KR102609297B1 - Superior cushioning and restorative flooring - Google Patents

Abstract

The present invention relates to a flooring material with excellent cushioning and restoration properties.

Description

Flooring material with excellent cushioning and restoration {Superior cushioning and restorative flooring}

The present invention relates to a flooring material with excellent cushioning and restoration properties.

If the interior floor of a building structure is exposed as a cement surface, the beauty of the exterior will inevitably deteriorate. For this reason, the interior floor of the building structure is finished with flooring material during the interior design process.

As an example of the flooring material, polyvinyl chloride (hereinafter referred to as 'PVC') flooring material is used as a residential flooring material, which has the advantages of relatively low product price, easy construction, and excellent decorative effect.

In general, it is recommended that PVC flooring maximize cushioning in order to achieve excellent shock absorption, but it must satisfy all of the conflicting physical properties of durability, which is the basic physical property of flooring, and good recovery to avoid crush marks. Therefore, it is necessary to improve the cushioning of flooring. There were limits.

For example, the PVC flooring material is disclosed in Republic of Korea Patent Publication No. 10-0805633 (announcement date: February 20, 2008).

KR 10-0805633 B (Announcement date: 2008.02.20)

The present invention was developed to solve the above problems, and its purpose is to provide a flooring material with excellent cushioning and restoration properties.

In order to achieve the above object, the present invention provides a flooring material having a pressing property (19mmΦ, 222N) of 35% or more and a residual pressing rate (KS M 3802, 1hr) of 3% or less.

The flooring material of the present invention has excellent cushioning properties and excellent restoration properties.

In addition, the flooring material of the present invention has excellent sound insulation properties.

1 is a cross-sectional view schematically showing an embodiment of the flooring material of the present invention.
Figure 2 is a cross-sectional view schematically showing another embodiment of the flooring material of the present invention.
Figure 3 is a configuration diagram schematically showing a manufacturing method of an embodiment of the flooring material of the present invention.

Hereinafter, the present invention will be described in detail along with the attached drawings.

The present invention relates to a flooring material having a pressing property (19mmΦ, 222N) of 35% or more and a residual pressing rate (KS M 3802, 1hr) of 3% or less.

Specifically, the flooring material of the present invention may have a compressibility of 35% or more or 40% or more, and if it is less than the above range, the cushioning feeling may be reduced. Additionally, the upper limit is not limited, but for example, it may be 100% or less or 80% or less.

The pressing property can be calculated by measuring the depth of the flooring material inserted by applying a load of 222N with a hemispherical steel bar with a diameter of 19mm and dividing this by the total thickness of the flooring material.

Additionally, the residual indentation ratio of the present invention may be 3% or less or 2.5% or less, and if it exceeds the above range, the stability may be reduced. In addition, the lower limit is not limited, but for example, it may be 0.1% or more or 0.2% or more.

The residual indentation rate is determined by applying a load of 222N to a hemispherical steel bar with a diameter of 19 mm as specified in KS M 3802, releasing it after 5 minutes, and then changing the thickness of the specimen after 1 hour to determine the residual indentation rate as follows. can be obtained.

Residual indentation rate = (T ₀ - T ₁ )/T ₀

T ₀ : Thickness before pressurization

T ₁ : Thickness after pressing

The flooring material of the present invention for realizing the above pressing properties and residual press rates includes, from bottom to top, a nonwoven fabric layer (10); Foam layer (30); Dimensional stability layer (40); Printing layer (50); and a transparent layer 70.

Hereinafter, each of the above layers will be described in more detail.

Non-woven layer (10)

The non-woven layer 10 of the present invention is located at the bottom of the flooring and serves to prevent the transfer of debris and cracks on the floor surface, prevent crack waves during floor heating, and provide sound insulation and lightweight properties to the flooring. 10') may be included.

Specifically, depending on the manufacturing method, fabric is largely divided into non-woven fabric, woven fabric, and circular knit.

The non-woven fabric refers to a fabric shape in which fiber aggregates are bonded to each other by chemical action, mechanical action, or appropriate moisture and heat treatment without woven fabric processes such as spinning, weaving, or knitting.

The woven fabric refers to a cloth formed by forming fiber aggregates into threads and then using the threads through a woven fabrication process. The woven fabric is a word commonly used for fabric. The woven fabric refers to a fabric in which two threads are intertwined in the horizontal and vertical directions. The vertical threads, or warp threads, and the horizontal threads, i.e., weft threads, are intertwined. It refers to fabric. The woven fabric can be divided into plain weave, twill weave, and main weave depending on the manufacturing method.

The knitted fabric refers to a fabric knitted with one or two or more threads in a continuous loop. Depending on the manufacturing method, it is divided into circular knitted fabric and warp knitted fabric. It can be. The circular knitting fabric refers to a fabric woven with yarns fed in the weft direction, and the warp knitting fabric refers to a fabric woven with yarns fed in the warp direction.

In particular, in the present invention, non-woven fabric is used to prevent transfer of dirt and cracks to the floor surface compared to flooring materials using woven fabric or knitted fabric, and has excellent physical properties such as sound insulation and pressing properties.

Meanwhile, in the present invention, debris refers to foreign substances such as gravel and sand on the floor (i.e., concrete floor).

Additionally, in the present invention, a crack refers to a gap in the floor surface.

In addition, in the present invention, a crack wave refers to a wave pattern generated on the surface of the flooring due to hot air rising from cracks in the floor.

The nonwoven fabric 10', for example, is a mixture of two or more types of thermoplastic resin fibers with different deniers, and has excellent dimensional stability, recovery rate, and elongation.

For example, the thermoplastic resin is selected from the group consisting of polyester (PET), polypropylene (PP), polyvinyl alcohol (PVA), polyamide, polyurethane (PU), and polyvinylidene chloride (PVDC). There may be one or more types.

In the present invention, as a specific example of the thermoplastic resin, polyester (PET), which has a high glass transition temperature and is not affected by temperature changes in the floor during floor heating, can be used, which has excellent dimensional stability.

The fiber may be a fiber chop, that is, a single fiber, with a length of about 4-7 cm or 5-6 cm, and has excellent dimensional stability within this range.

In one embodiment, the nonwoven fabric 10' is composed of 70-90% or 75-85% by weight of fiber (f ₁ ) with a fineness of 4-12 denier and a fiber (f ₂ ) with a fineness of 13-20 denier 10- It may be 30% by weight or 15-25% by weight mixed.

In another embodiment of the nonwoven fabric (10'), 35-50% by weight or 35-40% by weight of a fiber (f _1-1 ) with a fineness of 4-6 denier, and a fiber (f) with a fineness of 7-12 denier _1-2 ) 35-50% by weight or 35-40% by weight and 10-30% by weight or 15-25% by weight of fibers with a fineness of 13-20 denier (f ₂ ) may be mixed.

If the fineness of the fiber is less than 4 denier, the mechanical properties of the nonwoven fabric may deteriorate and spinning may be difficult, and if the fineness exceeds 20 denier, the bonding force between the fibers may decrease and the elongation of the nonwoven fabric may decrease, so the fineness within the above range Fibers having can be used.

If the content of the fiber (f ₁ )(f _1-1 )(f _1-2 ) with a fineness of 4-12 denier is less than the above range, the dimensional stability and recovery rate of the non-woven fabric, such as the size of the non-woven fabric being severely stretched and restoration not being possible. This may decrease, and if it exceeds the above range, the elongation of the nonwoven fabric decreases, so it can be included within the above content range.

Specifically, a typical nonwoven fabric has a tensile strength of about 1.0 kgf or more when stretched 40-60% in the longitudinal direction at 120-140 ℃, in one embodiment, 50% stretched at 130 ℃, and the upper PVC material layer described later has a tensile strength of about 1.0 kgf or more. The difference is very large compared to the tensile strength (about 0.2-0.4kgf), so when it is included in the flooring material, wrinkles occur in the non-woven layer when a co-embossing process is performed to match the embossed pattern on the flooring material with the printed pattern on the printed layer. There may be a problem.

However, the nonwoven fabric 10' of the present invention has a tensile strength of 0.3-0.8 kgf or 0.4-0.6 kgf when stretched 40-60% in the longitudinal direction at 120-140 ℃, in one embodiment, 50% stretched at 130 ℃. The tensile strength is smaller than that of a typical non-woven fabric, so the difference in tensile strength with the PVC material layer located at the top is very small. When the synchronous embossing process is performed, wrinkles do not occur in the non-woven fabric layer 10, thereby increasing the yield of the flooring material. It has excellent effects.

