KR20110008983U - Flooring material having biodegradable surface layer - Google Patents

Abstract

The present invention relates to a flooring material having a laminated structure, and more particularly, to a flooring material having a surface layer composed of a biopolymer resin.
The present invention includes a surface layer, an intermediate layer, a dimensionally stable layer and a back layer from above, wherein the surface layer is formed of a biopolymer sheet, and the intermediate layer and the back layer are formed of a non-biopolymer resin. do.
In this case, the biopolymer sheet is preferably composed of at least one resin selected from polylactic acid (PLA) and polycaprolactone (Polycaprolactone, PCL).

Description

Flooring material with biopolymer resin {FLOORING MATERIAL HAVING BIODEGRADABLE SURFACE LAYER}

The present invention relates to a flooring having a laminated structure, and more particularly to a flooring having a surface layer composed of a biopolymer resin.

Floor materials used in buildings such as houses, apartments, apartments, offices or stores are mainly used for flooring based on petroleum resin such as polyvinyl chloride (PVC).

The flooring material using said polyvinyl chloride etc. is manufactured by extrusion or a calendering method etc. using resin, such as polyvinyl chloride (PVC). However, since the raw material of polyvinyl chloride resin is based on petroleum resources, there may be a big problem in the supply and demand of raw materials in the future due to depletion of petroleum resources. Increasingly, the demand for the use of biopolymer resins made from plant resources is increasing.

In addition, in the case of phthalate-based plasticizers mainly used for soft nitriding in polyvinyl chloride, it is classified as a suspected environmental hormone substance, and the reluctance of consumers is increasing.

An object of the present invention is to provide an environmentally friendly flooring by forming a surface layer using a biopolymer resin in the flooring.

The present invention includes a surface layer, an intermediate layer and a back layer from above, wherein the surface layer is formed of a biopolymer sheet, and the intermediate layer or the back layer is provided with a flooring, characterized in that formed of petroleum resin.

In addition, the present invention includes a surface layer, an intermediate layer, a dimensionally stable layer and a back layer from above, wherein the surface layer is formed of a biopolymer sheet, and the intermediate layer or the back layer is formed of a non-biopolymer resin. To provide.

The present invention includes a surface treatment layer, a surface layer, an intermediate layer, a dimensionally stable layer and a back layer from above, wherein the surface treatment layer is formed of urethane acrylate resin, urethane resin or wax, and the surface layer is a biopolymer. It is formed of a sheet, the intermediate layer or the back layer provides a flooring, characterized in that formed of petroleum resin.

In the above case, the surface treatment layer or the dimensionally stable layer may be deleted as necessary.

In addition, in the above case, an adhesive layer and a back fiber layer can be added to the lower back layer as needed.

In this case, the biopolymer sheet is preferably composed of at least one resin selected from resins in which 40% or more of non-petroleum raw materials are used, such as polylactic acid (PLA) and copolymers thereof.

Flooring according to the present invention can implement an eco-friendly flooring by forming a surface layer with a biopolymer resin.

1 is a cross-sectional view showing a flooring having a biopolymer surface layer according to a first embodiment of the present invention,
2 is a cross-sectional view showing a flooring having a biopolymer surface layer according to a second embodiment of the present invention.
3 is a cross-sectional view showing a flooring material having a biopolymer surface layer according to a third embodiment of the present invention.
Figure 4 is a cross-sectional view showing a flooring having a biopolymer surface layer according to another embodiment of the present invention.

Advantages and features of the present invention, and methods for achieving them will be apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in a variety of different forms, only the embodiments to make the disclosure of the present invention is complete, the common knowledge in the art to which the present invention belongs It is provided to fully inform the person having the scope of the invention, which is only defined by the scope of the claims. Like reference numerals refer to like elements throughout.

Hereinafter, a flooring material having a biopolymer surface layer according to the present invention will be described in detail with reference to the accompanying drawings.

