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CA-3151985-C - TILE-TYPE DECORATIVE FLOORING MATERIAL COMPRISING NON-SLIP FOAM, AND METHOD FOR MANUFACTURING SAME

CA3151985CCA 3151985 CCA3151985 CCA 3151985CCA-3151985-C

Abstract

The present invention relates to a flooring material part including a surface-processed layer, a clear layer, a design-print layer and an underlayer; and a micro-embossed plastic foam part including a plastic foam layer and an adhesive film layer with micro-embossing. The present invention may provide the tile-type decorative flooring material with a significant improvement in terms of slippage between the product and the floor surface in a construction process not using an adhesive.

Inventors

  • Dong Jin OH

Assignees

  • DONGSHIN POLYMER CO., LTD.
  • SHINKOKASEI CO., LTD.

Dates

Publication Date
20260505
Application Date
20210128
Priority Date
20200210

Claims (11)

  1. What is claimed is: 1. A tile-type decorative flooring material comprising: a flooring material part including a surface-processed layer, a clear layer, a designprint layer, and an underlay er; a micro-embossed plastic foam part including a plastic foam layer and an adhesive film layer; the adhesive film layer having a micro-embossing in which irregularities having a depth (a) are provided at regular intervals (b), and the micro-embossing satisfies an expression a~ 1/3 * b, wherein: 0.08 mm::; a::; 0.8 mm, and 0.2 mm::; b::; 2 mm; the tile-type decorative flooring material having a coefficient of friction of 40 to 56 tested by using a pendulum ofBS-7976-2.
  2. 2. The tile-type decorative flooring material of claim 1, wherein the plastic foam layer includes 3 to 10 parts by weight of an azodicarbonamide foaming agent, 0.2 to 1.5 parts by weight of an accelerator, 0.1 to 1 part by weight of a foam stabilizer, and other additives, based on 100 parts by weight of olefin-based resin, and is a layer formed after extrusion processed and then foamed.
  3. 3. The tile-type decorative flooring material of claim 1, wherein the adhesive film layer includes 0.1 to 1 part by weight of an antioxidant, 0.1 to 1 part by weight of a processing aid, and other additives, based on 100 parts by weight of olefin-based resin, and is an olefine-based film having a thickness of 10 μm to 200 μm. 23 303080667.1 Date Re9ue/Date Received 2024-04-29
  4. 4. The tile-type decorative flooring material of claim 1, wherein the adhesive film layer is a PVC film having a thickness of 10 μm to 200 μm, the PVC film includes: PVC resin, 30 to 60 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, and other additives based on 100 parts by weight of PVC resin.
  5. 5. The tile-type decorative flooring material of claim 1, wherein the surface-processed layer has a thickness of 5 μm to 20 μm and is a layer in which a composition is hardened by ultraviolet rays; and, wherein the composition includes 20 to 40 parts by weight of monoester, 10 to 20 parts by weight of oligomer, 10 to 20 parts by weight of poly diacrylate, 0.5 to 5 parts by weight of silicon, and other additives.
  6. 6. The tile-type decorative flooring material of claim 1, wherein the clear layer includes PVC resin, 10 to 50 parts by weight of plasticizer, 1 to 5 parts by weight of a stabilizer, and other additives, based on 100 parts by weight of PVC resin and is a layer having a thickness of 0 .1 mm to 1 mm.
  7. 7. The tile-type decorative flooring material of claim 1, wherein the design-print layer includes PVC resin, 1 to 20 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 0 to 20 parts by weight of a filler, 1 to 5 parts by weight of a processing aid, and other additives based on 100 parts by weight of PVC resin, and is a layer having a thickness of 0.05 mm to 0.2 mm.
  8. 8. The tile-type decorative flooring material of claim 1, wherein the underlayer includes PVC resin, 10 to 60 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 50 to 600 parts by weight of a filler, 1 to 5 parts by weight of a processing aid, and other additives, based on 100 parts by weight of PVC resin, and is a layer having a thickness of 0.5 mm to 5 mm. 24 303080667.1 Date Re9ue/Date Received 2024-04-29
  9. 9. The tile-type decorative flooring material of claim 1, wherein the flooring material part further includes an intermediate layer provided between the design-print layer and the underlayer, in which the intermediate layer includes PVC resin, 10 to 60 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 50 to 500 parts by weight of a filler, 1 to 5 parts by weight of a processing aid, and other additives, based on 100 parts by weight of PVC resin, and is a layer having a thickness of 0.2 mm to 2 mm.
  10. 10. The tile-type decorative flooring material of claim 1, wherein the flooring material part further includes at least one layer selected from the group consisting of an intermediate layer, a dimension reinforcement layer, and a balance layer, the intermediate layer includes PVC resin, 10 to 60 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 50 to 500 parts by weight of a filler, 1 to 5 parts by weight of a processing aid, and other additives, based on 100 parts by weight of PVC resin, and is a layer having a thickness of 0.2 mm to 2 mm, the dimension reinforcement layer includes PVC paste resin, 50 to 90 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 10 to 150 parts by weight of a filler, 2 to 10 parts by weight of a viscosity modifier, and other additives, based on 100 parts by weight of PVC paste resin, and is a layer formed by impregnating a glass fiber mat in a liquid paste sol and heat-hardening the impregnated glass fiber mat, and the balance layer includes PVC resin, 10 to 60 parts by weight of a plasticizer, 1 to 5 parts by weight of a stabilizer, 50 to 500 parts by weight of a filler, 1 to 5 parts by weight of a processing aid, and other additives, based on 100 parts by weight of PVC resin, and is a layer having a thickness of 0.3 mm to 3 mm.
  11. 11. A method for manufacturing a tile-type floor decorative flooring material, the method compnsmg: forming a flooring material part by laminating an underlayer, a design-print layer, a clear layer, and a surface-processed layer; 303080667.1 Date Re9ue/Date Received 2024-04-29 forming a plastic foam layer by extruding a plastic foam layer composition on a rear surface of the underlayer, and electron beam crosslinking, and then foaming or chemical foaming the composition; and, forming an adhesive film layer by adhering an adhesive film layer composition to a rear surface of the plastic foam layer while extruding the adhesive film layer composition and simultaneously providing micro-embossing by using an emboss roll, the micro-embossing having irregularities having a depth (a) provided at regular intervals (b) to satisfy an expression a 2:: 1/3 * b, wherein: 0.08 mm :Sa :S 0.8 mm, and 0.2 mm :Sb :S 2 mm; the tile-type decorative flooring material having a coefficient of friction of 40 to 56 tested by using a pendulum ofBS-7976-2. 26 303080667.1 Date Re9ue/Date Received 2024-04-29

