KR100908661B1 - Ech-friendly floor coverings comprising copolymer containing propylene or ethylene and thermoplastic polyolefin series and manufacturing method thereof - Google Patents

Abstract

Eco-friendly decorative floor coverings comprising a propylene-ethylene copolymer and a polyolefin-based thermoplastic resin are provided to reduce casualties or property damages by substantially reducing the generation of toxic gases and smoke when a fire breaks out, and a method of manufacturing the same is provided. An eco- friendly decorative floor covering comprising a propylene-ethylene copolymer and a polyolefin-based thermoplastic resin comprises a surface protection layer(30), a pattern layer(50), a base layer, and a balance layer(80). The surface protection layer is a sheet made from a propylene-ethylene copolymer and a polyolefin-based thermoplastic resin. The pattern layer is laminated to the bottom of the surface protection layer by an adhesive and is obtained by printing patterns on a sheet that is made from the same material as the surface protection layer. The base layer is laminated to the bottom of the pattern layer and is a sheet that is made from the same material as the surface protection layer. The balance layer is laminated to the bottom of the base layer and is a sheet that is made from the same material as the surface protection layer. The eco- friendly decorative floor covering further comprises a surface coating layer(10) formed on the top side of the surface protection layer, and a contraction/expansion preventing layer(60) and another base layer formed between the base layer and balance layer.

Description

TECHNICAL FIELD [0001] The present invention relates to an eco-friendly flooring material comprising a copolymer containing propylene and ethylene, a thermoplastic polyolefin-based material, and a method for producing the same. BACKGROUND ART < RTI ID = 0.0 >

More particularly, the present invention relates to a floor covering made using a polyolefin-based material and a method of manufacturing the same. More particularly, the present invention relates to a floor covering and a method of manufacturing the same, , Polyethylene, etc.) is used as a surface layer (transparent layer), a pattern layer and all substrate layers. Environmentally friendly elements of polyolefin materials are used to reduce the generation of smoke and toxic gases and reduce the spread of flame. The present invention relates to a flooring material which can be used on floors of ships, trains, etc., and a manufacturing method thereof.

Background Art [0002] Floor materials (or tiles) having a polyvinyl chloride (PVC) layer bonded to a veneer have conventionally been used and are already known. Representative examples thereof are disclosed in Korean Utility Model Publication No. 1996-26856, Korean Patent Publication No. 1996-29093, Korean Patent Registration No. 292585, and Korean Patent Publication No. 1998-47176.

FIG. 1 is a cross-sectional view of a polyvinyl chloride resin flooring according to the prior art, which comprises a vinyl chloride surface protective layer 1 and a pattern layer 2, a stop layer 3 and a balance layer 4 below And most of them are manufactured in a manner of laminating by one of the multi-stage hot plate press or the roll pressing method.

Originally polyvinyl chloride (PVC) is widely used in various fields because of its excellent processability. However, since chlorine (Cl) is contained in PVC, smoke and toxic gas are generated in case of fire, and there is a possibility that the damage of people is spread. Also, in PVC products, additives are usually mixed and molded, and most of the additives themselves are toxic.

Therefore, in recent years, the use of polyvinyl chloride floor coverings has been limited to multi-use facilities such as karaoke, ships, trains, and large restaurants. In Europe, for example, a change to a non-toxic product is forcibly required. Moreover, since polyvinyl chloride resin is difficult to solve such a problem fundamentally, various substitutes using polyolefin-based materials such as polyethylene and polypropylene are being developed. However, such a polyolefin-based material has difficulty in processing and requires special manufacturing techniques.

DISCLOSURE OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and it is an object of the present invention to provide a flooring material which does not use additives of toxic substances as compared with flooring materials of existing polyvinyl chloride materials, The purpose of the present invention is to improve the problem of polyvinyl chloride flooring which can not be used in multiple use facilities by reducing damage.

Further, the present invention realizes weight reduction by using a small unit specific gravity, which is one of the advantages of polyolefin-based materials, so that the weight that can affect the building structure is reduced as compared with existing polyvinyl chloride flooring, The disadvantages of many changes in the dimensions of the materials are that they are overcome by the combination of additives and the improvement of the manufacturing process in the manufacturing method, thereby providing a flooring material excellent in workability and practicality than conventional vinyl chloride flooring materials.

