KR20210123233A - Flooring comprising nitrile rubber free foam, and method for producing the same - Google Patents

Abstract

The present invention relates to a floor material including nitrile rubber free foam and a manufacturing method thereof. More specifically, the present invention relates to the floor material which does not include nitrile rubber with heavy odor by processing, has excellent cushioning, noise blocking, and restoring performance, and prevents transfer of foreign matters and a crack on the floor and a crack wave during heating. The floor material comprises: a foam layer, a dimension stable layer; a printing layer; and a transparent layer, from the bottom to the top.

Description

FLOORING COMPRISING NITRILE RUBBER FREE FOAM, AND METHOD FOR PRODUCING THE SAME

The present invention relates to a flooring material comprising a nitrile rubber-free foam and a method for manufacturing the same, and more particularly, excellent cushioning properties, sound insulation properties and restoration properties at a high foaming ratio of 400% or more without including nitrile rubber with a strong odor during the process And, it relates to a flooring material capable of preventing debris on the floor, transfer of cracks, and crack wave prevention during heating, and a method for manufacturing the same.

If the floor surface of the interior part of the building structure is exposed to the cement surface as it is, the aesthetics of the exterior is inevitably reduced. For this reason, in the interior process, the floor surface of the interior part of the building structure is finished with a separate flooring material.

As an example of the flooring material, a flooring material made of polyvinyl chloride (hereinafter referred to as 'PVC'), which is relatively inexpensive, easy to construct, and has an excellent decorative effect, is used as a residential flooring material.

In general, as disclosed in Korean Patent Publication No. 10-0805633 (published on Feb. 20, 2008), PVC flooring materials have a back layer sequentially from the bottom to the top; foam layer; interstitial layer; dimensional stability layer; printed layer; transparent layer; and a surface treatment layer.

The foam layer typically uses a high-density foam, which has excellent elasticity due to its high density, and thus has an advantage of excellent stability of the flooring material when applied to the flooring material, but has a problem in that the weight of the flooring material becomes heavy.

In addition, it was difficult to manufacture the conventional foam to have a foaming ratio of 400% or more due to the rapid decomposition of the foaming agent during production, and even if it has a foaming ratio of 400% or more, the foamed cells are easily destroyed, resulting in cushioning, sound insulation and There was a problem that the recovery was greatly reduced.

In addition, in general, as disclosed in Korean Patent Publication No. 10-2003-0040695 (published on May 23, 2003), PVC flooring materials provide a three-dimensional appearance effect through a synchronized embossing process that synchronizes a printed pattern and an embossing pattern to provide It was able to have a sense of realism, a sense of depth and a sense of luxury.

However, when the PVC flooring as described above is used as a residential flooring material, debris and cracks on the floor are transferred to the surface of the flooring, reducing the luxury of the exterior, and especially when heating the floor, There was a problem in that a wave pattern (hereinafter referred to as a 'crack wave') appeared on the surface of the flooring material due to the hot air.

Accordingly, there is a need to develop a flooring material that has excellent restoration properties even at low density and is capable of preventing the transfer of debris and cracks on the floor surface and crack wave prevention during heating without reducing physical properties such as cushioning properties at a high magnification of 400% or more.

Korean Patent Registration No. 10-0805633 Korean Patent Publication No. 10-2003-0040695

In order to solve the problems of the prior art as described above, the present invention has excellent cushioning properties, sound insulation properties and restoration properties at a high foaming ratio of 400% or more without including a nitrile rubber with a strong odor during operation, and prevents debris and cracks on the floor. An object of the present invention is to provide a flooring material capable of preventing crack wave during transfer and heating, and a method for manufacturing the same.

The above and other objects of the present invention can all be achieved by the present invention described below.

In order to achieve the above object, the present invention is from the bottom to the top, the foam layer; dimensional stability layer; printed layer; and a transparent layer; wherein the foamed layer has an average length of the major and minor axes of the foamed cells of 100 to 400 μm, and an anisotropy calculated by the following Equation (1) of 1.0 to 1.25, characterized in that it comprises a nitrile rubber-free foam provides flooring.

[Equation 1]

Anisotropy = x / y

(In Equation 1, x is ^{the average value of the major axis length of the foam cells included in the unit area (1 mm 2} ) of the foam, and y is the minor axis length of the foam cells included in the unit area (1 mm ² ) of the foam. average value)

In addition, the present invention comprises the steps of preparing a pre-foaming layer or a foaming layer and a nonwoven fabric (S1); Applying and gelling the PVC sol on the pre-foaming layer or the lower part of the foaming layer (S3); forming a first semi-finished product by bonding the nonwoven fabric to the pre-foaming layer or the lower portion of the foaming layer (S5); and forming a second semi-finished product in which a dimensional stability layer, a printing layer, and a transparent layer are laminated from the bottom to the top (S7); wherein, the foam layer has an average length of a major axis and a minor axis of the foam cell of 100 to 400 μm, and , It provides a method of manufacturing a flooring material comprising a nitrile rubber-free foam having an anisotropy of 1.0 to 1.25 calculated by Equation 1 above.

Advantageous Effects of Invention According to the present invention, there is an effect of providing a flooring material having excellent sound insulation and excellent restoration properties due to weight reduction and a method for manufacturing the same.

In addition, the present invention has the effect of providing a flooring material capable of producing a foam having a high expansion ratio of 400% or more by preventing premature foaming in the calendar and improving thermal stability, and a method for manufacturing the same.

In addition, the present invention has an effect of providing a flooring material capable of reducing the load applied to the human body due to excellent cushioning properties and a method for manufacturing the same.

In addition, the present invention has the effect of providing a flooring material capable of preventing the transfer of debris and cracks on the floor, and also preventing crack waves during floor heating, and a method for manufacturing the same.

1 is a SEM (Scanning Electron Microscope) photograph of a vertical section of the foam prepared in Example 1 of the present invention.
2 is a graph showing the particle size distribution of the foam prepared in Example 1 of the present invention.
Figure 3 is a SEM (Scanning Electron Microscope) photograph of the vertical section of the foam prepared in Comparative Example 1 of the present invention.
4 is a graph showing the particle size distribution of the foam prepared in Comparative Example 1 of the present invention.
5 is a scanning electron microscope (SEM) photograph of a vertical section of the foam prepared in Comparative Example 2 of the present invention.
6 is a graph showing the particle size distribution of the foam prepared in Comparative Example 2 of the present invention.
7 is a photograph of crack waves appearing on the surface of a conventional flooring material during underfloor heating at 55°C and 22hr.

Hereinafter, a flooring material including the nitrile rubber-free foam of the present disclosure and a method for manufacturing the same will be described in detail.

The present inventors adjust the long axis and minor axis length and anisotropy of the foam cell during the manufacture of the foam, so that the cushioning property does not decrease at a high foaming ratio of 400% or more without including nitrile rubber with a strong odor in the process, and the flooring material with excellent sound insulation and restoration properties It was confirmed that it is possible to manufacture, and based on this, further intensive research was completed to complete the present invention.

Flooring of the present invention from the bottom to the top, the foam layer; dimensional stability layer; printed layer; and a transparent layer; wherein the foamed layer has an average length of the major and minor axes of the foamed cells of 100 to 400 μm, and an anisotropy calculated by the following Equation (1) of 1.0 to 1.25, characterized in that it comprises a nitrile rubber-free foam In this case, there is an advantage of excellent cushioning properties, sound insulation properties and restoration properties at a high foaming ratio of 400% or more.

[Equation 1]

Anisotropy = x / y

(In Equation 1, x is ^{the average value of the major axis length of the foam cells included in the unit area (1 mm 2} ) of the foam, and y is the minor axis length of the foam cells included in the unit area (1 mm ² ) of the foam. average value)

The flooring material, for example, from the bottom to the top, the foam layer; interstitial layer; dimensional stability layer; printed layer; transparent layer; And it may include a synchronized emboss; in this case, the desired effect of the present invention is well revealed.

In the present invention, the anisotropy is a specific example, after cutting the foam in the vertical direction, the cross section of the cut foam is measured with a scanning electron microscope (SEM), and then the measured SEM picture is imaged with an IMAGE J program It can be obtained by entering

The flooring material of the present invention is a flooring material including a nitrile rubber-free foam, and more preferably a flooring material including a rubber-free foam. Without open cell), it has excellent cushioning properties, sound insulation properties and restoration properties.

