Vehicle flooring and method for manufacturing the same

Abstract

The present invention relates to an improved vehicle flooring material that is low-cost and has improved physical properties so that it can be widely used as a vehicle flooring material, and a method for manufacturing the same. The present invention provides a vehicle flooring material comprising: a core layer; a real wood board layer laminated on each of the upper and lower outer surfaces of the core layer; a coating layer laminated on the upper surface of the real wood board layer laminated on the upper surface of the core layer; and an overlayer layer laminated on the upper surface of the coating layer; wherein the core layer is formed by laminating a plurality of wood papers impregnated with melamine resin.

Description

Technology Field

[0001] The present invention relates to a flooring material for vehicles and a method for manufacturing the same, and more specifically, to a flooring material for vehicles that is low-cost and has improved physical properties so that it can be widely used as a flooring material for vehicles, and a method for manufacturing the same. Background Technology

[0002] Conventional vehicle flooring materials include non-woven carpets or BCF (bulked continuous filament) loop pile carpets. These BCF loop pile carpets are hygienic products that do not shed lint because they are composed of continuous threads.

[0003] However, in the case of the aforementioned carpet, although the sound insulation effect is good due to the polyethylene (PE) coating on the underside, it lacks breathability and is heavy, and when moisture accumulates, the PE coating blocks breathability, causing mold to grow, odors to develop, and corrosion to occur on the metal of the vehicle floor.

[0004] In addition, there are glass mats that have a glass material applied to the bottom surface of conventional vehicle flooring materials. Although these glass mats have excellent rigidity, they are undesirable because the glass itself is harmful to the human body, they are difficult to manufacture and handle, have a high defect rate, and when the mat is installed on a rounded part, the mat is stiff, making it difficult to process the round.

[0005] There are also car floor mats mixed with stone powder; while these mats offer good sound insulation, they are heavy, have poor breathability, and do not allow moisture to escape, resulting in odors and corrosion of the car body floor.

[0006] Meanwhile, as high-end flooring for vehicles, there are also engineered wood flooring made by coating a film on plywood made by cutting wood into thin strips and interlacing them horizontally and vertically, and reinforced wood flooring made by coating a film on HDF (High-Density Fiberboard) made by crushing solid wood and bark, adding plastic resin, and compressing it at high temperature and high pressure.

[0007] The aforementioned engineered wood flooring features a uniform and smooth surface that provides a comfortable walking experience, and its high thermal conductivity makes it efficient for saving on heating costs. Additionally, it is resistant to moisture, resulting in minimal deformation and low noise levels.

[0008] However, engineered wood flooring has disadvantages such as being difficult to avoid surface scratches due to its film surface, difficult to repair, and high price.

[0009] In addition, the above-mentioned laminate flooring has the advantage of being easy to install or repair, and resistant to surface scratches and impacts.

[0010] However, in the case of laminate flooring, there are problems such as the floor being uneven because it does not adhere closely to the vehicle floor, vulnerability to moisture and humidity, and a high price.

[0011] As an alternative to such expensive engineered wood or laminate flooring, there is MDF (Medium-Density Fiberboard) flooring, which is a type of wood plywood made by grinding wood into particles, mixing them with adhesive, and then compressing them.

[0012] Since these MDF flooring materials are made by grinding up all the scraps of solid wood that are generally unusable as wood, they can be produced at a low cost, can be manufactured in any desired width, and have the advantage of a uniform texture.

[0013] However, MDF flooring is susceptible to water, so it swells when water is absorbed, and even if it dries, its strength decreases and its shape is not restored.

[0014] In addition, MDF flooring releases formaldehyde, a harmful substance, due to the large amount of adhesive added; it also has poor durability compared to solid wood and has the problem of warping and breaking easily compared to solid wood of the same thickness. Prior art literature

[0015] 1. Vehicle flooring material according to Registered Utility Model Publication No. 20-0351340 (Registered May 12, 2004) 2. Flooring material for mats having non-slip, sound-absorbing, and breathable properties according to Registered Patent Publication No. 10-0904047 (Registered June 15, 2009), and a method for manufacturing the same, as well as a mat manufactured using the said flooring material and a mat for automobile floors 3. Vehicle flooring material according to Registered Patent Publication No. 10-1343123 (Registered December 18, 2013) 4. Vehicle flooring material with improved adhesion and sound insulation according to Registered Patent Publication No. 10-2451050 (Registered September 29, 2022) The problem to be solved

