KR20050019529A - Floor harmonized with natural or aritificial fibers and foamed layer - Google Patents

Abstract

PURPOSE: A PVC-based floor material is provided to contain a fiber sheet within a foam layer, which gives a sterical texture to the product by varying expansion magnification within a foam layer. CONSTITUTION: The PVC-based floor material consists of: a substrate(1); a surface layer(8), which consists of a plurality of layers on the substrate(1) and contains an upper foam layer(2) having a fiber sheet(3) built-in; and a lower layer(7) placed on the backside of the substrate(1). The upper foam layer(2) with the fiber sheet(3) is obtained by the steps of: coating the upside of the substrate(1) with the upper foam sol; stacking a fiber sheet(3); and impregnating the fiber sheet(3) with the upper foam sol by heating, pressing, and gelling through a press roll and a gelling drum, and then expanding it. The fiber sheet(3) is nonwoven fabric or woven fabric prepared by mixing one, two or more selected from yarn-dyed cotton fibers, hemp fibers, wool textile, nylon, rayon, polyester fibers, carbon fibers, and metal fibers.

Description

FLOOR HARMONIZED WITH NATURAL OR ARITIFICIAL FIBERS AND FOAMED LAYER}

The present invention relates to a flooring material in which the fiber sheet and the foam layer are harmonized, and more specifically, the present invention is a foaming ratio according to the texture of the fiber by embedding the fiber sheet inside the foam layer made of PVC paste, and laminating and foaming the fiber sheet. Due to the difference, the three-dimensional texture is formed, and relates to the flooring harmonized sheet decorative properties of the pre-dyed synthetic fibers.

In the case of PVC-based flooring, an upper foamed layer is formed on the impregnated layer of the glass fiber mat in order to give the appearance decoration, and after printing with a predetermined pattern using various printing methods such as gravure printing or rotary screen, the transparent layer is laminated. And it is known as a well-known method to produce by the process of laminating the lower foam layer and foaming.

In addition, according to the pattern to give a three-dimensional impression, by forming a foam suppression printing on the upper foam layer and foaming, the unevenness formed by the foaming and foam suppression to form a flooring material having a synchronized texture matching the printed pattern, or decorative In order to multiply, natural fibers such as cotton, hemp, and wool, and high melting point synthetic fibers such as nylon, rayon, polyester, and carbon are mixed at a predetermined ratio, and the fabric sheet processed into a sheet in the form of a fabric is printed on top of the printed film. Alternatively, a technique for harmonizing pre-dyed synthetic fibers with printed patterns by thermal fusion and plywood at the bottom is also known in the art. In addition, in the manufacture of glass fiber mats, the colored fibers are mixed and manufactured, and then impregnated with a transparent PVC paste sol, predetermined printing on the upper or lower portion thereof, and then printing by a known method of laminating a transparent layer and a lower foam layer. Attempts have also been made to produce floorings with a combination of natural and colored fibres.

However, in the structure in which the pre-dyed synthetic fiber is simply laminated to the lower portion of the transparent layer as described above, since the fiber sheet is impregnated with a transparent PVC paste sol or melt-plyed with the transparent layer sheet, only the printed texture and the simple texture of the fiber sheet can be expressed. There was no. In addition, in the manufacture of glass fiber mats, after mixing the colored fibers, impregnating them with a transparent PVC paste sol, printing a predetermined portion on the upper or lower portion thereof, and then laminating the transparent layer and the lower foamed layer, Since only texture can be expressed, it was rather insufficient to manufacture a flooring decorative material in which the three-dimensional texture and the dye-dyed fiber sheet were harmonized.

Therefore, an object of the present invention is to solve the problems of the prior art as mentioned above, due to the difference in foaming ratio according to the fiber sheet included in a part in the upper foam layer in the production of PVC-based flooring, the three-dimensional texture is It is to provide a flooring in which the sheet decoration of the formed, dyed fiber is harmonized.

The flooring material of the present invention is a flooring material having a multi-layered flooring consisting of a plurality of surface layers 8 formed on the base layer and a lower layer formed below the base layer, wherein the surface layer 8 has a fiber sheet embedded therein. It is characterized in that the foam layer is included.

That is, according to the present invention, in the multi-layered flooring material, the fiber sheet is included in the upper layer capable of foaming and then foamed, whereby the portion containing the fiber in the upper foamed layer appears to have a low foaming magnification and does not contain the fiber. The part that does not have a high foaming ratio, so that the three-dimensional texture and natural fiber shape by the difference in the foaming ratio of each part is harmonized, and the flooring material that can create the appearance effect of various shapes and textures unlike the conventional simple printing texture and mechanical embossing It characterized in that to provide. The flooring material according to the present invention is a PVC flooring material which is completely different in structure, appearance and effect from a conventional vinyl flooring material containing PVC as a main material or a conventional carpet containing nylon, polyester and the like.