In the present invention, the synchronized embossing process means matching the printed pattern of the printed layer and the embossed pattern to ensure good focus and excellent appearance.

The tensile strength of the non-woven fabric (10') was measured according to KS K 0521. Specifically, the non-woven fabric specimen was kept in the chamber at 130°C for 1 minute, clamped in the clamp of the Universal Testing Machine (UTM, Instron), and measured for length. The tensile strength of the nonwoven fabric was measured when stretched by 50% in each direction.

In addition, the nonwoven fabric (10') of the present invention has an elongation at break of 80-200% or 90-180% in the longitudinal direction at 20-25°C, which is much higher than the elongation at break (15-30%) of conventional nonwoven fabrics. Although this is excellent, the difference is small when compared to the elongation at break (150-250%) of the upper PVC layer, so when the co-embossing process is performed, wrinkles do not occur in the non-woven layer, resulting in excellent flooring yield.

In addition, the elongation at break of the nonwoven fabric was measured by stretching until the nonwoven fabric broke under conditions of 20-25°C using a Universal Testing Machine (UTM, Instron).

In the present invention, the longitudinal direction means the machine direction, that is, Machine Direction (MD).

In addition, the non-woven fabric 10' may have a basis weight of 180-230 g/m ² or 190-220 g/m ² , and within the above range, it prevents the transfer of debris and cracks on the floor and prevents crack waves while maintaining lightness. It can be granted.

The basis weight may be measured according to the ERT method (EDANA RECOMMENDED TEST METHODS) 40.3-90.

In addition, the non-woven fabric 10' may have a thickness of 0.5-1.5 mm, or 0.6-1.2 mm, and within the above range, the thickness of the upper foam layer can be relatively reduced, thereby realizing an excellent lightweight effect, and the bottom It prevents the transfer of cracks and debris from cotton, prevents crack waves when heating the floor, and also provides a sound insulation effect.

foam layer (30)

The foam layer 30 of the present invention is located on the top of the non-woven fabric layer 10 and serves to provide cushioning to the flooring, as well as restoration and sound insulation, and may be formed of a composition for forming a foam layer. there is.

The composition for forming a foam layer contains 10-50 parts by weight of elastomer (b), 4-15 parts by weight of foaming agent, 20-70 parts by weight of filler, and 30-60 parts by weight of plasticizer, based on 100 parts by weight of polyvinyl chloride resin (a). It can be included.

The polyvinyl chloride resin (a) may be a mixed resin in which two types of polyvinyl chloride resins with different degrees of polymerization are mixed, and as a specific example, polyvinyl chloride resin (a1) with a degree of polymerization of 900-1100 or 950-1050. It may be a mixed resin containing a polyvinyl chloride resin (a2) having a degree of polymerization of 1200-1600 or 1250-1500.

The weight ratio of the polyvinyl chloride resin (a1) and the polyvinyl chloride resin (a2) may be 15-50:50-85 or 20-45:55-80. When the content of the polyvinyl chloride resin (a1) is less than the above range, the content of the polyvinyl chloride resin (a2), which has a relatively high degree of polymerization, increases, thereby increasing the torque applied during mixing in the mixer and, accordingly, the pressure within the mixer. Accordingly, it may be undesirable because it foams early before the foaming process, and if it exceeds the above range, the stability of the flooring may not be improved, so it may be included within the above weight ratio.

The elastomer is ethylene-propylene rubber, ethylene-propylene diene rubber, ethylene-butadiene rubber, ethylene-butene rubber, ethylene-octene rubber, propylene-butene rubber, styrene-ethylene-butadiene-styrene, ethylene-propylene-butene, and acrylic. It may be one or more selected from the group consisting of nitrile-butadiene rubber and styrene-butadiene rubber.

As a specific example of the elastomer in the present invention, acrylonitrile-butadiene rubber, which has excellent compatibility with the polyvinyl chloride resin (a), can be used.

In this case, the content of acrylonitrile contained in the acrylonitrile-butadiene rubber may be 20-50% by weight or 20-40% by weight, and within the above range, the durability and restoration of the flooring material may be excellent.

The elastomer may have a pattern viscosity (ML ₁₊₄ , 100°C) of 30-70 or 45-60, and within the above range, the rebound elasticity is excellent, so the restoration of the flooring material is improved and processability is excellent.

The elastomer may contain 10-50 parts by weight or 12-40 parts by weight based on 100 parts by weight of the polyvinyl chloride resin (a). If it is less than the above range, the stability of the flooring may not be improved, and if it exceeds the above range, the durability of the flooring may be reduced, so it may be included within the above content range.

The foaming agent is azodicarbonamide, p,p'-oxybisbenzene sulfonyl hydrazide, and p-toluene sulfonyl hydrazide. and benzene sulfonyl hydrazide, but is not limited thereto.

The foaming agent may be included in an amount of 4-15 parts by weight or 5-10 parts by weight based on 100 parts by weight of the polyvinyl chloride resin (a). If it is less than the above range, the foaming effect is insignificant and the foaming ratio may decrease, so sound insulation and cushioning may not be improved. If it exceeds the above range, the foam may be excessive and open cells may occur, which may affect mechanical properties such as durability. There is a problem that physical properties are deteriorated, so it is preferable that it is contained within the above range.

The filler is one or more selected from the group consisting of calcium carbonate, wood flour, mica, amorphous silica, talc, zeolite, magnesium carbonate, calcium sulfate, calcium phosphate, magnesium phosphate, aluminum oxide, kaolin, ATH (Alumina trihydrate), and talc. can be used, but calcium carbonate, which is inexpensive, can be preferably used.

The filler may be included in an amount of 20-70 parts by weight, or 30-60 parts by weight, based on 100 parts by weight of the polyvinyl chloride resin (a). The raw material value may be appropriate within the above range, and it has the effect of excellent processability.

The plasticizer may be one or more selected from a phthalate-based plasticizer, a terephthalate-based plasticizer, a benzoate-based plasticizer, a citrate-based plasticizer, a phosphate-based plasticizer, or an adipate-based plasticizer.

The plasticizer may be included in an amount of 30-60 parts by weight, or 40-55 parts by weight, based on 100 parts by weight of the polyvinyl chloride resin (a), and within the above range, processability and cushioning are excellent and plasticizer migration does not occur. The mechanical properties of the flooring material are excellent.

Optionally, the composition for forming a foam layer may further include one or more selected from the group consisting of a heat stabilizer, a lubricant, and a flame retardant, and their type and content are not particularly limited.

The foam layer 30 may have a thickness loss of 8% or less or 6% or less during a fatigue test (KS M ISO 3385), and if it exceeds the above range, the foam cell walls are not strong and the elasticity decreases at low density, resulting in loss of stability. This may decrease, resulting in fatigue within the above range.

Additionally, the lower limit of thickness loss during a fatigue test of the foam layer is not limited, but may be 0%, for example.

The fatigue test of the foam layer 30 was conducted by repeatedly applying a load of 800N to the foam 1000 times using a cyclic tensile compression tester (Material Test System, MTS Systems Corporation) in accordance with KS M ISO 3385, and then fatigue. The thickness loss of the area receiving the force was calculated as follows.

Thickness loss = (D ₀ - D ₁ )/D ₀

D ₀ : Thickness before pressing

D ₁ : Thickness after pressing

In addition, the residual indentation rate of the foam layer 30 may be 10% or less or 7% or less. If it exceeds the above range, the restoration may be reduced, so the residual indentation rate may be within the above range.

Additionally, the lower limit of the residual indentation rate of the foam layer is not limited, but may be 0%, for example.

The residual indentation rate is determined by applying a load of 222N to a hemispherical steel bar with a diameter of 19mm as specified in KS M 3802, releasing it after 5 minutes, and then measuring the change in thickness of the specimen (foam) after 1 hour as follows. The residual indentation rate can be obtained.

Residual indentation rate = (T ₀ - T ₁ )/T ₀

T ₀ : Thickness before pressurization

T ₁ : Thickness after pressing

In addition, the pressing property of the foam layer 30 may be 1.3-1.9 mm or 1.4-1.7 mm, and having the pressing property within the above range provides excellent cushioning.