[0016] The present invention was created to solve the aforementioned problems, and aims to provide a vehicle flooring material and a method for manufacturing the same, which is a low-cost flooring material such as MDF flooring and has improved physical properties so that it can be widely used as a vehicle flooring material. means of solving the problem

[0017] The vehicle flooring material of the present invention for achieving the above-mentioned purpose is,

[0018] Core layer and;

[0019] Real wood board layers laminated on each of the upper and lower outer surfaces of the core layer;

[0020] A coating layer laminated on the upper surface of the real wood board layer laminated on the upper surface of the core layer;

[0021] an overlayer layer laminated on the upper surface of the above coating layer; comprising,

[0022] The above-mentioned core layer is characterized by being formed by laminating a plurality of wood papers impregnated with melamine resin.

[0023] In the present invention, the wood paper comprises kraft paper with a thickness of 0.05 mm, the core layer is formed with a thickness of 4 to 5 mm so as to be used as a flooring material for vehicles, the real wood board layer is formed with a thickness of 0.5 mm, and the overlayer layer is formed by impregnating a thin film with melamine resin.

[0024] In the present invention, the thin film is composed of any one of a polypropylene film, a polyethylene film, a polyester film, a polyamide film, and a vinyl chloride film.

[0025] The method for manufacturing a vehicle flooring material according to the present invention for achieving the above-mentioned purpose is as follows:

[0026] (a) a step of manufacturing wood paper impregnated with melamine resin; and

[0027] (b) a step of manufacturing a core layer by stacking a plurality of wood papers impregnated with the melamine resin; and

[0028] (c) a step of manufacturing a real wood board layer to be laminated on each of the upper and lower outer surfaces of the core layer; and

[0029] (d) a step of forming a coating layer on the upper surface of the real wood board layer laminated on the upper surface of the core layer; and

[0030] (e) a step of manufacturing an overlayer layer to be laminated on the upper surface of the real wood board layer on which the above-mentioned coating layer is formed; and

[0031] (f) a step of sequentially laminating a real wood board layer and an overlayer layer having a coating layer formed on the upper surface of the core layer and placing a real wood board layer on the lower surface of the core layer; and

[0032] (g) A step of manufacturing a vehicle floor material by applying external pressure to make it a single unit while the laminated and arranged state is in step (f) above; characterized by including.

[0033] In the present invention, in step (g), pressure is applied so that the melamine resin impregnated in the core layer penetrates into the real wood board layer. Effects of the invention

[0034] According to an embodiment of the present invention, by impregnating and penetrating all applied materials with melamine resin, not only is surface scratch resistance (scratch resistance) improved, but water resistance and heat resistance are also improved, stiffness (tensile strength, breaking strength) is reinforced, elongation (%) is also improved, and in particular, flexural strength is increased to 700~800 kgf / ㎠.

[0035] In addition, the service life is increased due to the aforementioned improvement in physical properties.

[0036] Therefore, by compensating for the shortcomings of existing MDF flooring, it has become possible to use it in various ways as a low-cost automotive flooring material.

[0037] In other words, because the manufacturing cost is low, it can be applied to both flooring for goods transport vehicles and trunk flooring for vehicles. Brief explanation of the drawing

[0038] FIG. 1 is a cross-sectional view of a vehicle flooring material according to the present invention. FIG. 2 is a flowchart sequentially illustrating a method for manufacturing a vehicle flooring material according to the present invention. FIGS. 3 and FIGS. 4 are manufacturing process diagrams showing a method for manufacturing a vehicle flooring material according to the present invention. Specific details for implementing the invention

[0039] Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings.

[0040] FIG. 1 shows a cross-sectional view of a vehicle floor material according to the present invention.

[0041] Referring to FIG. 1, a vehicle floor material (100) according to the present invention comprises a core layer (10), real wood board layers (20a, 20b) laminated on the upper and lower outer surfaces of the core layer (10), a coating layer (30) laminated (or coated) on the upper surface of the real wood board layer (20a) laminated on the upper surface of the core layer (10), and an overlayer layer (40) laminated on the upper surface of the coating layer (30).

[0042] And the above core layer (10) is formed by stacking multiple wood papers (10b) impregnated with melamine resin, as shown in FIG. 3 described later.

[0043] The wood paper (10b) above includes kraft paper with a thickness of 0.05 mm.

