WO2014073792A1 - Floor tile and manufacturing method thereof - Google Patents

Abstract

Provided is a floor tile, comprising a surface treatment layer, a fabric layer, an acrylic-based binding layer, and a thermoplastic resin support layer, sequentially.

Description

Floor tile and its manufacturing method

A floor tile and a method of manufacturing the same.

In general, textile flooring is mainly made of carpet and carpet tiles, and these products have to be completely bonded to the floor during construction, and in particular, carpet tiles have to be aligned per piece, which is very cumbersome and time-consuming. In addition to the use, surface contamination, mold and bacteria propagation, dust generation, allergies, etc., caused by the demand is rapidly decreasing.

In addition, the prior art of the Republic of Korea Patent Publication No. 2002-0012044 consists of a surface layer consisting of a fabric and finished with a UV paint, in this configuration, the fabric is exposed to the top, the problem of damage to the fabric during use Have

In another conventional technique, the flooring material described in Utility Model Publication No. 98-012486 expresses a textile effect by gravure or transfer printing and prints a predetermined pattern on the glass fiber sheet layer, which is a base layer, and combines it with the vinyl chloride resin layer. By showing the fiber effect and at the same time had the convenience of construction, bacterial suppression, contaminants, etc., compared to the fabric had a disadvantage that can not escape the monotony of the appearance by the flat printing.

In addition, there is a flooring material integrating a glass fiber sheet layer with a colored fiber layer and a gravure printed vinyl chloride resin layer described in Korean Patent Publication No. 95-005535. There is a problem that can not escape the monotony of the appearance just to express the feeling of the fiber by.

In one embodiment of the invention, while providing a luxurious appearance of the natural fabric texture, it is intended to provide a floor tile that is easy to maintain.

In another embodiment of the present invention, a method of manufacturing the floor tile is provided.

In one embodiment of the present invention, there is provided a floor tile comprising a surface treatment layer, a fabric layer, an acrylic bonding layer and a thermoplastic resin support layer sequentially.

The fabric layer is cotton, hemp, wool, rayon, nylon, polyester (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polylactic acid (PLA), and combinations thereof It may include a fabric made from a fiber yarn selected from the group consisting of.

The thermoplastic resin support layer may include a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof.

The acrylic bonding layer may include a plastic material selected from the group consisting of 2-ethylhexyl acrylate, butyl acrylate, methyl acrylate, and combinations thereof.

The acrylic bonding layer may have a thickness of about 10 ㎛ to about 100 ㎛.

The surface treatment layer may include a thermosetting resin or an ultraviolet curable resin selected from the group consisting of polyurethane, polyacryl, and combinations thereof.

The floor tile may further include a dimensionally stable layer between the acrylic bonding layer and the thermoplastic resin support layer.

The dimensionally stable layer may comprise glass fibers.

The floor tile may further include a structural balance layer between the acrylic bonding layer and the dimensionally stable layer.

The structural balance layer may include a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof.

In another embodiment of the invention, preparing a thermoplastic resin support layer and a fabric layer; Forming a coating layer by applying a composition for forming an acrylic bonding layer on the thermoplastic resin support layer; Forming a laminated structure by laminating the fabric layer on a coating layer of the coated acrylic bonding layer forming composition; Heat-treating the laminated structure by applying pressure to plywood; And forming a surface treatment layer on the fabric layer of the outermost laminated laminate structure.

The heat treatment may be performed at about 80 to about 130 ℃.

The heat treatment may be carried out by pressing to about 0.5 to about 5 kgf / cm ² when plywood.

Before applying the composition for forming an acrylic bonding layer on the thermoplastic resin support layer, a dimensional stability layer may be laminated and formed, and then the composition for forming an acrylic bonding layer may be applied onto the dimensional stability layer.

Before applying the composition for forming the acrylic bonding layer on the dimensionally stable layer, a structural balance layer may be laminated and formed, and then the composition for forming the acrylic bonding layer may be applied onto the structural balance layer.

The floor tiles provide a luxurious appearance of natural fabric texture, while being easy to maintain.

1 is a cross-sectional view of a floor tile 100 according to one embodiment of the invention.

