.
  • the dispersant is used as one of the side ingredients, because the main ingredient of the paste and wood powder have different physicochemical properties, and thus the wood powder may not be uniformly distributed in/mixed with the paste.
  • the dispersant includes methyl methacrylate-butyl acrylate copolymer and is used in an amount of 0.1 ⁇ 10 wt% based on the total weight of the paste.
  • a foaming agent may be used in order to reduce the weight of the resultant flooring material and to impart a certain degree of elasticity.
  • the foaming agent may be used in an amount of 0.005 ⁇ 3 wt% based on the total weight of the paste.
  • Particular examples of the foraming agent include azodi- carbonamide.
  • a stabilizer When using the foaming agent, it is preferable to use a stabilizer to stabilize the foamed state.
  • the stabilizer may be used in an amount of 0.1 ⁇ 7 wt% based on the total weight of the paste.
  • Particular examples of the stabilizer include barium stearate and dibasic lead stearate.
  • a softening agent such as stearate or a lubricant such as polyethylene oxide homopolymer may be introduced in order to improve the quality of the resultant flooring material.
  • an embossing step S30 is carried out on the exposed surface of the laminated sheet obtained from the main sheet and the wood powder sheet.
  • the surface having the wood powder layer is embossed to impart a texture like a natrual material, such as wood or rock.
  • the embossing step may be performed before or after the step S50 of forming a pattern as described hereinafter.
  • embossed surfaces can be obtained simply by applying a roller having a predetermined pattern engraved in intaglio or in relief thereon to the laminated sheet, because the laminated sheet is not completely solidified.
  • a step S40 of preventing deformation of a flooring material may be performed in order to impart an improved dimensional stability to the flooring material by preventing the flooring material from being deformed due to variations in temperature and humidity during the storage or transport thereof, or before or after the construction thereof.
  • the step of preventing deformation may be carried out by passing the laminated sheet through a water bath filled with water at 20 ⁇ 30°C. Such a cooling step S40 is preferred because it allows the embossed surface to be solidified sufficiently.
  • a step S50 of forming a pattern is performed to provide the resultant panel with a predetermined pattern.
  • the step of forming a pattern may be performed by a transfer printing process, a gravure printing process or a combination thereof.
  • the panel is heated preferably to a temperature higher than the softening point of the main sheet, so as to facilitate and complete the transfer process.
  • the transfer temperature is preferably higher than about 17O 0 C (softening temperature of PP), and more preferably ranges from 180 ⁇ 200°C.
  • PET polyethylene terephthalate
  • the transfer sheet may be formed of PE, PP or SPS.
  • a release primer layer is formed on the base film (PET) so as to facilitate separation of the pattern from the PET film during the transfer process. Also, the release primer layer avoids any difficulty in separating the pattern, when the transfer process is performed under high-humidity conditions, or when heat conduction is not made sufficiently during the transfer process.
  • the release primer may comprise 2-5 wt% of an acrylic polymer, 8-20 wt% of a
  • PVC copolymer 0-2 wt% of nicrocellulose (NC), 30-70 wt% of methyl ethyl ketone (MEK), 0-2 wt% of silica and 0-2 wt% of a dispersant.
  • NC nicrocellulose
  • MEK methyl ethyl ketone
  • the release primer layer may be applied onto a synthetic resin film, sheet or article from depressions having a predetermined depth, pattern and volume, which are engraved in a printing cylinder via a mechanical or chemical process.
  • the release primer may be applied via a gravure printing process, which allows the release primer to be applied on a continuous film or sheet roll with high precision.
  • the ink generally comprises 6-17 wt% of a pigment, 50-110 wt% of methyl ethyl ketone (MEK) as a solvent and 50-70 wt% of a medium (e.g. an acrylic resin, a PVC copolymer and a solvent such as toluene or methyl ethyl ketone) for fixing the pigment to an object to be printed.
  • a medium e.g. an acrylic resin, a PVC copolymer and a solvent such as toluene or methyl ethyl ketone
  • an adhesvie primer layer is formed on the printed pattern layer.
  • the adhesive primer is a heat-sensitive adhesive which shows adhesion only upon heating, and includes an oil-based adhesive primer or an aqueous adhesive primer.
