Technical Field:

The invention relates to a composition used in coating the inorganic compounds used in the production of laminate flooring that enables to reduce the deformations on the surfaces of the press plates caused by inorganic compounds such as the aluminum oxide etc. applied to the internal portions of said layer during the pressing process of the laminate flooring so as to provide the OVERLAY layer as one of the main layers of the laminate flooring to gain resistance against abrasion, scratching and heat.

State of the Art:

Today, various materials are used as floorings. Materials such as wood products, PVC, ceramic, carpet, etc. can be referred to as examples. The first place is given to the laminate flooring among the wood product materials. Laminate flooring has various characteristics when compared to other wood products. The characteristics of being natural, being environment friendly, having a long life when used appropriately, easy application, low thermal conductivity, sound absorption structure, and easy availability in nature make the laminate flooring outstanding. Laminate flooring is a product that is produced as an alternative to the wood flooring with these characteristics.

Laminate flooring consists of four layers due to its main structure. These layers are as follows; OVERLAY as a protective top layer, pattern paper, HDF (High-Density Fiberboard) as a carrier layer, and balance paper.

OVERLAY is a film layer that is alpha-cellulose-based, aluminum oxide particles are applied to its internal sections and it is impregnated with melamine resin. Said OVERLAY layer gained resistance against abrasion, scratching, and heat by means of aluminum oxide particles. These particles attach to the film layer by means of the melamine resin. Moreover, during the pressing process, melamine resin completely melts and hardens, reduces the porosity, and reduces the adhesion of dust and stains on the surfaces, and provides hygiene by making cleaning easy. The pattern paper is achieved by printing the exact photographs of natural trees on special papers with advanced technology methods. Subsequently, the pattern paper is impregnated with melamine resin. HDF is high-density moisture-resistant fiberboard whose carcinogenic formaldehyde release is minimized. The balance paper is a film layer that is produced from papers obtained from wood type fibers with high stabilization, such as particularly eucalyptus, is impregnated with melamine resin, is resistant to moisture, and provides stabilization of flooring boards.

As a result of combining (by pressing), the by-products of the wood sector such as sawdust strips, etc., the high-strength wood fibers in the middle layer of the laminate flooring namely HDF are obtained. Pattern paper and OVERLAY layer as a protective layer are placed on the middle layer called HDF. The production of the laminate flooring is completed after the balance paper is located underside of HDF and pressed with a hot press.

Laminate floorings are classified according to different levels of use Classification must be in accordance with the regulation specified in EN 685 defined by TSE. Laminate flooring used in the houses is classified as light in classes of 21, 22, and 23, the ones used in the commercial areas are classified as normal and heavy in the classes of 31, 32, and 33, likewise they are classified as light, normal and heavy.

In the state of the art, the most preferred inorganic compound is aluminum oxide so as to give resistance to the OVERLAY layer against abrasion, scratching, and heat. Aluminum oxide mineral occurs based on the high sensitivity of aluminum metal against oxygen. They are preferred in the surface processing sector since they have high hardness and long physical life. However, the aluminum oxide particles applied on the internal sections of the OVERLAY layer contact with the press surfaces of the machine during the pressing process of the flooring in press machines and thus lead to abrasion and scratching of these surfaces in time. As a consequence of this, laminate flooring surfaces with the required pattern cannot be achieved. Therefore, when the amount of aluminum oxide applied to the OVERLAY layer increases, the economic life of the press surfaces of the press machines decreases proportionally. Press surfaces of the press machines are very expensive and also their repair processes are very expensive. Moreover, there is a significant time loss since the press machine cannot be used during the repair of the press surfaces.

In the state of the art, laminate flooring with dark color patterns are produced previously and lighter laminate flooring is produced later, so as to minimize the deformation effect on the press surfaces of the press machines caused by the aluminum oxide applied to the OVERLAY layer. Therefore, a technology that eliminates the deformation on the press surfaces of press machines caused by aluminum oxide is not seen in the prior art.

Aim of the Invention:

In the state of the art, the aluminum oxide particles applied onto the OVERLAY layer so as to give strength, contact the press surfaces of the machine during the pressing of the flooring in the press machines and thus cause deformation and shorten the economic life of the press surfaces.

This invention subject to the patent registration aims to eliminate the deformation caused by said inorganic compounds on press surfaces of the device, the machine, etc. equipment together with coating the inorganic compounds such as aluminum oxide, etc. with a composition which is applied so as to give strength to the OVERLAY layer. Therefore, the economic life of the press surfaces of the machines will be extended and time loss and repair cost to be subjected will be minimized.