In the present invention, nitrile rubber-free means that nitrile rubber is not intentionally added to the foam, and the nitrile rubber may be, for example, acrylonitrile butadiene rubber.

In addition, the flooring material of the present invention may be, for example, a flooring material including a glass bubble-free foam, and the glass bubble may improve lightness, but it is expensive and has disadvantages adversely affecting the health of workers, so it is preferable not to use it .

The flooring material of the present invention has the advantage that it is possible to reduce the weight without including glass bubbles.

Hereinafter, the flooring material of the present invention will be described in detail for each layer as follows.

non-woven fabric layer

The nonwoven fabric layer of the present invention may be located at the bottom of the flooring, for example.

The nonwoven layer may include, for example, a nonwoven fabric having a tensile strength of 0.3 to 0.8 kgf, preferably 0.4 to 0.6 kgf, when stretched 40 to 60% in the longitudinal direction at 120 to 150 ° C., or 120 to 140 ° C. The range is a reduced range compared to the tensile strength of the conventional nonwoven fabric of about 1.0 kgf or more, and within this range, dimensional stability and restoration properties are excellent, and then, when the synchronized embossing process of the flooring including the nonwoven fabric is performed, wrinkles are prevented from occurring. There is an advantage in that the yield of the flooring material is excellent.

As another example, the nonwoven fabric layer may include a nonwoven fabric having a tensile strength of 0.3 to 0.8 kgf, preferably 0.4 to 0.6 kgf, when stretched 50% in the longitudinal direction at 130° C., and dimensional stability and stability within this range There is an advantage in that it is possible to obtain a synchronized emboss with a reduced wrinkle generation rate when manufacturing a flooring material including the non-woven fabric layer while being excellent.

In the present invention, the tensile strength can be measured based on KS K 0521, and more specifically, the nonwoven specimen is kept in a chamber at 130° C. for 1 minute, and the length after being bitten by a clamp of a Universal Testing Machine (UTM, Instron) It may be a measure of the tensile strength of the nonwoven fabric when stretched by 50% in the direction.

The nonwoven fabric layer may include, for example, a nonwoven fabric having an elongation at break of 80 to 200% in the longitudinal direction at 20 to 25° C., preferably 90 to 180%, and this range is the elongation at break of the conventional nonwoven fabric (15 to 30%) ) to a very high range, and there is an advantage of improving the yield of the flooring material by preventing the generation of wrinkles when performing the synchronous embossing process on the flooring.

In the present invention, the elongation at break may be measured using a Universal Testing Machine (UTM, Instron) by stretching the nonwoven fabric at 20 to 25° C. until it breaks.

The longitudinal direction means a machine direction, that is, Machine Direction (MD).

The synchronized embossing process refers to a process of matching the printed pattern and the embossed pattern of the printed layer to realize an excellent appearance that fits well.

In the present invention, the non-woven fabric layer is formed including, for example, a non-woven fabric, wherein the non-woven fabric binds the fiber aggregate to each other by chemical action, mechanical action, or heat treatment with appropriate moisture without a woven process such as spinning, weaving, or knitting, for example. It may mean a cloth shape, which is located at the bottom of the flooring material to prevent transfer and crack wave of debris and cracks on the floor, and has the advantage of imparting sound insulation and lightness of the flooring material.

In the present invention, miscellaneous matter means foreign substances such as gravel and sand on the floor, and the floor surface may be, for example, a concrete floor.

In the present invention, a crack means a crack in the bottom surface.

In the present invention, a crack wave means a wave pattern generated on the surface of the flooring material due to the hot heat rising from cracks on the floor during floor heating, which can be confirmed through FIG. 7 .

The nonwoven fabric may be, for example, a mixture of two or more fibers having different fineness (denier) of the thermoplastic resin, and in this case, dimensional stability, recovery rate and elongation are excellent.

In a preferred example, the nonwoven fabric has a fineness may be a one honseom 4 to 12 denier, the fibers (f ₁₎ and the fibers (f ₂₎ fineness of 13 to 20 denier, in which case the well is emitted while maintaining the mechanical properties, There is an advantage in that the elongation of the nonwoven fabric is excellent because the bonding force between the fibers is excellent.

In another preferred embodiment, the nonwoven fabric is a fiber having a fineness of 4 to 6 denier (f _1-1 ), a fiber having a fineness of 7 to 12 denier (f _1-2 ), and a fiber having a fineness of 13 to 20 denier (f ₂ ) may be a mixed fiber, and in this case, the mechanical properties are maintained and spinning is good, and the bonding force between the fibers is excellent, so that the elongation of the nonwoven fabric is excellent.

In a specific example, the nonwoven fabric may include _{70 to 90% by weight of the fiber (f 1} ), or 75 to 85% by weight; And fiber (f ₂ ) 10 to 30% by weight, or 15 to 25% by weight; may be a mixed fiber, there is an advantage of excellent dimensional stability, recovery rate and elongation within this range.

In another specific example, the nonwoven fabric is the fiber (f _1-1 ) 35 to 50% by weight, or 35 to 40% by weight; 35 to 50% by weight, or 35 to 40% by weight of fibers (f _{1-2 );} And fiber (f ₂ ) 10 to 30% by weight, or 15 to 25% by weight; may be a mixed fiber, within this range, dimensional stability, recovery rate and elongation are all excellent advantages.

The thermoplastic resin is, for example, polyester (PET), polypropylene (PP), polyethylene (PE), polyvinyl alcohol (PVA), polyamide (Polyamide), polyurethane (PU) and polyvinylidene chloride (PVDC). It may be at least one selected from the group consisting of, preferably polyester (PET), and in this case, it is not affected by temperature changes during heating of the flooring formed thereafter due to a high glass transition temperature, so there is an advantage in excellent dimensional stability. .

The fiber may be, for example, a short fiber having a length of 4 to 7 cm, preferably 5 to 6 cm, that is, a fiber chop, and has excellent dimensional stability within this range.

The nonwoven fabric, for example, may have a basis weight of 180 to 230 g/m ² , preferably 190 to 220 g/m ² , and when included in the flooring within this range, it is lightweight while preventing the transfer of debris and cracks on the floor and crack waves It has the advantage of giving gender.

In the present invention, the basis weight may be measured based on the ERT method (EDANA RECOMMENDED TEST METHODS) 40.3 to 90.

The nonwoven fabric may have, for example, a thickness of 0.5 to 1.5 mm, or 0.6 to 1.2 mm, and when used as a flooring material within this range, it is possible to reduce the thickness of the foam layer on the upper side relatively while implementing an excellent light-weight effect, It has the advantage of preventing the transfer of cracks and foreign matter on the surface, preventing crack waves during floor heating, and implementing a sound insulation effect.

The nonwoven fabric layer may include, for example, a nonwoven fabric in which the PVC sol is penetrated to a depth of 30 to 70 μm, preferably 40 to 60 μm, and the peel strength of the pre-foamed layer or foam layer and the nonwoven fabric to be described later within this range. It has the advantage of improving the yield of the flooring material by preventing the nonwoven fabric from wrinkling during the subsequent synchronized embossing process by satisfying the tensile strength of the nonwoven fabric of the present invention while being excellent.

In the present invention, the depth of the PVC sol may be measured, for example, by measuring the depth of the PVC sol penetrating into the side cross-section of the cut nonwoven fabric using a scanning electron microscope (SEM) after cutting the flooring in the vertical direction.

foam layer

The foam layer of the present invention may be located on the upper portion of the nonwoven fabric layer or constitute the lowermost layer, for example.

The foam layer may include, for example, a nitrile rubber-free foam having an average length of a major axis and a minor axis of the foam cell of 100 to 400 μm, and having an anisotropy of 1.0 to 1.25 calculated by Equation 1, in which case it has little odor. It has excellent workability, and has excellent cushioning properties, sound insulation properties and restoration properties without open cells at a high foaming ratio of 400% or more.

The average length of the major axis of the foamed cells may be, for example, 100 to 400 μm, preferably 150 to 350 μm, more preferably 170 to 250 μm, and within this range, cushioning properties, sound insulation properties and restoration properties are all excellent. have.

In the present invention, the average length of the long axis of the foam cell is cut using a scanning electron microscope (SEM) after cutting the foam in the vertical direction. It is a value obtained by measuring the major axis length of the foam cell in the cross section of the foam and averaging it.

