ANTIMICROBIAL MELAMINE SHEET AND CONSTRUCTION MATERIAL COMPRISING THE SAME

Abstract

Disclosed is an antimicrobial melamine sheet with a base sheet impregnated with a base solution including a melamine resin, the antimicrobial melamine sheet including: a fine metal particle mixed to the base solution to be impregnated in the base sheet; and an auxiliary additive mixed with the base solution and the metal particle to uniformly distribute the metal particle in the formed base sheet. Thus, according to the disclosure, the metal particles having the antimicrobial function is uniformly distributed throughout the entire area as integrally coupled to the base solution including the melamine resin, and is excellent in durability and removes germs being in contact with the surface because the particles having the antimicrobial function are positioned close to the surface of the base as integrally coupled to the base solution.

Claims

1. An antimicrobial melamine sheet with a base sheet impregnated with a base solution comprising a melamine resin, the antimicrobial melamine sheet comprising: a fine metal particle mixed to the base solution to be impregnated in the base sheet; and an auxiliary additive mixed with the base solution and the metal particle to uniformly distribute the metal particle in the formed base sheet.

2. The antimicrobial melamine sheet according to claim 1, wherein the metal particle comprises at least one of copper (Cu), silver (Ag), and zinc (Zn).

3. The antimicrobial melamine sheet according to claim 1, wherein the metal particle has a size of 20200 m.

4. The antimicrobial melamine sheet according to claim 1, wherein the auxiliary additive comprises zeolite, glycol and silica.

5. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the zeolite is 325 wt %, the glycol is 0.530 wt %, and the silica is 110 wt %.

6. The antimicrobial melamine sheet according to claim 1, wherein the metal particle of 0.3 wt %20 wt % is mixed with respect to the base solution.

7. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the metal particle comprises one among copper, silver and zinc and is 0.5 wt %/o 20 wt %, and the zeolite is 3 wt %25 wt %, the glycol is 1 wt %30 wt %, and the silica is 3 wt %10 wt %.

8. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the metal particle comprises copper and silver and is 0.5 wt %10 wt %, and the zeolite is 3 wt %20 wt %, the glycol is 0.5 wt %15 wt %, and the silica is 1 wt %10 wt %.

9. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the metal particle comprises copper, silver and zinc and is 0.3 wt %15 wt %, and the zeolite is 3 wt %20 wt %, the glycol is 0.5 wt %20 wt %, and the silica is 1 wt %10 wt %.

10. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the metal particle comprises copper and zinc and is 1 wt %10 wt %, and the zeolite is 10 wt %20 wt %, the glycol is 5 wt % 15 wt %, and the silica is 5 wt %10 wt %.

11. The antimicrobial melamine sheet according to claim 4, wherein, with respect to the base solution, the metal particle comprises copper and zinc and is 1 wt % 20 wt %, and the zeolite is 5 wt %20 wt %, the glycol is 5 wt %15 wt %, and the silica is 5 wt %10 wt %.

12. The antimicrobial melamine sheet according to claim 1, wherein the base sheet comprises decorative paper.

13. A construction material comprising the antimicrobial melamine sheet according to claim 1, wherein the antimicrobial melamine sheet is coupled to a surface or rear of the construction material comprising a floor material.

14. The construction material according to claim 13, wherein the floor material comprises plywood, a medium-density fiberboard (MDF) or high-density fiberboard (HDF) plate formed by applying pressure to wood flour, a fiber board, and a magnesium board.

15. The antimicrobial melamine sheet according to claim 2, wherein the metal particle has a size of 20200 m.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above and/or the aspects will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings, in which:

[0031] FIG. 1 is a conceptual view schematically showing a manufacturing process of an antimicrobial melamine sheet according to an embodiment of the disclosure;

[0032] FIG. 2A is a cross-sectional view of low pressure melamine (LPM) laminated flooring in which a melamine sheet is coupled to a wood flour layer such as a medium density fiberboard (MDF) or high density fiberboard (HDF) plate;

[0033] FIG. 2B is a cross-sectional view of high pressure laminated (HPL) flooring in which a melamine sheet is coupled to a plywood layer;

[0034] FIG. 2C is a cross-sectional view of fiber flooring in which a melamine sheet is coupled to a fiberboard; and

[0035] FIG. 2D is a cross-sectional view of magnesium flooring in which a melamine sheet is coupled to a magnesium board.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0036] In the disclosure, various changes can be made and many embodiments are possible. Thus, exemplary embodiments will be illustrated in the accompanying drawings and described in the detailed description. However, it will be appreciated that the disclosure is not limited to the exemplary embodiments, and involves all the changes, equivalents or alternatives that belong to the concept and technical scope of the disclosure.