The compressibility can be measured by applying a load of 222N with a hemispherical steel bar with a diameter of 19mm and measuring the depth of the foam.

In addition, the compressibility of the foam layer 30 may be 50% or more, 70% or more, or 75% or more, and within the above range, excellent cushioning is achieved.

Additionally, the upper limit of the pressing property of the foam layer is not limited, but may be, for example, 100% or less or 95% or less.

The compressibility can be calculated by measuring the depth of the foam inserted by applying a load of 222 N with a hemispherical steel bar with a diameter of 19 mm and dividing this by the thickness of the foam.

Meanwhile, the average diameter of the foam cells included in the foam layer 30 may be 100-400 ㎛ or 200-300 ㎛, and by having an average diameter within the above range, the flooring material can have excellent cushioning, restoration, and sound insulation. You can.

In the present invention, the average diameter of the foam cell refers to the average value of the diameters that one foam cell can have. If the foam cell is spherical, it means the average diameter, and if the foam cell has a shape other than a spherical shape, it means the long axis. When divided into short axis and short axis, it may mean the average length of the long axis.

The average diameter of the foam cells was measured by cutting the flooring material in the vertical direction and measuring the average diameter of the foam cells on the side cross section of the cut foam layer using a scanning electron microscope (SEM).

In addition, the number of foam cells included in the foam layer 30 may be 10-30 or 15-25 per unit area of the side cross section of the foam layer (1 mm ² ), and by having the number of foam cells within the above range, the cushion of the flooring material can be It can have excellent sensitivity, restoration, and sound insulation.

The number of foam cells was measured by cutting the flooring material in the vertical direction and measuring the number of foam cells on the side cross section of the cut foam layer using an optical microscope.

In addition, the foaming ratio of the foam layer 30 may be 350-600% or 400-500%, and by having a foaming ratio within the above range, the cushioning, restoration, and sound insulation properties of the flooring may be excellent.

The expansion ratio of the foam layer is The thickness change before and after foaming was calculated as follows.

Expansion ratio = T _a /T _{a '}

T _a : Thickness after foaming

T _{a '} : Thickness before foaming

In addition, the foam layer 30 has a thickness of 1-3 mm, or 1.5-2.5 mm, and within this range, it is effective in providing excellent cushioning, restoration, and sound insulation to the flooring material.

Dimensionally stable layer (40)

The dimensional stability layer 40 of the present invention is a layer for providing dimensional stability to the flooring material. In one embodiment, the dimensional stability layer 40 is a glass fiber sheet impregnated with polyvinyl chloride sol (hereinafter referred to as 'PVC sol'). You can.

The glass fiber sheet may be woven glass fiber or non-woven fabric, but is not limited thereto.

As an example, the PVC sol may include 60-100 parts by weight of dioctyl terephthalate, 10-80 parts by weight of calcium carbonate, and 1-6 parts by weight of epoxidized soybean oil based on 100 parts by weight of the paste polyvinyl chloride resin.

The basis weight of the dimensional stability layer 40 may be 40-70 g/m ² or 45-65 g/m ² , and within the above range, the dimensional stability and flexibility of the flooring material are excellent.

In addition, the thickness of the dimensional stability layer 40 may be 0.1-0.6 mm or 0.2-0.5 mm, and within the above range, the dimensional stability of the flooring material is excellent.

printing layer (50)

The printed layer 50 of the present invention is laminated on top of the dimensional stability layer 40 to form various printed patterns, thereby providing aesthetics to the flooring. This printed layer 50 may be formed on the dimensionally stable layer 40 through one or more methods selected from the group consisting of direct transfer printing, gravure printing, screen printing, offset printing, rotary printing, and flexographic printing. there is.

In the present invention, an example of direct transfer printing on the dimensional stability layer 40 has been described, but the present invention is not limited to this and transfer printing is performed on the surface of a white sheet (not shown) laminated on the dimensional stability layer 40. , can be formed through gravure printing or screen printing.

The printed layer 50 may have a thickness of 0.01-0.05 mm or 0.02-0.04 mm. By having a thickness within the above range, the printed layer can achieve an aesthetically pleasing appearance and design effect at an appropriate manufacturing cost.

transparent layer (70)

The transparent layer 70 of the present invention is laminated on top of the printed layer 50 to improve the durability of the flooring and serves to protect the printed layer 50, and is made of polyvinyl chloride resin, polyethylene terephthalate resin, poly At least one selected from the group consisting of butylene terephthalate resin, polypropylene resin, polyethylene resin, polymethyl methacrylate resin, acrylonitrile-butadiene-styrene resin, polycarbonate resin, and styrene-acrylonitrile copolymer resin. It may be a film made of resin.

In the present invention, the transparent layer 70 is a specific example, and may be a film manufactured from a composition for forming a transparent layer containing polyvinyl chloride resin, which has excellent transparency and is inexpensive.

As an example, the composition for forming a transparent layer may include 15-35 parts by weight or 20-30 parts by weight of a plasticizer based on 100 parts by weight of polyvinyl chloride resin.

The degree of polymerization of the polyvinyl chloride resin may be 900-1200 or 950-1100, and within this range, calendering processability is excellent.

Since the plasticizer is the same as the plasticizer included in the foam layer 30 described above, duplicate description will be omitted.

Optionally, the composition for forming a transparent layer may further include one or more selected from the group consisting of a lubricant, a heat stabilizer, and a flame retardant, and their type and content are not particularly limited.

The transparent layer 70 may have a thickness of 0.1-1.0 mm or 0.3-0.9 mm, and within this range, it has the effect of improving the durability of the flooring and protecting the lower printing layer 50.

The flooring material (1) of the present invention may include synchronized embossing on the upper part of the transparent layer (70), where the emboss pattern matches the pattern of the lower printed layer (50). When the synchronized embossing is included, the depth of printing and You can feel the realism, making the flooring look more luxurious.

In addition, the present invention optionally further includes an intermediate layer 35 between the foam layer 30 and the dimension stabilizing layer 40 to improve the adhesion between the foam layer 30 and the dimension stabilizing layer 40. It can be done (see Figure 2).

The intermediate layer 35 may be formed of a composition for forming an intermediate layer containing 30-80 parts by weight of a plasticizer and 40-90 parts by weight of a filler based on 100 parts by weight of polyvinyl chloride resin.

Since the polyvinyl chloride resin is the same as the polyvinyl chloride resin included in the transparent layer 70 described above, and the plasticizer is the same as the plasticizer included in the foam layer 30 described above, duplicate description will be omitted.

The plasticizer may be included in an amount of 30-80 parts by weight or 40-70 parts by weight based on 100 parts by weight of the polyvinyl chloride resin, and within the above range, excellent processability is achieved.

The filler may be one in which a portion of the calcium carbonate used as a conventional filler is replaced with a hollow filler in order to further provide lightweight properties to the flooring material (1) of the present invention. Specifically, the filler may include the polyvinyl chloride resin 100. Based on parts by weight, 30-70 parts by weight or 40-60 parts by weight of calcium carbonate and 1-20 parts by weight or 5-15 parts by weight of hollow filler can be mixed.

If the calcium carbonate is less than the above content range, there is a risk of an increase in price, and if it exceeds the above range, it may not be desirable because it cannot provide lightweight properties to the flooring material, so it can be used within the above content range.

The hollow filler refers to a filler whose interior is hollow, and has a low density, which provides lightweight properties to the flooring (1) of the present invention and can further improve sound insulation.

In addition, the shape of the hollow filler is not particularly limited, and for example, it may be one or more types selected from the group consisting of plate shape (including scale shape), spherical shape, needle shape, rod shape, and fiber shape, , as a specific example, the hollow filler may have a spherical shape.

Specifically, the hollow filler may contain at least 90% by weight, 94% by weight, or 97% by weight of soda-lime-borosilicate glass. 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 , It may contain 0.005-1.5% by weight of sulfur or sulfur oxides. Specific examples of the soda-lime-borosilicate glass include 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 , It may include 0.125%-1.5% SO ₃ , but is not necessarily limited thereto.

The hollow filler may have a particle size of 20-80 ㎛ or 25-70 ㎛, and within this range, it can provide lightweight properties to the flooring.

In the present invention, the particle size may mean the diameter if the hollow filler has a spherical shape, and if the hollow filler has a shape other than a sphere, it may mean the length of the long axis when divided into the long axis and the short axis.

