KR20210067032A - Floor sheet and method for manufacturing the same - Google Patents

Abstract

The present invention relates to a flooring material comprising a foam layer, a dimensionally stable layer formed on the foam layer, and a labeling layer formed on the dimensionally stable layer, and a method for manufacturing the same. More particularly, the present invention relates to a flooring material and a method for manufacturing the same that can produce a flooring material by a co-extrusion process while satisfying the physical properties required as a flooring material by forming the dimensionally stable layer with a short fiber reinforced plastic resin, and can simplify the types of materials and manufacturing processes required for manufacturing flooring.

Description

FLOOR SHEET AND METHOD FOR MANUFACTURING THE SAME

The present invention relates to a flooring material and a method for manufacturing the same.

The flooring material used in a building is manufactured to include a foam layer, which is a foam that gives a certain level of cushioning properties so that it can have a comfort and sound insulation effect. These foams are generally prepared by adding a foaming agent to polyvinyl chloride resin, and a chemical foaming agent, which is one of the foaming agents, is decomposed by heat to form a gas to form pores (cells) in the resin.

When manufacturing a flooring including a foam layer, it is essential to insert a dimensional stability layer between the cover layer and the foam layer for reasons such as preventing the pattern of the layer from being transferred to the cover layer during the manufacturing process. Unlike the label layer and the foam layer manufactured based on the calendering process, the dimensionally stable layer is generally manufactured by impregnating glass fibers in a sol-type resin and then curing it. In addition, in order to manufacture a flooring product based on the above layers, a separate multi-step process of laminating each layer is required.

As such, in the case of manufacturing a flooring including a foam layer based on the conventional calendering process, there is a problem that the manufacturing process for each layer is different, and that several steps are essential in the manufacturing process. Accordingly, there is a continuing demand for the simplification of the flooring manufacturing process through improvement of raw materials and processes.

Republic of Korea Patent Publication No. 10-2007-0059811 Republic of Korea Patent Publication No. 10-2003-0018670

In order to solve the above problem, the present inventors manufacture a flooring material through a co-extrusion process rather than a conventional calendar process, and a short fiber reinforced thermoplastic plastic (Short) that is suitable for the co-extrusion process and allows the required physical properties to be expressed. By manufacturing a dimensionally stable layer, which is one of the components of the flooring material, using a fiber-reinforced thermoplastics) resin, it was confirmed that the manufacturing process of the flooring material can be simplified, and the present invention was completed.

Accordingly, an object of the present invention is to provide a flooring material manufactured by a simple manufacturing process and a manufacturing method thereof.

In order to achieve the above object, the present invention is a foam layer; a dimensionally stable layer formed on the foam layer; and a cover layer formed on the dimensionally stable layer, wherein the dimensionally stable layer includes Short Fiber-reinforced Thermoplastics (SFT).

The present invention also comprises the steps of: a) preparing a composition for a foaming layer comprising a polyvinyl chloride (PVC) resin and a foaming agent;

b) preparing a composition for a dimensionally stable layer comprising a short fiber reinforced plastic resin;

c) preparing a composition for a cover layer comprising a polyvinyl chloride (PVC) resin; and

d) co-extruding the composition for the foaming layer, the composition for the dimensionally stable layer, and the composition for the cover layer to form a foaming layer, a dimensionally stable layer and a cover layer at the same time as the foaming of the composition for the foaming layer; provides

The flooring material according to the present invention shortens the manufacturing process of the flooring material through a co-extrusion process including extrusion foaming instead of a calendering process in which the foaming layer, the dimensionally stable layer, and the cover layer included in the conventional flooring are respectively formed and bonded. productivity can be improved.

In addition, by using Short Fiber-reinforced Thermoplastics (SFT) as a raw material for the dimensionally stable layer included in the flooring material, the coextrusion process is smoothly performed to sufficiently exhibit the physical properties required as the dimensionally stable layer Flooring can be manufactured.

1 is a schematic diagram of a flooring material according to the present invention.
Figure 2 shows a schematic diagram of a short fiber-reinforced thermoplastics (Short Fiber-reinforced Thermoplastics) resin according to the present invention.
3 is a schematic diagram of a flooring co-extrusion apparatus according to the present invention.

Advantages and features of the present invention and methods of achieving them will become 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, and only these embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention belongs It is provided to fully inform the possessor of the scope of the invention, and the present invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout.