Description

TILE-TYPE DECORATIVE FLOORING MATERIAL COMPRISING NONSLIP FOAM, AND METHOD FOR MANUFACTURING SAME S [Technical Field] The present invention relates to a decorative flooring material applicable to a bottom or floor of a building, and more particularly, to a tile-type decorative flooring material with a significant improvement in terms of slippage 10 between the product and the floor surface in a construction process not using an adhesive in tile-structured products cut and constructed in unit sizes among decorative flooring material products. [Background Art] The background art of the present disclosure provided herein may not necessarily mean known art. In general, (decorative) flooring materials such as flooring pads or tiles are installed on a bottom or floor of a building. The flooring materials such as flooring pads or 20 tiles are manufactured using vinyl chloride as a main material that is light, flexible, and excellent in cushioning and sound-absorbing properties. For example, the flooring material is manufactured by mixing or laminating other materials with polyvinyl chloride (PVC) or vinyl chloride. 25 The above flooring material is usually laminated in multiple CA 03151985 2022- 3- 21 1 layers such as a clear layer, a printed layer, a resinimpregnated dimension reinforcement layer, a foaming layer, and an underlayer, in which the clear layer has a function of protecting an ink side printed on the printed layer, the 5 printed layer has a decorative function of giving a color or pattern, the resin-impregnated dimension reinforcement layer refers to a glass-fiber impregnated with PVC paste sol and has a function of reinforcing dimensional safety of a product, the foam layer has a function of providing 10 cushioning, and the underlayer has a function of reinforcing a thickness and anchoring with a floor surface. In addition a surface-processed layer for improving abrasion resistance or scratch resistance may be further formed on the top of the clear film layer as needed. The 15 above flooring material is produced by adding or subtracting each layer according to the purpose, and used in a wide range of fields. For example, the following Patent Document 1 applied by the applicant of the present disclosure and registered 20 discloses a technology related to the method for manufacturing of a decorative flooring material in which glass fiber or rock wool is prepared into a sheet between an upper PVC layer and a lower PVC layer to form a glass fiber mat layer, a printing layer and a clear film layer formed of 25 PVC resin are sequentially formed on the top of a base layer CA 03151985 2022- 3- 21 2 prepared by hot pressing the glass fiber mat layer, and a balance layer composed of PVC resin, plasticizers and fillers is formed under the bottom of the base layer. The flooring material of the above configuration may be used solely or 5 used after attached to various types of adherends with an adhesive therebetween in the process of finishing the floor of the building. In addition recently, in order to remove the odor caused by using adhesives and minimize the influence of 10 volatile organic compounds, flooring materials having an anti-slip function have been developed for forming a functional layer under the base layer to prevent the slip, thereby minimizing the use of adhesives during construction. Meanwhile, in the case of general flooring materials, 15 especially floor tiles cut into a unit size, an adhesive is applied to the floor and the tiles are installed thereon, and accordingly, it is common to minimize changes in dimensions after the tiles adhere to the floor. However, recently, the maleficence of adhesives are highlighted, and 20 flooring materials for minimizing changes in dimensions have been developed. Thus, loose-lay products, which are installed without applying adhesives or installed by simply placing the products with a small amount of adhesive on the floor, have been variously developed, and spotlighted as products 25 facilitating the installation, reducing costs, and having no CA 03151985 2022- 3- 21 3 harmful effects of adhesives. In general, the loose-lay product is manufactured by laminating a material, which has excellent adhesion to the floor, on a rear surface of the flooring material. Regarding 5 a product to which an olefin-based foam combined with polyethylene, polypropylene or the like adheres for absorbing impact sound, the foam has poor adhesion to the floor, and accordingly the loose-lay construction fails due to the slip. Thus, the adhesive is required to be used. 10 In order to improve this, conducted, such as treating a various attempts are being treatment agent having an adhesive function on a rear surface of plastic foam or laminating an adhesive sheet. However, adhesion during storage, that is a blocking, is caused, adhesive components 15 are transferred, or a surface layer of the flooring material is damaged. In particular, to improve the above problems, Patent Applicati