EMBODIMENT OF THE INVENTION Hereinafter, preferred embodiment of this invention is described with reference to drawings.

1 relates to a flooring of a foam structure having a cushioning property according to one embodiment of the present invention, after coating the upper foam layer sol on top of the base layer (1), by laminating the pre-dyed fiber sheet (3) The upper foam layer sol is sufficiently impregnated into the fibrous sheet 3 by pressure and gelling to form an upper foam layer 2 in which the fiber sheet is embedded, and on the upper foam layer 2, a gravure printing or a rotary screen The printing layer 4 is formed in accordance with a predetermined pattern by using a known printing method such as the above, and the foamed or non-foamed lower layer 7 is laminated on the back side of the substrate layer 1, and then foamed, and then surface treated. It is sectional drawing of the flooring which formed the layer 6.

In the present invention, the base layer is not particularly limited, but a glass fiber mat impregnated layer in which the glass fiber mat is impregnated with a PVC-based paste sol is preferable. As a glass fiber mat which can be used for the base material layer 1, for example, the fiberized glass filament of 5 to 24 microns is cut to a predetermined length, dispersed in water and irritated, and then each glass fiber is A known product manufactured by binding with a thermoplastic or thermosetting resin binder may be employed, and it is preferable to have excellent dimensional stability, low thermal deformation, and excellent mechanical strength.

This glass fiber mat is known by using a sol in which 40 to 70 parts by weight of plasticizer, 1 to 3 parts by weight of stabilizer, 50 to 200 parts by weight of filler, and other additives are mixed with 100 parts by weight of PVC paste resin, for example. It is impregnated by coating with a knife coating method and a comma coating method, followed by drying with a gelling drum at 130 to 170 ° C. The formed glass fiber mat impregnation layer 1 can be used as a base layer.

Although the upper foam layer 2 is laminated | stacked on the said base material layer (glass fiber mat impregnation layer) 1, For example, with respect to 100 weight part of PVC paste resins, a plasticizer 40-70 weight part and a stabilizer 1-3 weight Part, 0.2 to 3 parts by weight of blowing agent, 1 to 5 parts by weight of zinc-based accelerator and other additives, and a transparent upper foam layer for maintaining a viscosity of 1000 to 10,000 cps by mixing for 10 to 40 minutes in a mixer with a high speed impeller A sol is prepared or 40 to 70 parts by weight of plasticizer, 1 to 3 parts by weight of stabilizer, 0.2 to 3 parts by weight of blowing agent, 5 to 30 parts by weight of filler, and 1 to 5 parts by weight of zinc-based accelerator based on 100 parts by weight of PVC paste resin. 0.1-1 parts by weight of pigments having excellent colorability and dispersibility were quantitatively mixed and mixed in a mixer with a high speed impeller for 10-40 minutes to prepare a semi-transparent colored upper foam layer sol maintaining a viscosity of 1000-10,000 cps. Known knife coaters, river coaters, bar coaters, screen coaters The use of the 0.1 ~ 0.5mm and a coating on the substrate layer (1) to form an upper foam layer. Subsequently, the fibrous sheet 3 was laminated on the coated upper foam layer, and then the upper foamed sol was sufficiently impregnated into the fibrous sheet by heating, pressing and gelling with a press roll and a gelling drum at 130 to 170 캜. ) Forms the upper foam layer 2 inherent.

In said process, it is preferable that the pressure of a press roll is 1-10 kg / cm <2>. When the press pressure is lower than 1kg / cm 2, the fiber sheet 3 protrudes to the surface, so that the ink-free portion may be generated due to the poor smoothness during the next printing operation, and when the pressure is higher than 10 kg / cm 2, the upper foam layer This can lead to problems with poor smoothness of the fibers.

In addition, the fiber sheet 3 is a predetermined ratio of one or two or more of natural fibers such as dyed cotton, hemp and wool, and high melting point synthetic fibers such as nylon, rayon, polyester, and carbon, and metal fibers. It is manufactured in the form of a nonwoven fabric by mixing in the form of a nonwoven fabric, or woven into a woven sheet form including warp and weft yarns, and sheeting to 0.1 to 0.4 mm thinner than the thickness of the upper foam layer 2 It is preferable because the density difference of the fibers is not uniformly formed so that the upper foaming sol is easily impregnated, and the texture of the pre-dyed fiber sheet is naturally expressed. Various printed patterns may be provided on the surface of the fiber sheet 3.