  • the oil-based heat-sensitive adhesive comprises 1-20 wt% of polyurethane, 10-50 wt% of a PVC copolymer, 0-3 wt% of a dispersant, 0-2 wt% of a defoaming agent and 10-80 wt% of methyl ethyl ketone.
  • the aqueous heat-sensitive adhesive may comprise 10-50 wt% of an acrylic aresin, 3-20 wt% of water, 30-60 wt% of alcohol and 0-2 wt% of nitrocellulose.
  • the pattern obtained by the above step S50 of forming a pattern includes a wood- like pattern or a stone-like pattern, such as a pattern like marble stone or natural rock.
  • a step S60 of forming a functional coating layer may be carried out to form a coating layer having an anti-bacterial effect, anti-scratch effect or both.
  • Nanosilver may be used to form an anti-bacterial coating layer.
  • a UV protecting layer may be introduced to protect a product from UV rays.
  • a transparent film may be used to provide an anti-scratch effect or to protect the pattern, and such transparent films may be formed of a general plastic material (e.g. PVC) or a transparent HIPS (high impact polystryrene).
  • an additional embossing step may be carried out, since the laminated sheet is not completely solidified.
  • the above additional embossing step may be performed individually or in combionation with the aforementioned embossing step S30.
  • step (d) i.e. an aging step S70 is carried out in order to prevent a product from being deformed due to the shrinkage and exapnsion caused by variations in temperature and humidity, and thus to increase the dimensional stability of the resultant product.
  • the aging step is carried out by passing the laminated sheet through a water bath filled with water maintained at 90 ⁇ 100°C over a period of 30 sec. ⁇ 10 min.
  • step (e), i.e. a step S80 of post-treatment is performed by cooling the resultant product to room temperature, and drying, cutting and packaging the finished product.
  • the cutting step the product is subjected to trimming and cut into a desired size.
  • a flooring material comprises a laminate of a bottom layer, an intermediate layer and a top layer, stacked successiveively when viewed from the bottom to the top.
  • the method according to the present invention may be applied to the manufacture of the intermediate layer interposed between the bottom layer and the top layer in the above laminated multi-layer flooring material.
  • a layer impregnated with a fiber mat such as glass fiber is generallly formed in order to impart dimensional stability. Accordingly, a transfer printed layer is formed between the glass fiber-impregnated layer and the top layer (e.g. PVC) via a heat transfer process.
  • a fiber mat such as glass fiber
  • the top layer e.g. PVC
  • top surface of the top layer may be further coated with a UV coating layer or treated with polyurethane in order to impart anti-fouling property to the flooring material.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

Disclosed is a method of manufacturing a flooring material including wood powder so as to represent a texture like natural wood. The method comprises: (a) a step of softening a main sheet, wherein a synthetic resin sheet transferred continuously from a feed roller is heated and softened by using a heater; (b) a step of forming a wood powder layer, wherein a wood powder layer is formed on the softened main sheet to a predetermined thickness by using wood powder paste including 30~80 wt% of wood powder and 20~70 wt% of a synthetic resin containing an adhesive; and (c) a step of forming a pattern, wherein a predetermined pattern is introduced onto the sheet lamintaed with the wood powder layer.

Description

Description
MANUFACTURING METHOD FOR FLOORS INCLUDING
WOOD POWDER
Technical Field
[1] The present invention relates to a method of manufacturing a flooring material including wood powder so as to represent a texture like natural wood. Background Art
[2] In the field of flooring materials, such as tiles and floor covering sheets for use in houses and offices, many attempts have been made up to date. Such attempts have started from introducing various colors onto the top surface of a sheet made of a synthetic resin. Additionally, many studies have been conducted to improve durability, for example, by introducing a protective coating layer that prevents the surface of a flooring material from being broken or discolored, and to improve print quality so as to realize a texture like a natrual material, such as wood or marble stone, or like a carpet.
[3] Meanwhile, research and development for products, into which an anti-toxic ingredient such as a far infrared ray-emitting material, a deodorizing material or silver is introduced, has been conducted in order to solve the problem of discharge of environmental hormones from petrochemical products.
