KR101317063B1 - Wood flooring with composite core comprising Kenaf and fiber board - Google Patents

Abstract

The present invention relates to a flooring material to which a composite substrate structure including a kenaf board and a fiber board (MDF, HDF) is applied. More specifically, an intermediate product of plywood and HDF used as a base material of plywood flooring and reinforcement flooring is provided. The present invention relates to a flooring material applied to a composite substrate having characteristics of securing price competitiveness and supply and demand stability of raw materials compared to plywood, and securing excellent quality compared to HDF.

According to the present invention, the flooring composite material for flooring can replace the plywood, which is unstable supply and demand due to the current price of raw materials can bring a cost saving effect. In other words, price competitiveness can be secured when raw material supply and demand depend on imports. In addition, it is possible to secure stable basic properties (dimension stability, absorption thickness expansion rate) compared to HDF by laminating the horse board and fiber board in combination.

In addition, it is possible to produce products with a variety of structures by combining laminated boards and fibreboards, and to make products for various uses using materials that are easy to supply raw materials and good basic physical properties, and ultimately differentiated from other products Can be derived.

Flooring materials, composite materials, hemp boards, fiberboard

Description

Wood flooring with composite core comprising Kenaf and fiber board}

1 is a cross-sectional view of a floor covering according to a first embodiment of the present invention.

2 is a cross-sectional view of the floor covering according to a second embodiment of the present invention.

3 is a cross-sectional view of the floor covering according to a third embodiment of the present invention.

4 is a cross-sectional view of the floor covering according to a fourth embodiment of the present invention.

5 is a cross-sectional view of the floor covering according to a fifth embodiment of the present invention.

<Description of the symbols for the main parts of the drawings>

1a, 1b: composite substrate layer

10: surface treatment layer

20: surface layer

30: horse board

40: fiberboard

50: synthetic resin layer

60: reinforcement layer

The present invention relates to a flooring material to which a composite substrate structure including a horse board and a fiber board (MDF, HDF) is applied. More specifically, by developing an intermediate product between plywood and HDF, which is used as a base material of plywood flooring and reinforcement flooring, The present invention relates to a flooring material applied to a composite base material having characteristics of securing price competitiveness and supply / demand stability of plywood and excellent quality compared to HDF.

Sheep are also known as Kenaf, native to Africa and India. Stems stand straight, 3-5 m high, annual herb. After harvesting the fermentation, the fermented fiber is used as a substitute for hemp or jute, which is tougher, somewhat coarse, and less flexible than jute fiber. The length of the fiber is about 22 cm and is used as a sack, a fishing net, a rope, and a papermaking material. In addition, it is possible to apply to plate-shaped products by making the horses in board form.

Kenaf fiber is also used as a raw material for reinforced bioplastics, which is the addition of kenaf fiber as a reinforcement to corn-based polylactic acid. Kenaf is characterized by fast growth and high CO2 absorption, which has been pointed out as a cause of global warming in the cultivation process. Thus, using Kenaf fiber can further enhance heat resistance and strength, and thus can be used not only as a fiber material but also as a mobile phone and a refrigerator exterior material.

Generally, wood materials can be classified into six types: solid wood, modified wood, laminated composites, particle composites, fiber composites, and wood powder composites.

Among the various wood materials mentioned above, plywood and HDF are generally used as the base materials of flooring, but plywood, which is the base material of plywood floor, is unstable in supply and demand, and there is concern about cost increase and resource depletion in the future. HDF has the disadvantage of high absorption thickness expansion rate against water and poor dimensional stability.

In particular, in the case of plywood, Indonesia, a major importer of domestic plywood, has strong restrictions on illegal slaughter, and the price has soared recently due to a sharp increase in demand for raw materials ahead of the Beijing Olympics in China.

Accordingly, there is a need for a substrate to replace the plywood, the requirement of the replacement substrate is that the price must be cheaper than the plywood, and the physical properties should come out of the plywood level.

Japanese Patent No. 3753473 discloses a stucco plate, but the substrate has a single layer structure.

Japanese Patent No. 2925384 discloses a composite cosmetic flooring material, but uses plywood composed only of a single plate as a base material.

Japanese Patent Laid-Open No. 2006-7713 discloses a wooden composite stucco plate, but uses a synthetic rubber sheet in which impregnated paper is laminated on both sides as a substrate.

Japanese Laid-Open Patent Publication No. 1998-121706 discloses a composite floor having a heavy fiber plate as a surface layer, but uses a plywood composed of only a single plate as a base material.

Korean Utility Model Registration No. 250209 and No. 250210 disclose composite floorboards, but plywood is used as a base material.

