KR100415196B1 - Flooring with foam layer composed of PVC and modified TPO and the method for same - Google Patents

Abstract

The present invention relates to a floor decorative material comprising an elastic foam layer made of a foamed cell of an upright structure with excellent walking comfort, shock absorption, and resilience, and a method of manufacturing the same. By maximizing shock absorbency, resilience and resilience, the household life (household labor: 7 hours per day for housewives in their 20s and 30s: Korea Women's Development Institute) is reduced by fatigue and absorbs shocks even when children fall. Provides a special functional floor decoration that can minimize the

Description

Flooring with foam layer composed of F.B and modified Tipio and its manufacturing method {Flooring with foam layer composed of PVC and modified TPO and the method for same}

The present invention relates to a flooring decorative material having a foam layer composed of PVC and modified TPO and a method for manufacturing the same, and to maximize cushioning and walking feeling, shock absorption, restoring force and resilience that the conventional PVC flooring material is hardly provided. Domestic work (7 hours per day for housewives in their 20s and 30s: Korea Women's Development Institute) provides a specially functional floor covering that minimizes the damage by absorbing shock even when children fall down and absorbs the fatigue of extremely housewives and the elderly.

Vinyl chloride resin floor decorative materials are commonly used for decoration, thermal insulation, sound insulation and the like. In general, the vinyl chloride resin floor decorative material is composed of a transparent layer, a printing layer, a dimension reinforcing layer, and a foaming layer from above, and each layer has a function. The transparent layer protects the ink surface printed on the printing layer, and the printing layer gives color or pattern to decorate it, and the dimension reinforcement layer is glass fiber vinyl chloride sol impregnated layer to reinforce the dimensional stability of the product. The foam layer has a function of cushioning. The structure of the floor covering may vary depending on the application.

The foam layer of the conventional floor decoration material is manufactured by foaming in a foaming oven by mixing a foaming agent in a vinyl chloride resin, the purpose of which is mainly limited to cushioning and cost reduction. When the foam layer is photographed through an electron microscope (magnification: 100 times or 200 times), it can be seen that the foaming cell has a lying egg shape which is somewhat crushed in a circle. In general, the most ideal foam cell structure has been found to be excellent in physical properties such as restoring force and elasticity in the shape of an egg (hereinafter referred to as an "upright structure"). The melt viscosity and temperature gradient during foaming and the loading of the foam sheet itself could not be implemented.

In the present invention, an elastic foam layer made of vinyl chloride resin, modified thermoplastic olefin resin and ethylene vinyl acetate resin or styrene butadiene rubber or thermoplastic urethane resin is produced to maximize melt viscosity at the time of foaming. It was possible to achieve the purpose by forming a. Looking at each of the functions here, the modified thermoplastic olefin resin prevents the cell from being destroyed by foaming by providing a high melt viscosity, and at the same time serves to form a uniform cell by accelerating the initial melting rate due to the low melting point . In the case of ethylene vinyl acetate resin, styrene butadiene rubber or thermoplastic urethane resin, it improves calenderability and compatibility with vinyl chloride resin, thereby making the cell uniform.

In addition, in the case of ordinary PVC flooring, the foaming ratio does not usually exceed 200 to 300% due to the foam cell breakage and the deterioration of physical properties such as pressed marks. However, according to the present invention, cell destruction and other physical properties are reduced from 100% to 600%. The magnification can be adjusted arbitrarily without deterioration, and its use can be varied. If necessary, it can be said that the economic efficiency is also excellent because the magnification can be further increased when using additives and preparations.

The present invention, by overcoming the fundamental limitations of the foam layer of the conventional vinyl chloride floor decoration material and providing a composition and manufacturing method of the foam layer of the ideal upright cell structure, it is possible to feel a cushion even when walking daily life, The purpose of the present invention is to provide a special functional floor covering that relieves the fatigue on the joints and minimizes the impact even if children fall down.

It is another object of the present invention to provide a method for producing the above-mentioned floor covering.

1 is a cross-sectional view of the flooring according to the present invention,

Figure 2 is a flooring manufacturing process according to the present invention.

