KR101946987B1 - Non-pvc eco-friendly flooring material and manufacturing method thereof - Google Patents

Abstract

The surface protective layer, the printing layer, the base layer, and the balance layer are laminated in order from the top, a surface protective layer, a print layer, a base layer and a balance layer, A resin containing two or more kinds of resins, and a resin material selected from thermoplastic elastomers. Specifically, by using a copolymer or a thermo plastic elastomer containing a polyolefin resin, which is an eco-friendly material, or a mixture of two substances, harmful substances such as environmental hormones and dioxins, volatile organic compounds (VOC) Which is a problem of a conventional polyolefin decorative material such as an environmental friendliness which does not generate toxic substances such as formaldehyde (HCHO), surface durability, transparency, adhesion to a floor of a building, thermal adhesion between each nonpolar polyolefin resin, And to a method for producing the same.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an environmentally friendly flooring material,

The present invention relates to an eco-friendly flooring material and a method for producing the same, and more particularly, to an eco-friendly flooring material comprising a homopolymer of a polyolefin resin or a copolymer containing two or more kinds of polyolefin resins or a thermoplastic elastomer without using a polyvinyl chloride resin, And a manufacturing method thereof.

Commonly used flooring materials include polyvinyl chloride (PVC) resins. Flooring materials containing polyvinyl chloride resin can be expressed by using polyvinyl chloride resin to give stereoscopic effects in various forms to express realism, depth, and sense of quality, or by adding natural materials such as loess, charcoal, and elvan It has been widely used in various forms such as adding a related function or combining a polyvinyl chloride (PVC) layer with a veneer to give a natural appearance of a natural wood to give a sense of reality.

For example, a large number of patent documents such as Patent No. 10-0409091, Patent No. 10-0524171, Patent No. 10-0292585 and the like disclose flooring materials using a number of polyvinyl chloride resins. Fig. 1 shows a schematic cross-sectional view of a polyvinyl chloride resin flooring according to the prior art. Specifically, a surface protective layer 10 of polyvinyl chloride resin, a printed layer 11 of polyvinyl chloride resin, a polyvinyl chloride resin Sectional view of a polyvinyl chloride resin flooring having a base layer 12 of a polyvinyl chloride resin and a balance layer 13 of a polyvinyl chloride resin.

Originally, polyvinyl chloride (PVC) resin is widely used in various fields because of its excellent processability. Since polyvinyl chloride (PVC) resin contains a chlorine (Cl) component, a large amount of smoke and chlorine gas Which is not only fatal to the human body but also releases a large amount of dioxins which are harmful substances and seriously damages the human body.

In addition, VOC (volatile organic compound) and HCHO (formaldehyde), which are the poisonous substances that are the cause of the shedding group, are generated by the phthalate plasticizer (DOP) added to the flooring for the processing of polyvinyl chloride resin (PVC) And there are many harmful problems to human body, and various stabilizers and other raw materials used as additives often contain toxic and heavy metals, and often cause serious damage by heavy metals. Therefore, in July 2013, all the flooring products manufactured using polyvinyl chloride resin were announced by the Korea Technology Standards Agency under the Quality Management and Industrial Safety Management Act, and the regulations on the content of phthalate plasticizer .

Therefore, the use of polyvinyl chloride flooring materials is limited in many facilities such as vessels, trains, transportation facilities, daycare facilities such as daycare centers, kindergartens, welfare facilities such as nursing homes and nursing homes, hospitals and large restaurants , Particularly in Europe, the Americas, and other countries, it is forcibly required to change to eco-friendly products without toxicity.

In order to solve these social and environmental problems, various methods have been developed to improve the processing method and formulation of polyvinyl chloride resin. However, due to the limitation of polyvinyl chloride resin properties, it is difficult to fundamentally solve such problems.

Recently, a composite floor material having a polyolefin-based material such as polyethylene or polypropylene is blended with a polyvinyl chloride resin in a part of the upper surface layer has been developed. However, this also has a limitation in completely overcoming the problems of the polyvinyl chloride resin.

In addition, although a product made of a polyolefin resin has been developed as a whole layer constituting the flooring material, it is difficult to meet the physical properties required as a flooring material due to the difficulty of processing the polyolefin-based material, There is a required problem. 2 shows a schematic cross-sectional view of a composite flooring material in which a polyolefin resin and a vinyl chloride resin are laminated according to the prior art. Specifically, a surface protective layer 14 of a polyolefin resin, a printing layer 11 of a polyvinyl chloride resin, Sectional view of a composite flooring in which a polyolefin resin having a base layer 12 of a polyvinyl chloride resin and a balance layer 13 of a polyvinyl chloride resin are laminated with a vinyl chloride resin.

Korean Patent Registration No. 10-0908661 discloses an environmentally friendly flooring material comprising a copolymer containing propylene and ethylene and a thermoplastic polyolefin-based material in order to improve the human health due to the use of the flooring material of the polyvinyl chloride resin (PVC) And a manufacturing method thereof.

However, the eco-friendly flooring material manufactured in the above-mentioned patent uses polyolefin resin as a floor material to eliminate chlorine gas and smoke when a fire occurs, and to remove toxic VOC (volatile organic compound) HCHO (formaldehyde) is not generated, so there is a safety advantage to the human body from safety accidents and harmful substances. However, since the surface layer, the pattern layer, and all the base layers constituting the bottom material are made of the same material, a copolymer of propylene and ethylene and a sheet material of a thermoplastic polyolefin series material, It is impossible to laminate by pressing and the adhesive layer must be applied separately. However, the use of the adhesive is often harmful to health due to the harmfulness of the organic compound contained in the adhesive, and there is a problem that a separate aging space is required because aging time is required for drying and adhesion of the adhesive for 48 hours or more. In addition, due to the nature of the material, there is a problem in the use of the flooring due to the surface durability, transparency, flexibility, and flexural strength of the finished product, and the construction problem of poor adhesion between the non-polar material and the bottom surface of the building. In addition, since the semi-finished products are stacked one after another and then manufactured by the intermittent process using the press facility, the productivity and the work efficiency are remarkably lowered, leading to a rise in manufacturing cost and a decrease in the production amount, and the market competitiveness is greatly weakened.

