JP2000170361A - Melamine sheet-laminated decorative floor covering material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative floor covering material and its manufacturing method and especially to provide a melamine sheet-laminated decorative PVC floor covering material having the excellent surface physical properties and also to provide its manufacturing method. SOLUTION: A decorative floor covering material is composed of a base layer 100 and a balance layer 140 which is laid between melamine resin-impregnated papers 150 or under the base layer 100, and the balance layer 140 comprises of a material selected out of a sheet, a web or a nonwoven fabric. In the decorative floor covering material which is made up by joining an accumulated body formed by placing the balance layer 140 between the resin-impregnated layer and the PVC resin base layer under the resin-impregnated layer or under the PVC base layer and by applying pressing under heating and pressure, fibers in the balance layer 140 penetrate into the resin-impregnated layer and the PVC resin layer at the upside and underside, improving the adhesive strength between the resin-impregnated layer and the PVC resin layer, and since the fibers between the balance layer 140 and the balance layer 140 intensify the strength of entire matrix, curling before or after execution of work or bending occurring during transportation can be decreased.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative floor covering material and a method for producing the same, and more particularly, to a melamine sheet laminated polyvinyl chloride decorative floor covering in which a melamine sheet having excellent surface properties is laminated on a polyvinyl chloride sheet. It relates to a material and its manufacturing method.

[0002]

2. Description of the Related Art In general, polished stone or polyvinyl chloride tiles or the like as shown in FIG. 1 have been generally used as floor coverings for commercial buildings. The use of stone flooring such as marble and granite has become commonplace in major commercial buildings, including shopping districts.

[0003] However, while these stone products are excellent in durability, there has been a demand for the development of alternatives that take into account the practical aspects of being expensive and dependent on imports.

In consideration of these aspects, two or more known colored polyvinyl chloride sheet layers giving a marble feeling as shown in FIG. 2 are crushed into various irregular shapes and pressed or continuously crushed. A PVC tile product was developed that re-formed with a press to form a new, more natural, two-tone marble pattern.However, during the production of PVC tiles, it was attributed to the excess filler used. Due to the resulting hue and texture, there has been a limit to products that attempt to replace natural marble.

In order to solve the above problems, a floor covering material for decorative vinyl chloride resin in which a printing layer as shown in FIG. 3 is laminated on a polyvinyl chloride sheet layer has been developed.

FIG. 3 is a cross-sectional view of a conventional general floor covering material for vinyl chloride resin decoration.
There is also a base layer 1 for balancing, a printed layer 2 on the base layer 1 that provides a decorative effect with a beautiful pattern, the printed layer 2
Layer 3, which protects the pattern of the surface, surface coating layer 4, which gives stain resistance and scratch resistance to the product, and base layer 1
This shows a decorative floor covering material in which an integrated bundle, in which a balance layer 5 for similarly balancing is sequentially laminated underneath, is pressed and joined. At this time, if the decorative floor covering can be balanced by the base material layer 1 itself, the balance layer 5 can be omitted.

The process for producing such a conventional decorative floor covering comprises the following steps: rolling a soft or hard vinyl chloride resin compound with a calender.
Manufacturing the base layer 1 having a thickness of 3 mm; manufacturing the printing layer 2 and the transparent layer laminated on the base layer 1 and the balance layer 5 laminated below the base layer 1; 0.08 produced by calendering a soft or hard vinyl chloride resin compound containing 10 to 20% by weight of titanium oxide
Printing a natural stone pattern or a wood pattern using a gravure or transfer printing method on a polyvinyl chloride resin sheet having a thickness of about 0.15 mm, and then drying the printed layer 2; soft or hard vinyl chloride Produce a transparent layer 3 as a transparent vinyl chloride resin film of 0.10 to 0.95 mm thickness by calendering of resin compound; 0.32-0.000 by calendering of soft or hard vinyl chloride resin compound. The balance layer 5 having a thickness of 95 mm is manufactured; the printed layer 2 and the transparent layer 3 manufactured as described above.
Is placed on the base material layer 1 and the balance layer 5 is placed under the base material layer 1, and then the printing layer 2, the transparent layer 3 and the balance layer 5 to be heated and pressed by a press are laminated on the base material layer 1. Then, a surface coating agent containing a urethane acrylate resin as a main component is coated on the transparent layer 3 to a thickness of 5 to 60 μm and then cured with ultraviolet light, or a surface containing a urethane resin or an acrylic resin as a main component. After coating the coating agent on the transparent layer 3, it is cured by heat or ultraviolet rays to form the surface coating layer 4.
Produce decorative floor coverings of ~ 5.0 mm thickness.

Conventional decorative floor coverings manufactured by the above-mentioned method have been used for a long time because of their low cost and convenient construction. However, the uppermost layer of the surface coating layer is resistant to stain and stain. There is a problem that shoes are worn on decorative floor covering material that lacks scratching property, and there is a problem that it is easily stained when traffic is frequent and the surface is easily scratched. In shopping streets and the like, the amount of use has decreased.

In order to solve the above-mentioned problems, a decorative floor covering material having a melamine resin impregnated layer having high hardness surface properties as the uppermost layer has been recently introduced.
It was shown to. The prior art as described above is as follows.

FIG. 4 shows European Patent Application Publication 05.
61 086 A1 decorative laminate (decorative lamina)
FIG. 2 is a cross-sectional view of a te board, which is a decorative laminate in which a phenol resin adhesive layer 12 is sequentially laminated on a vinyl chloride resin layer 11.

FIG. 5 shows Japanese Patent Publication No. 9-12336.
6 is a cross-sectional view of the laminate of No. 6, showing a hot melt film 32 on rubber or thermoplastic resin 31;
This is a laminated body in which the pattern paper 33 and the melamine resin impregnated Ovalley 34 are laminated.

As described above, the decorative floor coverings using the conventional melamine resin impregnated layers shown in FIGS. 4 and 5 are all paper sheets in which melamine resin impregnated Ovalley 14 and melamine resin are impregnated in paper as the uppermost layer. Melamine resin impregnated layers, such as transparent protective layer 25 and melamine resin impregnated ovalley 34, have been used to solve the problem that scratches and contamination often occur on the surface of the decorative floor covering material, but both have poor adhesion. The following problems are involved in the adhesive layer used for bonding the resin impregnated layer and the vinyl chloride resin layer and other portions.

In the decorative laminate shown in FIG. 4, the phenolic resin of the phenolic resin adhesive layer 12 has poor compatibility with the vinyl chloride resin of the vinyl chloride resin layer 11, which is the lower layer, so that the adhesiveness is not good. There is no hard sheet to supplement the melamine resin, which has the property of being fragile due to the impact of the product, and the center part of the decorative laminate is recessed when lifting the edge of the decorative laminate There is a point.

In the laminate shown in FIG. 5, the hot melt film 32 used as an adhesive layer between the rubber or the thermoplastic resin 31 and the pattern paper 33 has increased crystallinity at the bonding temperature, and the hot melt film 32 itself There is a problem in the size stability such as shrinkage of the size, and there is a problem in that it is difficult to maintain the balance of the laminate due to changes in temperature and humidity.

Also, the conventional decorative floor covering shown in FIGS. 1-5 has a high degree of curling and bending problems. In particular, temperatures below −10 ° C. and 40 ° C.
Such bending (curling or bending) phenomenon often occurs at a temperature of not less than ° C. The reason is that macroscopically, it is affected by the four seasons, and microscopically, the matrix itself is vulnerable to thermal change due to the different shrinkage / expansion ratios to the temperature and humidity of the various layers formed. . To complement this, it is necessary to supplement the matrix configuration.

[0016]

SUMMARY OF THE INVENTION In view of the above-mentioned problems of the prior art, the present invention uses a resin-impregnated layer impregnated with a melamine resin or the like as a surface layer to provide a scratch-resistant decorative floor covering material. The present invention aims to provide a vinyl chloride resin decorative floor covering material having a hard surface property, which has significantly improved resistance and stain resistance, and a method for producing the same. Another object is to provide a resin impregnated layer and a vinyl chloride resin thereunder. An object of the present invention is to provide a decorative floor covering material in which a stack produced by placing a balance layer between the layers is pressed under heating and pressure. By this solution, the fibers in the balance layer enter both the resin impregnated layer and the vinyl chloride resin layer, which are the upper and lower layers of the balance layer, and improve the low adhesive strength between the resin impregnated layer and the vinyl chloride resin layer,
The balance layer and the fibers in the balance layer reinforce the overall matrix, reducing curling before and after construction and bending during handling.

[0017]

SUMMARY OF THE INVENTION The present invention provides a vinyl chloride resin decorative floor covering having a melamine resin impregnated paper layer 150 laminated and adhered on a vinyl chloride resin base layer 100. There is a vinyl chloride resin decorative floor covering material between the base layer 100 and the melamine resin impregnated paper layer 150 or the balance layer 14 laminated under the base layer 100.
0, and the material of the balance layer 140 is selected from the group consisting of a sheet, a woven fabric, or a non-woven fabric.

The balance layer 140 and the base layer 100
The floor covering for decorative vinyl chloride resin bonded by the adhesive layer 130 sandwiched between them can also be manufactured.