The length of the major axis of the foamed cell may be, for example, a minimum value of 100 to 160 µm, preferably 110 to 150 µm, and a maximum value of 200 to 500 µm, preferably 350 to 450 µm, within this range. There is an advantage in that cushioning properties, sound insulation properties and restoration properties are improved.

The minimum and maximum values of the long axis length are the minimum and maximum values measured based on the SEM of the major axis length of the foam cell in the cut cross-section after the foam is cut in the vertical direction.

The average short axis length of the foamed cells may be, for example, 100 to 400 μm, preferably 130 to 320 μm, and more preferably 160 to 220 μm, and within this range, cushioning properties and sound insulation are excellent even at a high expansion ratio. There is this.

In the present invention, the average length of the minor axis of the foam cell is the same except that the lengths of the minor axis are measured and averaged in the method for measuring the average length of the major axis.

The minor axis length of the foam cell may be, for example, a minimum value of 50 to 150 µm, preferably 90 to 110 µm, and a maximum value of 170 to 400 µm, preferably 250 to 320 µm, within this range. There is an advantage in that cushioning properties, sound insulation properties and restoration properties are improved.

The minimum and maximum values of the short axis length may be measured by the same method as the method of measuring the minimum and maximum values of the long axis length.

The standard deviation of the major and minor lengths may be, for example, 1 to 50 μm, preferably 5 to 45 μm, more preferably 10 to 43 μm, respectively, within this range, foam cells of a uniform size are formed, It has the advantage of being excellent in cushioning property and sound insulation.

In the present invention, the standard deviation of the major axis and minor axis length is, for example, after cutting the foam in the vertical direction and measuring the cross section of the cut foam with a scanning electron microscope (SEM), then the measured SEM photograph is image J ( IMAGE J) It can be obtained by entering it into the program.

The anisotropy calculated by Equation 1 may be, for example, from 1.0 to 1.25, preferably from 1.0 to 1.20, more preferably from 1.0 to 1.185, and the foaming ratio within this range is 400% or more while cushioning properties and without open cells. There is an advantage that the sound insulation is remarkably excellent.

When the anisotropy of the present invention is less than the above range, there is a problem in that sound insulation and cushioning properties are lowered, and when it exceeds the above range, there is a problem in that the residual indentation rate is lowered.

The foamed cells are, for example, ^{15 to 35 per unit area (1 mm 2} ), preferably 18 to 35, more preferably 18 to 33, even more preferably 20 to 32 may be included, It has the advantage of excellent stability and light impact sound within the range.

In the present invention, the number of foamed cells is a value obtained by measuring the number of foamed cells in the cross section of the cut foam using a scanning electron microscope after cutting the foam in the vertical direction.

The foam may have an expansion ratio of 400 to 700%, preferably 430 to 520%, more preferably 450 to 520%, which is calculated by Equation 2 below, and has significantly fewer open cells within this range. All of the cushioning properties, sound insulation properties and restoration properties are excellent.

[Equation 2]

Foaming ratio = T _a /T _b X 100%

(In Equation 2, T _a is the initial density of the foam specimen having a length and width of 50 mm X 50 mm, and T _b is a temperature of 160 ° C., a pressure of 500 kgf / cm ² Pressing the specimen for 15 minutes under conditions of pressure Density of the compressed specimen after removal)

The foam has a density in the example 1.0 to 1.3g / cm ^3, preferably from 1.0 to 1.28g / cm ^3, more preferably may be from 1.1 to 1.26g / cm ^3, to give a light weight in the range There is an advantage in that sound insulation is improved.

In the present invention, the density can be measured using a hydrometer at room temperature.

The foam may have a closed shape in which 30 to 90%, preferably 45 to 65% of the foam cells included in the cross-sectional area of ^{1 mm 2 are closed, for example, and cushioning properties are improved within this range.}

In the present invention, the area % of the closed cell foam can be obtained by measuring the closed cell contents using a closed cell rate meter (Ultra PYC 1200e).

The foam may have, for example, compressibility (19mmΦ, 222N) of 50% or more, 50 to 100%, or 75 to 100%, and has an excellent cushioning property within this range.

In the present invention, the compressibility of the foam means a value divided by the total thickness of the foam after measuring the depth of the foam entered by applying a load of 222 N for 1 minute with a hemispherical steel bar having a diameter of 19 mm .

The foam may have, for example, a residual indentation rate (based on KS M 3802, 1 hr, 500% expansion ratio) of 25% or less, preferably 15 to 25%, more preferably 20 to 25%, within this range. There is an advantage of excellent recovery.

In the present invention, as specified in KS M 3802, the residual indentation ratio is obtained by applying a load of 222N with a hemispherical steel bar having a diameter of 19 mm and releasing it after 5 minutes, and then, after 1 hour, through the change in the thickness of the specimen through the following equation It can be calculated based on 3.

[Equation 3]

Residual indentation = (T ₀ - T ₁ )/T ₀ X 100%

(In Equation 3, T ₀ is the thickness before applying the load, and T ₁ is the thickness when 1 hour has elapsed after the load is applied.)

The foam, for example, may have a light impact sound reduction amount of 20 to 40 dB, preferably 23 to 27 dB, and has the advantage of improving sound insulation within this range.

In the present invention, the light impact sound means the sound of a chair being dragged, the sound of a spoon falling, the sound of light footsteps, etc., and can be measured based on the standards of KS F 2810 (light impact sound test conditions).

The foam layer of the present invention may have a thickness of 1 to 3 mm, or 1.5 to 2.5 mm as an example, and there is an advantage in that the cushioning feeling, restoration property and sound insulation of the flooring material are excellent within this range.

The nitrile rubber-free foam is, for example, 100 parts by weight of polyvinyl chloride, 45 to 60 parts by weight of a plasticizer, 3 to 6 parts by weight of a foam stabilizer and 5 to 20 parts by weight of a filler, and the foam stabilizer is preferably 40 to 85% by weight of a heat stabilizer, 0 to 15% by weight of a cell controller, 5 to 40% by weight of a lubricant, and 5 to 15% by weight of a kicker Including weight %, there is an advantage that cushioning properties, sound insulation properties and restoration properties are all excellent while there are significantly fewer open cells at a high expansion ratio within this range.

The polyvinyl chloride may have, for example, a weight average molecular weight of 95,000 to 125,000 g/mol, preferably 100,000 to 115,000 g/mol, more preferably 105,000 to 115,000 g/mol, and cushioning properties and restoration properties within this range There are excellent advantages

In the present invention, the weight average molecular weight is a relative value to a standard PS (Standard polystyrene) sample using tetrahydrofuran (THF) as a solvent at a temperature of 40 ° C. through gel chromatography (GPC) filled with porous silica as a column packing material. can be obtained by measuring

The polyvinyl chloride may have, for example, a polymerization degree of 800 to 1,600, preferably 900 to 1,500, more preferably 900 to 1,100, even more preferably 950 to 1,050, and within this range, cushioning properties and excellent restoration properties There is this.

The polyvinyl chloride may be, for example, two or more types of polyvinyl chloride resins having different degrees of polymerization, and as a specific example, the polyvinyl chloride resin has a degree of polymerization of 900 to 1,100 or 950 to 1,050 with a polyvinyl chloride resin (a1) and a degree of polymerization It may be a mixed resin in which the polyvinyl chloride resin (a2) having 1200 to 1,600 or 1,250 to 1,500 is mixed.

The plasticizer may be, for example, at least one selected from the group consisting of a phthalate-based plasticizer, a terephthalate-based plasticizer, a benzoate-based plasticizer, a citrate-based plasticizer, a phosphate-based plasticizer, and an adipate-based plasticizer, but is not limited thereto.

The plasticizer may be, for example, 45 to 60 parts by weight, preferably 45 to 55 parts by weight, based on 100 parts by weight of polyvinyl chloride, and within this range, the plasticizer migration phenomenon does not occur while excellent processability and cushioning properties. There is an advantage of excellent physical properties.

The foam stabilizer may be, for example, 3 to 6 parts by weight, preferably 4 to 6 parts by weight, and more preferably 4.5 to 5.5 parts by weight, based on 100 parts by weight of polyvinyl chloride, and within this range, early foaming in the calendar There is an advantage in that it is possible to manufacture a foam having a high expansion ratio of 400% or more by preventing and improving thermal stability.