Accordingly, it is an object of the present invention to provide a polyolefin-based resin which is harmless to the human body, or a copolymer or a thermoplastic elastomer containing a mixture of the two, which is harmless to the human body, while using harmful substances such as environmental hormones and dioxins It is possible to perform thermal lamination by a continuous process without using each structural layer composed of a polyolefin resin layer as an adhesive while preventing the phenomenon of sick house syndrome caused by a plasticizer, It is necessary to design a composition that can improve the quality of the product.

In addition, an environmentally-friendly flooring material capable of securing productivity, workability, and workability while satisfying the physical properties required for flooring such as surface durability, transparency, dimensional stability, flexibility, curling property, to be.

SUMMARY OF THE INVENTION Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and it is an object of the present invention to provide a flame-retardant polyolefin resin composition which is free from smoke and chlorine gas generation during combustion, (VOC) and HCHO (formaldehyde), which are toxic substances that cause sick house syndrome due to phthalate plasticizer (DOP), are not generated, and heat stabilizers used in conventional polyvinyl chloride processing By not using other additive, it is aimed to solve the social and environmental problems by reducing damage to human life and property without toxic and heavy metal contained in heat stabilizer and other additive.

 In addition, there are problems in terms of dimensional stability, surface durability, transparency, flexibility, lowering of bending strength, quality problems of floor coverings using conventional polyolefin resins, problems in construction due to lowering of adhesion to the floor of buildings, Problems such as workability and productivity deteriorated due to application of an adhesive separately for laminating or heat treatment for a long time by using a press as an intermittent process facility and problems of harmfulness of the human body due to volatilization of organic compounds due to use of the adhesive are solved .

In addition to improving the dimensional stability, surface durability, transparency, flexibility and flexural strength, the additives and the manufacturing process are improved in the manufacturing process without using a separate adhesive, thereby greatly improving the workability and improving the quality and workability, workability, And an object of the present invention is to provide an excellent environmentally-friendly flooring material having health and health.

The surface protective layer, the printing layer, the base layer, and the balance layer are laminated in order from the top, a surface protective layer, a print layer, a base layer and a balance layer, A copolymer containing two or more kinds of thermoplastic elastomers, and a resin material selected from thermoplastic elastomers.

Preferably, the print layer comprises a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins, and the base layer comprises a thermoplastic elastomer.

Preferably, the environmentally friendly flooring material may further include a surface treatment layer on the surface protective layer.

Preferably, the thermoplastic elastomer is at least one selected from the group consisting of a polystyrene-based resin, a polyolefin-based resin and an engineering plastic-based resin.

Preferably, the polystyrene-based resin is a styrene-butadiene-styrene (SBS), a styrene-ethylene-butadiene-styrene (SEBS) or a styrene-isoprene-styrene (SIS) copolymer, (TPU), polyester type (TPEE) or polyamide type (TPA), and the engineering plastic type resin is a polyurethane type (TPO) or a polymerization type (r-TPO).

Preferably, the surface protective layer comprises 1 to 3 parts by weight of a nucleating agent per 100 parts by weight of the resin material.

Preferably, the nucleating agent is at least one of phosphoric acid ester metal salt and sodium benzoate.

Preferably, the print layer is a three-layer structure of a sealer layer, a center layer, and a matte layer, and the sealer layer comprises 100 parts by weight of a copolymer containing two or more polyolefin resins or a homopolymer of a polyolefin resin, Wherein the center layer comprises a homopolymer of a polyolefin resin or a copolymer containing at least two polyolefin resins, wherein the matte layer is a homopolymer of a polyolefin resin or a polyolefin resin 2 100 parts by weight of a copolymer containing at least one kind of polymer and 0.2 to 1 part by weight of a dispersing agent.

Preferably, the substrate layer comprises 100 parts by weight of a thermoplastic elastomer resin, 1 to 5 parts by weight of a surfactant, 20 to 30 parts by weight of ethylene vinyl acetate and 50 to 80 parts by weight of a filler.

Preferably, the balance layer includes the same resin material as the surface protective layer, and 3 to 5 parts by weight of a low melting point polyolefin resin based on 100 parts by weight of the resin material.

Preferably, the environmentally friendly flooring material further comprises a layer containing at least one selected from the group consisting of a nonwoven fabric layer and a cork sheet, which are formed of the same resin material as the surface protective layer, under the balance layer.

The present invention also relates to a method for producing an environmentally friendly floor material. Specifically, a step (S11) of printing a printed pattern on a sheet containing a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins to form a print layer; (S12) a surface protective layer comprising a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer on the print layer; (S13) forming a semi-finished product by coating the top of the surface protective layer with a primer and then forming a surface treatment layer; Forming a base layer comprising a thermoplastic elastomer (S14); (S15) forming a balance layer by adding a resin material, a filler, and a low-melting polyolefin-based resin, which are the same as the resin material contained in the surface protective layer, to a balance layer; And a step (S16) of successively thermally lapping the semi-finished product, the base layer and the balance layer in turn by embossing after winding them.

According to still another aspect of the present invention, there is provided a method for manufacturing an environmentally friendly floor material, comprising the steps of: (S21) forming a printed layer by printing a printed pattern on a sheet comprising a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins; (S22) a surface protective layer comprising a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer on the print layer; Forming a surface treatment layer on the upper surface of the surface protective layer with a primer to form an intermediate product (S23); Forming a balance layer (S24) by adding a resin material, a filler, and a low melting point polyolefin resin, which are the same as the resin material contained in the surface protective layer; And a step (S25) of continuously heat-joining the semi-finished product on the base material layer and the balance layer on the bottom of the base material layer while continuously forming the base material layer including the thermoplastic elastomer and the thermoplastic elastomer.

Preferably, further comprising the step of forming a nonwoven layer or a cork sheet layer below the balance layer after the step (S15 and S24) of forming the balance layer.