Hereinafter, the flooring material according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

flooring

1 shows a cross-sectional view of a flooring material according to the present invention. Flooring according to the present invention is a foam layer (10); a dimension stabilizing layer 20 formed on the 　foam layer; and a cover layer 30 formed on the 　 dimensionally stable layer 　, wherein the dimensionally stable layer may include a Short Fiber-reinforced Thermoplastics resin.

The flooring material according to the present invention may further include a fabric layer.

The fabric layer is a portion in contact with the bottom, and in order to secure rigidity, it is preferable that the fabric layer has a constant thickness, has high dimensional stability, and is not deformed by heat and pressure. The fabric layer may be a woven or nonwoven fabric including at least one of cotton, nylon, polyester and rayon.

The flooring material according to the present invention includes a foam layer (10).

The foam layer 10 may be formed from a foam layer composition including a polyvinyl chloride (PVC) resin and a foaming agent. The foamed layer 10 may be formed by mixing a polyvinyl chloride resin and a foaming agent to prepare a foamed layer composition, followed by extrusion foaming. The foam layer composition may include polyvinylidene chloride (PVDC) resin, chlorinated polyvinyl chloride (CPVC) resin, etc. in addition to polyvinyl chloride resin and foaming agent. The foam layer 10 may be formed on the bottom or the fabric layer.

The blowing agent is azodicarbonamide (ADCA, Azodicarbonamide), p,p'-oxybisbenzenesulfonyl hydrazide (p,p'-Oxybis(benzenesulfonyl hydrazide)), p-toluenesulfonyl hydrazide (p- toluenesulfonyl hydrazide) and sodium bicarbonate, but is not limited thereto. After the foaming agent is foamed, it may have a volume increase ratio of 100 to 500% by volume. In the process of foaming, the gas generated from the foaming agent may form bubbles, thereby forming foamed cells in the foaming layer 10 . The foamed cell may be a spherical foamed cell, and all of the walls of the pores are formed in a closed structure, so that the pores are not connected to other pores, and are also referred to as closed cells or closed cells. Since the foam cell is not deformed in shape by a physical external force, it is possible to improve soft properties and cushioning of the foam layer 10 .

In addition, the foaming layer 10 of the present invention contains a foaming stabilizer derived from the foaming agent in addition to the polyvinyl chloride (CPVC) resin. Since the foaming stabilizer is a metal salt, when used in a large amount, there is a problem such as environmental pollution.

In the present invention, by improving the foaming process to be described later, the amount of the foaming agent and foaming stabilizer used in the foaming process is minimized. Specifically, the content of the foaming stabilizer contained in the foaming layer is 100 weight of polyvinyl chloride (PVC) resin. It may be 2.0 parts by weight or less, preferably 1.5 parts by weight or less, more preferably 1.0 parts by weight or less, and most preferably 0.6 parts by weight or less.

As the foam stabilizer, a lead-based stabilizer, a Ca-Zn-based stabilizer, a Ba-Zn-based stabilizer, a tin-based stabilizer, or the like may be used. Specifically, lead-based stabilizers include tribasic lead sulphate (TLS), dibasic lead phosphite (DLP), dibasic lead stearate (DLS), lead stearate, etc. Can be used. In addition, as the Ca-Zn-based stabilizer, a mixture of calcium stearate and zinc stearate, a mixture of calcium carboxylate and zinc carboxylate, or the like can be used. Further, as the Ba-Zn-based stabilizer, a mixture of barium stearate and zinc stearate, a mixture of barium carboxylate and zinc carboxylate, or the like can be used. In addition, as a tin-based stabilizer, mercaptide tin salt, laurate tin salt, malate tin salt, and the like can be used.

The thickness of the foam layer formed through the foaming process may be 0.5 to 2.0 mm, preferably 0.5 to 1.5 mm.

When the thickness of the foam layer is less than 0.5 mm, it may be difficult to provide a cushioning feeling of a sufficient level because the thickness is thin. Conversely, if the thickness exceeds 2.0 mm, it may be difficult to form uniform foamed cells, thereby causing a problem of durability.

The flooring according to the present invention includes a dimensionally stable layer (20).

The dimensionally stable layer 20 may include Short Fiber-reinforced Thermoplastics (SFT), and by forming a dimensionally stable layer using the SFT, the flooring can be manufactured by a co-extrusion process. have.

