SOUND INSULATION AND NON-SLIP FLOORING MATERIAL AND METHOD OF PRODUCING THE SAME

Abstract

A sound insulation and non-slip flooring material, which is formed by laminating a plurality of layers through a calender rolling process such that a sound insulation and non-slip function is formed by utilizing a foaming agent contained in a non-slip functional film, and a method of producing the same are provided. The sound insulation and non-slip flooring material is formed by laminating a plurality of layers through a calender rolling process and includes a glass fiber layer interposed between the layers, an ultraviolet coating layer provided at an upper layer among the layers, and a sound insulation and non-slip layer provided at a lower layer among the layers. A non-slip function, a cushion feel, a shock absorption function, and floor serviceability, warming, insulation, soundproof, and dustproof effects of the flooring material are obtained.

Claims

1. A sound insulation and non-slip flooring material formed by laminating a plurality of layers through a calender rolling process, the sound insulation and non-slip flooring material comprising: a glass fiber layer interposed between the layers; an ultraviolet coating layer provided at an upper layer among the layers; and a sound insulation and non-slip layer provided at a lower layer among the layers.

2. The sound insulation and non-slip flooring material of claim 1, wherein the layers comprise a surface layer, a printing layer, an intermediate layer, an underlayer, and a balance layer, the glass fiber layer is interposed between the intermediate layer and the underlayer, the ultraviolet coating layer is provided on the surface layer, and the sound insulation and non-slip layer is coated on a lower portion of the balance layer.

3. The sound insulation and non-slip flooring material of claim 2, wherein the surface layer, the printing layer, and the balance layer include polyvinyl chloride (PVC) and a plasticizer, and wherein the intermediate layer, the underlayer, and the sound insulation and non-slip layer include the polyvinyl chloride (PVC), the plasticizer, and a reinforcement inorganic filler including a calcium carbonate (CaCO.sub.3).

4. The sound insulation and non-slip flooring material of claim 3, wherein the intermediate layer further comprises powders of a hydrous magnesium silicate mineral or elvan powders.

5. The sound insulation and non-slip flooring material of claim 2, wherein the flooring material has a whole thickness of 4.4 mm to 4.6 mm, the surface layer has a thickness of 0.40 mm to 0.70 mm, the printing layer has a thickness of 0.05 mm to 0.10 mm, the intermediate layer has a thickness of 0.5 mm to 0.8 mm, the glass fiber layer has a thickness of 0.35 mm to 0.55 mm, the underlayer has a thickness of 1.8 mm to 2.5 mm, the balance layer has a thickness of 0.2 mm to 1.0 mm, the sound insulation and non-slip layer has a thickness of 0.20 mm to 0.70 mm, and the ultraviolet coating layer has a thickness of 5 m to 12 m.

6. A method of producing a sound insulation and non-slip flooring material by laminating a plurality of layers through a calender rolling process, the method comprising: (a) separately providing an underlayer, an intermediate layer, a balance layer coated with a sound insulation and non-slip layer, a glass fiber layer, a printing layer, and a surface layer; (b) interposing and laminating the glass fiber layer between the underlayer and the intermediate layer through the calendar rolling process; (c) laminating the printing layer to an upper portion of the intermediate layer that is laminated in step (b); (d) laminating the surface layer to an upper portion of the printing layer that is laminated in step (c); (e) laminating the balance layer coated with the sound insulation and non-slip layer to a lower portion of the underlayer; and (f) performing ultraviolet coating with respect to an upper portion of the surface layer that is laminated in step (d).

7. The method of claim 6, wherein the surface layer, the printing layer, and the balance layer include polyvinyl chloride (PVC) and a plasticizer, and wherein the intermediate layer, the underlayer, and the sound insulation and non-slip layer include the polyvinyl chloride (PVC), the plasticizer, and a reinforcement inorganic filler including a calcium carbonate (CaCO.sub.3).