The present invention also provides a step of rolling the vinyl chloride resin compound with a calender to produce a base material layer 100;
A step of fabricating the backing layer 110, which is made by weaving the glass fiber like a woven fabric or pressing the glass fiber, impregnating the paper with melamine resin, drying in an oven and semi-curing at the same time as the resin-impregnated paper. Manufacturing the layer 150;
And a base material layer 1 on the glass fiber base material backing layer 110.
After successively laminating the resin-impregnated paper layers 150, a pressure of 10 to 80 kg / cm ^{2 and} a temperature of 120 to 180 ° C.
And pressing at a temperature of 10 to 40 minutes and heating. Also, between the base layer 100 and the resin-impregnated paper layer 150, natural fiber, polyester, glass fiber, glass fiber scrim, a mixture of glass fiber and polyester fiber, and a mixture of natural fiber and glass fiber. mixture,
Woven fibers, non-woven fibers or waddings made using one selected from the group consisting of pulp or paper
ng) A method for producing a vinyl chloride resin decorative floor covering material, characterized by adhering a sheet type balance layer 140.

The present invention also relates to a base material layer 100,
Under the lining layer 110 and the adhesive layer 13 on the base material layer 100.
0, a balance layer 140 and a resin-impregnated paper layer 150, the method for producing a vinyl chloride resin decorative floor covering material comprising: a) 80 to 300 g of an adhesive on the base material layer 100;
m ² or by laminating an adhesive film to form an adhesive layer 13
B) a high-pressure laminate (h) consisting of a resin-impregnated paper layer, ie, a balance layer 140, a core layer 151, a pattern layer 152, and a transparent protective layer 153 in order from the bottom on the adhesive layer of the step a).
igh pressure laminate: HPL)
Press plate temperature 130-160 ° C, pressure 10-30kg / cm
^2. Pressing for 10 to 20 minutes to produce a laminate in which the HPL sheet and the base material layer 100 are bonded;
And c) pressing the stack obtained by laminating the backing layer 110 under the laminate of the step b) at room temperature under a pressure of 10 to 30 kg / cm ² for 15 to 30 minutes. Also provided is a method of making the coating.

In the present invention, the balance layer 14 is formed from bottom to top.
0, a method for producing a vinyl chloride resin decorative floor covering material having an adhesive layer 130, a base layer 100, an adhesive layer 130, and a resin-impregnated paper layer 150: a) 80 to 300 g of an adhesive on the base layer 100; / M
² ) forming an adhesive layer 130 by applying ² ; b) a core layer 153 from below on the adhesive layer of step a);
After laminating a high-pressure laminate (HPL) sheet of a resin-impregnated paper layer composed of a pattern layer 152 and a transparent protective layer 153, a press plate temperature of 130 to 160 ° C and a pressure of 10 to 30 kg / c.
m ² , pressing for 10 to 20 minutes to produce a laminate in which the HPL sheet and the base material layer 100 are bonded; c) an adhesive 80 to 30 under the laminate of step b)
0 g / m ² to form another adhesive layer 130; and d) the balance layer 14 under the adhesive layer 130 in step c).
0 to form a decorative floor covering by compressing at normal temperature at a pressure of 3 to 8 kg / cm ² for 4 to 24 hours, or i) comprising a balance layer 140, a base material layer 100, and a sheet from below. Stacking each of the already manufactured layers in the order of the adhesive layer 130, the core layer 151, the pattern layer 152, and the transparent protective layer 153; and ii) pressing the stacked layers by hot pressing at a flat plate temperature of 13;
Production of a vinyl chloride resin decorative floor covering material including a step of producing a decorative floor covering material by pressing at 0 to 160 ° C. under a pressure of 10 to 30 kg / cm ² for 10 to 20 minutes, heating and then cooling to room temperature. A method is also provided.

The material of the adhesive layer is preferably a combination polymer or a sheet or film produced by a casting method, a calendering method, or a T-die method. The combination polymer is selected from the group consisting of neoprene resin, nitrile rubber, acrylic resin, polyester, urethane, rubber, vinyl, or epoxy (epoxy), casting method, calendaring method,
Or, the sheet or film manufactured by the T-die method is an amide resin, ethylene vinyl acetate resin, modified ethylene vinyl acetate resin, acrylic resin, modified acrylic resin, modified phenol resin, urethane resin, modified urethane resin, or epoxy resin. Selected from the group consisting of:

In particular, the material of the balance layer 140 is preferably a woven fabric, nonwoven fabric or wadding sheet of natural fibers, and the material of the woven fabric and nonwoven fabric is glass fiber, carbon fiber, PET (polyethylene terephthalate), polypropylene. , Polyester or nylon.

The resin-impregnated paper layer 150 can be composed of: a) a transparent protective layer 153; b) a pattern layer 152; and c) a core layer 151. 152; and b) a structure composed of a core layer 151, and further from the top, a) a transparent protective layer 153; and b).
Other structures consisting of the pattern layer 152 are also possible.

Further, as another structure of the floor covering material for decorative vinyl chloride resin, a) a melamine resin-impregnated paper layer 150 comprising a transparent protective layer 153; b) a balance layer 140;
A structure consisting of c) a printing layer 120; d) a base layer 100; and e) a backing layer 110 is also possible.

As another structure of the vinyl chloride resin decorative floor covering material, a) a resin-impregnated paper layer 15 comprising a transparent protective layer 153, a pattern layer 152 and a core layer 151 in order from the top.
0; b) balance layer 140; c) adhesive layer 130; d) substrate layer 100; and e) backing layer 110.

As another structure of the vinyl chloride resin decorative floor covering material, a) a resin-impregnated paper layer 15 comprising a transparent protective layer 153, a pattern layer 152, and a core layer 151 in order from the top.
0; b) balance layer 140; c) core layer 151; d) adhesive layer 130; e) substrate layer 100; and f) backing layer 110.
A structure consisting of

As another structure of the vinyl chloride resin decorative floor covering material, a) a melamine resin-impregnated paper layer 150 comprising a transparent protective layer 153, a pattern layer 152 and a core layer 151; 130; c) substrate layer 150;
A structure including d) adhesive layer 130; and e) balance layer 140 is also possible.

The transparent protective layer 153 is formed on a cellulose paper of 25 to 61 g / m ² in which abrasion-resistant silica or alumina is uniformly dispersed in a thickness of 200 to 8 g based on the weight of Ovalley paper.
After impregnating with 00% by weight of melamine resin, 130-1
Preference is given to resin-impregnated cellulose paper produced by drying at an oven temperature of 50 ° C. and simultaneously semi-curing.

The pattern layer 152 is formed on a gravure-printed 80-120 g / m ² titanium oxide-containing cellulose paper pattern paper by not more than 100% by weight of melamine resin, polyester resin, and phthalic acid based on the weight of the pattern paper. A resin-impregnated patterned paper manufactured by impregnating with a resin selected from the group consisting of diallyl resin or phenolic tree, and then drying at an oven temperature of 130 to 150 ° C. and semi-curing at the same time is preferred.

The core layer 151 is a phenolic resin-impregnated kraft paper manufactured by impregnating kraft paper of 198 g / m ² or less with a phenol resin in an amount of 20 to 100% by weight based on the weight of the kraft paper. a glass fiber paper impregnated with a phenolic resin or a glass fiber paper coated with a vinyl chloride resin or an acrylic resin, prepared by applying 20 to 100% by weight of a phenol resin to m ² glass fiber paper based on the weight of the glass fiber paper; A phenolic resin-impregnated glass fiber mat prepared by applying a phenolic resin to a glass fiber mat of 160 g / m ² in an amount of 20 to 60% by weight based on the weight of the glass fiber, or a glass coated with a vinyl chloride resin or an acrylic resin. Preferably, it is selected from the group consisting of fibers.

The base layer 100 of the vinyl chloride resin decorative floor covering material has a Shore hardness of 50 to 100 and a polymerization degree of 700 to 1500, 15 to 25% by weight of a vinyl chloride resin, and dioctyl phthalate as a plasticizer. After mixing 4 to 6% by weight, 65 to 80% by weight of calcium carbonate as a filler, and 1 to 4% by weight of a barium-zinc composition as an additive with a blender or a mixing mixer, a vinyl chloride resin compound kneaded with a Banbury mixer. Can be rolled at 120 to 170 ° C. with a calender to produce a hard vinyl chloride resin sheet having a thickness of 1.6 to 4.6 mm.

The lining layer 110 of the decorative floor covering is made of paper, woven fabric, or a non-woven fabric impregnated or coated with a phenolic resin, a melamine resin, or an acrylic resin. ), A flexible polyvinyl chloride resin sheet.

The material of the base layer 100 having a Shore hardness of 50 to 100 is selected from the group consisting of vinyl chloride resin, polyurethane, natural or synthetic rubber, polyolefin resin, polyester resin or elastomer (elastomer).

[0035]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.
A more complete evaluation of the present invention and the effects obtained therefrom will be readily apparent from an understanding of the present invention when considered in conjunction with the detailed description of the specification and the accompanying drawings.