In addition, various types of fabrics can be expressed according to the type, thickness, length, and density of colored fibers, and various types of natural texture effects and various colors can be expressed by using colored fibers in which single color or various colors are harmonized. In addition, it is possible to apply a metal-treated fibers in addition to natural fibers and synthetic fibers to create a variety of appearance effects.

Next, the printing layer 4 of various patterns and colors is formed on the upper foam layer 2 in which the fiber sheet is embedded. The printing may use a known printing method such as gravure printing, offset printing, and rotary screen printing. In this case, the gravure ink used may be melted or dispersed in a high speed mixer by, for example, 10 to 40 parts by weight of a PVC copolymer, 30 to 70 parts by weight of an organic solvent, and 0.1 to 20 parts by weight of an undispersed organic or inorganic pigment. It is preferable to apply, and 5-30 parts by weight of a TMA (trimetic anhydride) or a BTA (benzotriazole) -based foaming inhibitor may be mixed and added to the ink according to a desired printing pattern. .

After the printing layer 4 is formed, foaming is performed in an oven at 180 to 240 ° C., and the upper foam layer 2 including the fiber sheet 3 is foamed, and the foam is included in the foamed upper foam layer 2. The portion to be formed has a low foaming ratio, so that the portion not containing fibers forms a portion, and the irregularities formed to match the pattern of the fiber sheet and the colored fiber sheet 3 are harmonized, resulting in a three-dimensional three-dimensional conformation. The decoration and the fiber texture of the fiber sheet 3 are integrated.

By laminating and foaming the lower foam layer 7 on the back surface 1 of the foamed semi-finished substrate layer 1 as shown in FIG. 1, the bottom foam layer applied at this time may be, for example, PVC paste resin. 30 to 70 parts by weight of plasticizer, 1 to 3 parts by weight of stabilizer, 1 to 5 parts by weight of blowing agent, 10 to 50 parts by weight of filler, 1 to 5 parts by weight of zinc-based accelerator, 40 to 70 parts by weight of plasticizer, 1 to 3 parts by weight of stabilizer, 1 to 5 parts by weight of foaming agent, and 10 to 50 parts by weight of filler based on SOL processing method to mix by laminating in a known coating process and 100 parts by weight of PVC straight resin 1 ~ 5 parts by weight of zinc-based accelerators are mixed, mixed in a super mixer for 5-20 minutes, rolled in a calendar or extruded in a T die, and then foamed in an oven at 180 to 240 ° C. It is preferable. In addition, the lower layer 7 may not be a foam layer, and in this case, it is preferable to form by the method of laminating | stacking a non-foamed sheet layer or an easy layer which does not contain a foaming agent and an accelerator.

After the lamination or lamination and foaming of the lower layer, the surface treatment layer 6 is formed on the printed layer 4. The surface treatment layer 6 is formed by air knife or sponge roll, for example, a conventional UV layer composition, which consists of a urethane acrylate oligomer, ethylene or propylene acrylate monomer, a photoinitiator, an antifoaming agent, and a labeling agent on the above printing layer 4. It can be formed by coating and then curing with ultraviolet light.

Figure 2 is a cross-sectional view of the flooring according to another embodiment of the present invention, the manufacturing process is as follows.

The upper foam layer 2 is laminated on the substrate layer 1 impregnated with a PVC paste sol on a glass fiber mat, and the fiber sheet 3 is impregnated with the upper foam sol so that the fiber sheet 3 is contained inside the upper foam layer. The printing layer 4 is formed by heating, pressurizing and gelling with a gelling drum and a press roll to form a desired pattern, then foaming, and then foaming or non-foaming lower layer 7 on the back side of the base layer 1 After laminating the foam by foaming in an oven at 180 to 240 ° C., the portion containing the fiber in the upper foam layer 2 had a low foaming ratio and the portion containing no fiber showed a high foaming ratio, and thus the difference in foaming ratio for each region. The semi-finished product which is comprised so that a three-dimensional texture and natural fiber shape are harmonized is produced.

The transparent layer 5 is laminated on the printed layer 4 of the semi-finished product. The transparent layer 5 is, for example, 40 to 70 parts by weight of a plasticizer and 1 to 3 parts by weight of a stabilizer based on 100 parts by weight of PVC paste resin. 0.1-1 parts by weight of the ultraviolet absorber capable of absorbing ultraviolet rays and other additives are coated by a SOL processing method for mixing 10-40 minutes in a mixer with a high speed impeller like the upper foam layer 2, and 130-200 It is preferable to laminate | stack by laminating by heat-hardening in oven, a gelling drum, or a rolled sheet using a well-known calendar or T-die.

