JP2014529021A - Vinyl flooring for non-slip flooring and its manufacturing method - Google Patents

Abstract

In the floor material in which the PVC surface layer, the PVC base layer and the backing layer are formed in this order from above, the PVC surface layer is formed with irregularities in a thickness of 70 to 160 μm, and is made of glass paper, glass woven fabric and glass nonwoven fabric. A vinyl flooring further comprising a dimension reinforcing layer formed from one or more selected from the above. According to the present invention, it is possible to effectively prevent slipping by considering not only factors such as the coefficient of friction and roughness but also the angle of the ramp, and it is possible to effectively prevent slippage. A vinyl flooring with improved dimensional stability can be provided.

Description

  The present invention relates to a vinyl flooring for a non-slip flooring and a method for producing the same, and more specifically, the PVC surface layer, which is the uppermost layer of the vinyl flooring, is formed with unevenness with a specific thickness or more to prevent slipping. The present invention relates to a vinyl flooring that is effectively prevented and yet has dimensional stability.

  Normal vinyl flooring is obtained by printing a surface layer on top of the base material layer and forming a transparent vinyl chloride layer on it to prevent the printed pattern from being damaged during use of the flooring, The floor material obtained in this way has a problem that the vinyl transparent layer is directly exposed to the external environment and is easily soiled and slippery, and most floor materials have a separate layer above the vinyl transparent layer. A surface treatment layer has been formed.

  The surface treatment layer for non-slip flooring of ordinary vinyl flooring is formed by embossing or sprinkling inorganic particles, but in this case, the improvement in the coefficient of friction and surface roughness is poor. In addition, when applied to ramps etc., the tilt angle is also poor, so when there is water or oil, it is difficult to endure without slipping on it, and there is a limit as seen from the side of the anti-slip flooring ing.

  As a related conventional technique, for example, there is a flooring described in Patent Document 1 below. The floor material described in the same document is provided with a surface treatment layer containing beads and mica, and is intended to reinforce the anti-slip floor material as well as wear resistance and scratch resistance. By using spherical hollow beads with a very low specific gravity, it is difficult to disperse in liquid urethane (meth) acrylate resin, and the amount added to add beads to a level that gives sufficient anti-slip flooring properties In addition to being limited in view of this aspect, dimensional stability was not considered at all.

Korean Patent Publication No. 1607-0080897

  Then, when the present inventors repeated earnest research, when unevenness is formed more than a specific thickness in a PVC surface layer, and further using a specific reinforcing material for a dimension reinforcing layer, the dimensional stability is improved. Vinyl floor that exhibits improved anti-slip flooring performance even on ramps contaminated with water, sand, oil, etc., and can provide dimensional stability despite environmental changes such as temperature and humidity The present inventors have found that a material can be provided and have completed the present invention.

  That is, as described above, the object of the present invention is to form slippage on the PVC surface layer, which is the uppermost layer of the flooring material to be constructed on the floor surface for residential buildings and commercial districts, with a specific thickness or more. It is an object of the present invention to provide a vinyl flooring which can be effectively prevented and which can improve the dimensional stability in spite of environmental changes, and a method for producing the same.

  The vinyl flooring according to the present invention for achieving the above-described object is a flooring in which a PVC surface layer, a PVC base layer, and a backing layer are formed in this order from the top. It is characterized by being formed to a thickness of 160 μm.

  Moreover, the vinyl flooring according to the present invention is a flooring in which a PVC surface layer, a dimension reinforcing layer, a PVC base layer, and a backing layer are formed in this order from the top. The PVC surface layer has an unevenness of 70 to 160 μm. The dimension reinforcing layer is formed of at least one selected from glass paper, glass woven fabric, and glass nonwoven fabric.

  Hereinafter, the vinyl flooring according to the present invention will be described in detail with reference to the accompanying drawings.

  A technical feature of the present invention is to provide a vinyl flooring having an excellent anti-slip flooring property by providing a surface layer having irregularities formed to have a specific thickness or more.

