CN111132826B - 隔音地板材料 - Google Patents

隔音地板材料 Download PDF

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CN111132826B
CN111132826B CN201980002302.3A CN201980002302A CN111132826B CN 111132826 B CN111132826 B CN 111132826B CN 201980002302 A CN201980002302 A CN 201980002302A CN 111132826 B CN111132826 B CN 111132826B
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layer
composition
weight
flooring material
soundproof flooring
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CN111132826A (zh
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吴东珍
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Shinko Kasei Co Ltd
Dongxing Polymer Co ltd
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Dongxing Polymer Co ltd
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Abstract

本发明的耐热性、隔音性、附着力得到提高的隔音地板材料可以依次层叠复合层、第一平衡层、第二平衡层、底漆层、聚乙烯泡沫层以及聚乙烯离型纸层而成。其中，底漆层包括第一组合物、第二组合物以及固化剂，第一组合物包括树脂、丙醇、1‑甲氧基‑2‑丙醇、丙基乙酸、异丙醇、丁酮以及水。

Description

隔音地板材料
技术领域
本发明涉及一种适用于建筑物地面或地板的地板材料。更详细地，涉及一种改善耐热性、隔音性、附着力的隔音地板材料。
背景技术
通常，建筑物的地面或地板上都会使用地板纸或瓷砖等地板(装饰)材料。地板纸或瓷砖等地板材料由轻便、柔软且缓冲性及吸音性优秀的氯乙烯为主材料制成。
地板材料由聚氯乙烯(PVC，Poly Vinyl Chloride)制造或者将氯乙烯与其他材料混合或贴合制造。这种地板材料通常由透明层、印刷层、浸渍树脂尺寸加强层、发泡层及均衡层等多个层依次叠层构成。透明层起到保护印刷层的印刷面的功能，印刷层赋予颜色或图案起到装饰的功能，浸渍树脂尺寸加强层采用聚氨酯树脂处理的玻璃纤维(Glass-Fiber)，具有加强产品的尺寸安全性的功能，发泡层赋予缓冲的功能而且均衡层分别起到加固及与地面的安置功能。
透明膜层上端还可根据需要形成提高耐磨性或耐刮性的涂层。地板材料根据用途的不同可加减各层来制作，如下述专利文献所记载可在广泛领域中使用。
专利文献1：韩国授权专利公报第10-0510836号(2005年08月30日授权)
专利文献2：韩国授权专利公报第10-0600841号(2006年07月06日授权)
专利文献3：韩国授权专利公报第10-1149890号(2012年05月18日授权)
如上所述，以往的地板材料在耐热性、隔音性及附着力方面还是有些不足，所以需开发功能强、耐久性优秀的地板材料。
发明内容
要解决的技术问题
本发明的目的在于提供一种能够满足耐热性、隔音性及附着力的隔音地板材料。
