KR102294339B1 - A light flooring material - Google Patents

Abstract

This application relates to lightweight flooring.

Description

Lightweight Flooring {A LIGHT FLOORING MATERIAL}

This application relates to lightweight flooring.

Flooring materials used in buildings are manufactured by adding fillers to increase volume and improve processability. As the filler _{, coal (CaCO 3} ) is used a lot in the industry, but coal has a specific gravity of 2.4-2.7, and there is a limit in that the product becomes heavy when it contains a lot of filler to manufacture a high-thickness product or to improve processability.

Therefore, in the case of a high-thickness flooring material, there is a problem in that the workability is deteriorated or the thickness of the flooring material is limited in order to improve the workability.

In order to solve this problem, Laid-Open Patent Publication No. 10-2015-0122286 discloses a PVC flooring composition comprising fly ash, but there is still a demand for weight reduction of the flooring even in this disclosure.

KR10-2015-0122286A1 (2015.11.02)

The present application relates to a lightweight flooring material including a backing layer, a foaming layer, and an interleaving layer, wherein at least one layer of the backing layer, the foaming layer and the interleaving layer contains 1-12 parts by weight of glass bubbles based on 100 parts by weight of a thermoplastic resin, An object of the glass bubble is to provide a lightweight flooring material having an internal pressure level of 400-1000 psi and an average true density of 0.17-0.30 g/cc.

Hereinafter, the present application will be described in detail.

The present application relates to a lightweight flooring material including a backing layer, a foaming layer, and an interleaving layer, wherein at least one layer of the backing layer, the foaming layer and the interleaving layer contains 1-12 parts by weight of glass bubbles based on 100 parts by weight of a thermoplastic resin, The pressure level of the glass bubble is 400-1000psi and the average true density is 0.17-0.30g/cc to provide a lightweight flooring material.

The easy layer is located at the bottom of the flooring to balance the bending of the entire flooring, and serves to prevent bending and deformation of the flooring after flooring is installed.

The foam layer is located on the upper part of the backing layer and serves to provide a cushioning feeling to the flooring material, to absorb a shock, and to damp vibrations.

The interlayer layer is located on the foam layer and serves to improve the adhesion between the foam layer and the layer located on the interlayer layer.

Any one or more layers of the easy layer, the foaming layer and the interlayer layer, specifically, the easy layer is 6-10 parts by weight based on 100 parts by weight of the thermoplastic resin, and the foaming layer is 1-5 parts by weight based on 100 parts by weight of the thermoplastic resin. The interlayer layer may contain 6-12 parts by weight of glass bubbles based on 100 parts by weight of the thermoplastic resin. If it is included outside the above range, the physical properties may deteriorate and the quality of the product may deteriorate or processability may deteriorate, or process economics may deteriorate.

The thermoplastic resin is polyvinyl chloride (PVC: Poly Vinyl Chloride) resin, polystyrene (PS: Poly Styrene) resin, acrylonitrile butadiene styrene (ABS: Acrylonitrile Butadiene Styrene) resin, polylactic acid (PLA: Poly Lactic Acid) resin, Any one or more of polyethylene terephthalate (PET: Polyethylene Terephthalate) resin, polyolefin (PO: Poly Olefine) resin, and acrylic resin, specifically, polyvinyl chloride (PVC: Poly Vinyl Chloride) resin, polyethylene terephthalate ( PET: at least one resin selected from polyethylene terephthalate (PET) resin and polyolefin (PO: poly olefine) resin, for example, may be polyvinyl chloride (PVC: polyvinyl chloride) resin.

The glass bubble is a hollow spherical particle that can be used as a substitute for a filler such as conventional coal, and contains at least 90% by weight of soda-lime-borosilicate glass, 94% by weight or more, or 97% by weight of soda-lime-borosilicate glass It may contain more than % by weight. The soda-lime-borosilicate glass contains 50-90% by weight of SiO ₂ , 2-20% by weight of alkali metal oxide, 1-30% by weight of divalent metal oxide, 1-30% by weight of B ₂ O ₃ , 0.005-1.5% by weight of sulfur or sulfur oxides. As a specific example of the soda-lime-borosilicate glass, 70-80% by weight of SiO ₂ , 3-8% by weight of Na ₂ O, 8-15% by weight of CaO, 2-6% by weight of B ₂ O ₃ , 0.125%-1.5% of SO ₃ may be exemplified, but not necessarily limited thereto.