Figure 2 is a schematic view of a short fiber-reinforced plastic resin (Short Fiber-reinforced Thermoplastics, SFT) according to the present invention.

Referring to FIG. 2 , the SFT 21 may be a thermoplastic resin 21a including short fibers 21b. Specifically, the SFT 21 may be in a form in which the short fibers 21b are dispersed in the thermoplastic resin 21a in the form of pellets.

The short fibers may be fibers having a length of 1 mm or less, and the content of the short fibers is 5 to 30% by weight, preferably 5 to 20% by weight, more preferably 10 to 30% by weight based on the total weight of the SFT. 20% by weight. If the content of the short fibers is less than 10% by weight, the effect of dimensional stability may be reduced, and if it is more than 30% by weight, it may be difficult to manufacture in a roll form due to the rigidity of the layer.

The thermoplastic resin is polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyvinylidene fluoride (PVF), chlorinated polyvinyl chloride (CPVC), polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), It may be at least one selected from the group consisting of polyvinyl butyrate (PVB), polyethylene (PE), polypropylene (PP), olefin-based thermoplastic elastomer (O-TPE) and styrene-based thermoplastic elastomer (S-TPE), Preferably, it may be polyvinyl chloride (PVC), and preferably, the thermoplastic resin may be polyvinyl chloride (PVC).

In addition, the dimensional stability layer 20 may further include additional additives. The additive is, as a plasticizer, ATBC (Acetyl tributyl citrate); viscosity reducing agents; Calcium carbonate as an inorganic filler for cost reduction; and titanium dioxide (TiO ₂ ) as a white pigment; it may be at least one selected from the group consisting of.

The ATBC may be included in an amount of 40 to 150 parts by weight based on 100 parts by weight of the thermoplastic resin. If the content of the ATBC is less than 40 parts by weight, the hardness of the SFT may be increased and processability may be deteriorated. Conversely, if the content of the ATBC is more than 150 parts by weight, dimensional stability may be impaired due to compatibility problems with other components.

The viscosity reducing agent may be included in an amount of 30 parts by weight or less based on 100 parts by weight of the thermoplastic resin. If the content of the viscosity reducing agent is less than 30 parts by weight, moldability may be deteriorated due to excessive viscosity decrease.

The calcium carbonate may be included in an amount of 150 parts by weight or less based on 100 parts by weight of the thermoplastic resin. If the content of the calcium carbonate is more than 150% by weight, the adhesion with other components may be reduced, thereby reducing workability.

In the case of the titanium dioxide, it may be included in an amount of 20 parts by weight or less. If the content of the titanium dioxide is more than 20 parts by weight, the adhesion with other components may be reduced, thereby reducing workability.

In addition, the dimensional stability layer 20 may have a thickness of 0.2 to 1.0 mm. When the thickness of the dimensional stability layer 20 is less than 0.2 mm, the dimensional stability effect may be insufficient, and when the thickness of the dimensional stability layer 20 exceeds 1.0 mm, there is a possibility of securing more than necessary performance or using a material, so the overall cost may cause an increase.

The flooring material according to the present invention includes a cover layer (30).

The cover layer 30 is formed on the dimensional stability layer 20 to secure surface smoothness and provide color, and may be formed from a cover layer composition including polyvinyl chloride (PVC) resin. have. The polyvinyl chloride (PVC) resin includes a polyvinyl chloride resin, and in addition, a polyvinylidene chloride (PVDC) resin, a chlorinated polyvinyl chloride (CPVC) resin, and the like may be included.

The thickness of the cover layer 30 may be 0.5 to 1.0 mm. When the thickness of the cover layer 30 is less than 0.5 mm, it may be difficult to secure smoothness and durability, and when it exceeds 1.0 mm, performance more than necessary may be obtained.

The polyvinyl chloride (PVC) resin used in the foam layer 10, the dimensional stability layer 20 and the cover layer 30 of the present invention may be soft PVC. Specifically, the polyvinyl chloride (PVC) resin used in the foam layer 10, the dimensional stability layer 20 and the cover layer 30 of the present invention is based on 100 parts by weight of the polyvinyl chloride resin, and the content of the plasticizer is 50 weight. It may be more than parts, specifically 50 to 100 parts by weight of soft PVC.

The flooring material according to the present invention may further include a surface treatment layer (not shown).

