KR20050046176A - Pvc floor sheet and manufacturing process thereof - Google Patents

Abstract

The present invention relates to a PVC flooring material and a method of manufacturing the same, by performing color simulation in the flooring manufacturing process to derive the desired color by combining a variety of colors, it is possible to live-action inkjet printing, excellent in a simple process without the production of a separate printing roll It provides a manufacturing method of PVC flooring which can get design and color and can greatly reduce the process and cost.

Description

PVC flooring and its manufacturing method {PVC FLOOR SHEET AND MANUFACTURING PROCESS THEREOF}

The present invention relates to a PVC flooring material and a method of manufacturing the same, and more particularly, by performing color simulation in the flooring manufacturing process to derive a desired color, cost reduction and process by the roll production, and omission of color matching process to generate a cost The present invention relates to a method for manufacturing PVC flooring which is simplified and is very economical and can improve the quality of design by developing new colors.

In general, in the production process of PVC flooring and industrial sheet products, a gravure printing method in which ink is formed in ink pockets formed on the concave plates and transferred to a printing object is applied.

In addition, the manufacturing method of the flooring is generally divided into a prototype manufacturing process and a finished product process. 1 briefly illustrates a manufacturing process of the conventional flooring.

As shown in Figure 1, the prototype manufacturing process (st70) is a design process (st10), artwork evaluation process (st20), roll production process (st30), gravure printing process (st40), foaming process (st50), and Color matching process (st60).

In addition, the finished product manufacturing process in Figure 1 is made of a gravure printing process and a foaming process using a printing roll produced during the prototype, after which it is released to the market through the finished product evaluation process (st80).

In the production of the prototype, the roll production process st30 includes a separation plate st31, a print roll production st32, and an embossing roll production st33 operation.

In the gravure printing process (st40), the selected color is printed after the artwork evaluation.

The foaming process st50 includes a skin layer work st51, a foaming work st52 and an embossing work st53 of the artwork printed by the gravure printing process st40.

The color matching process (st60, st61) is a process of reviewing the product after the foaming process (st50), selecting an appropriate color, and adjusting the color by the color tone maker (st62).

In the finished product review process (st80), a review for a new color of the finished product completed by the above process is in progress. The finished product that has passed the finished product review process st80 is produced as a sample book and distributed to the market. Finished products determined to be insufficient in the finished product review process (st80) are discarded and the design process (st10) is resumed.

However, this method does not apply to the finished product when insufficient decision is made after the prototype evaluation. Therefore, the production roll has to be discarded and the fabric used in the color matching during the manufacturing of the prototype must be discarded. . In addition, the need to manufacture a prototype again causes a reduction in work efficiency and waste of time and money due to insufficient product quality.

As a result, the conventional flooring manufacturing method generates unnecessary costs due to the loss of production opportunities for new colors, and delays time to market of products when a lot of insufficient colors are generated.

In order to solve the above problems of the prior art, an object of the present invention is to perform a color simulation during the flooring manufacturing process, it is possible to omit the cost of roll production and color matching and to develop a new color process, time and cost In addition to greatly reducing the quality of the design to provide a method of manufacturing the PVC flooring material can be improved.

Another object of the present invention is to provide a PVC flooring having excellent design and color produced by the above method.

In order to achieve the above object, the present invention

The process of designing artwork on paper fabrics;

A color simulation process of selecting an optimal color for the artwork review result using a program means capable of combining colors;

Electronic separation and printing of the fabric according to the color simulation result; And

Process of foaming the product after the printing process

It provides a method of manufacturing a flooring comprising a.

In addition, the flooring of the present invention may be a prototype, or may be a finished product.

The finished product comprises the steps of: a) designing the artwork on the fabric; Judging the artwork; A color simulation process of selecting an optimal color for the artwork review result using a program means capable of combining colors; Electronic separation and printing of the fabric according to the color simulation result; A prototype manufacturing process comprising a step of foaming a product having undergone the printing process; And

b) electronically separating and producing a printing roll according to the prototype result; Gravure printing using the printing roll; And it may be made including a step of foaming the product passed through the printing process.

In addition, the finished product is a) a process of designing (art work) on the paper fabric; Judging the artwork; A color simulation process of selecting an optimal color for the artwork review result using a program means capable of combining colors; Electronic separation and printing of the fabric according to the color simulation result; A prototype manufacturing process comprising a step of foaming a product having undergone the printing process; And

b) printing with live inkjet according to the prototype result; And it may be made to include a step of foaming the product passed through the printing process.

In addition, the present invention provides a floor covering comprising a surface treatment layer, a printing layer, and a vinyl chloride resin substrate layer from above, wherein the printing layer is formed by a live inkjet printing method using solvent ink.