In addition, the glass bubble may have a diameter of 10-60 μm, specifically, 20-50 μm. When the diameter of the glass bubble is less than the above range, the density of the glass bubble increases and it is difficult to realize the weight reduction of the flooring material.

In addition, the withstand pressure level of the glass bubble may be 400-1000 psi, specifically 500-750 psi. When the pressure level of the glass bubble is less than the above range, the physical properties of the flooring material are deteriorated, and when it exceeds the above range, the flexibility of the flooring material is reduced, so it may be within the above range.

And, the average true density of the glass bubble may be 0.17-0.28g/cc, specifically, 0.18-0.27g/cc. When the average true density of the glass bubbles is less than the above range, the dispersibility of the glass bubbles decreases, resulting in decreased productivity.

The specific gravity of the glass bubble may be 0.12-0.7, specifically, 0.125-0.6. The above-mentioned glass bubble is 1/20-1/4 level compared to the specific gravity (2.4-2.7) of coal which is often used as a conventional filler, and even if a very small amount is used, it is possible to manufacture a flooring material having the same level of physical properties as coal. Therefore, it is possible to reduce the weight of the flooring material.

In the lightweight flooring material including the easy layer, the foam layer and the interleaving layer, the layer including the glass bubble may not further include an additional filler. That is, the layer including the glass bubble may include only the glass bubble as a filler. In order to improve the physical properties or surface quality of the flooring material, it may additionally include a conventional filler, but only glass bubbles can achieve the desired physical properties of the flooring material, and the effect of improvement by adding the conventional filler is insignificant. In consideration of this, additional conventional fillers may not be included.

In addition, the layer including the glass bubble is optionally one selected from 10 to 20 parts by weight of rubber, 30 to 70 parts by weight of a plasticizer, 1.0 to 2.0 parts by weight of a stabilizer, and 1.0 to 10 parts by weight of a foaming agent based on 100 parts by weight of the thermoplastic resin. The above may be further included.

The rubber is used to improve the durability, processability and physical properties of the polar thermoplastic resin, and also has an effect of reducing a weight impact sound. The rubber is natural rubber, nitrile butadiene rubber (NBR: Nitrile butadiene rubber), styrene butadiene rubber (SBR: Styrene-Butadiene Rubber), urethane rubber (PUR: Urethane Rubber), acrylic rubber (ACM: Acrylic rubber), isoprene rubber ( IR: Isoprene Rubber), silicone rubber (SR: Silicone Robber), may be chloroprene rubber (Chloroprene Rubber, CR), a specific example may be nitrile butadiene rubber (NBR: Nitrile butadiene rubbe). The rubber may be used in any form, and may be used in the form of a master batch mixed with PVC. As a specific example, the linear/crosslinked structure may contain 8.5% by weight of PVC based on the total weight and may be a masterbatch.

In addition, the plasticizer is for improving the processability of the thermoplastic resin, and may be at least one selected from a phthalate-based plasticizer, a terephthalate-based plasticizer, a benzoate-based plasticizer, a citrate-based plasticizer, and a phosphate-based plasticizer. As the phthalate-based plasticizer, diethylhexyl phthalate, diisononyl phthalate, diisodecyl phthalate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, dioctyl phthalate, dinonyl phthalate or ditridecyl phthalate may be used. However, it is not limited thereto. As the terephthalate-based plasticizer, dioctyl terephthalate may be used, but is not limited thereto. The benzoate-based plasticizer includes 2-(2-(2-phenylcarbonyloxyethoxy)ethoxy)ethyl benzoate, glyceryl tribenzoate, trimethylolpropane tribenzoate, isononylbenzoate, 1-methyl -2-(2-phenylcarbonyloxypropoxy)ethyl benzoate, 2,2,4-trimethyl-1,3-pentanediol dibenzoate, n-hexylbenzoate or trimethylolpropanetribenzoate can be used However, the present invention is not limited thereto. The citrate-based plasticizer may include, but is not limited to, acetyl tributyl citrate, tributyl citrate, acetyl triethylhexyl citrate, or triethylhexyl citrate. As the phosphate-based plasticizer, tricresyl phosphate or tributyl phosphate may be used, but is not limited thereto. However, in consideration of the environment-friendly issue, a non-phthalate-based plasticizer may be used.

