KR20150145804A - Foaming panel composition, foaming panel and manufacturing of the same - Google Patents

Abstract

Provided is a foaming panel composition comprising 5 to 50 parts by weight of an inorganic filler based on 100 parts by weight of a synthetic resin. Also, provided is a foaming panel including a foaming layer formed by foaming the foaming panel composition. Provided is a method for manufacturing a foaming panel, comprising the steps of: preparing a foaming panel composition including 5 to 50 parts by weight of an inorganic filler for 100 parts by weight of a synthetic resin; and forming a foaming layer by continuous foaming extrusion of the foaming panel composition.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a foam panel, a foam panel, and a method of manufacturing the foam panel.

A foam panel, and a method of manufacturing the same.

Generally, most of the buildings are constructed of concrete in consideration of durability and economical efficiency. However, in addition to being widely used as structural materials and finishing materials in the interior construction, panels used for interior decoration are mainly manufactured using wood to be.

However, when a wood panel is used as a structural material and a finishing material of a building, there is a problem that the wood is deformed and cracked or cracks occur, and the hardness of the wood itself is low so that surface damage easily occurs, It is not easy to remove foreign matter such as dust on the surface, and the color is changed. In addition, the economical efficiency is lower than that of the synthetic resin material.

In order to solve other problems including the above-mentioned problems, use of synthetic resin-based wood substitute has been proposed, and the application range is gradually increasing in the field.

One embodiment of the present invention provides a foam panel composition comprising a synthetic resin and an inorganic filler.

Another embodiment of the present invention provides a foam panel and a method of manufacturing the same that have a smaller rate of dimensional change with respect to heat and moisture than conventional plywood.

In one embodiment of the present invention, a foam panel composition comprising 5 parts by weight to 50 parts by weight of an inorganic filler per 100 parts by weight of synthetic resin is provided.

The synthetic resin may be selected from the group consisting of a vinyl chloride resin, a polyvinyl butyral resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyurethane resin, a polylactic acid resin, an acrylonitrile-butadiene-styrene resin, a nylon resin, It may be more than one selected.

The inorganic filler may be at least one selected from the group consisting of calcium carbonate, talc, diatomaceous earth, silica, aluminum hydroxide, titania, fly ash, asbestose, slag and combinations thereof.

And about 1 to about 20 parts by weight of an additive may be added to 100 parts by weight of the synthetic resin.

In another embodiment of the present invention, there is provided a foam panel comprising the foam layer formed by foaming the foam panel composition.

The foam layer may have a thickness of about 2 mm to about 10 mm.

The foam layer may have a closed cell ratio of from about 20% to about 80%.

The density of the foam layer may be from about 0.5 g / cm ³ to about 1.5 g / cm ³ .

And a printing layer or a surface protection layer on the foam layer.

A base layer may not be included between the foam layer and the print layer, and between the foam layer and the surface protection layer.

The base layer may comprise one or more resins selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyurethane, and combinations thereof.

The dimensional change rate of the foam panel with respect to the longitudinal direction or the dimensional change rate with respect to the width direction may be about -0.2% to about 0.5%.

In another embodiment of the present invention, there is provided a foam panel composition comprising: 5 parts by weight to 50 parts by weight of an inorganic filler per 100 parts by weight of synthetic resin; And continuously foaming and extruding the foam panel composition to form a foam layer.

And further annealing the formed foam layer.

By using the foam panel composition, the foam panel is highly resistant to heat and moisture, and the rate of dimensional change can be minimized by the external environment.

By manufacturing the foam panel by the foam panel manufacturing method, it is possible to secure price competitiveness, and the panel can be more easily processed and the application field can be expanded.

Hereinafter, embodiments of the present invention will be described in detail. However, the present invention is not limited thereto, and the present invention is only defined by the scope of the following claims.

firing panel  Composition

In one embodiment of the present invention, a foam panel composition comprising 5 parts by weight to 50 parts by weight of an inorganic filler per 100 parts by weight of synthetic resin is provided.

Generally, a high density fiberboard (HDF) and a medium density fiberboard (MDF) using plywood or wood are widely used as flooring panels, but they are vulnerable to twisting of panel due to moisture exposure, distortion of appearance, mold and microorganisms And there are various problems such as cracks in the panel used in the flooring due to expansion and contraction due to heat generated from the floor of the ondol.