[0037] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another.

[0038] It will be understood that when an element is referred to as being connected or coupled to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being directly connected or directly coupled to another element, there are no intervening elements present.

[0039] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises, includes, etc. when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0040] An antimicrobial melamine sheet according to an embodiment of the disclosure will be described in detail with reference to FIGS. 1 to 2D.

[0041] FIG. 1 is a conceptual view schematically showing a manufacturing process of an antimicrobial melamine sheet according to an embodiment of the disclosure; FIG. 2A is a cross-sectional view of low pressure melamine (LPM) laminated flooring in which a melamine sheet is coupled to a wood flour layer such as a medium density fiberboard (MDF) or high density fiberboard (HDF) plate; FIG. 2B is a cross-sectional view of high pressure laminated (HPL) flooring in which a melamine sheet is coupled to a plywood layer; FIG. 2C is a cross-sectional view of fiber flooring in which a melamine sheet is coupled to a fiberboard; and FIG. 2D is a cross-sectional view of magnesium flooring in which a melamine sheet is coupled to a magnesium board.

[0042] According to an embodiment of the disclosure, an antimicrobial melamine sheet 100 including a base sheet 120 impregnated with a base solution 110 containing a melamine resin (hereinafter, referred to as a melamine sheet) includes fine metal particles 130 mixed in the base solution 110 to be impregnated in the base sheet 120; and auxiliary additives (not shown) contained in the base solution 110 and the metal particles 130 so that the metal particles 130 can be uniformly distributed in the base sheet 120.

[0043] Here, the metal particles 130 may include at least one of copper (Cu), silver (Ag) and zinc (Zn), and may also include combination of these metal particles 130 to be described later. Such a metal particle 130 may have a size of 20200 m. When the metal particles 130 are larger than the size of 20200 m, the metal particles 130 have a strong tendency to sink due to specific gravity while forming a thin melamine sheet 100, and therefore it is difficult to uniformly distribute the metal particles 130 after a product is formed. Thus, the metal particles 130 are likely to agglomerate in an end product. Further, when the metal particle 130 is too big, the metal particles 130 may be exposed to the outside and thus make a surface not smooth.

[0044] On the other hand, when the metal particle 130 is too small, there is a limit to making the metal particles 130 small and there is a concern over stability (or safety) such as danger of explosion or the like.

[0045] Here, copper has an atomic number of 29, and is useful for various purposes as many as the expressions of copper alloys. For example, there are copper alloys such as bronze, brass and white copper, which respectively consist of tin, zinc and nickel and are named according to colors. Copper has good malleability and ductility, and is soft but becomes hard with addition of other elements. Copper is importantly used for many purposes in modern times, and there are an electric cable, a pipe for a heater, a radiator for a vehicle, a material for a roof, cookware, coin, etc. as examples of a familiar copper product. Copper has an antimicrobial function, and is harmless to humans.

[0046] Silver has an atomic number of 47, and its element symbol is Ag. In the periodic table, silver is in the same group as copper (Cu), gold (Au), etc. Silver is very excellent in malleability and ductility, and is soft but a littler harder than gold. Among all metals, pure silver at room temperature has the highest electric conductivity and the highest thermal conductivity, looks the whitest, has the highest reflectivity of light, and the lowest contact resistance with other metals. Silver has been conventionally used in coins (a silver coin and a silver alloy coin), medals, accessories, silverware, etc., but is currently used for various commercial purposes such as electric contact with an electronic product or conduct, an amalgam for filling a cavity of a tooth, a solder, ink, a reflection plate for a mirror or the like, a battery, etc. Silver ions and silver compounds are poisonous to some organisms such as viruses, algae, mold, etc. but harmless to humans, and therefore used in antimicrobial and antibiotic treatment.

