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WO2013036022A2 - Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof - Google Patents

Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof Download PDF

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Publication number
WO2013036022A2
WO2013036022A2 PCT/KR2012/007092 KR2012007092W WO2013036022A2 WO 2013036022 A2 WO2013036022 A2 WO 2013036022A2 KR 2012007092 W KR2012007092 W KR 2012007092W WO 2013036022 A2 WO2013036022 A2 WO 2013036022A2
Authority
WO
WIPO (PCT)
Prior art keywords
inlaid
floor sheet
layer
chip
polyvinyl chloride
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/KR2012/007092
Other languages
French (fr)
Other versions
WO2013036022A3 (en
Inventor
Sung Ha Park
Jae Wan Sung
Dae Jin Kim
Ki Jae JANG
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
LX Hausys Ltd
Original Assignee
LG Hausys Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by LG Hausys Ltd filed Critical LG Hausys Ltd
Priority to CN201280043037.1A priority Critical patent/CN103781629A/en
Priority to US14/343,014 priority patent/US20140213132A1/en
Publication of WO2013036022A2 publication Critical patent/WO2013036022A2/en
Publication of WO2013036022A3 publication Critical patent/WO2013036022A3/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/04—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/04—Coating on the layer surface on a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0214—Particles made of materials belonging to B32B27/00
    • B32B2264/0228—Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
    • B32B2264/0242—Vinyl halide, e.g. PVC, PVDC, PVF or PVDF (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]

