Adhesive Wall Finish Using Compressed Plastic Panel And Method For Manufacturing The Same

Abstract

The method of manufacturing an adhesive wall finish includes forming a compressed plastic panel having first and second sides, laminating a deco sheet onto the first side using an adhesive member, wherein the deco sheet is laminated with at least one decorative pattern, obtaining a PE foam sheet having a first side and a second side, forming a first adhesive face on the PE foam sheet by applying an adhesive member to the first side of the PE foam sheet and attaching a release paper thereto, forming a second adhesive face on the PE foam sheet by applying an adhesive member to the second side of the PE foam sheet and attaching a release paper thereto, laminating the second side of the compressed plastic panel with one side of the PE foam sheet through the first adhesive face, and cutting the compressed plastic panel to certain size specifications.

Claims

1. A method for manufacturing an adhesive wall finish using compressed plastic panel, comprising: a step of using an environmentally friendly plasticizer that does not contain lead and does not contain or use phthalate plasticizer as an ingredient to produce a compressed plastic panel having a thickness of about 1 to 3 mm and comprising a rigid vinyl chloride foam panel; a step of obtaining an environmentally friendly deco sheet laminated with various patterns and comprising at least one environmentally friendly synthetic resin, selected from the group consisting of PET, PP and PVC; a step of laminating the environmentally friendly deco sheet on one side of the compressed plastic panel using an adhesive member; a step of obtaining a PE foam sheet having a thickness of about 1 to 3 mm; a step of forming a first adhesive face of the PE foam sheet, wherein an adhesive member is applied on one side of the PE foam sheet and the first adhesive face of the PE foam sheet is finished by attaching a release paper thereto; a step of forming a second adhesive face of the PE foam sheet, wherein an adhesive member is applied to an opposite side of the PE foam sheet and the second adhesive face is finished by attaching a release paper thereto; a step of laminating an opposite side of the compressed plastic panel with one side of the PE foam sheet through the first adhesive face, from which the release paper has been removed; and a step of cutting the compressed plastic panel laminated on one side with deco sheet and laminated with PE foam sheet on the other to certain size specifications.

2. The method according to claim 1, wherein the step of producing the compressed plastic panel comprises: feeding a mixture of ingredients into a hopper of an extruder; passing the mixture through a barrel heated to about 150 to 195 C. of any one of a manifold-type flat die, T-die and coat hanger type die; and passing the mixture through a cooling water bath or at least two cooling rollers to continually produce vinyl chloride foam panels having: evenly distributed closed cells; a smooth surface; a foaming rate of about 30 to 60%; a specific gravity of about 0.7 to 0.8; a tensile strength of about 150 to 170 kg/cm; a stretch of about 30 to 40%; a flexural modulus of about 8000 to 9000 kg/cm.sup.2; an impact strength of about 11 to 19 kgf/cm.sup.2; and a hardness of about 20 to 30 N/mm.sup.2.

3. The method according to claim 1, further comprising, after the step of cutting to size specifications, a chamfering step wherein corners of the compressed plastic panel are sanded down to an incline or pressed such that arranging adhesive wall finishes side by side causes a V-shaped groove to give a sense of depth.

4. An adhesive wall finish using a compressed plastic panel manufactured according to the manufacturing method of claim 1.

5. A method for manufacturing an adhesive wall finish using compressed plastic panel, comprising: a step of using an environmentally friendly plasticizer that does not contain lead and does not contain or use phthalate plasticizer as an ingredient to produce a compressed plastic panel having a thickness of about 1 to 3 mm and comprising a rigid vinyl chloride foam panel; a step of obtaining an environmentally friendly deco sheet laminated with various patterns and comprising at least one environmentally friendly synthetic resin, selected from the group consisting of PET, PP and PVC; a step of laminating the environmentally friendly deco sheet on a first side of the compressed plastic panel using an adhesive member; a step of obtaining a PE foam sheet having a thickness of about 1 to 3 mm and having a first side and a second side; a step of applying an adhesive member to a second side of the compressed plastic panel and laminating the first side of the PE foam sheet thereonto; a step of forming an adhesive face by applying an adhesive member to the second side of the PE foam sheet and finishing the adhesive face by attaching a release paper thereto; and a step of cutting the compressed plastic panel laminated on the first side with the deco sheet laminated on the second side with the PE foam sheet to certain size specifications.