  First, the vinyl flooring used in the present invention may be a long flooring having a multilayer structure in which a plurality of PVC layers are laminated. As an example of such a vinyl flooring, as shown in FIG. 1A, a PVC surface layer, a PVC base layer, and a backing layer are formed in this order from the top.

  Although unevenness is formed on the PVC surface layer, the thickness is preferably 70 to 160 μm. This is disadvantageous because if the thickness of the unevenness is less than 70 μm, contaminants (for example, margarine and gear oil) are not caught between the unevenness, and if the thickness of the unevenness exceeds 160 μm, the contact area is narrowed. This is because the non-slip flooring property under poor and humid conditions or greasy conditions becomes poor.

  Although the said unevenness | corrugation is not limited to these, It is more efficient to form by the following three types of methods. First, there is a method of forming an unevenness of 70 to 160 μm on the upper surface of the surface layer by embossing. In this case, the cross-sectional shape of the surface layer is as shown in FIG. Second, the surface layer has a surface layer of inorganic waste or inorganic crushed material, or inorganic coated PVC waste to form 70-160 μm irregularities. In this case, the cross-sectional shape of the surface layer is as shown in FIG. As shown in (b). Third, the embossing process and the formation of grains or debris are simultaneously performed on the surface of the surface layer to form irregularities of 70 to 160 μm. In this case, the cross-sectional shape of the surface layer is as shown in FIG. It is.

  Among these, when used for an anti-slip flooring on an inclined road, it is more preferable to use the second or third method.

As the inorganic substance, one or more selected from quartz, SiO ₂ , A ₂ O ₃ and glass beads are crushed so as to have a # 2 to 100 mesh and a particle size of about 1.50 to 0.08 mm. It can be colored by coating with PVC, or the PVC compound can be crushed and processed into a scrap after using a calendaring or casting process to make the surface shape of the particles porous or rough. This is preferable because it is advantageous for a non-slip flooring.

  That is, the inorganic material is uneven by arranging waste / inorganic material on the PVC surface layer, setting the inorganic material while gelling the waste, or performing embossing on the surface as necessary. Can produce a surface layer with a thickness greater than or equal to a certain thickness.

  The backing layer is for preventing pressing and the like, and a layer selected from PVC, fabric and the like may be used.

  A PVC compound may be placed on top of the backing layer, and a PVC base layer may be produced by calendering or casting, and bonded to the surface layer, and then formed into a sheet or tile as required.

  In particular, the thickness of the surface layer varies depending on the use of the flooring, but in most cases is 3 mm or less, and more preferably 0.3 to 2 mm. More preferably, the base layer is 0.5 to 2.5 mm, the backing layer is 0.1 to 0.5 mm, and the total thickness is 0.2 to 0.6 mm.

  For reference, a specific manufacturing method will be described.

First, PVC straight resin 100 PHR, dioctyl phthalate (DOP) 20-60 PHR as plasticizer, BZ stabilizer 1-6 PHR, stearic acid / wax 0.3-5.0 PHR as lubricant, calcite as filler A backing compound having a thickness in the range of 0.5 to 2.5 mm is manufactured by calendering a PVC compound of 50 to 300 PHR. At this time, a polyester non-woven fabric / woven fabric is impregnated / coated with PVC sol and gelled by a heat drum at 120 to 180 ° C., and backing to the base layer using a bonding roll under a pressure of ^{2 to} 5 kg / cm ^2. Work by bonding materials together.

  On the other hand, the surface layer and finished product are PVC paste resin 100 PHR, DOP 20-60 PHR as plasticizer, BZ stabilizer 1-6 PHR, processing aid 3-15 PHR including viscosity reducing agent, calcite as filler A PVC sol composed of 0 to 100 PHR is prepared.