The foam stabilizer may include, for example, 40 to 85% by weight of a heat stabilizer, 0 to 15% by weight of a cell controller, 5 to 40% by weight of a lubricant, and 5 to 15% by weight of a kicker, which at a high expansion ratio There is an advantage of improving the cushioning properties, sound insulation properties and restoration properties of the foam while remarkably few open cells.

The thermal stabilizer included in the foam stabilizer may be, for example, at least one selected from the group consisting of zinc stearic acid, barium stearic acid and calcium stearic acid, and in this case, thermal stability is improved to enable manufacturing of a foam having a high expansion ratio.

The zinc stearic acid may be, for example, 0 to 10% by weight, or 5 to 10% by weight based on 100% by weight of the foam stabilizer, and has excellent initial thermal stability and initial discoloration prevention within this range.

The barium stearic acid may be, for example, 40 to 50% by weight, or 45 to 65% by weight based on 100% by weight of the foam stabilizer, and has an advantage of excellent long-term thermal stability within this range.

The calcium stearic acid may be, for example, 10 to 35% by weight, or 20 to 30% by weight based on 100% by weight of the foam stabilizer, and has an advantage of excellent long-term thermal stability within this range.

The cell controller included in the foam stabilizer may be, for example, an acrylic compound, and in this case, it has excellent compatibility with polyvinyl chloride and has the advantage of preventing the expansion of the foam cell indefinitely.

The cell controller may be, for example, 0 to 15% by weight, 5 to 15% by weight, or 10 to 15% by weight based on 100% by weight of the foam stabilizer, and has the advantage of uniformly controlling the size of the foaming cells within this range have.

The lubricant contained in the foam stabilizer may be, for example, stearic acid.

The lubricant may be, for example, 5 to 40% by weight, or 5 to 30% by weight based on 100% by weight of the foam stabilizer.

The accelerator included in the foam stabilizer may be zinc oxide, and in this case, there is an advantage of lowering the energy for initiating foaming.

The accelerator (kicker) may be 5 to 15% by weight, 5 to 13% by weight, or 8 to 13% by weight based on 100% by weight of the foam stabilizer, which is a value reduced by at least 1/2 compared to the prior art. There is an advantage of reducing and forming uniform cells.

In particular, as shown in Comparative Examples 1 to 4 below, as the accelerator content is reduced, premature foaming does not occur, thereby increasing the foaming ratio.

The filler is, for example, calcium carbonate, wood flour, mica, amorphous silica, talc, zeolite, magnesium carbonate, calcium sulfate, calcium phosphate, magnesium phosphate, aluminum oxide, kaolin, ATH (Alumina trihydrate) and 1 selected from the group consisting of talc It may be more than one species, preferably potassium carbonate, more preferably ground calcium carbonate, in which case it has an economic advantage by reducing the cost.

The filler may be, for example, 5 to 20 parts by weight, preferably 7 to 17 parts by weight, and more preferably 7 to 13 parts by weight, based on 100 parts by weight of polyvinyl chloride, and within this range, the rigidity while lowering the product price is It has the advantage of increasing.

The filler may have, for example, an average particle diameter of 2 to 20 μm, preferably 2 to 15 μm, and more preferably 4 to 12 μm, and has an excellent residual indentation rate even at a high expansion ratio of 400% or more within this range. There is this.

stratum

In addition, the present invention may optionally further include an interlayer between the foaming layer and the dimensionally stable layer in order to improve the adhesion between the foamed layer and the dimensionally stable layer.

The interlayer layer may be formed of, for example, a composition for interlayer molding comprising 100 parts by weight of polyvinyl chloride, 30 to 80 parts by weight of a plasticizer, and 40 to 90 parts by weight of a filler.

The polyvinyl chloride may have, for example, a polymerization degree of 900 to 1200, or 950 to 1100, and has excellent calendering processability within this range.

The type of the plasticizer may be within the same range as the plasticizer included in the above-described foam.

The plasticizer may be included, for example, in an amount of 30 to 80 parts by weight, or 40 to 70 parts by weight, based on 100 parts by weight of polyvinyl chloride, and has excellent processability within this range.

The filler may be, for example, a hollow filler in which a portion of calcium carbonate used as a conventional filler is replaced with a hollow filler in order to further improve the lightness of the flooring material.

As a specific example, the filler may not include a hollow filler, or may necessarily include it.

When the filler includes a hollow filler, the filler is, for example, 100 parts by weight of polyvinyl chloride; 30 to 70 parts by weight of calcium carbonate, or 40 to 60 parts by weight; and 1 to 20 parts by weight of a hollow filler, or 5 to 15 parts by weight; may be used by mixing, and has the advantage of imparting lightness to the flooring material at an appropriate price within this range.

The hollow filler means a filler having a hollow interior, and has a low density, which gives lightness to the flooring material of the present invention, and has the advantage of further improving sound insulation.

The shape of the hollow filler is not particularly limited, but may be, for example, at least one selected from the group consisting of a plate shape (including a scaly shape), a spherical shape, a needle shape, a rod shape, and a fiber shape, preferably may be a spherical hollow filler, and the definition of these shapes may follow commonly known definitions in the art to which the present invention pertains.

The hollow filler may include, for example, 90% by weight or more, 94% by weight or more, or 97% by weight or more of soda-lime-borosilicate glass.

The soda-lime-borosilicate glass is, for example, 50 to 90% by weight of SiO ₂ , 2 to 20% by weight of alkali metal oxide, 1 to 30% by weight of divalent metal oxide, 1 to 30% by weight of B ₂ O ₃ , 0.005 to 1.5% by weight of sulfur or sulfur oxide may be included.

In another example, the soda-lime-borosilicate glass contains 70 to 80% by weight of SiO ₂ , 3 to 8% by weight of Na ₂ O, 8 to 15% by weight of CaO, 2 to 6% by weight of B ₂ O ₃ , 0.125 to 1.5% by weight of SO ₃ may be included.

The hollow filler may have, for example, a particle size of 20 to 80 μm, or 25 to 70 μm, and has an advantage in that the lightness of the flooring material is improved within this range.

The particle size of the hollow filler means a diameter when the hollow filler has a spherical shape, and when the hollow filler has a shape other than the spherical shape, it means the length of the major axis when divided into a major axis and a minor axis.

The particle size of the hollow filler may be measured using, for example, a particle size analyzer (S3500, Microtrac Corporation).

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

The interlayer layer may have, for example, a thickness of 0.1 to 1.2 mm, or 0.3 to 1.0 mm, within this range, the advantage of implementing excellent adhesion between the foam layer and the dimensional stability layer and imparting lightness of the flooring material at the same time There is this.

dimensional stability layer

The dimensional stability layer of the present invention may be located on the foam layer as an example, which is a layer for imparting dimensional stability to the flooring material.

The dimensional stability layer may be, for example, a glass fiber sheet impregnated with polyvinyl chloride sol.

The glass fiber sheet may be, for example, a glass fiber woven fabric or a glass fiber nonwoven fabric, but is not limited thereto.

The vinyl chloride sol may include, for example, 100 parts by weight of polyvinyl chloride, 60 to 100 parts by weight of dioctyl terephthalate, 10 to 80 parts by weight of calcium carbonate, and 1 to 6 parts by weight of epoxidized soybean oil.

The dimensional stability layer may have, for example, a basis weight of 40 to 70 g/m ² , or 45 to 65 g/m ² , and has excellent dimensional stability and flexibility of the flooring material within this range.

The dimensional stability layer may have, for example, a thickness of 0.1 to 0.6mm or 0.2 to 0.5mm, and within this range, the dimensional stability of the flooring material is excellent.

print layer

The printed layer of the present invention may be located on the dimensional stability layer, for example, which is a layer for imparting aesthetics to the flooring material by forming various printed patterns on the dimensional stability layer.

The printed layer may be printed, for example, on the dimensionally stable layer, but is not limited thereto.

The printing may be, for example, one or more types of printing selected from the group consisting of transfer printing, gravure printing, and screen printing.