[4] Further, there has been an attempt to form surface roughness with various patterns on the surface of a flooring material, so as to realize a texture as well as a color like wood, stone or fiber. Disclosure of Invention Technical Problem
[5] The present invention has been made to develop an advanced flooring material showing a texture like wood by introducing a natural ingredient, particularly wood po wder, into the flooring material itself.
[6] Accordingly, it is an object of the present invention to provide a method of manufacturing a flooring material, the method comprising: a step of forming a wood powder layer, wherein a main sheet formed of a synthetic resin such as PP, PE, SPS or PET is laminated with a wood powder layer, in particular, a separately formed wood powder sheet, by using wood powder paste including wood powder; and a step of forming a pattern, wherein transfer printing and/or gravure printing is performed on the wood powder layer.
[7] It is another object of the present invention to provide a method of manufacturing a flooring material, which further comprises an aging step, wherein the flooring material obtained as described above is aged by passing it through a water bath filled with water at 90~100°C so as to prevent the flooring material from being deformed due to the shrinkage and expansion causd by variations in temperature and humidity.
[8] It is still another object of the present invention to provide a method of manufacturing a flooring material, which further comprises an embossing step for imparting a wood- like texture to the flooring material, and a step of forming a coating layer for imparting anti-bacterial and anti-scratch properties to the flooring material. Technical Solution
[9] In order to accomplish the above objects, there is provided a method of manufacturing a flooring material including wood powder, the method comprising: (a) a step of softening a main sheet, wherein a synthetic resin sheet transferred continuously from a feed roller is heated and softened by using a heater; (b) a step of forming a wood powder layer, wherein a wood powder layer is formed on the softened main sheet to a predetermined thickness by using wood powder paste including 30~80 wt% of wood powder and 20~70 wt% of a synthetic resin containing an adhesive; and (c) a step of forming a pattern, wherein a predetermined pattern is introduced onto the sheet lamintaed with the wood powder layer.
[10] As used herein, the term "flooring material" includes all kinds of materials that can be used as flooring materials, for example, tiles, floor covering sheets, and other floor mats (e.g. impact-absorbing mats for children).
[11] According to a preferred embodiment of the method of manufacturing a flooring matrial including wood powder, wood powder itself is formed into a sheet to facilitate the lamination of wood powder with the main sheet, and thus to increase the productivity. To perform this, step (b), i.e. the step of forming a wood powder layer is carried out by laminating the main sheet obtained from step (a) with a wood powder sheet having a predetermined thickness. More particularly, the wood powder sheet is formed by the process comprising the steps of: introducing wood powder paste, which comprises 30~80 wt% of the wood powder, and 20~70 wt% of the synthetic resin further comprising 15~50 wt% of an adhesive and 5~20 wt% of side materials including a dispersant, based on the total weight of the wood powder paste, into a blender via a hopper; heating and melting the materials to provide wood powder paste; and passing the wood powder paste through a calender having a heating roller assembly and a cooling roller assembly.
[12] Further, in addition to the dispersant, the side materials may include a foaming agent, a stabilizer, a lubricant, and a softening agent to obtain a product having a lower weight and improved stability.
[13] According to another preferred embodiment of present invention, the method of manufacturing a flooring material including wood powder may further comprise additional steps to increase the dimensional stability of the flooring material by preventing the flooring material from being deformed due to the shrinkage and expansion caused by variations in temperature and humidity. More particularly, the method accoriding to the present invention may further comprises step (d) of aging the flooring material by passing it through a water bath filled with water maintained at 90~100°C, after step (c) of forming a pattern.
[14] According to still another preferred embodiment of the present invention, the method further comprises a step of preventing deformation of the flooring material by cooling the laminated sheet to 20~35°C, after step (b) of forming a wood powder layer. More preferably, the method according to the present invention further comprises step (e) of carrying out post-treatment by cooling, drying and cutting the resultant flooring material.
[15] According to yet another preferred embodiment of the present invention, step (c) of forming a pattern may be carried out by a transfer printing process, a gravure printing process or a combination thereof. More particularly, the transfer printing process uses a PET film as a base film of the transfer sheet. Preferably, the transfer temperature in the transfer printing process is higher than the softening point of the synthetic resin forming the main sheet. For this reason, the method according to the present invention comprises an additional step of heating the main sheet to a temperature higher than the softening point.