After that, as in the process of Figure 1, by laminating the lower foam layer (7) and foamed in an oven at 180 ~ 240 ℃, the conventional UV layer composition by air knife or sponge roll coating, and then cured with ultraviolet light surface treatment By forming the layer 6, the irregularities and the colored fiber sheet 3 formed by forming the recesses and the recesses in the upper foam layer 2 in which the surface is smooth but in which the foamed synthetic fibers are embedded correspond to the fiber sheet pattern. It is harmonized to obtain a floor covering which integrates the three-dimensional stereoscopic decoration along the perspective and the fiber texture of the synthetic fiber sheet 3.

In the above embodiments, the foaming of the upper foaming layer 2 and the lower foaming layer 7 is carried out in separate steps, respectively, but the foaming once after laminating the lower foaming layer 7 as in the following examples. It is also possible to simultaneously foam the upper foam layer 2 and the lower foam layer 7 by the treatment. In addition, unlike the above embodiments, the flooring material having the structure in which the printed layer 4 is omitted is also included in the present invention.

Dioctyl phthalate (DOP), texanoxobutyrate (TXIB), butylbenzyl phthalate (BBP), epoxidized soybean oil (ESO), etc. can be used as a plasticizer for each constituent layer of the flooring material, and barium-zinc-based Heat stabilizers, cadmium-barium-zinc heat stabilizers, organic tin stabilizers, etc. may be used, and calcium carbonate, silica powder, etc. may be used as fillers, and azodicarbonamide (ADCA), diphenyltriazole ( DPT), 4,4-oxybisbenzenesulfonylhydrazide (OBSH), and the like, and ZnO may be used as an accelerator. In addition, a well-known pigment, a viscosity reducing agent, etc. which are normally recognized as being used as an additive to a flooring material can be added to each constituent layer of the flooring material. In addition to the above-described examples of the additives, it will be apparent to those skilled in the art belonging to the configuration of the present invention.

In addition, a well-known pigment, a viscosity reducing agent, etc. which are normally recognized as being used as an additive to a flooring material can be added to each constituent layer of the flooring material.

Hereinafter, the present invention will be described through specific examples and comparative examples, but the present invention is not limited thereto.

Example

[Manufacture of Natural or Synthetic Fiber Sheets]

Natural fibers such as dyed cotton, hemp, and wool and high melting point synthetic fibers such as nylon, rayon, polyester, and carbon are mixed in a proportion to produce nonwoven fabrics, or in the form of woven sheets including warp and weft yarns. It was prepared by weaving.

[Production of Base Layer 1]

40 parts by weight of dioctylphthalate as a plasticizer, 15 parts by weight of butylbenzylphthalate, 3 parts by weight of epoxy compound, and 3 parts by weight of barium-zinc-based heat stabilizer as stabilizers based on 100 parts by weight of vinyl chloride resin having a polymerization degree of 1700 in the glass fiber mat. , Knife-coated to 0.4mm thickness of the composition containing 7 parts by weight of DOSL-240R as a viscosity reducing agent, 150 parts by weight of calcium carbonate as a filler, 20 minutes at a speed of 35m / min in a gelling drum at 160 ℃ It heated for 2 seconds and gelatinized and the base material layer 1 was produced.

[Formation of Upper Foam Layer 2 Embedded with Fiber Sheet 3]

37 parts by weight of dioctylphthalate as a plasticizer, 8 parts by weight of DOSL-240R as a white kerosene component as a viscosity lowering agent, and 3 parts by weight of azodicarbonamide as a foaming agent with respect to 100 parts by weight of a vinyl chloride resin having a polymerization degree of 1300 on the substrate layer 1. , 40 parts by weight of calcium carbonate as a filler, 3 parts by weight of a barium-zinc-based heat stabilizer as a stabilizer, and 3 parts by weight of Zn-O as a promoter were knife-coated to a thickness of 0.5 mm to form a top foam layer (2).

On the upper foam layer (2), a pre-fabricated 0.3 mm thick fiber sheet was laminated on the coated upper foam layer, and heated at a rate of 35 m / min in an oven at 160 ° C. with a 10 kg / cm 2 press roll for 1 minute and 20 seconds. By pressing gelling with the gelling drum, the fiber sheet 3 was sufficiently submerged in the upper foam layer 2 to form the upper foam layer 2 having the fiber sheet 3 embedded therein.

[Formation of Printing Layer 4]

Gravure printing was performed on the upper foam layer 2, and the gravure ink used was 35 parts by weight of a PVC-based copolymer, 60 parts by weight of an organic solvent, and 5 parts by weight of an undispersed organic pigment, and melted with a high speed mixer. The printed layer 4 was formed using the dispersion mixing.

