KR20250009624A - Semi-incombustible melamine veneer with glass fiber fabric and its manufacturing method - Google Patents

Abstract

A method for manufacturing a semi-fireproof melamine decorative panel with a built-in glass fiber fabric, characterized by comprising: a deco paper processing process; an overlay paper processing process; a core paper processing process; a resin-compatible glass fiber fabric processing process; and a decorative panel forming machine, in which the core paper obtained from the core paper processing process, the resin-compatible glass fiber fabric obtained from the resin-compatible glass fiber fabric processing process, the core paper obtained from the core paper processing process, the decorative paper obtained from the deco paper processing process, and the overlay paper obtained from the overlay paper processing process are sequentially laminated from below, and then the same is heat-pressurized at a temperature of 130°C to 140°C under a pressure condition of 50 to 100 kgf/㎡ for 60 to 90 minutes and then the press plate is cooled to room temperature with water to demold the mold.

Description

{Semi-incombustible melamine veneer with glass fiber fabric and its manufacturing method}

The present invention relates to a semi-fireproof melamine decorative board with glass fiber fabric embedded and a method for manufacturing the same, and more particularly, to a semi-fireproof melamine decorative board with glass fiber fabric embedded, which is safe from fire when used as an architectural finishing and interior material, and has the characteristics of preventing the spread of flames and not generating toxic gases, and a method for manufacturing the same.

Typically, flame-retardant composite panels are made up of a melamine resin-impregnated surface protection layer, a melamine resin-impregnated pattern layer, and a core layer made of kraft paper impregnated with phenol resin, and are formed at high temperature and high pressure using a multi-stage press.

However, these cosmetic plates contain a large amount of resin and pulp layers, so they have the disadvantage of being vulnerable to fire.

Therefore, for interior and exterior materials and furniture of commercial buildings that require fire resistance, stone, etc. are polished and used, metal is processed and used, or tiles such as ceramics or porcelain are attached. However, while these materials are durable and have excellent fire resistance, they have the disadvantages of being expensive to manufacture, heavy, difficult to process, and have limitations in displaying splendid decoration.

The current Building Act and Fire Protection Act regulate the use of non-combustible, semi-combustible, and flame-retardant materials for finishing and interior materials used in buildings, and to prevent the spread of fire and protect human life, buildings of a certain size or larger are required to have fire compartments, and doors passing through them must be installed with fire doors, and the law regulates the use of materials that can withstand fire for 30 minutes or 1 hour.

The standards and performance test methods according to these legal regulations are set to satisfy the performance standards of flame retardancy level 1 (non-combustible materials), flame retardancy level 2 (semi-combustible materials), and flame retardancy level 3 (flame retardant materials) according to the Korean Industrial Standard KS F2271 (flame retardancy performance test method for buildings) for finishing and interior materials.

This is a regulation that has been adopted not only in our country but also in most countries around the world. There may be some differences depending on the content, but the regulations that require the use of something that meets the performance standards are almost the same.

This is because it is intended to prevent the spread of flames in case of fire and to ensure the safety of life and property from toxic gases generated during combustion.

Accordingly, various forms of architectural finishing and interior materials with non-combustible, semi-combustible, and flame-retardant properties are currently being developed.

MDF and plywood are the most widely used architectural interior products today because they have the characteristics of easy workability, constructability, lightness, and low price. However, they have poor water resistance, and as flammable materials, they do not have the performance of fireproofing, semi-fireproofing, or flame retardancy, so they are easily combusted by flames and the fire spreads, so their use is restricted by current laws.

In addition, gypsum board is a representative building interior and finishing material that currently has performance standards for non-combustible, semi-combustible, and flame retardant, but it is very weak to moisture, has low strength, is easily damaged, generates a lot of dust during processing, and has problems with environmental pollution such as the inability to recycle waste gypsum board. In addition, there are problems such as paper attached to the surface, which limits its use in various designs and purposes.

On the other hand, cement boards have high strength, excellent non-combustible, semi-combustible, flame-retardant performance, and good water resistance, but they have poor workability and constructability, are heavy, and break easily upon impact, so they are mainly used as exterior walls or surface materials for buildings, and are rarely used as architectural finishing or interior materials.

In order to improve the above-mentioned problems, the patent documents that have been applied for patents so far are as follows.