The particle size of the hollow filler can be measured using a particle size analyzer (S3500, Microtrac).

In addition, the hollow filler may have an average true density of 0.2-0.45 g/cc or 0.27-0.38 g/cc, and can impart lightness to the flooring of the present invention without being crushed within the above range. there is.

In the present invention, the average true density may mean a quotient obtained by dividing the mass of the sample of the hollow filler by the true volume of the hollow filler of that mass measured by a gas pycnometer.

Specifically, the average true density of the hollow filler was determined according to the ASTM D2840-69 standard (average true particle density of hollow microspheres, Average True Particle Density of Hollow) using a pycnometer (specific example, AccuPcy 1330, Micromeritics). Microspheres) or similar protocols known in the art.

On the other hand, if the hollow filler is less than the above content range, it may not be able to improve the lightweight of the flooring, and if it exceeds the above range, the tensile strength of the flooring may be reduced, so it can be used within the above content range.

Optionally, the composition for forming the interlayer layer may further include one or more selected from the group consisting of a heat stabilizer, a lubricant, and a flame retardant, and their type and content are not particularly limited.

The thickness of the intermediate layer 35 may be 0.1-1.2 mm or 0.3-1.0 mm, and by having a thickness in the above range, excellent adhesion is achieved between the foam layer 30 and the dimensional stability layer 40. In addition, lightweight properties can be imparted to the flooring material.

In addition, the flooring material 1 of the present invention may optionally further include a surface treatment layer (not shown) formed by applying a surface treatment agent to the top to prevent contamination.

The surface treatment layer may be formed by coating a typical UV-curable resin.

The surface treatment layer may have a thickness of 0.01-0.05mm, or 0.02-0.03mm, but is not limited thereto.

The flooring material (1) of the present invention may have a height of 0.9 mm or more, 1.0 mm or more, or 1.2 mm or more when transfer of the floor surface occurs, and within the above range, the effect of preventing transfer of the floor surface may be excellent. . Additionally, the upper limit of the height of the debris is not particularly limited, but may be, for example, 5 cm or less, 3 cm or less, or 2.5 cm or less.

The height of the debris can be measured with a tape measure.

In addition, the flooring material (1) of the present invention has a crack level difference of 0.7 mm or more, 0.9 mm or more, or 1.0 mm or more when the floor surface is transferred to the floor material surface, so the effect of preventing transfer of the crack level can be excellent. In addition, the upper limit of the level difference of the crack is not particularly limited, but may be, for example, 5 cm or less, 3 cm or less, or 2.5 cm or less.

The level difference of the crack can be measured with a tape measure.

In addition, the flooring material (1) of the present invention has a light impact sound of 51 dB or less or 49 dB or less, and has excellent sound insulation by having a light impact sound in the above range. In addition, the lower limit of the light impact sound is not particularly limited, but for example, may be 0 dB or more.

Here, light impact sounds refer to the sound of a chair being dragged, the sound of a spoon falling, or the sound of light footsteps. The light impact sound can be measured according to the standards of KS F 2810 (light impact sound test conditions).

In addition, the flooring material (1) of the present invention has a weight of 5.0-5.8kg or 5.1-5.5kg per unit area (1.83m ² ), and by having a weight within the above range, the effect is reduced by 15-20% compared to the conventional flooring material. there is.

The weight of the flooring can be measured using a scale.

In addition, the flooring material (1) of the present invention has a surface hardness (Shore D hardness) of 31-45 or 32-40, and has a surface hardness within the above range, so that the surface hardness is higher than that of the conventional flooring material and the emboss is formed deeply, creating a three-dimensional appearance. The texture effect is excellent, resulting in excellent aesthetics.

The surface hardness can be measured with a Shore D hardness tester (ASKER, Kobunshi keiki).

In addition, the synchronization rate of the flooring material of the present invention may be 2 mm or less or 1.5 mm or less, and within the above range, the print pattern of the printed layer and the position of the synchronization emboss are consistent, resulting in excellent three-dimensional texture and aesthetics.

The tuning rate may be measured using a vernier caliper.

In addition, the flooring material of the present invention may have a residual indentation rate (at the end of one day) of 1.5% or less or 1.4% or less, and the lower limit thereof is not limited, but for example, the residual indentation rate within the above range may be 0.1% or more or 0.2% or more. By having a ratio, there is an effect of excellent restoration.

The residual indentation rate is determined by applying a load of 222N to a hemispherical steel bar with a diameter of 19 mm as specified in KS M 3802, releasing it after 5 minutes, and then changing the thickness of the specimen after 1 day to determine the residual indentation rate as follows. can be obtained.

Residual indentation rate = (T ₀ - T ₁ )/T ₀

T ₀ : Thickness before pressurization

T ₁ : Thickness after pressing

Then, the method of manufacturing the flooring material according to the present invention having the above configuration is as follows.

Referring to Figure 3, first, polyvinyl chloride sol (hereinafter referred to as 'PVC sol') is applied and gelled (not shown) on the lower part of the pre-foam layer 30', and then the lower part of the pre-foam layer 30' Attach the nonwoven fabric (10') to the.

Subsequently, an intermediate layer 35 is selectively laminated on the upper part of the prefoam layer 30' to which the non-woven fabric 10' is bonded, and then first thermally laminated at a temperature of 140-170°C.

The pre-foam layer 30' is foamed in a foam oven to be described later to form the foam layer 30. The pre-foam layer forming composition is kneaded at 140-160° C. and then passed through a calender roll at 160-170° C. It can be manufactured by calendaring and molding.

Since the composition for forming the pre-foam layer is the same as the composition for forming the foam layer described above, duplicate descriptions will be omitted.

In addition, the nonwoven fabric 10' goes through a blending process in which fibers are mixed at a certain ratio, then goes through a carding process to form a web, and then goes through a bonding process to combine a plurality of the webs, and then goes through a heat calendar. It can be manufactured by passing it through.

More specifically, 70-90% by weight of fibers with a length of about 4-7 cm and a fineness of 4-12 denier in the hopper (f ₁ ) 70-90% by weight or 75-85% by weight and a fineness of 13-20 denier (f ₂ ) 10 -Mix 30% by weight or 15-25% by weight evenly.

In another example, fibers with a fineness of 4-6 denier (f _1-1 ) 35-50% by weight or 35-40% by weight, fibers with a fineness of 7-12 denier (f _1-2 ) 35-50 % by weight or 35-40% by weight and 10-30% by weight or 15-25% by weight of fiber (f ₂ ) with a fineness of 13-20 denier are uniformly mixed.

Next, a carding process is performed to form a flat sheet-like web of a certain weight and width by combing the raw cotton supplied in the above blending process through a cotton comb and a carding machine and mixing it evenly so as not to have directionality, and then applying the carded web to an appropriate layer. It goes through a cross lapper process to fold it.

Next, a plurality of the webs are joined using one or more bonding processes selected from chemical adhesion, thermal adhesion, or mechanical bonding. In the present invention, a mechanical bonding method can be used, and more specifically, a needle punching bonding method using a needle can be used to ensure that the nonwoven fabric has a specific elongation at break and tensile strength.

Subsequently, the combined web can be pressed again through a heat calendar with a heating temperature of 520-600°C or 540-560°C to produce the nonwoven fabric 10' used in the nonwoven fabric layer 10 of the present invention.

The method of applying the PVC sol to the lower part of the pre-foam layer 30' may be, for example, one method selected from bar coating, knife coating, slit coating, or gravure coating, but is not limited thereto.

Since the PVC sol is the same as the PVC sol used to form the dimensionally stable layer 40 described above, duplicate descriptions will be omitted.

In addition, the application amount of the PVC sol may be 50-200 g/m ² or 70-150 g/m ² , and when applied within the above range, the peel strength between the pre-foam layer (30') and the non-woven fabric (10') is excellent and the non-woven fabric It can satisfy a certain range of tensile strength when stretched at high temperature, so wrinkles do not occur in the nonwoven layer during the synchronous embossing process, resulting in excellent flooring yield.

In addition, gelling after application may be performed, for example, at 130-170°C or 140-160°C for 1-5 seconds in a heating drum.