The environmentally friendly flooring material according to the present invention is harmless to the human body because it does not generate harmful substances such as environmental hormones and dioxins, toxic substances such as volatile organic compounds (VOC) and formaldehyde (HCHO) unlike the conventional polyvinyl chloride flooring materials . In addition, when a natural cork sheet (layer) is included, a health-beneficial function such as a far-infrared radiation function, an antibacterial function, an insect repellent function and the like can be given to the human body.

In addition, the conventional olefin flooring has a problem that the surface durability of the olefin flooring is lowered, the transparency thereof is lowered, the adhesion of the building to the floor surface is insufficient, and the lack of thermal adhesion between the polyolefin resins, By solving this problem through the formulation of copolymer or thermoplastic elastomer resin formulation, the eco-friendly flooring according to the present invention is excellent in surface durability, transparency, adhesion to the floor of the building, and continuous processing by embossing molding, The efficiency can be improved.

1 is a schematic cross-sectional view of a polyvinyl chloride resin flooring according to the prior art.
2 is a schematic cross-sectional view of a composite flooring laminated with an olefin resin and a polyvinyl chloride resin according to the prior art.
3 is a cross-sectional view of a NON-PVC eco-friendly floor material according to an embodiment of the present invention.
4 is a cross-sectional view of a NON-PVC eco-friendly flooring according to another embodiment of the present invention.
5 is a cross-sectional view of a NON-PVC eco-friendly flooring according to another embodiment of the present invention.
6 is a process diagram showing a method for manufacturing a NON-PVC eco-friendly flooring material according to an embodiment of the present invention.
7 is a process diagram illustrating a method of manufacturing a NON-PVC eco-friendly floor material according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. However, this is merely an example, and the present invention is not limited thereto.

The NON-PVC eco-friendly flooring material according to the present invention can sequentially laminate the surface protective layer 21, the print layer 22, the base layer 23 and the balance layer 24 from the top. 3 is a cross-sectional view of a NON-PVC environmentally acceptable floor covering according to an embodiment of the present invention.

The environmentally friendly flooring material according to the present invention is characterized in that the surface protective layer 21, the printing layer 22, the base layer 23 and the balance layer 24 are formed of a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins , Or a thermoplastic elastomer.

The polyolefin-based resin in the copolymer resin containing the polyolefin-based resin alone or in a mixture of the two means polypropylene, polyethylene, polypropylene-ethylene polymer, polyolefin-based elastomer and the like, and the polypropylene- Rosene-polypropylene, or homo-polypropylene, and random-polypropylene.

The thermoplastic elastomer may be at least one selected from the group consisting of polystyrene, polyolefin, and engineering plastics. Specifically, a polystyrene thermoplastic elastomer (TPS) is a thermoplastic elastomer such as a styrene-butadiene-styrene (SBS), a styrene-ethylene-butadiene-styrene (SEBS), and a styrene-isoprene- TPO (Thermoplastic Olefin) is used in a simple brand type (S-TPO) and a polymerization type (R-TPO), and polypropylene or polyethylene is mainly used as a hard segment, and ethylene propylene rubber (EPM, EPDM), nitrobutyl rubber (NBR), and the like. The engineering plastics can be selected from among polyurethane (TPU), polyester (TPEE) and polyamide (TPA).

A detailed examination of each layer is as follows.

The surface protective layer 21 is a layer which is formed on the upper surface of the print layer 22 and finishes the surface of the bottom material. The surface protective layer 21 is composed of a resin selected from a copolymer resin containing a polyolefin resin alone or a mixture of two or a thermoplastic elastomer And 1 to 3 parts by weight of a nucleating agent per 100 parts by weight of the resin material.

The nucleating agent is added to improve the surface durability and transparency of one kind of resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer. The nucleating agent may be at least one of an aromatic phosphate ester metal salt and sodium benzoate. In the case of the aromatic phosphoric acid ester metal salt, it may be a metal salt such as sodium (Na), zinc (Zn), aluminum (Al) and the like. It is preferable to use a nucleating agent having an average particle diameter of 10 μm or less and a bulk specific gravity of 0.1 g / cm ³ or more. The surface durability is more than doubled and the transparency is improved by using a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer by the addition of a nucleating agent .

The printing layer 22 is a layer for creating a pleasant and beautiful indoor space by imparting the interior property of the flooring material. The printing layer 22 is formed of a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins , Or a thermoplastic elastomer, and it may preferably be a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins.

In one embodiment, the print layer 22 may comprise 5 to 10 parts by weight of pigment, 3 to 5 parts by weight of ethylene vinyl acetate, and 0.2 to 1 part by weight of a dispersant, based on 100 parts by weight of the resin material.

In another embodiment, the printing layer 22 may be composed of a non-drawn three-layered laminate structure (sealer layer, center layer, and matte layer) imparting thermal adhesiveness and printing suitability. Specifically, a core layer comprising a homopolymer of a polyolefin resin or a copolymer resin containing two or more polyolefin resins, a sealer layer located on one side of the core layer and for improving the adhesion between the base layer and the core layer, And a matte layer located on the other side and improving the printability of the center layer may be made of a coextruded triple structure.

Ethylene vinyl acetate contained in the print layer can be added for the purpose of improving adhesion at a low temperature even at a low temperature by improving adhesion at a low temperature with a surface protective layer and a base layer. Ethylene vinyl acetate may be used in an amount of 3 to 5 parts by weight based on 100 parts by weight of the resin material, and preferably has a vinyl acetate content of 20 to 30% and a melt flow index of about 0.1 to 5 g / 10 min. The higher the vinyl acetate content, the better the low-temperature adhesive strength, but the lower the melt viscosity, the more difficult it is to extrude.

The pigment may be titanium dioxide (TiO ₂ ) which is added for the purpose of improving whiteness and hiding power. In this case, the titanium oxide is preferably added in an amount of 5 to 10 parts by weight, and in the case of a surface for improving printing suitability on both sides, 0.2 to 1 part by weight of a dispersant may be added in addition to the composition ratio to improve the sharpness of printing have. If the amount of the dispersing agent is more than 1 part by weight, it may be unmelted or fish-eye may be generated. If the amount of the dispersing agent is less than 0.2 parts by weight, the desired effect may not be obtained. In addition, in the case of a surface for improving low-temperature thermal adhesiveness, 3 to 5 parts by weight of ethyl vinyl acetate may be further included in addition to the composition ratio.