[0044] It is preferable that such a core layer (10) be formed by laminating wood paper (10b) to a thickness of about 4 to 5 mm so that it can be used as a flooring material (100) for vehicles.

[0045] Meanwhile, although melamine resin was applied as the impregnation material in the present invention, it is not limited thereto, and any thermosetting resin can be applied.

[0046] However, among thermosetting resins, phenolic resin (PH) has good physical properties (rigidity), but it is not only harmful to the human body but also not environmentally friendly, so it is not desirable to apply it.

[0047] And in the case of the above-mentioned melamine resin impregnation method (or method), a method using an impregnation roller and an impregnation tube, or a method of dipping into a tank containing a melamine resin solution, can be applied.

[0048] The above real wood board layers (20a, 20b) are laminated on the upper and lower surfaces, respectively, to prevent bending of the core layer (10) formed by laminating kraft paper (10b) impregnated with melamine resin, and it is preferable that the thickness of each is about 0.5 mm.

[0049] In addition, the formation of the above-mentioned coating layer (30) provides light resistance to the vehicle floor material (100), and this coating layer (30) is a paint specifically for vehicles, and is not limited to a specific type of paint as long as it is a paint that provides the above-mentioned light resistance.

[0050] The above overlayer layer (40) is formed by impregnating a thin film with melamine resin, thereby preventing surface wear and improving scratch resistance.

[0051] The above thin film may be composed of, for example, any one of a polypropylene (PP) film, a polyethylene (PE) film, a polyester film, a polyamide film, or a vinyl chloride (PVC) film.

[0052] FIG. 2 shows a flowchart sequentially illustrating a method for manufacturing a vehicle flooring material according to the present invention.

[0053] And FIGS. 3 and FIGS. 4 sequentially illustrate a manufacturing process diagram showing a method for manufacturing a vehicle flooring material according to the present invention.

[0054] Referring to FIGS. 2 to 4, as shown in FIG. 3(a), a wood paper (10a) of a predetermined thickness is impregnated with melamine resin to produce a wood paper (10b) impregnated with melamine resin as shown in FIG. 3(b). (Step 110)

[0055] Next, a core layer (10) is manufactured by stacking multiple layers of the wood paper (10b) impregnated with melamine resin from step 110 to a thickness of 4 to 5 mm, as shown in (c) of FIG. 3. (Step 120)

[0056] In addition, real wood board layers (20a, 20b) with a thickness of 0.5 mm are manufactured to be laminated on each of the upper and lower outer surfaces of the core layer (10). (Step 130)

[0057] Then, a coating layer (30) is formed on the upper surface of the real wood board layer (20a) laminated on the upper surface of the core layer (10). (Step 140)

[0058] The above coating layer (30) is preferably coated with an automotive paint having good scratch resistance and water resistance.

[0059] In addition, an overlayer layer (40) to be laminated on the upper surface of the real wood board layers (20a, 20b) on which the coating layer (30) is formed is manufactured (step 150).

[0060] Next, as shown in FIG. 4, a real wood board layer (20a) with a coating layer (30) formed on the upper surface of each core layer (10) manufactured as above and an overlayer layer (40) are sequentially laminated, and a real wood board layer (20b) is placed on the lower surface of the core layer (10). (Step 160)

[0061] In the state of being stacked and arranged as in Step 160 above, the outer surface, the top surface, or / and the bottom surface are pressed together, for example, with a press device to form a single unit, thereby completing the manufacture of the vehicle floor material (Step 170).

[0062] Then, a vehicle floor material (100) according to the present invention as shown in Fig. 1 is completed.

[0063] That is, the wood paper (10b) comprises kraft paper with a thickness of 0.05 mm, the core layer (10) is formed with a thickness of 4 to 5 mm so as to be used as a flooring material (100) for vehicles, the real wood board layer (20a, 20b) is formed with a thickness of 0.5 mm, and the overlayer layer (40) is formed by impregnating a thin film with melamine resin.

[0064] Meanwhile, since steps 110 to 150 above are processes for manufacturing each layer, it is not a problem if the order is changed.

[0065] And the flooring material (100) completed by pressing with a press device in step 170 above is pressed so that the melamine resin impregnated in the core layer (10) penetrates into the real wood board layer (20a, 20b).