The present invention relates to an integrated bundle (bundle) manufactured by interposing a balance layer between a resin-impregnated paper layer and a vinyl chloride resin layer thereunder or by overlaying a balance layer under a vinyl chloride resin layer.
dle) is pressed with a high press and heated and bonded to provide a floor covering material for vinyl chloride resin decoration, in which the fibers in the balance layer are formed above and below the balance layer with the resin-impregnated layer, which is the lower layer. By penetrating into the vinyl resin layer, the low adhesion between the resin-impregnated layer and the vinyl chloride resin layer is improved, and the balance layer and the fibers in the balance layer reinforce the entire matrix, curling phenomena before and after construction and handling during handling. It is intended to reduce the bending phenomenon and to provide a method for producing the same.

This balance layer has a role of preventing curling that appears after construction and suppressing the occurrence of bending that appears during transportation, in addition to the role of balancing the thickness, which has been conventionally performed, to keep the thickness constant. Improves adhesive strength with vinyl chloride resin base material layer.

The pattern layer provides a pattern which gives the decorative floor covering a decorative beauty.

The core layer provides thickness, impact resistance, and allows for adhesive bonding of the core layer up and down.
Also, it plays a role of facilitating the production of the HPL (high pressure laminate) of the resin impregnation layer and the balance layer.

The decorative floor covering according to the present invention, shown in FIGS. 6 to 9, is made of the glass fiber substrate backing layer 110 of FIGS.
A resin-impregnated paper layer 150 including the base layer 100, the balance layer 140, and the pattern layer 152, and the glass fiber base layer 110, the base layer 100, the print layer 120, the balance layer 140, and the pattern layer of FIG. Resin-impregnated paper layer 15 containing no
0. The former is a case where the pattern layer 152 of the resin-impregnated paper layer 150 is used as a layer for providing a decorative effect, and the latter is a case where the printed layer 12 is used as a layer for providing a decorative effect.
0 is used.

The details are as follows. FIG.
The decorative floor covering materials in Nos. 8 to 8 include the base layer 100, the balance layer 140 on the base layer, and the pattern layer 15 on the balance layer.
2, a resin-impregnated paper layer 150 containing, in order from the bottom, a core layer 151, a pattern layer 152, and a transparent protective layer 153, or a core layer 151 and a pattern layer 152,
Alternatively, the resin-impregnated paper layer 150 including the pattern layer 152 and the pattern layer 152 and the transparent protective layer 153 is formed.

FIG. 6 shows the base layer 100, the balance layer 140 on the base layer 100, and the resin-impregnated paper layer 15 on the balance layer.
0 is a cross-sectional view of a decorative floor covering comprising a glass fiber base material lining layer 110 and the resin-impregnated paper layer comprising a core layer 151, a pattern layer 152 and a transparent protective layer 153 in order from the bottom.

A production example of such a decorative floor covering material will be described below. First, the base material layer 100 which gives thickness to a product and balances it is manufactured.

The base material layer 100 is manufactured by rolling a vinyl chloride resin compound by a calender to form a sheet having a thickness of 1.6 to 4.6 mm. The appropriate temperature of the calendar is 120 ~
170 ° C.

At this time, 100% by weight of the vinyl chloride resin having a degree of polymerization of 700 to 1500, 20 to 40% by weight of dioctyl phthalate as a plasticizer, 2 to 5% by weight of a barium-zinc compound as a stabilizer, It is manufactured by mixing 200 to 700% by weight of calcium carbonate as a filler with a blender and a mixing mixer, and kneading with a Banbury mixer.

Next, a backing layer 110 of a glass fiber base material for reinforcing the base material layer 100. The backing layer 110 of the glass fiber base material is made by weaving glass fibers like a woven fabric, or is a sheet obtained by pressing glass fibers, and preferably has a weight per unit area of 20 to 100 g / m ^2. .

Next, the base layer 100 and the resin-impregnated paper layer 150
The balance layer 140 to be overlapped between is manufactured.

The balance layer 140 is a kind of fiber in the group of natural fiber, polyester fiber, glass fiber, glass scrim, mixture of glass fiber and polyester fiber, and mixture of natural fiber and glass fiber. To produce a woven, non-woven or wadding sheet. The balance layer 140 preferably has a weight per unit area of 10 to 300 g / m ² . At this time, pulp, paper or the like may be used in addition to the fibers.

Next, a resin-impregnated paper layer 150 for imparting stain resistance and scratch resistance to the product is manufactured. The resin-impregnated paper layer 150 is provided with a thickness in order from the bottom, and a core layer 151 for adjusting the balance, a pattern layer 152 for providing a decorative effect with a beautiful pattern, and a transparent protective layer 1 for protecting the pattern layer 152.
53, each layer is manufactured individually and then sequentially laminated.

The core layer 151 is formed by impregnating kraft paper having a weight per unit area of 100 to 200 g / m ² with a phenolic resin at 40 to 180% by weight based on the weight of the kraft paper, and then 30 to 150 ° C. At the oven temperature of 1 to 3 minutes and semi-cured at the same time.

At this time, the phenol resin is phenol 30
~ 46% by weight, formaldehyde 46 ~ 30% by weight,
It is a mixture of 4 to 6% by weight of ethyl alcohol as a solvent, 2 to 5% by weight of water, 15 to 5% by weight of an amine-based basic catalyst as a modifier, and 3 to 8% by weight of orthocresol.

The pattern layer 152 is formed by impregnating a melamine resin in a pattern paper having a weight per unit area of 80 to 120 g / m ² with 60 to 150% by weight based on the weight of the pattern paper.
It is dried at an oven temperature of 0 to 150 ° C. for 1 to 5 minutes and at the same time is semi-cured.

At this time, the melamine resin is melamine 30-4.
5% by weight, formaldehyde 40 to 20% by weight 18 to 27% by weight of water as a solvent, 1 to 5% by weight of diethylene glycol or acetoguanamine as a modifier, 1% by weight of sodium hydroxide for adjusting pH, and an amine as a curing agent Is mixed with 10 to 2% by weight of the basic catalyst.

The pattern paper is obtained by printing a predetermined pattern on white paper made by adding titanium oxide to natural fibers by a method such as gravure printing.

The transparent protective layer 153 is made of melamine resin on a unit surface.
Weight per product is 20-50g / m ^TwoOvalley
Paper contains 200-400% of the weight of Ovalley paper
Soak it in an oven temperature of 100-150 ° C
Dry for 5 minutes and semi-cur at the same time.

At this time, the melamine resin is applied to the pattern layer 152.
Melamine 30-45% by weight, formaldehyde 40-20% by weight, water 18-
27% by weight, 1 to 5% by weight of diethylene glycol or acetoguanamine as a modifier, 1% by weight of sodium hydroxide for adjusting pH, and 10 to 2% by weight of an amine-based basic catalyst as a curing agent. .

Ovalley paper is a highly purified cellulose paper.

As described above, after each layer constituting the decorative floor covering material is individually manufactured, the glass fiber base material backing layer 110 is formed.
Substrate layer 100, balance layer 140, and core layer 1
After sequentially laminating the resin-impregnated paper layer 150 including the pattern layer 51, the pattern layer 152, and the transparent protective layer 153,
The plurality of layers are simultaneously pressed under heating and pressing conditions at a pressure of 0 to 80 kg / cm ² and a temperature of 120 to 180 ° C. to produce a decorative floor covering according to the present invention.

By pressing and heating with a press as described above, the glass fiber base material backing layer 110 enters the base material layer 100, reinforces the base material layer 100, and the fibers of the balance layer 140 The resin-impregnated paper layer 150 and the base material layer 100 penetrate into the resin-impregnated paper layer 150 as the upper and lower layers and the base material layer 100 as the vinyl chloride resin layer.
And the semi-cured core layer 151 and the pattern layer 15
2 and the transparent protective layer 153 are completely cured, and in particular, in a semi-cured state, the transparent protective layer 153 which is milky white like a writing paper becomes transparent by press-compression.

FIG. 7 shows a base layer 100, a balance layer 140 on the base layer 100, and a resin-impregnated paper layer 150 on the balance layer 140. It is sectional drawing of the decorative floor covering material which consists of a pattern layer 152.

The method for producing such a vinyl chloride resin decorative floor covering material is very similar to the case of FIG. 6 except that the resin-impregnated paper layer 150 comprises a core layer 151 and a pattern layer 152.

That is, the base material layer 100, the glass fiber base material lining layer 110, the balance layer 140, the core layer 151, and the resin-impregnated paper layer 150 including the pattern layer 152, which are constituents of the decorative floor covering material, are individually manufactured. After that, the base material layer 100, the balance layer 140, the resin-impregnated paper layer 150 including the core layer 151 and the pattern layer are sequentially laminated on the glass fiber base material lining layer 110, and then 10 to 80 kg / cm ² , 120-180 ° C
Is pressed simultaneously for 10 to 40 minutes under the conditions described above to produce a decorative floor covering according to the present invention.

FIG. 8 includes a base layer 100, a balance layer 140 on the base layer 100, a resin-impregnated paper layer on the balance layer 140, and a glass fiber base lining layer 110 below the base layer 100. The resin-impregnated paper layer 150 has the pattern layer 152 sequentially from the bottom.
It is sectional drawing of the decorative floor material which consists of a transparent protective layer 153.

The method for producing such a decorative floor covering material is as follows.
The resin-impregnated paper layer 150 is composed of the pattern layer 152 and the transparent protective layer 153.
This is very similar to the case of FIG.