[0047] Zinc has an atomic number of 30, and its atomic symbol is Zn. Zinc is bluish-white metal which is hard and friable with little malleability and ductility at room temperature but is so malleable at a temperature of 100150 C. as to be processed as a fine line or a thin plate. Zinc is a relatively good electric conductor, has relatively low melting and boiling points, and easily sublimates. The most common use of zinc is anticorrosive plating for iron. Further, zinc is used to be alloyed with different metal like brass. Zinc is a microelement essential for almost every living thing, and zinc is the second most transition metal in a human body after iron. As an element of many enzymes, Zinc affects synthesis and degradation of biomolecules such as carbohydrates, protein, nucleic acid, etc., and also affects growth, skeletogeny, reproduction and immune function. Zinc sulfide (ZnS) is used in luminous paint, deodorant, additives of an anti-dandruff shampoo, a wood preservation agent, antimicrobial agricultural chemicals, etc.

[0048] That is, the foregoing metal particles, i.e. copper, silver, and zinc are metal having the antimicrobial or sterilization function.

[0049] The auxiliary additives to be contained in the base solution 110 may include zeolite, glycol and silica. Here, zeolite may be 325 wt %, glycol may be 0.530 wt %, and silica may be 110 wt %. Of course, the auxiliary additives may be mixed with the base solution 110 and the metal particles 130.

[0050] The base solution 110 may include a melamine resin, and may additionally include various kinds of synthetic resin as necessary.

[0051] Here, zeolite serves as a catalyst for the metal particles and causes the metal particles to release more ions and active oxygen, thereby making the released ions and active oxygen be easily adsorbed to germs harmful to humans and enhancing antimicrobial or sterilization activity.

[0052] Further, glycol makes the fine metal particles be uniformly distributed throughout a wide area, and silica makes the fine metal particles be uniformly distributed in a relatively narrow unit area. Such glycol and silica make the metal particles having high specific gravity be uniformly distributed in the base solution 110, thereby functioning to uniformly distribute the metal particles 130 in the wide area and the narrow area when the melamine sheet 100 is manufactured as a long and thin plate.

[0053] Here, a procedure of manufacturing the melamine sheet 100 shaped like a thin plate and a procedure of carrying out the antimicrobial activity will be described with reference to FIG. 1.

[0054] First, it will be assumed that copper is used for the metal particles 130 and the base solution 110 is selected as the melamine resin. As shown in FIG. 1, copper nano-powder 130, and natural ingredients of zeolite, glycol, silica, etc. are thoroughly mixed with the melamine resin to be used as a base to manufacture the melamine sheet 100 shaped like a thin plate and having the base sheet 120 impregnated with the copper nano-particles 130 and auxiliary additives. Such a mixture is made in the form of a compound, and the mixed compound is heated and liquefied.

[0055] To prevent heavy copper particles of high specific gravity from sinking during such a mixing procedure, the mixture is agitated and liquefied (see an agitator in FIG. 1). The base sheet 120 including paper absorbing the base solution 110 and having a decorative effect is impregnated with the base solution 110 while passing through the base solution 110. The base sheet 120 impregnated with the base solution 110 passes through a plurality of rollers (see squeeze rolls in FIG. 1) so that the thickness of the base solution 110 can be uniformly formed on the base sheet 120. The melamine sheet 100 having the base solution 110 formed to have the uniform thickness on the surface of the base sheet 120 is hardened and dried through a hardening furnace (see a hardening furnace in FIG. 1). Then, the hardened melamine sheet 100 is cut at both ends thereof or cut as necessary based on standards, and thus manufactured as an end product.