If gelling is not performed before bonding the nonwoven fabric (10') to the lower part of the prefoam layer (30'), or if gelling is performed below the above temperature and time range and then bonded to the nonwoven fabric, most of the PVC sol penetrates into the nonwoven fabric. This may reduce the elongation of the non-woven fabric, so when performing the tuning embossing process, wrinkles occur in the non-woven fabric layer and storage is not easy. If gelling is performed beyond the above temperature and time range, the pre-foaming layer (30' ) may not detach from the heating drum, so gelling can be performed within the above temperature and time range.

The depth of the PVC sol penetrated into the nonwoven fabric of the present invention through the above bonding method may be 30-70㎛ or 40-60㎛, and penetration within the above range causes peeling of the prefoam layer (30') and the nonwoven fabric (10'). While the strength is excellent, the non-woven fabric can satisfy a certain range of tensile strength when stretched at high temperature, so wrinkles do not occur in the non-woven fabric layer during the synchronous embossing process, resulting in excellent flooring yield.

The depth of PVC sol penetrated into the nonwoven fabric was measured by cutting the flooring material in the vertical direction and then using a scanning electron microscope (SEM) to measure the depth of PVC sol penetrating into the side cross section of the cut nonwoven layer.

In addition, the intermediate layer 35 can be manufactured by kneading the composition for forming the intermediate layer at 140-160°C and then passing it through a calender roll at 160-170°C and calendering.

Next, a nonwoven fabric (10') laminated from above; Pre-foam layer (30'); And optionally, the intermediate layer 35 is placed in a foaming oven and foamed at 180-220°C or 190-210°C for 30-70 seconds or 40-60 seconds to form a nonwoven fabric layer 10 from bottom to top; Foam layer (30); And optionally, the intermediate layer 35 is laminated to form a first semi-finished product.

If the temperature and time range are below the above temperature and time range, the foaming may be minimal and the cushioning, restoration and sound insulation properties of the flooring may be reduced. If the temperature and time range are exceeded, the foam cells may become excessively large and the durability of the flooring may be reduced, thereby reducing the durability of the flooring material. and time range.

Since other characteristics of the foam layer are the same as described above, redundant description will be omitted.

Separately, a printed pattern is directly transferred and printed on the upper part of the dimensional stability layer 40 to form a printed layer 50, and then a transparent layer 70, which is a transparent film, is laminated on the dimensionally stable layer 40 on which the printed pattern is formed. The second semi-finished product is formed by secondary heat laminating at 140-170°C.

The dimensionally stable layer 40 can be manufactured by impregnating a glass fiber sheet with polyvinyl chloride sol.

In addition, the transparent layer 70 can be manufactured by kneading the above transparent layer forming composition at 140-160°C and then passing it through a calender roll at 160-170°C and calendering.

Subsequently, after placing the second semi-product on top of the first semi-product, a temperature of 120-140°C and a pressure of 3-7 kg/cm ² were applied on an embossing roll for synchronized embossing to form the first and second semi-products into the third semi-product. Simultaneously with thermal plywood, synchronized embossing is formed on the transparent layer 70, which is the uppermost part of the second semi-finished product.

On the other hand, if a conventional non-woven fabric is used to form a non-woven fabric layer at the bottom of the flooring material, then a non-woven fabric layer is formed from the bottom to the top; foam layer; optionally an intermediate layer; (first semi-finished product) and a dimensionally stable layer; printed layer; And when a synchronous embossing process is performed on the flooring material on which the transparent layer (second semi-finished product) is laminated, the tensile strength of the non-woven fabric when stretched at a high temperature is much higher than the tensile strength of the upper PVC layer, so wrinkles appear in the non-woven fabric layer. The yield of flooring materials may decrease.

Accordingly, there is no choice but to use a method of manufacturing the flooring by performing a synchronization embossing process in advance on the transparent layer of the second semi-product and then heat laminating the second semi-product on which the synchronization emboss is formed with the first semi-product. There may be a problem that the synchronized embossing previously formed by heat plying of the second semi-finished product collapses, resulting in a low emboss retention rate, and because the synchronous embossing process and the plywood process are carried out separately, the flooring process is too long, which reduces the yield of the flooring material.

However, the present invention is a one-pass process that can perform a synchronous embossing process on the first and second semi-finished products at the same time as the third heat plywood by using a non-woven fabric layer containing non-woven fabric that has a specific range of tensile strength when stretched at high temperature. It can be manufactured so that wrinkles do not occur in the non-woven fabric layer and the emboss retention rate is high, while the process is shortened, resulting in excellent flooring yield.

Then, optionally, a UV-curable paint is applied to the upper part of the flooring on which the synchronized embossing is formed and then UV-cured to form a surface treatment layer, thereby completing the final flooring.

Since other characteristics of the surface treatment layer are the same as described above, redundant description will be omitted.

Below, preferred embodiments are presented to aid understanding of the present invention. However, the following examples are merely illustrative of the present invention, and it is clear to those skilled in the art that various changes and modifications are possible within the scope and spirit of the present invention. It is natural that such changes and modifications fall within the scope of the attached patent claims.

[ Example ]

< Example 1>

1. Non-woven fabric, Pre-foam layer , interstitial layer formation stage

40% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 6 denier, 40% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 7 denier, and polyester with a length of 6 cm and a fineness of 16 denier ( After going through a blending process of mixing 20% by weight of PET) fibers, a web is formed through a carding process.

Next, the carded web is folded into an appropriate layer through the cross-wrapper process, performed a needle punching process, and passed through a heat calendar at 540-560°C to produce a nonwoven fabric (HS Glotech Co., Ltd.) with a basis weight of 200 g/m ² and a thickness of 0.8 mm. Company, 0820) was manufactured.

In addition, 100 parts by weight of a mixed resin mixed with a polyvinyl chloride resin with a degree of polymerization of 1000 (LG Chemical, LS100) and a polyvinyl chloride resin with a polymerization degree of 1300 (LG Chemical, LS130) at a weight ratio of 20:80, acrylic A composition for pre-foaming layer molding containing 20 parts by weight of nitrile-butadiene rubber, 5 parts by weight of foaming agent, 40 parts by weight of calcium carbonate, 55 parts by weight of plasticizer (LG Chemical, GL300), and 2 parts by weight of heat stabilizer was mixed with a Banbari mixer at 160°C. After kneading, it was passed through a calender roll at 160-170°C to prepare a pre-foam layer with a thickness of 0.4 mm.

In addition, 100 parts by weight of polyvinyl chloride resin (LG Chemical, LS100), plasticizer (LG Chemical, A composition for forming an intermediate layer containing 50 parts by weight of dioctyl terephthalate), 50 parts by weight of calcium carbonate, 10 parts by weight of hollow filler (3M Company, S32), and 0.95 parts by weight of a heat stabilizer were kneaded at 160°C with a Banbari mixer. An interleaf layer with a thickness of 0.55 mm was prepared by passing it through a calender roll at 160-170°C.

2. First plywood stage

At the bottom of the pre-foaming layer, 100 parts by weight of paste polyvinyl chloride resin (LG Chemical, PB1202), 80 parts by weight of plasticizer (LG Chemical, dioctyl terephthalate), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil were added. After applying PVC sol at a dosage of 100 g/m ² and gelling it at 150°C for 2 seconds, the nonwoven fabric was bonded. At this time, the depth of PVC sol penetrated into the nonwoven fabric was 50㎛.

Subsequently, an interleaf layer was laminated on the upper part of the prefoam layer to which the nonwoven fabric was bonded to the lower part and subjected to primary heat lamination at 150°C.

3. Foam molding step

The heat laminated nonwoven fabric; Pre-foam layer; And the intermediate layer was placed in a foaming oven and foamed at 200° C. for 50 seconds to form a non-woven fabric layer from the bottom to the top; foam layer; and a first semi-finished product in which the interleaving layer was laminated was formed.

Here, the thickness of the foam layer was 1.9 mm, the expansion ratio was about 470%, the foam cell size was 250 μm, and the number of foam cells per unit area (1 mm ² ) was 16.

4. Dimensionally stable layer and transparent layer formation stage

Paste the glass fiber nonwoven fabric into PVC containing 100 parts by weight of polyvinyl chloride resin (LG Chemical, PB1202), 80 parts by weight of plasticizer (LG Chemical, dioctyl terephthalate), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil. It was impregnated with sol to prepare a dimensionally stable layer with a basis weight of 60 g/m ² and a thickness of 0.35 mm.