[16] According to yet another preferred embodiment of the present invention, the method of manufacturing a flooring material including wood powder further comprises an embossing step, before or after step (c) of forming a pattern, so as to impart a texture like a natrual material, such as wood or rock, to the flooring material.
[17] More preferably, the method of manufacturing a flooring material further includes a step of forming a functional coating layer having at least one effect selected from the group consisting of an anti-bacterial effect, a UV protecting effect and an anti-scratch effect, so as to further increase the reliability of the flooring material.
Advantageous Effects
[18] As described above, the method of manufacturing a flooring material including wood powder according to the present invention comprises a step of forming a wood powder layer, wherein a main sheet formed of a synthetic resin such as PP, PE or PET is laminated with a wood powder layer, in particular, a separately formed wood powder sheet, by using wood powder paste including wood powder, and a step of forming a pattern, wherein transfer printing and/or gravure printing is performed on the wood powder layer. Hence, the flooring material obtained by the method represents a texture like natural wood. Additionally, according to the present invention, the flooring matrial is aged by passing it through a water bath filled with water at 90~100°C. Hecne, it is possible to prevent the flooring material from being deformed due to the shrinkage and expansion caused by variations in temperature and humidity. Further, according to the present invention, it is possible to improve the quality of a flooring material by performing an embossing step for imparting a wood-like texture to the flooring material, and by forming an anti-bacterial and anti-scratch coating layer. Brief Description of the Drawings
[19] FIG. 1 is a schematic block diagram illustrating the method of manufacturing a flooring material including wood powder according to a preferred embodinent of the present invention.
Best Mode for Carrying Out the Invention
[20] Hereinafter, the method of manufacturing a flooring material according to the present invention will be explained in more detail with reference to the accompanying drawing.
[21] First, step (a), i.e. the softening step SlO is carried out by heating and softening a main sheet transferred continuously from a feed roller around which the laminated synthetic resin sheet is wound. This facilitates lamination of wood powder paste with a predetermined thickness in the subsequent step (b), i.e. the step S20 of forming a wood powder layer.
[22] The softening treatment may be performed by using a heated transfer roller or a separate electric heater.
[23] The main sheet may be formed of a material selected from general plastic materials with a high cost efficiency. In other words, the main sheet may be formed of a material selected from the group consisting of PVC, PE, PET, PP, SPS and combinations thereof.
[24] In general, PVC has been widely used as a material for a floor covering sheet.
However, PVC is problematic in that it has a low heat resistance and a relatively high electrostatic property.
[25] The material for the main sheet is preferably selected considering advantages and disadvantages of various general plastic materials. Polypropylene (PP) is particularly preferred, because it is superior in terms of printability, heat resistance (m.p. 160~170°C), gloss, antistatic property, water steam protectability, mechanical strength, light weight and cost efficiency.
[26] Next, step (b), i.e. the step S20 of forming a wood powder layer is carried out. In step (b), a wood powder layer with a predetermined thickness is formed on the softened main sheet by using wood powder paste including 30~80 wt% of wood powder and 20~70 wt% of a synthetic resin containing an adhesive. [27] Particular examples of the wood powder that may be used in the present invention include pure wood materials such as freshly crushed dry wood or waste saw dust, rice hulls, or a mixture of pure wood materials with rice hulls. Preferably, the wood powder has a water content of 5% or less and an average particle diameter of 20~500D so as to be mixed well with other synthetic resins. The wood powder may be present in an amount of 30~80 wt% based on the total weight of the wood powder paste.
[28] To form the wood powder layer on the softened main sheet, the wood powder paste may be applied directly onto the main sheet by using an extruder such as a T-die, and then passed through a roller so that the wood powder paste can be attached onto the main sheet under pressure.
[29] However, according to the present invention, the wood powder paste is formed into a separate wood powder sheet, and then laminated with the main sheet, in order to increase the productivity.