[0056] By catalysis of zeolite, copper ions (Cu.sup.2+) and activated oxygen are more activated and released from copper contained in the antimicrobial sheet 100 and reach germs' cell membrane, thereby destructing a structure of a cell while being adsorbed to a cell membrane or the like protein. The copper ions adsorbed to the protein such as a cell membrane, an enzyme, etc. are coupled to a cysteine group of composition amino acid, and slow down energy metabolism of a cell, and the amino acid is turned into a sulfide. Meanwhile, activated oxygen is partially turned into active oxygen (O.sup.2+, O.sup.2, O) by catalysis of copper ions, and active oxygen carries out strong disinfection action like ozone or hydrogen peroxide.

[0057] For effective sterilization or antimicrobial action of nano copper particles, more metal ions and activated oxygen have to be released. To this end, natural zeolite having an excellent effect on the catalysis of the nano copper particles is used.

[0058] Further, copper has a specific gravity of 89, which is considerably higher than other metals (e.g. iron has a specific gravity of about 7), and therefore has a disadvantage of quickly sinking down even through it has a nanosized diameter. To uniformly distribute nano copper particles to the base solution 110, i.e. the PVC film, glycol is used.

[0059] In such a manufactured melamine sheet 100, the metal particles 130 including copper in a unit area of 10 mm*10 mm may for example be uniformly distributed within an error range of +10%.

[0060] Embodiments based on such a manufacturing method will be described as follows.

Embodiment 1

[0061] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 0.520 wt % copper, 325 wt % zeolite, 130 wt % glycol, and 310 wt % silica with respect to 100 wt % base solution. In the foregoing examples, this embodiment, and the following embodiments, the components of the melamine resin have been publicly known and do not form the core of the disclosure, and therefore detailed descriptions about the components of the melamine resin will be omitted.

Embodiment 2

[0062] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 0.520 wt % silver, 325 wt % zeolite, 130 wt % glycol, and 310 wt % silica with respect to 100 wt % base solution.

Embodiment 3

[0063] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 0.520 wt % zinc, 325 wt % zeolite, 130 wt % glycol, and 310 wt % silica with respect to 100 wt % base solution.

Embodiment 4

[0064] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 0.315 wt % copper, silver and zinc, 320 wt % zeolite, 0.520 wt % glycol, and 110 wt % silica with respect to 100 wt % base solution.

Embodiment 5

[0065] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 0.510 wt % copper and silver, 320 wt % zeolite, 0.515 wt % glycol, and 110 wt % silica with respect to 100 wt % base solution.

Embodiment 6

[0066] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 110 wt % copper and zinc, 1020 wt % zeolite, 515 wt % glycol, and 510 wt % silica with respect to 100 wt % base solution.

Embodiment 7

[0067] An antimicrobial melamine sheet was manufactured by mixing a melamine resin, i.e. a base solution with metal particles, i.e. 110 wt % silver and zinc, 520 wt % zeolite, 515 wt % glycol, and 510 wt % silica with respect to 100 wt % base solution.

[0068] Results of comparison in performance between the melamine sheet 100, in which the base sheet 120 of decorative paper is impregnated with the base solution 110 including the metal particles 130 of copper with the base of the melamine resin and then hardened, according to the embodiment 1 and a conventional antimicrobial melamine film 300 formed by coating a melamine sheet 310 with an antimicrobial coating film 330 are tabulated in <Table 1>.

[0069] Here CS17 is a kind of sandpaper.

[0070] The melamine sheet 100 of the disclosure used in this case was manufactured according to the embodiment 1 by mixing the melamine resin with 2 wt % copper, 5 wt % zeolite, 2 wt % glycol, and 3 wt % silica, impregnating the base sheet with the mixture, drying the impregnated base sheet, and combining the dried base sheet to the plywood having a thickness of 7 mm, a width of 20 mm and a length of 20 mm. In the related art, an antimicrobial coating film was prepared to have a thickness of 12 m and coupled to the plywood for the base having a thickness of 7 mm and having the same width and length as those of the disclosure.

[0071] The foregoing Table shows results of culturing germs after the melamine sheet 100 formed by impregnating and hardening the base sheet 120 with the melamine resin according to the disclosure and the conventional melamine sheet having the antimicrobial coating film are subjected to abrasion tests.

[0072] First, the sheets of the disclosure and the related art were moved forward and backward 500 times under the condition that sandpaper CS-17 with a weight of 250 g is put thereon.