6. A method for manufacturing an adhesive wall finish using compressed plastic panel, comprising: forming a compressed plastic panel having a first side and a second side; laminating a deco sheet onto the first side of the compressed plastic panel using an adhesive member, wherein the deco sheet is laminated with at least one decorative pattern; obtaining a PE foam sheet having a first side and a second side; forming a first adhesive face on the PE foam sheet by applying an adhesive member to the first side of the PE foam sheet and attaching a release paper thereto; forming a second adhesive face on the PE foam sheet by applying an adhesive member to the second side of the PE foam sheet and attaching a release paper thereto; laminating the second side of the compressed plastic panel with one side of the PE foam sheet through the first adhesive face, from which the release paper has been removed; and cutting the compressed plastic panel to certain size specifications.

7. The method according to claim 6, wherein the compressed plastic panel has a thickness of about 1 to 3 mm.

8. The method according to claim 6, wherein the compressed plastic panel comprises an environmentally friendly plasticizer that does not contain lead or phthalate plasticizer as an ingredient.

9. The method according to claim 6, wherein the compressed plastic panel comprises a rigid vinyl chloride foam panel.

10. The method according to claim 6, wherein the deco sheet comprises at least one environmentally friendly synthetic resin selected from the group consisting of PET, PP and PVC.

11. The method according to claim 6, wherein the PE foam sheet has a thickness of about 1 to 3 mm.

12. The method according to claim 6, wherein the step of forming the compressed plastic panel comprises: feeding a mixture of ingredients into an extruder; passing the mixture through a barrel heated to about 150 to 195 C.; and passing the mixture through a cooling chamber.

13. An adhesive wall finish, comprising: a compressed plastic panel having a thickness of about 1 to 3 mm, a first side and a second side, wherein the compressed plastic panel comprises a rigid vinyl chloride foam panel; a deco sheet laminated with at least one decorative pattern and comprising at least one synthetic resin, selected from the group consisting of PET, PP and PVC, wherein the deco sheet is laminated onto the first side of the compressed plastic panel using an adhesive member; and a PE foam sheet having a thickness of about 1 to 3 mm, a first side and a second side, wherein the first side of the PE foam sheet is laminated onto the second side of the compressed plastic panel using an adhesive member; wherein the second side of the PE foam sheet has an adhesive face comprising an adhesive member applied to the second side of the PE foam sheet and a removable release paper applied to the adhesive member.

14. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a foaming rate of about 30 to 60%.

15. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a specific gravity of about 0.7 to 0.8.

16. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a tensile strength of about 150 to 170 kg/cm.

17. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a stretch of about 30 to 40%.

18. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a flexural modulus of about 8000 to 9000 kg/cm.sup.2.

19. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has an impact strength of about 11 to 19 kgf/cm.sup.2.

20. The adhesive wall finish according to claim 13, wherein the compressed plastic panel has a hardness of about 20 to 30 N/mm.sup.2.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 is a perspective exploded view showing the adhesive wall finish using compressed plastic panel according to one embodiment of the present invention separated into the environmentally friendly deco sheet, the compressed plastic panel, and the PE foam sheet.

[0034] FIG. 2 is a perspective view showing the adhesive wall finish using compressed plastic panel according to one embodiment of the present invention with the environmentally friendly deco sheet, the compressed plastic panel, and the PE foam sheet joined together.

[0035] FIG. 3 is a flow chart illustrating the method for manufacturing the adhesive wall finish using compressed plastic panel according to one embodiment of the present invention.

[0036] FIG. 4 is a flow chart illustrating the method for manufacturing the adhesive wall finish using compressed plastic panel according to another embodiment of the present invention.

[0037] FIG. 5 is an enlarged view showing key parts of the adhesive wall finish using compressed plastic panel according to one embodiment of the present invention when installed on a wall surface.

DETAILED DESCRIPTION OF THE INVENTION

[0038] In the following, the present invention is explained in further detail with reference to the attached drawings. Note that, in explaining the present invention, where it is judged that detailed explanation of known relevant functions or components may unnecessary obscure the subject matter of the present invention, such detailed explanation was omitted. Further, the terms used in the following are terms defined in light of their function in the present invention, and may vary depending on users' or operators' intentions or practices. Therefore, the terms should be defined based on the entirety of the specification.