The printed layer may have a thickness of, for example, 0.01 to 0.05 mm or 0.02 to 0.04 mm, and within this range, there is an advantage in that an appearance and design with excellent aesthetics can be realized at an appropriate manufacturing cost.

transparent layer

The transparent layer of the present invention, for example, may be positioned on the printed layer, which is a layer that improves durability and serves to protect the printed layer.

The transparent layer is, for example, polyvinyl chloride, polyethylene terephthalate resin, polybutylene terephthalate resin, polypropylene resin, polyethylene resin, polymethyl methacrylate resin, acrylonitrile-butadiene-styrene resin, polycarbonate resin and styrene- It may be a film made of at least one resin selected from the group consisting of acrylonitrile copolymer resins, preferably a film containing polyvinyl chloride, more specifically 100 parts by weight of polyvinyl chloride; and 15 to 35 parts by weight of a plasticizer, or 20 to 30 parts by weight of a plasticizer; may be a film made of a composition for forming a transparent layer including, in this case, excellent transparency and low price.

The polyvinyl chloride and the plasticizer may be within the same range as the polyvinyl chloride and the plasticizer included in the interlayer layer described above.

The composition for molding the transparent layer may further include one or more selected from the group consisting of, for example, a lubricant, a heat stabilizer and a flame retardant, and the types and contents thereof are not particularly limited.

The transparent layer may be prepared by, for example, kneading the composition for forming the transparent layer at 140 to 160° C. and then passing it through a calendar roll at 160 to 170° C., followed by calendering molding.

The transparent layer may have a thickness of, for example, 0.1 to 1.0 mm, preferably 0.3 to 0.9 mm, and has the effect of improving the durability of the flooring within this range and protecting the printed layer below.

The flooring material of the present invention may include a synchronized emboss in which the embossed pattern matches the pattern of the lower printed layer on the upper part of the transparent layer. It has a more luxurious effect.

surface treatment layer

The flooring material of the present invention may further include a surface treatment agent on top of the flooring material, for example, which has the advantage of preventing contamination.

The surface treatment layer may be formed by, for example, coating a conventional UV curable resin.

The surface treatment layer may have, for example, a thickness of 0.01 to 0.05 mm, preferably 0.02 to 0.03 mm, but is not limited thereto.

flooring

The flooring material of the present invention may have, for example, compressibility (19mmΦ, 222N) of 50% or more, preferably 50 to 100%, more preferably 50 to 80%, and has an advantage of excellent cushioning properties within this range.

The flooring material of the present invention may have, for example, a residual indentation rate (based on KS M 3802, 1hr, 500% foaming ratio) of 20% or less, preferably 0 to 10%, more preferably 0 to 8%, within this range There is an advantage of excellent recovery within the.

The flooring material of the present invention may have, for example, a light weight impact sound reduction (KS F 2810) of 35 dB or less, preferably 21 to 30 dB, more preferably 23 to 27 dB, and has an excellent sound insulation property within this range.

The flooring material of the present invention may have a ^{weight per unit area (1 mm 2} ) of 2 to 7 kg, preferably 3 to 6 kg, more preferably 3 to 4 kg, and the range is a reduced value compared to the prior art within this range. There is an advantage of excellent sound insulation.

The flooring material of the present invention may have a height of 0.9mm or more, 1.0mm or more, or 1.2mm or more when the transfer of the floor surface to the flooring surface of the flooring material of the present invention occurs, for example, the upper limit of the height of the object is not particularly limited, but for example 5.0cm or less, or 3.0 cm or less, or 2.5 cm or less, the transfer prevention effect of the bottom surface is excellent within this range.

In the flooring material of the present invention, for example, when the transfer of the floor surface to the surface of the flooring material occurs, the crack step may be 0.7mm or more, 0.9mm or more, or 1.0mm or more, and the upper limit of the crack step is not particularly limited, but for example 5.0cm or less , may be 3.0 cm or less or 2.5 cm or less, and the transfer prevention effect of the bottom surface is excellent within this range.

The height of the object and the step of the crack may be measured using, for example, a tape measure.

In the flooring material of the present invention, for example, crack waves may not occur during heating of the flooring material, and the occurrence of crack waves may be evaluated with the naked eye.

The flooring material of the present invention may have, for example, a tuning rate of 2 mm or less, or 1.5 mm or less, and the lower limit of the tuning ratio is not particularly limited, but may be, for example, 0 mm or more. It has the advantage of having excellent three-dimensional texture and esthetics because the positions are matched.

The tuning rate may be measured, for example, based on a caliper.

Hereinafter, a method for manufacturing the flooring material of the present invention will be described. In describing the method for manufacturing the flooring material, all contents of the above-described flooring material may be included.

The manufacturing method of the flooring material of the present invention includes, for example, preparing a pre-foaming layer or a foaming layer and a nonwoven fabric (S1); Applying and gelling the PVC sol on the pre-foaming layer or the lower part of the foaming layer (S3); forming a first semi-finished product by bonding the nonwoven fabric to the pre-foaming layer or the lower portion of the foaming layer (S5); and forming a second semi-finished product in which a dimensional stability layer, a printing layer, and a transparent layer are laminated from the bottom to the top (S7); wherein, the foam layer has an average length of a major axis and a minor axis of the foam cell of 100 to 400 μm, and , may include a foam having an anisotropy of 1.0 to 1.25 calculated by Equation 1, and in this case, it is possible to manufacture a flooring material having excellent cushioning properties, sound insulation properties and restoration properties.

The step (S1) of preparing the pre-foaming layer or the foaming layer and the non-woven fabric may be, for example, preparing the pre-foaming layer, the foaming layer, and the non-woven fabric, respectively.

The preliminary foaming layer preparation step is, for example, 40 to 85% by weight of a heat stabilizer, 0 to 15% by weight of a cell controller, 5 to 40% by weight of a lubricant, and 5 to 15% by weight of a kicker to prepare a foaming stabilizer. ; preparing a foam composition by kneading 3 to 6 parts by weight of the foam stabilizer, 100 parts by weight of polyvinyl chloride, 45 to 60 parts by weight of a plasticizer, 4 to 15 parts by weight of a foaming agent, and 5 to 20 parts by weight of a filler; and calendering the foam composition to prepare a pre-foaming layer; in this case, there is an advantage of excellent cushioning properties, sound insulation properties and restoration properties at a high expansion ratio of 400% or more.

The foam composition manufacturing step may be, for example, a step of kneading the foam stabilizer, polyvinyl chloride, plasticizer, foaming agent and filler at 120 to 160 °C, or 140 to 160 °C.

In the foam composition manufacturing step, the foaming agent may be, for example, 4 to 15 parts by weight, preferably 5 to 10 parts by weight, more preferably 7 to 9 parts by weight, within this range, based on 100 parts by weight of polyvinyl chloride. There is an advantage in that cushioning properties are improved due to a high expansion ratio without generating open cells.

The blowing agent is, for example, azodicarbonamide (azodicarbonamide), p,p'-oxybisbenzenesulfonylhydrazide (p,p'-oxybisbenzene sulfonyl hydrazide), p-toluenesulfonylhydrazide (p-toluene sulfonyl) hydrazide) and may be at least one selected from the group consisting of benzene sulfonyl hydrazide, but is not limited thereto.

The pre-foaming layer manufacturing step may be, for example, a step of preparing a sheet-shaped pre-foaming layer by calendering the prepared foam composition through a calender roll at 160 to 190°C, or 160 to 170°C.

The foaming layer manufacturing step may be, for example, putting the prepared pre-foaming layer in a foaming oven and foaming at 190 to 250°C, or 200 to 220°C for 40 to 70 seconds, or 40 to 60 seconds.

The nonwoven fabric is, for example, after a blending process of mixing fibers in a certain ratio, forming a web through a carding process, and then passing between thermal calendars after a bonding process of combining a plurality of the webs. Can be produced, In this case, there is an advantage in that a nonwoven fabric having excellent elongation, dimensional stability and restoration properties can be obtained.

The carding process is a process of, for example, combing the raw cotton supplied in the mixing process through a cotton mill and a card machine and mixing them evenly so as not to have directionality to form a flat sheet-like web of a certain weight and width, and then It may further include a cross lapper (cross lapper) process for folding the layer.

The bonding process may be at least one bonding process selected from chemical bonding, thermal bonding, or mechanical bonding, preferably mechanical bonding, as a specific example, having a specific elongation at break and tensile strength of the nonwoven fabric. It may be a needle punching bonding process using a needle for this purpose.