Patent application No. 10-1998-0014300 (April 22, 1998) relates to a decorative sheet including one or more polyester film layers and a photographic printing layer laminated on the polyester film layers, wherein the displacement value on the surface of the polyester film layer in contact with the photographic printing layer is 0.4 to 30. Patent application No. 10-2001-0020511 (April 17, 2001) relates to a flame-retardant melamine sheet, and the purpose is to improve the flame retardancy of various melamine sheets, including decorative boards, so that they do not burn easily in the event of a fire while still maintaining their beauty. The purpose is to impregnate patterned paper in a melamine resin impregnation solution with a resin impregnation amount of 55% to 65%, then dry it, and place the dried melamine resin-impregnated paper on one or both sides of a flame-retardant material impregnated in a phenol resin impregnation solution, an epoxy resin impregnation solution, or a polyester impregnation solution with a resin impregnation amount of 25% to 35%, and then press-form the same under heat and pressure conditions of 50 kgf/cm2 to 60 kgf/cm2 at a temperature of 130°C to 140°C for 15 to 30 minutes, and then press the hot plate. In a method for manufacturing a melamine sheet by cooling to room temperature and demolding, a method for manufacturing a flame-retardant melamine sheet is provided, characterized in that 5 to 10 parts by weight of gypsum is included per 100 parts by weight of the total composition as the phenol resin impregnation liquid, epoxy resin impregnation liquid or polyester impregnation liquid. Patent application No. 10-2001-0086923 (December 28, 2001) relates to a thermosetting resin decorative board and a manufacturing method thereof, which uses patterned paper of the same material as the patterned paper as the core material instead of kraft paper in order to match the colors of the core material and the patterned paper, but which is then impregnated with phenol resin and dried and used. The method utilizes a method of laminating melamine resin-impregnated paper, etc. in a plate shape and then compressing and manufacturing with a multi-opening press, and since patterned paper impregnated with phenol resin is used as the core material, even without using the CPL method, a high-quality resin decorative board with matching colors of the core material and the patterned paper can be manufactured. In addition, since the resin decorative board does not need to be cut or straightened separately when bonding it to MDF, etc., the manufacturing process is simplified and bonding with the adhesive is improved. In addition, since the resin decorative board can be manufactured so that it is not too thin, surface treatment work on the bonding surface becomes easy. Patent application No. 10-2007-0010105 (January 31, 2007) is for providing a non-combustible board, non-combustible furniture, or fire doors, etc., which are safe from fire when used as a board for architectural finishing and interior materials, and have performance and properties such as preventing the spread of flames and not generating toxic gases, and are non-combustible molded products for industrial use, the composition comprising 1 to 70 wt% of fibrous organic matter; 1 to 30 wt% of fly ash or artificial silica; 10 to 60 wt% of a flame retardant curing agent which is sodium silicate, potassium silicate, or a mixture thereof; and 1 to 15 wt% of a flame retardant resin for curing. Patent application No. 10-2009-0076559 (August 19, 2009) relates to a method for manufacturing a conductive non-combustible sheet and a double flooring material including the sheet, wherein a conductive non-woven sheet, a glass fiber sheet or a magnesium board, a conductive melamine cosmetic board, and a protective paper sheet are sequentially laminated and formed by hot high-pressure pressing at 125 to 130°C and a pressure of 50 to 80 kg/cm2 for 20 to 25 minutes, and the glass fiber sheet is a conductive non-combustible sheet manufactured by impregnating glass fiber paper with phenol resin. Patent application No. 10-2011-0033252 (April 11, 2011) relates to a method for weaving glass fabric using a water jet loom, which can weave glass fabric having a uniform surface, density, and thinner thickness than before by utilizing the property of glass fibers composed of filaments bonded by water-based silane to spread in water by using a water jet loom when weaving glass fabric. The method for weaving glass fabric in which warp and weft yarns made of glass fibers are interwoven is provided, characterized in that the warp and weft yarns are interwoven by a water jet loom using water to dissolve the silane of the glass fibers forming the weft yarn so that the weft yarn spreads, thereby manufacturing a glass fabric having a uniform surface, density, and thinness. Patent application No. 10-2012-0024088 (2012.03.08) relates to an environmentally friendly composite panel for ship furniture containing non-combustible interior materials, comprising: a foam board processed by mixing 100 parts by weight of coal fly ash having a diameter of 1 to 100 ㎛, 10 to 25 parts by weight of waste glass powder, and 20 to 35 parts by weight of silica, and firing the mixture at 1000 to 1200°C; a flame-retardant core material laminated on the upper and lower edges of the foam board; a mesh laminated on the upper and lower surfaces of the flame-retardant core material; and high pressure melamine impregnated paper (HPM) adhered to the upper and lower surfaces of the mesh using a melamine or phenol resin adhesive. Patent application No. 10-2014-0113537 (August 28, 2014) relates to a decorative flooring for a building, comprising: a substrate layer formed by bonding a magnesium oxide board to a wood core; a sheet layer formed by laminating a core layer, a pattern layer, and an overlay layer, and bonded to the upper side of the substrate layer; and a functional member formed by interposing noise-blocking glass fiber and electromagnetic wave-attenuating carbon black between the substrate layer and the sheet layer. Patent application No. 10-2014-0122874 (2014.09.16) relates to a non-combustible sheet applied to decorative flooring, comprising: a core layer formed by impregnating a non-combustible phenol resin; a pattern layer formed by impregnating a non-combustible melamine resin and bonded to the upper side of the core layer; and an overlay layer formed by impregnating a non-combustible melamine resin and bonded to the upper side of the pattern layer. Patent application No. 10-2015-0162330 (2015.11.19) discloses a natural mineral-containing composition comprising a process of mixing one or more of natural minerals, such as kaolin, yellow clay, mica, pozzolan, raw ore, clay, and vermiculite, in a fine powder of 100 to 1,000 mesh, with natural pulp or natural fiber and water in a weight ratio of 1 to 3 : 1 to 3 : 3 to 15, and then adding 1 to 5 g of binder, 1 to 5 g of expandable agent, 5 to 30 g of flame retardant, 0.1 to 5 g of flexible agent, and 1.0 to 10.0 g of calcium complex or zinc complex of at least one oil selected from the group consisting of tea tree oil, castor