Wood flooring with laminated wood and plastic layers using symmetric structure and method of

Wood flooring with laminated wood and plastic layers using symmetric structure and method of

1. A wood flooring, comprising: a lower layer including a first veneer layer and a first adhesive layer on the first veneer layer; a core layer including a first plastic layer on the first adhesive layer and a second adhesive layer on the first plastic layer; and an upper layer including a laminated wood layer on the second adhesive layer, wherein the upper layer and the lower layer are symmetric with respect to the core layer, and the first plastic layer comprises calcium carbonate in an amount of at least 70% by weight based on the total weight of the first plastic layer.

2. A wood flooring, comprising: a lower layer including a first veneer layer and a first adhesive layer on the first veneer layer; a core layer including a first plastic layer on the first adhesive layer, a second adhesive layer on the first plastic layer, a second veneer layer on the second adhesive layer, a third adhesive layer on the second veneer layer, a second plastic layer on the third adhesive layer, and a fourth adhesive layer on the second plastic layer; and an upper layer including a laminated wood layer on the second adhesive layer, wherein the upper layer and the lower layer are symmetric with respect to the core layer and the first or second plastic layer comprises calcium carbonate in an amount of at least 70% by weight based on the total weight of the first or second plastic layer.

3. The wood flooring of claim 1, wherein the veneer layer of the lower layer is made of the same material as the laminated wood layer of the upper layer to form a symmetric structure.

4. The wood flooring of claim 1, further comprising a surface painting layer pilled on the laminated wood layer of the upper layer.

5. The wood flooring of claim 1, wherein the laminated wood layer includes a laminated wood sliced from material wood, HPL (high pressure laminate) or LPM (low pressure melamine), the HPL and LPM having wood pattern.

6. The wood flooring of claim 1, wherein the first or second plastic layer comprises at least one selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), rubber and polyurethane (PU) as a base polymer.

7. The wood flooring of claim 1, wherein the first plastic layer further comprises at least one selected from the group consisting of elvan, jade and loess, in an amount of 10 to 20% by weight based on the total weight of the calcium carbonate.

8. The wood flooring of claim 1, wherein a soundproof layer is further contained, or wherein the first plastic layer further comprises iron in an amount of at least 100 parts by weight per 100 parts by weight of the base polymer, wherein the amount of the calcium carbonate is reduced to be 150 to 200 parts by weight per 100 parts by weight of the base polymer.

9. A method of manufacturing a wood flooring, comprising: making a lower layer including a first veneer layer and coating an adhesive on the first veneer layer; making a core layer including a first plastic layer and coating the adhesive on the first plastic layer; sequentially piling up the lower layer, the core layer, and an upper layer including a laminated wood layer coated with the adhesive to form a symmetric structure of the lower and upper layers with respect to the core layer, and pressing the piled layers into an integrated body; and making a surface painting layer on the laminated wood layer of the integrated body and cutting the integrated body on which the surface painting layer is made, wherein the lower layer and the upper layer are symmetric to each other with respect to the core layer, and the first plastic layer comprises calcium carbonate in an amount of at least 70% by weight based on the total weight of the first plastic layer.

10. A method of manufacturing a wood flooring, comprising: making a lower layer including a first veneer layer and coating an adhesive on the first veneer layer; making a core layer including a first plastic layer, a second veneer layer and a second plastic layer, and then coating the adhesive on the first plastic layer, the second veneer layer and the second plastic layer; sequentially piling up the lower layer, the core layer, and an upper layer including a laminated wood layer coated with the adhesive to form a symmetric structure of the lower and upper layers with respect to the core layer, and pressing the piled layers into an integrated body; and making a surface painting layer on the laminated wood layer of the integrated body and cutting the integrated body on which the surface painting layer is made, wherein the lower layer and the upper layer are symmetric to each other with respect to the core layer, and the first or second plastic layer comprises calcium carbonate in an amount of at least 70% by weight based on the total weight of the first or second plastic layer.

11. The method of claim 10, wherein making a core layer comprises pressing and integrating the piled first plastic layer, second veneer layer and second plastic layer, and wherein the laminated wood layer of the upper layer and the first veneer layer of the lower layer are added to the integrated core layer.

12. The method of claim 9, wherein pressing the piled layers into an integrated body comprises pressing the piled layers under a constant pressure with continued heating and cooling.

13. The method of claim 12, wherein the pressing is carried out at a heating temperature of 110 to 150° C.

14. The method of claim 9, wherein the first veneer layer of the lower layer and the laminated wood layer of the upper layer are symmetric to each other.

15. The wood flooring of claim 2, wherein the veneer layer of the lower layer is made of the same material as the laminated wood layer of the upper layer to form a symmetric structure.

16. The wood flooring of claim 2, further comprising a surface painting layer pilled on the laminated wood layer of the upper layer.

17. The wood flooring of claim 2, wherein the laminated wood layer includes a laminated wood sliced from material wood, HPL (high pressure laminate) or LPM (low pressure melamine), the HPL and LPM having wood pattern.