An object of the present invention is to provide a flooring material applying a composite substrate structure that is excellent in supply-demand stability and price competitiveness than the plywood which is the main substrate of the flooring material, which can ensure the absorption thickness expansion rate and dimensional stability superior to HDF.

In order to achieve the above object, the present invention provides a flooring material, characterized in that it has a composite substrate structure comprising a horse board and a fiber board.

The composite substrate according to the first embodiment of the present invention consists of a horse board, a fiber board, and a horse board from above. The configuration of this embodiment is the most preferable composite substrate structure of the present invention, and it is most preferable that the structure is particularly composed of a horse board, HDF, and a horse board.

The composite substrate according to the second embodiment of the present invention is composed of a fiber board, a horse board, and a fiber board from above.

The fiber board used in the present invention is MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard). More preferably, a ground hard fiber board (HDF) of 0.85 g / cm 3 or more is used as the floor substrate use.

The floor covering according to the first to second embodiments of the present invention comprises a surface treatment layer, a surface layer, and a composite substrate layer from above. This structure is the most common structure of plywood floors and is characterized by having a composite base layer as a base material.

Flooring material according to a third embodiment of the present invention is composed of a surface treatment layer, a surface layer, a composite substrate layer, a surface layer, a surface treatment layer from above.

Flooring material according to a fourth embodiment of the present invention is composed of a surface treatment layer, a surface layer, a composite substrate layer, a synthetic resin layer from above.

Flooring material according to a fifth embodiment of the present invention is composed of a surface treatment layer, a surface layer, a dimensional reinforcement layer, a composite substrate layer from above.

In the present invention, the surface layer may be made of at least one material selected from veneer, PVC, PE, PP, olefin, glass fiber, inorganic, sponge, styrofoam, gypsum. For plywood floors, veneers typically 0.35 to 0.5 mm thick are used, and for reinforced floors LPL is applied. Particularly, floors in which veneers (single plates) of 2 mm or more are applied as the surface layer are called solid wood floors.

In the present invention, the synthetic resin layer may be made of at least one material selected from PVC (Poly Vinyl Chloride), PE (Poly Ethylene), and PP (Poly Propylene). Particularly, the synthetic resin layer may include coalite (calcium carbonate) to exhibit a saddle field effect, and the content of the coalite is preferably 70% by weight or more with respect to the total weight of the synthetic resin layer so as to exhibit a saddle field effect.

In the present invention, the reinforcing layer is one or more wood materials selected from solid wood, particle board, HPL (High Pressure Laminate), LPL (Low Pressure Laminate), OSB (Oriented Strand Board), Flake board, corrugated cardboard, paper It may be made of.

The flooring material of the present invention includes at least one functional material selected from among charcoal, loess, silver, elvan, germanium, magnetite, jade, antimicrobial agent, and insect repellent on at least one layer of the flooring material to provide various functionalities; At least one curing resin selected from epoxy, phenol, acrylic, melamine, polyurethane, unsaturated polyester, and diallyl phthalate; At least one filler selected from calcium carbonate, talc, titanium oxide, silica, glass powder, and silicon dioxide; And / or at least one flame retardant selected from phosphoric esters, halogenated hydrocarbons, antimony oxide, aluminum hydroxy, phosphate compounds, and dicyandiamide.

In the present invention, when laminating the yam board and the fiber board, the physical properties of the inherent density, water content, fiber anisotropy, etc. of each wood material and the interaction between the different physical properties between these materials Consideration should be given.

In this way, various product configurations are possible by analyzing factors that may affect product properties such as density, thickness, and water content, and selectively applying them according to the usage of products and the trend of supply and demand for raw materials.

The present invention relates to a flooring material to which a composite substrate is applied to form a new structure by combining the sheath board and the fiber board in various wood materials, an example of the laminated structure is the same as the structure of Figs.

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

1 is a cross-sectional view of a floor covering according to a first embodiment of the present invention. The floor covering of this embodiment is composed of a surface treatment layer 10, a surface layer 20, and a composite substrate layer 1a from above. The layer 1a is composed of a horse board 30, a fiber board 40, and a horse board 30 from above.

The surface treatment layer 10 is a layer formed by applying and curing a urethane acrylate-based ultraviolet curable resin for imparting stain resistance to the uppermost portion, and may be embossed as necessary.

The surface layer 20 is a layer constituting the surface of the flooring material, it may be made of at least one material selected from veneer, PVC, PE, PP, olefin, glass fiber, inorganic, sponge, styrofoam, gypsum.

The horse board 30 is a board made of the sheep fiber, and excellent in heat resistance and strength.

Fibreboard 40 has no orientation and is very inexpensive compared to plywood. MDF or HDF is used as the fiber board, and HDF is particularly preferable.