Thus, the foam panel composition maximizes the resistance to the growth of microorganisms such as fungi by containing a certain amount of inorganic filler in the synthetic resin, and by improving the dimensional stability against heat and moisture by passing through an annealing process, To compensate for the disadvantages of panels.

The synthetic resin serves as a binder and allows the foam panel to be processed into various shapes. Since the inorganic filler is cost competitive and the amount of the inorganic filler is increased, the cost of the inorganic filler is not increased, and as the content of the inorganic filler is increased, the content of the relatively expensive synthetic resin is lowered and the cost of the foam panel can be lowered.

Further, it secures the resistance to the defects such as deformation of moisture, mold and the like and the thermal dimensional stability of the ordinary wood material.

The synthetic resin may be selected from the group consisting of a vinyl chloride resin, a polyvinyl butyral resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyurethane resin, a polylactic acid resin, an acrylonitrile-butadiene-styrene resin, a nylon resin, It may be more than one selected. For example, the use of the vinyl chloride resin is advantageous in that it can economically change physical properties easily only by the change of the additive, and thus it is possible to produce foam panels of various shapes.

The inorganic filler may be at least one selected from the group consisting of calcium carbonate, talc, diatomaceous earth, silica, aluminum hydroxide, titania, fly ash, asbestose, slag and combinations thereof.

By including the synthetic resin and the inorganic filler, the foam panel panel realizes durable foam panels such as wood, and is highly resistant to heat and moisture, thus securing excellent dimensional stability.

Specifically, the inorganic filler may include about 5 parts by weight to about 50 parts by weight, specifically about 20 parts by weight to about 50 parts by weight, based on 100 parts by weight of the synthetic resin. When the amount of the inorganic filler is less than about 5 parts by weight, dimensional stability against heat may be deteriorated. When the amount of the inorganic filler is more than about 50 parts by weight, molding of the foam panel is difficult. By including the content within the above range, The foaming can be easily realized during the manufacturing process of the foam panel.

And about 1 to about 20 parts by weight of an additive may be added to 100 parts by weight of the synthetic resin. The additive may be at least one selected from the group consisting of a plasticizer, a foaming agent, a stabilizer, a processing aid, an impact modifier, a pigment, a lubricant, and a combination thereof. Stability can be realized, the color of the foam panel can be adjusted, and the impact stability can be ensured.

Specifically, the blowing agent may be at least one selected from the group consisting of azodicarbonamide, p, p'-oxybisbenzenesulfonylhydrazide, p-toluenesulfonylhydrazide, Benzenesulfonylhydarazide, and combinations thereof. The term " a "

For example, the plasticizer may be dioctyl phthalate, the stabilizer may be a TIN stabilizer, the processing aid may be polymethyl methacrylate, the impact modifier may be methacrylate butadiene styrene, and the pigment may be titanium dioxide. In addition, the lubricant may be any one of wax, ester, and stearic acid.

firing panel

In another embodiment of the present invention, there is provided a foam panel comprising a foam layer formed by foaming a foam panel composition.

The foaming panel refers to a panel foamed with the foam panel composition and is a building material having excellent low temperature insulation and mechanical strength. For example, the foaming panel can be used as a flooring material, The panel is highly resistant to heat and moisture, and the rate of change of the numerical value can be minimized by the external environment.

The foam layer is a layer formed by foaming the foam panel composition, and it is important to maintain a proper thickness and density for cost competitiveness and durability of the foam panel.

Specifically, the foam layer may have a thickness of about 2 mm to about 10 mm. When the thickness of the foam layer is out of the above range, it is difficult to secure the strength of the foam panel after molding, and stability and economical efficiency may be deteriorated. As a result, the foaming effect can be easily realized by maintaining the above range.

Further, the density of the foam layer may be about 0.5 g / cm ³ to about 1.5 g / cm ³ . Since the foam panel itself is expensive compared to conventional plywood, a panel having a reduced density is to be manufactured by a foam extrusion process to be described later in order to secure price competitiveness. In order to maintain the density in the above range, Do.