oil, and linseed oil, to the natural pulp or natural fiber, characterized in that the natural mineral is contained therein. Its composition consists of natural building materials. Patent application No. 10-2016-0150445 (November 11, 2016) relates to a composite panel based on a thermosetting resin with semi-non-combustibility, comprising: an outer skin formed by impregnating a substrate made of laminated paper and fabric with melamine resin; and a core formed by impregnating the substrate with a phenol resin containing triazole, and bonding multiple layers in the middle of the outer skin. Patent application No. 10-2017-0051579 (April 21, 2017) relates to a method for manufacturing an eco-friendly kraft deco paper, a melamine decorative board utilizing the same, and a method for manufacturing the same. The method for manufacturing a melamine decorative board utilizing the eco-friendly kraft deco paper of the present invention comprises the steps of: applying white titanium and ink on kraft paper and drying it to obtain kraft paper with a specific design printed on it; impregnating an overlay with melamine resin and drying it to produce a melamine-coated overlay; impregnating the kraft paper obtained in the step of obtaining the kraft paper with phenol and drying it to obtain phenol-impregnated kraft paper; and laminating an overlay on the kraft paper obtained in each of the above steps and pressing and forming it to obtain a melamine decorative board. Patent application No. 10-2018-0092135 (August 8, 2018) relates to a carbon fiber panel interior material, and includes the steps of carding carbon fibers by passing them through a conditioning heater and carding the yarns with a carding machine, laminating the carded carbon raw material and then impregnating them with a soluble silicate, pressurizing the carbon fibers to which the soluble silicate has been added at a predetermined pressure, and heating the pressurized carbon fibers at 400 degrees Celsius to 600 degrees Celsius for 10 minutes to 1 hour, and a method for manufacturing a carbon fiber panel interior material, and a carbon fiber panel interior material manufactured using the method for manufacturing a carbon fiber panel interior material. Patent application No. 10-2019-0048986 (April 26, 2019) provides a semi-fireproof composite panel for interior and exterior use, which includes a non-combustible layer made of a semi-fireproof material and a PF non-combustible layer formed on one surface of the non-combustible layer. In addition, one or more non-combustible layers having quasi-fire properties are provided and positioned to be in contact with each other, and the PF non-combustible layer is positioned between one or more non-combustible layers. According to the present invention, the non-combustible layer having quasi-fire properties is provided with a fiber material, and therefore has excellent processability and price competitiveness, and the non-combustible layer having quasi-fire properties is configured to include sodium silicate and vermiculite, and therefore has excellent fire resistance. Patent application No. 10-2020-0103758 (August 19, 2020) discloses a non-combustible low-pressure melamine board having a digitally printed image surface. The low-pressure melamine board according to the present invention includes a board body formed in a plate shape by adding magnesium oxide and an adhesive to wood fiber or wood powder, white melamine-impregnated paper attached to the surface of the board body, a transparent primer layer formed by applying a transparent primer paint to the surface of the melamine-impregnated paper, a UV ink image printing curing layer formed by UV curing while printing an image file by a digital plotter on the primer coating layer to form a surface decoration, and a transparent UV protective layer coated with a transparent UV paint on the UV ink image printing curing layer and cured. Utility Model Registration Application No. 20-2000-0037082 (Dec. 29, 2000) relates to a non-combustible decorative panel containing yellow clay, which has excellent fire resistance and a small rate of dimensional change, and can be used for architectural interior and exterior materials such as subway walls, restroom walls, indoor kitchen walls, ceilings, and floors, railway passenger car floors, interiors, and furniture. The non-combustible decorative panel comprises: a) a pattern layer impregnated with or coated with a thermosetting resin on pattern paper; and b) a core layer impregnated or coated with a resin blend of a phenol-modified resin or a melamine-modified resin containing an inorganic filler having yellow clay as a main component on a woven or non-woven fabric of inorganic fibers, or a paper substrate. Utility model registration application No. 20-2003-0037766 (December 3, 2003) relates to a flooring board or flooring block made mainly of solid wood or laminated wood, a decorative wood flooring board made mainly of plywood, MDF, or HDF, a decorative wood flooring board with a patterned wood grain bonded to plywood, MDF, or HDF, and a laminated flooring board made by bonding multiple layers of thin wood, by bonding or fixing a non-combustible material such as wood light (decorative asbestos cement board) or bamlite (fiber-reinforced cement board) and master board (magnesium board) with high water resistance to the back of various flooring boards, thereby improving workability and preventing noise and moisture and reducing deformation. The bamlite (fiber-reinforced cement board) of the non-combustible board material is manufactured by specially mixing inorganic fibers, cement, and inorganic admixtures on the back of the above various flooring boards and then forcing them with a press. Or, one of the masterboards (magnesium boards) made by mixing wood light (decorative asbestos cement board) or magnesium oxide (MgO) and magnesium chloride (MgCl2) with gypsum and glue, putting it in a mold, and baking it with heat is fixed with adhesive or pieces. Utility model registration application No. 20-2006-0032869 (Dec. 29, 2006) relates to a non-combustible double flooring material, and more specifically, to a non-combustible double flooring material including a core made of an inorganic material, a thermosetting resin decorative plate adhered to an upper surface of the core, and a panel including a laminate adhered to a lower surface of the core, a lower plate adhered to a lower surface of the panel and formed of either steel or wood, a support plate adhered to the lower surface of the lower plate and supporting the lower plate, and a plurality of support members joined to the lower portion of the support plate and supporting the lower plate by lifting it from the floor to a predetermined height. According to the present invention, by adhering a non-combustible inorganic panel to the upper portion of the double flooring material, flames and toxic gases are not generated when a fire occurs in a building, and therefore, a non-combustible double flooring material that can be used as a building finishing and interior decoration material, particularly as a sheet material of the double flooring material, can be provided.