That is, the base material layer 100, the glass fiber base material lining layer 110, the balance layer 140, and the resin-impregnated paper layer 150 including the pattern layer 152 and the transparent protective layer 153, which are constituents of the decorative floor covering material, are individually formed. After the production, the substrate layer 100 and the balance layer 140 are placed on the glass fiber substrate backing layer 110.
After sequentially laminating a resin-impregnated paper layer 150 composed of a pattern layer 152 and a transparent protective layer 153, 10 to 80 kg / cm ² ,
The plurality of layers are simultaneously pressed at 120 to 180 ° C. for 10 to 40 minutes to produce the decorative floor covering according to the present invention.

In FIG. 9, the decorative floor covering material includes a base layer 100, a printed layer 120, a balance layer 140, and a resin-impregnated paper layer 150 that does not include a pattern layer. In addition, the resin-impregnated paper layer 150 includes a transparent protective layer 153.

The method for producing such a decorative floor covering material is as follows.
The base material layer 100 and the glass fiber base material lining layer 1
10, including the production of the resin-impregnated paper layer 150 of the balance layer 140 and the transparent protective layer 153.

Further, the printing paper 120 for producing a beautiful pattern decoration effect is manufactured. The printing paper 120 is manufactured by printing a predetermined pattern on a vinyl chloride resin sheet by a method such as gravure printing or transfer printing, and then printing.

The vinyl chloride resin sheet is obtained by rolling a vinyl chloride resin compound with a calender to obtain a sheet of 0.07 to 0.2.
Manufactured into sheets with a thickness of 0 mm. A suitable temperature for the calender is 150-190 ° C.

At this time, the vinyl chloride resin compound is 100% by weight of a vinyl chloride resin having a degree of polymerization of 700 to 3000, 10 to 30% by weight of dioctyl phthalate as a plasticizer, 2 to 5% by weight of a barium-zinc compound as a stabilizer, a pigment After mixing 10 to 30% by weight of titanium oxide having a good hiding power and 0 to 50% by weight of calcium carbonate as a filler in a blender or a mixing mixer, the mixture was kneaded with a Banbury mixer.

As described above, after the components of the decorative floor covering material are individually manufactured, the base material layer 100, the printed layer 120, the balance layer 140, and the transparent protective layer 153 are formed on the glass fiber base material backing layer 110. And then simultaneously pressing the layers under conditions of 10 to 80 kg / cm ² and 120 to 180 ° C. for 10 to 40 minutes to produce a decorative floor covering according to the present invention. .

By pressing and heating with a press, the glass fibers of the glass fiber substrate backing layer 110 enter the substrate layer 100 and reinforce the substrate layer 100, and the fibers of the balance layer 140 A resin-impregnated paper layer 150 as upper and lower layers and a printing layer 120 as a vinyl chloride resin layer
At the same time, the resin impregnated paper layer 150 and the printed layer 12
0 and the semi-cured transparent protective layer 153 becomes transparent by pressing.

The base layer 100 and the resin-impregnated paper layer 150 or the printed layer 12 of the decorative floor covering material shown in FIGS.
0 and the base layer 100 so as to assist the balance layer 140 serving as an adhesive between the resin-impregnated paper layer 150.
An adhesive layer may be formed between the printing layer 120 and the balance layer 140, or between the printing layer 120 and the balance layer 140, as shown in FIGS.

The adhesive layer 130 is made of an amide resin, ethylene vinyl acetate resin, modified ethylene acetate resin,
Acrylic resin, modified acrylic resin, modified phenol resin, urethane resin, one selected from the group consisting of modified urethane resin, using a calender method or T-die method to a thickness of 0.02 to 0.2 mm To be made into sheets.

FIG. 10 shows the base material layer 1 of the decorative floor covering material shown in FIG.
It is sectional drawing of the decorative floor covering material which formed the adhesive layer 130 between 00 and the balance layer 140.

FIG. 11 shows the base material layer 1 of the decorative floor covering material shown in FIG.
It is sectional drawing of the decorative floor covering material which formed the adhesive layer 130 between 00 and the balance layer 140.

FIG. 12 shows the base material layer 1 of the decorative floor covering material shown in FIG.
It is sectional drawing of the decorative floor covering material which formed the adhesive layer 130 between 00 and the balance layer 140.

FIG. 13 shows the base material layer 1 of the decorative floor covering material shown in FIG.
It is sectional drawing of the decorative floor covering material which formed the adhesive layer 130 between 00 and the balance layer 140.

Another method of manufacturing a decorative floor covering according to the present invention shown in FIG. 10 is to apply an adhesive of 80 to 300 g / m ² on the base material layer 100 or to have a thickness of 0 to 300 g / m ^2. The adhesive layer 16 is formed by laminating a film having a thickness of 0.05 to 0.2 mm.
After forming a transparent protective layer consisting of a balance layer, a core layer, a pattern layer, and a resin-impregnated paper layer of high-pressure lamenate (HPL) on top of each other, pressing at high temperature and high pressure, the HPL and the substrate This is a method of manufacturing a laminate in which the layer 100 is adhered, laminating a backing layer under the laminate, and pressing at room temperature under a pressure of 10 to 30 kg / cm ² for 15 to 30 minutes.

The conditions for laminating the HPL and the substrate layer are preferably as follows: press plate temperature 130 to 160 ° C., pressure 1
0 to 30 kg / cm ² , compression time of 10 to 20 minutes, cooling to room temperature after pressing.

FIG. 14 is a cross-sectional view showing one example of the decorative floor covering material of the present invention, in which a modified phenol resin or the like is impregnated upward on a vinyl chloride resin base material layer 100. An adhesive layer 130 made of a paper sheet
Core layer 1 made of paper sheet impregnated with phenolic resin
51, a pattern layer 152 made of a printing paper sheet impregnated with a melamine resin, and a transparent protective layer 153 made of a paper sheet impregnated with a melamine resin are sequentially laminated, and directed downward below the vinyl chloride resin base material layer 100. Decoration made by laminating a balance layer 140 composed of a paper sheet impregnated with a melamine resin, a phenol resin, a modified phenol resin or an acrylic resin, a glass fiber or a nonwoven fiber impregnated with a vinyl chloride resin, or a soft vinyl chloride sheet. Floor covering material.

The thickness of the decorative floor covering according to the invention of FIGS. 6 to 14 is preferably between 2.0 and 5.0 mm.

The present invention has been described in detail with reference to preferred embodiments. However, these techniques may be variously modified based on the embodiments without departing from the technical spirit and scope of the present invention described in the claims. Can be modified or substituted.

[0084]

Example 1 (Production of base material layer 100) 100 parts by weight of vinyl chloride resin,
A mixture consisting of 36 parts by weight of dioctyl phthalate, 3 parts by weight of a barium-zinc compound and 500 parts by weight of calcium carbonate was added to a mixing mixer, mixed, and then added to a Banbury mixer and kneaded. The mixture was rolled with a calendar having a temperature of 130 to 160 ° C. The base material layer 100 having a thickness of 2.6 mm
Was manufactured.

(Production of Backing Layer 110) The backing layer 1 made of a glass fiber mat having a weight of 30 g / m ² by pressing glass fibers
10 were produced.

(Production of Balance Layer 140) The natural fibers were wadded to produce a 30 g / m ² sheet balance layer 140.

(Production of Pattern Layer 152) A liquid obtained by mixing a mixture of 37 parts by weight of melamine, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethylene glycol, and 3.7 parts by weight of an amine-based basic catalyst. After the melamine resin is impregnated with 80 g / m ² of printed pattern paper at 100% by weight based on the weight of the pattern paper, the temperature is 120 to 14%.
While drying in an oven at 0 ° C for 2-3 minutes,
A semi-cured pattern layer 152 made of a melamine resin-impregnated paper sheet was produced.

(Production of Transparent Protective Layer 153) Melamine 37
38 g / m ² of liquid melamine resin obtained by mixing a mixture of 3 parts by weight of formaldehyde, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethyl glycol, and 3.7 parts by weight of an amine-based basic catalyst. Is impregnated with 250% of the weight of Ovalley paper,
The transparent protective layer 153 made of a melamine-impregnated paper sheet was manufactured by drying in an oven at 140 ° C. for 2 to 3 minutes and semi-curing at the same time.

(Vinyl chloride resin decorative floor covering material (FIG. 8)
Production) Backing layer 110, base layer 100, balance layer 14
0 and a resin-impregnated paper layer 150 composed of a pattern layer 152 and a transparent protective layer 153 are sequentially laminated, and then pressed using a press.
At a pressure of 0 kg / cm ² and a press temperature of 130-140 ° C.
By pressing and heating all layers simultaneously for 0 to 30 minutes, the vinyl chloride resin decorative floor covering of FIG. 8 was produced.

Example 2 (Production of base material layer 100) 100 parts by weight of vinyl chloride resin
A mixture consisting of 36 parts by weight of dioctyl phthalate, 3 parts by weight of a barium-zinc compound and 500 parts by weight of calcium carbonate is added to a mixing mixer and mixed, and then the mixture is added to a Banbury mixer and kneaded, and the mixture is calendered at a temperature of 130 to 160 ° C. Was rolled to produce a substrate layer 100 having a thickness of 2.6 mm.

(Production of Backing Layer 110) The glass fiber was pressed to obtain a backing layer 110 of a glass fiber mat of 30 g / m ^2.
Was manufactured.