解决问题的技术方案
为了实现上述技术问题，本发明提供的隔音地板材料，其特征在于，包括：复合层；第一平衡层，形成于上述复合层的下部；第二平衡层，形成于上述第一平衡层的下部；底漆层，形成于上述第二平衡层的下部；聚乙烯泡沫层，形成于上述底漆层的下部；以及聚乙烯离型纸层，形成于上述聚乙烯泡沫层的下部。
上述底漆层由包括第一组合物、第二组合物以及固化剂的组合物形成，而上述第一组合物包括树脂、丙醇、1-甲氧基-2-丙醇、丙基乙酸、异丙醇、丁酮以及水。
发明的有益效果
本发明的隔音地板材料中包含规定成分的底漆层，可提高耐热性及附着力，并采用了电子线交联聚乙烯泡沫，隔音性与以往相比更具效果。
附图说明
图1示出根据本发明的隔音地板材料的一实施例。
具体实施方式
以下详细说明优选实施例。在说明本发明的过程中，为使本发明的要旨明确，而省略对公知的功能或构成的说明。
图1示出根据本发明的隔音地板材料的一实施例。
参照图1，根据本发明的隔音地板材料包括复合层100、第一平衡层200、第二平衡层300、底漆层400、聚乙烯泡沫层500以及聚乙烯离型纸层600。可依次形成复合层100、第一平衡层200、第二平衡层300、底漆层400、聚乙烯泡沫层500以及聚乙烯离型纸层600。即，可在复合层100的下部形成第一平衡层200，在第一平衡层200的下部形成第二平衡层300，在第二平衡层300的下部形成底漆层400，在底漆层400的下部形成聚乙烯泡沫层500，在聚乙烯泡沫层500的下部形成聚乙烯离型纸层600。其中，“下部”可以为相应层的下面，但并不限于此，多个层之间也可形成额外层。
如图1所示，复合层100可包括涂层110、表面层120、印刷层130、中纸层140、玻璃纤维层150及下纸层160。
优选地，涂层110为UV涂层，可形成于表面层120的上部，厚度为5μm～12μm。优选地，表面层120可形成于涂层110的下部，相对于100重量份的PVC可包含25重量份～35重量份的可塑剂，厚度为0.40mm～0.70mm。优选地，印刷层130可形成于表面层130的下部，相对于100重量份的PVC可包含6重量份～10重量份的可塑剂，厚度为0.05mm～0.10mm。
中纸层140可形成于印刷层130的下部，相对于100重量份的PVC可包含40重量份～60重量份的可塑剂和400重量份～550重量份的110至130筛目大小的CaCO3，也可包含作为镁的含水硅酸盐矿物的粉末滑石(TALC)或麦饭石粉末。其中，滑石属于具有如云母结晶结构的单斜晶系岩石，可具有白色、银白色、淡绿色等颜色，与叶腊石相同属于2∶1型硅酸盐类，微细粉末在医学、工业方面称为滑石粉。优选地，中纸层140的厚度为0.5mm～0.8mm。
玻璃纤维层150可形成于中纸层140的下部，相对于100重量份的PVC可混合60重量份～90重量份的可塑剂和50重量份～70重量份的加固用无机填充剂CaCO3，并在容器内形成溶胶(sol)形态，在该容器内浸渍玻璃纤维并通过干燥获取，可使中纸层140与下纸层160贴合。例如，玻璃纤维层150中可含有55g/cm2的G/F。玻璃纤维层150起到防止影响产品周围温度的收缩、膨胀、弯曲的功能，若没有玻璃纤维层150，也生产不出在实际地板上施工使用的地板材料。优选地，玻璃纤维层150的厚度为0.35mm～0.55mm。
下纸层160可形成于玻璃纤维层150的下部，相对于100重量份的PVC可包含40重量份～60重量份的可塑剂和400重量份～550重量份的60至80筛目大小的CaCO3，优选厚度为1.8mm～2.5mm。
第一平衡层200可形成于下纸层160的下部，相对于100重量份的PVC可包含20重量份～30重量份的可塑剂，优选厚度为0.2mm～1.0mm。
