Wood boards with improved waterproofing and durability with elastomer coating and method for manufacturing the same

Abstract

The present invention relates to a wooden board for architectural landscaping. The above-described wooden board comprises: a dried wooden substrate having an elongated cuboidal shape; an elastomer coating layer coated on the upper, lower, left, and right sides of the wooden substrate, excluding the front and rear surfaces, for waterproofing performance; and further comprises a resin coating layer coated between the surface of the wooden substrate and the elastomer coating layer to fill pores on the surface of the wooden substrate. According to this composition, a wood board and a method for manufacturing the same can be provided, which solve the problem of the elastomer coating layer peeling off from the wood substrate due to moisture inside the wood by forming an elastomer coating layer having excellent water resistance on the surface of the wood and including a resin coating layer between the surface of the wood substrate and the elastomer coating layer to fill the pores on the surface of the wood substrate.

Description

Technology Field

[0001] The present invention relates to a wooden board for architectural landscaping, and more specifically, to a wooden board with improved long-term durability that includes a structure capable of effectively releasing internal water vapor pressure while simultaneously providing impact resistance, water resistance, and wear resistance by applying an elastomer coating to the surface of the wood, and a method for manufacturing the same. Background Technology

[0002] Wood is widely used in various fields such as architecture, interior design, and furniture due to its advantages, including excellent workability, aesthetics, and renewableity.

[0003] However, wood is inherently vulnerable to moisture, heat, impact, and abrasion, so when exposed to the external environment, problems such as deformation, cracking, decay, and reduced durability may occur.

[0004] To address this, technologies such as waterproof coating, protective film formation, and paint application have been applied to the surface of wood. In particular, elastomer-based coatings are gaining popularity as protective coatings for wood because they can provide excellent elasticity, impact resistance, water resistance, and abrasion resistance.

[0005] Conventional elastomer coating technologies are mostly focused on surface protection. If internal moisture in the wood remains beneath the coating film, rising temperatures increase water vapor pressure, which can lead to problems such as lifting or peeling of the coating layer. This results in a long-term decrease in the durability of the wood and undermines the reliability of the structure.

[0006] Therefore, there is a need for wood that can ensure long-term durability and performance stability by including a structure that provides impact resistance, water resistance, and wear resistance by applying an elastomer coating layer to the surface of the wood, while preventing the elastomer coating layer from lifting or peeling, and simultaneously preventing moisture penetration from the outside of the wood while effectively releasing water vapor from the inside of the wood. Prior art literature

[0007] Republic of Korea Registered Patent No. 10-2054457 The problem to be solved

[0008] Accordingly, the present invention was made in consideration of the above circumstances, and aims to provide a wooden board and a method for manufacturing the same that can form an elastomer coating layer with excellent water resistance on the surface of wood, solve the problem of the coating layer peeling off due to moisture inside the wood, and form a passage for moisture to be discharged. means of solving the problem

[0009] A wooden board according to the present invention for implementing the purpose described above comprises: a wood substrate having a long cuboid shape and having been dried; and an elastomer coating layer coated on the upper, lower, left, and right sides of the wood substrate, excluding the front and rear surfaces, for waterproofing performance.

[0010] In addition, it further includes a resin coating layer coated between the surface of the wood substrate and the elastomer coating layer to fill the pores on the surface of the wood substrate.

[0011] In addition, it further includes a water-repellent coating layer that is applied to the front and back surfaces of the wood substrate with a resin for a water-repellent effect and to release water vapor inside the wood substrate, and has a plurality of pores in the applied state.

[0012] A method for manufacturing a wood board according to another embodiment of the present invention comprises: a step of providing a wood substrate having an elongated cuboid shape; a step of forming a resin coating layer on the upper, lower, left, and right sides of the wood substrate, excluding the front and rear surfaces, to fill pores on the surface of the wood substrate; and a step of forming an elastomer coating layer on the surface of the resin coating layer for waterproofing performance. Effects of the invention

[0013] According to the present invention, a wood board and a method for manufacturing the same can be provided, which solve the problem of the elastomer coating layer peeling off from the wood substrate due to moisture inside the wood by forming an elastomer coating layer having excellent water resistance on the surface of the wood and including a resin coating layer between the surface of the wood substrate and the elastomer coating layer to fill the pores on the surface of the wood substrate.