[0039] The method for manufacturing the adhesive wall finish using compressed plastic panel of the present invention comprises: a step of using an environmentally friendly plasticizer that does not contain lead and does not contain or use phthalate plasticizer as an ingredient to produce a compressed plastic panel (10) which is about 1 to 3 mm in thickness and is a rigid vinyl chloride foam panel (100); a step of obtaining environmentally friendly deco sheet (20) laminated with various patterns (21); a step of laminating the environmentally friendly deco sheet (20) on one side of the compressed plastic panel (10) using an adhesive member (120); a step of obtaining a PE foam sheet (30) having a thickness of about 1 to 3 mm (130); a step of forming an adhesive face (31) of the PE foam sheet wherein an adhesive member (31a) is applied on one side of the PE foam sheet (30) and the adhesive face (31) is finished by attaching release paper (31b) thereto (140); a step of forming an adhesive face (32) of the PE foam sheet wherein an adhesive member (32a) is applied to the other side of the PE foam sheet (30) and the adhesive face (32) is finished by attaching release paper (32b) thereto (150); a step of laminating the other face of the compressed plastic panel (10) on one side of which the deco sheet (20) is laminated with one side of the PE foam sheet (30) through the adhesive face (31) form which the release paper (31b) has been removed (160); a step of cutting the compressed plastic panel (10) laminated on one side with deco sheet (20) and laminated with PE foam sheet (30) on the other to certain size specifications (170), and; a chamfering step (180) wherein corners are sanded down to an incline or pressed so that arranging the adhesive wall finishes (1) side by side causes a V-shaped groove to give a sense of depth.

[0040] In the above, rigid vinyl chloride refers to vinyl chloride resin to which no plasticizer has been added or only a small amount thereof has been added. It refers to soft or plasticized vinyl chloride resin. Rigid vinyl chloride has good mechanical properties except impact resistance, and also has good chemical resistance, and is therefore used in pipes, the linings of chemical tanks or chemical engineering tanks, packings for refrigerator doors, signboards, and ice cream cups, etc.

[0041] In the step of producing a compressed plastic panel (10) that is a rigid vinyl chloride foam panel (100), ingredients including thermoplastic resin, which include vinyl chloride resin, foaming agent, foaming aid, heat stabilizer, processing aid, slip agent, impact modifier, plasticizer, dye, and filler are fed into a cylinder of an extruder, then melted from the heat of 150 to 195 C. from a heated barrel and pressure from a screw; are extruded in plate form out of the extruder by passing through any one of a flat manifold die, T-die or coat hanger die, and; the extruded plates pass through a cooling water bath or two or more cooling rollers, to continually produce compressed plastic panels (10) that are rigid vinyl chloride foam panel having: evenly distributed closed cells; a smooth surface; a foaming rate of about 30 to 60%; a specific gravity of about 0.7 to 0.8 (DIN53479 testing method), tensile strength of about 150 to 170 kg/cm (DIN53455), stretch of about 30 to 40% (DIN53452), flexural modulus of about 8000 to 9000 kg/cm.sup.2 (DIN53452), impact strength (Charpy) of about 11 to 19 kgf/cm.sup.2 (DIN53453), hardness (Shore Hardness) of about 20 to 30 N/mm.sup.2 (DIN53456), Vicat softening temperature of about 80 C. (DIN53460), heat distortion temperature (HDT) of about 60 C. (DIN53467), heat conduction of about 0.081 W/mK at 10 mm thickness and about 0.045 to 0.062 W/mK at 20 to 30 mm thickness (DIN52616), absorbance of about <1% (DIN53495), flame resistance that meets the UL94V-0 standard, and sound absorption of about 31 dB at 11 mm and about 34 dB at 19 mm (DIN5210).

[0042] Here, the vinyl chloride resin may be a vinyl chloride homopolymer; the foaming agent may be azodicarbonamide; the foaming aid may be para toluene zinc sulfate; the heat stabilizer may be zinc stearate; the slip agent may be high molecular weight polyethylene wax added for synergistic effects with dibasic red stearate; the processing aid may be methyl methacrylate; the impact modifier may be acrylonitrile/butadiene/styrene copolymer; the polymer may be not a phthalate plasticizer but either epoxidized linseed oil (ELO) which has been approved by the FDA for use in food or the environmentally friendly plasticizer DOTP (dioctylterephthalate); the dye may be the rutile type white titanium dioxide dye, and; the filler may be calcium carbonate.

[0043] Further, in the step of producing a compressed plastic panel (10) that is a rigid vinyl chloride foam panel (100), flame retardant agent may be added to produce flame retardant (Flame retardant Class 3) products which may be used as a flame retardant wall finish.

[0044] Epoxidized linseed oil (W-109, Oxirane oxygen: 4.8%) is an epoxy plasticizer. Epoxy plasticizers having an epoxy group generated by reacting the double bond of linseed oil or ester compounds thereof with peracetic acid or performic acid have superior heat and cold resistance, while functioning as a stabilizer. They are highly compatible with PVC, and are being used widely in applications that require non-toxicity as an indirect food additive.

