Method of manufacturing hpl with improved flexibility

Abstract

A method for manufacturing HPL with improved flexibility according to the present invention comprises the steps of: mixing a lignin solution and a sulfite solution to produce a lignin-sulfite mixture, and adding the lignin-sulfite mixture to a thermosetting resin solution to produce a mixed resin solution; impregnating the mixed resin solution into at least one of a transparent paper, a picture paper, and a kraft paper; drying the impregnated material at a specific temperature to achieve a specific ratio of moisture content; and laminating the impregnated transparent paper, picture paper, and kraft paper and then thermosetting them to produce HPL.

Description

Technology Field

[0001] The present invention relates to a method for manufacturing HPL with improved flexibility, and more specifically, to a method for manufacturing HPL with improved flexibility that utilizes a lignin and sulfite solution to increase the flexibility of HPL while maintaining the strength and durability of existing HPL, thereby developing an HPL suitable for curved surfaces that can be easily applied even to surfaces with complex structures. Background Technology

[0003] HPL (High Pressure Laminate) is a high-performance surface material used for various purposes, such as building interior materials, furniture surfaces, and wall panels. It is widely utilized in diverse industrial fields due to its excellent strength and durability, as well as its superior heat and chemical resistance.

[0004] Generally, HPL is manufactured by laminating paper impregnated with a thermosetting resin solution under high temperature and high pressure conditions, and is evaluated as a product possessing both durability and practicality because its surface layer exhibits excellent scratch resistance and water resistance.

[0005] For this reason, HPL has established itself as an important material in various fields, such as residential kitchen countertops, commercial flooring, and laboratory surfaces.

[0006] However, while conventional HPL excels in rigidity and durability, it has limitations in terms of flexibility and bendability, which restricted its use in applications involving complex shapes or curved surfaces.

[0007] This is because melamine resin and phenolic resin, which are the main components of conventional HPL, provide high strength and heat resistance, but reduce the flexibility and processability of the material. Therefore, there is a growing need to develop a new HPL material that combines flexibility and durability, which can be easily applied to curved or irregular surfaces. The problem to be solved

[0009] The present invention aims to provide a method for manufacturing HPL with enhanced flexibility that utilizes a lignin and sulfite solution to increase the flexibility of HPL while maintaining the strength and durability of existing HPL, thereby developing an HPL suitable for curved surfaces that can be easily applied even to surfaces with complex structures.

[0010] In addition, the present invention aims to provide a method for manufacturing HPL with improved flexibility, which improves quality in impregnation and heat curing processes and reduces the possibility of product deformation by significantly improving the processability of the mixed resin solution through increased water solubility of the sulfite.

[0011] In addition, the present invention aims to provide a flexible HPL manufacturing method that enhances the eco-friendliness of the HPL manufacturing process, minimizes the use of chemicals, and contributes to sustainable industrial development by utilizing lignin, which is a renewable resource obtained from nature.

[0012] Furthermore, the present invention aims to provide a method for manufacturing HPL with enhanced flexibility that overcomes the limitations of existing HPL and enables its use not only in general flat surfaces but also in curved surfaces and complex designs for furniture and interior / exterior architectural materials.

[0014] The objects of the present invention are not limited to those mentioned above, and other unmentioned objects and advantages of the present invention may be understood from the following description and will be more clearly understood by the embodiments of the present invention. Furthermore, it will be readily apparent that the objects and advantages of the present invention can be realized by the means and combinations thereof set forth in the claims. means of solving the problem

[0016] A method for manufacturing HPL with improved flexibility to achieve these objectives comprises the steps of: mixing a lignin solution and a sulfite solution to produce a lignin-sulfite mixture and adding the lignin-sulfite mixture to a thermosetting resin solution to produce a mixed resin solution; impregnating at least one of a transparent paper, a picture paper, and a kraft paper with the mixed resin solution; drying the impregnated material at a specific temperature to achieve a specific ratio of moisture content; and laminating the impregnated transparent paper, picture paper, and kraft paper and then thermosetting them to produce HPL.

[0017] In one embodiment, the step of drying the impregnated material at a specific temperature to obtain a specific moisture content may include drying at a temperature of 120°C to 190°C for a specific time and obtaining a moisture content of 5 to 7%.

[0018] In one embodiment, the step of manufacturing HPL by laminating the impregnated transparent paper, picture paper, and kraft paper and then heat-curing them may include the step of manufacturing HPL by heat-curing at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm² for a specific time and then cooling. Effects of the invention

[0020] According to the present invention as described above, by utilizing a lignin and sulfite solution, the flexibility of the HPL is increased while maintaining the strength and durability of the existing HPL, thereby developing an HPL suitable for curved surfaces that can be easily applied even to surfaces with complex structures.