The surface treatment layer is formed on the cover layer 30, and improves scratch resistance, stain resistance and surface properties, and provides an environmentally friendly effect. Such a surface treatment layer may be formed using those commonly used in the industry.

Method of manufacturing flooring

A method for manufacturing a flooring material according to the present invention,

a) preparing a composition for a foaming layer comprising a polyvinyl chloride (PVC) resin and a foaming agent;

b) preparing a composition for a dimensionally stable layer comprising a short fiber reinforced plastic resin; and

c) preparing a composition for a cover layer comprising a polyvinyl chloride (PVC) resin; and

d) co-extruding the composition for the foam layer, the composition for the dimensional stability layer, and the composition for the label layer to form a foam layer, a dimensional stability layer and a label layer at the same time as the foaming of the composition for the foam layer.

Figure 3 shows a manufacturing process diagram of the flooring material according to the present invention.

Referring to FIG. 3, the composition for foaming layer (③), the composition for dimensional stability layer (②) and the composition for cover layer (①) were prepared by a co-extrusion process to form each layer and at the same time to prepare three layers into one multi-layered structure can do.

First, the method of manufacturing a flooring material according to the present invention includes a) step of preparing a composition for a foaming layer comprising a polyvinyl chloride (PVC) resin and a foaming agent.

The composition for the foaming layer may include 0.1 to 5.0 parts by weight of a foaming agent, more preferably 0.3 to 2.5 parts by weight, based on 100 parts by weight of the polyvinyl chloride resin. When the foaming agent is included in less than 0.1 parts by weight, the foaming ratio may not come out as much as desired. Conversely, when it exceeds 5.0 parts by weight, over-foaming may occur, resulting in destruction of the foam cell structure and deterioration of physical properties.

The foam layer composition may further include a foam stabilizer to control the foaming agent during foaming. The foam stabilizer may include 0.1 to 2.0 parts by weight of the foam stabilizer based on 100 parts by weight of the polyvinyl chloride resin. In addition, a plasticizer and a heat-resistant stabilizer may be included to control melt properties and improve heat-resistance stability.

Other than that, the contents of the polyvinyl chloride (PVC) resin, the foaming agent, and the foaming stabilizer are the same as described above.

Next, the method for manufacturing a flooring material according to the present invention may include a step b) of preparing a composition for a dimensionally stable layer comprising a short fiber reinforced plastic resin.

The composition for the dimensional stability layer may include a short fiber reinforced plastic resin, and may further include additional additives. The type and content of the additive are the same as described above.

Next, the method for manufacturing a flooring material according to the present invention includes a step b) of preparing a composition for a cover layer comprising a polyvinyl chloride (PVC) resin.

The composition for the cover layer includes a polyvinyl chloride (PVC) resin.

Other than that, the content of the polyvinyl chloride (PVC) resin is the same as described above.

The polyvinyl chloride (PVC) resin used in the composition for the foam layer, the composition for the dimensional stability layer, and the composition for the cover layer may be soft PVC. Specifically, the polyvinyl chloride (PVC) resin used in the composition for a foam layer, the composition for a dimensional stability layer, and the composition for a printing layer of the present invention may be soft PVC having a plasticizer content of 50 parts by weight or more. Specifically, the composition for the foaming layer, the composition for the dimensional stability layer, and the composition for the foaming layer may include 50 to 100 parts by weight of a plasticizer based on 100 parts by weight of the polyvinyl chloride resin.

Next, the method for manufacturing a flooring material according to the present invention comprises the steps of preparing a composition for a foam layer, a composition for a dimensional stability layer, and a composition for a cover layer by co-extrusion to form each foam layer, a dimensionally stable layer and a cover layer at the same time as foaming; can do.

The co-extrusion may be performed under conditions of a foaming layer processing temperature of 180 to 210°C, a dimensionally stable layer processing temperature of 150 to 180°C, and a labeling layer processing temperature of 150 to 180°C. Preferably, the foaming layer processing temperature may be 181 to 210 ℃, more preferably 190 to 210 ℃.

If the processing temperature of the foam layer is less than 180 ℃ foaming may not be made, if it exceeds 210 ℃, the processing temperature is excessively high, the durability of the foam layer may be reduced. The composition for the foaming layer may be extruded and foamed when the process is performed above the starting temperature of the foaming agent. In this way, since foaming is carried out using the extrusion process, the process of forming the foam layer in the present invention may be referred to as extrusion foaming.