[0045] Products known as environmentally friendly plasticizers are products that do not contain or use as an ingredient phthalate, which is a suspected environmental hormone. Representative environmentally friendly plasticizers available domestically include NEO-T, NEO-T3, NEO-S, PYROCIZER, OLICIZER-10N, OLICIZER-20N, and OLI-3 from Aekyung Petrochemical, GL-100, GL-300, EBN and BET from LG Chemicals, EASTMAN KODA's DOTP, Songwon Industrial Group's P series, as well as WRAPCIZER (Aekyung Petrochemical), CITROCIZER-A(ATBC) (Aekyung Petrochemical), CITROCIZER-W (Aekyung Petrochemical), NEO-A (Aekyung Petrochemical), NEO-E(Aekyung Petrochemical), LGflex EBN-W(N) (LG Chemicals), AMG (Aekyung Petrochemical, Ilshin Wells, Riken (Japan)), among others.

[0046] Among these, the greatest advantage of DOTP (dioctyl terephthalate), whose use as an environmentally friendly plasticizer is increasing, is its environmental friendliness. In various toxicity testing data announced until now, DOTP has been found to have no toxic effect on the human body, including carcinogenicity. Also, its boiling point, freezing point and density, etc. are similar to those of DOP (dioctyl phthalate; synonymous with polychloride vinyl plasticizer not only in Japan and the US, but globally; causes substances suspected to be environmental hormones), and therefore it exhibits advantages in volatility and electrical insulation.

[0047] The compressed plastic panels (10) of about 1 to 3 mm in thickness produced through the step (100) of producing a compressed plastic panel (10) have a specific gravity of about 0.7 to 0.8 (DIN53479 testing method), about 150 to 170 kg/cm (DIN53455) tensile strength, about 30 to 40% (DIN53452) stretch, flexural modulus of about 8000 to 9000 kg/cm.sup.2 (DIN53452), impact strength (Charpy) of about 11 to 19 kgf/cm.sup.2 (DIN53453) and hardness (Shore Hardness) of about 20 to 30 N/mm.sup.2 (DIN53456). Compared to conventional PVC tile products whose flexibility was high but had low hardness and were prone to thermal expansion and contraction, they are highly moisture resistance and suitably flexible to allow for processability while maintaining hardness.

[0048] The present invention is manufactured through: a step of producing a compressed plastic panel (100); a step of obtaining environmentally friendly deco sheet (20) laminated with various patterns (21), and; a step of laminating the environmentally friendly deco sheet (20) on one side of the compressed plastic panel (10) using an adhesive member (120).

[0049] This is followed by a step of obtaining a PE foam sheet (30) having a thickness of about 1 to 3 mm(130); a step of forming an adhesive face (31) of the PE foam sheet wherein an adhesive member (31a) is applied on one side of the PE foam sheet(30) and the adhesive face (31) is finished by attaching release paper (31b) thereto (140), and; a step of forming an adhesive face (32) of the PE foam sheet wherein an adhesive member (32a) is applied to the other side of the PE foam sheet (30) and the adhesive face (32) is finished by attaching release paper (32b) thereto (150).

[0050] Next are a step of laminating the other face of the compressed plastic panel (10) on one side of which the deco sheet (20) is laminated with one side of the PE foam sheet (30) through the adhesive face (31) form which the release paper (31b) has been removed (160); a step of cutting the compressed plastic panel (10) laminated on one side with deco sheet (20) and laminated with PE foam sheet (30) on the other to certain size specifications (170), and; a chamfering step (180) (270) wherein corners are sanded down to an incline or pressed so that arranging the adhesive wall finishes (1) side by side causes a V-shaped groove to give a sense of depth. This yields adhesive wall finishes of various sizes having deco sheet (20) laminated with patterning (21) on one side.

[0051] By forming, as described in the above, a deco sheet (20) laminated with patterning (21) on one side of a compressed plastic panel (10), an adhesive wall finish (1) where bending of the compressed plastic panel (10) in one direction can be prevented beforehand is obtained.

[0052] The adhesive wall finish (1) may be installed by a user by removing the release paper (32a) of the PE foam sheet (30) beneath the compressed plastic panel (10) to expose the adhesive face (32), then attaching the wall finishes on the desired indoor wall surface of a building, firmly securing the adhesive wall finishes (1).

[0053] Here, the adhesive face (32) of the adhesive wall finish (1) allows easy detaching and re-attaching if improperly attached by the consumer.