Definitions

  • the present invention relates to an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, and more particularly to an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, in which a plain-weave type dimensionally reinforcing layer is provided at a lower side of the inlaid type floor sheet having polyvinyl chloride chip, thereby improving durability, realizing dimensional stability and balance of a product and increasing adhesive force with a construction floor.
  • Fig. 1 is a cross-sectional view of a conventional inlaid type floor sheet having polyvinyl chloride chip (hereinafter, called 'floor sheet').
  • the conventional floor sheet 10 is a non-foaming type and includes an inside layer 11 which is adhered to a construction floor, a dimensionally reinforcing layer 12 which is disposed on the inside layer 11 and formed of glass fiber, a polyvinyl chloride chip layer 13 which is disposed on the dimensionally reinforcing layer 12, and a UV curable paint layer 14 which is coated on the polyvinyl chloride chip layer 13, wherein each layer is stacked in turn from a lower side to an upper side of the drawing.
  • the floor sheet 10 has the polyvinyl chloride chip layer 13 which provides relatively higher durability than a general PVC floor sheet, and the polyvinyl chloride chip layer 13 functions to maintain the surface shape of a product as much as possible, even though the surface of the product is worn. Therefore, the floor sheet 10 is used in some places where high durability of the product is required due to frequent use by many people. Meanwhile, as a thickness of the polyvinyl chloride chip layer 13 is increased, the durability of the floor sheet 10 is enhanced, but it is substantially limited to increase the thickness of the polyvinyl chloride chip layer 13.
  • Fig. 2 shows another example of the conventional floor sheet for overcoming the above-mentioned problem.
  • the conventional floor sheet 20 is a non-foaming type and includes a polyvinyl chloride chip layer 21 and a UV curable paint layer 22 which is coated on the polyvinyl chloride chip layer 21.
  • the floor sheet 20 which includes the dimensionally reinforcing layer 12 as shown in Fig. 1 is called 'a Hetero homogeneous type'
  • the floor sheet 20 which includes only the polyvinyl chloride chip layer 21 as shown in Fig. 2 is called 'a homogeneous type'.
  • the thickness of the polyvinyl chloride chip layer 13, which is directly associated with the durability of the product, is formed to be thin, i.e., about 1.25mm, and thus it has a durability of about 10 years.
  • the dimensionally reinforcing layer 12 it is advantageous to realize the dimensional stability and balance of the product and also it is facile to handle and construct it.
  • the polyvinyl chloride chip layer 21 is thicker than that of the Hetero homogeneous type floor sheet 10, and thus it has a longer durability of about 15 years. However, its dimensional stability is low, and since the polyvinyl chloride chip layer 21 formed of a hard material is directly contacted with the construction floor, it is difficult to handle and construct it.
  • An object of the present invention is to provide an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, in which a plain-weave type dimensionally reinforcing layer is provided at a lower side of the inlaid type floor sheet having polyvinyl chloride chip, thereby improving durability, realizing dimensional stability and balance of a product and increasing adhesive force with a construction floor.
  • the present invention provides an inlaid type floor sheet having polyvinyl chloride (PVC) chip, including an inlaid chip layer in which polyvinyl chloride is formed into chips; a UV paint layer which is coated on the inlaid chip layer; and a dimensionally reinforcing layer which is formed of a fabric and pressed on a lower surface of the inlaid chip layer at high temperature.
  • PVC polyvinyl chloride
  • the dimensionally reinforcing layer is formed of a plain weave prepared through a high temperature scouring process.
  • the dimensionally reinforcing layer 130 has a grid of 1 x 1mm.
  • the present invention provides a method of manufacturing an inlaid type floor sheet having PVC chip, including (a) transporting a dimensionally reinforcing member formed of a fabric; (b) coating PVC chips on the dimensionally reinforcing member; (c) pre-heating an intermediate molded member formed through the coating of the PVC chips; (d) pressing the intermediate molded member up and donw; and (e) coating and curing a UV curable paint on a final molded member formed through the pressing of the intermediate molded member.
  • the dimensionally reinforcing member is formed of a plain weave prepared through a high temperature scouring process.
  • the plain-weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.
  • Figs. 1 and 2 are cross-sectional views of a conventional floor sheet.
  • Fig. 3 is a cross-sectional view of an inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
  • Fig. 4 is a perspective view of a dimensionally reinforcing layer in the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention.
  • Fig. 5 is a flow chart showing a manufacturing method of the inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
  • UV paint layer 130 dimensionally reinforcing layer
  • Fig. 3 is a cross-sectional view of an inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention
