KR960004517B1 - Flooring sheet and the method for making the same - Google Patents

Abstract

The polyvinyl chloride(PVC) flooring material is mfd. by (a) gelling a glass fiber layer or a nonwoven fabric layer, impregnated with a low viscosity PVC paste transparent gel in the gravure roll coater unit, in the heating drum to make a synthetic resin fiber sheet, (b) forming a printed layer on the upper or the lower of the sheet, and (c) laminating a cushion (or noncushion) layer on the lower of the printed layer, and coating a ultra-violet paint on the upper part of the printed layer. The PVC flooring material useful as a carpet has a sound proofing and heat insulating effect.

Description

PVC flooring material incorporating natural fiber material and three-dimensional printing effect and its manufacturing method

1 is a partial cutaway perspective view of a state in which the cushion flooring material is expanded using a synthetic fiber sheet.

2 is a partial cutaway perspective view of the state unfolded non-cushion flooring using a synthetic fiber sheet.

3A and 3B are cross-sectional views of cushion flooring using synthetic fiber sheets.

Figure 3c, Figure 3d is a cross-sectional view of each non-cushion flooring using a synthetic fiber sheet.

* Explanation of symbols for main parts of the drawings

1: surface ultraviolet paint layer 2: upper transparent film layer

3: printed transparent film layer

4: new material glass fiber layer mixed with high melting point colored fiber

5: New material nonwoven fabric layer mixed with colored fibers of high melting point

6: glass fiber layer 7: nonwoven fabric layer

8: flat PVC layer 9: rubber shaped product layer

10: Non-foaming layer laminated with # type glass scrim

The present invention relates to a structure of a unique product of PVC flooring material in which a natural fiber shape of a natural material texture and a three-dimensional printing effect are harmonized, and a method of manufacturing the same, and this product is a conventional vinyl flooring material made of PVC or nylon or polyester. The present invention relates to a PVC flooring product which is completely different in structure and effect from a conventional carpet mainly made of lamps. The surface layer is excellent in scratch resistance and stain resistance, and has an antistatic effect and a beautiful gloss effect. Laminated upper and lower layers of special synthetic fiber sheet (new material glass fiber or nonwoven fiber layer) consisting of a UV coating layer and transparent PVC film layer, and the middle layer below the surface layer is given a natural fiber shape of natural material texture. By integrating a high-precision gravure print film Sex was the natural fibrous texture of a natural material contained in the fiber sheet with three-dimensional effect of the print formed blend, the underlying layer of the lower intermediate layer was able to be separated by the attached cushion merchandise and non cushion merchandise in accordance with the intended use.

As described above, the special synthetic fiber sheet (new material glass fiber layer) in the intermediate layer of this product is made of natural fiber such as cotton, hemp, wool, etc. pre-dyed to the conventional glass fiber layer, or synthetic fibers such as nylon, rayon, polyester, and carbon. It is a new material glass fiber that is continuously sheeted by mixing the fibers at a certain ratio.The high-precision print film on the upper or lower part and the glass fiber layer which is an inorganic material when heat-sealed plywood and the low melting point thermoplastic resin (SBR + ACRYL +) PVA) part becomes transparent and only natural weave shape of high melting point dyed natural fiber or synthetic fiber contained in the glass fiber layer appears to be in harmony with the three-dimensional printing effect of the upper or lower precision printing film. Herein, the special synthetic fiber sheet (new material nonwoven fabric layer) is made of natural fibers such as cotton, hemp, wool, nylon, rayon, and the like, pre-dyed with a thermoplastic resin (PP: polypropylene) having a low melting point (melting point: 165 ° C. or less) having excellent transparency. High-melting point (melting point: 250 ℃ or higher) of polyester, carbon, etc., by mixing synthetic fibers at a certain ratio and weaving them into sheets in the form of fabrics. When the high-precision print film and the heat-sealed plywood have a low melting point, the thermoplastic part becomes transparent and the surface melts to act as an adhesive, and only the natural fabric shape of the high melting point dyed natural fiber or synthetic fiber contained in the thermoplastic resin appears. It is designed to harmonize with the three-dimensional printing effect of the high or high precision print film. In addition, various types of fabrics can be displayed depending on the type of dyed dyed fiber, the thickness (DENIER) and the length (short fiber-long fiber), and the density (content), and the monochromatic color or various colors are harmonized. By using colored fibers of mixed color, it is possible to have various forms of natural texture effect or various color surface, and also create various appearance effects by using metal fibers of Ph.D., Gold and Silver company in addition to natural and synthetic fibers.