The base layer 23 is a layer that corrects the thickness of the bottom material and imparts functions such as cushioning, walking feeling, shock absorption, and the like. The substrate layer 23 may be a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer, and may preferably be a thermoplastic elastomer resin. The substrate layer may comprise 100 parts by weight of a thermoplastic elastomer resin, 1 to 5 parts by weight of a surfactant, 20 to 30 parts by weight of ethylene vinyl acetate and 50 to 80 parts by weight of a filler. More specifically, 100 parts by weight of a thermoplastic elastomer, 1 to 5 parts by weight of a surfactant, 1 to 5 parts by weight of a surfactant, 1 to 5 parts by weight of a pigment, 20 to 30 parts by weight of ethylene vinyl acetate and 50 to 80 parts by weight of a filler.

The thermoplastic elastomer resin used for the base layer 23 preferably has a hardness Shore A of 70 to 90, a melt index of 0.6 to 2.0 g / 10 min (230 캜 / 2.6 KG) and a specific gravity of 0.90 to 1.15 g / cm ³ .

The heat stabilizer is added in order to prevent aging and deformation due to heat during the molding of the bottom material, and all the heat stabilizers used in the technical field can be used, and preferably calcium stearate can be used.

The heat stabilizer may contain 1 to 5 parts by weight based on 100 parts by weight of the resin material. When the thermosetting agent is used in an amount of less than 1 part by weight, the deterioration preventing effect is poor. When the thermosetting agent is used in an amount exceeding 5 parts by weight, This may cause the aggregation phenomenon to occur.

The surfactant is added to improve the dispersibility of the filler, and at least one of an aliphatic amine salt and an aromatic quaternary ammonium salt can be used. The surfactant may include 1 to 5 parts by weight based on 100 parts by weight of the resin material used for the substrate layer. When the surfactant is contained in an amount of less than 1 part by weight, the flowability of the thermoplastic elastomer resin is lowered And if it exceeds 5 parts by weight, the mechanical properties of the bottom material may be deteriorated.

The filler is filled to improve overall cost reduction and dimensional stability of the bottom material, and may include at least one of calcium carbonate, barium sulfate, calcium sulfate, silica, talc, and mica. The filler may be contained in an amount of 50 to 80 parts by weight with respect to 100 parts by weight of the resin material used for the substrate layer. When the filler is less than 50 parts by weight, the dimensional stability and the cost reduction effect of the flooring material may be insufficient. The flexibility and bonding strength may be weakened by increasing the density of the flooring.

Ethylene vinyl acetate can be added for the purpose of improving adhesion at low temperatures and adhesion to print and balance layers at low temperatures.

The balance layer 24 is a layer that finishes to the lower layer of the flooring to control and balance the curling phenomenon and dome phenomenon of the flooring, prevent deformation due to floor moisture after installation, and improve adhesion to the building floor, And may include the same resin material as the surface protective layer 21. The balance layer 24 may include 100 parts by weight of a resin material, 200 parts by weight of a filler, and 3 to 5 parts by weight of a low melting point polyolefin resin.

The low melting point polyolefin resin contained in the balance layer 24 preferably has a hardness Shore A 90, a melt index of 5 to 7 g / 10 min, and a specific gravity of 0.89 to 0.91 g / cm ³ . The low melting point polyolefin resin is preferably used in an amount of 3 to 5 parts by weight based on 100 parts by weight of the resin material of the balance layer. It is used for the purpose of improving the thermal bonding strength with the substrate layer at a low temperature by using a low melting temperature of 140 캜 or less.

The surface treatment layer 20 is formed on the upper surface of the surface protective layer 21 to prevent deterioration of the physical properties and aging of the bottom material, as well as to prevent contamination and scratching of the bottom material and to facilitate cleaning. The surface treatment layer 20 may be selected from at least one of an unsaturated polyester resin type epoxy acrylate type, a urethane acrylate type, and a polyester acrylate type.

Also, the eco-friendly flooring according to the present invention may include at least one additional layer selected from a nonwoven fabric and a cork sheet.

The additional layer 30 including the nonwoven fabric can be widened to a lower layer of the flooring to provide an improved appearance as well as to improve the adhesion of the adhesive by increasing the area of adhesion with the floor of the building. The nonwoven fabric preferably uses a long-fiber nonwoven fabric 30 made of the same material as the surface protective layer 21, and a nonwoven fabric having a weight of 50 g / m 2 can be used. Figure 4 shows a cross-sectional view of an eco-friendly flooring having an additional layer (30) comprising a nonwoven.

The additional layer 40 including the cork sheet is useful for human health and contains a far infrared ray radiation function, an antibacterial function, an antiseptic function, etc. of the natural cork sheet itself, and can be closed to the lower layer of the flooring . The cork sheet used as the cork layer 40 may be a cork sheet having a diameter of about 1 to 10 mm, a thickness of 1 to 2 mm, and a specific gravity of 0.2 to 0.4 g / cm 3. In addition, the more cow's water content, the greater the shrinkage or expansion caused by heat, so it is preferable to use water having a moisture content of 2% or less. Figure 5 shows a cross-sectional view of an eco-friendly flooring having an additional layer (40) comprising a cork sheet.

The method for manufacturing the NON-PVC eco-friendly flooring according to the present invention is as follows.