Such a PVC sol prepared in the coating to a thickness of 0.3~2.0mm the base layer and the backing with the base layer, of quartz on _{the, SiO 2, A 2 O 3} , glass beads, SiC, One or more types selected from ZeO ₂ , SUS balls, etc. are crushed so as to have a grain size of # 2 to 100 and about 1.50 to 0.07 mm, or are coated with PVC and colored, or PVC After compounding into a sheet by calendering or casting process, it is crushed and processed into scraps having a mesh size of # 2 to 100 and approximately 1.50 to 0.07 mm to arrange one or more scraps and grains and, allowed to gel for 1 to 5 minutes in an oven of 150 to 160 ° C., forming irregularities by embossing roll pressure of 3~10kg / cm ² is applied It is possible to manufacture the slip floorings Te (see Example 1 and 2).

  As will be apparent from the following examples, the floor material thus produced has a maximum friction coefficient of 35, a minimum roughness (Rz) of 70 to 160, and an inclination angle of 10 to 35 °. .

  Not only that, the vinyl flooring according to the present invention has a PVC surface layer, a dimension reinforcing layer, a PVC base layer, and a backing layer formed in this order from the top as shown in FIG. 1B.

  On the other hand, the dimension reinforcing layer is for imparting dimensional stability regardless of environmental changes such as temperature and humidity, and is a reinforcing material using one of glass paper, glass woven fabric and glass nonwoven fabric. The role of can be fully performed.

  Specifically, after selecting one or more of glass paper, glass woven fabric and glass nonwoven fabric, a PVC sol is impregnated to produce a dimension reinforcing layer, and on the dimension reinforcing layer, as described above, The surface layer can be produced by forming irregularities having a specific thickness or more. Other bonding processes, cutting processes, and the like are as described above.

At this time, as described above, the thickness of each layer, that is, the thickness of the surface layer is 3 mm or less, particularly 0.3 to 2 mm, the dimension reinforcing layer is 0.2 to 0.6 mm, and the base layer Is preferably 0.5 to 2.5 mm, and the backing layer is preferably 0.1 to 0.5 mm. Particularly, the thickness of the dimension reinforcing layer is a glass paper or nonwoven fabric having a basis weight of 25 to 100 g / m ² , More preferably, a woven fabric or the like is impregnated with PVC sol so that the total thickness is about 0.2 to 0.6 mm.

Specifically, after producing the above-described base layer or base layer with a backing layer, PVC paste resin 100PHR, DOP60-120PHR as a plasticizer on a glass paper having a basis weight of 20-100 g / m ² as a dimension reinforcing layer, BZ-based stabilizer 1-6 PHR, processing aid 3-15 PHR such as viscosity reducing agent, PVC sol consisting of filler 70-150 PHR such as calcite is impregnated and touched a 140-160 ° C. heat drum. Fabricate to a thickness of 2 to 0.8 mm.

  The surface sol shown in Example 1 was coated on the dimensional reinforcing layer thus obtained in an amount of 0.3 to 2.0 mm and gelled in an oven at 150 to 160 ° C. to produce a surface layer with a dimensional reinforcing layer. To do.

Next, the base layer and the surface layer with the dimension reinforcing layer are bonded together using a 140 ° C. heat drum, and an unevenness is formed by an embossing roll that applies a pressure of 3 to 10 kg / cm ² to produce an anti-slip flooring. (See Example 3).

On the other hand, after producing such a base layer or a base layer with a backing layer and a dimension reinforcing layer, the base layer and the dimension reinforcing layer are bonded using a heat drum and a bonding roll, and then without forming irregularities, The above-mentioned PVC surface sol is coated with 0.3 to 2.0 mm, gelled in an oven at 150 to 160 ° C. for 1 to 5 minutes, and various kinds of debris and grains having a particle size of 5 to 50 # when removed from the oven Using an embossing roll with a pressure of 0.5 to ² km / cm ² , produce an anti-slip floor material with unevenness so that debris and grains are driven onto the PVC surface layer. (See Example 4).