Description of the Figures:

Figure 1. Layers of the laminate flooring Description of the References in the Figures

The equivalents of the reference numbers shown in the figures are given herein below. 1. OVERLAY

2. Pattern paper

3. HDF

4. Balance paper Description of the Invention:

The invention is a composition used in coating the inorganic compounds used in the production of laminate flooring that enables to reduce the deformations on the surfaces of the press plates caused by inorganic compounds such as the aluminum oxide etc. applied to the internal portions of said layer during the pressing process of the laminate flooring so as to provide the OVERLAY layer as the protective top layer of laminate flooring to gain resistance against abrasion, scratching and heat.

Aluminum oxide is the second mineral which has the highest hardness after diamond. There are various problems in terms of the hardness given by the aluminum oxide to the material although it provides strength.

The invention is applied to the mineral and covers the mineral so as to eliminate the deformations without giving damage to the resistance that the invention gives to the material where aluminum oxide mineral is used. The deformations caused as a result of the contact of aluminum oxide particles coated with the developed composition with the press plates of the device, machine, etc. equipment are minimized.

The invention is a compound that is used in coating inorganic compounds such as aluminum oxide etc. consisting of melamine-formaldehyde resin, cellulose, epoxy resin, caprolactam, and diethylene glycol. Melamine formaldehyde is in a ratio of 40- 70%, cellulose is in a ratio of 10-45%, epoxy resin is in a ratio of 3-10%, caprolactam is in a ratio of 1-5% and di ethylene glycol is in a ratio of 2-7 in this composition. This composition which is subject to patent registration is prepared by means of heating and applied on the inorganic compound to be coated. The application amount is 8-50 g/m2. This ratio is changed according to the expected protection rate.

Melamine formaldehyde resin is an amine resin obtained as a consequence of polycondensation of melamine and formaldehyde. The formaldehyde enters into the amine groups in melamine and thus gives derivatives containing different numbers of methylol groups, in the reaction between formaldehyde and melamine. The number of methylol groups can increase up to six. The water-soluble methylols are converted into the melamine-formaldehyde resin by means of cross-linking at high temperatures over methylene or ether bridges.

Cellulose (C6H10O5) is the main substance of the cell walls of the plants. Cellulose makes the plant hard and strong. Cellulose comprises 44% carbon, 6.2% hydrogen and 49% oxygen. The biggest usage area of cellulose is the paper industry although it is used in the production of some plastics and fabrics.

Epoxy resin is a plastic material in the thermosets group that is famously known for its very high adhesion power. It has wide application areas due to this feature thereof. They exhibit excellent resistance to moisture, heat, chemicals, and abrasion and have long economic life. Generally, they are formed as a consequence of the reaction which is realized by mixing two components. These components are in general biphenol A and epichlorhydride. Similar to the other thermoset plastics, they pass from the liquid phase to the solid phase and reach their final hardness after they are cured for a period of time. Epoxy resin is used as an adhesive material or surface coating material in wind turbines used for energy production today, solar panels, floors on which we walk, vessels, a metro that we use for transportation, and in many areas.

Caprolactam is a white, crystalline, cyclic amide (C6H11NO) compound that is used as a raw material in the production of polyamide 6 polymer and fiber. Caprolactam is used as an auxiliary activator in producing various chemicals, resin paint, glue, and adhesive production, and in the MDF wallboard coating group.

Diethylene glycol (C4H10O3) is colorless, low volatility, low viscosity, hygroscopic liquid. It can be mixed with water and many organic fluids completely. Diethylene glycol is significantly less volatile compared to ethylene glycol since it has high molecular weight and it is sufficiently different in terms of its specific uses. The reactivity and solubility of diethylene glycol form the basis for many applications. Diethylene glycol is not compatible with strong oxidizing agents. Diethylene glycol is also not compatible with strong bases. Diethylene glycol sulphuric acid and other dehydrating agents react with nitric acid, oxygen, hydrogen peroxide, perchloric acid, and strong acids. Diethylene glycol is used in the production of unsaturated polyester resins, polyurethanes, and plasticizers, as a dye ink and a solvent in the textile dyeing; as a humectant in the tobacco industry; as a snow spray in airplanes and railways; as a thinner in glue industry, as a selective solvent for the aromatics in oil refining.

Industrial Applicability of the Invention The invention relates to a development made in the production process of laminate flooring and can be easily applied and used.