  • Fig. 4 is a perspective view of a dimensionally reinforcing layer in the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention
  • Fig. 5 is a flow chart showing a manufacturing method of the inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
  • an inlaid type floor sheet 100 (hereinafter, called 'floor sheet') having polyvinyl chloride (PVC) chip according to an embodiment of the present invention incldues an inlaid chip layer 110 in which PVC is formed into chips, a UV paint layer 120 which is coated on the inlaid chip layer 110, and a dimensionally reinforcing layer 130 which is attached to a lower surface of the inlaid chip layer 110.
  • PVC polyvinyl chloride
  • the inlaid chip layer 110 is formed by coating irregular or regular shaped chips on the dimensionally reinforcing layer 130.
  • the inlaid chip layer 110 is formed to have a thickness t of 1.8 to 2.0mm which is increased by about 50% compared to the conventional one.
  • the inlaid chip layer 110 has a great influence on the durability of the floor sheet 100. In the embodimenet, the durability of the floor sheet 100 can be remarkably increased by increasing the thickness of the inlaid chip layer 110.
  • the thickness t of the inlaid chip layer 110 may be equal to or larger than that of the PVC chip layer 21 in the conventional homogeneous type floor sheet.
  • the UV paint layer 120 is formed by coating a UV paint on the inlaid chip layer 110.
  • the UV paint layer 120 functions to prevent a liquid contaminant from be penetrated into the inlaid chip layer 110 and also allows surface contamination to be easily removed.
  • the dimensionally reinforcing layer 130 which can satisfy the dimensional stability and durability of the floor sheet 100 is attached to the lower surface of the inlaid chip layer 110.
  • the dimensionally reinforcing layer 130 is formed into a fabric type, thereby further improving adhesive force of the floor sheet 100 with respect to a construction floor.
  • the dimensionally reinforcing layer 130 has a desired elongation rate in all directions so as to prevent sliding of the floor sheet 100, and preferably, the dimensionally reinforcing layer 130 is fomred of a plain weave.
  • the dimensionally reinforcing layer 130 is a fabric formed of braid, there is a high probability that dimensionally reinforcing layer 130 is slid on the construction floor.
  • the dimensionally reinforcing layer 130 is formed into the plain weave type manufactured through a high temperature scouring process. Further, as shown in Fig. 4, the dimensionally reinforcing layer 130 is formed to have a density of 25mesh, more detailedly a grid of 1x1mm.
  • the dimensionally reinforcing layer 130 is formed into the plain weave type and also formed to have a density of about 25mesh, it is possible to increase the dimensional stability of the floor sheet 100 and also to improve the balance of the floor sheet 100 in all directions. Furthermore, since the dimensionally reinforcing layer 130 is formed into the plain weave type, frictional force with respect to the construction floor is increased and thus the adhesive force of the floor sheet 100 is also increased.
  • the dimensional stability means a degree of dimensional change of the floor sheet 100 with respect to a preset size thereof.
  • the dimensional stability and the adhesive strength in each of the floor sheet 100 of the present invention and the conventional Homogeneous floor sheet 20 will be compared.
  • a test piece of 30cm x 30cm is put in a dry oven of about 80°C for 6 hours and then the degree of the dimensional change is measured.
  • a test piece of 25cm x 25cm is attached to a slate plate using an aqueous acrylic adhesive and then stretched using a tensile tester so as to measure a peel strength.
  • the dimensional stability and the adhesive strength were measured using the floor sheet 100 in which the UV paint layer 120, the inlaid chip layer 110 and the dimensionally reinforcing layer 130 were stacked in turn.
  • the dimensional stability and the adhesive strength were measured using the floor sheet 100 in which the UV paint layer 22 and the PVC chip layer 21 were stacked in turn.
  • the floor sheet 100 of the present invention has the lower degree of dimensional change and the higher adhesive strength than the conventional Homogeneous type floor sheet 20.
  • a manufacturing method of manufacturing the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention.
  • the manufacturing method includes the steps of (a) transporting a dimensionally reinforcing member 160 formed of a fabric; (b) coating PVC chips on the dimensionally reinforcing member 160; (c) pre-heating an intermediate molded member 180 formed through the step (b); (d) pressing the intermediate molded member 180 up and donw; and (e) coating and curing a UV curable paint on a final molded member 190 formed through the step (d). And after the step (e), the manufacturing method further includes a step of winding the final molded member 190 passed through the step (e).
  • the dimensionally reinforcing member 160 is prepared through the high temperature scouring process in order to increase the dimensional stability and the adhesive strength.
  • the plain-weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Laminated Bodies (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)