[0073] In result, abrasion occurred in both the disclosure and the related art (the thickness was abraded as much as 0.5 mm in the disclosure, and 0.4 mm in the related art). However, the disclosure showed that only the metal particles 130 from the abraded part were removed because the metal particles 130 were contained in the base solution 110, but the related art showed that the antimicrobial coating film 330 coated on the surface was almost removed.

[0074] Here, the abrasion test was based on KS M ISO 5470-1 (2016).

[0075] After the abrasion test, germs were cultured on the surfaces, and the disclosure and the related art were compared. In result, 99.9% germs were killed in the disclosure. Here, the germ test was based on JIS Z 2801 (2010E).

[0076] The following <Table 2> shows results from antimicrobial activity tests.

TABLE-US-00001 TABLE 2 Initial bacteria Bacteria number Test number after 24 hrs Antimicrobial microorganisms (CFU/film) at 35 1 C. activity (%) Escherichia coli 3.4 10.sup.5 1st <25 >99.9 (ATCC 8739) 2nd <25 3rd <25 Staphylococcus 3.9 10.sup.5 1st <25 >99.9 aureus 2nd <25 (ATCC 6538) 3rd <25

[0077] The related art may have a complicated process and cost much because the melanin sheet is formed and then the antimicrobial coating film is applied to or coated on the surface and/or rear of the melanin sheet. On the other hand, the disclosure shows a simpler process and remarkably better sterilization durability than the related art because the antimicrobial melamine sheet is formed at once by mixing the metal particles 130 and other elements, i.e. auxiliary additives to the base solution 110, and the metal particles 130 are present close to both the surface and rear as mixed and contained in the base solution 110.

[0078] Thus, according to the disclosure, there is provided the antimicrobial melamine sheet in which the metal particles having the antimicrobial function are present as integrally coupled to and uniformly distributed throughout the base solution containing the melamine resin.

[0079] Further, there is provided the antimicrobial melamine sheet in which the metal particles having the antimicrobial function are positioned close to the surface of the melamine sheet as integrally coupled to the base solution, which is excellent in durability and capable of eliminating the germs in contact with the surface thereof.

[0080] Further, there is provided the antimicrobial melamine sheet in which the metal particles having the antimicrobial function are promoted to generate ions and active oxygen, thereby maximizing and continuously keeping the antimicrobial function.

[0081] Further, there is provided the antimicrobial melamine sheet which is easy and convenient to use as coupled to the surfaces of various the construction material.

[0082] That is, for example, FIG. 2A is a cross-sectional view of LPM laminated flooring in which a melamine sheet is coupled to a wood flour layer such as an MDF or HDF plate; FIG. 2B is a cross-sectional view of HPL flooring in which a melamine sheet is coupled to a plywood layer; FIG. 2C is a cross-sectional view of fiber flooring in which a melamine sheet is coupled to a fiberboard; and FIG. 2D is a cross-sectional view of magnesium flooring in which a melamine sheet is coupled to a magnesium board.

[0083] Like this, the melamine sheet 100 is very widely utilized since it is applicable as coupling with construction materials including various kinds of flooring.

[0084] Therefore, there is provided an antimicrobial melamine sheet in which metal particles having an antimicrobial function are not only integrally coupled to a base solution containing a melamine resin but also uniformly applied throughout an entire area.

[0085] Further, there is provided an antimicrobial melamine sheet which is excellent in durability and kills germs on a surface thereof because metal particles having an antimicrobial function is positioned close to the surface of the melamine sheet as integrally coupled to a base solution.

[0086] Further, there is provided an antimicrobial melamine sheet, in which metal particles having an antimicrobial function are promoted to generate ions and active oxygen, thereby maximizing and continuously keeping antimicrobial functionality.

[0087] Further, there is provided an antimicrobial melamine sheet which is simple and convenient to be used as coupled to surfaces of various construction materials.

[0088] Although a few exemplary embodiments of the disclosure have been shown and described, it will be appreciated by those skilled in the art that various changes and equivalent embodiments may be made in these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.