[0014] In addition, by further including a water-repellent coating layer applied to the front and back surfaces of a wood substrate with a resin for a water-repellent effect and to release water vapor from within the wood substrate, a wood board and a method for manufacturing the same can be provided, which can prevent moisture penetration from the outside of the wood and form a passage for releasing moisture from within the wood. Brief explanation of the drawing

[0015] FIG. 1 is a drawing illustrating the overall composition of a wooden board according to an embodiment of the present invention. FIGS. 2a to 2e are drawings sequentially illustrating a method for manufacturing a wooden board according to an embodiment of the present invention. Specific details for implementing the invention

[0016] The structure and operation of a preferred embodiment of the present invention will be described in detail below with reference to the attached drawings. It should be noted that in assigning reference numerals to the components of each drawing, identical components are denoted by the same numeral whenever possible, even if they are shown in different drawings.

[0017] FIG. 1 is a drawing illustrating the overall configuration of a wooden board according to an embodiment of the present invention. FIGS. 2a to 2e are drawings sequentially illustrating a method for manufacturing a wooden board according to an embodiment of the present invention.

[0018] Referring to FIGS. 1 to 2e, the wooden board (100) used for architectural landscaping according to the present invention comprises a wooden substrate (10), a resin coating layer (110), an elastomer coating layer (120), a non-slip coating layer (121), and a water-repellent coating layer (130).

[0019] The wooden substrate (10) has a long cuboid shape and has an upper surface, a lower surface, a left side, a right side, a front surface, and a rear surface. Here, the left side and the right side refer to long sides connected to the upper surface and the lower surface, and the front surface and the rear surface refer to short sides connected to the upper surface and the lower surface.

[0020] The wood substrate (10) is dried and has a moisture content of 8 to 15%.

[0021] A resin coating layer (110) is coated on the surface of the wood substrate (10) on the upper, lower, left, and right sides, excluding the front and rear sides of the wood substrate (10), in order to fill the pores on the surface of the wood substrate. The resin coating layer (110) fills the pores on the surface of the wood substrate so that water vapor inside the wood substrate is not discharged through the resin coating layer (110).

[0022] The front and rear surfaces of the wood substrate (10) are not coated with a resin coating layer (110) to provide a passage for the discharge of water vapor inside the wood substrate (10). The resin coating layer (110) may be a urethane-based resin, bio-epoxy, etc.

[0023] The elastomer coating layer (120) is formed by coating an elastomer on the surface of the resin coating layer (110) to prevent deformation of the wood substrate (10) and to provide waterproofing performance. Accordingly, the elastomer coating layer (120) is coated on the top, bottom, left, and right sides of the wood substrate (10), excluding the front and back surfaces. Elastomer refers to a polymer material that is elastic like rubber and is widely used in industrial fields due to its excellent wear resistance, chemical resistance, and weather resistance.

[0024] Among elastomers, polyurea is a high-performance polymer coating material that has superior durability and curing speed compared to conventional urethane or epoxy. Polyurea has high elasticity and flexibility, and is characterized by curing rapidly within seconds to minutes after application, providing an immediate waterproofing effect. In the present invention, the elastomer coating layer (120) can be a coating layer using polyurea.

[0025] Polyurea possesses high chemical resistance and durability, and because it is applied via a spray method, it can form a continuous, seam-free waterproof membrane. Furthermore, polyurea exhibits excellent adhesion to various substrates such as concrete, metal, and wood, preventing peeling or delamination and ensuring long-lasting waterproofing performance. Polyurea offers superior abrasion and impact resistance, as well as strong weather and UV resistance, allowing for extended outdoor use.

[0026] The elastomer coating layer (120) is coated on the upper, lower, left, and right sides of the wood having the resin coating layer (110) to a thickness of 0.5 to 2 mm. Since the resin coating layer (110) is formed between the wood substrate (10) and the elastomer coating layer (120), the phenomenon of the elastomer coating layer (120) lifting or peeling off due to moisture inside the wood can be prevented.

[0027] A non-slip coating layer (121) is applied over an elastomer coating layer (120) formed on the upper surface of a wooden substrate (10) to form a surface embossing for elasticity and anti-slip properties. In this embodiment, the non-slip coating layer (121) can be formed using silanized silica. Silanized silica is a material in which the surface is modified by reacting a silane compound with silica (SiO2).

[0028] When silane is bonded to the surface of silica particles, the hydroxyl groups (-OH) of the hydrophilic silica are replaced with hydrophobic functional groups, thereby acquiring the property of repelling water. The hydrophobic silica powder surface-treated in this way forms a fine nanostructure, and since water droplets do not spread on the surface but instead clump together and roll off, the water-repellent performance can be significantly improved.