In manufacturing a decorative panel used for decorating the surface of decorative panels or furniture wood with flame retardancy, a conventional flame retardant method up to now has been to manufacture a flame retardant decorative panel by bonding flame retardant kraft paper impregnated with an impregnating resin polymerized by adding a liquid flame retardant to modified phenolresole to a pattern paper impregnated with melamine.

However, since the flame retardancy of such flame retardant cosmetic boards is determined by the thickness of the kraft paper used as the substrate, it is impossible to secure perfect flame retardancy in cosmetic boards that must satisfy a thin thickness.

Therefore, up until now, we had to be satisfied with flame retardancy that only minimizes the combustion area within a certain period of time.

In this regard, we developed a product that increased the mineral content of kraft paper or used glass non-woven fabric to increase the mineral content, but this also increased the thickness of the cosmetic board and was easily damaged, limiting post-processing properties (post-forming properties), making it unsuitable for use in interiors or furniture that form curved surfaces.

It is a well-known fact that the thinner the finish, the better the finish is, so the most ideal finish is one that has the minimum thickness while providing maximum flame retardancy.

Accordingly, the purpose of the present invention is to provide a semi-fireproof melamine cosmetic board having a glass fiber fabric layer integrally bonded to a melamine cosmetic board, thereby minimizing the thickness and weight of the cosmetic board and maximizing flame retardancy.