(Production of Printed Layer 120)
100 parts by weight of a vinyl chloride resin, 20 parts by weight of dioctyl phthalate, 3 parts by weight of a barium-zinc compound, 20 parts by weight of titanium oxide and 10 parts by weight of calcium carbonate are added to a mixing mixer and mixed, and the mixture is mixed in a Banbury mixer. The mixture was added and kneaded, and the mixture was rolled with a calender having a temperature of 170 to 180 ° C. to produce a vinyl chloride resin sheet having a thickness of 0.10 mm. After drying, a pattern was printed on the vinyl chloride resin sheet by a gravure printing method to produce a printed layer 120 of a melamine resin-impregnated paper sheet.

(Manufacture of Balance Layer 140) Natural fibers are wadded to form a balance layer 14 of 30 g / m ² sheet.
0 was produced.

(Production of Transparent Protective Layer 153) Melamine 37
A liquid melamine resin obtained by mixing a mixture of 3 parts by weight of formaldehyde, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethylene glycol, and 3.7 parts by weight of an amine-based basic catalyst on 38 g / m ² of Ovalley paper, Impregnated with 250% by weight of the weight of the Ovalley paper,
The transparent protective layer 153 of the melamine resin-impregnated paper sheet was manufactured by drying in an oven at a temperature of about 140 ° C. for about 2 to 3 minutes and at the same time semi-curing.

(Vinyl chloride resin decorative floor covering material (FIG. 9)
Manufacture of) backing layer 110, base layer 100, printing layer 120,
After sequentially laminating the resin-impregnated paper layer 150 composed of the balance layer 140 and the transparent protective layer 153, the resin
20 kg / cm ² pressure and 130-140 ° C pressing temperature
Pressing and heating all layers simultaneously for ３０30 minutes produced the vinyl chloride resin decorative floor covering of FIG.

Example 3 (Production of base material layer 100) 100 parts by weight of vinyl chloride resin,
A mixture consisting of 36 parts by weight of dioctyl phthalate, 3 parts by weight of a barium-zinc compound and 500 parts by weight of calcium carbonate was added to a mixing mixer and mixed, and then the mixture was added to a Banbury mixer and kneaded, followed by rolling with a calender having a temperature of 130 to 160 ° C. The base material layer 100 having a thickness of 2.6 mm
Was manufactured.

(Production of Backing Layer 110) Glass fiber was pressed to produce a backing layer 110 of a glass fiber mat of 30 g / m ² .

(Production of adhesive layer 130) The adhesive layer 13 of a sheet having a thickness of 0.07 mm was prepared by using an amide resin with a calendar.
0 was produced.

(Production of the balance layer 140) The natural layer was wadded, and the balance layer 14 of a 30 g / m ² sheet was prepared.
0 was produced.

(Production of core layer 151) 43 parts by weight of phenol, 33 parts by weight of formaldehyde, 5 parts by weight of ethyl alcohol, 3 parts by weight of water, 3.7 parts by weight of an amine-based basic catalyst and 6 parts by weight of orthocresol The mixture is mixed to form a liquid phenolic resin, and kraft paper of 80 g / m ² is impregnated with 60% by weight based on the weight of the kraft paper, and then is heated in an oven having a temperature of 100 to 120 ° C. for 2 to 3 minutes. The core layer 151 of the phenol formaldehyde resin impregnated paper sheet was manufactured by drying and semi-curing at the same time.

(Production of Pattern Layer 152) A mixture of 37 parts by weight of melamine, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethylene glycol and 3.7 parts by weight of an amine-based basic catalyst is obtained. 80 g / m ² of printed pattern paper is impregnated with 100% by weight of the liquid melamine resin based on the weight of the pattern paper, and the temperature is 120 to 140 ° C.
Was dried in an oven for 2 to 3 minutes and semi-cured at the same time to produce a pattern layer 152 of a melamine resin-impregnated sheet.

(Production of Transparent Protective Layer 153) Melamine 37
A liquid melamine resin obtained by mixing a mixture of 3 parts by weight of formaldehyde, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethylene glycol and 3.7 parts by weight of an amine-based basic catalyst was mixed with 38 g / m ² of Ovalley paper. Is impregnated with 250% by weight of the weight of Ovalley paper,
After drying in an oven at 20 to 140 ° C. for 2 to 3 minutes and semi-curing, a transparent protective layer 153 of a melamine resin-impregnated paper sheet was produced.

(Vinyl chloride resin decorative floor covering material (FIG. 1)
0) Production) Backing layer 110, base layer 100, adhesive layer 13
0, balance layer 140, core layer 151, pattern layer 15
2. Resin-impregnated paper sheet 150 comprising a transparent protective layer 153
After lamination, a pressure of 40 kg / cm ² and 1
By simultaneously pressing and heating all layers at a pressing temperature of 30 to 140 ° C. for 20 to 30 minutes, the floor covering material for decorative vinyl chloride resin of FIG. 10 was produced.

Example 4 (Production of base layer 100) 25 to 15 parts by weight of vinyl chloride resin, 6 to 4 parts by weight of dioctyl phthalate plasticizer, 4 to 1 part by weight of barium-zinc stabilizer compound, and 65 to 80 parts by weight of calcium carbonate After mixing the mixture consisting of parts into a mixing mixer and mixing, the mixture is added to a Banbury mixer and kneaded,
The mixture was rolled using a calender having a temperature of 130 to 160 ° C. to produce a base layer 100 having a thickness of 2 to 4 mm.

(Production of Backing Layer 110) Vinyl Chloride Resin 5
0-60 parts by weight, dioctyl phthalate plasticizer 15-1
0 parts by weight, a mixture consisting of 5 to 10 parts by weight of a barium-zinc stabilizer compound and 30 to 20 parts by weight of calcium carbonate is added to a mixing mixer and mixed, and then the mixture is added to a Banbury mixer and kneaded. The mixture was rolled using a calender to produce a backing layer 110 having a thickness of 0.05 to 0.5 mm.

(Production of Balance Layer 140) 50 g / m ²
The balance layer 140 made of polypropylene nonwoven fabric was manufactured.

(Production of core layer 151) 43 parts by weight of phenol, 33 parts by weight of formaldehyde, 5 parts by weight of ethyl alcohol, 3 parts by weight of water, 3.7 basic amine catalyst
A 80 g / m ² kraft paper is impregnated with a liquid phenol resin obtained by mixing a mixture of 6 parts by weight of ortho-cresol and 60 parts by weight of kraft paper at a weight of 100 to 120 ° C. Was dried in an oven for 2 to 3 minutes and simultaneously semi-cured to produce a core layer 151 of a phenol formaldehyde resin-impregnated paper sheet.

(Production of pattern layer 152) A mixture of 37 parts by weight of melamine, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethylene glycol and 3.7 parts by weight of an amine-based basic catalyst was obtained. A liquid melamine resin is impregnated into 80 g / m ² of printed pattern paper at 100% by weight based on the weight of the pattern paper, and is dried in an oven at a temperature of 120 to 140 ° C. for 2 to 3 minutes while being semi-cured. Then, the pattern layer 152 of the melamine resin impregnated paper sheet was manufactured.

(Production of Transparent Protective Layer 153) Melamine 37
A liquid melamine resin obtained by mixing a mixture of 3 parts by weight of formaldehyde, 33 parts by weight of formaldehyde, 25 parts by weight of water, 1 part by weight of diethyl glycol and 3.7 parts by weight of an amine-based basic catalyst was used to obtain a 38 g / m ² Ovale liquid melamine resin. The paper is impregnated with 250% by weight based on the weight of the Ovalley paper,
The transparent protective layer 153 of the melamine resin impregnated paper sheet was manufactured by drying in an oven at 140 ° C. for 2 to 3 minutes and semi-curing at the same time.

(Production of High Pressure Laminate) Balance Layer 14
0, the core layer 151, the pattern layer 152, and the transparent protective layer 153
After laminating the resin-impregnated paper sheet 150 made of, a pressure of 55 to 100 kg / cm ² and 130 to 1 kg by an open press.
The layers were simultaneously pressed at a pressing temperature of 50 ° C. for 20-30 minutes and heated to produce a high pressure laminate (HPL).

(Production of Adhesive Layer 130) The adhesive layer 130 was produced by applying a urethane adhesive having a solid content of 40% by weight to the base layer 100 by using a coating roll at 60 to 150 g / m ² .

[0112] (Vinyl chloride resin decorative floor covering (Fig. 1
0) Production) After laminating a high-pressure laminate including the backing layer 110, the base material layer 100, and the balance layer 140, the core layer 151, the pattern layer 152, and the transparent protective layer 153, 10 to 30 kg / cm ² using a press. Pressure and 80-120 ℃
Pressing all the layers simultaneously for 15 to 30 minutes at a pressing temperature of 30 ° C. and heating, a 3.0 mm thick FIG.
Of vinyl chloride resin decorative floor covering material.

Example 5 (Production of base material layer 100) A base material layer 100 was produced in the same manner as in Example 4.

(Production of Backing Layer 110) A backing layer 110 was produced in the same manner as in Example 4.

(Production of Balance Layer 140) A balance layer 140 was produced in the same manner as in Example 4.