[0066] That is, by applying pressure with the above press device, the melamine resin passes through the real wood board layer (20a, 20b) and adheres to the core layer (10).

[0067] As described above, the vehicle flooring material (100) manufactured by the method for manufacturing vehicle flooring material according to the present invention is manufactured using low-cost materials, so the manufacturing cost is low.

[0068] In addition, the physical properties of the vehicle flooring were improved by impregnating and penetrating all applied materials with melamine resin.

[0069] That is, the vehicle floor material (100) according to the present invention not only has improved rigidity, but also improved water resistance and heat resistance, reinforced rigidity (tensile strength, breaking strength), and improved elongation (%).

[0070] In particular, light resistance is imparted by forming a coating layer (30) with a paint specifically designed for vehicles.

[0071] In addition, by impregnating the overlay layer (40) with melamine resin, surface scratches are reinforced and surface wear is prevented.

[0072] In this way, the vehicle flooring material (100) according to the present invention has an increased service life due to the improvement of the physical properties described above.

[0073] Accordingly, the vehicle flooring material (100) according to the present invention can be used in various ways as a low-cost vehicle flooring material by compensating for the disadvantages of existing MDF flooring materials.

[0074] As described above, the present invention has been explained with reference to an embodiment illustrated in the drawings, but this is merely illustrative, and those skilled in the art will understand that various modifications and equivalent embodiments are possible therefrom.

[0075] Therefore, the true scope of protection of the present invention must be determined solely by the appended claims. Explanation of the symbols

[0076] 10. Core layer 10a. Wood paper 10b. Wood paper impregnated with melamine resin 20a, 20b. Real wood board layer 30. Coating layer 40. Overlayer 100. Automotive flooring

Claims

Claim 1 A vehicle flooring material comprising: a core layer formed by laminating a plurality of wood papers impregnated with melamine resin; a real wood board layer laminated on the upper outer surface and the lower outer surface of the core layer, respectively; a coating layer formed on the upper surface of the real wood board layer laminated on the upper outer surface of the core layer; and an overlayer layer laminated on the upper surface of the coating layer and formed by impregnating a thin film with melamine resin; wherein the core layer, the real wood board layer, the coating layer, and the overlayer layer are integrated by external pressure while in a laminated state, and the melamine resin impregnated in the core layer penetrates into the real wood board layer by the pressure, and the melamine resin passes through the real wood board layer and adheres to the core layer, thereby attaching the core layer and the real wood board layer. Claim 2 A vehicle flooring material according to claim 1, characterized in that the core layer is formed with a thickness of 4 to 5 mm so as to be used as a vehicle flooring material, and the real wood board layer is formed with a thickness of 0.5 mm. Claim 3 A vehicle flooring material according to claim 1, wherein the thin film is composed of any one of a polypropylene film, a polyethylene film, a polyester film, a polyamide film, or a vinyl chloride film. Claim 4 A method for manufacturing a flooring material for a vehicle, comprising: (a) a step of manufacturing wood paper impregnated with melamine resin; (b) a step of manufacturing a core layer by stacking a plurality of the wood papers impregnated with melamine resin; (c) a step of manufacturing a real wood board layer to be stacked on the upper outer surface and the lower outer surface of the core layer, respectively; (d) a step of forming a coating layer on the upper surface of the real wood board layer to be stacked on the upper outer surface of the core layer; (e) a step of manufacturing an overlayer layer formed by impregnating a thin film with melamine resin; (f) a step of sequentially stacking the real wood board layer with the coating layer formed on the upper outer surface of the core layer and the overlayer layer, and placing the real wood board layer on the lower outer surface of the core layer; and (g) a step of integrating the core layer, the real wood board layer, the coating layer, and the overlayer layer by applying external pressure to the laminated body in the state of stacking and placing in step (f). Claim 5 A method for manufacturing a vehicle flooring material according to claim 4, wherein in step (g), the laminate is pressed so that the melamine resin impregnated in the core layer penetrates to the real wood board layer. Claim 6 A method for manufacturing a vehicle flooring material according to claim 4, characterized in that in step (a), the wood paper is manufactured by impregnating kraft paper with melamine resin. Claim 7 A method for manufacturing a vehicle flooring material according to claim 4, wherein in step (b), a plurality of wood papers impregnated with melamine resin are laminated so that the core layer has a thickness of 4 mm to 5 mm, and the real wood board layer has a thickness of 0.5 mm.

Images