The stabilizer is added to prevent various changes in physical properties that occur due to the separation of HCl from polyvinyl chloride and the chromophore forming a polyene structure, resulting in cutting and crosslinking of the main chain. A stearic acid salt such as cadmium and a dibutyl tin compound have been widely used. However, these metal compounds have a disadvantage in that they have toxicity or contamination to the human body or the environment. Therefore, in the present application, a barium-zinc (Ba-Zn-based) stabilizer such as a barium-zinc complex stearate may be used as a stabilizer.

The foaming agent is included in order to be heated and foamed after being mixed with the thermoplastic resin. at least one sulfonyl hydrazide selected from p,p'oxybis(benzenesulfonyl hydrazide), benzenesulfonyl hydrazide or toluenesulfonyl hydrazide as a blowing agent; at least one azo compound selected from azodicarbonamide (ADCA) or azobis isoptylonitrile; An organic foaming agent comprising any one nitroso compound selected from N,N'dinitrosopentamethylenetetramine or N,N'dimethyl-N,N'dinitrosoterephthalamide, inorganic including sodium bicarbonate or ammonium bicarbonate It may be one or more chemical blowing agents selected from the blowing agents, or a master batch containing the same, and more specifically, a PVC master batch containing 20-50 wt% of azodicarbonamide (ADCA). The chemical foaming agent, for example, may also be decomposed at 200-205°C to generate a gas amount of 280-300ml/gr.

The lightweight flooring material may further include a known laminated structure to meet the purpose of the flooring material, for example, may further include a dimension reinforcement layer, a transparent layer, a surface protection layer, etc. on the interlayer layer.

The lightweight flooring of the present application includes only glass bubbles, which have a very low specific gravity compared to the conventional filler, carbon stone, in any one or more of the backing layer, the foaming layer, and the interleaving layer, so that it can be lightened compared to the conventional flooring material, and through this, the high thickness As a flooring material, the workability is also excellent, and by reducing the vibration through the hollow of the glass bubble, the light impact sound can also be reduced.

In addition, the lightweight flooring material of the present application may be manufactured by a known method, but specifically, a thermoplastic resin, glass bubble and other additives are put in a Banbari mixer, kneaded, and then calendered to form an easy layer, a foaming layer and an interleaving layer, respectively. The flooring material can be manufactured by laminating (thermal compression) and foaming in the order of an easy layer, a foaming layer, and an interleaving layer from the bottom.

The lightweight flooring material of the present application may have a weight reduction rate of greater than 0 and less than or equal to 20% compared to the case of using coal as a filler.

The lightweight flooring of the present application includes a glass bubble, which has a very low specific gravity compared to coal, which is a conventional filler, as a filler in any one or more of the backing layer, the foaming layer, and the interleaving layer. As a flooring material, the workability is also excellent, and by reducing the vibration through the hollow of the glass bubble, the light impact sound can also be reduced.

1 is a SEM photograph of the foam layer prepared in Example 1.
2 is a SEM photograph of the foam layer prepared in Comparative Example 1.

Hereinafter, the present application will be described in more detail through examples. However, the embodiment is only an example of the present application, and the scope of the present application is not limited to the embodiment.

<Example>

Example 1 and comparative example 1 to 3: of foam layer Produce

100 parts by weight of PVC, 15 parts by weight of rubber, 50 parts by weight of plasticizer, 1.6 parts by weight of stabilizer, 8.1 parts by weight of foaming agent, and 2 parts by weight of glass bubble (Example 1) as a filler, 0.5 parts by weight of glass bubble (Comparative Example 2), glass 20 parts by weight of bubbles (Comparative Example 3) or 20 parts by weight of tanseok (Comparative Example 1) were kneaded at 120° C. in a Banbari mixer, followed by primary and secondary mixing in two rolls at 150° C. The mixture was used to prepare a sheet having a thickness of 0.5 mm using a calender.

The sheet was passed through a foaming oven at 225° C. at a speed of 11 m/min to prepare a foam layer.

The pressure level of the glass bubble was 500-750 psi, and the average true density was 0.18-0.27 g/cc.

Experimental example One: foam layer my of glass bubble Confirm

The foam layer of Example 1 and Comparative Example 1 was confirmed, and it was photographed by SEM, and it is shown in FIG. 1 (Example 1) and FIG. 2 (Comparative Example 1). As can be seen in FIGS. 1 and 2 , it can be confirmed that the foamed cell of Example 1 has a spherical shape and excellent foaming quality compared to Comparative Example 1.