8. The method of claim 7, wherein the surface layer includes 25-35 weight parts of the plasticizer based on 100 weight parts of the polyvinyl chloride (PVC), the printing layer includes 6-10 weight parts of the plasticizer based on 100 weight parts of the polyvinyl chloride (PVC), the intermediate layer includes 40-60 weight parts of the plasticizer and 400-550 weight parts of the reinforcement inorganic filler including the calcium carbonate (CaCO.sub.3) based on 100 weight parts of the polyvinyl chloride (PVC), the underlayer includes 40-60 weight parts of the plasticizer and 400-550 weight parts of the calcium carbonate (CaCO.sub.3) based on 100 weight parts of the polyvinyl chloride (PVC), the balance layer includes 20-30 weight parts of the plasticizer based on 100 weight parts of the polyvinyl chloride (PVC), and the sound insulation and non-slip layer includes 80-100 weight parts of the plasticizer, 10-30 weight parts of the calcium carbonate (CaCO.sub.3), and 6-10 weight parts of a foaming agent based on 100 weight parts of the polyvinyl chloride (PVC), wherein the glass fiber layer is formed by mixing 60-90 weight parts of the plasticizer, and 50-70 weight parts of the reinforcement inorganic filler including the calcium carbonate (CaCO.sub.3) based on 100 weight parts of the polyvinyl chloride (PVC), providing the mixture in a sol state into a container, impregnating the container with glass fiber, and drying the glass fiber, and wherein the foaming agent includes a foaming cell formed at a foaming ratio of 180-250%.

9. The method of claim 8, wherein the laminating in the step (b) to step (e) is performed at a temperature of 150-170 C., under pressure of 4-6 kg/cm.sup.2, and at a speed of 15-25 m/mins.

10. The method of claim 8, wherein the surface layer, the printing layer, the intermediate layer, the underlayer, and the balance layer are formed at a temperature of 150-180 C. and a speed of 35-45 m/mins.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 is a sectional view showing a sound insulation and non-slip flooring material produced using PVC according to the present invention.

[0032] FIG. 2 is a flowchart the production process of the sound insulation and non-slip flooring material using the PVC according to the present invention.

[0033] FIG. 3 is a photograph showing a UV coating layer of FIG. 1.

[0034] FIG. 4 is a photograph showing the sound insulation and non-slip flooring material of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0035] The object, other objects, and features of the present invention can be more concretely comprehended on the basis of the present description and accompanying drawings.

[0036] Hereinafter, the configuration of the present invention will be described with reference to accompanying drawings.

[0037] FIG. 1 is a sectional view showing a sound insulation and non-slip flooring material produced using polyvinyl chloride (PVC) according to the present invention.

[0038] As shown in FIG. 1, the sound insulation and non-slip flooring material according to the present invention is formed by laminating a plurality of layers through a calender rolling process, and includes a glass fiber layer 30 interposed between the layers, an ultraviolet (UV) coating layer 80 provided at an upper layer among the layers, and a sound insulation and non-slip layer 70 provided at a lower layer among the layers.

[0039] The layers include a surface layer 60, a printing layer 50, an intermediate layer 40, an underlayer 10, and a balance layer 20. The glass fiber layer 30 is interposed between the intermediate layer 40 and the underlayer 10, the UV coating layer 80 is provided on the surface layer 60, and the sound insulation and non-slip layer 70 is coated on a lower portion of the balance layer 20.

[0040] The glass fiber layer 30 prevents shrinkage, expansion, and curling which sensitively exert an influence on a surrounding temperature of a product. If the glass fiber layer 30 is not provided, a product, which can be placed on a real floor for the use thereof, may not be produced.

[0041] The glass fiber layer 30 according to the present invention is provided by mixing 60-90 weight parts of a plasticizer, and 50-70 weight parts of calcium carbonate (CaCO.sub.3), which serves as a reinforcement inorganic filler, based on 100 weight parts of PVC, providing the mixture in a sol state in a container, impregnating the container with glass fiber, and drying the result, thereby allowing the lamination between the intermediate layer 40 and the underlayer 10. For example, the glass fiber layer 30 contains 55 g/cm.sup.2 of G/F.