In order to achieve the above object, the present invention provides an eco-friendly flooring material made of a copolymer containing propylene and ethylene and a thermoplastic polyolefin-based material, which comprises a copolymer containing propylene and ethylene, a thermoplastic polyolefin- A surface protective layer which is a sheet material; A pattern layer printed with a pattern on a sheet material of the same material as the surface protective layer and laminated under the surface protective layer with an adhesive; A sheet material of the same material as the surface protective layer, the stop layer being a base layer laminated under the pattern layer; And a balance layer laminated under the stop layer as a sheet material of the same material as the surface protection layer.

Preferably, the flooring material further comprises a surface coating layer applied to the upper surface of the surface protective layer bonded to the pattern layer.

In addition, it is preferable that the flooring material further includes a shrinking expansion prevention layer and another stopping layer on the bottom surface of the stopping layer.

A method for producing an environmentally friendly flooring material using a copolymer containing propylene and ethylene and a thermoplastic polyolefin based material according to the present invention is characterized in that the surface protective layer of a copolymer containing propylene and ethylene and a thermoplastic polyolefin- Applying corona treatment to the surface of the corona using a high frequency wave, compressing and bonding the waveguide layer with an adhesive, and laminating; Applying a surface coating layer to the laminated surface protective layer and the pattern layer, and performing heat treatment; And a step of sequentially stacking the stop layer and the balance layer under the laminated surface protective layer and the pattern layer and laminating them by pressing.

In the step of lapping the stop layer and the balance layer, it is preferable that the stop layer, the shrinkage expansion prevention layer, the stop layer, and the balance layer are sequentially stacked under the lapped surface protective layer and the pattern layer, .

Further, in the step of laminating the stop layer and the balance layer, the embossing pattern plate of the press machine is further stacked on the upper surface of the semi-finished product, and the press machine is press-processed at a temperature of 130 to 150 캜 for 20 to 30 minutes .

According to the eco-friendly flooring material comprising the propylene-ethylene-containing copolymer and the thermoplastic polyolefin-based material according to the present invention and the method for producing the same, as a flooring material which does not use toxic additive as compared with the existing flooring material of polyvinyl chloride, It is possible to improve the problem of the polyvinyl chloride flooring material which can not be used in the multi-use facilities by reducing the toxic gas and smoke generation in the case of fire to reduce the damage to human life and property.

Further, the present invention realizes weight reduction by using a small unit specific gravity, which is one of the advantages of polyolefin-based materials, so that the weight that can affect the building structure is reduced as compared with existing polyvinyl chloride flooring, The disadvantages of the material varying in size are that the combination of additives and the improvement of the manufacturing process overcome the disadvantages of the manufacturing method, thereby providing a flooring material excellent in workability and practicality than existing vinyl chloride flooring materials.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 2 is a cross-sectional view of an eco-friendly flooring material reduced in smoke density and toxic gas generated using a polyolefin-based material according to a preferred embodiment of the present invention.

The layer structure of the flooring according to the first embodiment of the present invention includes a surface protection layer 30, a pattern layer 50, a stop layer 70, and a balance layer 80 in this order from top to bottom. In this embodiment, not only the stop layer 70, which is a base layer, but also all layers are basically formed by using a copolymer containing propylene and ethylene and a thermoplastic polyolefin-based material. Although the present embodiment is not directly shown in the drawings, it is possible to refer to another embodiment of Fig.

The surface protective layer 30 is transparent due to the nature of the material, so that the pattern of the pattern layer 50 laminated beneath the surface protective layer 30 can be seen as it is.

The pattern layer 50 is made of a sheet having a predetermined thickness as the material, and then a pattern of a desired design is printed on the upper surface thereof. The thus formed pattern layer 50 is bonded to the lower surface of the corona-treated surface protective layer 30 by an adhesive. Since the adhesive applied here also forms one layer, the adhesive layer 40 is used in FIG.

The stop layer 70 is a substrate layer made of a copolymer containing propylene and ethylene and a thermoplastic polyolefin-based material. Therefore, in order to achieve the excellent flame retardancy of the flooring material, which is the thickest of the four layers and is included in the object of the present invention, the material is most important.

The balance layer 80 is a bottom layer of the bottom material according to the present invention and is basically made of the same material as the stop layer 70. However, the flame retardant and calcium carbonate to be described later are added to the respective layers at different rates.