Abstract

Disclosed is an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof. The inlaid type floor sheet having polyvinyl chloride (PVC) chip, includes an inlaid chip layer in which polyvinyl chloride is formed into chips; a UV paint layer which is coated on the inlaid chip layer; and a dimensionally reinforcing layer which is formed of a fabric and pressed on a lower surface of the inlaid chip layer at high temperature. According to the present invention, since the plain-weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.

Description

INLAID TYPE FLOOR SHEET HAVING POLYVINYL CHLORIDE CHIP AND THE METHOD OF MANUFACTURING THEREOF
The present invention relates to an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, and more particularly to an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, in which a plain-weave type dimensionally reinforcing layer is provided at a lower side of the inlaid type floor sheet having polyvinyl chloride chip, thereby improving durability, realizing dimensional stability and balance of a product and increasing adhesive force with a construction floor.
Fig. 1 is a cross-sectional view of a conventional inlaid type floor sheet having polyvinyl chloride chip (hereinafter, called 'floor sheet').
As shown in Fig. 1, the conventional floor sheet 10 is a non-foaming type and includes an inside layer 11 which is adhered to a construction floor, a dimensionally reinforcing layer 12 which is disposed on the inside layer 11 and formed of glass fiber, a polyvinyl chloride chip layer 13 which is disposed on the dimensionally reinforcing layer 12, and a UV curable paint layer 14 which is coated on the polyvinyl chloride chip layer 13, wherein each layer is stacked in turn from a lower side to an upper side of the drawing.
As described above, the floor sheet 10 has the polyvinyl chloride chip layer 13 which provides relatively higher durability than a general PVC floor sheet, and the polyvinyl chloride chip layer 13 functions to maintain the surface shape of a product as much as possible, even though the surface of the product is worn. Therefore, the floor sheet 10 is used in some places where high durability of the product is required due to frequent use by many people. Meanwhile, as a thickness of the polyvinyl chloride chip layer 13 is increased, the durability of the floor sheet 10 is enhanced, but it is substantially limited to increase the thickness of the polyvinyl chloride chip layer 13.
Fig. 2 shows another example of the conventional floor sheet for overcoming the above-mentioned problem.
As shown in Fig. 2, the conventional floor sheet 20 is a non-foaming type and includes a polyvinyl chloride chip layer 21 and a UV curable paint layer 22 which is coated on the polyvinyl chloride chip layer 21.
Meanwhile, the floor sheet 20 which includes the dimensionally reinforcing layer 12 as shown in Fig. 1 is called 'a Hetero homogeneous type', and the floor sheet 20 which includes only the polyvinyl chloride chip layer 21 as shown in Fig. 2 is called 'a homogeneous type'.
In case of the Hetero homogeneous type floor sheet 10 shown in Fig. 1, the thickness of the polyvinyl chloride chip layer 13, which is directly associated with the durability of the product, is formed to be thin, i.e., about 1.25mm, and thus it has a durability of about 10 years. However, since it has the dimensionally reinforcing layer 12, it is advantageous to realize the dimensional stability and balance of the product and also it is facile to handle and construct it.
And in case of the homogeneous type floor sheet 10 shonw in Fig. 2, the polyvinyl chloride chip layer 21 is thicker than that of the Hetero homogeneous type floor sheet 10, and thus it has a longer durability of about 15 years. However, its dimensional stability is low, and since the polyvinyl chloride chip layer 21 formed of a hard material is directly contacted with the construction floor, it is difficult to handle and construct it.
An object of the present invention is to provide an inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof, in which a plain-weave type dimensionally reinforcing layer is provided at a lower side of the inlaid type floor sheet having polyvinyl chloride chip, thereby improving durability, realizing dimensional stability and balance of a product and increasing adhesive force with a construction floor.
The object of the present invention is not limited to this, and other objects will be understood from the below description.
To achieve the object of the present invention, the present invention provides an inlaid type floor sheet having polyvinyl chloride (PVC) chip, including an inlaid chip layer in which polyvinyl chloride is formed into chips; a UV paint layer which is coated on the inlaid chip layer; and a dimensionally reinforcing layer which is formed of a fabric and pressed on a lower surface of the inlaid chip layer at high temperature.
Preferably, the dimensionally reinforcing layer is formed of a plain weave prepared through a high temperature scouring process.
Preferably, the dimensionally reinforcing layer 130 has a grid of 1 x 1mm.
Further, the present invention provides a method of manufacturing an inlaid type floor sheet having PVC chip, including (a) transporting a dimensionally reinforcing member formed of a fabric; (b) coating PVC chips on the dimensionally reinforcing member; (c) pre-heating an intermediate molded member formed through the coating of the PVC chips; (d) pressing the intermediate molded member up and donw; and (e) coating and curing a UV curable paint on a final molded member formed through the pressing of the intermediate molded member.
Preferably, the dimensionally reinforcing member is formed of a plain weave prepared through a high temperature scouring process.
According to the inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof of the present invention, since the plain-weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.
The effect of the present invention is not limited to this, and other effects will be understood from the below description.
The above and other objects, fretures and advantages of the present invention will becom apparaent from the following description of preferred embodiments given in conjunction with the accompany drawings, in which:
Figs. 1 and 2 are cross-sectional views of a conventional floor sheet.
Fig. 3 is a cross-sectional view of an inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
Fig. 4 is a perspective view of a dimensionally reinforcing layer in the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention.
Fig. 5 is a flow chart showing a manufacturing method of the inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
[Detailed Description of Main Elements]
100: floor sheet 110: inlaid chip layer