The foam layer may have a closed cell ratio of from about 20% to about 80%. The foam layer is formed by foaming the foam panel composition, and includes bubbles. The bubbles may have a certain degree of independent void ratio.

The closed-cell structure refers to a structure in which bubbles are not opened but independently closed. On the contrary, when the cells are not independently closed, the open cell structure has an open structure. It is called an open structure.

Specifically, when the closed cell ratio of the foam layer satisfies the above range, it is possible to structurally absorb moisture in the foam panel effectively to increase the resistance to moisture.

The average diameter of the bubbles contained in the foam layer may be about 0.1 um to about 1 mm. The average diameter refers to the average value of the diameter of the bubble particles. By maintaining the diameter in the above range, the dimensional stability of the foam panel can be improved with an independent void ratio in the above range.

And a printing layer or a surface protection layer on the foam layer. The foam layer replaces a plywood, a high-density fiberboard, and a medium-density fiberboard that have been used as a core material of a conventional floor material. The foam layer may further include a print layer or a surface protective layer on the foam layer.

The printing layer is for imparting an aesthetic sensation and a three-dimensional feeling to the foam panel. The printing layer can be formed by gravure printing of a compound containing ink, and characters, pictures, letters, patterns, symbols, It can be designed to enhance sincerity and stereoscopic effect by directing.

The printing layer may be applied in a thickness of about 5 [micro] m to about 40 [micro] m. By maintaining the above range, the printing layer exhibits a certain color and does not cause a process abnormality or a process delay.

The surface treatment layer improves the surface quality such as scratch resistance and abrasion resistance of the foam panel and can improve the stain resistance. The surface treatment layer may include polyurethane, urethane acrylate, wax, and the like.

For example, when the surface treatment layer is formed using urethane acrylate, the urethane acrylate UV curable composition may be cured by irradiating ultraviolet rays.

The surface treatment layer may have a thickness of about 0.01 mm to about 0.1 mm, and maintaining the above range is advantageous in terms of ensuring scratch resistance and securing the appearance quality of the panel.

A base layer may not be included between the foam layer and the print layer, and between the foam layer and the surface protection layer. Conventionally, when a fiberboard using plywood or wood is used as a flooring panel, a base layer is formed between the plywood and the print layer and between the plywood and the surface protective layer in order to suppress moisture penetration through the plywood and fiberboard .

Specifically, the base layer may comprise at least one resin selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyurethane, and combinations thereof, and may further comprise a small amount of inorganic filler, Minimization of moisture penetration.

However, since the foam layer includes a large amount of inorganic filler in the synthetic resin to replace conventional plywood or veneer, the dimensional stability against moisture and heat of the foam layer itself is increased, , And the base layer may not be separately included between the surface protective layers.

As a result, the single foam layer can replace the laminated structure of the conventional plywood and base layer, and at the same time, a superior effect can be achieved even in the prevention of moisture infiltration.

The dimensional change rate of the foam panel with respect to the longitudinal direction and the dimensional change rate with respect to the width direction may be about -0.2% to about 0.5%. The longitudinal direction refers to the height and thickness direction of the foam panel, and the width direction refers to the width and width direction of the foam panel.

The dimensional change rate refers to a change amount with respect to the length and width of the foam panel before and after the foam panel periodically undergoes a 'change', wherein the 'change' means that the foam panel is subjected to heat treatment at 80 ° C. for 24 hours, A change 2 to allow the foam panel to stand for 30 minutes, and a change 2 to allow the foam panel to be left at 20 ° C and 65% relative humidity (HR) for 24 hours.

The thickness and length of the foam panel before the change of the foam panel are measured at room temperature (25 캜).

Wherein the foam panel has a foam layer by foaming a foam panel composition containing a certain amount of an inorganic filler in a synthetic resin, and the foam layer contains the foam layer, so that the dimensional change rate in the longitudinal direction of the range, The dimensional change ratio with respect to the width direction can be maintained, durability corresponding to ordinary wood material can be ensured, and cracking due to heat and moisture can be minimized.

firing panel  Manufacturing method

In another embodiment of the present invention, there is provided a foam panel composition comprising: 5 parts by weight to 50 parts by weight of an inorganic filler per 100 parts by weight of synthetic resin; And continuously foaming and extruding the foam panel composition to form a foam layer.