2, the balance layer 80, the stop layer 70, the shrinking and swelling prevention layer 60, the stop layer 70, A layer 70, a pattern layer 50, an adhesive layer 40, a copolymer containing propylene and ethylene, a thermoplastic polyolefin-based surface protective layer 30, and a surface coating layer 10.

The balance layer 80, the pattern layer 50, the adhesive layer 40, and the surface protection layer 30 in this embodiment are substantially the same as those in the embodiment described above, and thus the detailed description thereof is omitted here.

On the other hand, in this embodiment, the stop layer 70 is laminated on the upper and lower sides of the shrinkage-expansion preventing layer 60, respectively. Compared with the first embodiment, the stop layer is formed to be relatively thick in the first embodiment, while in the second embodiment, the stop layer 70, the shrinking and swelling prevention layer 60, The three layers of the stop layer 70 are formed to have a thickness equal to or greater than the thickness of the stop layer of the first embodiment. In other words, it can be considered that the stop layer is divided into two layers, and the shrinkage prevention layer 60 is inserted therebetween.

The shrinking and swelling prevention layer 60 is made of a material such as glass fiber or non-woven fabric, and serves to prevent shrinkage or expansion of the jointed flooring material during manufacturing of the flooring material or using the finished product flooring material. Conventionally, attempts have been made to prevent shrinkage or swelling mainly by adding an additive to the stop layer, but the effect has not reached a desired level. In the present embodiment, the shrinkage expansion preventing layer 60 is interposed between the stop layers separately, so that the effect of preventing shrinkage or expansion of the flooring material can be remarkably improved.

The surface coating layer 10 is composed of two layers of a primer layer 12 and a top layer 11 as described later. The primer layer 11 is applied after the primer layer 12 is applied and cured, .

3, there is shown a process diagram for producing an environmentally friendly floor covering with reduced smoke density and toxic gases generated using a copolymer containing propylene and ethylene according to a preferred embodiment of the present invention and a thermoplastic polyolefin-based raw material.

In the first embodiment of the present invention, the surface protective layer 30 of a copolymer containing propylene and ethylene and the thermoplastic polyolefin-based surface protective layer 30 is subjected to corona treatment using an electric high frequency wave, ) And compressing and lapping with the pattern layer (50); Applying a surface coating layer (10) to the surface protective layer (30) and the pattern layer (50) and thermally treating the surface protective layer (30); And stacking the stop layer (70) and the balance layer (80) under the surface protective layer (30) and the pattern layer (50) one after another and pressing them together by pressing.

The step of lapping the stop layer 70 and the balance layer 80 may be performed by forming a stop layer 70 and a shrinking and swelling prevention layer 70 under the lapped surface protective layer 30 and the pattern layer 50 60, the stop layer 70, and the balance layer 80 may be sequentially stacked and laminated by a press.

More preferably, in the step of laminating the stop layer 70 and the balance layer 80, an embossing pattern plate (not shown) of a press machine is further stacked on the upper surface of the semi-finished article, and the temperature of the press machine is set at 130 To 150 ° C for 20 to 30 minutes.

The method for manufacturing a flooring material according to the most preferred embodiment of the present invention is characterized in that a corona treatment is performed by using an electric high frequency wave to a surface protective layer (30) having a thickness of 0.1 to 1.0 mm of a copolymer containing propylene and ethylene and a thermoplastic polyolefin series Applying an adhesive 40 to the lower surface thereof, and pressing the adhesive layer 40 with a thickness of 0.07 to 0.15 mm to form a total thickness of 0.2 to 1.1 mm; Applying a surface coating layer (10) to the surface protective layer (30) and the pattern layer (50); Cutting the semi-finished product of the surface protective layer (30) and the pattern layer (50) with the surface coating layer (10) into predetermined dimensions and shapes; A stop layer 70, a shrinkage expansion preventing layer 60, a stop layer 70, a balance layer 80, and an embossing pattern plate are sequentially stacked under the lapped surface protective layer 30 and the pattern layer 50 step; Placing the loaded semi-finished products in a multi-stage press and lapping them at an appropriate pressure; Heat treating the laminated semi-finished product; And cutting and heat-treating the heat-treated semi-finished product according to a predetermined standard.

The manufacturing process will be described in detail below.