The step of passing between the thermal calendars may be, for example, a step of heating and pressing the bonded web at a temperature of 520 to 600°C, or 540 to 560°C.

In the step (S3) of applying and gelling the PVC sol on the pre-foaming layer or the lower part of the foaming layer, the application may be, for example, one type of method selected from bar coating, knife coating, slit coating and gravure coating, but is limited thereto it is not

The PVC sol is, for example, 100 parts by weight of polyvinyl chloride resin; 60 to 100 parts by weight of a plasticizer, or 70 to 90 parts by weight; 10 to 80 parts by weight of a filler, or 20 to 70 parts by weight; and 1 to 6 parts by weight, or 2 to 5 parts by weight of a heat stabilizer, and in this case, the pre-foaming layer or the foaming layer and the nonwoven fabric have excellent peel strength and tensile strength in a specific range when the nonwoven fabric is stretched at a high temperature. As it can be satisfied, there is an advantage in that the yield of the flooring material is excellent because wrinkles do not occur in the nonwoven fabric during the synchronized embossing process.

The application amount of the PVC sol may be, for example, 50 to 200 g/m ² , or 70 to 150 g/m ² , and when applied within this range, the pre-foaming layer or foaming layer and the non-woven fabric have excellent peel strength while the non-woven fabric is heated at a high temperature. It can satisfy the tensile strength of a certain range when stretching in the synchronous embossing process, the non-woven fabric does not wrinkle, which has the advantage of excellent yield of the flooring material.

The gelling may be performed, for example, in a heating drum at 130 to 170°C, or 140 to 160°C for 1 to 5 seconds, or 1.5 to 4.5 seconds, and in this case, the elongation is excellent and wrinkles are prevented and stored at the same time This has the advantage of being easy.

Forming the first semi-finished product (S5) may be, for example, a step of bonding the nonwoven fabric to the lower portion of the pre-foaming layer or the foaming layer and then performing primary thermal plywood to form the first semi-finished product.

The primary thermal plywood may be, for example, plywood at 140 to 170 ℃, or 145 to 165 ℃.

Forming the first semi-finished product (S5) is, for example, in the case of bonding the nonwoven fabric to the lower portion of the pre-foaming layer, the pre-foaming layer to which the non-woven fabric is bonded to the lower portion is heated at 180 to 220°C, or 190 to 210°C at 30 to 70°C. It can be foam-molded under the conditions of seconds, or 40 to 60 seconds, and in this case, it has the advantage of having an appropriate foam cell size and excellent durability.

Forming the first semi-finished product (S5) may further include, for example, laminating an interlayer layer on the pre-foaming layer or the foaming layer.

The step of laminating the interlayer layer may be, for example, a step of thermally plying after placing the interlayer layer on top of the pre-foamed layer or the foam layer to which the nonwoven fabric is bonded to the lower portion.

In the step (S7) of forming the second semi-finished product, for example, separately from the formation of the first semi-finished product, a printed pattern is directly transferred and printed on the upper part of the dimensional stability layer to form a printed layer, and then a transparent layer is laminated on the printed layer. to 140 to 170 ℃, or 145 to 165 ℃ secondary heat plywood to form a second semi-finished product.

As a preferred example, the method for manufacturing the flooring material may further include a step (S9) of performing a synchronized embossing process while plying the first semi-finished product and the second semi-finished product with a third heat after step (S7), in this case, the embossing retention rate And there is an advantage that the yield of the flooring is excellent.

As a specific example, the method of manufacturing the flooring material is a temperature of 120 to 140 ℃, or 125 to 135 ℃ in an embossing roll for synchronized embossing after positioning the second semi-finished product on the foam layer or interlayer layer of the first semi-finished product, 3 to 7kg/cm ² or 4 to 6kg/cm ² A pressure of 4 to 6kg/cm 2 may be applied to thermally laminate the first semi-finished product and the second semi-finished product and at the same time form a synchronized embossing on the transparent layer, which is the uppermost part of the second semi-finished product.

As another example, in the method for manufacturing the flooring material, after performing a synchronized embossing process on the transparent layer of the second semi-finished product, the second semi-finished product having the synchronized embossing is thermally laminated with the first semi-finished product (S9'). may include

The method for manufacturing the flooring material may further include, for example, forming a surface treatment layer on the uppermost portion of the flooring material after the step (S9), in which case there is an effect of preventing contamination.

The step of forming the surface treatment layer may be, for example, a method of manufacturing a final flooring material by applying a UV-curable paint to the upper portion of the flooring having the embossed synchronously formed thereon and then UV curing to form a surface treatment layer.

Hereinafter, preferred examples are presented to aid the understanding of the present invention, but the following examples are merely illustrative of the present invention and it will be apparent to those skilled in the art that various changes and modifications are possible within the scope and spirit of the present invention, It goes without saying that such variations and modifications fall within the scope of the appended claims.

ingredient Kinds heat stabilizer Mixture of Zinc Stearic Acid, Barium Stearic Acid and Calcium Stearic Acid cell controller acrylate compound lubricant stearic acid kicker zinc oxide polyvinyl chloride (a) Polyvinyl chloride resin having a weight average molecular weight of 100,000 to 110,000 g/mol and a polymerization degree of 1000 (LS100 manufactured by LG Chem) polyvinyl chloride (b) Polyvinyl chloride resin having a weight average molecular weight of 120,000 to 130,000 g/mol and a polymerization degree of 1300 (LS130 by LG Chem) plasticizer LG Chem's GL300 blowing agent Azodicarbonamide (PMA50 from Kumyang) filler Heavy calcium carbonate with an average particle diameter of 8 ㎛ (H type of Yabashi Korea)

[Example]

Example 1

Foam stabilizer manufacturing

A foam stabilizer comprising 70% by weight of a heat stabilizer, 10% by weight of a cell controller, 10% by weight of a lubricant and 10% by weight of an accelerator was prepared.

Pre-foaming layer preparation step (S1)

100 parts by weight of polyvinyl chloride (a), 5 parts by weight of the foam stabilizer prepared in Example 1, 45 to 55 parts by weight of a plasticizer, 6 to 12 parts by weight of a foaming agent, and 5 to 15 parts by weight of a filler were added to the Banbari mixer A foam composition was prepared by kneading under the conditions of 160 ° C., and passed through a calendar roll under the conditions of 160 to 170 ° C. to prepare a pre-foaming layer. After that, the prepared pre-foam was put into a foaming oven and foamed at 200° C. for 50 seconds to prepare a foam.

flooring manufacturing

A flooring material was manufactured by laminating a semi-finished product in which a dimensionally stable layer, a printed layer, and a transparent layer were sequentially laminated on the foam layer made of the manufactured foam, and the specific manufacturing method is as follows.

First, a PVC sol containing 100 parts by weight of a paste polyvinyl chloride resin (PB1202 from LG Chem), 80 parts by weight of a plasticizer (dioctyl phthalate from LG Chem), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil to a glass fiber nonwoven fabric was impregnated to form a dimensionally stable layer having a basis weight of 60 g/m ^{2 and a thickness of 0.35 mm.}

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

In addition, 100 parts by weight of polyvinyl chloride resin (LS100 manufactured by LG Chem), 28 parts by weight of a plasticizer (dioctyl phthalate manufactured by LG Chem), and 2 to 4 parts by weight of a heat stabilizer are kneaded at 160° C. with a Banbari mixer. After passing through a calendar roll at 160 to 170 ° C., a transparent layer having a thickness of 0.55 mm was formed.

Then, the prepared transparent layer was laminated on the dimensionally stable layer on which the printed pattern was formed and thermally laminated at 150° C. to form a semi-finished product.

Thereafter, after placing the semi-finished product on top of the prepared foam layer ^{, thermal plywood at 130° C. under a pressure of 5 kgf/cm 2 with} a synchronized embossing roll, and at the same time performing a synchronized embossing process on the transparent layer, a printed layer formed on the dimensional stability layer A synchronized embossing matching the print pattern of was formed.

A surface treatment agent containing a photocurable resin was applied on the transparent layer on which the synchronized embossing was formed, and then UV irradiated to form a surface treatment layer having a thickness of 0.03 mm to finally prepare a flooring material having a thickness of 6.5 mm.