Among the configurations of Figure 1, the configuration of the horse board 30, HDF 40, the horse board 30 is the most preferable, because the price is cheaper than plywood, but the physical properties are close to the plywood level.

Figure 2 is a cross-sectional view of the floor covering according to a second embodiment of the present invention, the floor covering of this embodiment is composed of a surface treatment layer 10, a surface layer 20, a composite substrate layer (1b) from above, The layer 1b is composed of a fiber board 40, a horse board 30, and a fiber board 40 from above.

3 is a cross-sectional view of a floor covering according to a third embodiment of the present invention, wherein the floor covering of this embodiment is a surface treatment layer 10, a surface layer 20, a composite substrate layer 1a, a surface layer 20, It is made of a surface treatment layer 10, the composite substrate layer (1a) is composed of a horse board 30, a fiber board 40, a horse board 30 from above.

4 is a cross-sectional view of the floor covering according to the fourth embodiment of the present invention, wherein the floor covering according to this embodiment is a surface treatment layer 10, a surface layer 20, a composite substrate layer 1a, a synthetic resin layer 50 from above. Comprised of, the composite base layer (1a) is made of a horse board 30, a fiber board 40, a horse board 30 from above.

The synthetic resin layer 50 may be made of at least one material selected from PVC, PE, and PP.

The synthetic resin layer can be imparted with health by pulverizing and adding ganbanite, jade, ocher, etc., in particular, by laminating the sound insulating sheet layer on the synthetic resin layer or by using the synthetic resin layer as the sound insulating sheet layer. Compared with the heat transfer effect, it can be used in any environment.

5 is a cross-sectional view of the floor covering according to the fifth embodiment of the present invention, wherein the floor covering of this embodiment is a surface treatment layer 10, a surface layer 20, a dimensional reinforcement layer 60, a composite substrate layer 1a from above. Comprised of, the composite base layer (1a) is made of a horse board 30, a fiber board 40, a horse board 30 from above.

The dimensional reinforcement layer 60 is one or more wood materials selected from solid wood, particle board, high pressure laminate (HPL), low pressure laminate (LPL), oriented strand board (OSB), flake board, corrugated cardboard, and paper. It may be made of. The dimensional reinforcement layer can induce strength complement and balancing effects of the surface layer.

In order to impart various functionalities to the flooring material of the present invention, at least one of the surface treatment layer 10, the surface layer 20, the yam board 30, the fiber board 40, the synthetic resin layer 50, the dimensional reinforcement layer 60 Functional materials such as charcoal, loess, silver, elvan, germanium, magnetite, jade, antibacterial and insect repellent can be added to the layer to impart beneficial functions such as far-infrared radiation, anion divergence, antibacterial and insect repellent. In addition, curing resins such as epoxy, phenol, acrylic, melamine, polyurethane, unsaturated polyester, and diallyl phthalate can be added to improve physical properties such as durability, abrasion resistance, and water resistance, and calcium carbonate, talc, titanium oxide. , Fillers such as silica, glass powder, silicon dioxide, etc. can be added to provide functions such as good ball field effect and thermal conductivity improvement.Phosphoric ester, halogenated hydrocarbon, antimony oxide, aluminum hydroxy, phosphate compound, dicyandiamide, etc. Flame retardants may be added to provide flame retardant function.

[Example]

From above, the board, the fiber board 40, and the board of the horse board 30 were integrated by pressing to produce a flooring composite material 1a.

At this time, the yam board 30 applied to the upper layer and the lower layer had a specific gravity of 0.71, a thickness of about 1.5 mm, and a moisture content of 7.1%. The HDF 40 had a specific gravity of 0.87, a moisture content of 7.6%, and a thickness of about 4.5. The thing of mm was used. The adhesive used melamine resin. Looking at the manufacturing process of the substrate in detail, after laminating each layer was integrated into a press, the pressure was 8 kgf / ㎠, the pressurization time 6 minutes, the hot plate temperature was carried out at 125 ℃.

After applying the PVAc-based adhesive on the composite substrate layer (1a) prepared in the above manner, the veneer as a surface layer 20, plywood and heat-treated at 120 ℃ for 30 seconds and cured for 48 hours. Then, the surface was polished and cured for 24 hours after under UV coating.

Flexibility was given to the flooring through back grooving, and tongue & groove (T & G) structures were formed by gang-rip processing and tenoner processing. Finally, the product was finished with top coat UV to prepare a flooring material having a structure as shown in FIG. 1 having a surface treatment layer 10.