As an example, a method of manufacturing an eco-friendly flooring material according to the present invention includes a step (S11) of producing a print layer 22, a step (S12) of laminating a surface protective layer 21 on a print layer 22, (S13), a base layer 23 manufacturing step (S14), a balance layer (24) manufacturing step (S15), a step of coating the upper surface of the protective layer (21) with a primer, And a surface layer 21 on which the surface treatment layer 20 is coated and a base layer 23 and a balance layer 24 under the print layer 22 are sequentially wound and then continuously laminated together using an embossing machine. (S16). Specifically, a step (S11) of printing a printed pattern on a sheet containing a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins to form a print layer 22; A surface protective layer 21 comprising a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer is laminated on the print layer 22 Step S12; (S13) forming a semi-finished product (50) by forming a surface treatment layer (20) after coating the upper surface of the surface protective layer with a primer; Forming a base layer (23) comprising a thermoplastic elastomer (S14); A step (S15) of forming a balance layer (24) by adding a resin material, a filler and a low melting point polyolefin resin, which are the same as the resin material contained in the surface protective layer (21); And a step (S16) of successively thermally lapping the semi-finished product (50), the base layer (23) and the balance layer (24) by winding them in order by embossing.

The step (S11) of forming the print layer 22 is carried out by first forming a three-layered structure in which a core layer is a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins, and a surface layer is co- . One surface of the both surfaces is a surface (matte layer) for improving printing suitability and the other surface is a surface (sealer layer) for improving low-temperature thermal adhesion with the substrate layer

A homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins contained in the print layer 22 is mixed using a kneader or a Banbury mixer at a temperature higher than the melting point of 130 to 190 캜, Is fed from a kneader to an extruder hopper, and the molten resin composition is extruded through a T-die (T-DIE) at 150 to 220 ° C using a single screw or twin-screw extruder to prepare a sheet. If the temperature of the extruder is less than 150 ° C, the resin can not be sufficiently melted and the melt pressure of the resin excessively increases, which makes extrusion difficult. If the temperature exceeds 220 ° C, the resin is easily melted but the resin can easily be oxidized. The printed sheet is manufactured, and the printed layer 22 can be manufactured by corona treating the surface of the printed sheet using an electric high frequency and then printing a certain shape.

In the step S12 of laminating the surface protective layer 21 on the upper surface of the print layer 22, the compositions constituting the surface protective layer 21 are mixed at a predetermined ratio as described above, Layer 22 is passed through a cooled embossing roll while being extruded onto the print layer 22 by the same manufacturing process for producing the layer 22 to make the print layer 23 and the surface protective layer 21 into a laminated sheet state .

As described above, the eco-friendly floor material according to the present invention is not an adhesive system for bonding the print layer 22 and the surface protection layer 21 through an adhesive, but a heat fusion process in which each layer is mutually adhered using heat energy that each layer has in a molten state . ≪ / RTI > Such a thermal fusion method is advantageous in that the adhesive strength is superior to that of the method using an adhesive, and there is no contamination or odor of the product due to the adhesive.

Next, the surface protection layer is coated with a primer and then the surface treatment layer 20 is formed to form a semi-finished product 50 (S13). The surface treatment layer 20 is formed of an unsaturated polyester resin system, an epoxy acrylate system, a urethane acrylate system, and a urethane acrylate system in order to prevent deterioration of the physical properties of the bottom material and aging and to prevent contamination and scratching of the bottom material and to facilitate cleaning. A polyester acrylate system, and applying ultraviolet curing.

A polyolefin resin as a surface protective layer (21) resin, or a copolymer resin or a thermoplastic elastomer resin containing a mixture of two resins, which is a saturated polyester resin, an epoxy acrylate resin, a urethane acrylate resin , And polyester acrylate, it is preferable that primer (pretreatment) treatment is performed before coating because there is no compatibility with resins used. The chemicals that are pretreated for the purpose of increasing compatibility with aqueous UV coatings are called primers. Thermoplastic olefin resins are nonpolar and have low adhesion to other materials. Therefore, in order to form a protective layer stably, a pre-treatment process that maximizes the compatibility of both materials is indispensable.

(S14) of forming a base layer (23) comprising a thermoplastic elastomer and a resin material, a filler and a low melting point polyolefin resin which are the same as the resin material contained in the surface protective layer (21) (S15) is performed by the same manufacturing method of manufacturing the print layer 22 by mixing the respective compositions added in the predetermined ratio as described above, through T-die extrusion molding, Can be produced in a sheet form.

The method may further include the step of further producing a nonwoven layer or a cork sheet layer after the base layer and the surface protective layer are produced. The nonwoven fabric layer, the homopolymer of the polyolefin resin, and the long-fiber nonwoven fabric layer 30 including the copolymer containing two or more polyolefin resins can prevent shrinkage of the product on the lower surface of the balance layer 24, And also facilitates adhesion. Alternatively, a cork sheet layer 40, which is a natural material, may be used in place of the long-fiber nonwoven fabric to add functionalities beneficial to human health such as far-infrared radiation function, antibacterial function, and insect repellent function.

The semifinished product 50 having the surface treatment layer, the surface protective layer, and the print layer thus produced laminated, the base layer and the semi-finished product of the balance layer were prepared and wound on a mounting table, and each of the semi-finished products was preheated to about 130 to 150 ° C Followed by thermosetting while passing each of the embossing apparatuses having the heating drums of 140 to 180 ° C and laminating them by a continuous process.

The finished semi-finished product is cut into a certain size, passed through a heat bath of 80 ℃ or more for 2 ~ 5 minutes and cooled in a cooling water bath at 20 ~ 25 ℃ for 2 ~ 5 minutes to prevent deformation of the finished product, It is possible to keep the temperature of the surface of the product constant and to keep the cut surface clean during cutting.

When the above process is completed, it is cut into a knife mold using a hydraulic press according to a certain size standard, and then packed and shipped.

Another manufacturing method includes a step (S21) of printing a printed pattern on a sheet containing a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins to form a print layer 22; A surface protective layer 21 comprising a resin material selected from a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, or a thermoplastic elastomer is laminated on the print layer 22 Step S22; Coating the upper surface of the surface protective layer 21 with a primer and then forming a surface treatment layer 20 to form an intermediate product 50 (S23); A step (S24) of forming a balance layer (24) by adding a resin material, a filler and a low melting point polyolefin resin, which are the same as the resin material contained in the surface protective layer (21); Placing the semi-finished product (50) on the base layer (23) and the balance layer (24) on the lower part of the base layer while forming the base layer (23) comprising the thermoplastic elastomer (S25). 7 is a process diagram illustrating a method of manufacturing a NON-PVC eco-friendly floor material according to another embodiment of the present invention.