In addition, a composition for forming a transparent layer containing 28 parts by weight of a plasticizer and 2-4 parts by weight of a heat stabilizer based on 100 parts by weight of polyvinyl chloride resin (LG Chemical, LS100) was mixed with a Banbari mixer at 160°C, and then mixed at 160- A transparent layer was prepared as a film with a thickness of 0.55 mm by passing through a calender roll at 170°C.

5. printing layer formation stage

The printed pattern was directly transferred and printed on the top of the dimensional stability layer to form a printed layer with a thickness of 0.02 mm.

6. Second plywood stage

The transparent layer was laminated on top of the dimensionally stable layer on which the printed pattern was formed and subjected to secondary heat lamination at 150°C to form a second semi-finished product.

7. Tertiary plywood and Synchronized embossing process

Subsequently, after placing the second semi-finished product on top of the first semi-finished product manufactured above, a co-embossing process is performed on the transparent layer simultaneously with heat plying under a temperature of 130° C. and a pressure of 5 kgf/cm ² with a co-embossing roll to obtain the dimensions. A synchronous emboss was formed that matched the printing pattern of the printed layer formed on the top of the stable layer.

8. Surface treatment layer formation stage

A surface treatment agent containing a UV-curable resin was applied to the upper part of the transparent layer on which the synchronized embossing was formed, and then UV was irradiated to form a surface treatment layer with a thickness of 0.03 mm, thereby manufacturing the flooring material of the present invention with a thickness of 4.2 mm.

< Example 2>

The fiber used in the production of non-woven fabric is a mixture of 80% by weight of polyester (PET) fiber with a length of 5cm and a fineness of 8 denier and 20% by weight of polyester (PET) fiber with a length of 6cm and a fineness of 14 denier. Flooring was manufactured in the same manner as in Example 1, except that.

< Comparative example 1>

One. Made of PVC material Pre-foam layer , interstitial layer formation

100 parts by weight of polyvinyl chloride resin with a degree of polymerization of 1000 (LG Chemical, LS100), 5 parts by weight of acrylonitrile-butadiene rubber, 3 parts by weight of foaming agent, 60 parts by weight of calcium carbonate, plasticizer (LG Chemical, dioctyl terephthalate) ) The composition for forming a pre-foam layer containing 40 parts by weight and 3 parts by weight of a heat stabilizer was kneaded at 160°C with a Banbari mixer and then passed through a calender roll at 160-170°C to prepare a pre-foam layer with a thickness of 1.07 mm.

In addition, a composition for forming an interlayer layer containing 100 parts by weight of polyvinyl chloride resin (LG Chemical, LS100), 50 parts by weight of plasticizer (LG Chemical, dioctyl terephthalate), 120 parts by weight of calcium carbonate, and 4 parts by weight of heat stabilizer. After kneading at 160°C with a Banbari mixer, the mixture was passed through a calender roll at 160-170°C to prepare an intermediate layer with a thickness of 0.7mm.

2. First plywood stage

Sequentially from bottom to top, a pre-foam layer; and the interleaving layer were laminated and subjected to primary heat lamination at 150°C.

3. Foam molding step

The heat laminated prefoam layer; and the intermediate layer was placed in a foaming oven and foamed at 200° C. for 50 seconds to form a foam layer from the bottom to the top; and a first semi-finished product in which the interleaving layer was laminated was formed.

Here, the thickness of the foam layer was 2.8mm, the expansion ratio was 200%, the foam cell size was 190㎛, and the number of foam cells per unit area (1mm ² ) was 35.

4. Dimensionally stable layer and transparent layer formation stage

Paste the glass fiber nonwoven fabric into PVC containing 100 parts by weight of polyvinyl chloride resin (LG Chemical, PB1202), 80 parts by weight of plasticizer (LG Chemical, dioctyl terephthalate), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil. It was impregnated with sol to prepare a dimensionally stable layer with a basis weight of 50 g/m ² and a thickness of 0.35 mm.

In addition, a composition for forming a transparent layer containing 28 parts by weight of a plasticizer and 2-4 parts by weight of a heat stabilizer based on 100 parts by weight of polyvinyl chloride resin (LG Chemical, LS100) was mixed with a Banbari mixer at 160°C, and then mixed at 160- A transparent layer was prepared as a film with a thickness of 0.55 mm by passing through a calender roll at 170°C.

5. printing layer formation stage

The printed pattern was directly transferred and printed on the top of the dimensional stability layer to form a printed layer with a thickness of 0.05 mm.

6. Second plywood stage

A transparent layer was laminated on top of the dimensionally stable layer on which the printed pattern was formed and subjected to secondary heat lamination at 150°C.

7. Tertiary plywood and Synchronized embossing process

Subsequently, after placing the second semi-finished product on top of the first semi-finished product manufactured above, a synchronous embossing process is performed on the transparent layer simultaneously with heat plywood under a temperature of 130° C. and a pressure of 5 kgf/cm ² with a synchronous embossing roll to form a transparent layer. A synchronous emboss was formed that matched the printed pattern formed at the bottom.

8. Surface treatment layer formation stage

A surface treatment agent containing a UV-curable resin was applied to the upper part of the transparent layer on which the synchronized embossing was formed, and then UV was irradiated to form a surface treatment layer with a thickness of 0.05 mm to prepare the flooring of Comparative Example 1 with a thickness of 4.5 mm.

< Comparative example 2>

One. web , Pre-foam layer , interstitial layer formation stage

Warp and weft yarns were prepared by spinning 100% by weight of polyester (PET) fiber. Subsequently, the warp was wound and warped, and the warp and weft yarns were woven to produce a woven fabric (plain weave) with a mesh structure having a thickness of 0.05 mm.

The prefoam layer and the intermediate layer were prepared as in Example 1.

2 - 5. First plywood stage; foam molding step; Forming a dimensionally stable layer and a transparent layer; And printing layer forming step; was performed in the same manner as Example 1.

6. Secondary plywood and Synchronized embossing process

A transparent layer was laminated on top of the dimensionally stable layer on which the printed pattern was formed and subjected to secondary heat lamination at 150°C.

Subsequently, a synchronous embossing process was performed on the upper part of the transparent layer using a synchronized embossing roll at a temperature of 130°C and a pressure of 5 kgf/cm ² to match the printed pattern, thereby manufacturing a second semi-finished product with synchronized embossing.

7. Third plywood stage

Next, the second semi-finished product was placed on top of the first semi-finished product manufactured above, and heat laminated at 160°C for the third time.

8. Surface treatment layer formation stage

A surface treatment agent containing a UV curable resin was applied to the upper part of the transparent layer on which the synchronized embossing was formed, and then UV was irradiated to form a surface treatment layer to prepare the flooring of Comparative Example 2 with a thickness of 3.45 mm.

< Reference example 1>

1. Non-woven fabric, Pre-foam layer , interstitial layer formation stage

After forming a web through a carding process with 100% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 3 denier, the carded web was folded into an appropriate layer through a cross wrapper process and a needle punching process was performed. Then, it was passed through a heat calendar at 540-560°C to produce a nonwoven fabric (HS Glotech Co., Ltd., 0823) with a basis weight of 230 g/m ² and a thickness of 0.8 mm.

The prefoam layer and the intermediate layer were prepared as in Example 1.

2 - 8. First plywood stage; foam molding step; Forming a dimensionally stable layer and a transparent layer; Printing layer forming step; Secondary plywood and co-embossing process; Third plywood stage; And surface treatment layer forming step; was performed in the same manner as Comparative Example 2.

< Reference example 2>

20% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 6 denier, 20% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 7 denier, and polyester with a length of 6 cm and a fineness of 16 denier ( After going through a blending process of mixing 60% by weight of PET) fibers, a web is formed through a carding process.

Next, the carded web was folded into an appropriate layer through the cross-wrapper process, performed a needle punching process, and then passed through a heat calendar at 540-560°C, except for the use of non-woven fabric with a basis weight of 200 g/m ² and a thickness of 0.8 mm. Then, the flooring material was manufactured in the same manner as in Example 1.

< Reference example 3>

85% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 6 denier, 10% by weight of polyester (PET) fiber with a length of 5 cm and a fineness of 7 denier, and polyester with a length of 6 cm and a fineness of 16 denier ( After going through a blending process of mixing 5% by weight of PET) fiber, a web is formed through a carding process.