1 is a cross-sectional view showing a flooring material having a biopolymer surface layer according to a first embodiment of the present invention, Figure 2 is a cross-sectional view showing a flooring material having a biopolymer surface layer according to a second embodiment of the present invention, Figure 3 Is a cross-sectional view showing a flooring having a biopolymer surface layer according to a third embodiment of the present invention.

In the first embodiment of FIG. 1, the flooring consists of a surface layer 10, an intermediate layer 20, and a backing layer 40. In the second embodiment of FIG. 2, the flooring comprises a surface layer 10, an intermediate layer 20, and dimensions. It consists of a stable layer 30 and the back layer 40, the third embodiment of Figure 3 is a flooring material surface treatment layer 50, surface layer 10, intermediate layer 20, dimensional stability layer 30 and the back surface Layer 40.

The present invention is characterized in that the surface layer 10 is composed of a biopolymer sheet.

On the other hand, the term "biopolymer sheet" used in the present invention is a sheet manufactured using a resin composition containing a biopolymer resin, characterized in that the raw material of 40 parts by weight or more is derived from fossil raw materials such as plants and microorganisms. Or it means the molded object of film shape.

The range of the biopolymer sheet of the present invention includes a sheet or film-shaped foam and non-foamed body prepared using the resin composition. In the present invention, in some cases, embossing may be performed on part or all of the sheet or film-shaped molded article.

In addition, in the present invention, preferably, the biopolymer sheet may be a sheet manufactured by a calendering method, that is, a calendering sheet. In the present invention, when the calendering sheet is used as described above, a sheet having excellent physical properties such as durability, weather resistance and surface strength can be obtained as compared with the case produced by other manufacturing methods (ex. Extrusion, press, etc.).

It does not specifically limit as such a biopolymer resin, A polylactic acid resin, a polylactic acid resin copolymer, etc. can be used, It is also possible to use resin other than polylactic acid, if the raw material of resin originates in a plant.

Polylactic acid is a lactide or a thermoplastic polyester of lactic acid, and is typically a resin containing a repeating unit as shown in the following formula (1).

The polylactic acid as described above may be prepared by polymerizing lactic acid produced by fermenting starch extracted from renewable plant resources, for example, corn, potato, sweet potato, etc., thereby effectively coping with the problem of depletion of petroleum resources. In addition, the polylactic acid is significantly less than the petroleum resources such as polyvinyl chloride in the discharge of environmentally harmful substances such as CO2 during use or disposal process, and has an environmentally friendly property that can be easily decomposed under natural environment at the time of disposal.

Such polylactic acid may be generally classified into D-polylactic acid, L-polylactic acid, D, L-polylactic acid, or meso-polylactic acid, but the present invention is not limited thereto, and among One kind or a mixture of two or more kinds may be used, and among them, L-polylactic acid (PLLA) is more preferably used in view of securing strength of the biopolymer sheet. That is, in the present invention, the biopolymer resin may be composed of only L-polylactic acid or may be composed of a mixture of L-polylactic acid and another biopolymer resin. When L-polylactic acid is mixed with other biopolymer resins, the content thereof is preferably 50% or more by weight, but is not limited thereto.

On the other hand, the polylactic acid used in the present invention, as described above, can be prepared by polymerizing lactic acid or lactide, if necessary, glycol compounds such as ethylene glycol or propylene glycol, ethanedioic acid (ethanedioic acid) Or hydroxycarboxylic acids such as dicarboxylic acid such as terephthalic acid, glycolic acid or 2-hydroxybenzoic acid; Alternatively, suitable copolymerization components such as lactones such as caprolactone or propiolactone may be further copolymerized.

In the present invention, the resin composition constituting the biopolymer sheet may include an additional resin together with the above-described biopolymer resin. When the resin composition includes a separate resin together with the biopolymer resin, the resin is preferably a resin having compatibility or miscibility with the biopolymer resin. The term "miscibility" used in the present invention means a property that when two or more components (ex. Resin component) are mixed, the interface separation phenomenon does not occur between the components, and can be uniformly mixed.