[0021] In addition, according to the present invention, the sulfite has the advantage of significantly improving the processability of the mixed resin solution by increasing water solubility, thereby improving quality in the impregnation and heat curing processes and reducing the possibility of product deformation.

[0022] In addition, according to the present invention, lignin is a renewable resource obtained from nature, and utilizing it has the advantage of enhancing the eco-friendliness of the HPL manufacturing process, minimizing the use of chemicals, and contributing to sustainable industrial development.

[0023] Furthermore, the present invention aims to provide a method for manufacturing HPL with enhanced flexibility that overcomes the limitations of existing HPL and enables its use not only in general flat surfaces but also in curved surfaces and complex designs for furniture and interior / exterior architectural materials. Brief explanation of the drawing

[0025] FIG. 1 is a flowchart illustrating a first embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 2 is a flowchart illustrating a second embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 3 is a flowchart illustrating a third embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 4 is a flowchart illustrating a fourth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 5 is a flowchart illustrating a fifth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 6 is a flowchart illustrating a sixth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. FIG. 7 is a flowchart illustrating a seventh embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. Specific details for implementing the invention

[0026] The aforementioned objectives, signatures, and advantages are described in detail below with reference to the attached drawings, thereby enabling those skilled in the art to easily implement the technical concept of the present invention. In describing the present invention, detailed descriptions of known technologies related to the present invention are omitted if it is determined that such descriptions would unnecessarily obscure the essence of the invention. Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings. In the drawings, the same reference numerals are used to indicate the same or similar components.

[0028] Among the terms used in this specification, "thermosetting resin liquid" may be implemented as any one of a melamine resin liquid, a phenol resin liquid, and a resin liquid mixed with a melamine resin liquid and a phenol resin liquid.

[0030] FIG. 1 is a flowchart illustrating a first embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 1 relates to an embodiment of manufacturing HPL after impregnating a transparent paper with a mixed resin solution.

[0031] Referring to Fig. 1, in step S110, a lignin solution and a sulfite solution are prepared.

[0032] In one embodiment for step S110, 7 to 15 weight% of lignin solution and 7 to 15 weight% of sulfite solution are prepared.

[0033] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0034] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0035] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0036] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0037] In one embodiment of step S120, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0038] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0039] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a lignin solution and 7 to 15 weight percent of a sulfite solution with 100 weight percent of such a heat-cured resin solution.

[0040] In step S130, the mixed resin solution is maintained at 30°C and the prepared transparent paper is impregnated with the mixed resin solution for 10 seconds, and the impregnated material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0041] In step S140, the impregnated and dried transparent paper, the pre-prepared drawing paper, and the pre-prepared kraft paper are each laminated in sequence.

[0042] As described above, the laminated material is placed in a high-temperature press and heat-cured for a specific time at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press to complete the final HPL.

[0044] FIG. 2 is a flowchart illustrating a second embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 2 relates to an embodiment of manufacturing HPL after impregnating a drawing paper with a mixed resin solution.

[0045] Referring to Fig. 2, in step S210, a lignin solution and a sulfite solution are prepared.

[0046] In one embodiment for step S210, 7 to 15 weight% of a lignin solution and 7 to 15 weight% of a sulfite solution are prepared.

[0047] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0048] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0049] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0050] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0051] In one embodiment of step S220, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0052] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0053] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0054] In step S230, the mixed resin solution is maintained at 30°C and the prepared drawing paper is immersed in the mixed resin solution for 10 seconds, and the immersed material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0055] In step S240, the pre-prepared transparent paper, the impregnated and dried drawing paper, and the pre-prepared kraft paper are each laminated in sequence.

[0056] As described above, the laminated material is placed in a high-temperature press and heat-cured for a specific time at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press to complete the final HPL.

[0058] FIG. 3 is a flowchart illustrating a third embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 3 relates to an embodiment in which HPL is manufactured after impregnating kraft paper with a mixed resin solution.

[0059] Referring to Fig. 3, in step S310, a lignin solution and a sulfite solution are prepared.

[0060] In one embodiment for step S310, 7 to 15 weight% of lignin solution and 7 to 15 weight% of sulfite solution are prepared.

[0061] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0062] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0063] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0064] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0065] In one embodiment of step S320, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0066] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0067] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0068] In step S330, the mixed resin solution is maintained at 30°C and the prepared kraft paper is impregnated with the mixed resin solution for 10 seconds, and the impregnated material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0069] In step S340, the pre-prepared transparent paper, the pre-prepared drawing paper, and the impregnated and dried kraft paper are each laminated in sequence.