2 is a cross-sectional view of a floor tile 200 according to another embodiment of the present invention.

3 is a cross-sectional view of a floor tile 300 according to another embodiment of the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.

In order to clearly describe the present invention, parts irrelevant to the description are omitted, and like reference numerals designate like elements throughout the specification.

In the drawings, the thickness of layers, films, panels, regions, etc., are exaggerated for clarity. In the drawings, the thicknesses of layers and regions are exaggerated for clarity.

In the following, any configuration is formed on the "top (or bottom)" of the substrate not only means that the arbitrary configuration is formed in contact with the upper surface (or lower surface) of the substrate, but also on the substrate and the substrate (or It is not limited to not including any other configuration between any of the configurations formed under).

Hereinafter, a floor tile according to an embodiment of the present invention will be described with reference to FIG. 1.

1 is a cross-sectional view of a floor tile 100 according to one embodiment of the invention. The floor tile 100 sequentially includes a surface treatment layer 110, a woven layer 120, an acrylic bonding layer 130, and a thermoplastic resin support layer 140.

The floor tile 100 includes a fabric layer 120 made of fabric, while providing a luxurious appearance of a natural fabric texture, and includes a surface treatment layer 110 for easy maintenance.

The fabric included in the fabric layer 120 is cotton, hemp, wool, rayon, nylon, polyester (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polylactic acid ( It is a sheet made using fiber yarn produced using PLA) as a raw material, and the fabric is divided into two types, which are textile sheets which are woven by a general weaving machine or by using a jacquard weaving method. . Thus, various types of fabrics can be used as they are or fabricated by impregnating resin (impregnating agent) and drying or impregnating with PVC sol and gelling.

The surface treatment layer 120 is to improve stain resistance, scratch resistance, abrasion, durability, etc. on the top of the floor tile 100, and apply a heat curable or ultraviolet curable resin such as polyurethane-based or polyacryl and heat Alternatively, the surface treatment layer 120 may be formed by UV curing. Since the surface treatment layer 120 prevents contaminants from penetrating into the fabric layer 120, it is possible to overcome the disadvantages of dust blowing and dirt removal, which are disadvantages of existing carpet tiles, and as a result, the floor tiles ( 100 is easy to maintain and manage. The surface treatment layer 120 may be formed to a thickness of about 10 ㎛ to about 30 ㎛.

The thermoplastic resin support layer 140 may include a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof.

The acrylic bonding layer 130 may be disposed between the fabric layer 120 and the thermoplastic resin support layer 140 to laminate both layers.

The acrylic bonding layer 130 may include a plastic material selected from the group consisting of acrylic resins, for example, 2-ethylhexyl acrylate, butyl acrylate, methyl acrylate, and combinations thereof. To directly bond the thermoplastic resin support layer 140 and the fabric layer 120, the plywood should be plywood at a high temperature, for example, about 130 ° C., but the floor tile 100 may have the acrylic bonding layer 130. ) Is interposed between the thermoplastic resin support layer 140 and the fabric layer 120, thereby imparting a bonding force even at a much lower temperature than the case where the thermoplastic resin support layer 140 and the fabric layer 120 are directly bonded. You can do it. For example, the floor tile 100 may be manufactured by applying a bonding force by applying pressure and heat at about 80 to about 130 ° C. Since the floor tile 100 may process the temperature range, damage of the fabric layer 120 may be minimized.

The acrylic bonding layer may have a thickness of about 10 ㎛ to about 100 ㎛, it can be given excellent bonding strength in the above range.

The floor tile 100 is implemented as a resin-based floor tile having a fabric surface by the structure, as described above to be useful as a floor decoration material that can produce a differentiated space design by implementing a luxurious appearance of the natural fabric texture Can be.

2 is a cross-sectional view of a floor tile 200 according to another embodiment of the present invention. The floor tile 200 sequentially includes a surface treatment layer 210, a fabric layer 220, an acrylic bonding layer 230, a dimensionally stable layer 250, and a thermoplastic resin support layer 240.

As shown in FIG. 2, the floor tile 200 may further include a dimension stabilization layer 250 between the acrylic bonding layer 230 and the thermoplastic support layer 240.