Moreover, after producing such a base layer or a base layer with a backing layer and a dimension reinforcing layer, the base layer and the dimension reinforcing layer are bonded together using a heat drum and a bonding roll, and then without forming irregularities, The above-mentioned PVC surface sol is coated with 0.3 to 2.0 mm, gelled in an oven at 150 to 160 ° C. for 1 to 5 minutes, and various scraps and grains having a particle size of 2 to 50 # when removed from the oven 1 or more, and an embossing roll that applies a pressure of 3 to 5 km / cm ² may be used to produce an anti-slip floor material with unevenness so that debris and grains are driven deep into the PVC surface layer. (See Example 5).

  The floor material in which the PVC surface layer, the dimension reinforcing layer, the PVC base layer, and the backing layer are laminated in this order from above is formed into a sheet or tile as necessary. As will be apparent from the examples below, the material has a maximum coefficient of friction of 35, a minimum roughness (Rz) of 70-160, an inclination angle of 10-35 °, and also dimensional stability. It satisfies the error of ± 0.10 and is a good product.

  INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a flooring having dimensional stability by effectively forming slippage on a PVC surface layer, which is the uppermost layer of the flooring, with a thickness greater than a specific thickness and preventing slippage.

The structure of the vinyl flooring which concerns on this invention is shown, and is an example which is not provided with the dimension reinforcement layer. The structure of the vinyl flooring which concerns on this invention is shown, and is an example provided with the dimension reinforcement layer. The cross-sectional shape of the PVC surface layer is classified into three types according to the type, (a) is the shape obtained by Example 3, (b) is the shape obtained by Example 4, and (c) is This is the shape obtained by Example 5.

[Examples 1 and 2, Comparative Examples 1 and 2-Demonstration experiment of appropriate thickness of irregularities]
1. Calendering a PVC compound comprising 100 PHR of PVC straight resin, 35 PHR of dioctyl phthalate (DOP) as plasticizer, 5 PHR of BZ stabilizer, 3.0 PHR of stearic acid as lubricant, and 100 PHR of calcite as filler. A backing layer having a thickness in the range of 0 mm was fabricated. At this time, the polyester non-woven fabric was impregnated with PVC sol and gelled in a heat drum at 150 ° C., and the backing material was bonded to the base layer using a bonding roll to which a pressure of 4 kg / cm ² was applied.

  On the other hand, the surface layer and the finished product were produced according to the following procedure. First, a PVC sol composed of PVC paste resin 100PHR, DOP40PHR as a plasticizer, BZ-based stabilizer 3PHR, a viscosity reducing agent 10PHR as a processing aid, and calcite 30PHR as a filler was prepared.

This is coated on a base layer or a base layer with a backing to a thickness of 1.0 mm, and glass beads and SUS balls are crushed on the # 10 mesh and have a particle size of about 1.07 mm, or PVC coated. One or more scraps by coloring them, or by pulverizing them after forming them into sheets by calendering or casting process and processing them into scraps having a # 10 mesh and a particle size of about 1.0 mm The particles were arranged and gelled in an oven at 180 ° C. for 3 minutes, and an unevenness was formed by an embossing roll to which a pressure of 5 kg / cm ² was applied to produce an anti-slip flooring. The shape of the product thus obtained is shown in FIG. 1A.

  The depth of the unevenness was 70 μm at the minimum roughness in Example 1, 160 μm in Example 2, 65 μm in Comparative Example 1, and 165 μm in Comparative Example 2.

  The friction coefficient, roughness, slip angle, and dimensional stability (%) were measured for each of the irregularities produced according to Examples 1 and 2 and Comparative Examples 1 and 2, and are summarized in Table 1 below.

  As apparent from Table 1 above, in the case of the present invention, if the unevenness is not formed within 70 to 160 μm, an appropriate contact area cannot be secured in a greasy state, and the test of DIN 51130 suitable for an anti-slip flooring It was confirmed that it was effective even on a slope of 10 ° or more in the standard.

[Example 3]
A base layer or a base layer with a backing layer was produced in the same manner as in Example 1 described above. Next, a glass paper having a basis weight of 50 g / m ² as a dimension reinforcing layer is impregnated with PVC sol consisting of 100 PHR of PVC paste resin, DOP 80 PHR as plasticizer, 4 PHR of BZ stabilizer, 10 PHR of viscosity reducing agent, and 70 PHR of calcite. The heat drum at 0 ° C. was touched to produce a thickness of 0.5 mm.