[30] To perform this, the wood powder sheet is formed first by the process comprising the steps of: introducing wood powder paste, which comprises 30~80 wt% of the wood powder, and 20~70 wt% of the synthetic resin further comprising 15~50 wt% of an adhesive and 5~20 wt% of side ingredients including a dispersant, based on the total weight of the wood powder paste, into a blender via a hopper; heating, mixing and melting the materials at a temperature higher than the softening point of the synthetic resin to provide wood powder paste; extruding the wood powder paste via an extrusion device such as a T-die, and forming a sheet while passing the wood powder paste directly through a calender; and laminating the wood powder sheet with the main sheet obtained from step (a), i.e. step SlO. More particularly, the calender includes a series of heating rollers warmed to a temperature higher than the melting point of the synthetic resin, at the begining part thereof, in order to prevent the molten materials from being cooled upon the contact with the ambient atmosphere. The heating rollers are followed by a series of cooling rollers in order to cure the wood powder sheet stably.
[31] The dispersant is used as one of the side ingredients, because the main ingredient of the paste and wood powder have different physicochemical properties, and thus the wood powder may not be uniformly distributed in/mixed with the paste. For example, the dispersant includes methyl methacrylate-butyl acrylate copolymer and is used in an amount of 0.1~10 wt% based on the total weight of the paste.
[32] In addition to the dispersant, a foaming agent may be used in order to reduce the weight of the resultant flooring material and to impart a certain degree of elasticity. The foaming agent may be used in an amount of 0.005~3 wt% based on the total weight of the paste. Particular examples of the foraming agent include azodi- carbonamide. [33] When using the foaming agent, it is preferable to use a stabilizer to stabilize the foamed state. The stabilizer may be used in an amount of 0.1~7 wt% based on the total weight of the paste. Particular examples of the stabilizer include barium stearate and dibasic lead stearate.
[34] Further, a softening agent such as stearate or a lubricant such as polyethylene oxide homopolymer may be introduced in order to improve the quality of the resultant flooring material.
[35] Then, an embossing step S30 is carried out on the exposed surface of the laminated sheet obtained from the main sheet and the wood powder sheet. Particularly, the surface having the wood powder layer is embossed to impart a texture like a natrual material, such as wood or rock.
[36] The embossing step may be performed before or after the step S50 of forming a pattern as described hereinafter. When the embossing step is performed after the step S20 of laminating the main sheet with the wood powder sheet, as shown in FIG. 1, embossed surfaces can be obtained simply by applying a roller having a predetermined pattern engraved in intaglio or in relief thereon to the laminated sheet, because the laminated sheet is not completely solidified.
[37] Then, a step S40 of preventing deformation of a flooring material may be performed in order to impart an improved dimensional stability to the flooring material by preventing the flooring material from being deformed due to variations in temperature and humidity during the storage or transport thereof, or before or after the construction thereof.
[38] The step of preventing deformation may be carried out by passing the laminated sheet through a water bath filled with water at 20~30°C. Such a cooling step S40 is preferred because it allows the embossed surface to be solidified sufficiently.
[39] Then, a step S50 of forming a pattern is performed to provide the resultant panel with a predetermined pattern. The step of forming a pattern may be performed by a transfer printing process, a gravure printing process or a combination thereof.
[40] Particularly, in the case of a transfer printing process, the panel is heated preferably to a temperature higher than the softening point of the main sheet, so as to facilitate and complete the transfer process.
[41] If the main sheet is formed of PP, the transfer temperature is preferably higher than about 17O0C (softening temperature of PP), and more preferably ranges from 180~200°C.
[42] For this reason, it is preferable to use a PET (polyethylene terephthalate) film, which has a heat resistance sufficient to endure the above temperature range and is cost efficient, as a base film of the transfer sheet.
[43] In addition to PET, the transfer sheet may be formed of PE, PP or SPS. Ad- ditionally, a release primer layer is formed on the base film (PET) so as to facilitate separation of the pattern from the PET film during the transfer process. Also, the release primer layer avoids any difficulty in separating the pattern, when the transfer process is performed under high-humidity conditions, or when heat conduction is not made sufficiently during the transfer process.
[44] The release primer may comprise 2-5 wt% of an acrylic polymer, 8-20 wt% of a
PVC copolymer, 0-2 wt% of nicrocellulose (NC), 30-70 wt% of methyl ethyl ketone (MEK), 0-2 wt% of silica and 0-2 wt% of a dispersant.