[0070] As described above, the laminated material is placed in a high-temperature press and heat-cured for 20 to 30 minutes at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press for 30 minutes to complete the final HPL.

[0072] FIG. 4 is a flowchart illustrating a fourth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 4 relates to an embodiment of manufacturing HPL after impregnating a transparent paper and a picture paper with a mixed resin solution.

[0073] Referring to Fig. 4, in step S410, a lignin solution and a sulfite solution are prepared.

[0074] In one embodiment for step S410, 7 to 15 weight% of a lignin solution and 7 to 15 weight% of a sulfite solution are prepared.

[0075] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0076] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0077] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0078] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0079] In one embodiment for step S420, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0080] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0081] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0082] In step S430, the mixed resin solution is maintained at 30°C and the prepared transparent paper and picture paper are impregnated with the mixed resin solution for 10 seconds, and the impregnated material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0083] In step S440, the impregnated and dried transparent paper, the impregnated and dried picture paper, and the pre-prepared kraft paper are each laminated in sequence.

[0084] As described above, the laminated material is placed in a high-temperature press and heat-cured for a specific time at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press to complete the final HPL.

[0086] FIG. 5 is a flowchart illustrating a fifth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 5 relates to an embodiment in which HPL is manufactured after impregnating drawing paper and kraft paper with a mixed resin solution.

[0087] Referring to Fig. 5, in step S510, a lignin solution and a sulfite solution are prepared.

[0088] In one embodiment for step S510, 7 to 15 weight% of a lignin solution and 7 to 15 weight% of a sulfite solution are prepared.

[0089] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0090] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0091] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0092] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0093] In one embodiment for step S520, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0094] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0095] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0096] In step S530, the mixed resin solution is maintained at 30°C and the prepared drawing paper and kraft paper are impregnated with the mixed resin solution for 10 seconds, and the impregnated material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0097] In step S540, the pre-prepared transparent paper, the impregnated and dried picture paper, and the impregnated and dried kraft paper are each laminated in sequence.

[0098] As described above, the laminated material is placed in a high-temperature press and heat-cured for a specific time at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press to complete the final HPL.

[0100] FIG. 6 is a flowchart illustrating a sixth embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 6 relates to an embodiment in which HPL is manufactured after impregnating transparent paper and kraft paper with a mixed resin solution.

[0101] Referring to Fig. 6, in step S610, a lignin solution and a sulfite solution are prepared.

[0102] In one embodiment for step S610, 7 to 15 weight% of lignin solution and 7 to 15 weight% of sulfite solution are prepared.

[0103] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0104] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0105] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0106] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0107] In one embodiment of step S620, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0108] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0109] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0110] In step S630, the mixed resin solution is maintained at 30°C and the prepared transparent paper and kraft paper are impregnated with the mixed resin solution for 10 seconds, and the impregnated material is passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0111] In step S640, the impregnated and dried transparent paper, the pre-prepared drawing paper, and the impregnated and dried kraft paper are each laminated in sequence.

[0112] As described above, the laminated material is placed in a high-temperature press and heat-cured for 20 to 30 minutes at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press for 30 minutes to complete the final HPL.

[0114] FIG. 7 is a flowchart illustrating a seventh embodiment of a method for manufacturing HPL with improved flexibility according to the present invention. One embodiment of FIG. 7 relates to an embodiment in which HPL is manufactured after impregnating transparent paper, picture paper, and kraft paper with a mixed resin solution.

[0115] In one embodiment for step S710, 7 to 15 weight% of lignin solution and 7 to 15 weight% of sulfite solution are prepared.

[0116] If the concentration of the above lignin solution is too high, the concentration of lignin molecules increases excessively, which can lead to an excessively high viscosity of the solution. This reduces the flowability of the solution and may make mixing and processing difficult. Furthermore, an overly concentrated lignin solution may reduce reactivity with the resin or result in uneven mixing.

[0117] If the lignin concentration is too low, the reactivity of lignin becomes insufficient, which can weaken the bonding strength with the thermosetting resin solution (such as melamine resin or phenolic resin). This may result in a decrease in the mechanical strength or durability of the final product. Additionally, a low concentration may make it difficult to form a composite material with desired properties.

[0118] If the concentration of the aforementioned sulfite solution is too high, excessive chemical modification of lignin may occur, leading to excessive structural deformation of the lignin. This can result in a decrease in physical properties such as lignin strength and chemical resistance, and make it difficult to maintain consistent properties of the composite material. Furthermore, if the sulfite concentration is excessively high, residual sulfites may remain, which can affect the quality of the final product.