Next, the carded web was folded into an appropriate layer through a cross-wrapper process, then performed a needle punching process, and then passed through a heat calendar at 540-560°C to produce a non-woven fabric with a basis weight of 200 g/m ² and a thickness of 0.8 mm. Flooring was manufactured in the same manner as in Example 1, except that.

< Reference example 4>

40% by weight polyethylene (PE) fibers with a fineness of 6 denier and 15 cm in length, 40% by weight polyethylene (PE) fibers with a fineness of 7 denier and 15 cm in length and 40% by weight polyethylene (PE) fibers with a fineness of 16 denier and 15 cm in length. After mixing 20% by weight to form a web using a spunboard molding device, a plurality of the webs are stacked and bonded by heat bonding to form a spunbond nonwoven fabric with a basis weight of 200g/m ² and a thickness of 0.8mm. Flooring was manufactured in the same manner as in Example 1 except that.

< Reference example 5>

Flooring was manufactured in the same manner as in Example 1, except that polyethylene (PE) fibers, rather than polyester (PET) fibers, were used as the fibers used in producing the non-woven fabric.

< Reference example 6>

A flooring material was manufactured in the same manner as in Example 1, except that PVC sol was applied to the lower part of the prefoam layer in the first plywood step of Example 1, and then the nonwoven fabric was joined without gelling.

At this time, the depth of PVC sol penetrated into the nonwoven fabric was 150㎛.

< Reference example 7>

100 parts by weight of a mixed resin containing polyvinyl chloride resin with a degree of polymerization of 1000 (LG Chemical, LS100) and polyvinyl chloride resin with a degree of polymerization of 1300 (LS130, LG Chemical) at a weight ratio of 10:90, acrylonitrile- A composition for pre-foaming layer molding containing 20 parts by weight of butadiene rubber, 5 parts by weight of foaming agent, 40 parts by weight of calcium carbonate, 55 parts by weight of plasticizer (LG Chemical, GL300), and 2 parts by weight of heat stabilizer is mixed at 160°C with a Banbari mixer. A flooring material was manufactured in the same manner as in Example 1, except that a pre-foam layer prepared by passing through a calender roll at 160-170°C was used.

Here, the thickness of the foam layer was 1.28mm, the expansion ratio was about 320%, the size of the foam cells was 210㎛, and the number of foam cells per unit area (1mm ² ) was 32.

[ Test example ]

Using the flooring materials of Example 1-2, Comparative Example 1-2, and Reference Example 1-7 prepared above, the height of debris and the level of cracks when transferring to the floor surface, the presence or absence of crack waves when heating the floor, Light impact noise, weight, surface hardness, crushability, residual indentation rate, synchronization rate, and flooring thickness were measured, and the results are shown in Table 1 below.

In addition, the tensile strength and elongation at break of the nonwoven or woven fabric used to manufacture the flooring materials of Example 1-2, Comparative Example 2, and Reference Example 1-7 were measured, and the results are shown in Table 1 below.

In addition, during the fatigue test of the foam layers of Example 1-2, Comparative Example 1-2, and Reference Example 1-7, the thickness loss, residual indentation rate, and pressing property were measured, and the results are shown in Table 1 below.

(1) The height of debris when transfer to the floor surface was measured with a tape measure when transfer of debris to the floor surface occurred. If the measured height of debris was greater than 0.9 mm, the transfer prevention to the floor surface was excellent. It was evaluated as

(2) The difference in crack level when transfer to the floor surface was measured with a tape measure on the surface of the flooring material. If the measured level difference is 0.7 mm or more, it is excellent at preventing crack transfer to the floor surface. It was evaluated as

(3) When heating the floor material, the occurrence of crack waves was determined by visually measuring whether the crack wave occurred when the flooring material was installed on the floor and heating conditions were applied at 55°C for 22 hours. If it did not occur, it was marked as ○, and if it did not occur, it was marked as X.

(4) The light impact sound of the flooring was measured according to the standards of KS F 2810. The control group was a cement floor that was not finished with flooring, and the light impact sound of the control group was 70dB.

(5) The weight of the flooring material was measured using a scale.

(6) The surface hardness of the flooring material was measured using a Shore D hardness tester (ASKER, Kobunshi keiki).

(7) The crushability of the flooring material was calculated by dividing the depth by applying a load of 222N to a hemispherical steel bar with a diameter of 19mm and dividing this depth by the total thickness of the flooring material.

(8) The residual indentation rate of the flooring material is as specified in KS M 3802, where a load of 222N is applied with a hemispherical steel bar with a diameter of 19mm, released after 5 minutes, and then the thickness of the specimen is changed after 1 hour and 1 day. The residual indentation rate was obtained as follows.

Residual indentation rate = (T ₀ - T ₁ )/T ₀

T ₀ : Thickness before pressurization

T ₁ : Thickness after pressing

(9) The synchronization rate of the flooring was measured by the degree to which the printed pattern of the printed layer and the synchronization emboss of the transparent layer deviated in the length or width direction using a vernier caliper. If the synchronization rate was 2 mm or less, the three-dimensional texture and aesthetics were evaluated as excellent. .

(10) The thickness of the flooring was measured using Mitutoyo No.2046S.

(11) The tensile strength of the non-woven or woven fabric was measured according to KS K 0521. Specifically, a specimen cut from the non-woven or woven fabric was kept in a chamber at 130°C for 1 minute and tested using a Universal Testing Machine (UTM, Instron). The tensile strength of the nonwoven or woven fabric was measured when stretched by 50% in the longitudinal direction after being clamped.

(12) The elongation at break of the nonwoven or woven fabric was measured by stretching in the longitudinal direction until the nonwoven or woven fabric broke at room temperature (20-25°C) using a Universal Testing Machine (UTM).

(13) The fatigue test of the foam layer was conducted by repeatedly applying a load of 800N 1000 times to the foam using a cyclic tensile compression tester (Material Test System, MTS Systems Corporation) in accordance with KS M ISO 3385, and then measuring fatigue. The thickness loss of the received area was calculated as follows.

Thickness loss = (D ₀ - D ₁ )/D ₀

D ₀ : Thickness before pressing

D ₁ : Thickness after pressing

(14) As specified in KS M 3802, the residual indentation rate of the foam layer is determined by applying a load of 222N with a hemispherical steel bar with a diameter of 19mm and releasing it after 5 minutes, and then measuring the thickness of the specimen (foam) after 1 hour. Through the changes, it was calculated as follows.

Residual indentation rate = (T ₀ - T ₁ )/T ₀

T ₀ : Thickness before pressurization

T ₁ : Thickness after pressing

(15) The compressibility of the foam layer was calculated by applying a load of 222N to a hemispherical steel bar with a diameter of 19 mm and dividing the penetration depth by the thickness of the foam.

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Reference example 1 Reference example 2 Reference example 3 Reference example 4 Reference example 5 Reference example 6 Reference example 7 Non-woven fibrous
texture PET PET - - PET PET PET P.E.
spunbond P.E. PET PET fibrous
Fineness
(denier) 6/7/16 8/
14 - 3 6/7/16 6/7/16 6/7/16
6/7/16 6/7/16 6/7/
16 mixing ratio
(weight ratio) 4:4:2 8:2 - 100 2:2:6 85:10:5 4:4:2 4:4:2 4:4:2 4:4:2 web - - - PET - - - - - - - Properties flooring miscellaneous
Height (mm) 1.2 0.9 0.5 0.5 1.2 0.7 0.8 - - 2.5 0.8 crack
Step difference (mm) 1.2 0.9 0.5 0.5 1.2 0.7 0.8 - - 2.5 0.8 crack
wave
Occurrence or not X X ○ X X X X - - X X Light impact sound (dB) 48 49 52 52 50 49 49 - - 48 50 Weight (kg/1.83m ² ) 5.29 5.29 6.45 5.10 5.29 5.29 5.29 - - 5.29 5.29 Surface hardness (D) 34 34 30.5 34 34 34 34 - - 34 34 Compressibility (mm) 1.8 1.9 1.5 1.1 1.7 1.8 1.8 - - 1.7 1.3 (%) 43 45 33 32 40 43 43 - - 40 36 residual
Indentation rate (%) (1hr/1day) 1.7/
1.2 2.3/
1.4 5.3/
3.3 2.1/1.9 1.7
/1.3 2.2
/1.9 2.1
/1.9 - - 1.5/
1.4 1.3/1.2 Tuning rate (mm) One One One 0 0 One 0 - - 0 One Thickness of flooring (mm) 4.2 4.2 4.5 3.45 4.2 4.2 4.2 - - 4.2 3.6 Non-woven/
web Tensile strength (kgf) 0.5 0.4 - 1.72 1.46 0.24 0.9 1.0 0.5 0.5 0.5 Elongation at break (%) 90 130 - 10 15 210 60 40 90 90 90 foam layer Thickness loss (%) during fatigue test 3 3 10 3 3 3 3 3 3 3 8.5 residual
Indentation rate (%) 6 6 13 6 6 6 6 6 6 6 5 Pressability (%) 79 84 43 79 79 79 79 79 79 79 70