[0054] Further, by virtue of the PE foam sheet (30), the adhesive wall finish can be easily attached and fixed to wall surfaces with bumps.

[0055] Another method for manufacturing the adhesive wall finish using compressed plastic panel of the present invention comprises: a step of producing a compressed plastic panel (10) which is about 1 to 3 mm in thickness and is a rigid vinyl chloride foam panel (200); a step of obtaining environmentally friendly deco sheet (20) laminated with various patterns (21) (210); a step of laminating the environmentally friendly deco sheet (20) on one side of the compressed plastic panel (10) using an adhesive member (220); a step of obtaining a PE foam sheet (30) having a thickness of about 1 to 3 mm (230); a step of applying an adhesive member (31a) to the opposite side of the compressed plastic panel (10) on one side of which deco sheet (20) is laminated, then laminating one side of the PE foam sheet (30) thereonto (240); a step of forming an adhesive face (32) by applying an adhesive member (32a) to the other face of the PE foam sheet (30) laminated onto the other face of the compressed plastic panel (10) and finishing the adhesive face (32) by attaching release paper (32b) (250); a step of cutting the compressed plastic panel (10) laminated on one side with deco sheet (20) and laminated with PE foam sheet (30) on the other to certain size specifications (260), and; a chamfering step (180) (270) wherein corners are sanded down to an incline or pressed so that arranging the adhesive wall finishes (1) side by side causes a V-shaped groove to give a sense of depth.

[0056] The adhesive wall finish (1) of the present invention described above, by using environmentally friendly plasticizers that do not contain phthalates suspected to be environmental hormones or do not use them as ingredients, being an environmentally friendly product, does not cause any problems to the human body with respect to environmental hormones even when used as a finish for building wall surfaces. Further, it has strong moisture resistance, flexibility and sound insulation, while maintaining processability and high strength to allow for easy firsthand cutting and processing by consumers and make possible great savings in the overall cost of production.

[0057] The physical properties of the adhesive wall finish (1) of the present invention and conventional PVC tile are compared in Table 1 below:

TABLE-US-00001 Conventional Adhesive tile of the PVC invention Test Item Unit SPEC tile #1 #2 #3 Average Residual indentation % 8 2.8~5.7 32.44 30.56 29.28 30.76 Indentation 20 mm 0.25 0.33~0.36 0.78 0.80 0.76 0.78 45 mm 1.20 0.45~0.65 0.92 0.92 0.92 0.92 Heating loss % 0.50 0.10~0.19 1.54 1.17 1.17 1.29 Length change MD % 0.25 0.04~0.07 2.62 under heat CD % 0.25 0.04~0.07 0.86

[0058] That is, in the adhesive wall finish (1) of the present invention, use of a rigid vinyl chloride foam board ensures strength, flexibility and processability of the product. Whereas the material is rigid, being a foam, it can be easy cut as needed by a consumer using a box cutter or scissors. Also, while flexible, the material is not soft, and is able to maintain a flat surface.

[0059] Further, the adhesive wall finish (1) of the present invention is a sticker type product which can be installed quickly and conveniently firsthand by a consumer at a low cost. By using PE foam on the rear adhesive face, the wall finish adheres well even to uneven wall surfaces. Also, as the finished product is in the shape of a panel or tile, it is possible to give a 3D effect.

[0060] Additionally, the adhesive wall finish (1) of the present invention, being made of synthetic resin material, has high moisture resistance, and, being a foam product, has a certain noise proofing effect. By laminating the surface with synthetic resin, it is possible to realize various colors and patterns.

[0061] Explanation of referenced features shown in the drawings:

TABLE-US-00002 1: Adhesive wall finish 10: Compressed plastic panel 20: Deco sheet 21: Patterning 30: PE foam sheet 31: Adhesive face 31a: Adhesive member 31b: Release paper 32: Adhesive face 32a: Adhesive member 32b: Release paper 100: Compressed plastic panel producing step 110: Step of laminating pattern to obtain deco sheet 120: Step of laminating deco sheet 130: Step of obtaining PE foam sheet 140: Step of forming PE foam sheet adhesive face 150: Step of forming PE foam sheet adhesive face 160: Step of laminating PE foam sheet 170: Step of cutting to specification 180: Chamfering step 200: Compressed plastic panel producing step 210: Step of laminating pattern to obtain deco sheet 220: Step of laminating deco sheet 230: Step of obtaining PE foam sheet 240: Step of laminating PE foam sheet 250: Step of forming PE foam sheet adhesive face 260: Step of cutting to specification 270: Chamfering step.