  On the dimension reinforcing layer thus obtained, 0.5 mm of the surface sol described in Example 1 was coated and gelled in an oven at 150 ° C. to produce a surface layer with a dimension reinforcing layer.

The base layer and the surface layer with the dimension reinforcing layer are bonded together using a 140 ° C. heat drum, and an unevenness having a minimum roughness of 100 μm is formed by an embossing roll that applies a pressure of 3 to 10 kg / cm ² to prevent slipping. Made the material. The cross-sectional shape of the product thus obtained is shown in FIG.

[Example 4]
As described in Example 3, a base layer or a base layer with a backing layer and a dimension reinforcing layer were fabricated. Next, the base layer and the dimension reinforcing layer were bonded using a heat drum and a bonding roll.

Such a semi-finished product is coated with 1.0 mm of the PVC surface sol shown in Example 1, gelled in an oven at 150 ° C. for 5 minutes, and various particles having a particle size of 5 to 50 # when removed from the oven. One or more kinds of scraps and grains were sprinkled and the scraps and grains were driven onto the PVC surface layer using an embossing roll that applied a pressure of 1 km / cm ² .

  As a result, unevenness having an overall minimum roughness of 100 μm was formed to produce a non-slip flooring. The cross-sectional shape of the obtained product is shown in FIG.

[Example 5]
As described in Example 3, a base layer or a base layer with a backing layer and a dimension reinforcing layer were fabricated. Next, the base layer and the dimension reinforcing layer were bonded using a heat drum and a bonding roll.

Such a semi-finished product is coated with 1.5 mm of the PVC surface sol shown in Example 1, gelled in an oven at 150 ° C. for 5 minutes, and various particles having a particle size of 2-50 # when removed from the oven. One or more kinds of scraps and grains were sprinkled, and the scraps and grains were driven deep into the PVC surface layer using an embossing roll that applied a pressure of 4 km / cm ² .

  As a result, unevenness having an overall minimum roughness of 100 μm was formed to produce a non-slip flooring. The cross-sectional shape of the obtained product is shown in FIG.

[Comparative Example 3]
A base layer or a base layer with a backing layer was prepared as described in Example 1. This semi-finished product is coated with 1.0 mm of the PVC surface sol shown in Example 1, gelled in an oven at 200 ° C. for 3 minutes, and an embossing roll to which a pressure of 10 km / cm ² is applied when removed from the oven. As a result, an unevenness having a minimum roughness of 100 μm was formed to produce an anti-slip flooring.

[Comparative Example 4]
A base layer or a base layer with a backing layer was prepared as described in Example 1. Such a semi-finished product is coated with 1.5 mm of the PVC surface sol shown in Example 1, gelled in an oven at 150 ° C. for 5 minutes, and various particles having a particle size of 8 to 50 # when removed from the oven. One or more kinds of scraps and grains were sprinkled, and the scraps and grains were driven deep into the PVC surface layer using an embossing roll that applied a pressure of 4 km / cm ² .

  As a result, unevenness having an overall minimum roughness of 100 μm was formed to produce a non-slip flooring.

  For the unevenness produced according to Examples 3 to 5 and Comparative Examples 3 and 4, the coefficient of friction, roughness, slip angle and dimensional stability (%) were measured respectively under greasy conditions where the flooring was contaminated with gear oil. Are summarized in Table 2 below.

  As is apparent from Table 2 above, in the case of Comparative Examples 3 and 4, the slip angle indicated by DIN 51130 is 10 ° or less, so that slip cannot be sufficiently prevented, and the basic physical properties of the flooring While some dimensional stability was insufficient, Examples 3 to 5 of the present invention were excellent in dimensional stability, which is a basic physical property of the flooring.