120: UV paint layer 130: dimensionally reinforcing layer
160: dimensionally reinforcing member
170: polyvinyl chloride chip
180: intermediate molded member 190: final molded member
Hereinafter, the embodiments of the present invention will be described in detail with reference to accompanying drawings.
Fig. 3 is a cross-sectional view of an inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention, Fig. 4 is a perspective view of a dimensionally reinforcing layer in the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention, and Fig. 5 is a flow chart showing a manufacturing method of the inlaid type floor sheet having polyvinyl chloride chip according to an embodiment of the present invention.
As shown in the drawings, an inlaid type floor sheet 100 (hereinafter, called 'floor sheet') having polyvinyl chloride (PVC) chip according to an embodiment of the present invention incldues an inlaid chip layer 110 in which PVC is formed into chips, a UV paint layer 120 which is coated on the inlaid chip layer 110, and a dimensionally reinforcing layer 130 which is attached to a lower surface of the inlaid chip layer 110.
As shown in Fig. 3, the inlaid chip layer 110 is formed by coating irregular or regular shaped chips on the dimensionally reinforcing layer 130. In the embodiment, the inlaid chip layer 110 is formed to have a thickness t of 1.8 to 2.0mm which is increased by about 50% compared to the conventional one. The inlaid chip layer 110 has a great influence on the durability of the floor sheet 100. In the embodimenet, the durability of the floor sheet 100 can be remarkably increased by increasing the thickness of the inlaid chip layer 110. According to the embodiment, the thickness t of the inlaid chip layer 110 may be equal to or larger than that of the PVC chip layer 21 in the conventional homogeneous type floor sheet.
The UV paint layer 120 is formed by coating a UV paint on the inlaid chip layer 110. The UV paint layer 120 functions to prevent a liquid contaminant from be penetrated into the inlaid chip layer 110 and also allows surface contamination to be easily removed.
In the embodiment, as shown in Figs. 3 and 4, the dimensionally reinforcing layer 130 which can satisfy the dimensional stability and durability of the floor sheet 100 is attached to the lower surface of the inlaid chip layer 110. The dimensionally reinforcing layer 130 is formed into a fabric type, thereby further improving adhesive force of the floor sheet 100 with respect to a construction floor.
Meanwhile, the dimensionally reinforcing layer 130 has a desired elongation rate in all directions so as to prevent sliding of the floor sheet 100, and preferably, the dimensionally reinforcing layer 130 is fomred of a plain weave. For example, in case that the dimensionally reinforcing layer 130 is a fabric formed of braid, there is a high probability that dimensionally reinforcing layer 130 is slid on the construction floor.
In addition, since the plain weave type fabric has a bad effect on a shrinkage rate due to its weakness in heat, it is preferable that the dimensionally reinforcing layer 130 is formed into the plain weave type manufactured through a high temperature scouring process. Further, as shown in Fig. 4, the dimensionally reinforcing layer 130 is formed to have a density of 25mesh, more detailedly a grid of 1x1mm.
In other words, since the dimensionally reinforcing layer 130 is formed into the plain weave type and also formed to have a density of about 25mesh, it is possible to increase the dimensional stability of the floor sheet 100 and also to improve the balance of the floor sheet 100 in all directions. Furthermore, since the dimensionally reinforcing layer 130 is formed into the plain weave type, frictional force with respect to the construction floor is increased and thus the adhesive force of the floor sheet 100 is also increased. Herein, the dimensional stability means a degree of dimensional change of the floor sheet 100 with respect to a preset size thereof.
Hereinafter, referring to table 1, the dimensional stability and the adhesive strength in each of the floor sheet 100 of the present invention and the conventional Homogeneous floor sheet 20 will be compared. Herein, in order to test the dimensional stability, a test piece of 30cm x 30cm is put in a dry oven of about 80℃ for 6 hours and then the degree of the dimensional change is measured. Further, in order to test the adhesive strength, a test piece of 25cm x 25cm is attached to a slate plate using an aqueous acrylic adhesive and then stretched using a tensile tester so as to measure a peel strength.
[Embodiment]
The dimensional stability and the adhesive strength were measured using the floor sheet 100 in which the UV paint layer 120, the inlaid chip layer 110 and the dimensionally reinforcing layer 130 were stacked in turn.
[Comparative example]
As shown in Fig. 2, the dimensional stability and the adhesive strength were measured using the floor sheet 100 in which the UV paint layer 22 and the PVC chip layer 21 were stacked in turn.
Table 1
Comparative example (Homogeneous type) Embodiment
Dimensional stabililty (%) 0.6 0.3
Adhesive strength (Kgf) 61 82
Referring to table 1, the floor sheet 100 of the present invention has the lower degree of dimensional change and the higher adhesive strength than the conventional Homogeneous type floor sheet 20.
Hereinafter, a method (hereinafter, called "a manufacturing method") of manufacturing the inlaid type floor sheet having polyvinyl chloride chip according to the embodiment of the present invention will be described.
As shown in Fig. 5, the manufacturing method according to the present invention includes the steps of (a) transporting a dimensionally reinforcing member 160 formed of a fabric; (b) coating PVC chips on the dimensionally reinforcing member 160; (c) pre-heating an intermediate molded member 180 formed through the step (b); (d) pressing the intermediate molded member 180 up and donw; and (e) coating and curing a UV curable paint on a final molded member 190 formed through the step (d). And after the step (e), the manufacturing method further includes a step of winding the final molded member 190 passed through the step (e).
Herein, preferably, the dimensionally reinforcing member 160 is prepared through the high temperature scouring process in order to increase the dimensional stability and the adhesive strength.
As described above, since the plain-weave type dimensionally reinforcing layer is provided at the lower side of the inlaid type floor sheet having polyvinyl chloride chip, it is possible to improve the durability, realize the dimensional stability and balance of the product and increase the adhesive force with the construction floor.
While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.