A step S21 of forming the print layer 22 and a step S22 of extruding the surface protective layer 21 on the print layer 22 and a step S22 of bonding the surface protective layer 21 and the print layer 22, (S23) of forming a semi-finished product (50) by coating a primer on the upper surface of the base layer (23) and applying the coating to the surface treatment layer (20) (24) The prescription and method used for manufacturing are the same as the previously mentioned method. The fact that the semifinished product 50 and the balance layer 24, which are laminated with the surface treatment layer 20, the surface protective layer 21 and the print layer 22, are simultaneously and continuously heated in the step of producing the base layer, Which is different from the above-mentioned method of manufacturing an eco-friendly flooring. The heat of the heat-sealed semi-finished product, the cooling aging condition, and the cutting and shipping method can be made the same. Alternatively, the method may be performed by thermocompression bonding using a temperature of the extruder at 150 to 220 ° C, which is generated in the process of forming the substrate layer, followed by lapping in a continuous process, aging in a hot water bath and cooling water bath for 4 to 10 minutes . In addition, this method can further include a nonwoven fabric layer or a cork sheet layer at the bottom of the balance layer.

Since the manufacturing method of the eco-friendly flooring according to the present invention is performed in the process of producing the base layer without passing through the separate embossing facility, the process can be simplified, and the manufacturing cost, productivity, and work efficiency can be greatly improved.

 Hereinafter, the present invention will be described in more detail with reference to Examples. It is to be understood by those skilled in the art that these embodiments are only for describing the present invention more specifically and that the scope of the present invention is not limited by these embodiments in accordance with the gist of the present invention.

Example  1

Each semifinished product constituting the NON - PVC eco - friendly flooring was prepared. The printed layer was prepared by mixing 8 parts by weight of titanium oxide (TiO ₂ ), 5 parts by weight of ethylene vinyl acetate, and 0.5 part by weight of a dispersant (ADVAWAX 280, ROHM HARS, USA) as 100 parts by weight of a copolymer resin of homopolymer of propylene and random propylene The sheet was prepared to a thickness of 0.08 mm and then a specific pattern was printed and prepared. 100 parts by weight of a copolymer of homopropylene and random propylene as a surface protective layer and 2 parts by weight of sodium phosphate as a nucleating agent were mixed and extruded through a T-die to a thickness of 0.3 mm on the upper surface of the print layer, The semi-finished product 1 was prepared by processing a urethane resin-based primer on its upper surface, UV-curing the surface-treated layer, and then curing it. 100 parts by weight of thermoplastic elastomer resin of a simple brand type (S-TPO) obtained by mixing 40% of rubber-like ethylene propylene rubber (EPDM) with polypropylene resin as a thermoplastic elastomer resin, 3 parts by weight of calcium stearate as a heat stabilizer Prepared by mixing 2 parts by weight of an aromatic quaternary ammonium salt as a surfactant, 3 parts by weight of titanium oxide (TiO ₂ ), 25 parts by weight of ethylene vinyl acetate and 70 parts by weight of calcium carbonate (CaCO ₃ ) as a filler, The balance layer was prepared by mixing 100 parts by weight of a homopolymer of a propylene homopolymer and a random propylene copolymer as a polyolefin resin, 3 parts by weight of a low melting point polyolefin resin having a melt index of 7 g / 10 min, and 200 parts by weight of calcium carbonate as a filler 0.35 mm in thickness and semi-finished product 3 was prepared.

The semi-finished products 1, 2 and 3 were wound in turn on a stage, and each semi-finished product was preheated to about 130 ° C and hot-pressed while passing through an embossing facility having a heating drum at 160 ° C. The laminated semi-finished product was cut into a certain size, passed through a 90 ° C water bath for 5 minutes, cooled in a cooling water bath at 25 ° C for 5 minutes, cut into a certain size with a knife die,

Comparative Example  Preparation of 1 and 2

According to the same material and method as in Example 1 of the present invention in which a nucleating agent and a low melting point polyolefin-based resin were added to the surface protective layer and the balance layer for improving the abrasion resistance and bond adhesiveness to the concrete bottom surface, Comparative Example 1 was prepared in the same manner as in Example 1, except that no resin was used. Also, a flooring material containing polyvinyl chloride resin (aka a print tile or a PVC decor tile) was purchased and tested as Comparative Example 2, as shown in Fig. 1, which is on the market. In Comparative Example 2, a transparent top sheet having a thickness of 0.3 mm, a layer structure similar to that of the present invention, and a thickness similar to that of each layer were selected.

Experimental Example One ; additive  Comparison of flooring materials according to presence or absence

The exterior appearance, transparency, abrasion resistance, interlayer adhesion, adhesion to the floor of the building, and environmental friendliness of NON - PVC environmentally - coated flooring materials manufactured with and without additives were compared with those of commercially available polyvinyl chloride flooring materials. The above properties are based on KS M 3802 (PVC (vinyl) flooring) test standard, JIS K 7136 (haze measurement method of plastic transparent material), ASTM D 3389 (abrasion resistance measurement method) Respectively. The results are shown in Table 6.

The appearance, transparency, abrasion resistance, interlayer adhesion, adhesion to the floor, and environmental friendliness of the eco-friendly flooring samples prepared according to the following Examples and Comparative Examples were measured as follows.