第二平衡层300可形成于第一平衡层200的下部，相对于100重量份的PVC可包含20重量份～30重量份的可塑剂，为了提高生产效率，优选地与第一平衡层200的厚度相同。
底漆层400可形成于第二平衡层300的下部，可包括第一组合物、第二组合物以及固化剂，优选地，相对于100重量份的第一组合物，可包含45重量份～55重量份的第二组合物、4重量份～6重量份的固化剂。为了提高附着力可进行电晕处理或合并进行电晕处理和涂敷处理，但因本发明的第二平衡层以PVC材料为主，所以不宜进行电晕处理。
说明底漆层400的形成工序，在第二平衡层300的下部涂敷包含第一组合物、第二组合物及固化剂的底漆组合物，涂敷完后在50℃的干燥箱中进行热风干燥，随后在40℃的熟成室中进行40小时至50小时的熟成后将底漆层400形成于第二平衡层300的下部面。
本发明的第一组合物可包括树脂、丙醇、1-甲氧基-2-丙醇、丙基乙酸、异丙醇、丁酮以及水。第一组合物为形成底漆层400的基本成分的组合物。
树脂可以为聚氨酯类树脂、环氧树脂等可用于底漆的多种树脂成分，可包括35重量百分比至45重量百分比。丙醇(PROPANOL)可以为由化学式CH3CH2CH2OH表示的1-丙醇(1-Propanol)，也可以为CAS号71-23-8的物质丙醇(Propyl alcohol)。1-甲氧基-2-丙醇(1-METHOXY-2-PROPANOL)可以为由化学式CH3CH(OH)CH2OCH3表示的CAS号107-98-2的物质。丙基乙酸(Propyl Acetate)可以为由化学式CH3COOCH2CH2CH3表示的CAS号109-60-4的物质。异丙醇(Isopropanol)可以为由化学式(CH3)2CHOH表示的CAS号67-63-0的物质。丁酮(Butanone)可以为由化学式C2H5COCH3表示的CAS号78-93-3的物质。可包括重量比在1：1.5～1：3.5的范围内的1-甲氧基-2-丙醇和丁酮。
下述表1示出根据1-甲氧基-2-丙醇与丁酮的重量比产生变化的附着力。第二平衡层300与聚乙烯泡沫层500之间形成底漆层400，根据KS F 2561附着力实验方法测试了附着强度。并固定规定含量的后述第二组合物和固化剂进行了实验。
表1
Figure BDA0002262403880000041
参照表1可知，包含于底漆层400的第一组合物中的1-甲氧基-2-丙醇与丁酮的重量比发生变化时，附着强度也发生变化。当1-甲氧基-2-丙醇与丁酮的重量比为1：1.5时，附着强度急剧上升，为1：4时附着强度降低，1-甲氧基-2-丙醇与丁酮的重量比为1：1.5～1：3.5时，具有最佳附着强度。
第一组合物可包括35重量百分比～45重量百分比的树脂、1重量百分比～10重量百分比丙醇、5重量百分比～15重量百分比的1-甲氧基-2-丙醇、1重量百分比～10重量百分比的丙基乙酸、1重量百分比～5重量百分比的异丙醇以及15重量百分比～25重量百分比的丁酮。经实验确认，这些物质的含量范围为通过多种物质的有机结合关系达到本发明目的的最佳含量范围。
第二组合物可包括异丙醇(Isopropyl alcohol)、乙酸乙酯(Ethyl acetate)及甲基乙基酮(Methyl ethyl ketone)。可包括15重量百分比～25重量百分比的异丙醇、35重量百分比～45重量百分比的乙酸乙酯、35重量百分比～45重量百分比的甲基乙基酮。第二组合物可以以稀释剂的用途使用。
其中，异丙醇与甲基乙基酮的重量比可以为1：2.5～1：3。下述表2为根据异丙醇与甲基乙基酮的重量比产生变化的附着力(附着强度)及耐热性的实验结果。根据KS F 2561附着力实验方法，使用了与上述表1相同的实验方法，以测试在130℃的烘箱中变色(变黄)所需的时间来测定了耐热性。并固定规定含量的后述第二组合物和固化剂进行了实验。
表2