The foam panel composition and the foam layer are as described above.

The method may further include annealing the formed foam layer. The foam panel has resistance and dimensional stability to heat and moisture by controlling the content of the synthetic resin and the inorganic filler, but the size change can be further minimized by annealing during the manufacturing process.

The annealing is a process for moderately heating a certain material to remove the influence of heat history and machining remaining in the internal structure of the material, and the annealing process may include a forming process, a heat treatment process, and a cooling process.

Specifically, the foamed layer is extruded, heated to a temperature of 100 캜, and cooled slowly to stabilize the internal structure of the foamed layer, thereby making it possible to produce a foamed panel having better dimensional stability against heat and moisture .

Therefore, by manufacturing the foam panel by the foam panel manufacturing method, it is possible to secure price competitiveness, and the foam panel can be more easily processed and the application field can be expanded.

Hereinafter, specific embodiments of the present invention will be described. However, the embodiments described below are only intended to illustrate or explain the present invention, and thus the present invention should not be limited thereto.

< Example  And Comparative Example >

Example  One

5 parts by weight of a processing aid, 5 parts by weight of a composite stabilizer and 0.5 part by weight of a foaming agent were added to a foamed panel composition containing 5 parts by weight of calcium carbonate per 100 parts by weight of a vinyl chloride resin and then extruded at a temperature of 150 to 175 캜 in a thermomeque extruder (Thermo Haake Extruder) to produce a foam panel including a foam layer having a thickness of 7.2 mm and a density of 0.8 g / cm ³ .

Example  2 and 3

A foam panel was prepared in the same manner as in Example 1, except that 30 parts by weight of pellets (Example 2) and 50 parts by weight (Example 3) were used.

Comparative Example  1 to 3

A comparative example 1 was prepared in the same manner as in Example 1 except that the plywood (LG Hausys, steel green) having a thickness of 5.2 mm and the thickness of 5.2 mm were used as the comparative example 1, , Deco tile) was prepared in Comparative Example 3.

Comparative Example  4 and 5

A foam panel was prepared in the same manner as in Example 1 except that the content of pellets was changed to 3 parts by weight (Comparative Example 4) and 60 parts by weight (Comparative Example 5).

< Experimental Example > - foam Panel  Dimensional stability

The foam panels of the above Examples and Comparative Examples were heat-treated at 80 ° C for 24 hours, left to stand at room temperature for 30 minutes (change 1), allowed to stand (change 2) at 20 ° C and 65% RH for 24 hours, And the change 1 and the change 2 were periodically repeated.

Thereafter, the rate of change in the longitudinal direction or width direction of the foam panel with respect to each of the change 1 and the change 2 is measured using a vernier caliper. At a distance of 10 mm from the edge in the longitudinal direction or the width direction of the foam panel.

Example 1 Example 2 Example 3 Dimensional change ratio (%) Dimensional change ratio (%) Dimensional change ratio (%) Lengthwise Width direction Lengthwise Width direction Lengthwise Width direction Before change 0 0 0 0 0 0 Change 1 -0.2 0.08 -0.13 0.11 -0.12 -0.05 Change 2 -0.08 0.15 -0.11 0.18 -0.13 0.18 Change 1 -0.2 0.16 -0.13 0.17 -0.13 0.1 Change 2 -0.06 0.15 -0.1 0.17 -0.15 0.1 Change 1 -0.2 0.18 -0.1 0.17 -0.15 0.1 Change 2 -0.05 0.13 -0.14 0015 -0.15 0.11 Change 1 -0.2 0.12 -0.13 0.12 -0.15 0.1 Change 2 -0.05 0.12 -0.13 0.125 -0.15 0.1