[45] The release primer layer may be applied onto a synthetic resin film, sheet or article from depressions having a predetermined depth, pattern and volume, which are engraved in a printing cylinder via a mechanical or chemical process. In other words, the release primer may be applied via a gravure printing process, which allows the release primer to be applied on a continuous film or sheet roll with high precision.
[46] Then, a pattern is printed with ink on the top of the release primer layer, wherein the ink generally comprises 6-17 wt% of a pigment, 50-110 wt% of methyl ethyl ketone (MEK) as a solvent and 50-70 wt% of a medium (e.g. an acrylic resin, a PVC copolymer and a solvent such as toluene or methyl ethyl ketone) for fixing the pigment to an object to be printed.
[47] Additionally, an adhesvie primer layer is formed on the printed pattern layer. The adhesive primer is a heat-sensitive adhesive which shows adhesion only upon heating, and includes an oil-based adhesive primer or an aqueous adhesive primer. For example, the oil-based heat-sensitive adhesive comprises 1-20 wt% of polyurethane, 10-50 wt% of a PVC copolymer, 0-3 wt% of a dispersant, 0-2 wt% of a defoaming agent and 10-80 wt% of methyl ethyl ketone. The aqueous heat-sensitive adhesive may comprise 10-50 wt% of an acrylic aresin, 3-20 wt% of water, 30-60 wt% of alcohol and 0-2 wt% of nitrocellulose.
[48] The pattern obtained by the above step S50 of forming a pattern includes a wood- like pattern or a stone-like pattern, such as a pattern like marble stone or natural rock.
[49] After that, a step S60 of forming a functional coating layer may be carried out to form a coating layer having an anti-bacterial effect, anti-scratch effect or both. Nanosilver may be used to form an anti-bacterial coating layer. Further, a UV protecting layer may be introduced to protect a product from UV rays. A transparent film may be used to provide an anti-scratch effect or to protect the pattern, and such transparent films may be formed of a general plastic material (e.g. PVC) or a transparent HIPS (high impact polystryrene).
[50] After the above coating step S60, an additional embossing step may be carried out, since the laminated sheet is not completely solidified. The above additional embossing step may be performed individually or in combionation with the aforementioned embossing step S30.
[51] Then, in addition to the aforementioned step S40 of preventing deformation via cooling, step (d), i.e. an aging step S70 is carried out in order to prevent a product from being deformed due to the shrinkage and exapnsion caused by variations in temperature and humidity, and thus to increase the dimensional stability of the resultant product.
[52] Preferably, the aging step is carried out by passing the laminated sheet through a water bath filled with water maintained at 90~100°C over a period of 30 sec. ~ 10 min.
[53] Finally, step (e), i.e. a step S80 of post-treatment is performed by cooling the resultant product to room temperature, and drying, cutting and packaging the finished product. In the cutting step, the product is subjected to trimming and cut into a desired size.
Mode for the Invention
[54] Practically, a flooring material comprises a laminate of a bottom layer, an intermediate layer and a top layer, stacked succesively when viewed from the bottom to the top. The method according to the present invention may be applied to the manufacture of the intermediate layer interposed between the bottom layer and the top layer in the above laminated multi-layer flooring material.
[55] In this case, a layer impregnated with a fiber mat such as glass fiber is generallly formed in order to impart dimensional stability. Accordingly, a transfer printed layer is formed between the glass fiber-impregnated layer and the top layer (e.g. PVC) via a heat transfer process.
[56] Additionally, the top surface of the top layer may be further coated with a UV coating layer or treated with polyurethane in order to impart anti-fouling property to the flooring material. Industrial Applicability
[57] As can be seen from the foregoing, according to the present invention, it is possible to proivde a flooring material including wood powder so as to represent a texture like natural wood.
[58] In the foregoing text, detailed description on the conventional technique generally known to those skilled in the art, such as master batch, blending, melting, sheet forming, lamination, embossing, or the like, are omitted. However, those skilled in the art will appreciate the same.