Explanation of symbols on the main parts of the drawings

1: surface treatment layer 2: transparent layer

3: immersion immersion reinforcement layer 4: interlayer

5: elastic foam layer 6: easy layer

The present invention, in order to achieve the above object, in a plurality of laminated synthetic resin floor decoration material,

a) polyvinyl chloride

b) modified thermoplastic olefin resin

c) ethylene vinyl acetate resin or styrene butadiene rubber or thermoplastic urethane resin

It provides a floor decorative material having an elastic foam layer comprising a.

In addition, the present invention,

a) preparing an elastic foam layer comprising polyvinyl chloride and modified thermoplastic olefin resin and styrene butadiene rubber or ethylene vinyl acetate resin or thermoplastic urethane resin;

b) preparing a transparent layer, an interlayer and an easy layer;

c) stacking in the order of interlayer, elastic foam layer, easy layer;

d) aging and foaming the laminated layers into a foaming oven;

e) thermally plywood the foam obtained through step d) with the transparent layer and the printed sol immersion reinforcement layer;

f) imparting backside embossing after finishing the product obtained in step e) with a surface treatment agent;

It provides a method of manufacturing a floor decoration material.

Hereinafter, the present invention will be described in detail.

The function and composition of the layers is as follows.

First, the surface treatment layer 1 prevents contaminant adhesion and scratches, and facilitates cleaning. The surface treatment layer is composed of ordinary photocurable urethane acrylate.

The transparent layer 2 under the surface treatment layer 1 functions to protect the printed pattern of the sol immersion reinforcement layer 3. The transparent layer 2 is 100 parts by weight of polyvinyl chloride having a degree of polymerization of 1000 to 1700, 30 to 60 parts by weight of plasticizer dioctylphthalate (DOP), 1 to 3 parts by weight of epoxidized soybean oil (ESO), and barium-zinc 2 to 6 parts by weight of the stabilizer.

The sol impregnation dimension reinforcing layer 3 reinforces the dimensional stability of the flooring material, and glass fibers impregnated with vinyl chloride sol are preferable. In this case, impregnation with vinyl chloride sol allows the glass fiber to be easily laminated with other layers, and at the same time, to serve as a printing substrate. The vinyl chloride sol is 100 parts by weight of polyvinyl chloride having a polymerization degree of 1200 to 1700, 50 to 100 parts by weight of plasticizer dioctylphthalate, 1 to 3 parts by weight of epoxidized soybean oil, 2 to 6 parts by weight of barium-zinc stabilizer, and calcium carbonate A sol containing 10 to 80 parts by weight of (CaCO ₃ ) and 5 to 50 parts by weight of titanium dioxide as a white pigment is preferable.

The interlayer 4 improves the adhesive strength of the glass fiber and the elastic foam layer 5 and prevents the impact directly on the elastic foam layer 5. The composition of the interlayer 4 is 100 parts by weight of polyvinyl chloride having a polymerization degree of 1000 to 1700, 30 to 70 parts by weight of plasticizer dioctylphthalate, 1 to 3 parts by weight of epoxidized soybean oil, 1 to 6 parts by weight of barium-zinc stabilizer, and 1 to 150 parts by weight of calcium carbonate (CaCO ₃ ).

The elastic foam layer 5 provides cushioning and shock absorbing functions, 100 parts by weight of polyvinyl chloride having a polymerization degree of 1000 to 1700, 5 to 300 parts by weight of modified thermoplastic olefin resin, 5 to 80 parts by weight of ethylene vinyl acetate resin, and a plasticizer. 50 to 85 parts by weight of dioctylphthalate, 1 to 5 parts by weight of a barium-zinc stabilizer as foaming stabilizer, 2 to 6 parts by weight of azodicarbonamide as foaming agent, 1 to 80 parts by weight of calcium carbonate (CaCO ₃ ), and Pigments.

The easy layer 6 serves to balance the warpage of the floor decorative material and prevents deformation of the elastic foam layer 5 and the sol immersion reinforcement layer due to the floor moisture after construction. The easy layer 6 is 100 parts by weight of polyvinyl chloride having a polymerization degree of 1000 to 1700, 30 to 80 parts by weight of a plasticizer DOP, 5 to 50 parts by weight of acrylonitrile butadiene rubber, 1 to 3 parts by weight of epoxidized soybean oil, barium-zinc 2 to 6 parts by weight of stabilizer, 1 to 100 parts by weight of calcium carbonate (CaCO ₃ ), and a pigment, and may include polyester plain weave or polyester nonwoven fabric.