A process for processing Deco Paper, which is composed of 70-80% pulp and 20-30% titanium and has a thickness of 0.1-0.15 mm and a pattern printed on it, is dried in a dryer at 100-140°C to have a moisture content of 50-65%, then impregnated with melamine resin at 25-35°C to coat/impregnate the melamine resin, and then dried in a dryer, and then cut to a size of 1260 mm×1870 mm or 1260 mm×2480 mm or 1260 mm×3680 mm depending on the intended use, and then separated and laminated by size; An overlay paper processing process in which an overlay paper containing aluminum oxide, which is wear-resistant, transparent, has a specific gravity of 18 to 40 g/㎡, and a thickness of 0.02 to 0.04 mm, is dried in a dryer at 100 to 140°C to have a moisture content of 50 to 65%, then impregnated with melamine resin at 25 to 35°C, and when coated/impregnated with the melamine resin, dried in a dryer, and cut to a size of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and then separated and laminated by size; A core paper processing process in which kraft paper with a thickness of 0.05 to 0.5 mm made of pure pulp with a moisture content of 50 to 65%, dried in a dryer at 100 to 140°C, impregnated with phenol resin (for forming, for S/T) at 25 to 35°C, and then coated/impregnated with phenol resin, is dried in a dryer, and cut into sizes of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and then separated and laminated by size; A process for processing a resin-compatible glass fiber fabric, which comprises removing the binder of the glass fiber fabric, silane-treating it, impregnating it with a curable resin solution to coat/include the resin, curing it, cutting it into sizes of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1226 mm x 3680 mm depending on the intended use, and separating and laminating it by size; A method for manufacturing a semi-fireproof melamine cosmetic panel with embedded glass fiber fabric is completed by sequentially laminating, in a cosmetic panel forming machine, a core paper obtained from the above Core Paper processing process, a resin-compatible glass fiber fabric obtained from the above Resin-compatible Glass Fiber Fabric Processing Process, a core paper obtained from the above Core Paper processing process, a deco paper obtained from the above Deco Paper processing process, and an overlay paper obtained from the above Overlay Paper processing process, and heat-pressing them at a temperature of 130°C to 140°C under a pressure condition of 50 to 100 kgf/㎡ for 60 to 90 minutes, and then cooling the press plate to room temperature with water to demold it.

Here, the resin-compatible glass fiber fabric processing process comprises a glass fiber fabric heat treatment step of removing the binder of the glass fiber fabric by passing the glass fiber fabric through a heating furnace maintained at 300 to 500°C at a speed of 50 to 250 m/min, thereby manufacturing a glass fiber fabric from which the binder has been removed; A silane solution preparation step of sequentially adding 1,000 parts by weight of an alcohol selected from 70 to 80 wt% of methanol or ethanol to a reactor, 100 to 200 parts by weight of a silane selected from a silane compound selected from among methoxypropyltrimethoxysilane, tetraethoxysilane, glycerylpropyltrimethoxysilane, and methyltrimethoxysilane, and 1 to 5 parts by weight of an acid catalyst selected from acetic acid or hydrochloric acid, and stirring the mixture at a speed of 50 to 200 RPM for 10 to 30 minutes to prepare a silane solution; A glass fiber fabric silane treatment step for manufacturing a silane-treated glass fiber fabric by sequentially passing the glass fiber fabric from which the binder has been removed in the glass fiber fabric heat treatment step into a silane solution manufactured in the silane solution manufacturing step and passing it through a drying furnace maintained at 60 to 100°C at a speed of 50 to 250 m/min; A curable resin solution comprising: a phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde; a melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde; or an epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde; 0.1 to 5 parts by weight of a polymerization catalyst selected from an acid catalyst such as sulfuric acid, hydrochloric acid, or nitric acid, or a proton catalyst such as benzenesulfonic acid or toluenesulfonic acid, added to 1,000 parts by weight of the resin solution; and stirred at a speed of 10 to 100 RPM for 10 to 30 minutes; and impregnated by passing the silane-treated glass fibers produced in the glass fiber fabric silane treatment step into the curable resin solution to produce a surface-curable glass fiber fabric; The surface-curable glass fiber fabric manufactured in the above-mentioned curable resin solution impregnation step is passed through a heating furnace maintained at 100 to 250°C at a speed of 20 to 50 m/min to cure, thereby completing the curing step of manufacturing a glass fiber fabric with improved commercializability.

The above-mentioned method for manufacturing a semi-fireproof melamine cosmetic board with embedded glass fiber fabric is performed, and an overlay paper coated/containing melamine resin having a thickness of 0.02 to 0.04 mm, which contains aluminum oxide from the surface to provide wear resistance and transparency and has a specific gravity of 18 to 40 g/㎡, a patterned paper (Deco Paper) coated/containing melamine resin with a thickness of 0.1 to 0.15 mm and printed with a pattern, a core paper which is kraft paper containing/coated with phenol resin and has a thickness of 0.05 to 0.5 mm, a resin-compatible glass fiber fabric, and a core paper which is kraft paper containing/coated with phenol resin and has a thickness of 0.05 to 0.5 mm are sequentially bonded together to complete a semi-fireproof melamine cosmetic board with embedded glass fiber fabric.

Here, the resin-compatible glass fiber fabric is formed by heat-treating a glass fiber fabric at 300 to 500°C to remove the binder, impregnating the fabric with a silane solution to perform silane treatment, and then adding 0.1 to 5 parts by weight of a polymerization catalyst selected from a proton catalyst to 1,000 parts by weight of a resin solution selected from a phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde, a melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde, and an epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde, thereby impregnating the fabric with a curable resin solution to harden the surface.