Compared to Comparative Example 1, the flooring materials of Examples 1 and 2 had a height of 1.2 mm/0.9 mm and a crack level of 1.2 mm/0.9 mm when transfer occurred on the floor, so the transfer of debris and cracks on the floor surface was 1.2 mm/0.9 mm. Excellent prevention, crack waves do not occur even after floor heating, light impact noise is reduced by 22dB/21dB compared to a bare floor, excellent sound insulation, weight is reduced to 5.29kg/ ^1.83m2 , and surface hardness (shore D) is excellent. ) is 34, which is somewhat hard, so the appearance is beautiful due to the deep embossing. The compression resistance is 43%/45%, and the residual compression rate is 1.7%/2.3% based on 1 hour and 1.2%/1.4% based on 1 day, making the cushion comfortable. It was confirmed that the sensitivity and restoration properties were excellent.

In addition, the tensile strength of the nonwoven fabric used in the flooring of Examples 1 and 2 when stretched at high temperature (130°C) was 0.5kgf/0.4kgf, and the elongation at break was 90%/130 at room temperature (20-25°C). The values when compared with the tensile strength (0.3kgf) and elongation at break (150-250%) of the upper PVC material layer compared to the woven fabric of Comparative Example 2, which has low elongation and high tensile strength in %, and the non-woven fabric of Reference Example 1. During the similar bar co-embossing process, wrinkles did not form in the non-woven layer, so tertiary plywood and co-embossing processes could be performed at the same time, which had the effect of increasing the yield of flooring materials while providing excellent co-tuning.

On the other hand, the flooring material of Comparative Example 1, which is a conventional PVC flooring material that does not include a non-woven fabric layer in the bottom layer of the flooring material, has a height of 0.5 mm of miscellaneous matter transferred to the floor surface and a crack step of 0.5 mm, which means that compared to the example, the transfer material to the floor surface is 0.5 mm. Prevention is not effective, crack waves occur when heating the floor, the thickness of the foam layer is thick, and the interlayer layer contains only calcium carbonate as a filler, so it is heavier than the example, and has sound insulation and cushioning compared to the example. It was confirmed that the stability and stability were deteriorated. In addition, it was confirmed that the surface hardness was lower than that of the example and the emboss could not be deeply impressed, making it impossible to achieve a beautiful appearance.

On the other hand, the flooring material of Comparative Example 2 using a woven fabric and the flooring material of Reference Example 1 using a non-woven fabric rather than a blended fabric have the tensile strengths of the woven fabric of Comparative Example 2 and the non-woven fabric of Reference Example 1 when stretched at a high temperature (130°C), respectively. It is very large at 1.72kgf and 1.46kgf, and at room temperature (20-25℃), the elongation at break is 10% and 15%, respectively, so the tensile strength (0.3kgf) and elongation at break (100-250%) of the upper PVC material layer ), the difference was so large that when co-embossing was performed on the flooring, wrinkles occurred in the non-woven layer, making it impossible to perform plywood and co-embossing processes at the same time.

Therefore, inevitably, a process of heat plying the second semi-product with the first semi-product on which synchronous embossing was formed in advance was used. In this case, the emboss was broken by the heat plywood, resulting in a low emboss retention rate, and the plywood and synchronous embossing processes were performed separately. There was a disadvantage in that the yield of flooring material was reduced.

In particular, in the flooring material of Comparative Example 2 using woven fabric, it was confirmed that the woven fabric was too thin, so it was not effective in preventing transfer of the floor surface compared to the Example, and the sound insulation and pressing properties were reduced.

In addition, the flooring material of Reference Example 2, which used a nonwoven fabric containing many fibers with high denier fineness, had a problem in that the size of the nonwoven fabric layer significantly increased during the co-embossing process due to the low tensile strength of the nonwoven fabric when stretched at high temperature, and the low denier fineness was also low. The flooring material of Reference Example 3 using a nonwoven fabric containing many fibers had a problem of wrinkles forming in the nonwoven fabric layer during the synchronous embossing process because the nonwoven fabric had a large tensile strength when stretched at high temperature.

In addition, Reference Example 4 using a non-woven fabric manufactured by the spunbond method, which uses polyethylene fibers rather than polyester fibers and bonds them by applying heat rather than needle punching, and using a non-woven fabric manufactured by using polyethylene fibers and needle punching. Reference Example 5 had the disadvantage that the polyethylene fibers melted during the flooring manufacturing process (particularly during plywood), making it impossible to apply the nonwoven fabric to the flooring.

In addition, the flooring material of Reference Example 6, in which PVC sol was applied to the lower part of the foam layer in the bonding process of the non-woven fabric and the foam layer and then the non-woven fabric was bonded without gelling, was excellent in crack transfer, but too much PVC sol penetrated into the non-woven fabric. It was confirmed that when synchronous embossing was performed on the flooring material, wrinkles appeared in the non-woven layer and the yield decreased.

In addition, the flooring material of Reference Example 7, which contained an excessive amount of PVC resin with a high degree of polymerization as the PVC resin in the foam layer, had a low foaming ratio due to early foaming of the foaming agent before the foaming process, resulting in lower cushioning and sound insulation compared to Examples 1 and 2. I was able to confirm that it was happening.

1: Flooring 10': Non-woven
10: Non-woven layer 30': Pre-foam layer
30: foam layer 35: intermediate layer
40: Dimensionally stable layer 50: Printing layer
70: transparent layer

Claims (15)

From bottom to top, non-woven layer 10; Foam layer (30); Dimensional stability layer (40); Printing layer (50); And a transparent layer 70;
The nonwoven layer 10 includes a nonwoven fabric in which two or more types of fibers of different fineness (denier) of polyester (PET) are mixed, and the mixed nonwoven fabric has (i) a fineness of 4 based on its total weight. - A blend of 70-90% by weight of fibers of 12 denier and 10-30% by weight of fibers of 13-20 denier, or (ii) 35-50% by weight of fibers of 4-6 denier, with a fineness of 7 -35-50% by weight of fiber with a denier of 12 and 10-30% by weight of fiber with a fineness of 13-20 denier are mixed,
The foam layer 30 includes a mixed resin of PVC with a degree of polymerization of 900-1100 and PVC with a degree of polymerization of 1200-1600,
A flooring material with a pressability (19mmΦ, 222N) of 35% or more and a residual press rate (KS M 3802, 1hr) of 3% or less. delete delete delete According to clause 1,
The nonwoven fabric is a flooring material having a tensile strength of 0.3-0.8kgf when stretched 40-60% in the longitudinal direction at 120-140°C. According to clause 1,
The foam layer 30 is a flooring material with a thickness loss of 8% or less during a fatigue test (KS M ISO 3385). According to clause 1,
The foam layer 30 is a flooring material whose residual press rate (KS M 3802, 1hr) is 10% or less. According to clause 1,
The foam layer (30) is a flooring material with a pressing property (19mmΦ, 222N) of 50% or more. According to clause 1,
A flooring material in which 10 to 30 foam cells with an average diameter of 100 to 400 ㎛ are included in the foam layer (30) per unit area (1 mm ² ) of the side cross section of the foam layer (30). According to clause 1,
The foam layer (30) is a flooring material with a thickness of 1-3 mm. According to clause 1,
The flooring material further includes an intermediate layer (35) between the foam layer (30) and the dimension stabilization layer (40). According to clause 11,
The flooring layer 35 includes polyvinyl chloride resin, plasticizer, calcium carbonate, and hollow filler. According to clause 12,
The hollow filler has a particle size of 20-80㎛ and an average true density of 0.2-0.45g/cc. According to clause 1,
The flooring material has a light impact sound (KS F 2810) of 51 dB or less. According to clause 1,
The flooring material has a surface hardness (Shore D) of 31-45.