(Production of core layer 151) Phenol 43% by weight, formaldehyde 33% by weight, ethyl alcohol 5% by weight, water 3% by weight, amine-based basic catalyst 3.7
% By weight and a mixture of 6% by weight of ortho-cresol was impregnated with 40 to 160 g / m ² of glass fiber paper with 40 to 60% by weight based on the weight of the glass fiber paper. The glass fiber paper sheet impregnated with phenol formaldehyde resin was produced by drying in an oven at a temperature of 100 to 120 ° C. for 2 to 3 minutes and semi-curing at the same time. The core layer 151 was formed by stacking two glass fiber paper sheets impregnated with a phenol resin.

(Production of Pattern Layer 152) The pattern layer 152 was produced in the same manner as in Example 4.

(Production of Transparent Protective Layer 153) A transparent protective layer 153 was produced in the same manner as in Example 4.

(Production of High Pressure Laminate) Balance Layer 14
0, and after laminating the resin-impregnated paper layer 150 including the two core layers 151, the pattern layer 152, and the transparent protective layer 153,
55-100 kg / cm ^{2 by} open press for all layers simultaneously
At a pressure of 130-150 ° C. for 20-30 minutes and heated to produce a high pressure laminate.

(Production of Adhesive Layer 130) An adhesive layer 130 of a polyamide film having a thickness of 0.10 mm was produced.

(Vinyl chloride resin decorative floor covering material (FIG. 1)
0) Production) Backing layer 110, base layer 100, adhesive layer 13
0, a high-pressure laminate comprising the balance layer 140, the two core layers 151, the pattern layer 152, and the transparent protective layer 153, and then using a press at a pressure of 10 to 20 kg / cm ² and a press of 100 to 140 ° C. 2. simultaneously pressing and heating all layers for 15-30 minutes at temperature;
The 0 mm thick vinyl chloride resin decorative floor covering of FIG. 10 was produced.

Example 6 (Production of base material layer 100) A base material layer 100 was produced in the same manner as in Example 4.

(Production of Backing Layer 110) A backing layer 110 was produced in the same manner as in Example 4.

(Balance Layer 140) A balance layer 140 was manufactured in the same manner as in Example 4.

(Production of core layer 151) In the same manner as in Example 5, a glass fiber paper sheet impregnated with a phenol formaldehyde resin was produced. The core layer 151 was manufactured by laminating two glass fiber paper sheets impregnated with a phenol formaldehyde resin.

(Production of Pattern Layer 152) The pattern layer 152 was produced in the same manner as in Example 4.

(Production of transparent protective layer 153) A transparent protective layer 153 was produced in the same manner as in Example 4.

(Production of High Pressure Laminate) Balance Layer 14
0, and after laminating the two core layers 151, the pattern layer 152, the two core layers 151, and the resin-impregnated paper layer 150 including the transparent protective layer 153, 55 to 100 by open press.
20 kg / cm ² pressure and 130-150 ° C pressing temperature
All layers were simultaneously pressed and heated for ~ 30 minutes to produce a high pressure laminate.

(Production of Adhesive Layer 130) The adhesive layer 130 made of an epoxy film having a thickness of 0.10 mm was produced.

(Vinyl chloride resin decorative floor covering material (FIG. 1)
0) Production) Backing layer 110, base layer 100, adhesive layer 13
0, balance layer 140, core layer 151, pattern layer 15
2 and a high-pressure laminate composed of a transparent protective layer 153, and then, using a press, a pressure of 10 to 20 kg / cm ² and 1
By simultaneously pressing and heating all layers at a pressing temperature of 00-140 ° C. for 15-30 minutes, 3.0 mm
The vinyl chloride resin decorative floor covering of FIG. 10 having a thickness of FIG. 10 was produced.

Example 7 (Production of base material layer 100) The same base material layer 100 as in Example 4 was produced.

(Production of Backing Layer 110) The same backing layer 110 as in Example 4 was produced.

(Production of Balance Layer 140) The same balance layer 140 as in Example 4 was produced.

(Production of Core Layer 1) A core layer 1 made of the same material as in Example 4 was produced.

(Production of Core Layer 2) A core layer 2 of the same material as that of Example 5 was produced.

(Production of Pattern Layer 152) The same pattern layer 152 as in Example 4 was produced.

(Production of Transparent Protective Layer 153) The same transparent protective layer 153 as in Example 4 was produced.

(Production of decorative floor laminate) Backing layer 11
0, a base layer 100, a core layer 2, a balance layer 140,
After sequentially laminating the core layer 1, the pattern layer 152, and the transparent protective layer 153, the plurality of layers are simultaneously pressed using a press at a pressure of 10 to 30 kg / cm ² and a temperature of 130 to 150 ° C. for 15 to 30 minutes. And heating to 3.0
A decorative floor covering of mm thickness was produced.

Example 8 400 × 400 × 3 mm of the decorative floor covering of Example 4
Of the size of the thermostat (thermostat)
For 24 hours to measure the degree of curling. The relative humidity is fixed at 60 ± 5%, and -10, 23, 30, 40,
At a temperature of 60 ° C., the degree of curling according to the measured temperature is shown in Table 1, and at a relative humidity of 20, 40, 60, 80, and 95%, the degree of curling according to the measured humidity is shown in Table 2.

The degree of curling is shown in accordance with the following equation 1.

[Formula 1] Curling (%) = height of bow-shaped overhang / sample length × 10
0

The height of the bow-shaped overhang is a height measured from the surface to the inflection point when the sample sheet after being treated for 24 hours is placed on a flat surface in a thermostat and the sample sheet is bent. In the case where the resin-impregnated paper layer of the sample was bent to show protrusion, the value was indicated by a positive value, and in the case of showing the opposite dent, the value was indicated by a negative value.

[0143]

[Table 1]

[0144]

[Table 2]

As can be seen from the above results, the decorative floor covering material in which the balance layer was interposed between the resin impregnated layer and the underlying vinyl chloride resin base layer was resistant to changes in temperature and humidity. There is.

Example 9 (Production of base material layer 100) The same base material layer as in Example 4 was produced.

(Balance Layer 140) The same balance layer as in Example 4 was manufactured.

(Production of Core Layer 151) The same core layer as in Example 4 was produced.

(Production of Pattern Layer 152) The same pattern layer 152 as in Example 4 was produced.

(Production of Transparent Protective Layer 153) The same transparent protective layer 153 as in Example 4 was produced.

(Production of High Pressure Laminate)
Each of the manufactured layers was sequentially laminated with a transparent protective layer 153, a pattern layer 152, and a core layer 151 of a resin-impregnated paper layer 150 from the top and then pressed. HPL (high pressure lamination)
Was manufactured by pressing and heating this bundle at a pressure of 55 to 100 kg / cm ² and a temperature of 130 to 150 ° C. for a pressing time of 20 to 30 minutes.

(Production of Adhesive Layer 130) An adhesive layer was produced by applying a urethane adhesive having a solid content of 40% on the above-mentioned base layer 100 by using a coating roll at 60 to 150 g / m ² .

(Adhesion) After the resin-impregnated paper layer 150 and the base material 100 coated with the coating layer 130 are sequentially laminated, a pressure of 10 to 30 kg / cm ^{2 and} a pressure of 80 to
The resin-impregnated paper layer 150 and the applied base material layer 100 were bonded by pressing and heating at a temperature of 120 ° C. for a pressing time of 15 to 30 minutes.

(Production of Adhesive Layer 130) A urethane adhesive having a solid content of 40% was mixed with the resin-impregnated paper layer 150 and the base material layer 10.
0 to 60 to 150 using a coating roll under the base material layer 100 which is adhered through the adhesive layer 130 between the base material layer 100 and the base material layer 100.
g / m ^{2 was} applied to produce another adhesive layer 130.

(Production of decorative floor covering material (FIG. 14)) After laminating the balance layer 140 under the base material layer,
Pressing was performed under a pressure of 30 kg / cm ² for a pressurizing time of 4 to 24 hours to produce the decorative floor covering material of FIG.

[Brief description of the drawings]

FIG. 1 is a side sectional view of a conventional decorative floor covering.

FIG. 2 is a side sectional view of a conventional decorative floor covering.

FIG. 3 is a side sectional view of a conventional decorative floor covering.

FIG. 4 is a side sectional view of a conventional decorative floor covering.

FIG. 5 is a side sectional view of a conventional decorative floor covering.

FIG. 6 is a side sectional view of the decorative floor covering of the present invention.

FIG. 7 is a side sectional view of the decorative floor covering of the present invention.

FIG. 8 is a side sectional view of the decorative floor covering of the present invention.

FIG. 9 is a side sectional view of the decorative floor covering of the present invention.

FIG. 10 is a side sectional view of the decorative floor covering of the present invention.

FIG. 11 is a side sectional view of the decorative floor covering of the present invention.

FIG. 12 is a side sectional view of the decorative floor covering of the present invention.

FIG. 13 is a side sectional view of the decorative floor covering of the present invention.