[0042] In addition, a typical flooring material is placed by using an adhesive to volatilize a total volatile organic compound (TVOC) which is harmful to a human body. In order to solve the above problem, as described above, the present invention suggests the sound insulation and non-slip layer 70.

[0043] In other words, according to the present invention, the sound insulation and non-slip layer 70 is formed, so that the flooring material can be placed without an adhesive. Accordingly, the flooring material according to the present invention is not harmful to a human body and produces an economical effect. The sound insulation and non-slip layer 70 is formed by mixing 80-100 weight parts of a plasticizer, 10-30 weight parts of CaCO.sub.3, which serves as a reinforcement inorganic filler, and 6-10 weight parts of a foaming agent based on 100 weight parts of PVC, and coating the mixture on a lower portion of the balance layer 20. The sound insulation and non-slip layer 70 is formed by forming a foaming cell at a foaming ratio of 180-250%, preferably, 200% in, for example, a foaming oven, directly coating the foaming cell on the lower portion of the balance layer 20, and drying the coating result. The foaming agent may include azodicarbonamide, but the present invention is not limited thereto.

[0044] The sound insulation and non-slip layer 70 has a non-slip function, a cushion feel, a shock absorption function, and floor serviceability, warming, insulation, soundproof effect, and dustproof effects of the flooring material.

[0045] In addition, the surface layer 60 includes 25-35 weight parts of a plasticizer based on 100 weight parts of PVC. The printing layer 50 includes 6-10 weight parts of the plasticizer based on 100 weight parts of the PVC. The intermediate layer 40 includes 40-60 weight parts of the plasticizer and 400-550 weight parts of CaCO.sub.3 based on 100 weight parts of the PVC. The underlayer 10 includes 40-60 weight parts of the plasticizer and 400-550 weight parts of CaCO.sub.3 based on 100 weight parts of the PVC. The balance layer 20 includes 20-30 weight parts of the plasticizer based on 100 weight parts of the PVC.

[0046] Meanwhile, the intermediate layer may include powders of a hydrous magnesium silicate mineral or elvan powders.

[0047] In addition, the intermediate layer may include TALC, which is powders of the hydrous magnesium silicate mineral, or elvan powders.

[0048] The TALC is rock belonging to a monoclinic system having a crystal structure similar to that of mica, and has color of white, silver-while, and pale green. In addition, TALC belongs to 2:1 phyllosilicate similarly to pyrophyllite. The fine powders of the TALC are referred to talcum powders in medicine and industry fields.

[0049] As described above, the whole thickness of the flooring material is in the range of 4.4-4.6 mm. The surface layer 60 has the thickness of 0.40-0.70 mm. The printing layer 50 has the thickness of 0.05-0.10 mm. The intermediate layer 40 has the thickness of 0.5-0.8 mm. The glass fiber layer 30 has the thickness of 0.35-0.55 mm. The underlayer 10 has the thickness of 1.8-2.5 mm. The balance layer 20 has the thickness of 0.2-1.0 mm. The sound insulation and non-slip layer 70 has the thickness of 0.20-0.70 mm. The UV coating layer 80 preferably has the thickness of 5-12 m.

[0050] Meanwhile, the UV coating layer 80 preferably has the thickness of 8 m, and the average thickness of the flooring material is preferably in the range of 4.5 mm0.05 mm for the saving of the production costs and the production time.

[0051] However, the thickness of each layer of the sound insulation and non-slip flooring material is not limited to the above thickness, but may have various thicknesses according to the use places of the flooring material.

[0052] Hereinafter, a method of producing the sound insulation and non-slip flooring material shown in FIG. 1 will be described with reference to FIGS. 2 to 4.