Claims (5)

  1. An inlaid type floor sheet having polyvinyl chloride (PVC) chip, comprising:
    an inlaid chip layer 110 in which polyvinyl chloride is formed into chips;
    a UV paint layer 120 which is coated on the inlaid chip layer 110; and
    a dimensionally reinforcing layer 130 which is formed of a fabric and pressed on a lower surface of the inlaid chip layer 110 at high temperature.
  2. The inlaid type floor sheet according to claim 1, wherein the dimensionally reinforcing layer 130 is formed of a plain weave prepared through a high temperature scouring process.
  3. The inlaid type floor sheet according to claim 1, wherein the dimensionally reinforcing layer 130 has a grid of 1 x 1mm.
  4. A method of manufacturing an inlaid type floor sheet having PVC chip, comprising:
    (a) transporting a dimensionally reinforcing member 160 formed of a fabric;
    (b) coating PVC chips on the dimensionally reinforcing member 160;
    (c) pre-heating an intermediate molded member 180 formed through the coating of the PVC chips;
    (d) pressing the intermediate molded member 180 up and donw; and
    (e) coating and curing a UV curable paint on a final molded member 190 formed through the pressing of the intermediate molded member 180.
  5. The method according to claim 4, wherein the dimensionally reinforcing member 160 is formed of a plain weave prepared through a high temperature scouring process.
PCT/KR2012/007092 2011-09-06 2012-09-05 Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof Ceased WO2013036022A2 (en)

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CN201280043037.1A CN103781629A (en) 2011-09-06 2012-09-05 Inlaid type floor sheet having polyvinyl chloride chip and method of manufacturing thereof
US14/343,014 US20140213132A1 (en) 2011-09-06 2012-09-05 Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof

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KR20110089910A KR20130026629A (en) 2011-09-06 2011-09-06 Inlaid type floor sheet having polyvinyl chloride chip and the method of manufacturing thereof

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KR102443375B1 (en) 2018-11-26 2022-09-14 (주)엘엑스하우시스 Single-layer sheet flooring and manufacturing method thereof
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US20140213132A1 (en) 2014-07-31
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CN103781629A (en) 2014-05-07
JP2014529696A (en) 2014-11-13

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