[0029] Silica can have a size of 10 to 50 μm. In this case, the particles are of a suitable size and effectively perform the role of physical protrusions, allowing them to maintain high friction even in wet environments. Although silica of this size has a smaller surface area than nano-silica, it can be attached sufficiently firmly through silane treatment.

[0030] A non-slip water-repellent surface can be obtained by high-pressure spraying silane-treated silica while the elastomer coating layer (120) is still sticky before it is completely cured. When silane-treated silica is sprayed onto the surface before the elastomer coating layer (120) hardens, silica particles are embedded in the coating film to form a rough surface. These fine protrusions increase friction with shoes or tires, effectively preventing slipping. This method can improve the uniformity and aesthetics of the surface finish compared to the conventional non-slip powder mixing method.

[0031] The pre-curing elastomer coating layer (120) acts as an adhesive that firmly fixes the sprayed silica particles. Silane-treated silica provides much stronger and more permanent adhesion through the excellent adhesion between the elastomer coating layer (120), for example, polyurea and silane, than simple silica alone.

[0032] This non-slip coating layer (121) provides two functionalities simultaneously—non-slip and water-repellent—thereby increasing the durability and practicality of the painted surface. When fine powder is uniformly applied, the rough surface is finished beautifully, and a transparent or translucent coating can be created as needed to maintain aesthetic appeal. Additionally, thanks to the water-repellent performance, even if contaminants adhere to the surface, they can be easily removed by rainwater or water cleaning, offering the advantage of easy maintenance.

[0033] Next, a water-repellent coating layer (130) is applied to the front and back surfaces of the wood substrate (10) with resin for water-repellent effects and to release water vapor inside the wood. In FIG. 1, the upper drawing shows the water-repellent coating layer (130) applied to the front surface of the wood substrate (10), and the lower drawing shows the water-repellent coating layer applied to the back surface of the wood substrate (10).

[0034] The water-repellent coating layer (130) refers to a thin layer treated to be waterproof or water-repellent so that water is not absorbed into the surface but bounces off. Except for the front and back surfaces of the wood substrate (10) on which the water-repellent coating layer (130) is formed, the resin coating layer (110) is coated on the top, bottom, left, and right surfaces, so that water vapor inside the wood can be discharged only through the water-repellent coating layer (130).

[0035] The water-repellent coating layer (130) has a plurality of pores to provide a passage for water vapor inside the wood substrate (10) to be discharged to the outside. The water-repellent coating layer (130) can be formed by immersing the wood substrate (10) in a water-repellent resin or by spraying the resin onto the front and back surfaces of the wood substrate (10) on-site. After applying the resin to the wood substrate (10), the water-repellent coating layer (130) is slowly dried in the shade.

[0036] The water-repellent coating layer (130) has a pore diameter of 0.01 to 10 μm and a porosity of 5 to 60%, so that external liquid water under atmospheric pressure cannot penetrate, but water vapor inside the wood substrate (10) whose pressure has risen due to a rise in temperature, etc. can be released by the water vapor pressure.

[0037] The water-repellent coating layer (130) may be a water-repellent and flame-retardant composite composition comprising 1 to 10 wt% chitosan, 0.5 to 5 wt% phytate, and 0.1 to 3 wt% TiO2-ZnO nanoparticles, having a pH of 4 to 7 and a viscosity of 10 to 100 cP. This water-repellent and flame-retardant composite composition may have a flame-retardant rating LOI ≥ 32 and a contact angle ≥ 110°.

[0038] Hereinafter, a method for manufacturing the wooden board (100) of FIG. 1 will be described sequentially with reference to FIG. 2a to 2e.

[0039] Referring to FIG. 2a, a wooden substrate (10) having an elongated cuboid shape is first prepared. The wooden substrate (10) has an upper surface, a lower surface, a left side, a right side, a front surface, and a rear surface. Here, the left side and the right side are long sides connected to the upper surface and the lower surface, and the front surface and the rear surface are short sides connected to the upper surface and the lower surface.

[0040] Next, referring to FIG. 2b, a resin coating layer (110) is formed on the surface of the wood on the upper, lower, left, and right sides, excluding the front and rear sides of the wood substrate (10), to fill the pores on the wood surface. The resin coating layer (110) can be formed by creating a vacuum of 0.1 MPa or less on the wood substrate (10) for 5 minutes, then infiltrating the resin for 10 minutes at a pressure of 0.5 to 1 MPa, and curing it at 50 to 70°C for 1 to 3 hours. Alternatively, the resin coating layer (110) may be dried at room temperature.