Hereinafter, the present invention will be described in detail.

The flooring manufacturing method of the present invention can derive a desired color by combining a variety of colors by performing a color simulation after the artwork evaluation, so that real-world inkjet printing is possible, can exhibit excellent design and color, and the effect of new color development for a short time Can get on. In addition, the printing roll manufacturing process and color matching process during the production of prototypes in the conventional flooring manufacturing process may be omitted, thereby greatly reducing the process and cost.

The manufacturing method of the flooring material of this invention consists of a design process, an artwork evaluation process, a color simulation process, a printing process, and a foaming process.

In the present invention, the color simulation process is preferably performed by adjusting the color by a program in the computer's barco system. In addition, the color simulation process includes a process of reviewing an internal and external customer with a prototype completed in the prototype manufacturing process, and a process of reviewing a prototype sample book.

In particular, the printing process in the present invention consists of a live-action inkjet method using solvent ink.

In addition, the roll manufacturing process in the present invention includes a step of finely adjusting the separation plate, printing roll and emboss roll based on the prototype produced through the prototype manufacturing process and the color simulation process. The separation may be implemented as a program in a computer's Barco system, which is connected to printing means.

The flooring material thus obtained may be a prototype, and may be used as a finished product as the design and color are equivalent to the finished product.

In the case of the finished product, the present invention manufactures a prototype by a design process, artwork evaluation process, color simulation process, printing process, foaming process, gravure after electronic separation and printing rolls are produced according to the result of the prototype after the color simulation Printing and foaming process. The present invention may use a live inkjet method instead of a gravure printing process in the printing process.

Hereinafter, with reference to the accompanying drawings will be described in detail with respect to the manufacturing method of the flooring according to an embodiment of the present invention.

Figure 2 is a process diagram of the flooring manufacturing method according to the present invention, showing that it can be used as a finished product immediately after the production of the prototype. In Figure 2, the manufacturing method of the flooring material of the present invention comprises a design process (ST10), artwork evaluation process (ST20), color simulation process (ST30), prototype production process (ST40) and finished product evaluation (ST50) process.

In addition, the manufacturing method of the flooring material of the present invention in Figure 3 is a design process (ST10), artwork evaluation process (ST20), color simulation process (ST30), prototype production process (ST40), roll production process (ST50), printing process (ST60), foaming step (ST70), and finished product evaluation step (ST80).

The design process ST10 examines the customers and their inclinations, and produces the artwork according to the findings.

The artwork evaluation step ST20 evaluates whether the artwork produced by the design step ST10 is insufficient.

The color simulation process (ST30) includes a process of reviewing the prototypes completed in the prototype manufacturing process by internal and external customers, and a process of reviewing the prototype sample book.

The roll manufacturing process ST50 finely adjusts the separation plate, the printing roll, and the embossing roll through the prototype produced by the color simulation process ST40.

The printing process ST60 is a process of printing the finished product in the optimal color selected by color simulation. It is preferable that printing process ST60 consists of a live inkjet method using a solvent ink.

The foaming step ST70 completes the product through the skin layer work, the foaming work, and the embossing work on the finished product printed by the printing step ST60.

The finished product evaluation step ST80 reviews the finished product completed by the foaming step ST70. Flooring completed in this process is shipped to the market.

The flooring material of the present invention manufactured by the above method is basically composed of a surface treatment layer 30, a printing layer 20, and a vinyl chloride resin substrate layer 10 from above as shown in FIG. It is not particularly limited.

Preferably, the PVC flooring material of the present invention may include a surface treatment layer, a transparent film layer, a printing layer, a vinyl chloride resin interlayer, a vinyl chloride resin base layer from above.

In addition, the PVC flooring material of the present invention may include a UV coating layer, a transparent layer, a printing layer, an upper foam layer, a base layer, a lower foam layer, and a sizing layer from above.

The vinyl chloride resin base layer may be manufactured using a method of coating a vinyl chloride sol (plastisol) on the lower part of the sheet, and is not particularly limited.

The printing layer is preferably formed by an inkjet printing method using solvent ink. The PVC flooring may further include a film that can improve performance as needed.

The surface treatment layer is used to impart a synergistic effect of fouling resistance or durability to the surface of the flooring material of the present invention, but is not particularly limited, it is preferable that it can block UV. For example, the UV surface treatment layer may use urethane acrylate, silicone acrylate, epoxy acrylate, and the like, and in order to improve heat resistance, it is preferable to further include acrylic or urethane beads. The curing method is crosslinked and cured by ultraviolet rays or electron beams. Depending on the composition, the urethane acrylic resin may be cured by ultraviolet irradiation, and the aqueous urethane resin may be cured by heat.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the following examples are merely to illustrate the invention and the scope of the present invention is not limited to the following examples.