Example 2

Pre-foaming layer and non-woven fabric preparation step (S1)

100 parts by weight of polyvinyl chloride (b), 5 parts by weight of the foam stabilizer prepared in Example 1, 45 to 55 parts by weight of a plasticizer, 6 to 12 parts by weight of a foaming agent, and 5 to 15 parts by weight of a filler were added to the Banbari mixer A foam composition was prepared by kneading under the conditions of 160° C., and passed through a calendar roll under the conditions of 160 to 170° C. to prepare a pre-foam.

In addition, 40% by weight of polyester (PET) fibers having a length of 5cm and a fineness of 6 denier, 40% by weight of polyester (PET) fibers having a length of 5cm and a fineness of 7 denier, and a poly having a length of 6cm and a fineness of 16 denier After a blending process of mixing 20% by weight of ester (PET) fibers, a web was formed through a carding process.

Next, the carded web and then folded in an appropriate semi-layer through a cross-wrapper process after performing a needle punching process to the 540 to 560 ℃ pass between the calendar open non-woven fabric of a basis weight of 200g / m ^2, thickness 0.8mm (㈜ H. Sglotech, E0820) was manufactured. The tensile strength (130°C, 50% elongation) of the prepared nonwoven fabric was 0.5 kgf.

Applying and gelling the PVC sol under the pre-foaming layer (S3)

100 parts by weight of a paste polyvinyl chloride resin (LG Chem, PB1202), 80 parts by weight of a plasticizer (LG Chem, dioctyl terephthalate), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil on the lower part of the prepared pre-foaming layer PVC sol containing parts ^{was applied at an application amount of 100 g/m 2} , and then gelled at 150° C. for 2 seconds.

First semi-finished product forming step (S5)

The nonwoven fabric was bonded to the lower portion of the pre-foaming layer. At this time, the depth of the PVC sol penetrated into the nonwoven fabric was 50㎛. 100 parts by weight of polyvinyl chloride resin (LG Chem, LS100), 50 parts by weight of plasticizer (LG Chem, dioctyl phthalate), 50 parts by weight of calcium carbonate, hollow filler ( 3M Company, S32) A composition for forming an interlayer layer comprising 10 parts by weight and 0.95 parts by weight of a heat stabilizer is kneaded at 160° C. by a Banbari mixer, and then passed through a calendar roll at 160 to 170° C. to have a thickness of 0.55 mm. was laminated and first thermally laminated at 150 °C.

Then, the thermal laminated non-woven fabric; pre-foaming layer; and a nonwoven layer from the bottom to the top by foaming the interlayer layer in a foaming oven at 200° C. for 50 seconds; foam layer; and a first semi-finished product in which an interlayer layer was laminated. At this time, the prepared foam layer included a nitrile rubber-free foam having an average length of 100 to 400 μm and an anisotropy of 1.0 to 1.25 of the major and minor axes of the foam cells.

Second semi-finished product forming step (S7)

PVC containing glass fiber nonwoven fabric paste 100 parts by weight of polyvinyl chloride resin (LG Chem, PB1202), 80 parts by weight of plasticizer (LG Chem, dioctyl terephthalate), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil The sol was impregnated to form a dimensionally stable layer having a basis weight of 60 g/m ^{2 and a thickness of 0.35 mm.}

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

In addition, after kneading a composition for molding a transparent layer comprising 28 parts by weight of a plasticizer and 2 to 4 parts by weight of a heat stabilizer with respect to 100 parts by weight of a polyvinyl chloride resin (LG Chem, LS100) at 160° C. with a Banbari mixer, 160 to A transparent layer was formed as a film having a thickness of 0.55 mm by passing a calendar roll at 170°C.

Then, the transparent layer was laminated on the dimensionally stable layer on which the printed pattern was formed, and secondary thermal plywood was formed at 150° C. to form a second semi-finished product.

Plywood step of the first semi-finished product and the second semi-finished product (S9)

Then, after placing the second semi-finished product on top of the interlayer layer of the first semi-finished product prepared above, the ^{third thermal plywood at a temperature of 130° C. and a pressure of 5 kgf/cm 2} with a synchronized embossing process at the same time as the synchronized embossing process on the transparent layer was performed to form a synchronized embossing matching the printed pattern of the printed layer formed on the dimensional stability layer.

Surface treatment layer forming step (S11)

A surface treatment agent containing a photocurable resin was applied on the transparent layer on which the tuning embossing was formed, and then UV irradiated to form a surface treatment layer having a thickness of 0.03 mm to prepare the flooring material of the present invention having a thickness of 4.2 mm.

Comparative Example 1

Foam stabilizer manufacturing

A foam stabilizer comprising 63 wt% of a heat stabilizer, 5 wt% of a cell controller, 12 wt% of a lubricant, and 20 wt% of an accelerator was prepared.

Foam manufacturing

100 parts by weight of polyvinyl chloride (a), 1.2 to 2.4 parts by weight of the prepared foam stabilizer, 45 to 55 parts by weight of a plasticizer, 6 to 12 parts by weight of a foaming agent, and 5 to 15 parts by weight of a filler were added to the Banbari mixer, and then 160° C. A foam composition was prepared by kneading under the conditions of, and passed through a calendar roll under the conditions of 160 to 170° C. to prepare a pre-foam. After that, the prepared pre-foam was put into a foaming oven and foamed at 200° C. for 50 seconds to prepare a foam.

flooring manufacturing

A flooring material was manufactured by laminating a semi-finished product in which a dimensionally stable layer, a printed layer, and a transparent layer were sequentially laminated on the foam layer made of the manufactured foam, and the specific manufacturing method is as follows.

First, a PVC sol containing 100 parts by weight of a paste polyvinyl chloride resin (PB1202 from LG Chem), 80 parts by weight of a plasticizer (dioctyl phthalate from LG Chem), 60 parts by weight of calcium carbonate, and 2 parts by weight of epoxidized soybean oil to a glass fiber nonwoven fabric was impregnated to form a dimensionally stable layer having a basis weight of 60 g/m ^{2 and a thickness of 0.35 mm.}

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

In addition, 100 parts by weight of polyvinyl chloride resin (LS100 manufactured by LG Chem), 28 parts by weight of a plasticizer (dioctyl phthalate manufactured by LG Chem), and 2 to 4 parts by weight of a heat stabilizer are kneaded at 160° C. with a Banbari mixer. After passing through a calendar roll at 160 to 170 ° C., a transparent layer having a thickness of 0.55 mm was formed.

Then, the prepared transparent layer was laminated on the dimensionally stable layer on which the printed pattern was formed and thermally laminated at 150° C. to form a semi-finished product.

Thereafter, after placing the semi-finished product on top of the prepared foam layer ^{, thermal plywood at 130° C. under a pressure of 5 kgf/cm 2 with} a synchronized embossing roll, and at the same time performing a synchronized embossing process on the transparent layer, a printed layer formed on the dimensional stability layer A synchronized embossing matching the print pattern of was formed.

A surface treatment agent containing a photocurable resin was applied on the transparent layer on which the synchronized embossing was formed, and then UV irradiated to form a surface treatment layer having a thickness of 0.03 mm to finally prepare a flooring material having a thickness of 6.5 mm.

Comparative Example 2

It was carried out in the same manner as in Example 1, except that 7 parts by weight of the foam stabilizer was used to use the foam prepared in Example 1.

Comparative Example 3

It was carried out in the same manner as in Example 1, except that 10 parts by weight of the foam stabilizer was used to use the foam prepared in Example 1.

Comparative Example 4

It was carried out in the same manner as in Example 1, except that 2 parts by weight of the foam stabilizer was used to use the foam prepared in Example 1.

[Test Example]

The properties of the foams and flooring materials prepared in Examples 1 to 2 and Comparative Examples 1 to 4 were measured by the following method, and the results are shown in Table 2 below.

* Anisotropy: Anisotropy was calculated using Equation 1 below.

[Equation 1]

Anisotropy = x / y

(In Equation 1, x is ^{the average value of the major axis length of the foam cells included in the unit area (1 mm 2} ) of the foam, and y is the minor axis length of the foam cells included in the unit area (1 mm ² ) of the foam. average value)

* Number of foamed cells [pcs/mm ² ]: After the foam was cut in the vertical direction, the number of foamed cells was measured in the cross section of the cut foam using a scanning electron microscope (SEM).