异丙醇与甲基乙基酮的重量比 1：1 1：1.5 1：2 1：2.5 1：3 1：3.5 1：4
附着强度(N/nm<sup>2</sup>) 3.5 3.6 4.0 4.1 4.1 4.2 3.8
耐热性(Hr) 25 26 28 32 35 36 36
参照表2可知，第二组合物的异丙醇与甲基乙基酮的重量比发生变化时，附着强度及耐热性也发生变化。就根据异丙醇与甲基乙基酮重量比的附着强度而言，当异丙醇与甲基乙基酮的重量比在1：2～1：3.5时最佳，耐热性在1：2.5以上时最佳。因此，第二组合物中异丙醇与甲基乙基酮的重量比为1：2.5～1：3.5时，具有最佳附着强度与耐热性。
最优选地，异丙醇和乙酸乙酯及甲基乙基酮的重量比为1：5.5～1：6.5，经实验确认，若低于1：5.5，则附着力降低，而若超过1：6.5，则耐热性降低。
固化剂可包括50重量百分比～60重量百分比的乙酸乙酯(Acetic acid ethylester)和40重量百分比～50重量百分比的树脂。
以100重量份的第一组合物为基准，第二组合物可以为45重量份～55重量份。
下述表3示出根据以100重量份的第一组合物为基准的第二组合物的重量来测试其附着力及耐热性的结果。实验方法与表1及表2相同。以第二组合物中的异丙醇：乙酸乙酯：甲基乙基酮的重量比(组合比)为2：4：4的比例进行了测试。
表3
第二组合物的重量 30 40 45 50 55 60
附着强度(N/nm<sup>2</sup>) 4.1 4.5 4.5 4.6 4.6 4.3
耐热性(Hr) 32 33 38 38 38.5 38
参照表3可知，以100重量份的第一组合物为基准的第二组合物的重量发生变化时，附着强度及耐热性也发生变化。以100重量份的第一组合物为基准的第二组合物的重量为45重量份～55重量份时，附着力最佳，在45重量份以上时，耐热性最佳。因此以100重量份的第一组合物为基准的第二组合物的重量为45重量份～55重量份时，具有最佳附着强度与耐热性。
底漆层400由包括第一组合物、第二组合物及固化剂的底漆组合物以45μm～50μm涂敷于第二平衡层的下部，在50℃的干燥箱中进行1次干燥后，通过40℃的熟成室的熟成过程形成。涂敷有底漆层400的第二平衡层300可贴合于第一平衡层200的下部来形成。在底漆层为45μm以下时存在着附着力降低的问题，而为50μm以上时存在着耐热性降低的问题。
聚乙烯泡沫层500可形成于底漆层400的下部，可以为电子线交联聚乙烯泡沫。电子线交联聚乙烯泡沫可以以低密度聚乙烯为基体树脂，以重碳酸钠(sodium bicarbonate)为发泡剂形成。经实验确认，本发明以电子线交联方式的聚乙烯泡沫形成均匀的发泡层，从而提高了隔音性。并且，比普通聚乙烯泡沫相比进一步提高了底漆层400的附着力。
电子线可以为伽马射线，伽马射线的照射量可以为120kGy～150kGy。
下述表4示出根据伽马射线的照射量，测试其隔音性及尺寸变化率的结果。以图1示出的完成品为对象，根据伽马射线的照射量仅变换聚乙烯泡沫层来进行了实验。轻量撞击声实验隔音性(吸音性)(测定方法：以10cm为间隔排列5个500g的钢锤，分别从4cm高度以0.1秒为间隔使其连续自由降落后，用Tapping Machine测量，尺寸变化率在80℃的温度下进行24小时的加热，并测量其收缩或膨胀的尺寸，按百分比计算)。
表4
Figure BDA0002262403880000071