Experiment 1) Evaluation of appearance condition

As a measure of appearance, it is a measure of defects, cracks, cracks, cuts, bends, holes, peeling, wrinkles, curvature, curvature, uneven irregularities, unevenness in shape, The appearance of the foreign matter was visually inspected based on the evaluation criteria shown in Table 1 below.

division ◎ (excellent) ○ (Good) △ (Normal) × (poor) Appearance condition No faults 1 to 2 defects at 6M intervals 3 to 5 defects at 6M intervals 5 or more defects in 6M interval

Experiment 2) Evaluation of transparency

The haze state of the sheet layer used for the transparent protective layer in accordance with JIS K 7136 as a measure of transparency was evaluated through the HUNTER LAB COLOR QUEST XE equipment based on the evaluation criteria shown in Table 2 below.

division ◎ (excellent) ○ (Good) △ (Normal) × (poor) Haze 30 or less 40 or more
Less than 50 Over 50
Less than 60 60 or more

Experiment 3) Evaluation of abrasion resistance

The abrasion resistance was evaluated on the basis of the evaluation criteria shown in the following Table 3 for the number of times until the 0.3 mm transparent protective layer of the bottom material was worn under the condition of the wear wheel H-18 and the applied load 2 Kg in accordance with ASTM D3389 as a measure of abrasion resistance.

division ◎ (excellent) ○ (Good) △ (Normal) × (poor) Number of abrasions More than 15,000 More than 13,000
Less than 15,000 10,000 or more
Less than 13,000 Less than 10,000

Experiment 4) Interlayer adhesion and evaluation of adhesiveness to the bottom

As a measure of adhesiveness, peeling was carried out in a 180 ° direction at a tensile speed of 200 ± 20 mm / min by peeling off the layer to a position of about 20 mm using a tensile tester according to KS M 3802 on the basis of the evaluation criteria shown in Table 4 The adhesion was evaluated.

division ◎ (excellent) ○ (Good) △ (Normal) × (poor) Peel strength (N / cm) 5 or more 3 or more
Less than 5 1 or more
Less than 3 Less than 1

Experiment 5) Evaluation of environment friendliness

TVOC emission amount, formaldehyde emission amount and toluene emission amount based on the indoor air quality test standard as a measure of environment friendliness were evaluated based on the evaluation criteria shown in Table 5 below.

Eco-friendliness evaluation criteria (after 7 days) division ◎ (excellent) ○ (Good) △ (Normal) × (poor) TVOC emission
(mg / m 2 h) 0.1 or less 0.1 or more
Less than 0.2 0.2 or more
Less than 0.4 0.4 or less Formaldehyde Emission (mg / m 2 h) 0.015
Below 0.015 or more
Less than 0.020 0.020 or more
Less than 0.030 0.030 or more Toluene emission
(mg / m 2 h) 0.1 or less 0.1 or more
Less than 0.2 0.2 or more
Less than 0.4 0.4 or less

Table 6 shows the evaluation results of the flooring materials in which the methods of Experiments 1) to 5) were evaluated.

Appearance condition transparency Abrasion resistance Interlayer
Adhesiveness Adhesion to floor Eco-friendly Example 1 ◎ ◎ ◎ ◎ ◎ ◎ Comparative Example 1 ○ △ △ △ × ◎ Comparative Example 2 ◎ ○ × ◎ ◎ △

As can be seen from the above Table 6, the flooring material (Example 1) produced according to the present invention had better appearance, transparency, abrasion resistance, interlayer adhesion, adhesion to the floor of the building, Environment-friendliness, and the like.

As described above, the NON-PVC eco-friendly flooring material of the present invention and the method of manufacturing the same are described as concrete examples, but the present invention is not limited thereto. It is possible to adopt a structure that is not specified, but this is also within the scope of the present invention. In addition, it is obvious that the embodiments disclosed on the basis of this specification can be easily changed or modified, and such changes or modifications fall within the scope of the present invention.

10: Surface protective layer of polyvinyl chloride resin
11: Printed layer of polyvinyl chloride resin
12: Base layer of polyvinyl chloride resin
13: Balance layer of polyvinyl chloride resin
14: Surface protective layer of polyolfin resin
20: Surface treatment layer
21: a copolymer resin containing a polyolefin resin alone or a mixture of two resins or
The thermoplastic elastomer surface protective layer
22: Copolymer resin printing layer containing a polyolefin resin alone or a mixture of two
23: Base layer of thermoplastic elastomer
24: a copolymer resin containing a polyolefin resin alone or a mixture of two resins or
The thermoplastic elastomer balance layer
30: a polyolefin resin alone or a copolymer resin containing a mixture of two resins or
The thermoplastic elastomer nonwoven fabric layer
40: cork sheet layer
50: semi-finished product in which a surface treatment layer, a surface protective layer and a print layer are laminated

Claims (14)