Typically, the resin having a certain degree of polarity may exhibit excellent miscibility with the polylactic acid described above. Specific types of the resin that can be used in admixture with the above-mentioned polylactic acid in the present invention are not particularly limited as long as they exhibit the above-described physical properties, and examples thereof include acrylic resins, polyvinyl chloride (PVC), and polyvinylacetate (PVAc). ), Polyethylene glycol (PEG), ionomer, polyglycolide, ethylene vinyl acetate resin, polycarbonate (PC), polycaprolactone, polyhydroxyalkanoate, polyester, maleic anhydride, etc. Polyolefins or acrylic resins modified with a polar group of an epoxidized natural rubber and other epoxidized polymers, such as one or a mixture of two or more kinds thereof may be mentioned. Vinyl chloride (PVC), polyvinylacetate (PVAc), polyethylene glycol and ionomer are preferred, but are not limited thereto.

The surface layer 10 uses a polylactic acid resin as a binder, and includes a non-phthalate plasticizer and an acrylic copolymer as a melt strength enhancer.

Non-phthalate eco-friendly plasticizers facilitate molding at high temperatures by softening polylactic acid resins to increase thermoplasticity. In the present invention, the plasticizer may be an environmentally friendly plasticizer ATBC (Acetyl tributyl citrate).

The plasticizer is preferably used in a ratio of 5 to 50 parts by weight based on 100 parts by weight of polylactic acid resin, and in the case of the intermediate layer 20 and the back layer 40, it is used in a ratio of 5 to 60 parts by weight based on 100 parts by weight of the PLA resin. It is desirable to.

When the plasticizer is used in an amount less than 5 parts by weight based on 100 parts by weight of the polylactic acid resin, the hardness of the polylactic acid resin may be increased, and workability may be reduced, and when the plasticizer is used in excess of a given ratio in each layer, compatibility with other components is achieved. Physical properties may be deteriorated due to deterioration.

The acrylic copolymer used as a melt strength reinforcing agent serves to reinforce the strength of the polylactic acid resin having poor impact strength or heat resistance at the time of melt extrusion. In addition, the acrylic copolymer was capable of calendering and pressing the polylactic acid resin. The weight average molecular weight (Mw) of the acrylic copolymer is not particularly limited, but considering the improvement in melt strength and the like and compatibility of other material light during processing, it is preferable to use 800,000 to 6 million.

Such an acrylic copolymer can be used in the ratio of 0.1-20 weight part with respect to 100 weight part of polylactic acid resins. When the content of the acrylic copolymer is less than 0.1 parts by weight, the improvement of the efficiency of melting and improving the melt strength of the polylactic acid resin is insufficient. When the content of the acrylic copolymer exceeds 20 parts by weight, the manufacturing cost of each layer constituting the flooring increases. The overall physical properties of each layer may be lowered due to compatibility problems with other materials constituting each layer.

The polylactic acid resin may further include a lubricant to prevent accumulation of deposits or crosslinked materials in melt extrusion.

Although there are various types of such lubricants, the present invention uses environmentally friendly higher fatty acids as lubricants, and in particular, stearic acid, which is a saturated higher fatty acid having 18 carbon atoms, may be used.

The lubricant may be used in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the polylactic acid resin. If the amount of the lubricant is less than 0.01 part by weight based on 100 parts by weight of the polylactic acid resin in the polylactic acid resin, the effect of using the lubricant is not obtained. If the amount of the lubricant is more than 10 parts by weight based on 100 parts by weight of the PLA resin, the impact resistance of the polylactic acid resin, There is a problem that may deteriorate heat resistance, glossiness, and the like.

In addition, a chain extender may be further added to the polylactic acid resin in order to increase the molecular weight through chain extension to improve tensile strength and heat resistance.

Such a chain extender may be a diisocyanate, a hydroxycarboxylic acid compound, or the like, but this is just one example, and various kinds of chain extenders currently used may be used without limitation.