In another aspect, the present invention provides a method for producing the floor decoration material.

Each layer included in the floor covering of the present invention is manufactured by a calendering method except for the dimension reinforcing layer 7. Figure 2 shows a manufacturing process diagram of the flooring decorative material using a calendering method, the manufacturing process is largely a raw material mixing process, a kneading process for uniformly gelling by heating and pressing the mixed raw materials, and a calendering process for forming the final sheet shape Is done.

In order to produce each layer of flooring, first, each liquid and powder raw material is evenly mixed and dispersed by a super mixer. The evenly mixed raw materials are kneaded with screws in a Banbury mixer at 80 to 140 ° C. The kneaded raw materials are first mixed and secondly mixed in two bone rolls at 120 to 150 ° C., respectively, and a sheet having a thickness of 0.1 to 1.0 mm is prepared using an inverted L-shaped four bone roll calender. . In the case of the sol immersion reinforcement layer 3, which requires printing, the glass fabric is impregnated with a sol composed of paste vinyl chloride, a plasticizer and a stabilizer through a roll coater, and then the pattern is formed by gravure, screen or transfer printing on the gelled fabric. Print

The plywood layer, elastic foam layer, and easy layer thus prepared were thermally laminated through an embossing roll, and passed through an oven of a foaming machine in a foaming oven for 1 minute to 3 minutes at a speed of 6 to 20 m / min under 200 to 250 ° C. After passing through foaming, both the preheated transparent layer 2 and the printed sol impregnated dimensional reinforcement layer through a heating drum at 120 to 180 ° C. were simultaneously passed through an embossing roll to thermally laminate.

After cooling it, the photocurable resin is coated on the front surface through a coater, and then passed through an ultraviolet curing machine, and the final product is completed.If necessary, the easy layer is preheated using a far-infrared heater of 100 to 600 ° C, and then embossed with specific irregularities. Pass the roll to give the desired pattern. The product thus obtained obtains a more elegant appearance and improves the seatability of the product.

Hereinafter, the present invention will be described in more detail with reference to the following examples. However, an Example is for illustrating this invention and this invention is not limited only to these.

Example 1

Each layer except the dimensional reinforcing layer (3) was prepared by the calendering method.

(Production of Icebreaker Layer)

In order to prepare the interlayer 4, 100 parts by weight of polyvinyl chloride having a degree of polymerization of 1000, 50 parts by weight of dioctylphthalate, 2 parts by weight of epoxidized soybean oil, 1.8 parts by weight of barium-zinc stabilizer, and 60 parts by weight of calcium carbonate were used.

The mixture was kneaded at 150 ° C. in a half-barrier mixer and then mixed first and second in a two roll at 150 ° C. The mixture was calendered to produce 0.3 mm thick sheets.

(Production of Elastic Foam Layer)

The elastic foam layer 5 was also prepared in the same manner as the interlayer layer 4 except for the composition and content of the raw material. As the raw material of the elastic foam layer 5, 100 parts by weight of polyvinyl chloride having a degree of polymerization of 1000, 50 parts by weight of modified thermoplastic olefin resin, 20 parts by weight of ethylene vinyl acetate, 70 parts by weight of dioctylphthalate, 2.5 parts by weight of barium-zinc stabilizer , 4 parts by weight of azodicarbonamide, 10 parts by weight of calcium carbonate, and 0.1 part by weight of pigment were used. The mixture was kneaded at 120 ° C. in a half-barrier mixer and then mixed first and second in a two-bone roll at 150 ° C. The mixture was calendered to produce a 0.5 mm thick sheet.

(Easy layer production)

In order to manufacture the easy layer 6, 100 parts by weight of polyvinyl chloride having a degree of polymerization of 1000, 48 parts by weight of plasticizer dioctylphthalate, 15 parts by weight of acrylonitrile butadiene rubber, 3 parts by weight of epoxidized soybean oil, 3 parts by weight of barium-zinc stabilizer Parts and 50 parts by weight of calcium carbonate were mixed evenly with a supermixer. The mixture was kneaded at 150 ° C. in a half-barrier mixer, and then primary and secondary mixed in two bone rolls at 150 ° C. The mixture was prepared using a calender to prepare a 0.2 mm thick sheet.