Experimental example 2: of foam layer Check physical properties

The foaming ratio of the foaming layers of Example 1 and Comparative Example 1, the specific gravity of the mixture before foaming, the residual indentation ratio, and the G value and lightness regarding impact absorption were checked, and the results are shown in Table 1. Specifically, the residual indentation rate of the foam layer meets KS M 3802 standards. The value of G was measured by measuring the impact acceleration value generated when a silver 4 kg head weight was freely dropped from a height of 20 cm.

Lightweight was converted into % by weight of the foam layer based on the weight of the product of Comparative Example 1 using carbon stone as a filler.

Physical properties of the foam layer according to the type and content of the filler division Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 glass bubble ( parts by weight ) 2 - 0.5 20 coal ( parts by weight ) - 20 - - Foaming magnification 400% 410% 400% 370% importance( before firing ) 1.15 1.30 1.27 1.07 Residual indentation rate 2.7% 2.3% 2.4% 3.7% G value 105G 102G 103G 110G lightness 80% 100% 95% 70%

As a result, it can be confirmed that the specific gravity of the mixture of Example 1 was reduced compared to Comparative Example 1 not containing glass bubbles in the specific gravity of the mixture before foaming, and after foaming, it was confirmed that the weight was reduced by 20% compared to Comparative Example 1. there was. Through this, it can be seen that the foam layer of the present application can contribute to weight reduction of the flooring material.

In addition, in terms of the expansion ratio, the residual indentation ratio, and the G value, the foamed layer of Example 1 showed equivalent values as compared to the foamed layer of Comparative Example 1, and it was confirmed that it could be substituted for the conventional foamed layer.

On the other hand, in the case of Comparative Examples 2 and 3 containing less than or more than a specific content of glass bubbles, the light weight is insignificant (Comparative Example 2), or the physical properties such as the residual indentation ratio are bad (Comparative Example 3). In Example 3, there is a problem in that the manufacturing cost is increased due to the excessive inclusion of glass bubbles having a high unit price.

Experimental example 3: noise blocking ability Confirm

Table 2 shows the light impact sound blocking ability of the foam layers of Example 1 and Comparative Examples 1-3. Specifically, the light impact sound was measured at room temperature by laminating the foam layers of Examples and Comparative Examples on 150 mm slab.

Confirmation of noise blocking ability according to filler type and content division Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 glass bubble ( parts by weight ) 2 - 0.5 20 coal ( parts by weight ) - 20 - - light impact sound △7dB △6dB △6dB △6dB

As shown in Table 2, compared to the foam layer of Comparative Example 1-3, the foam layer of Example 1 showed 1 dB higher light-weight impact sound reduction effect, confirming that the noise blocking ability, particularly the interlayer noise blocking ability, was excellent.

Claims (7)

As a lightweight flooring material comprising a backing layer, a foaming layer and an interleaving layer from below,
Any one or more layers of the easy layer, the foaming layer and the interleaving layer contain 1-12 parts by weight of glass bubbles based on 100 parts by weight of the thermoplastic resin,
The thermoplastic resin is a polyvinyl chloride resin,
The layer including the glass bubble contains 10 to 20 parts by weight of rubber based on 100 parts by weight of the thermoplastic resin,
The glass bubble contains at least 90% by weight of soda-lime-borosilicate glass, and the soda-lime-borosilicate glass is 50-90% by weight of SiO ₂ , 2-20% by weight of alkali metal oxides, 1-30% by weight of divalent metal oxides, 1-30% by weight of B ₂ O ₃ , and 0.005-1.5% by weight of sulfur or sulfur oxides,
The pressure level of the glass bubble is 400-1000psi and the average true density is 0.17-0.30g/cc of lightweight flooring. According to claim 1,
The glass bubble is soda-lime-borosilicate glass (soda-lime-borosilicate glass) lightweight flooring comprising at least 94% by weight. delete According to claim 1,
The glass bubble has a diameter of 10-60㎛ and a light weight flooring material with a specific gravity of 0.12-0.7 According to claim 1,
The layer comprising the glass bubble is a lightweight flooring material that does not further include a filler. According to claim 1,
The layer including the glass bubble further comprises at least one selected from 10 to 20 parts by weight of a rubber, 30 to 70 parts by weight of a plasticizer, 1.0 to 2.0 parts by weight of a stabilizer, and 1.0 to 10 parts by weight of a foaming agent based on 100 parts by weight of the thermoplastic resin. lightweight flooring. According to claim 1,
The lightweight flooring material has a weight reduction rate of more than 0 and 20% or less compared to the case of using coal as a filler.

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