18. The wood flooring of claim 2, wherein the first or second plastic layer comprises at least one selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), rubber and polyurethane (PU) as a base polymer.

19. The method of claim 10, wherein pressing the piled layers into an integrated body comprises pressing the piled layers under a constant pressure with continued heating and cooling.

20. The method of claim 10, wherein the first veneer layer of the lower layer and the laminated wood layer of the upper layer are symmetric to each other.

Description:

TECHNICAL FIELD

The present invention relates to a wood flooring having laminated wood and/plastic layers symmetric to each other and method of manufacturing the same. More specifically, the present invention provides a wood flooring including an upper layer having laminated wood, a core layer having plastic sheets manufactured by calendaring, and a lower layer having veneer board, the lower layer being made of the same material as the upper layer, in which the lower, core and upper layers being piled up symmetrically in order to keep the balance between the upper layer and the lower layer, and then integrated under a constant temperature and pressure to form suitable layers made by wood and plastic, thereby providing natural feeling in surface and solving the problem of distortion according to the change of environment.

BACKGROUND ART

FIG. 1 is a schematic cross-sectional view of a conventional natural wood flooring. From the bottom, a plywood layer (60 ) constituted by five veneer boards, a laminated wood layer (20 ), and a surface painting layer (10 ) are shown in the wood flooring.

The conventional natural wood flooring is manufactured by piling simply a laminated wood on a plywood and painting the surface to finish, which has a good point of natural feeling due to the laminated wood. In this wood flooring, however, the moisture from a ground has transmitted to the plywood, which is apt to be moldy. Further, when this wood flooring is used in the Korean under-floor heating system, its low heat conduction results in much heat loss before it gets warm. The wood flooring also has low soundproof effect since it is made of wood of low density. Moreover, the wood flooring consists of wood as a whole, which makes the shape changed severely due to moisture, thereby resulting in distortion caused by high contraction and expansion.

FIG. 2 is a schematic cross-sectional view of a natural wood flooring PVC tile which is disclosed in Korean Patent Laid-open Publication No. 1998-47176. The PVC tile is manufactured by piling a PVC sheet (70 ) on a laminated wood (20 ), combining them into one body by hot press at 180° C. and then attaching a back sheet (80 ) as a lower layer. In this case, however, in order to combine a laminated wood with a plastic layer (which has different properties from the laminated wood) into one body with minimized deformation of the plastic layer, it is required to press them under sequential hot and cold condition. Under the temperature of 180° C. the plastic layer expands excessively and deforms severely until it gets to the room temperature after released from the press. Therefore, it is difficult for the PVC tile manufactured as such to be used as a finished product.

FIG. 3 is a schematic cross-sectional view of a wood flooring with laminated wood which is disclosed in Korean Patent Registration No. 292,585. The wood flooring has a lower layer reinforced by glass fiber and is more settled than the PVC tile of Korean Patent Laid-open Publication No. 1998-47176. Nonetheless, the wood flooring does not have sufficient balancing effect due to its asymmetric structure in the upper and lower sides.

DISCLOSURE OF THE INVENTION

Accordingly, the present invention provides a wood flooring which includes an upper layer having laminated wood for giving natural feeling, a core layer having plastic for minimizing the deformation due to moisture and heat, improving the dimension stability greatly compared to conventional wood floorings when used in the Korean under-floor heating system, and blocking the moisture from a ground to minimize its adverse effect, and a lower layer having the same material as the upper layer for preventing the distortion due to heat and moisture, thereby giving the stability due to the symmetric structure and being suitable to the Korean under-floor heating system.

The present invention provides a wood flooring which includes elvan, jade, loess, etc. in a plastic layer to increase the radiation of far infrared ray, thereby being good for the health.

The present invention provides a wood flooring which has a soundproof sheet layer manufactured separately or has soundproof materials in a plastic layer for increasing the soundproof effect and decreasing the ground crashing sound.

The present invention provides a method of manufacturing a wood flooring which ensures the structural stability by pressing under a constant pressure with heating and cooling sequently in the condition of a temperature ranging from 110 to 150° C. and releasing the pressure to maintain the temperature of product below room temperature, and maintains the balance of symmetric structure by using for the lower layer not a plastic sheet but the same material as the upper layer.

The present invention relates to a wood flooring having laminated wood and plastic layers symmetric to each other. The wood flooring comprises an upper layer including a laminated wood, a core layer including plastic sheets manufactured by calendaring, and a lower layer including veneer boards, the lower layer being made of the same material as the upper layer, in which the upper, core and lower layers are pressed into an integrated body under a constant temperature and pressure, and a method of manufacturing the same.

In accordance with one aspect of the present invention, it is provided a wood flooring comprising, a lower layer including a first veneer layer and a first adhesive layer on the first veneer layer, a core layer including a first plastic layer on the first adhesive layer and a second adhesive layer on the first plastic layer, and an upper layer including a laminated wood layer on the second adhesive layer, wherein the upper layer and the lower layer are symmetric with respect to the core layer.