The surface protective layer, the print layer, the base layer and the balance layer are successively thermally laminated from above,
Wherein the surface protective layer comprises 100 parts by weight of one resin material selected from the group consisting of a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins and a thermoplastic elastomer, and 1 to 3 parts by weight of a nucleating agent, Wherein the nucleating agent is at least one of an aromatic phosphate ester metal salt and sodium benzoate and has an average particle diameter of 10 mu m or less and a bulk specific gravity of 0.1 g /
Wherein the printing layer comprises 100 parts by weight of a resin material comprising a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins, 5 to 10 parts by weight of pigment, 3 to 5 parts by weight of ethylene vinyl acetate and 0.2 to 1 part by weight of a dispersant Wherein the ethylene vinyl acetate has a melt flow index of 0.1 to 5 g / 10 min,
Wherein the substrate layer comprises 100 parts by weight of a resin material made of a thermoplastic elastomer resin, 1 to 5 parts by weight of a surfactant, 20 to 30 parts by weight of ethylene vinyl acetate, 50 to 80 parts by weight of a filler and 1 to 5 parts by weight of a heat stabilizer, and thermoplastic elastomer resins hardness Shore a 70 ~ 90, melt index of 0.6 ~ 2.0g / 10min (230 ℃ / 2.6 KG), specific gravity 0.90 ~ 1.15 g / cm ^3,
Wherein the balance layer comprises the same resin material as the surface protective layer and 3 to 5 parts by weight of a low melting point polyolefin resin based on 100 parts by weight of the resin material, wherein the low melting point polyolefin resin has a hardness Shore A 90, An index of 5 to 7 g / 10 min, and a specific gravity of 0.89 to 0.91 g / cm ³ . The method according to claim 1,
Wherein the environmentally friendly flooring further comprises a surface treatment layer on top of the surface protection layer. The method according to claim 1,
Wherein the thermoplastic elastomer is at least one selected from the group consisting of a polystyrene-based resin, a polyolefin-based resin, and an engineering plastic-based resin. The method of claim 3,
The polystyrene-based resin is a styrene-butadiene-styrene (SBS), a styrene-ethylene-butadiene-styrene (SEBS) or a styrene-isoprene-styrene (SIS)
The polyolefin-based resin is a simple brand type (s-TPO) or a polymerization type (r-TPO)
Wherein the engineering plastic resin is a polyurethane system (TPU), a polyester system (TPEE), or a polyamide system (TPA). The printing method according to claim 1, wherein the printing layer has a three-layer structure of a sealer layer, a center layer and a matte layer,
Wherein the sealer layer comprises a homopolymer of a polyolefin resin or 100 parts by weight of a copolymer containing two or more polyolefin resins and 3 to 5 parts by weight of ethylene vinyl acetate,
Wherein the core layer comprises a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins,
Wherein the matte layer comprises 100 parts by weight of a copolymer containing two or more polyolefin resins or a homopolymer of a polyolefin resin and 0.2 to 1 part by weight of a dispersant. The eco-friendly floor material according to claim 1, wherein the environmentally-friendly floor material further comprises a layer containing at least one selected from the group consisting of a non-woven fabric layer and a cork sheet, Flooring. 100 parts by weight of a resin material comprising a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins, 5 to 10 parts by weight of a pigment, 3 to 5 parts by weight of ethylene vinyl acetate and 0.2 to 1 part by weight of a dispersant (S11) printing a print pattern on a sheet having a melt flow index of ethylene vinyl acetate of 0.1 to 5 g / 10 min to form a print layer,
The sheet is prepared by mixing a resin material, a pigment, ethylene vinyl acetate and a dispersant at a temperature of 130-190 ° C using a kneader or a Banbury mixer, melting the resin composition in an extruder at 150-220 ° C, (S11) which will be formed by extrusion;
100 parts by weight of one resin material selected from the group consisting of a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, and a thermoplastic elastomer, and 1 to 3 parts by weight of a nucleating agent, (S12) of thermally laminating a surface protective layer having an average particle diameter of 10 mu m or less and a bulk specific gravity of 0.1 g / cm3 or more, wherein the nucleating agent is at least one of an aromatic phosphate ester metal salt and sodium benzoate;
(S13) forming a semi-finished product by coating the top of the surface protective layer with a primer and then forming a surface treatment layer;
1 to 5 parts by weight of a surfactant, 20 to 30 parts by weight of ethylene vinyl acetate, 50 to 80 parts by weight of a filler, and 1 to 5 parts by weight of a heat stabilizer, wherein the thermoplastic elastomer resin comprises 100 parts by weight of a thermoplastic elastomer resin, hardness Shore a 70 ~ 90, melt index of 0.6 ~ 2.0g / 10min (230 ℃ / 2.6 KG), forming a specific gravity 0.90 ~ 1.15 g / cm ³ of the base layer (S14);
Wherein the low melting point polyolefin resin has a hardness Shore A 90, a melt index of 5 to 7 g, and a melting point of 5 to 7 g. / 10 min and a specific gravity of 0.89 to 0.91 g / cm ³ (S15); And
After the semi-finished product, the base layer and the balance layer are wound one after another, they are preheated to about 130 to 150 ° C, and then heat-sealed by embossing to pass through the embossing apparatus having a heating drum at 140 to 180 ° C (S16). ≪ / RTI > 100 parts by weight of a resin material comprising a homopolymer of a polyolefin resin or a copolymer containing two or more polyolefin resins, 5 to 10 parts by weight of a pigment, 3 to 5 parts by weight of ethylene vinyl acetate and 0.2 to 1 part by weight of a dispersant , A printing pattern is printed on a sheet having a melt flow index of ethylene vinyl acetate of 0.1 to 5 g / 10 min to form a printing layer,
The sheet is prepared by mixing a resin material, a pigment, ethylene vinyl acetate and a dispersant at a temperature of 130-190 ° C using a kneader or a Banbury mixer, then transferring the mixed resin composition from the kneader to an extruder hopper, (S21), which is melted at 150 to 220 deg.
100 parts by weight of one resin material selected from the group consisting of a homopolymer of a polyolefin resin, a copolymer containing two or more polyolefin resins, and a thermoplastic elastomer, and 1 to 3 parts by weight of a nucleating agent, (S22) of thermally laminating a surface protective layer having an average particle diameter of 10 mu m or less and a bulk specific gravity of 0.1 g / cm3 or more, wherein the nucleating agent is at least one of an aromatic phosphate ester metal salt and sodium benzoate;
Forming a surface treatment layer on the upper surface of the surface protective layer with a primer to form an intermediate product (S23);
Wherein the low melting point polyolefin resin has a hardness Shore A 90, a melt index of 5 to 7 g, and a melting point of 5 to 7 g. / 10 min, and a specific gravity of 0.89 to 0.91 g / cm ³ (S24); And
1 to 5 parts by weight of a surfactant, 20 to 30 parts by weight of ethylene vinyl acetate, 50 to 80 parts by weight of a filler, and 1 to 5 parts by weight of a heat stabilizer, wherein the thermoplastic elastomer resin comprises 100 parts by weight of a thermoplastic elastomer resin, And the base material layer having a hardness Shore A of 70 to 90, a melt index of 0.6 to 2.0 g / 10 min (230 캜 / 2.6 KG) and a specific gravity of 0.90 to 1.15 g / cm ³ , (S25), placing the balance layer in a lower part of the heating zone, continuously laminating the mixture at a temperature of 150 to 220 DEG C, and aging in a hot water and a cooling water bath for 4 to 10 minutes. 9. The method according to claim 7 or 8,
Further comprising the step of forming a nonwoven layer or a cork sheet layer below the balance layer after the step (S15 and S24) of forming the balance layer. delete delete delete delete delete

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