Example 1

All the possible variables for prototyping paper artwork were derived from Table 1 below.

Possible variables Artwork Finished The gap between artwork and finished product Prototype Possibility fabric paper PVC Whiteness, surface tension ○ Separation - 5 degree separation Contrast ○ ink Jet print ink Gravure ink Color development, transparency × Print method Plateless printing Intaglio printing resolution × Foaming Process No foam In foam Sharpness, delicateness △ Skin presence No emboss With emboss Transparency, gloss △ Embossing Process No skin With skin Texture, reality △

As shown in Table 1, when the fabric of the artwork is paper and the fabric of the finished product is PVC, the artwork and the finished product have a gap in whiteness and surface tension, and the gap allows the paper fabric to be used as a prototype.

If the artwork is with or without separation and the finished product is a 5 degree separation, the artwork and finished product have a gap in sharpness, which allows the application of the separation to the prototype.

However, when the ink of the artwork is jet print ink and the finished ink is gravure ink, the artwork and the finished product have a gap in color development and transparency, which makes the jet print ink inapplicable to the prototype.

If the artwork is printed on plateless printing and the finished product is intaglio printing, the artwork and finished product have gaps in resolution, and this gap prevents the application of plateless printing to the prototype.

If the artwork does not go through the foaming process and the finished product goes through the foaming process, the artwork and the finished product have a gap in clarity and detail, which makes the foam less likely to be applied to the prototype.

If the artwork does not go through the embossing process and the finished product goes through the embossing process, the artwork and finished product have gaps in transparency and gloss, and this gap lowers the possibility of applying the embossing process to the prototype.

If the artwork does not go through the skin layer process and the finished product goes through the skin layer process, there is a gap in texture and realism, and this gap lowers the possibility of applying the skin layer process to the prototype.

Example 2

An experiment was performed to determine a printing method having the same effect as the gravure printing method from the possible variables as in Example 1.

A schematic diagram of the printing method for determining the printing method is shown in FIG. 4. In FIG. 4, the plateless printing method is an inkjet method for delivering ink by an electric signal, and the flat printing method is an offset printing method using chemical repellency of lipophilic and hydrophilicity, and the stencil printing method punctures the film of the non-wire portion to make ink. It is a silk screen method of delivering, and the top plate printing method is a gravure method that transfers ink directly to the embossed ink.

The comparison results for the printing method are shown in Table 2 below, and the numerical values of the respective items are relative values, and the printing effect means a level compared with the gravure printing effect.

Monolium Fabric Application Print size Printing effect Lead time cost (a) Non-printing (inkjet) △ 5 4 5 5 (b) off-set printing ○ 2 4 3 2 (c) stencil printing (silk screen) ○ 2 3 2 2 (d) Copper plate printing (gravure printing) ○ 5 5 2 2

In Table 2, it can be seen that in comparison of the four printing methods, the live inkjet method, which is a plateless printing method, is an optimal printing method having an excellent printing effect compared to other printing methods.

Example 3

The present invention was subjected to the following test in order to derive the ink that does not discolor in the subsequent step of the foaming process.

The test was carried out with the first test with an idea, the second test by coating and printing on the PVC fabric, and the third test with ink that can be printed directly on the PVC fabric.

In the first test, an oily pigment was used to test the PVC fabric on the real-time output machine. As a result, spreading occurred when printing on the PVC fabric, and printing was possible only on dedicated paper.

The second test was a coating test after coating the PVC fabric with an oily pigment, and as a result, coating equipment size was limited, and coating deformation occurred due to heat after the foaming process.

The third test was carried out with a testable ink coated on a PVC fabric, the results are shown in Table 3 below.

Ink type Monolium Fabric Printing Effervescent Economics Aqueous dyes × × × UV curing ○ ○ × Water-based pigment × × × Disperse Pigments × × × Torch Dispersion × ○ × Solvent ○ ○ ○

In Table 3, the aqueous dye ink is not suitable for PVC fabric printing, foamability and economics, the UV curable ink is suitable for PVC fabric printing and foaming, and is unsuitable in economics, and the aqueous pigment and disperse dye ink are PVC fabric printing, foamability And not economically suitable, the toner dispersion ink is unsuitable for PVC fabric printing and economics and suitable for foaming, and the solvent ink is suitable for both PVC fabric printing, foaming and economics.

As a result of the 1st, 2nd, 3rd test, it can be seen that the solvent ink, which can be printed on the PVC fabric and has no deformation (5) in the foaming process, is the optimal ink.