Comparative Example 1 Comparative Example 2 Comparative Example 3 Dimensional change ratio (%) Dimensional change ratio (%) Dimensional change ratio (%) Lengthwise Width direction Lengthwise Width direction Lengthwise Width direction Before change 0 0 0 0 0 0 Change 1 -0.25 -0.22 -0.22 -0.2 -0.2 -0.2 Change 2 -0.25 -0.08 -0.27 -0.15 -0.2 -0.15 Change 1 -0.26 -0.2 -0.28 -0.22 -0.22 -0.22 Change 2 -0.27 -0.06 -0.25 -0.04 -0.2 -0.07 Change 1 -0.27 -0.2 -0.29 -0.25 -0.23 -0.25 Change 2 -0.27 -0.06 -0.25 -0.09 -0.22 -0.09 Change 1 -0.32 -0.25 -0.23 -0.28 -0.28 -0.29 Change 2 -0.32 -0.05 -0.2 -0.1 -0.23 -0.1

In Comparative Examples 1 to 3, the rate of dimensional change was abruptly changed due to sensitivity to environmental changes. However, in Examples 1 to 3, a rapid dimensional change was observed at an early stage due to a sudden change in the environment, but a stable dimensional change was maintained after the second period.

Specifically, in the case of Example 1, the initial dimensional change ratio in the longitudinal direction and the width direction was abrupt due to the change in the initial environment, but after the elapse of a certain time, To 3 were found to be stable with almost no change in dimensional change.

Comparative Example 4 Comparative Example 5 Dimensional change ratio (%) Dimensional change ratio (%) Lengthwise Width direction Lengthwise Width direction Before change 0 0 0 0 Change 1  -7.06 3.26 No experiment No experiment Change 2 -7.08 3.17 No experiment No experiment Change 1 -7.23 3.15 No experiment No experiment Change 2 -7.21 3.17 No experiment No experiment Change 1 -7.31 3.20 No experiment No experiment Change 2 -7.31 3.21 No experiment No experiment Change 1 -7.31 3.19 No experiment No experiment Change 2 -7.31 3.21 No experiment No experiment

Comparative Example 4 was formed to contain less than 5 parts by weight of inorganic filler. The rate of dimensional change was abrupt as compared with Examples 1 to 3, and it can be seen that the content of inorganic filler affects the dimensional stability of the foam panel.

 On the other hand, in the case of Comparative Example 5, since the extruding equipment is severely worn on the screw portion and the foaming panel is difficult to form itself, the experiment on the dimensional change is not proceeded I did not.

Claims (14)

And 5 parts by weight to 50 parts by weight of an inorganic filler based on 100 parts by weight of the synthetic resin
Foam panel composition.
The method according to claim 1,
The synthetic resin may be selected from the group consisting of a vinyl chloride resin, a polyvinyl butyral resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyurethane resin, a polylactic acid resin, an acrylonitrile-butadiene-styrene resin, a nylon resin, One or more selected
Foam panel composition.
The method according to claim 1,
The inorganic filler may be at least one selected from the group consisting of calcium carbonate, talc, diatomaceous earth, silica, aluminum hydroxide, titania, fly ash, asbestose, slag,
Foam panel composition.
The method according to claim 1,
And 1 to 20 parts by weight of an additive to 100 parts by weight of the synthetic resin
Foam panel composition.
A foam panel according to claim 1, wherein the foam panel comprises a foam layer formed by foaming
Foam panel.
6. The method of claim 5,
The foam layer has a thickness of 2 mm to 10 mm
Foam panel.
6. The method of claim 5,
Wherein the foam layer has a closed cell ratio of 20% to 80%
Foam panel.
6. The method of claim 5,
The density of the foam layer is of 0.5g / cm ³ to 1.5g / cm ³
Foam panel.
6. The method of claim 5,
And a printed layer or a surface protective layer on the foam layer
Foam panel.
10. The method of claim 9,
A base layer between the foam layer and the print layer, between the foam layer and the surface protection layer
Foam panel.
11. The method of claim 10,
Wherein the base layer comprises one or more resins selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyurethane, and combinations thereof
Foam panel.
6. The method of claim 5,
Wherein the dimensional change rate of the foam panel with respect to the longitudinal direction or the dimensional change rate with respect to the width direction is -0.2% to 0.5%
Foam panel.
Providing a foam panel composition comprising 5 to 50 parts by weight of an inorganic filler per 100 parts by weight of a synthetic resin; And
And continuously foaming and extruding the foam panel composition to form a foam layer
Method of manufacturing foam panel.
14. The method of claim 13,
Further comprising annealing the formed foam layer
Method of manufacturing foam panel.