[59] Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. [60]

Claims

Claims
[1] A method of manufacturing a flooring material including wood powder, the method comprising:
(a) a step of softening a main sheet, wherein a synthetic resin sheet transferred continuously from a feed roller is heated and softened by using a heater;
(b) a step of forming a wood powder layer, wherein a wood powder layer is formed on the softened main sheet to a predetermined thickness by using wood powder paste including 30~80 wt% of wood powder and 20~70 wt% of a synthetic resin containing an adhesive; and
(c) a step of forming a pattern, wherein a predetermined pattern is introduced onto the sheet lamintaed with the wood powder layer.
[2] A method of manufacturing a flooring material including wood powder as claimed in claim 1, wherein step (b) of forming a wood powder layer is carried out by laminating the main sheet obtained from step (a) with a wood powder sheet having a predetermined thickness, the wood powder sheet being formed by the process comprising the steps of: introducing wood powder paste, which comprises 30~80 wt% of the wood powder, and 20~70 wt% of the synthetic resin further comprising 15~50 wt% of an adhesive and 5~20 wt% of side ingredients including a dispersant, based on the total weight of the wood powder paste, into a blender via a hopper; heating and melting the materials to provide wood powder paste; and passing the wood powder paste through a calender having a heating roller assembly and a cooling roller assembly.
[3] A method of manufacturing a flooring material including wood powder as claimed in claim 2, wherein the side ingredients further comprise a foaming agent, a stabilizer, a lubricant and a softening agent, in addition to the dispersant.
[4] A method of manufacturing a flooring material including wood powder as claimed in any one of claims 1 to 3, which further comprises:
(d) a step of aging the flooring material by passing it through a water bath filled with water maintained at 90~100°C, after step (c) of forming a pattern; and
(e) a step of carrying out post-treatment by cooling, drying and cutting the flooring material.
[5] A method of manufacturing a flooring material including wood powder as claimed in claim 4, wherein step (c) of forming a pattern is performed by a transfer printing process.
[6] A method of manufacturing a flooring material including wood powder as claimed in claim 5, wherein step (c) of forming a pattern performed by a transfer printing process utilizes a film formed of PET as a base film for a transfer sheet, the transfer process is performed at a transfer temperature higher than the softening point of the main sheet, and a step of heating the main sheet is added to obtain the transfer temperature. [7] A method of manufacturing a flooring material including wood powder as claimed in claim 4, wherein step (c) of forming a pattern is performed by a gravure printing process. [8] A method of manufacturing a flooring material including wood powder as claimed in claim 4, which further comprises a step of forming a functional coating layer to impart at least one effect selected from the group consisting of an anti-bactrial effect, a UV protecting effect and an anti-scratch effect. [9] A method of manufacturing a flooring material including wood powder as claimed in claim 4, which further comprises an embossing step before or after step (c) of forming a pattern. [10] A method of manufacturing a flooring material including wood powder as claimed in claim 4, which further comprises a step of preventing deformation of the laminated sheet by cooling the laminated sheet to 20~35°C, after step (b) of forming a wood powder layer.
PCT/KR2006/001919 2006-02-24 2006-05-22 Manufacturing method for floors including wood powder WO2007097497A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
KR10-2006-0018041 2006-02-24
KR20060018041 2006-02-24
KR10-2006-0036546 2006-04-24
KR20060036546 2006-04-24

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH08169092A (en) * 1994-12-20 1996-07-02 Fukuvi Chem Ind Co Ltd Wood powder filled resin coated extrusion molding and production thereof
KR19980047302A (en) * 1996-12-10 1998-09-15 성재갑 Floor decoration material using natural wood powder and its manufacturing method
KR19990007018U (en) * 1997-07-30 1999-02-25 김희연 Wood ash
KR19990018964A (en) * 1997-08-28 1999-03-15 이종학 Flooring material with wood flour print layer and its manufacturing method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH08169092A (en) * 1994-12-20 1996-07-02 Fukuvi Chem Ind Co Ltd Wood powder filled resin coated extrusion molding and production thereof
KR19980047302A (en) * 1996-12-10 1998-09-15 성재갑 Floor decoration material using natural wood powder and its manufacturing method
KR19990007018U (en) * 1997-07-30 1999-02-25 김희연 Wood ash
KR19990018964A (en) * 1997-08-28 1999-03-15 이종학 Flooring material with wood flour print layer and its manufacturing method

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