Process for manufacturing a multi-layer solid wood composite floor with a paper impregnated laminate finish

Abstract

The application discloses a process for manufacturing a multi-layer solid wood composite floor with a paper impregnated laminated decorative surface, comprising the following steps: A, placing paper made of non-woven wood pulp mixed with PE and plant fibers in a melamine resin and an additive after impregnation, drying and pressing to obtain a melamine impregnated paper; B, pressing three wood boards with the same thickness alternately with glue to obtain a base material; C, covering the melamine impregnated paper on the surface of the base material and sending it into a hot press for hot pressing treatment; D, placing the hot pressed product on a flat storage table for three days after the hot pressing is completed. The three wood boards are bonded with synthetic glue and laminated with the melamine impregnated paper, which can effectively ensure the surface flatness of the solid wood floor, and the floor has excellent wear resistance, corrosion resistance and fire resistance, and high internal bonding strength and surface bonding strength, and the floor surface has various patterns and uniform thickness, and the production process is convenient and easy to mass produce.

Description

Technical Field

[0001] This invention relates to the field of solid wood flooring processing technology, specifically to the process of creating multi-layer solid wood composite flooring with a paper-laminated finish. Background Technology

[0002] Solid wood flooring is a floor covering material made from natural wood that has been dried and processed. Also known as hardwood flooring, it is made directly from solid wood and features the natural grain of the wood. It is a poor conductor of heat, providing warmth in winter and coolness in summer. It is comfortable underfoot and safe to use, making it an ideal material for bedrooms, living rooms, and studies. However, existing solid wood flooring is prone to uneven surface gloss, poor adhesion of the lacquer film which easily peels off, and poor surface wear resistance, stain resistance, and fire resistance, thus reducing its lifespan and limiting its application. Summary of the Invention

[0003] The purpose of this invention is to provide a process for making multi-layer solid wood composite flooring with a paper-laminated finish, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a process for manufacturing multi-layer solid wood composite flooring with a paper-laminated finish, comprising the following steps:

[0005] A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper.

[0006] B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate;

[0007] C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing treatment;

[0008] D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate.

[0009] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0010] Preferably, the plant fiber in step A is one or more of coconut fiber, flax fiber, bamboo fiber, cotton fiber, larch fiber, or red pine fiber, and the additive is composed of phenolic resin, urea-formaldehyde resin, release agent, paraffin wax, silicone oil, ammonium phosphate, zinc borate, titanium dioxide, zinc oxide, nano silver, aluminum oxide, and calcium carbonate, with the following weight proportions: phenolic resin 10-15 parts; urea-formaldehyde resin 15-20 parts; release agent 7-12 parts; paraffin wax 2-4 parts; silicone oil 3-6 parts; ammonium phosphate 1-3 parts; zinc borate 2-5 parts; titanium dioxide 0.5-1.2 parts; zinc oxide 1-1.8 parts; nano silver 2-7 parts; aluminum oxide 4-10 parts; and calcium carbonate 3-8 parts.

[0011] Preferably, in step B, the upper layer of wood is made of one of oak, walnut, oak, birch, ash, green mulberry, merbau, meranti or teak; the middle layer of wood is made of one of pine, spruce or poplar; and the bottom layer of wood is made of one of poplar, birch or pine.

[0012] Preferably, in step C, the hot press operates for 5-8 minutes, at a temperature of 130-160°C, and at a pressure of 10-13 MPa. Before the melamine-impregnated paper is applied to the substrate surface, the substrate surface needs to be cleaned, including cutting, polishing, and dust removal.

[0013] Preferably, the groove opened in step D is a U-shaped structure with a groove width of 3.5-4mm and a groove depth of 0.3-0.5 times the thickness of the plate. In addition, a dust collection mechanism is provided during the grooving and cutting process, and the dust collection head of the dust collection mechanism always moves with the blades of the grooving machine and the cutting machine.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0015] This invention uses synthetic adhesive to bond three-layer wood boards and then presses them with melamine-impregnated paper. This effectively ensures the surface flatness of the solid wood flooring, and provides excellent wear resistance, corrosion resistance, and fire resistance. At the same time, it has high internal bond strength and surface adhesive strength, a variety of flooring patterns, uniform thickness, and the production process is convenient and easy to mass-produce. Detailed Implementation

[0016] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0017] The process of applying a paper-laminated finish to multi-layer engineered wood flooring includes the following steps:

[0018] A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper.

[0019] B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate;

[0020] C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing.

[0021] D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate.

[0022] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0023] Bonding three-layer wood panels with synthetic adhesive and then pressing them with melamine-impregnated paper effectively ensures the surface flatness of the solid wood flooring. It also boasts excellent wear resistance, corrosion resistance, and fire resistance. Furthermore, it exhibits high internal bond strength and surface adhesive strength, offers a variety of flooring patterns, uniform thickness, and a convenient production process suitable for mass production.