The chain extender may be used in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the polylactic acid resin. If the amount of the chain extender used in the polylactic acid resin is less than 0.01 part by weight based on 100 parts by weight of the polylactic acid resin, the effect of using the chain extender cannot be obtained, and the amount of the chain extender used is 10 parts by weight based on 100 parts by weight of the polylactic acid resin. If it exceeds, the glossiness of polylactic acid resin etc. may fall.

In addition, a second plasticizer such as ESO (epoxidized soybean oil) or MSO may be additionally added to the polylactic acid resin. The second plasticizer is also formed of an environmentally friendly material to improve molding properties at high temperatures of the polylactic acid resin.

Such a second plasticizer is preferably added in an amount ratio of 20 parts by weight or less with respect to 100 parts by weight of polylactic acid resin. If the second plasticizer is added in excess of the above range, the physical properties of each layer due to the excessive addition of the second plasticizer may be rapidly deteriorated.

In addition, in order to prevent mechanical properties such as impact resistance from being lowered through hydrolysis of the polylactic acid resin, an anti-hydrolysis agent may be additionally added to the polylactic acid resin. The hydrolysis agent can be used without limitation so long as it is usually used as a hydrolysis agent such as carbodiimide and oxazoline.

It is preferable that such a hydrolysis agent is added in the range of 10 weight part or less with respect to 100 weight part of polylactic acid resins. When the hydrolysis agent exceeds 10 parts by weight relative to 100 parts by weight of the polylactic acid resin, molding processability may decrease.

Further, titanium dioxide (TiO ₂ ) may be further added to the polylactic acid resin as a white pigment for the purpose of reinforcing inorganic filler calcium carbonate (CaCO ₃ ) or to impart aesthetics.

In the case of calcium carbonate, it is preferable to use 100 parts by weight or less relative to 100 parts by weight of polylactic acid resin. In the case of titanium dioxide, it is preferably used in an amount of 50 parts by weight or less based on 100 parts by weight of polylactic acid resin.

When calcium carbonate or titanium dioxide is used in excess of the above range, the binding force of other components may be lowered, thereby decreasing workability.

In addition, wood powder or rosin may be additionally added to the surface layer 10 to impart the texture and natural wood fragrance of natural wood.

Wood powder is preferably added in an amount of 200 parts by weight or less relative to 100 parts by weight of polylactic acid resin, and in the case of rosin, it is preferably added in an amount of 20 parts by weight or less based on 100 parts by weight of polylactic acid resin. The more wood powder and rosin are included, the more natural wood texture can be given. However, the binding strength of other components may be reduced, resulting in deterioration of physical properties such as workability.

In addition, the polylactic acid resin may further include a lubricant, a chain extender, a second plasticizer, a hydrolysis agent, and the like.

Hereinafter, look at each layer constituting the PLA flooring according to the present invention.

In the present invention, as described above, the surface layer 10 may use a PLA resin containing a plasticizer and an acrylic copolymer, and may further include a lubricant, a chain extender, a second plasticizer, a hydrolysis agent, and the like.

The surface layer 10 preferably has a thickness of 0.10 to 1.0 mm. If the surface layer has a thickness of less than 0.10 mm, it is difficult to form, and it wears out quickly during use, and it is difficult to fully realize the inherent effects of using the bio resin on the surface layer. On the other hand, if the thickness of the surface layer 10 exceeds 1.0 mm can cause a rise in the flooring manufacturing cost without further effect increase.

In the present invention, the intermediate layer 20 and the back layer 40 may include foamed or non-foamed sheets, and gravure printing, screen printing, offset printing, and rotary printing may be performed on the surface of the petroleum resin of the intermediate layer 20 as necessary. Or by forming a pattern in a variety of ways, such as flexographic printing serves to give the floor aesthetics.

In the present invention, the dimensionally stable layer 30 serves to compensate for low dimensional stability. In the case of a flooring material using a biopolymer resin, the dimension may change due to a difference in temperature and humidity, and a phenomenon such as a connection between floorings may be opened due to shrinkage, and thus, the dimensional stability layer 30 may secure such dimensional stability. This phenomenon is prevented.