The present invention as described above has solved the problem so far of not being able to integrally bond a glass fiber fabric layer to a melamine cosmetic board containing phenol resin and melamine resin as main raw materials because the glass fiber fabric is not affinity to phenol resin or melamine resin, thereby minimizing the thickness and weight of the cosmetic board and allowing the production and distribution of a semi-flammable melamine cosmetic board containing a glass fiber fabric with enhanced flame retardancy.

Figure 1 is an exemplary process diagram for completing the present invention.
Figure 2 is an exemplary diagram showing the steps of carrying out a resin-compatible glass fiber fabric processing process, which is a key part of the present invention.
Figure 3 is an example of the configuration state of the present invention.
Figure 4 is an example of the configuration of a glass fiber fabric, which is a key part of the present invention.

The method for manufacturing a semi-flame-resistant melamine cosmetic board with built-in glass fiber fabric to complete the present invention is described in detail based on the process diagram of Fig. 1 as follows.

Deco Paper Processing Process;

Deco Paper, composed of 70-80% pulp and 20-30% titanium, with a thickness of 0.1-0.15 mm and a pattern printed on it, is dried in a dryer at 100-140°C to a moisture content of 50-65%, then impregnated with melamine resin at 25-35°C. Once coated/impregnated with the melamine resin, it is dried in a dryer, and depending on the intended use, it is cut to a size of 1260 mm x 1870 mm, 1260 mm x 2480 mm, or 1260 mm x 3680 mm, and then separated and laminated by size.

This process is an essential process for manufacturing cosmetic plates, but it is very important to select the thickness of the pattern paper.

Overlay Paper Process;

Overlay Paper, which contains aluminum oxide and is wear-resistant, transparent, has a specific gravity of 18-40 g/㎡, and a thickness of 0.02-0.04 mm, is dried in a dryer at 100-140℃ until the moisture content becomes 50-65%, then impregnated with melamine resin at 25-35℃, and when coated/impregnated with the melamine resin, dried in a dryer, and cut to a size of 1260 mm×1870 mm or 1260 mm×2480 mm or 1260 mm×3680 mm depending on the intended use, and then separated and laminated by size.

This process is also an essential process for manufacturing cosmetic plates, but it is very important to select the thickness of the pattern paper.

Core Paper Processing Process;

Kraft paper with a thickness of 0.05 to 0.5 mm made of pure pulp with a moisture content of 50 to 65%, dried in a dryer at 100 to 140°C, impregnated with phenol resin (for forming, for S/T) at 25 to 35°C, and when coated/impregnated with phenol resin, dried in a dryer, and cut to a size of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and separated and laminated by size.

This process is also an essential process for manufacturing cosmetic plates, but it is very important to select the thickness of the pattern paper.

Resin-compatible glass fiber fabric processing process;

The binder of the glass fiber fabric is removed, silane-treated, impregnated with a curable resin solution to coat/contain the resin, and then cured. Depending on the intended use, the fabric is cut to a size of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm and then separated and laminated by size.

This process is an important point in completing the present invention. Until now, the glass fiber fabric has not evolved with the resin, so when manufacturing a cosmetic plate, the glass fiber fabric layer is separated, and the product cannot function.

Therefore, it was impossible to perfectly embed glass fiber fabric in a cosmetic plate without performing the resin-compatible glass fiber fabric processing process of the present invention. The present invention solves this problem.

Cosmetic panel completion process;

In a cosmetic board forming machine, a core paper obtained from the above Core Paper processing process, a resin-compatible glass fiber fabric obtained from the above Resin-compatible Glass Fiber Fabric Processing Process, a core paper obtained from the above Core Paper processing process, a deco paper obtained from the above Deco Paper processing process, and an overlay paper obtained from the above Overlay Paper processing process are sequentially laminated, and then the same is heat-pressed and molded at a temperature of 130°C to 140°C under a pressure condition of 50 to 100 kgf/㎡ for 60 to 90 minutes, and then the press plate is cooled in water to room temperature and demolded to complete a semi-fireproof melamine cosmetic board with embedded glass fiber fabric.

This process is also a conventional process used to produce cosmetic panels, but the most important thing here is that it is different from the previous process in that it involves molding a resin-compatible glass fiber fabric between two core papers to produce the cosmetic panel.

An example for completing a resin-compatible glass fiber fabric processing process, which is one of the main parts of the present invention, is examined step by step based on Fig. 2.

Glass fiber fabric heat treatment step;

The glass fiber fabric is passed through a heating furnace maintained at 300 to 500°C at a speed of 50 to 250 m/min to remove the binder of the glass fiber fabric, thereby manufacturing a glass fiber fabric from which the binder has been removed.

This step is performed because it is essential to coat the glass fiber yarn with a binder in order to weave a glass fiber fabric. However, if the resin of the present invention is used as the binder of the glass fiber yarn, this step may be omitted.