[0041] Next, referring to FIG. 2c, an elastomer coating layer (120) is formed on the surface of the resin coating layer (110) for waterproofing performance. The elastomer coating layer (120) is applied to the wood surface with a thickness of 0.5 to 2 mm using a high-pressure spray while maintaining the resin temperature of the main component and the curing agent at 60 to 80°C. After forming the elastomer coating layer (120) on the wood surface, it is dried at room temperature. The elastomer coating layer (120) can be formed using polyurea.

[0042] Next, referring to FIG. 2d, a non-slip coating layer (121) is formed to prevent pedestrians, etc. from slipping on the surface of the wooden board. The non-slip coating layer (121) can be formed by applying it over an elastomer coating layer (120) formed on the upper surface of the wooden substrate (10).

[0043] Next, referring to FIG. 2e, a water-repellent coating layer (130) is formed on the front and rear surfaces of the wood substrate (10) to provide a water-repellent effect and to discharge water vapor inside the wood substrate (10).

[0044] In FIG. 2e, the upper drawing shows that a water-repellent coating layer (130) is applied to the front surface of the wood substrate (10), and the lower drawing shows that it is applied to the back surface of the wood substrate (10).

[0045] According to the wood board and the method of manufacturing the same of the present invention as described above, the weaknesses of existing wood are compensated for by the elastomer coating layer (120), making it possible to develop a wood board that is elastic and has excellent chemical resistance, durability, weather resistance, and water resistance.

[0046] In addition, a resin coating layer (110) is positioned between the wood substrate (10) and the elastomer coating layer (120), thereby preventing the elastomer coating layer (120) from lifting or peeling off due to water vapor inside the wood substrate (10).

[0047] In addition, a water-repellent coating layer (130) is formed on the front and rear surfaces of the wood substrate (10), allowing water vapor inside the wood substrate (10), which has increased pressure due to a rise in temperature, to be discharged to the outside, while preventing external moisture from penetrating into the wood substrate (10).

[0048] The wooden panel of the present invention can be used, for example, as a decking material. In this case, since the material and thickness of the core wood can be selected according to the intended use, an economical, high-durability decking material can be secured through a coating treatment of wood that is relatively inexpensive compared to high-grade tropical hardwoods, composite wood, or aluminum decking.

[0049] Furthermore, price competitiveness can be enhanced by using inexpensive wood or plywood as the base material, which lacks the strength or density suitable for decking, instead of expensive hardwood. Environmental friendliness can be improved by using recycled wood as the base, and business scalability can be increased by repairing existing wooden decks through coating applications.

[0050] It is obvious to those skilled in the art that the present invention is not limited to the above embodiments and can be implemented with various modifications or variations within the scope of the technical essence of the present invention. Explanation of the symbols

[0051] 10 : Wood material 100 : Wooden boards 110: Resin coating layer 120: Elastomer coating layer 121: Non-slip coating layer 130: Water-repellent coating layer

Claims

Claim 1 A wooden board comprising: a dried wooden substrate having an elongated cuboidal shape; a resin coating layer formed on the upper, lower, left, and right sides excluding the front and rear surfaces of the wooden substrate to fill pores on the surface of the wooden substrate; an elastomer coating layer formed on the outer surface of the resin coating layer for waterproofing performance; and a water-repellent coating layer formed on the front and rear surfaces of the wooden substrate to provide a water-repellent effect and discharge water vapor inside the wooden substrate, having a pore diameter of 0.01 to 10 μm and a porosity of 5 to 60%; wherein the resin coating layer is formed to fill pores on the surface of the wooden substrate so that water vapor inside the wooden substrate is not discharged through the resin coating layer, and the water-repellent coating layer is configured to suppress the penetration of external liquid water under atmospheric pressure while allowing the discharge of water vapor with increased pressure inside the wooden substrate. Claim 2 delete Claim 3 delete Claim 4 A method for manufacturing a wood board comprises: a step of providing a dried wood substrate having an elongated cuboid shape; a step of forming a resin coating layer on the upper, lower, left, and right surfaces of the wood substrate, excluding the front and rear surfaces, to fill the pores on the surface of the wood substrate so as not to discharge water vapor inside the wood substrate through the upper, lower, left, and right surfaces; a step of forming an elastomer coating layer on the surface of the resin coating layer for waterproofing performance; and a step of forming a water-repellent coating layer on the front and rear surfaces of the wood substrate, having a pore diameter of 0.01 to 10 μm and a porosity of 5 to 60%, to discharge water vapor inside the wood substrate while providing a water-repellent effect; wherein the water-repellent coating layer is formed to suppress the penetration of external liquid water under atmospheric pressure while allowing water vapor inside the wood substrate to be discharged to the outside by water vapor pressure.

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