The dimensionally stable layer may be formed by impregnating an acrylic resin, melamine resin, PLA resin, etc., having excellent transparency and moldability, on woven fabrics and nonwoven fabrics having excellent dimensional stability such as glass fibers.

In this case, the glass fiber preferably has a mass per unit area of 30 ~ 150 g / m ² . If the mass per unit area of the glass fiber is less than 30 g / m ² , the effect of dimensional stability reinforcement may be insufficient, and the mass per unit area of the glass fiber is 150 When g / m ² is exceeded, there is a problem that the adhesion between the intermediate layer 20 and the dimensional stability layer 30 or the adhesion between the back layer 40 and the dimensional stability layer 30 may be lowered.

The dimensional stabilization layer 30 may be used alone or two kinds of ATBC, viscosity reducing agent, inorganic filler for reducing cost, calcium carbonate, white pigment titanium dioxide (TiO ₂ ), etc. The above may be further included.

The materials added to the dimensionally stable layer 30 are preferably added in an amount of 40 to 150 parts by weight with respect to 100 parts by weight of the resin in the case of ATBC, 30 parts by weight or less for the viscosity reducing agent, 150 parts by weight or less for the calcium carbonate In the case of titanium dioxide, it is preferably added in an amount of 20 parts by weight or less.

ATBC is less than 40 parts by weight compared to 100 parts by weight of acrylic resin may increase the hardness of the glass fiber impregnated layer may decrease the processability, on the contrary, if it exceeds 150 parts by weight dimensional stability due to compatibility problems with other components May inhibit. In the case of the viscosity lowering agent, when the amount is added in excess of 30 parts by weight based on 100 parts by weight of the acrylic resin, moldability may be reduced due to excessive viscosity decrease. In the case of calcium carbonate and titanium dioxide, when added in excess of the above range, the adhesive strength with other components may be lowered, thereby lowering the workability.

The dimensionally stable layer 30 preferably has a thickness of 0.20 ~ 1.0 mm. If the thickness of the dimensionally stable layer 30 is less than 0.2 mm, the dimensional stability effect may be insufficient. If the thickness of the dimensionally stable layer 30 exceeds 1.0 mm, a sufficient dimension stability effect may be obtained even with a thickness of 1.0 mm or less. Although thicker, the overall cost increases.

The intermediate layer 20 and the back layer 40 are preferably made of a non-biopolymer resin, and in particular, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyolefin (TPO), thermoplastic polyurethane ( TPU), thermoplastic starch (TPS), styrene ethylene butadiene styrene (SEBS), polyurethane (PU), polyester (Polyester), nitrile butadiene rubber (NBR) and styrene butadiene styrene (SBS) It is desirable to.

The surface treatment layer 50 is formed on the surface layer 10 for the purpose of improving surface quality such as scratch resistance and abrasion resistance of the flooring material, and improving cleaning resistance to facilitate cleaning. The surface treatment layer 50 may include polyurethane, urethane acrylate, wax and the like.

There are various methods for forming the surface treatment layer 50. For example, when urethane acrylate is used, the urethane acrylate UV curable composition may be applied onto the surface layer 10 and cured through ultraviolet irradiation. In addition, the thermosetting wax may be applied on the surface layer 10 and formed by curing through a hot air oven.

As described above, the flooring according to the present invention has an environmentally-friendly advantage than the flooring using a conventional polyvinyl chloride as a binder by using a biopolymer resin as a binder of the surface layer.

In the above description with reference to the embodiment of the present invention, this is merely an example, and those skilled in the art will understand that various modifications and equivalent other embodiments are possible therefrom. . Therefore, the true technical protection scope of the present invention should be judged by the claims described below.