The dimensional stability layer 250 may provide dimensional stability according to the temperature change. The dimensionally stable layer 250 may include glass fiber. For example, glass fibers and pulp are properly mixed with a binder to prepare a sheet, and the sheet is impregnated with a vinyl chloride sol and then gelled to form a sheet. It may be a layer.

3 is a cross-sectional view of a floor tile 300 according to another embodiment of the present invention. The floor tile 300 sequentially includes a surface treatment layer 310, a fabric layer 320, an acrylic bonding layer 330, a structural balance layer 360, a dimensional stability layer 350, and a thermoplastic resin support layer 340. Include.

As shown in FIG. 3, the floor tile 300 may further include the structure balance layer 360 between the acrylic bonding layer 330 and the dimensional stability layer 350. The floor tile 300 includes the structural balance layer 360 together with the dimension stabilization layer 350 to balance the structure of the upper and lower parts, and when the structural balance is not correct, the floor tile is bent up and down. The warping can be prevented and as a result, the ease of construction can be improved.

The structural balance layer 360 may be formed of a resin sheet including a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof. have.

In another embodiment of the present invention, preparing a thermoplastic resin support layer and a fabric layer; Forming a coating layer by applying a composition for forming an acrylic bonding layer on the thermoplastic resin support layer; Forming a laminated structure by laminating the fabric layer on a coating layer of the coated acrylic bonding layer forming composition; Heat-treating the laminated structure by applying pressure to plywood; And forming a surface treatment layer on the fabric layer of the outermost laminated laminate structure. The floor tile described above may be manufactured by the method of manufacturing the floor tile.

Each layer included in the floor tile may be manufactured according to a known method using the above-described materials, and a lamination method may also use a known method, and is not limited to a specific method.

In addition, each layer formed to be included in the floor tile may include not only the materials described above, but also known and suitable additives such as plasticizers, thermal stabilizers, light stabilizers, antioxidants, lubricants, fillers, etc., or combinations thereof, depending on the use and need. It may include.

The heat treatment may be performed at about 80 to about 130 ℃. Since the bonding force can be imparted using the acrylic bonding layer when the fabric layer is laminated, it is possible to heat-treat within a temperature not exceedingly high, that is, within the range.

In plywood, the heat treatment may be carried out by pressurization, for example at a pressure of about 0.5 to about 5 kgf / cm ² .

As described above, the floor tile may be manufactured by further stacking the dimensionally stable layer and / or the structural balance layer. In one embodiment, prior to applying the composition for forming the acrylic bonding layer on the thermoplastic resin support layer is formed by laminating a dimensional stability layer, and then applying a composition for forming the acrylic bonding layer on the dimensional stability layer and then heat treatment Can be plywood In another embodiment, the structural balance layer is formed by laminating a dimensional stability layer before applying the composition for forming the acrylic bonding layer on the thermoplastic resin support layer, and applying the composition for forming the acrylic bonding layer on the dimensional stability layer. Forming by laminating, and then applying a composition for forming an acrylic bonding layer on the structural balance layer may be laminated by heat treatment.

The method of laminating the dimensional stability layer and the structural balance layer may also be performed according to a known method, and is not limited to a specific method.

Hereinafter, examples and comparative examples of the present invention are described. Such following examples are only examples of the present invention, and the present invention is not limited to the following examples.

(Example)

Example 1

A 2 mm thick, 120 mm long PVC support layer was prepared. The support layer was prepared by mixing and gelling using a 2bon roll using a composition comprising 100 phr of PVC, 500 phr of filler, 30 phr of plasticizer and 1 phr of lubricant. An acrylic bonding layer was coated to a thickness of 65 μm by using a coating bar on the prepared PVC support layer. The component of the acrylic bonding layer was prepared by including 20 parts by weight of 2-ethylhexyl acrylate, 20 parts by weight of butyl acrylate, 10 parts by weight of methyl acrylate, 50 parts by weight of butyl acrylate and an aziridine-based curing agent. The acrylic bonding layer coated PVC support layer was put in an 85 ° C. oven to volatilize the solvent of the acrylic bonding layer. The acrylic bonding layer coated PVC support layer was aged in a 45 ° C. oven for 36 hours to allow the acrylic bonding layer to sufficiently polymerize.