Silane solution preparation step;

In a reactor, 1,000 parts by weight of an alcohol selected from 70 to 80 wt% methanol or ethanol, 100 to 200 parts by weight of a silane selected from a silane compound selected from methoxypropyltrimethoxysilane, tetraethoxysilane, glycerylpropyltrimethoxysilane, and methyltrimethoxysilane, and 1 to 5 parts by weight of an acid catalyst selected from acetic acid or hydrochloric acid are sequentially added, and stirred at a speed of 50 to 200 RPM for 10 to 30 minutes to prepare a silane solution.

Glass fiber fabric silane treatment step;

In the above glass fiber fabric heat treatment step, the glass fiber fabric from which the binder has been removed is impregnated in the silane solution prepared in the silane solution preparation step, and is sequentially passed through a drying furnace maintained at 60 to 100°C at a speed of 50 to 250 m/min to prepare a silane-treated glass fiber fabric.

This step is performed because the silane acts as a bond between the glass fiber and the resin.

Impregnation step of curable resin solution;

A surface-curable glass fiber fabric is manufactured by impregnating the silane-treated glass fiber manufactured in the glass fiber fabric silane treatment step while passing it through the curable resin solution manufactured by mixing phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde, melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde, or epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde.

hardening stage;

The surface-curable glass fiber fabric manufactured in the above-mentioned curable resin solution impregnation step is cured by passing it through a heating furnace maintained at 100 to 250°C at a speed of 20 to 50 m/min, thereby manufacturing a glass fiber fabric with improved compatibility.

By carrying out the above-mentioned method for manufacturing a semi-fireproof melamine decorative board with embedded glass fiber fabric, a semi-fireproof melamine decorative board is obtained by integrally bonding in sequence an overlay paper (10) containing aluminum oxide from the surface, having wear resistance, transparency, a specific gravity of 18 to 40 g/㎡, and a thickness of 0.02 to 0.04 mm coated/containing melamine resin, a deco paper (20) having a printed pattern and a thickness of 0.1 to 0.15 mm coated/containing melamine resin, a core paper (30) which is a kraft paper containing/coated with phenol resin and a thickness of 0.05 to 0.5 mm, a resin-compatible glass fiber fabric (40), and a core paper (30) which is a kraft paper containing/coated with phenol resin and a thickness of 0.05 to 0.5 mm.

At this time, the resin-compatible glass fiber fabric (30) is formed by heat-treating the glass fiber fabric at 300 to 500°C to remove the binder, impregnating it in a silane solution and performing silane treatment, and then adding 0.1 to 5 parts by weight of a polymerization catalyst selected from a proton catalyst to 1,000 parts by weight of a resin solution selected from among a phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde, a melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde, and an epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde, and impregnating it in a curable resin solution prepared by surface-curing.

The present invention provides a semi-fireproof decorative board by integrally embedding glass fiber fabric inside the decorative board to increase fire resistance, thereby preventing the initial spread of fire when used as a building wall board or floor board, and thus has great industrial value.

10: Overlay Paper 20: Deco Paper
30: Core Paper 40: Resin-compatible glass fiber fabric

Claims (4)