In accordance with another aspect of the present invention, the core layer further includes a second veneer layer on the second adhesive layer, a third adhesive layer on the second veneer layer, a second plastic layer on the third adhesive layer, and a fourth adhesive layer on the second plastic layer.

According to the present invention, wood material is used for both the veneer layer of the lower layer and the laminated wood layer of the upper layer, in the same manner for maximizing the balancing effect of the symmetric structure.

A laminated wood layer generally shows the appearance of natural wood material and is obtained from suitable species of tree in compliance with one’s taste, such as cherry, maple, oak, birch, etc. Each tree has a different texture and pattern of wood from the others’ and may be classified into straight-grain wood and cross-grain wood according to the texture of wood.

For instance, the veneer board of the first veneer layer may be obtained from such wood as used in the manufacture of plywood, in the interior of furniture, in a railroad tie, or in a building, which has higher density, strength and dimension stability than that used in the upper layer. Examples of such trees are the species of keruing, kapur and mersawa, which grow naturally in Southeast Asia.

Wood flooring with laminated wood and plastic layers using symmetric structure and method of

A painting layer is preferably coated on the laminated wood layer, and it includes a top, middle and bottom painting layers.

The laminated wood layer may include a laminated wood sliced from material wood, HPL (high pressure laminate) or LPM (low pressure melamine). The HPL and LPM include wood pattern.

In the wood flooring of the present invention, the first or second plastic layer includes at least one selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), rubber and polyurethane (PU), as a base polymer. Preferable base polymer is polyvinyl chloride.

The wood flooring of the present invention may further include calcium carbonate in the first or second plastic layer for increasing the effect of under-floor heating system. The calcium carbonate is preferably added in an amount of at least 70% by weight of the total weight of the first or second plastic layer.

Further, the wood flooring of the present invention may further include at least one selected from the group consisting of elvan, jade and loess for promoting health. Preferably, the elvan, jade or loss may be added in an amount of 10 to 20% by weight of the total weight of the calcium carbonate, in order to increase radiation of far infrared ray without affecting the physical property of wood flooring.

In the wood flooring of the present invention, a soundproof layer may be further contained or iron may be added to the plastic layer for enhancing the soundproof effect. For sufficient soundproof effect, the iron is preferably added in an amount of at least 100 parts by weight per 100 parts by weight of the base polymer. In this case, the amount of calcium carbonate is reduced to be 150 to 200 parts by weight per 100 parts by weight of the base polymer.

The method of manufacturing the wood flooring, according to one embodiment of the present invention, comprises making a lower layer including a first veneer layer and coating an adhesive on the first veneer layer; making a core layer including a first plastic layer and coating the adhesive on the first plastic layer; sequentially piling up the lower layer, the core layer, and an upper layer including a laminated wood layer and pressing the piled layers into an integrated body; and making a surface painting layer on the laminated wood layer of the integrated body and cutting the integrated body on which the surface painting layer is made.

According to another embodiment of the present invention, making the core layer further comprises: making a second veneer layer and a second plastic layer; and coating the adhesive on the second veneer layer and the second plastic layer, wherein the the second veneer layer and the second plastic layer are sequentially piled on the first plastic layer.

According to another embodiment of the present invention, making the core layer further includes pressing and integrating the piled first plastic layer, second veneer layer and second plastic layer.

In exemplary embodiments of the invention, pressing the piled layer into an integrated body includes pressing the laminated wood and the first and second plastic layers, which have different properties from the laminated wood, under a constant pressure with sequent heating and cooling, into the integrated body so as to minimize the deformation of the first and second plastic layers. Preferably, the heating temperature of pressing is 110 to 150° C. since higher temperature results in excessive swelling of the plastic layers and also causes serious deformation until the product is cool to a room temperature after the release of pressure. Further, it is preferred to pile up the lower veneer layer having the same texture, thickness and pattern direction as the upper laminated wood layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic cross-sectional view of a conventional natural wood flooring.

FIG. 2 is a schematic cross-sectional view of a natural wood flooring PVC tile which is disclosed in Korean Patent Laid-open Publication No. 1998-47176.

FIG. 3 is a schematic cross-sectional view of a wood flooring with laminated wood which is disclosed in Korean Patent Registration No. 292,585.

FIG. 4 is a schematic cross-sectional view of a wood flooring with a symmetric structure according to an embodiment of the present invention.

FIG. 5 is a schematic cross-sectional view of a wood flooring with a symmetric structure according to another embodiment of the present invention.

FIGS. 6a and 6 b are schemes for illustrating the manufacturing process of a wood flooring with a symmetric structure according to the present invention.

FIG. 7 is a schematic cross-sectional view of a wood flooring with a symmetric structure according to the present invention which is constructed by T & G cutting.

EXPLANATION OF REFERENCE NUMBERS IN DRAWINGS


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