FIG. 14 is a side sectional view of the decorative floor covering of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material layer 2 Printing layer 3 Transparent layer 4 Surface coating layer 5 Balance layer 11 Vinyl chloride resin layer 12 Phenolic resin adhesive layer 13 Melamine resin impregnated paper layer 14 Melamine resin impregnated overlay 31 Rubber or thermoplastic resin 32 Hot melt film 33 Pattern Paper 34 Ovalley 100 Base layer 110 Backing layer 120 Printing layer 130 Adhesive layer 140 Balance layer 150 Resin impregnated paper layer 151 Core layer 152 Pattern layer 153 Transparent protective layer

[Cross Reference for Related Applications] This application is based on application Nos. 98-53570 and 99-12854 filed with the Korean Patent Office on December 8, 1998 and April 12, 1999, respectively. , The contents of which are incorporated herein by reference.

Continuing on the front page (72) Inventor Kim Yong-ki 46-2, 1026, Kuriyang-dong, Sangtang-gu, Cheongju-si, Chungcheongbuk-do, Republic of Korea term (reference) 4F100 AA19B AA20B AA21B AD11C AG00B AG00C AG00D AJ01C AJ01G AJ05B AK02G AK07C AK15A AK15B AK15D AK25B AK25D AK25G AK27G AK28G AK33B AK33D AK33G AK36B AK36D AK36G AK41B AK41C AK41G AK42B AK42C AK46C AK46G AK51G AK53G AK68G AL06G AN00G AN02G AT00A AT00C BA03 BA04 BA10A BA10B CB00 DG01C DG01D DG01G DG10B DG10D DG10G DG12B DG12C DG12D DG15C DG15D DH02B DH02D EA041 EA061 EC041 EC182 EH032 EH171 EH46D EJ08B EJ081 EJ171 EJ181 EJ192 EJ371 EJ422 EJ82B EJ82D EJ82G EJ821 EJ861 EK04 GB08 GB81 HB00 HB00B HB35 HB35B JK09B JK12A JK14 JN01B YY00A

Claims (39)