In the present invention, in order to accomplish the object of the present invention and to easily process the surface protective layer 30, 30% of the copolymer of propylene and ethylene and the thermoplastic polyolefin-based material, The mixture is mixed at a proper mixing ratio of 100% to 0%. Then, the mixture is produced in the form of a flat sheet having a predetermined size in a calender or an extruder at a temperature of 130 to 180 ° C without adding a plasticizer, It is rolled into a rolled state while being treated, but powder is not applied to the surface for the post-processing.

The corrugated surface protective layer 30 is then corona-treated again to bond the surface protective layer 30 with the pattern layer 50 so that the adhesion force of the adhesive can be increased. Then, a specially developed environmentally friendly adhesive (a hardener + curing agent) After primary curing at about 60 ° C, the laminate is laminated with the pattern layer 50 in a laminate roll heated to about 60 to 80 ° C.

It is also preferable to maintain the thermoplastic polyolefin-based surface protective layer 30 and the pattern layer 50 in a separate aging chamber at a temperature of 60 DEG C for at least 48 hours so that the copolymer containing propylene and ethylene and the thermoplastic polyolefin- .

In order to improve the contamination and the abrasion resistance of the semi-finished product of the surface protective layer 30 and the pattern layer 50 which have undergone such a process, the undercoat layer 12 is applied and cured with a gravure roll, and a secondary polyurethane, The upper layer 11 as a coating layer which undergoes a surface treatment is applied and cured, and then cut to a predetermined standard.

In order to achieve the object of the present invention in achieving the stop layer 70, the balance layer 80, and to achieve the physical properties required in the flooring, a copolymer of propylene and ethylene and a thermoplastic polyolefin series Since the retardation layer 70 and the balance layer 80 have different physical properties, the retardation layer 70 and the balance layer 80 are added to the raw material in a predetermined ratio to prepare a sheet shape and cut to a predetermined standard. Specifically, the calcium carbonate contained in the balance layer 80 is subjected to a heat treatment in which all of the layers constituting the bottom layer are loaded and then subjected to heat treatment in order to balance the prepared surface protective layer 30 against shrinkage of the surface protective layer 30 It is preferred that less than the layer 70 is contained.

The surface protective layer 30, the stop layer 70, and the shrinking and swelling prevention layer 60 thus produced. The material of the balance layer 80 is prepared, the balance layer 80 is laid on the floor from the lower layer on the floor, and the embossing plate is raised thereon to complete the stacking to form the desired embossed shape on the product.

The material of the stacked state is pushed into the multistage press and the press machine is raised and brought into close contact with the pressure gauge so that the pressure of the press machine is 30 to 50 kg / cm ^{2. The} steam valve is opened to set the temperature of the press machine to 130 to 150 ° C. While adjusting, adjust the timer so that the time is 20 to 30 minutes.

When the lamination is completed by heat and pressure in the press, the steam valve is closed, the cooling water valve is opened to operate all the valves so that the cooling water can be supplied to the press, and the pressing pressure of the press is adjusted to 50 to 100 kg / cm ² to 3 levels.

When the cooling is completed, it is pulled out from the multi-stage press, separated in a state of being lapped, and aged at room temperature for 24 hours or more. After the aging at room temperature is completed, the mixture is transferred to a secondary aging unit, passed through a heat chamber at a temperature of 80 ° C or higher for 2 minutes, and lowered in a cooling bath to prevent deformation of the finished product and ensure dimensional stability.

Once all the processes are completed, the mold is cut from the hydraulic press machine according to the specified standard.

The construction of the present invention will be described in detail with reference to test results of the embodiments.

<Environmental friendliness test: IMO PART2, PART5>

IMO stands for the International Maritime Organization, which defines the characterization criteria for materials used in ships. IMO PART2 and PART5 refer to two of them.

In the table below, the flame propagation test is a test to measure the average combustion duration heat (MJ / m ² ), the critical radiant heat flux (kW / m ² ), the total release heat (MJ) And a relative average of the embodiment and the comparative example when the IMO standard is taken as 10.

In addition, the toxicity test measured the contents of various toxic substances, but only the content of CO, which is a representative toxic substance.

division Flame propagation Toxicity test Example 4 356 ppm Comparative Example 100 1027ppm

As a result, the floor coverings of the present invention have proven to be safer and more environmentally friendly than conventional floor coverings.