Put the fabric layer of the structure coated with PVC on the PET core on the acrylic bonding layer and put it on the press device maintaining the temperature condition of 85 ℃, pressurized for 30 seconds at a pressure of 0.75 kgf / cm ² and then cooled to room temperature The sample was taken out, and then the polyurethane-based thermosetting resin composition was applied and cured to form a surface treatment layer to prepare a floor tile sample laminated with a surface treatment layer, a fabric layer, an acrylic bonding layer and a thermoplastic resin support layer.

The side surfaces were cut so that the prepared floor tile samples were each 100 mm long.

Comparative Example 1

Without forming the acrylic bonding layer in Example 1, the fabric layer was directly placed on the PVC support layer and plywood in the same manner as in Example 1 to prepare a floor tile sample.

Experimental Example

For the samples of Example 1 and Comparative Example 1, the plywood force between the upper fabric layer and the lower PVC support layer was measured using a tensioner and the results are shown in Table 1 below.

Table 1 division Tensile strength (kg / cm²) Remarks Example 1 2.5 - Comparative Example 1 0.0 Not joined             

[Description of the code]

100, 200, 300: floor tiles

110, 210, 310: surface treatment layer

120, 220, 320: fabric layer

130, 230, 330: acrylic bonding layer

140, 240, 340: thermoplastic support layer

250, 350: dimensionally stable layer

360: structure balance layer

Claims (15)

A floor tile comprising a surface treatment layer, a fabric layer, an acrylic bonding layer and a thermoplastic support layer sequentially. The method of claim 1, The fabric layer is cotton, hemp, wool, rayon, nylon, polyester (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polylactic acid (PLA), and combinations thereof Fabric comprising a fiber yarn selected from the group consisting of Floor tiles. The method of claim 1, The thermoplastic resin support layer may include a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof. Floor tiles. The method of claim 1, The acrylic bonding layer includes a plastic material selected from the group consisting of 2-ethylhexyl acrylate, butyl acrylate, methyl acrylate, and combinations thereof. Floor tiles. The method of claim 1, The acrylic bonding layer has a thickness of 10 ㎛ to 100 ㎛ Floor tiles. The method of claim 1, The surface treatment layer includes a thermosetting resin or an ultraviolet curable resin selected from the group consisting of polyurethane, polyacryl, and combinations thereof. Floor tiles. The method of claim 1, The floor tile further includes a dimensionally stable layer between the acrylic bonding layer and the thermoplastic resin support layer. Floor tiles. The method of claim 7, wherein The dimensionally stable layer comprises a glass fiber Floor tiles. The method of claim 7, wherein The floor tile further includes a structural balance layer between the acrylic bonding layer and the dimensionally stable layer. Floor tiles. The method of claim 9, The structural balance layer includes a plastic material selected from the group consisting of polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polylactic acid, polyurethane, rubber, and combinations thereof. Floor tiles. Preparing a thermoplastic support layer and a fabric layer; Forming a coating layer by applying a composition for forming an acrylic bonding layer on the thermoplastic resin support layer; Forming a laminated structure by laminating the fabric layer on a coating layer of the coated acrylic bonding layer forming composition; Heat-treating the laminated structure by applying pressure to plywood; And Forming a surface treatment layer on the fabric layer of the outermost laminated structure Method of manufacturing a floor tile comprising a. The method of claim 11, The heat treatment is carried out at 80 to 130 ℃ Method of manufacturing floor tiles. The method of claim 11, Pressurized to 0.5 to 5 kgf / cm ² when the heat treatment by plywood Method of manufacturing floor tiles. The method of claim 11, Before applying the composition for forming the acrylic bonding layer on the thermoplastic resin support layer, a dimensional stabilization layer is formed by laminating, and then the composition for forming the acrylic bonding layer is applied onto the dimensional stability layer. Method of manufacturing floor tiles. The method of claim 14, Before applying the composition for forming the acrylic bonding layer on the dimensional stability layer is formed by laminating a structural balance layer, and then applying the composition for forming the acrylic bonding layer on the structural balance layer. Method of manufacturing floor tiles.

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