A process for processing Deco Paper, which consists of 70-80% pulp and 20-30% titanium, and has a thickness of 0.1-0.15 mm and a pattern printed on it, and is dried in a dryer at 100-140°C to have a moisture content of 50-65%, and then impregnated with melamine resin at 25-35°C, and when coated/impregnated with the melamine resin, dried in a dryer, and cut to a size of 1260 mm×1870 mm or 1260 mm×2480 mm or 1260 mm×3680 mm depending on the intended use, and then separated and laminated by size;
An overlay paper processing process in which an overlay paper containing aluminum oxide, which is wear-resistant, transparent, has a specific gravity of 18 to 40 g/㎡, and a thickness of 0.02 to 0.04 mm, is dried in a dryer at 100 to 140°C to have a moisture content of 50 to 65%, then impregnated with melamine resin at 25 to 35°C, and when coated/impregnated with the melamine resin, dried in a dryer, and cut to a size of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and then separated and laminated by size;
A core paper processing process in which kraft paper with a thickness of 0.05 to 0.5 mm made of pure pulp with a moisture content of 50 to 65%, dried in a dryer at 100 to 140°C, impregnated with phenol resin (for forming, for S/T) at 25 to 35°C, and then dried in a dryer after being coated/impregnated with phenol resin, and then cut into sizes of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and then separated and laminated by size;
A process for processing a resin-compatible glass fiber fabric, which comprises removing the binder of the glass fiber fabric, silane-treating it, impregnating it with a curable resin solution to coat/include the resin, curing it, cutting it into sizes of 1260 mm x 1870 mm or 1260 mm x 2480 mm or 1260 mm x 3680 mm depending on the intended use, and separating and laminating it by size;
A method for manufacturing a semi-fireproof melamine cosmetic board with built-in glass fiber fabric, characterized in that the method comprises a cosmetic board completion process, including sequentially laminating, in a cosmetic board forming machine, a core paper obtained from the above Core Paper processing process, a resin-compatible glass fiber fabric obtained from the above Resin-compatible Glass Fiber Fabric Processing Process, a core paper obtained from the above Core Paper processing process, a deco paper obtained from the above Deco Paper processing process, and an overlay paper obtained from the above Overlay Paper processing process, and heat-pressuring them at a temperature of 130°C to 140°C under a pressure condition of 50 to 100 kgf/㎡ for 60 to 90 minutes, and then demolding the press plate by cooling it down to room temperature. In the first paragraph,
The above resin-friendly glass fiber fabric processing process is,
A glass fiber fabric heat treatment step for removing the binder of the glass fiber fabric by passing the glass fiber fabric through a heating furnace maintained at 300 to 500°C at a speed of 50 to 250 m/min to manufacture a glass fiber fabric from which the binder has been removed;
A silane solution preparation step of sequentially adding 1,000 parts by weight of an alcohol selected from 70 to 80 wt% of methanol or ethanol to a reactor, 100 to 200 parts by weight of a silane selected from a silane compound selected from among methoxypropyltrimethoxysilane, tetraethoxysilane, glycerylpropyltrimethoxysilane, and methyltrimethoxysilane, and 1 to 5 parts by weight of an acid catalyst selected from acetic acid or hydrochloric acid, and stirring the mixture at a speed of 50 to 200 RPM for 10 to 30 minutes to prepare a silane solution;
A glass fiber fabric silane treatment step for manufacturing a silane-treated glass fiber fabric by sequentially passing the glass fiber fabric from which the binder has been removed in the glass fiber fabric heat treatment step into a silane solution manufactured in the silane solution manufacturing step and passing it through a drying furnace maintained at 60 to 100°C at a speed of 50 to 250 m/min;
A curable resin solution comprising: a phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde; a melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde; or an epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde; 0.1 to 5 parts by weight of a polymerization catalyst selected from an acid catalyst such as sulfuric acid, hydrochloric acid, or nitric acid, or a proton catalyst such as benzenesulfonic acid or toluenesulfonic acid, added to 1,000 parts by weight of the resin solution; and stirred at a speed of 10 to 100 RPM for 10 to 30 minutes; and impregnated by passing the silane-treated glass fibers produced in the glass fiber fabric silane treatment step into the curable resin solution to produce a surface-curable glass fiber fabric;
A semi-fireproof melamine decorative board with built-in glass fiber fabric and a method for manufacturing the same, characterized in that the surface-curable glass fiber fabric manufactured in the above-mentioned curable resin solution impregnation step is cured by passing it through a heating furnace maintained at 100 to 250°C at a speed of 20 to 50 m/min to manufacture a glass fiber fabric with improved commerciality. In a melamine decorative board, the overlay paper, deco paper, and core paper are laminated in order from the surface and bonded together as one piece.
The above-mentioned core paper (30) is composed of two layers, and a resin-compatible glass fiber fabric (40) is placed between them, so that an overlay paper (10) containing aluminum oxide from the surface, which is wear-resistant and transparent, has a specific gravity of 18 to 40 g/㎡, and is coated/contained with a melamine resin having a thickness of 0.02 to 0.04 mm, a patterned paper (Deco Paper) (20) coated/contained with a melamine resin having a thickness of 0.1 to 0.15 mm and printed with a pattern, a kraft paper containing/coated with a phenol resin having a thickness of 0.05 to 0.5 mm, a resin-compatible glass fiber fabric (40), and a kraft paper containing/coated with a phenol resin having a thickness of 0.05 to 0.5 mm are integrally bonded in this order. Semi-flame retardant melamine vanity board with fiberglass fabric lining. In the third paragraph,
The above resin-compatible glass fiber fabric (40) is characterized in that the glass fiber fabric is heat-treated at 300 to 500°C to remove the binder, impregnated in a silane solution and silane-treated, and then 1,000 parts by weight of a resin solution selected from among a phenol formaldehyde resin composed of 20 to 40% phenol resin and 60 to 80% formaldehyde, a melamine formaldehyde resin composed of 20 to 40% melamine resin and 60 to 80% formaldehyde, and an epoxy formaldehyde resin composed of 20 to 40% epoxy resin and 60 to 80% formaldehyde, and 0.1 to 5 parts by weight of a polymerization catalyst selected from a proton catalyst is added thereto to impregnate the glass fiber fabric and harden the surface thereof.