&Lt; Light Weight Test of Material >

division Surface protective layer Stop layer Balance layer Example 0.27 kg / m ² 2.57 kg / m ² 1.95 kg / m ² Comparative Example 0.39 kg / m ² 2.66 kg / m ² 2.23 kg / m ² Comparison result 31% reduction 3.4% reduction Decreased by 12.6%

As a result, the flooring material of the present invention has been proved to be reduced in weight overall as compared with conventional flooring materials.

As described above, the conventional polyvinyl chloride resin flooring has been used only for the limited use of smoke and poisonous gases and additive toxic gases at the time of fire, and it has been difficult to use due to the fire fighting law and IMO specifications. However, The decorative material is made of non-toxic raw materials that can be used in all kinds of facilities such as ships and trains. It is an environmentally friendly, harmless and excellent flooring material which can be recycled. It is applied thickly on the surface protection layer and further coated on the surface, .

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of illustration, Changes will be possible.

1 is a schematic cross-sectional view of a vinyl chloride resin flooring according to the prior art.

Figure 2 is a cross-sectional view of an environmentally friendly floor covering with reduced smoke density and toxic gases generated using a copolymer containing propylene and ethylene and a polyolefin-based material in accordance with a preferred embodiment of the present invention.

FIG. 3 is a process flow diagram of a method for manufacturing an environmentally friendly flooring material in which smoke density and toxic gas generated by using a copolymer containing propylene and ethylene and a polyolefin-based material according to a preferred embodiment of the present invention are reduced.

Description of the Related Art

10: Surface coating layer

11: Top layer

12: Lower layer

30: a copolymer containing propylene and ethylene and a thermoplastic polyolefin-based surface protective layer

40: adhesive layer

50: pattern layer

60: Shrinkage expansion prevention layer (glass fiber, nonwoven fabric)

70: Copolymer containing propylene and ethylene and thermoplastic polyolefin-based stop layer

80: A copolymer containing propylene and ethylene and a balance layer of a thermoplastic polyolefin series

Claims (6)

A surface protective layer 30 which is a sheet material of a thermoplastic polyolefin-based material, and a copolymer containing propylene and ethylene; A pattern layer 50 printed with a pattern on a sheet material of the same material as the surface protective layer 30 and laminated under the surface protective layer 30 with an adhesive; A sheet material of the same material as the surface protective layer 30, the stop layer 70 being a base layer laminated under the pattern layer 50; And A sheet material of the same material as the surface protection layer 30, the balance layer 80 being laminated under the stop layer 70; And a thermoplastic polyolefin-based material, wherein the propylene-ethylene copolymer is a thermoplastic polyolefin-based material. The method according to claim 1, The floor covering further comprises a surface coating layer (10) applied to the top surface of the surface protection layer (30), characterized in that the environmentally friendly floor comprising a copolymer containing propylene and ethylene and a thermoplastic polyolefin based material Decorative material. 3. The method according to claim 1 or 2, Characterized in that the flooring further comprises a shrinkage inflating barrier layer (60) and another stop layer (70) on the lower surface of the stop layer (70), and a thermoplastic polyolefin series Eco-friendly floor covering material. The surface protective layer 30 made of a copolymer containing propylene and ethylene and a thermoplastic polyolefin based material is subjected to corona treatment using an electric high frequency wave and then an adhesive 40 is applied to the surface of the surface protective layer 30 and compressed with the pattern layer 50, ; Applying a surface coating layer (10) on the surface protective layer (30) and performing a heat treatment; And Stacking a stop layer (70) and a balance layer (80) under the pattern layer (50) one after another and pressing them together by pressing; Comprising a propylene-ethylene containing copolymer and a thermoplastic polyolefin-based material. 5. The method of claim 4, The step of joining the stop layer (70) and the balance layer (80) Characterized in that a stop layer (70), an anti-shrinkage prevention layer (60), a stop layer (70) and a balance layer (80) are sequentially stacked under the pattern layer (50) and lapped with a press machine. And a thermoplastic polyolefin-based material. The method according to claim 4 or 5, In the step of laminating the stop layer 70 and the balance layer 80, Characterized in that an embossing pattern plate of a press machine is further loaded on the upper surface of the semi-finished article which is stacked in order and the press machine is press-processed at a temperature of the press machine at 130 to 150 DEG C for 20 to 30 minutes. A method for manufacturing an environmentally friendly floor covering comprising a thermoplastic polyolefin based material.

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