In addition, it is possible to impart elasticity and shock absorption by selecting various thicknesses (0.1 to 0.1 mm) and weight (10 to 100 g / m 2) of the special fiber sheet, and to prevent static electricity from being generated by antistatic treatment on colored fibers.

Therefore, it is possible to obtain the appearance effect of natural carpet sensation which was not possible in the conventional vinyl flooring based on PVC, and also to improve the defects of abrasion, moisture permeation, corrosion and contamination of the products which were problematic in the conventional carpet, and more. Furthermore, it is a product with a better sound insulation and insulation effect than a conventional carpet, and it is easier to manage glass (cleaning) than the existing carpet, and the appearance of high-end carpet texture is possible by displaying various patterns by gravure roll printing.

Therefore, the cushion type shown in FIG. 1 is suitable for apartment living room and barium, salon and restaurant, hotel and building corridor, ship and car, etc. The non-cushion type blade shown in FIG. 2 is also suitable for use, and is suitable for use in difficult to use carpet due to the problem of wearability and contamination of the existing carpet for heavy walking.

Hereinafter, the product structure and manufacturing method will be described in detail with reference to the present invention flooring.

Example 1

First, the colored fiber mixed glass fiber impregnated with the low viscosity PVC paste transparent sol in the gravure two roll coater unit is gelled and calender rolled in a heating drum of high temperature (160 ~ 180 ° C) to have a sufficiently smooth surface and adhesion. The upper transparent film layer and the lower printed film layer sheeted by the method are heat-sealed.

Next, the printing unit is overprinted in various colors of 1- or 5-color using low concentration of high hiding power ink with high pigment content at the bottom of the lower printing film layer, and then operated at 180-250 ° C. in the foaming process. It is made of laminating plywood by proceeding with a working oven and 160 ~ 180 ℃ hot working. Depending on the shape, the surface of the finished product can be either matte UV paint or semi-gloss or glossy UV paint for gloss. do.

(1) an ultraviolet paint layer having a thickness of 10 to 15 μm,

(2) 0.2 ~ 0.3mm thick transparent film layer,

(4) 40 ~ 60G / M ² colored fiber mixed new material glass fiber,

(3) 0.1 ~ 0.2mm thick print film layer,

(8) 0.1 ~ 0.2mm thick sheet PVC layer,

(9) 0.3 ~ 0.6mm thick rubber shaped product layer (1),

(9) Consists of a rubber-shaped product layer (2) of 0.3 ~ 0.6mm thickness,

Example 2

First, in the gravure two roll coder unit, a conventional glass fiber layer impregnated with a low-viscosity PVC paste transparent sol, an upper colored fiber mixed nonwoven fiber manufactured by a special method, and a lower printed film layer seated by a calender rolling method were used. Heat-sealed plywood. Other manufacturing processes are the same as in Example 1.

(1) an ultraviolet paint layer having a thickness of 10 to 15 μm,

(2) 0.2 ~ 0.3mm thick transparent film layer,

(5) 10 ~ 30G / M ² colored fiber mixed new material nonwoven fiber,

(6) 40 ~ 60G / M ² glass fiber layer (glass fiber),

(3) 0.1 ~ 0.2mm thick print film layer,

(8) 0.1 ~ 0.2mm thick sheet PVC layer,

(9) 0.3 ~ 0.6mm thick rubber shaped product layer (1),

(8) Composed of 0.2 ~ 0.3mm thick sheet PVC layer,

Example 3

First, in the gravure two-roll coater unit, the upper print film layer sheeted by the calender rolling method is colored onto the colored fiber mixed glass fiber impregnated with a low-viscosity PVC paste transparent sol.

Next, the printing unit prints in various colors of 1-color or 5-color using low concentration high hiding power ink with high pigment content on top of the upper printing film layer, and then proceeds to hot processing at 16 ~ 180 ℃ in the embossing process. The process proceeds to the laminated plywood. Depending on the shape of the finished product, it is possible to use matt UV paint or semi-gloss or glossy UV paint for gloss. The back side of the product is foamed and the product surface is embossed with various special embossing patterns. After cooling, the edges are trimmed, inspected and packed.