[Formation of the transparent layer 5]

30 parts by weight of dioctylphthalate as a plasticizer, 3 parts by weight of epoxy compound, 3 parts by weight of barium-zinc-based compound as heat stabilizer, and a viscosity reducing agent based on 100 parts by weight of vinyl chloride resin having a polymerization degree of 1700 on the printed layer 4. 5 parts by weight of a white kerosene component, DOSL-240R and 0.5 parts by weight of a hydroxybenzotriazole hydroxybenzophenone-based ultraviolet absorber were kneaded to a thickness of 0.2 mm, and then a speed of 30 m / min in an oven at 170 ° C. Heated for 1 minute and 30 seconds to form a transparent layer (5).

[Formation of Lower Foam Layer 7]

37 parts by weight of dioctylphthalate as a plasticizer, 8 parts by weight of DOSL-240R as a white kerosene component as a viscosity reducing agent, and 3 weights of azodicarbonamide as a foaming agent to 100 parts by weight of a vinyl chloride resin having a polymerization degree of 1700 on the back surface of the product obtained above. In addition, 40 parts by weight of calcium carbonate as a filler, 2 parts by weight of a barium-zinc-based heat stabilizer as a stabilizer, and 3 parts by weight of ZnO as a promoter were knife-coated to a thickness of 0.4 mm, and then 30 m / min in an oven at 205 캜. The lower foam layer 7 and the upper foam layer 2 were simultaneously foamed while heating at the rate for 2 minutes.

[Formation of Surface Treatment Layer 25]

The UV curable polyurethane paint was laminated on the transparent layer 5 to a thickness of 15 μm, and cured using seven UV lamps having 80 Watt / in output at a speed of 30 m / min to form a surface treatment layer 6.

[Product inspection and packaging]

Finally, both ends of the finished flooring material were cut, cut to a certain length, inspected and packed.

In the flooring of the present invention, the fiber sheet is included in the upper foam layer, and the portion including the fiber in the upper foam layer has a low foaming magnification and the portion not containing the fiber has a high foaming magnification, resulting in a difference in foaming ratio for each region. Since it is possible to form a natural three-dimensional texture by, it is possible to provide a flooring material that is completely different in structure and appearance effect than the conventional products laminated with a simple printing texture or synthetic fibers.

1 is a cross-sectional view of the flooring, foamed by laminating a top foam layer embedded with a fiber sheet,

FIG. 2 is a cross-sectional view of a flooring material having a smooth surface, in which a foam sheet is laminated and foamed, and a transparent layer is laminated.

Explanation of symbols for the main parts of the drawings

1. Base layer

2. Upper foam layer

3. Fiber sheet

4. Printed layer

5. Transparent layer

6. Surface treatment layer

7. Foamed or non-foamed bottom layer

8. Surface layer

Claims (7)

A flooring material having a multi-layer structure comprising a base layer, a surface layer composed of a plurality of layers stacked on the base layer, and a lower layer stacked below the base layer, wherein the top layer includes an upper foam layer having a fiber sheet embedded therein. PVC-based flooring, characterized in that. The upper foam layer of claim 1, wherein the upper foam layer having the fiber sheet is coated with the upper foamed sol on the base layer, and then the fibrous sheet is laminated and heated, pressurized, and gelled with a press roll and a gelling drum. PVC-based flooring, characterized in that formed by being impregnated into a fiber sheet and foamed. The nonwoven fabric or woven fabric according to claim 1, wherein the fibrous sheet is manufactured by mixing one or two or more kinds of fibers such as dyed cotton, hemp, wool, nylon, rayon, polyester, carbon fiber, and metal fiber at a predetermined ratio. PVC flooring, characterized in that. The PVC-based flooring material according to claim 1, wherein the fiber sheet is provided with various printed patterns on its surface. The PVC-based flooring according to any one of claims 1 to 4, wherein the foamed or non-foamed lower layer, the base layer, the upper foamed layer in which the fiber sheet is embedded, the printed layer, and the surface treatment layer are laminated from the bottom of the flooring material. . The PVC-based flooring material according to any one of claims 1 to 4, wherein a foamed or non-foamed lower layer, a base layer, an upper foamed layer containing a fiber sheet, a transparent layer, and a surface treatment layer are laminated from the bottom of the flooring material. The PVC according to any one of claims 1 to 4, wherein the lower foamed or non-foamed lower layer, the base layer, the upper foamed layer in which the fiber sheet is embedded, the printed layer, the transparent layer and the surface treatment layer are laminated from the bottom of the flooring material. System flooring.