[0024] Example 1:

[0025] The process of applying a paper-laminated finish to multi-layer engineered wood flooring includes the following steps:

[0026] A. A paper made from a mixture of nonwoven wood pulp, PE, and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper. The plant fibers are a combination of coconut fiber, bamboo fiber, cotton fiber, and red pine fiber, with the following weight proportions: coconut fiber 10-15 parts; bamboo fiber 6-10 parts; cotton fiber 3-6 parts; red pine fiber 1-5 parts. The additives consist of phenolic resin, urea-formaldehyde resin, release agent, paraffin wax, silicone oil, ammonium phosphate, zinc borate, titanium dioxide, zinc oxide, nano silver, aluminum oxide, and calcium carbonate, with the following weight proportions: phenolic resin 10 parts; urea-formaldehyde resin 20 parts; release agent 7 parts; paraffin wax 2 parts; silicone oil 4 parts; ammonium phosphate 2 parts; zinc borate 3 parts; titanium dioxide 1 part; zinc oxide 1 part; nano silver 5 parts; aluminum oxide 5 parts; calcium carbonate 5 parts.

[0027] B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate;

[0028] C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing.

[0029] D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate.

[0030] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0031] Example 2:

[0032] The process of applying a paper-laminated finish to multi-layer engineered wood flooring includes the following steps:

[0033] A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper.

[0034] B. The substrate is obtained by pressing three layers of wood boards of the same thickness together with glue. The top layer of wood board is made of oak, the middle layer of wood board is made of spruce, and the bottom layer of wood board is made of poplar.

[0035] C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing.

[0036] D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate.

[0037] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0038] Example 3:

[0039] The process of applying a paper-laminated finish to multi-layer engineered wood flooring includes the following steps:

[0040] A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper.

[0041] B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate;

[0042] C. Cover the surface of the substrate with melamine-impregnated paper and put it into a hot press for hot pressing. The hot press works for 6 minutes, the temperature is 140℃ and the pressure is 11MPa. Before the melamine-impregnated paper is covered on the surface of the substrate, the surface of the substrate needs to be cleaned, including cutting, polishing and dust removal.

[0043] D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate.

[0044] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0045] Example 4:

[0046] The process of applying a paper-laminated finish to multi-layer engineered wood flooring includes the following steps:

[0047] A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper.

[0048] B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate;

[0049] C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing treatment;

[0050] D. After hot pressing, place it on a flat platform for three days. Then, use a grooving machine to groove the board and use a cutting machine to cut the upper and lower layers of the substrate. The groove is U-shaped, 4mm wide, and 0.3 times the thickness of the board. A dust collection mechanism is also provided during the grooving and cutting process. The dust collection head always moves with the blades of the grooving machine and the cutting machine.

[0051] E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

[0052] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-layer solid wood composite flooring process with a paper-laminated finish, characterized by: Includes the following steps: A. Paper made from a mixture of nonwoven wood pulp, PE and plant fibers is impregnated with melamine resin and additives, then dried and pressed to obtain melamine-impregnated paper. B. Three layers of wood boards of the same thickness are interlaced and pressed together with glue to obtain the substrate; C. Cover the surface of the substrate with melamine-impregnated paper and send it into a hot press for hot pressing treatment; D. After hot pressing, place it on a flat platform for three days, then use a grooving machine to groove the board and a cutting machine to cut the upper and lower layers of the substrate. E. After the processed solid wood composite flooring is coated and sealed with wax, it can be packaged and stored.

2. The process for making multi-layer solid wood composite flooring with a paper-laminated finish according to claim 1, characterized in that: The plant fiber in step A is one or more of coconut fiber, flax fiber, bamboo fiber, cotton fiber, larch fiber, or red pine fiber. The additive consists of phenolic resin, urea-formaldehyde resin, release agent, paraffin wax, silicone oil, ammonium phosphate, zinc borate, titanium dioxide, zinc oxide, nano silver, aluminum oxide, and calcium carbonate, with the following weight proportions: 10-15 parts phenolic resin; 15-20 parts urea-formaldehyde resin; and 7-12 parts release agent. Paraffin wax 2-4 parts; silicone oil 3-6 parts; ammonium phosphate 1-3 parts; zinc borate 2-5 parts; titanium dioxide 0.5-1.2 parts; zinc oxide 1-1.8 parts; nano silver 2-7 parts; aluminum oxide 4-10 parts; calcium carbonate 3-8 parts.

3. The process for creating a multi-layer solid wood composite floor with a paper-laminated finish according to claim 1, characterized in that: In step B, the upper layer of wood is made of one of the following: oak, walnut, quince, birch, ash, green mulberry, merbau, meranti, or teak; the middle layer of wood is made of one of the following: pine, spruce, or poplar; and the bottom layer of wood is made of one of the following: poplar, birch, or pine.

4. The process for making multi-layer solid wood composite flooring with a paper-laminated finish according to claim 1, characterized in that: The hot press in step C operates for 5-8 minutes at a temperature of 130-160°C and a pressure of 10-13 MPa. Before the melamine-impregnated paper is applied to the substrate surface, the substrate surface needs to be cleaned, including cutting, polishing, and dust removal.

5. The process for creating a multi-layer solid wood composite floor with a paper-laminated finish according to claim 1, characterized in that: The groove opened in step D is a U-shaped structure with a width of 3.5-4mm and a depth of 0.3-0.5 times the thickness of the plate. In addition, a dust collection mechanism is provided during the grooving and cutting process, and the dust collection head of the dust collection mechanism always moves with the blades of the grooving machine and the cutting machine.