(1) an ultraviolet paint layer having a thickness of 10 to 15 μm,

(2) 0.2 ~ 0.3mm thick transparent film layer,

(3) 0.1 ~ 0.2mm thick print film layer,

(4) 40 ~ 60G / M ² colored fiber mixed new material glass fiber,

(8) 0.1 ~ 0.2mm thick sheet PVC layer,

(10) 0.4-0.7 mm thick non-foaming glass scrim layer,

(8) 0.1 ~ 0.2mm thick sheet PVC layer,

(9) 0.2 ~ 0.3mm thick PVC foam layer,

Example 4

First, in the gravure two roll coater unit, heat-sealing the conventional printing fiber layer impregnated with a low-viscosity PVC paste transparent sol and the upper printing film layer sheeted by the CAL method and the colored fiber mixed nonwoven fiber manufactured by the special method. Plywood. Other processes are the same as in Example 3.

(1) an ultraviolet paint layer having a thickness of 10 to 15 μm,

(2) 0.2 ~ 0.3mm thick transparent film layer,

(3) 0.1 ~ 0.2mm thick print film layer,

(5) 10 ~ 30G / M ² colored fiber mixed new material nonwoven fiber,

(6) 40 ~ 60G / M ² glass fiber layer (glass fiber),

(8) 0.1 ~ 0.2mm thick sheet PVC layer,

(10) 0.4-0.5 mm thick non-foaming glass scrim layer,

(7) 0.3-0.9 mm thick nonwoven layer.

In Examples 1 and 2, the pre-dyed natural fiber shape of the natural material texture contained in the special synthetic fiber sheet appeared on the product surface, and harmonized with the three-dimensional printing effect of gravure overprinted on the bottom of the lower print film layer. In addition, the transparent film layer and the special glass fiber layer which are calender rolled sheeting create a visual space, showing the stereoscopic effect by showing the dye-like fiber shape of the fabric type contained in the special synthetic fiber sheet and the printed pattern of gravure. Gentle and smooth appearance by overprinting with transparent organic pigments or upper transparent or lower print film layers containing very small amounts of pigments or with various colored pearl inks at the bottom of the upper transparent film layer Possible to create and excellent elasticity like natural rubber under the product By using gomyu-like crosslinked foam of 200 to 300 magnification it is also excellent having high cushion performance and soft can not have a resident in the main ingredient of conventional PVC sound insulation, moisture barrier and insulation effect.

In Examples 3 and 4, the beautiful design of the three-dimensional printing effect of the gravure printed on the upper printing film layer and the natural fiber shape of the natural material texture contained in the lower special synthetic fiber sheet were combined to create the interior decoration effect. Due to the characteristics of the CAL method, the lower part of the product generates tension and heats each part, causing stress (expansion in the longitudinal direction and contraction in the width direction) to the plywood flooring material. In order to improve the problem that the expansion of the stress in the contracted width direction caused by the expansion of the bellows to improve the problem that the weave # -type glass scrim woven in a mesh shape on the top of the non-foaming layer to prevent the tension generated in the CAL and embossing .

Claims (5)

A layer coated with UV paint on top of the transparent PVC layer is used as the surface layer, and a layer composed of a synthetic fiber sheet and a gravure printed film on the upper or lower part of the second layer is used as an intermediate layer, and a cushion or non-cushion layer is provided under the intermediate layer. PVC flooring material with a three-dimensional printing effect and a fiber material attached to the. According to claim 1, Synthetic fiber sheet (new material glass fiber layer) is continuous by mixing one or two or more fibers of cotton, hemp, wool, nylon, rayon, polyester, carbon fiber pre-dyed to the glass fiber layer in a constant ratio PVC flooring material with integrated three-dimensional printing effect, characterized in that the sheet material. The method of claim 1, wherein the synthetic fiber sheet (new material nonwoven fabric layer) is a certain ratio of one or two or more fibers of cotton, hemp, wool, nylon, rayon, polyester, carbon fiber in a PP (polypropylene) resin layer. PVC flooring material with three-dimensional printing effect, which is characterized by continuous sheeting by mixing. The method according to claim 2 or 3, wherein the type, thickness, length, density (content) and color (monochrome or mixed color) of the colored fibers mixed in the new glass fiber layer or the new nonwoven fabric layer are changed. PVC flooring with integrated three-dimensional printing effect and synthetic fiber sheet produced according to various. In a gravure two roll coater unit, a new glass fiber layer or a new nonwoven fabric layer impregnated with a low-viscosity PVC paste transparent sol was subjected to a heating drum to make a synthetic fiber sheet, and a layer to be printed on top or bottom thereof was heat-sealed. A method of manufacturing a PVC flooring material incorporating a fibrous material and a three-dimensional printing effect, characterized in that the printing is performed by laminating a cushion or non-cushion layer on the bottom and UV coating on the top.