Example 4

It is shown in Table 4 by comparing the difference in the pattern sharpness of the prototype and the finished product produced by the method of the present invention.

Color similarity Color clarity Delicate pattern Color, vividness of the pattern Rating 1 ◎ ◎ ◎ ○ Evaluation 2 ◎ ◎ ○ ○ Evaluation 3 ○ ◎ ○ ○ Evaluation 4 ◎ ○ ○ ○ Evaluation 5 ◎ ◎ ○ ◎ Evaluation 6 ◎ ◎ △ ◎

week)

◎: same level (100%: non-visual classification)

○: similarity level (90% ~ 99%: slight difference)

△: Normal level (80% ~ 89%: Visual classification possible)

×: insufficient level (less than 80%: difference is obvious)

In Table 4, the prototype using the printing method and the ink of the present invention is almost similar to the finished product, and it can be seen that a slight gap exists only in the sharpness of the pattern. That is, in the comparison between the prototype and the finished product, it can be seen that the similarity of color, the sharpness of the color, the delicate pattern expression, and the color and the sharpness of the pattern are the same level or the similar level.

Example 5

In the present invention, the resolution and the printing method were determined through the color simulation process (ST40), as shown in Figure 5 to reduce the gap between the pattern sharpness of the prototype and the finished product.

The present invention reproduces the effect of clarity by connecting the spot color separation system of the Barco system rather than the primary color separation method used in the first inkjet printer. Spot color separations are inkjet print control software.

The present invention found that the resolution most similar to the finished product was 720 × 720 through the resolution adjustment.

In addition, by adjusting the printing method, it is possible to change the general bidirectional printing style from unidirectional printing to increase the fineness of printing.

The flooring manufacturing method of the present invention can derive a desired color by combining a variety of colors by performing a color simulation during the manufacturing of the flooring, so that the inkjet printing can be realistic, it is possible to obtain a prototype having a design and color equivalent to the finished product. The effect of new color development can be obtained in a short time. In addition, the printing roll manufacturing process and color matching process during the production of the prototype of the conventional flooring manufacturing process are omitted, thereby greatly reducing the process and cost. In addition, the present invention can reduce the cost of failure due to delay in time-to-market, prevent roll disposal, improve roll yield, and prevent fabric waste to reduce fabric test costs. In addition, the present invention enables full color simulation and rich color test and pearl effect test while selecting an optimal color.

1 is a process diagram of a flooring manufacturing method according to the prior art.

Figure 2 is a process of the flooring manufacturing method according to an embodiment of the present invention.

Figure 3 is a process of the flooring manufacturing method according to an embodiment of the present invention.

Figure 4 is a schematic diagram of the printing method for producing a prototype of Example 2 of the present invention.

Fig. 5 is a schematic diagram showing a comparison between the printing method and the resolution determination of the fifth embodiment of the present invention.

Figure 6 is a basic cross-sectional view of the PVC flooring of the present invention.

Reference numeral 10 is a vinyl chloride resin base layer, 20 is a printing layer, and 30 is a surface treatment layer.

Claims (10)

The process of designing artwork on paper fabrics; A color simulation process of selecting an optimal color for the artwork review result using a program means capable of combining colors; An electronic separation process according to the color simulation result and a real inkjet printing of the original fabric; And Process of foaming the product after the printing process PVC flooring manufacturing method comprising a. The method of claim 1, wherein the color simulation process is performed by adjusting color with a program in a computer's barco system. The method of claim 1, wherein the printing process uses solvent ink. The method of claim 1 wherein the flooring is a prototype. The method of claim 1, wherein the flooring is a finished product. The method of claim 5, a) the process of designing the art work on the fabric; Judging the artwork; A color simulation process of selecting an optimal color for the artwork review result using a program means capable of combining colors; An electronic separation process according to the color simulation result and a real inkjet printing of the original fabric; A prototype manufacturing process comprising a step of foaming a product having undergone the printing process; And b) electronically separating and producing a printing roll according to the prototype result; Gravure printing using the printing roll; And foaming the product which has passed the printing process. PVC flooring manufacturing method comprising a. As a flooring material containing a surface treatment layer, a printing layer, and a vinyl chloride resin base layer from the above, The printed layer is a PVC flooring is formed by a live inkjet printing method. The PVC flooring material as claimed in claim 7, wherein solvent ink is used in the inkjet printing method. The method of claim 7, wherein PVC flooring material comprising a surface treatment layer, a transparent film layer, a printing layer, a vinyl chloride resin interlayer, and a vinyl chloride resin base layer from above. The method of claim 7, wherein PVC flooring comprising a UV coating layer, a transparent layer, a printing layer, an upper foam layer, a base layer, a lower foam layer, and a sizing layer from above.