Comparative Example 1

Plywood floor based on plywood

Comparative Example 2

Reinforced floor based on HDF

[Test Example]

Dimensional stability and absorption thickness expansion ratio were measured for the flooring material of Example and the conventional plywood floor (Comparative Example 1) and reinforced floor (Comparative Example 2), and the results are shown in Table 1.

The absorption thickness expansion ratio of the floor covering including the composite substrate prepared in Example was superior to the floor covering of the comparative example.

Dimensional stability measured the dimensional change of 48 hours before and after the immersion conditions in the water bath and oven drying conditions of high temperature (80 ℃).

Here, the absorption thickness expansion rate was measured by comparing the thickness before and after immersion in 20 ℃ water for 24 hours, 70 ℃ water for 2 hours in a constant temperature bath according to KSF 3200 standard.

Test Items Example Comparative Example 1 Comparative Example 2 size
stability Cold water immersion
48 hours width 0.22 0.22 0.21 Length 0.14 0.07 0.16 High temperature (80 ℃)
48 hours of drying width -0.14 -0.21 -0.36 Length -0.12 -0.17 -0.34 Absorption thickness
Expansion rate 20 ℃ 24 hours 6.19 7.53 23.02 70 ℃ 2 hours 9.39 25.84 138.04

The dimensional stability shows better results as the temperature nears zero for both immersion and high temperature drying conditions. That is, in the case of Example, physical properties similar to plywood floor and reinforcement floor were shown in the width direction of immersion in normal temperature water, and physical properties were lower than that of plywood floor in the length direction, but showed better results than reinforcement floor. In hot drying conditions, the examples showed the best results.

In the case of the absorption thickness expansion ratio, the examples showed the best values at 20 ° C 24 hours and 70 ° C 2 hours.

The composite substrate for flooring floorings presented in the present invention may bring cost saving effects by replacing plywood that is unstable in supply and demand due to current raw material price hikes. In other words, price competitiveness can be secured when raw material supply and demand depend on imports. In addition, it is possible to secure stable basic properties (dimension stability, absorption thickness expansion rate) compared to HDF by laminating the horse board and fiber board in combination.

In addition, it is possible to produce products with a variety of structures by combining laminated boards and fibreboards, and to make products for various uses using materials that are easy to supply raw materials and good basic physical properties, and ultimately differentiated from other products Can be induced.

Claims (15)

Comprising a composite substrate in which the yam board and the fiber board is compressed to be integrated, and provided with a surface layer and a surface treatment layer on any one side or both sides of the composite substrate, the surface treatment layer is provided with a dimensional reinforcement layer and a synthetic resin layer, Flooring material, characterized in that far-infrared, anionic or antimicrobial material is added to any one of the layer of the horse board, fiberboard, surface layer, surface treatment layer and synthetic resin layer. The flooring material according to claim 1, wherein the composite base material is formed by compressing a horse board, a fiber board and a horse board from above. The flooring material according to claim 1, wherein the composite base material is made of a fiber board, a horse board, and a fiber board from above. The floor covering according to any one of claims 1 to 3, wherein the fibrous board is MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard). delete The flooring material according to claim 1, wherein the flooring material comprises a surface treatment layer, a surface layer, a composite substrate layer, a surface layer, and a surface treatment layer from above. The floor covering according to claim 1, wherein the floor covering comprises a surface treatment layer, a surface layer, a composite substrate layer and a synthetic resin layer from above. delete The surface layer according to any one of claims 6 to 7, wherein the surface layer is selected from veneer, poly vinyl chloride (PVC), poly ethylene (PE), poly propylene (PP), olefin, glass fiber, inorganic, sponge, styrofoam and gypsum. Flooring material comprising at least one material selected. 8. The flooring material according to claim 7, wherein the synthetic resin layer is made of at least one material selected from polyvinyl chloride (PVC), poly ethylene (PE), and polypropylene (PP). The method of claim 1, wherein the dimensional reinforcement layer is selected from solid wood, particle board, high pressure laminate (HPL), low pressure laminate (LPL), oriented strand board (OSB), flake board, corrugated cardboard, and paper. Flooring material comprising the above wood material. delete The floor covering according to claim 1, wherein at least one layer of the floor covering comprises at least one cured resin selected from epoxy, phenol, acrylic, melamine, polyurethane, unsaturated polyester, and diallyl phthalate. The floor covering according to claim 1, wherein at least one layer of the floor covering comprises at least one filler selected from calcium carbonate, talc, titanium oxide, silica, glass powder, and silicon dioxide. The floor covering according to claim 1, wherein at least one layer of the floor covering comprises at least one flame retardant selected from phosphoric esters, halogenated hydrocarbons, antimony oxide, aluminum hydroxy, phosphoric acid compounds, and dicyandiamide.

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