If the processing temperature of the dimensionally stable layer is less than 150 ℃, the dimensionally stable layer may not be formed, and if it exceeds 180 ℃, the dimensional stability of the flooring may be reduced.

If the processing temperature of the cover layer is less than 150° C., the cover layer may not be formed, and if it exceeds 180° C., the appearance of the flooring material may be unevenly formed.

The method for manufacturing a flooring material according to the present invention uses the co-extrusion as described above, and co-extrudes the composition for the foam layer, the composition for the dimensional stability layer, and the composition for the cover layer to form each layer, and simultaneously foams the foam layer, the printed layer and the transparent layer. This laminated flooring material can be manufactured, so that the flooring material can be manufactured in a single process without a separate lamination process. In addition to this, in the conventional process, a small amount of less than 1 part by weight based on 100 parts by weight of the polyvinyl chloride resin, unlike the normal foaming process, only when an excessive amount of 5 parts by weight or more of the foaming agent is used with respect to 100 parts by weight of the polyvinyl chloride resin. Since foaming can proceed only by using the foaming agent, there is an advantage in that various harmful impurities derived from the foaming agent can be minimized.

The method for manufacturing a flooring material according to the present invention may further include; step e) of forming a surface treatment layer after step d), if necessary.

Step e) is performed to improve scratch resistance, stain resistance and surface properties, and to provide an environmentally friendly effect, and a conventional method used in the art may be used.

As described above, the flooring material according to the present invention can improve productivity by simplifying the manufacturing process of the flooring material through a co-extrusion process instead of a conventional calendering process. At this time, by using SFT, which is a material suitable as a material for the dimensional stability layer of the flooring material and also suitable for performing the co-extrusion process, the flooring material can be manufactured by a simplified material type and process compared to the conventional calendering process.

10: foam layer
20: dimensionally stable layer
21: short fiber reinforced plastic resin (SFT)
21a: thermoplastic resin
21b: short fiber
30: cover layer

Claims (11)

foam layer;
a dimensionally stable layer formed on the foam layer; and
Including; a label layer formed on the dimensionally stable layer;
The dimensionally stable layer comprises a short fiber reinforced plastic resin (Short Fiber-reinforced Thermoplastics, SFT), flooring. According to claim 1,
The short fiber reinforced plastic resin is a thermoplastic resin comprising short fibers, flooring. 3. The method of claim 2,
The thermoplastic resin is polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyvinylidene fluoride (PVF), chlorinated polyvinyl chloride (CPVC), polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), At least one selected from the group consisting of polyvinyl butyrate (PVB), polyethylene (PE), polypropylene (PP), olefin-based thermoplastic elastomer (O-TPE) and styrene-based thermoplastic elastomer (S-TPE), flooring. According to claim 1,
The foam layer is a flooring material comprising a polyvinyl chloride (PVC) resin and a foaming agent. According to claim 1,
The cover layer comprises a polyvinyl chloride (PVC) resin, flooring. According to claim 1,
The flooring material further comprising; a surface treatment layer formed on the cover layer. a) preparing a composition for a foaming layer comprising a polyvinyl chloride (PVC) resin and a foaming agent;
b) preparing a composition for a dimensionally stable layer comprising a short fiber reinforced plastic resin;
c) preparing a composition for a cover layer comprising a polyvinyl chloride (PVC) resin; and
d) co-extruding the composition for the foaming layer, the composition for the dimensionally stable layer, and the composition for the cover layer to form a foaming layer, a dimensionally stable layer and a cover layer at the same time as the foaming of the composition for the foaming layer; . 8. The method of claim 7,
The composition for the foaming layer comprises 0.1 to 2.0 parts by weight of a foaming agent, based on 100 parts by weight of the polyvinyl chloride resin. 8. The method of claim 7,
The composition for the dimensionally stable layer comprises a short fiber reinforced plastic resin, a method of manufacturing a flooring material. 8. The method of claim 7,
The co-extrusion is carried out under the conditions of a foaming layer processing temperature of 180 to 210 ℃, a dimensionally stable layer processing temperature of 150 to 180 ℃, and a cover layer processing temperature of 150 to 180 ℃, a method of manufacturing a flooring material. 8. The method of claim 7,
After step d), e) forming a surface treatment layer; further comprising, a method of manufacturing a flooring material.

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