  Further, among Examples 3 to 5, as in Example 3, the most uneven part is provided with fine irregularities (FIG. 2 (a)), and Example 4 (FIG. 2 (b)) or Example. 5 (FIG. 2 (c)), the most prominent part is an inorganic material, PVC inorganic material, or a material having a porous surface shape and rough PVC scrap, but the slip angle is also in a greasy state indicated by DIN51130. From the fact that it has an anti-slip function of 10 ° or more, it is understood that it is most preferable.

Claims (14)

In the floor material in which the PVC surface layer, the PVC base layer and the backing layer are formed in this order from above,
A vinyl flooring, wherein the PVC surface layer is formed with irregularities in a thickness of 70 to 160 μm. In the floor material in which the PVC surface layer, the dimension reinforcing layer, the PVC base layer and the backing layer are formed in this order from above,
A vinyl flooring, wherein the PVC surface layer is formed with irregularities in a thickness of 70 to 160 μm. ^2. The vinyl flooring according to claim 1, wherein the unevenness on the PVC surface layer is formed using an embossing roll in which a pressure of ³ to 10 kg / cm ² is applied to the surface after bonding the layers. The unevenness on the PVC surface layer is obtained by sprinkling PVC scraps or inorganic particles having a particle size of 5 to 50 # on the surface after bonding the layers and using an embossing roll to which a pressure of 0.5 to ² km / cm ² is applied. 2. The vinyl flooring according to claim 1, wherein the scrap or grain is formed into a shape driven into a surface. The unevenness on the PVC surface layer is obtained by sprinkling 2-50 # PVC waste or inorganic particles on the surface after bonding the layers, and using an embossing roll to which a pressure of 3-5 km / cm ² is applied. The vinyl flooring according to claim 1, wherein the vinyl flooring is formed in a shape in which the grains are driven deep into the PVC surface layer. The dimension reinforcing layer has a basis weight in the range of 25 to 100 g / m ² and is formed by impregnating PVC sol into one or more selected from glass paper, glass woven fabric and glass nonwoven fabric. The vinyl flooring according to claim 2, which is characterized by the following. The said unevenness | corrugation is formed using the embossing roll which bonds each layer after impregnating a dimension reinforcement layer in PVC sol, and applies the pressure of 3-10 kg / cm < ² > on the surface. Vinyl flooring. The unevenness on the PVC surface layer is obtained by sprinkling PVC scraps or inorganic particles having a particle size of 5 to 50 # on the surface after bonding the layers and using an embossing roll to which a pressure of 0.5 to ² km / cm ² is applied. The vinyl flooring according to claim 6, wherein the scrap or grain is formed into a shape driven into a surface. The unevenness on the PVC surface layer is obtained by sprinkling 2-50 # PVC waste or inorganic particles on the surface after bonding the layers, and using an embossing roll to which a pressure of 3-5 km / cm ² is applied. The vinyl flooring according to claim 6, wherein the vinyl flooring is formed in a shape in which the grains are driven deep into the PVC surface layer.   The vinyl flooring according to claim 1 or 2, wherein the backing layer is made of PVC or fabric.   11. The vinyl flooring according to claim 10, wherein a PVC base layer is formed by placing a PVC compound on the backing layer and performing a calendering or casting process.   PVC surface layer 0.3-2mm, base layer 0.5-2.5mm, backing layer 0.1-0.5mm thickness, total thickness 0.2-0.6mm, friction The vinyl flooring according to claim 1, wherein the coefficient satisfies a maximum of 35, a surface roughness (Rz) of 75 to 160, and an inclination angle of 10 to 35 °.   The thickness of the PVC surface layer is 0.3 to 2 mm, the dimension reinforcing layer is 0.2 to 0.6 mm, the base layer is 0.5 to 2.5 mm, the backing layer is 0.1 to 0.5 mm, and the total thickness is 0. .2 to 0.6 mm, friction coefficient is maximum 35, surface roughness (Rz) is 75 to 160, inclination angle is in the range of 10 to 35 °, and dimensional stability satisfies ± 0.10. The vinyl flooring according to claim 2, wherein:   The vinyl flooring according to claim 12 or 13, wherein the flooring is a sheet or a tile.

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