(Manufacture of Dimension Reinforcement Layer)

As the impregnating sol raw material of the dimensional reinforcing layer 3, 100 parts by weight of polyvinyl chloride having a polymerization degree of 1200, 90 parts by weight of dioctylphthalate, 2 parts by weight of epoxidized soybean oil, 2 parts by weight of barium-zinc stabilizer, and 40 parts by weight of calcium carbonate, 17 parts by weight of pigment was used. After mixing the raw materials to prepare a sol phase, the glass fiber was impregnated with a roll coater to prepare a dimensional reinforcement layer (3). This was given a pattern through gravure printing.

(Production of Transparent Layer)

The transparent layer 2 was also prepared in the same manner as the interlayer layer 4 except for the composition and the content of the raw materials. As a raw material for the transparent layer 2, 100 parts by weight of polyvinyl chloride having a polymerization degree of 1000, 42 parts by weight of dioctylphthalate, 2 parts by weight of epoxidized soybean oil, and 3.5 parts by weight of barium-zinc stabilizer were used. The mixture was kneaded at 150 ° C. in a half-barrier mixer, and then primary and secondary mixed in two bone rolls at 150 ° C. The mixture was prepared using a calender to prepare a 0.5 mm thick sheet.

(1st lamination and foaming, 2nd lamination process)

The prepared interlayer, elastic foam layer, and easy layer were preheated by passing a heating drum at 100 to 170 ° C. in a foaming machine, and then passed through an embossing roll to be thermally laminated, and a foam oven at 225 ° C. at a speed of 11 m / min. Passed and foamed 500% for 2 minutes 10 seconds. Subsequently, the transparent layer and the sol-impregnated dimensional reinforcing layer were preheated by passing through a heating drum at 100 to 170 ° C., and then thermally laminated by embossing with the previously obtained foam to obtain a product having a thickness of 3.5 mm.

(Surface Treatment Process / Backside Embossing Process)

The product was coated with a urethane acrylate resin, which is a photocurable treatment agent, in a roll coater and cured by passing through an ultraviolet lamp, and then preheated to the back layer using a 600 C far infrared heater for 30 seconds, and then embossed.

The floor decoration material of the present invention can significantly improve the walking and shock absorbency of the conventional floor decoration material to feel a cushion even when walking in everyday life, relieve fatigue applied to the joints of the human body, Even if it fell, it could provide the ability to minimize the impact.

Claims (4)

A plurality of laminated synthetic resin floor coverings, a) polyvinyl chloride (PVC); And b) modified thermoplastic olefin resin (TPO); And c) ethylene vinyl acetate resin (EVA) or styrene butadiene rubber (SBR) or thermoplastic urethane resin (TPU); Floor decorative material having an elastic foam layer comprising a. The method of claim 1, wherein the elastic foam layer a) 100 parts by weight of polyvinyl chloride having a degree of polymerization of 1000 to 1700; And b) 5 to 300 parts by weight of the modified thermoplastic olefin resin; And c) 5 to 80 parts by weight of ethylene vinyl acetate resin (EVA) or styrene butadiene rubber (SBR) or thermoplastic urethane resin (TPU); And d) 1 to 5 parts by weight of the foam stabilizer; And e) 2 to 6 parts by weight of blowing agent Floor decoration material comprising a. The method of claim 2, wherein the elastic foam layer 1 to 80 parts by weight of calcium carbonate, 0.01 to 20 parts by weight of pigment further comprises a floor decorative material, characterized in that it further comprises. In the manufacturing method of polyvinyl chloride-based flooring decorative material excellent in walking feeling and shock absorption a) polyvinyl chloride; And Ii) modified thermoplastic olefin resins (TPO); And Iii) ethylene vinyl acetate resin (EVA) or styrene butadiene rubber (SBR) or thermoplastic urethane resin (TPU); Preparing an elastic foam layer comprising a; b) providing a surface treatment layer, a transparent layer, an interlayer, a reinforcement layer and an interlayer, an easy layer; c) stacking in the order of the interlayer, elastic foam layer, easy layer; d) injecting the laminated layers into a foamer to age and foam; And e) thermally plying the foamed layers with a transparent layer, a soaked dimensional reinforcement layer in an embossing roll Method for producing a polyvinyl chloride-based floor decoration material.