[0119] If the sulfite concentration is too low, lignin modification may not occur sufficiently, leading to reduced lignin solubility or a failure to induce desired chemical changes. As a result, the lignin may lack sufficient properties or the bond with the resin may weaken, leading to a decline in the performance of the composite material.

[0120] In one embodiment of step S720, a lignin solution and a sulfite solution are mixed to produce a lignin sulfite mixture, and the lignin sulfite mixture is added to a thermosetting resin solution and mixed at a speed of 500 rpm for 10 minutes. After mixing as described above, the mixture is heated to 50°C to 60°C for 30 minutes to ensure that the mixed resin solution is uniformly formed.

[0121] Thermosetting resin liquid is transparent, stable against heat and light, and resistant to friction. When paper impregnated with thermosetting resin liquid is processed at high temperature and high pressure, the cellulose of the paper and the thermosetting resin liquid combine to form a hard and glossy material, which is a representative material for flooring.

[0122] The present invention prepares a mixed resin solution by mixing 7 to 15 weight percent of a graphene solution and 7 to 15 weight percent of an antiviral solution with 100 weight percent of such a heat-cured resin solution.

[0123] In step S630, the mixed resin solution is maintained at 30°C and the prepared transparent paper, drawing paper, and kraft paper are impregnated with the mixed resin solution for 10 seconds, and the impregnated materials are passed through a drying tunnel and dried at a temperature of 120°C to 190°C for a specific time to adjust the moisture content to 5 to 7%.

[0124] In step S640, each of the impregnated and dried transparent paper, impregnated and dried picture paper, and impregnated and dried kraft paper is laminated.

[0125] As described above, the laminated material is placed in a high-temperature press and heat-cured at a temperature of 130°C to 140°C and a pressure of 40 to 70 Kgf / cm², and then cooled with a cooling press for a specific time to complete the final HPL.

[0127] [Experimental Table]

[0128]

[0130] As in Example 1, when the mixed resin liquid is impregnated only into the transparent paper, the flexibility increases when the resin is impregnated only into the transparent paper, but the effect is relatively lower compared to when combined with other lipids.

[0131] As in Example 2, when only the drawing paper is impregnated with the mixed resin liquid, the strength and durability are greatly improved, but the flexibility is limited.

[0132] As in Example 3, when only the kraft paper is impregnated with the mixed resin liquid, the strength and durability are greatly improved, and the flexibility is improved to an intermediate level.

[0133] As in Example 4, when a mixed resin solution is impregnated into a transparent paper + picture paper, flexibility, strength, and durability are all improved and a balanced effect is shown; as in Example 5, when a mixed resin solution is impregnated into a picture paper + kraft paper, there is a very large improvement in strength and durability, but flexibility is somewhat limited; and as in Example 6, when a mixed resin solution is impregnated into a transparent paper + kraft paper, flexibility and durability are improved, and strength is improved to a relatively moderate level.

[0134] In addition, impregnating transparent paper + drawing paper + kraft paper with a mixed resin solution provides optimal effects in terms of flexibility, strength, and durability, and results in balanced improvement.

Claims

Claim 1 A step of preparing 7 to 15 weight% of a lignin solution and 7 to 15 weight% of a sulfite solution; a step of mixing the lignin solution and the sulfite solution to produce a lignin-sulfite mixture, and then adding the mixture to 100 weight% of a thermosetting resin solution to form a low-viscosity mixed resin solution capable of penetrating into the cellulose of paper fibers, wherein the mixed resin solution is mixed at a speed of 500 rpm for 10 minutes and maintained at 50°C to 60°C so that the lignin and sulfite are uniformly dispersed within the thermosetting resin; a step of impregnating at least one of transparent paper, graphic paper, and kraft paper with the mixed resin solution so that the mixed resin solution penetrates into the cellulose fibers of the paper; a step of drying the impregnated paper at 120°C to 190°C to control the moisture content to 5 to 7%, thereby controlling the interfacial bonding state between the paper and the resin; and a step of laminating a plurality of the impregnated and dried papers, wherein the transparent paper is a surface layer for expressing flexibility and the graphic paper is strength A method for manufacturing an HPL with improved flexibility, characterized by comprising: a step of laminating at least one of different paper types such that the kraft paper functions as an intermediate layer for maintenance and as a substrate layer for mechanical support; and a step of heat-curing the laminated paper under conditions of 130°C to 140°C and 40 to 70 kgf / cm² to form a structure that allows local bending deformation at the lamination interface between the surface layer and the substrate layer, thereby manufacturing an HPL having flexibility applicable to the surface of a curved structure while maintaining a high-pressure laminated structure. Claim 2 delete Claim 3 delete

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