10: surface layer
20: middle layer
30: dimensionally stable layer
40: back layer
50: surface treatment layer

Claims (19)

Including from above the surface treatment layer, surface layer, intermediate layer and back layer,
The surface layer is formed of a biopolymer sheet,
The intermediate layer or the back layer is flooring, characterized in that formed of a non-biopolymer resin.
Including from above the surface treating layer, the surface layer, the intermediate layer, the dimensionally stable layer and the back layer,
The surface layer is formed of a biopolymer sheet,
The intermediate layer or the back layer is flooring, characterized in that formed of a non-biopolymer resin.
The method of claim 2,
The dimensionally stable layer is a flooring, characterized in that formed of a non-biopolymer resin.
The method according to any one of claims 1 to 3,
The biopolymer sheet is a flooring material comprising at least one biopolymer resin, characterized in that at least 40 parts by weight of the raw material of the resin originates from the fossil raw material.
The method according to any one of claims 1 to 3,
The biopolymer sheet is
Flooring, characterized in that composed of at least one polylactic acid-based resin selected from polylactic acid (Ploylactic acid, PLA) or polylactic acid copolymer.
The method of claim 5,
The biopolymer sheet is a flooring material comprising an acrylic copolymer as the polylactic acid resin, a nonphthalate plasticizer and a melt strength enhancer as a binder.
The method of claim 6,
The biopolymer sheet is a flooring material comprising 5 to 50 parts by weight of the plasticizer and 0.1 to 20 parts by weight of the melt strength reinforcing agent with respect to 100 parts by weight of the polylactic acid resin.
The method of claim 7, wherein
The biopolymer sheet includes 0.01 to 10 parts by weight of a higher fatty acid, 0.01 to 10 parts by weight of a chain extender, ESO (epoxidized soybean oil) and MSO based on 100 parts by weight of the polylactic acid resin. A flooring material further comprising at least one of 20 parts by weight or less of a merchant second plasticizer and 10 parts by weight or less of an anti-hydrolysis agent.
The method according to any one of claims 1 to 3,
The surface layer is a flooring, characterized in that having a thickness of 0.10 ~ 1.0 mm.
The method according to any one of claims 1 to 3,
The intermediate layer and the back layer
Polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyolefin (TPO), thermoplastic polyurethane (TPU), thermoplastic starch (TPS), styrene ethylene butadiene styrene (SEBS), polyurethane (PU), Flooring, characterized in that it comprises a material selected from polyester, nitrile butadiene rubber (NBR) and styrene butadiene styrene (SBS).
The method of claim 2,
The dimensionally stable layer is a flooring material, characterized in that the glass fiber is impregnated with at least one material selected from acrylic resin, melamine resin and PLA resin.
The method of claim 11,
The glass fiber is a flooring, characterized in that having a unit mass per area of 30 ~ 150 g / m ² .
The method of claim 11,
The dimensionally stable layer is one or more of 40 to 150 parts by weight of a non-phthalate plasticizer, 30 parts by weight or less of viscosity reducing agent, 150 parts by weight or less of calcium carbonate and 20 parts by weight or less of titanium dioxide (TiO ₂ ) to 100 parts by weight of the resin. Flooring characterized in that it further comprises.
The method of claim 13,
The dimensionally stable layer is a flooring, characterized in that having a thickness of 0.20 ~ 1.0 mm.
The method according to any one of claims 1 to 3,
The surface treatment layer is a flooring, characterized in that it comprises at least one of polyurethane, urethane acrylate and wax.
The method according to any one of claims 1 to 3,
The thickness of the surface treatment layer is flooring, characterized in that 0.01 to 0.1mm
Including a top layer, a middle layer and a back layer from above,
The surface layer is formed of a biopolymer sheet,
The intermediate layer or the back layer is flooring, characterized in that formed of a non-biopolymer resin.
The method of claim 17,
Flooring, characterized in that further comprising a dimensionally stable layer between the intermediate layer and the back layer.
The method of claim 18,
The dimensionally stable layer is a flooring, characterized in that formed of a non-biopolymer resin.

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