[Claims] 1. A substrate layer of a vinyl chloride resin.
yer) a floor covering for decorative vinyl chloride resin, which is adhered by pressing a bundle in which a melamine resin-impregnated paper layer 150 is superimposed on 100, selected from the group consisting of sheet, woven cloth or non-woven cloth The balance layer 140 of the material to be formed includes the balance layer 140 formed by pressing and pressing the accumulated bundle stacked between the base layer 100 and the melamine resin-impregnated paper layer 150 or under the base layer 100. Floor covering material for vinyl chloride resin decoration. 2. The floor covering for decorative vinyl chloride resin,
A lining material 110 stacked on the lowermost layer, the material of which is a paper sheet or woven fabric impregnated with a phenolic resin, a melamine resin, or an acrylic resin, or a glass fiber nonwoven fabric impregnated or coated with a vinyl chloride resin. The vinyl chloride resin decorative floor covering according to claim 1, comprising a backing layer (110) selected from the group. 3. The vinyl chloride resin decorative floor covering according to claim 1, wherein an integrated bundle obtained by interposing an adhesive layer 130 between the balance layer 140 and the base material layer 100 is pressed and bonded. Wood. 4. The material of the adhesive layer is a combination polymer or a cast method, a calendar method (calendere).
d) or a sheet or film by the T-die method, wherein the combination polymer is neoprene (neopr).
ene) resin, nitrile rubber (nitrile rubber), acrylic resin, polyester, urethane, rubber, vinyl or epoxy (epoxy), the sheet or film is an amide resin, ethylene vinyl acetate resin, modified ethylene vinyl acetate The vinyl chloride resin decorative floor covering material according to claim 3, which is selected from the group consisting of a resin, an acrylic resin, a modified acrylic resin, a modified phenol resin, a urethane resin, a modified urethane resin or an epoxy resin. 5. A resin produced by impregnating paper with a resin selected from the group consisting of a wadding sheet using natural fibers and a melamine resin, a phenol resin, and an acrylic resin. 2. A resin-impregnated paper sheet.
4. A floor covering material for decorative vinyl chloride resin according to the above. 6. The woven fabric comprises natural fibers,
A woven woven fabric made of fibers selected from the group consisting of glass fiber, carbon fiber, PET (polyethylene terephthalate), polypropylene, polyester or nylon;
The floor covering material for vinyl chloride resin decoration according to claim 1, which is a woven fiber (PVC resin impregnated woven fiber) produced by impregnating a woven fiber with a vinyl chloride resin. . 7. The non-woven fabric according to claim 1, wherein the non-woven fabric is a natural fiber,
Weaved non-woven made of fibers selected from the group consisting of carbon fiber, PET (polyethylene terephthalate), polypropylene, polyester and nylon
fabric), or a woven nonwoven fabric impregnated with vinyl chloride resin,
The vinyl chloride resin decorative floor covering material according to claim 1, which is an impregnated non-woven fabric). 8. The vinyl chloride resin decoration according to claim 1, wherein the melamine resin-impregnated paper layer 150 comprises, in order from the top, a) a transparent protective layer 153; b) a pattern layer 152; and c) a core layer 151. Floor coverings. 9. The vinyl chloride resin decorative floor covering material according to claim 1, wherein the melamine resin-impregnated paper layer 150 comprises, in order from the top, a) a pattern layer 152; and b) a core layer 151. 10. The vinyl chloride resin decorative floor covering material according to claim 1, wherein the melamine resin-impregnated paper layer 150 comprises, in order from the top, a) a transparent protective layer 153; and b) a pattern layer 152. 11. A melamine resin-impregnated paper layer 1 comprising a transparent protective layer 153 in order from the top.
2. A vinyl chloride resin decorative floor covering according to claim 1, comprising: b) a balance layer 140; c) a print layer 120; d) a base layer 100; and e) the backing layer 110. . 12. In order from the top, a) a transparent protective layer 153, a pattern layer 152, and a core layer 151.
The vinyl chloride resin decorative floor covering according to claim 1, comprising: a melamine resin-impregnated paper layer comprising: b) a balance layer 140; c) an adhesive layer 130; d) a base layer 100; and e) a backing layer 110. Wood. 13. In order from the top, a) a transparent protective layer 153, a pattern layer 152, and a core layer 151.
The melamine resin impregnated paper layer 150 comprising: b) a balance layer 140; c) a core layer 151; d) an adhesive layer 130; e) a base layer 100; and f) a backing layer 110. Floor covering material for vinyl chloride resin decoration. 14. From the top, a) a transparent protective layer 153, a pattern layer 152, and a core layer 151
The vinyl chloride resin decorative floor according to claim 1, comprising: a melamine resin-impregnated paper layer 150 comprising: b) an adhesive layer 130; c) a base layer 100; d) an adhesive layer 130; and e) a balance layer 140. Coating material. 15. The transparent protective layer 153 is formed of 25 to 61 g / m 2 in which abrasion-resistant silica or alumina is uniformly dispersed.
² cellulosic paper, 20% by weight of ovalley paper
9. A resin-impregnated cellulose paper manufactured by impregnation and semi-curing of 0 to 800% by weight of a melamine resin.
Or a vinyl chloride resin decorative floor covering material according to any one of 10 to 14. 16. The pattern layer 152 is gravure-printed, and is coated on 80-120 g / m ² cellulose paper containing titanium oxide in a melamine resin or polyester in an amount of 100% by weight or less based on the weight of the pattern paper. 15. A resin-impregnated patterned paper produced by impregnation and semi-curing of a resin selected from the group consisting of resin, diallyl phthalate resin and phenol resin. Floor covering for resin decoration. 17. The phenolic resin-impregnated kraft paper produced by impregnating kraft paper of 198 g / m ² or less with a phenolic resin in an amount of 20 to 100% by weight based on the weight of the kraft paper, A phenolic resin impregnated glass fiber paper manufactured by applying a phenol resin to a glass fiber paper of 160 g / m ² at 20 to 100% by weight based on the weight of the glass fiber paper, or a vinyl chloride resin or an acrylic resin was applied. Resin coated glass fiber paper, 40-16
A phenolic resin-impregnated glass fiber mat prepared by applying a phenol resin to a glass fiber mat of 0 g / m ² in an amount of 20 to 60% by weight based on the weight of the glass fiber, or a resin coated with a vinyl chloride resin or an acrylic resin 9. The method of claim 8, wherein the glass fiber is selected from the group consisting of coated glass fibers.
15. The floor covering material for decorative vinyl chloride resin according to any one of 1, 13, and 14. 18. The shore hardness (sho) of the base material layer 100
The floor covering material for vinyl chloride resin decoration according to claim 1, wherein the resin has a hardness of from 50 to 100. 19. A step of manufacturing a substrate layer 100 by rolling a polyvinyl chloride resin compound with a calender; a step of weaving glass fibers like a woven fabric or a step of pressing glass fibers to manufacture a backing layer 110; Is impregnated into paper and then dried in an oven and semi-cured to produce a resin-impregnated paper layer 150; and a substrate layer 100 and a resin-impregnated paper layer 1 on the glass fiber substrate backing layer 110.
After successively stacking 50, 10 to 80 kg /
A method for producing a vinyl chloride resin decorative floor covering, comprising pressing and heating at a pressure of cm ² and a temperature of 120 to 180 ° C. for 10 to 40 minutes. 20. The resin-impregnated paper layer 150 is arranged in this order from the top: a) a transparent protective layer 1 which is impregnated with a liquid melamine resin in an oval paper, dried in an oven and semi-cured at the same time.
53) b) impregnating the pattern paper with the liquid melamine resin and drying in an oven and simultaneously semi-curing the pattern layer 152; and c) impregnating the kraft paper with the liquid phenol resin and drying in the oven and Cured core layer 151
The method for producing a vinyl chloride resin decorative floor covering material according to claim 19, comprising: 21. The resin-impregnated paper layer 150 comprises, in order from the top: a) a pattern layer 152 which is impregnated with a liquid melamine resin on a pattern paper, dried in an oven and simultaneously semi-cured; and b) a liquid phenol resin. Is impregnated with kraft paper and dried in an oven, and at the same time, a semi-cured core layer 151.
The method for producing a vinyl chloride resin decorative floor covering material according to claim 19, comprising: 22. The resin-impregnated paper layer 150 is, in order from the top, a) a transparent protective layer 15 which is impregnated with a liquid melamine resin in an oval paper, dried in an oven, and simultaneously semi-cured.
20. The method for producing a floor covering material for decorative vinyl chloride resin according to claim 19, further comprising: 3) and b) a pattern layer 152 impregnated with liquid melamine resin on the pattern paper, dried in an oven, and semi-cured at the same time. 23. The resin-impregnated paper layer 150 includes a transparent protective layer 153 impregnated with a liquid melamine resin in an Ovalley paper, dried in an oven, and semi-cured at the same time, and a balance layer 140 has a print layer thereunder. Including the printing layer 120
Is obtained by rolling a vinyl chloride resin compound with a calender to produce a vinyl chloride resin sheet, and performing gravure printing or transfer printing on the sheet, followed by drying.
4. The method for producing a vinyl chloride resin decorative floor covering material according to item 1. 24. The method of claim 19, wherein the balance layer 140 is of a woven fabric, a nonwoven fabric, or a wadding sheet type based on natural fibers. Method. 25. An adhesive layer 130 placed under the balance layer 140 is made of an amide resin, ethylene vinyl acetate resin, modified ethylene acetate resin, acrylic resin, modified acrylic resin, modified phenol resin, urethane resin,
The production of a floor covering according to any one of claims 18 to 23, wherein the resin selected from the group consisting of the modified urethane resin is produced in a sheet shape by a calendering method or a T-die method. Method. 26. The method according to claim 25, wherein the balance layer 140 is a woven fabric, a nonwoven fabric or a wadding sheet type made of natural fibers. 27. A base layer 100, a backing layer 110 below the base layer 100, an adhesive layer 130 on the base layer, and a balance layer 1
A method for producing a vinyl chloride resin decorative floor covering material, comprising: 40) and a resin-impregnated paper layer 150, comprising: a) 80 to 300 g of an adhesive on the base material layer 100;
step to produce the adhesive layer 130 overlapping the adhesive film or m ² is applied; b) a resin impregnated paper layer on the adhesive layer of the a) step, i.e. the balance layer 140 in this order from the bottom, the core layer 151, the pattern layer 152 -Pressure laminate consisting of a transparent protective layer 153
(HPL: high pressure laminate) After laminating sheets, press plate temperature 130 ~ 160 ℃, pressure 10 ~ 30kg
Pressing at 10 / cm ² for 10 to 20 minutes to produce a laminate in which the HPL sheet and the substrate layer are adhered; and c) an integration obtained by laminating the backing layer 110 under the laminate of the step b). A method for producing a vinyl chloride resin decorative floor covering material, comprising a step of pressing the bundle at room temperature at a pressure of 10 to 30 kg / cm ² for 15 to 30 minutes. 28. The balance layer, the core layer, the pattern layer, and the transparent protective layer on which the HPL sheet of the step b) is manufactured, respectively, are sequentially stacked from the bottom, and the pressing plate temperature is 130-1.
50 ° C., pressure 55 to 100 kg / cm ² , pressurization time 15 to 3
The method for producing a floor decoration material for vinyl chloride resin decoration according to claim 27, which is produced by pressing in 0 minutes. 29. The vinyl chloride resin decorative floor according to claim 27, wherein the material of the balance layer 140 is selected from the group consisting of a sheet, a woven fabric, a nonwoven fabric, and a melamine resin or a phenol resin impregnated paper. Manufacturing method of coating material. 30. The floor covering according to claim 29, wherein the material of the woven fabric is selected from the group consisting of glass fiber, carbon fiber, PET (polyethylene terephthalate), polypropylene, polyester or nylon. Manufacturing method. 31. The vinyl chloride resin decorative floor covering material according to claim 29, wherein the material of the nonwoven fabric is selected from the group consisting of glass fiber, carbon fiber, PET (polyethylene terephthalate), polypropylene, polyester or nylon. Production method. 32. The transparent protective layer 153 is formed on a 25-61 g / m ² cellulose paper in which abrasion-resistant silica or alumina is dispersed.
After impregnating with 0% by weight of melamine resin, 130 to 15
The method for producing a vinyl chloride resin decorative floor covering according to claim 27, which is a resin-impregnated cellulose paper produced by drying in an oven at 0 ° C and semi-curing at the same time. 33. A melamine resin, wherein the pattern layer 152 contains titanium oxide and is gravure-printed on a 80-120 g / m ² cellulose paper pattern paper and has a melamine resin content of 100% by weight or less based on the weight of the pattern paper. A resin-impregnated patterned paper manufactured by impregnating a resin selected from the group consisting of polyester resin, diallyl phthalate resin and phenol resin, followed by drying in an oven at 130 to 150 ° C and semi-curing at the same time. Item 28. The method for producing a vinyl chloride resin decorative floor covering material according to Item 27. 34. The core layer 151 has a thickness of 198 g / m ^2.
The phenolic resin in the following kraft paper, phenolic resin-impregnated kraft paper were prepared by impregnating 20 to 100% by weight relative to the weight of the kraft paper, 40 to 60 g / m ² glass fiber paper phenolic resin glass fiber Phenol resin impregnated glass fiber paper or glass fiber paper coated with vinyl chloride resin or acrylic resin manufactured by applying 20 to 100% by weight based on the weight of paper, glass fiber mat of 40 to 160 g / m ² 28) is selected from the group consisting of phenolic resin-impregnated glass fiber mats or glass fibers coated with vinyl chloride resin or acrylic resin, which are produced by applying 20 to 60% by weight of a phenolic resin to the weight of the glass fiber. 4. The method for producing a vinyl chloride resin decorative floor covering material according to item 1. 35. The adhesive of claim 27, wherein the adhesive in step a) is one or more combination polymers selected from the group consisting of neoprene resin, nitrile rubber, acrylic resin, polyester, urethane, rubber, vinyl, epoxy. Of producing a floor covering for decorative vinyl chloride resin. 36. The adhesive film of step a) is selected from the group consisting of amide, ethylene vinyl acetate resin, modified ethylene vinyl acetate resin, modified acrylic resin, modified phenol resin, urethane resin, modified urethane resin, and epoxy resin. 28. The method for producing a vinyl chloride resin decorative floor covering material according to claim 27, which is a sheet or film produced by processing the material by a casting method, a calendar method, or a T-die method. 37. A floor covering for vinyl chloride resin decoration comprising a base layer 100, an adhesive layer 130 and a balance layer 140 under the base layer 100, and an adhesive layer 130 and a resin-impregnated paper layer 150 on the base layer 100. A method for producing a material, comprising: a) an adhesive of 80 to 300 g / m on the base material layer 100;
²⁾ to form an adhesive layer 130; b) the core layer 15 in order from the bottom on the adhesive layer in the step a).
3. After laminating a high-pressure laminate sheet of a resin-impregnated paper layer consisting of a pattern layer 152 and a transparent protective layer 153, press at a press plate temperature of 130 to 160 ° C. and a pressure of 10 to 30 kg / cm ² for 10 seconds.
Pressing for ~ 20 minutes to produce a laminate in which the HPL sheet and the substrate layer 100 are adhered; c) adhesive 80-30 under the laminate of step b)
0 g / m ² to form another adhesive layer 130; and d) the balance layer 14 under the adhesive layer 130 in step c).
A method for producing a decorative floor covering material for vinyl chloride resin, comprising a step of producing a decorative floor covering material by superimposing 0 and pressing at room temperature under a pressure of 3 to 8 kg / cm ² for 4 to 24 hours. 38) a) From below, the balance layer 140 and the base material layer 1
00, adhesive layer sheet 130, core layer 151, pattern layer 15
2) stacking each of the already manufactured layers in the order of 2 and the transparent protective layer 153; and b) pressing the stacked layers with a hot press at a press plate temperature of 13;
Pressing at 0 to 160 ° C. under a pressure of 10 to 30 kg / cm ² for 10 to 20 minutes, heating, and then cooling to room temperature to produce a decorative floor covering. Production method. 39. A vinyl chloride resin decorative floor covering comprising a base layer 100, a backing layer 110 under the base layer 100, and a resin-impregnated paper layer 150 on the base layer 100, wherein: a) 50 A base layer 100 of a material selected from the group consisting of vinyl chloride resin, polyurethane, natural or synthetic rubber, polyolefin resin, polyester resin or elastomer;
And b) a balance layer 140 is placed between the base layer 100 and the resin-impregnated paper layer 150 to balance the material selected from the group consisting of sheet, woven fabric, nonwoven fabric, or melamine resin or phenol resin impregnated paper. A floor covering for decorative vinyl chloride resin comprising a layer 140.