* Expansion ratio [%]: The expansion ratio of the specimen was calculated using Equation 2 below.

[Equation 2]

Foaming ratio = T _a /T _b X 100%

(In Equation 2, T _a is the initial density of the foam specimen having a length and width of 50 mm X 50 mm, and T _b is a temperature of 160 ° C., a pressure of 500 kgf / cm ² Pressing the specimen for 15 minutes under conditions of pressure Density of the compressed specimen after removal)

* Density [g/cm ³ ]: Measured at room temperature using a hydrometer.

* Compressibility [%]: A load of 222N was applied with a hemispherical steel bar with a diameter of 19 mm, maintained for 1 minute, and then the depth of the inserted specimen was measured, and then this was measured as the value divided by the total thickness of the specimen.

* Residual indentation rate [%]: As specified in KS M 3802, a load of 222N is applied with a hemispherical steel bar with a diameter of 19mm and released after 5 minutes, and then, after 1 hour has elapsed, the thickness of the specimen is changed through the following mathematics It was calculated based on Equation 3.

[Equation 3]

Residual indentation = (T ₀ - T ₁ )/T ₀ X 100%

(In Equation 3, T ₀ is the thickness before applying the load, and T ₁ is the thickness when 1 hour has elapsed after the load is applied.)

* Light impact sound reduction [dB]: Measured according to the standard of KS F 2810 (light impact sound test conditions).

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 foam anisotropy 1.1841 1.1841 1.1841 1.3602 1.3602 1.1840 Standard deviation of long axis [㎛] 43 43 40 83 83 40 Standard deviation of short axis [㎛] 36 36 36 68 68 36 Number of foam cells [pcs/mm ² ] 20-35 20-35 15-30 15-30 15-30 15-30 Foaming ratio [%] over 450 over 500 420 390 360 405 Density [g/cm ³ ] 1.26 1.26 1.37 1.37 1.37 1.37 Residual indentation ratio [%] (based on 500% foaming ratio) 20-25 20-25 30-35 30-35 30-35 30-35 flooring compressibility [%] 50 or more 50 or more 45-48 45 or less 40 or less 45-48 Residual indentation rate [%] 6-8 6-8 6-8 6-8 6-8 6-8 Light impact sound reduction [dB] 24 24 22 19 19 22 Weight [kg/1mm ² ] 3.3 3.3 3.6 4.2 4.2 3.6

As shown in Table 2, the flooring material of the present invention controls the length and anisotropy of the long and short axes of the foam cells as in Examples 1 and 2, and thus has a high foaming rate of 400% or more without including a nitrile rubber with a strong odor in the process. In the magnification, it was confirmed that the compressibility, residual indentation rate, and light impact sound reduction were all excellent without premature foaming, and were lighter than Comparative Examples 1 to 4.

More specifically, the flooring materials (Examples 1 to 2) of the present invention are lighter than Comparative Examples 1 to 4, and thus have excellent sound insulation properties and excellent restoration properties without deterioration. could confirm that there was

On the other hand, it was confirmed that the flooring materials (Comparative Examples 2 to 3) prepared including the foam having an anisotropy of the foam cell exceeding 1.25 decreased the amount of reduction in pressability and light impact sound compared to Example 1.

In addition, in the case of Comparative Example 1, in which the foaming accelerator content is excessive, unlike Examples 1 and 2 of the present invention, compared to Examples 1 and 2, the compressibility, residual indentation rate, and light impact sound reduction amount are lowered, and it is confirmed that the sound insulation property is also lowered because it is heavy. could

In addition, as shown in Figs. 1 to 6, the foam prepared in Example 1 of the present invention (Figs. 1 and 2) is the foam prepared in Comparative Example 1 (Figs. 3 and 4) and the foam prepared in Comparative Example 2 (Figs. 5 and 6), it was possible to visually confirm that it had a uniform cell and excellent anisotropy, and it was also confirmed that it had excellent anisotropy through the measured lengths of the major and minor axes and standard deviation values of the foam cells. .

In conclusion, according to the present invention, it is excellent in preventing the transfer of debris and crack steps on the floor surface, crack waves do not occur even after heating the floor, and the light-weight impact sound reduction is improved compared to the conventional flooring material, so the sound insulation is excellent and the printed pattern of the printed layer It was confirmed that the position of the synchronized embossed and the synchronized embossed coincided with each other, making it suitable for providing a flooring material with excellent three-dimensional effect and aesthetics.

Claims (15)

From bottom to top, the foam layer; dimensional stability layer; printed layer; and a transparent layer; wherein the foamed layer has an average length of the major and minor axes of the foamed cells of 100 to 400 μm, and an anisotropy calculated by the following Equation (1) of 1.0 to 1.25, characterized in that it comprises a nitrile rubber-free foam flooring material.
[Equation 1]
Anisotropy = x / y
(In Equation 1, x is ^{the average value of the major axis length of the foam cells included in the unit area (1 mm 2} ) of the foam, and y is the minor axis length of the foam cells included in the unit area (1 mm ² ) of the foam. average value) The method of claim 1,
The standard deviation of the length of the major axis and the minor axis is a flooring, characterized in that 1 to 50㎛, respectively. The method of claim 1,
The nitrile-free foam comprises 100 parts by weight of polyvinyl chloride, 45 to 60 parts by weight of a plasticizer, 3 to 6 parts by weight of a foam stabilizer, and 5 to 20 parts by weight of a filler,
The foam stabilizer is 40 to 85% by weight of a heat stabilizer, 0 to 15% by weight of a cell controller, 5 to 40% by weight of a lubricant, and 5 to 15% by weight of a kicker flooring material. The method of claim 1,
The flooring material has a compressibility (19mmΦ, 222N) of 50% or more, and a residual indentation ratio (based on KS M 3802, 1hr, foaming ratio 500%) of 20% or less. The method of claim 1,
The flooring material, characterized in that the light-weight impact sound reduction (KS F 2810) of 35 dB or less. The method of claim 1,
A flooring material comprising a nonwoven fabric layer having a tensile strength of 0.3 to 0.8 kgf when stretched 40 to 60% in the longitudinal direction at 120 to 150° C. under the foam layer. 7. The method of claim 6,
The nonwoven layer is a flooring material comprising a nonwoven fabric having an elongation at break of 80 to 200% in the longitudinal direction at 20 to 25°C. 8. The method of claim 7,
The nonwoven fabric is a flooring material, characterized in that two or more fibers having different fineness (denier) of the thermoplastic resin are mixed. 9. The method of claim 8,
The thermoplastic resin is a flooring material, characterized in that polyester (PET). 9. The method of claim 8,
The fiber is a flooring material, characterized in that the short fibers of 4 to 7cm in length. 9. The method of claim 8,
The nonwoven fabric has a fineness of 4 to 12 denier fibers (f ₁ ) and a fineness of 13 to 20 denier fibers (f ₂ ) Flooring, characterized in that the mixed fibers. The method of claim 1,
The nonwoven layer is a flooring material, characterized in that it comprises a nonwoven fabric in which the PVC sol is penetrated to a depth of 30 to 70 μm. 13. The method of claim 12,
The nonwoven fabric is a flooring material, characterized in that the PVC sol is penetrated to a depth of 40 to 60㎛. Preparing a pre-foaming layer or a foaming layer and a nonwoven fabric (S1); Applying and gelling the PVC sol on the pre-foaming layer or the lower part of the foaming layer (S3); forming a first semi-finished product by bonding the nonwoven fabric to the pre-foaming layer or the lower portion of the foaming layer (S5); and forming a second semi-finished product in which a dimensional stability layer, a printed layer and a transparent layer are laminated from the bottom to the top (S7);
The foam layer has an average length of the major and minor axes of the foam cells of 100 to 400 μm, and the anisotropy calculated by the following Equation 1 is 1.0 to 1.25.
[Equation 1]
Anisotropy = x / y
(In Equation 1, x is ^{the average value of the major axis length of the foam cells included in the unit area (1 mm 2} ) of the foam, and y is the minor axis length of the foam cells included in the unit area (1 mm ² ) of the foam. average value) 15. The method of claim 14,
The PVC sol is 100 parts by weight of polyvinyl chloride resin, 60 to 100 parts by weight of a plasticizer, 10 to 80 parts by weight of a filler, and 1 to 6 parts by weight of a heat stabilizer.

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