参照表4可知，伽马射线的照射量发生变化时，隔音性及尺寸变化率也发生变化。隔音性在伽马射线的照射量为120kGy～160kGy时最佳，尺寸变化率在伽马射线的照射量的照射量为120kGy～150kGy时最佳。因此，在形成聚乙烯泡沫层时，在伽马射线的照射量为120kGy～150kGy时本发明的隔音地板材料的隔音性及尺寸变化率为最佳。经确认，这种隔音性及尺寸变化率与根据伽马射线照射量的MD(Mechanical Direction)和TD(TransverseDirection)的拉伸率变化而进行的实验结果相一致。即，经实验确认，当伽马射线的照射量为120kGy～150kGy时，MD(Mechanical Direction)的拉伸率比TD(Transverse Direction)的拉伸率急剧增大。
作为另一实施方式，聚乙烯泡沫层500可形成为密度均匀变化的聚乙烯泡沫层。可形成上部，即与底漆层400相接合的面的密度高，且越往下其密度就越低的形态。
聚乙烯离型纸层600可形成于聚乙烯泡沫层500的下部。聚乙烯离型纸层600可以为聚乙烯薄片，并包括涂敷聚乙烯树脂或浸渍的纸。优选地，聚乙烯离型纸层600可在粘结产品时剥离使用。
为了提升聚乙烯泡沫层500和聚乙烯离型纸层600的粘结力，在聚乙烯泡沫层500与聚乙烯离型纸600之间可追加额外的粘结层10。
优选地，根据本发明的隔音地板材料应用压延工艺形成。对于相关技术人员而言，有关压延工艺的技术属于众所周知的技术，所以省略其说明。即，公知的压延工艺的多种实施形态可适用于本发明的地板材料制造工序。
本发明所属领域的普通技术人员应理解，本发明并不受上述实施例所限制，在不超出本发明的思想及范围内可进行多种修改及变形。
产业上的可利用性
根据本发明的隔音地板材料具有优秀的附着力、耐热性及隔音性，可适用于建筑物的地面或地板。

Claims (11)

1.一种隔音地板材料，其特征在于，
包括：
复合层；
第一平衡层，形成于上述复合层的下部；
第二平衡层，形成于上述第一平衡层的下部；
底漆层，形成于上述第二平衡层的下部；
聚乙烯泡沫层，形成于上述底漆层的下部；以及
聚乙烯离型纸层，形成于上述聚乙烯泡沫层的下部，
上述底漆层包括第一组合物、第二组合物以及固化剂，
上述第一组合物包括：
35重量百分比～45重量百分比的树脂；
1重量百分比～10重量百分比的丙醇；
5重量百分比～15重量百分比的1-甲氧基-2-丙醇；
1重量百分比～10重量百分比的丙基乙酸；
1重量百分比～5重量百分比的异丙醇；
15重量百分比～25重量百分比的丁酮；以及
水，
上述第二组合物包括15重量百分比～25重量百分比的异丙醇、35重量百分比～45重量百分比的乙酸乙酯及35重量百分比～45重量百分比的甲基乙基酮。
2.根据权利要求1所述的隔音地板材料，其特征在于，上述聚乙烯泡沫层为电子线交联聚乙烯泡沫。
3.根据权利要求2所述的隔音地板材料，其特征在于，上述电子线交联聚乙烯泡沫以低密度聚乙烯为基体树脂，以重碳酸钠为发泡剂。
4.根据权利要求2所述的隔音地板材料，其特征在于，上述电子线为伽马射线。
5.根据权利要求4所述的隔音地板材料，其特征在于，上述伽马射线的照射量为120kGy～150kGy。
6.根据权利要求1所述的隔音地板材料，其特征在于，上述复合层包括涂层、表面层、印刷层、中纸层、玻璃纤维层及下纸层。
7.根据权利要求1所述的隔音地板材料，其特征在于，以100重量份的上述第一组合物为基准，上述第二组合物为45重量份～55重量份。
8.根据权利要求1所述的隔音地板材料，其特征在于，上述1-甲氧基-2-丙醇与上述丁酮的重量比为1：1.5～1：3.5。
9.根据权利要求1所述的隔音地板材料，其特征在于，上述异丙醇和上述甲基乙基酮的重量比为1：2.5～1：3.5。
10.根据权利要求1所述的隔音地板材料，其特征在于，上述异丙醇和上述乙酸乙酯及甲基乙基酮的重量比为1：5.5～1：6.5。
11.根据权利要求1所述的隔音地板材料，其特征在于，上述固化剂包括50重量百分比～60重量百分比的乙酸乙酯。
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