[0053] FIG. 2 is a flowchart the production process of the sound insulation and non-slip flooring material using the PVC according to the present invention. FIG. 3 is a photograph showing the UV coating layer of FIG. 1. FIG. 4 is a photograph showing the sound insulation and non-slip flooring material of FIG. 1.

[0054] As shown in FIG. 2, the method of producing the sound insulation and non-slip flooring material according to the present invention is to form the sound insulation and non-slip flooring material by laminating a plurality of layers through a calender rolling process. First, according to the method, the underlayer 10, the glass fiber layer 30, the intermediate layer 40, and the balance layer 20 coated with the sound insulation and non-slip layer 70, the printing layer 50, and the surface layer 60 are separately provided (step S10).

[0055] In detail, the underlayer 10 is formed of 40-60 weight parts of a plasticizer and 400-550 weight parts of CaCO.sub.3 based on 100 weight parts of PVC. In this case, CaCO.sub.3 applied to the underlayer 10 preferably has a 70-mesh size.

[0056] The balance layer 20 is formed of 20-30 weight parts of a plasticizer based on 100 weight parts of PVC. The mixture of 80-100 weight parts of the plasticizer, 10-30 weight parts of CaCO.sub.3, which serves as the reinforcement inorganic filler, and 6-10 weight parts of the foaming agent based on 100 weight parts of PVC is coated with the thickness of 0.20-0.70 mm onto the lower portion of the balance layer 20 to form the sound insulation and non-slip layer 70. Preferably, CaCO.sub.3 having a 70-120 mesh size is applied to the sound insulation and non-slip layer 70.

[0057] In addition, 60-90 weight parts of the plasticizer, and 50-70 weight parts of CaCO.sub.3, which serves as a reinforcement inorganic filler, based on 100 weight parts of PVC, are mixed and provided in a sol state in the container, and the container is impregnated with glass fiber and the glass fiber is dried to form the glass fiber layer 30.

[0058] The intermediate layer 40 is formed of 40-60 weight parts of the plasticizer and 400-550 weight parts of CaCO.sub.3 based on 100 weight parts of PVC. In this case, CaCO.sub.3 applied to the intermediate layer 40 preferably has a 120-mesh size.

[0059] The printing layer 50 is formed of 6-10 weight parts of the plasticizer based on 100 weight parts of PVC.

[0060] In addition, the surface layer 60 is formed of 25-35 weight parts of the plasticizer based on 100 weight parts of PVC.

[0061] Next, the glass fiber layer 30 is interposed and laminated between the underlayer 10 and the intermediate layer 40, which are separately provided in step S10, through the calender rolling process (step S20). In addition, the glass fiber layer 30 is fed onto the underlayer 10 and the intermediate layer 40 is fed onto the glass fiber layer 30, and the layers are laminated.

[0062] Thereafter, the printing layer 50 is laminated to an upper portion of the intermediate layer 40 laminated in step S20 (step S30).

[0063] Subsequently, the surface layer 60 as shown in FIG. 3 is laminated to an upper portion of the printing layer 50 which is laminated in the step S30 (step S40).

[0064] The upper portion of the balance layer 20 provided at the lower portion thereof with the sound insulation and non-slip layer 70 is laminated to the lower portion of the underlayer 10 laminated in step S40 (step S50).

[0065] The laminating works in steps S20 to S50 are performed through the calender rolling process, and subsequently performed at the temperature of 150-170 C., under the pressure of 4-6 kg/cm.sup.2, and at the speed of 15-25 m/mins, preferably, 21 m/mins.

[0066] Meanwhile, the surface layer 60, the printing layer 50, the intermediate layer 40, the underlayer 10, and the balance layer 20 are preferably formed at the temperature of 150-180 C. and at the speed of 35-45 m/mins.

[0067] Subsequently, UV coating is performed with respect to the upper portion of the surface layer 60 that is laminated in step S50 (step S60), so that the sound insulation and non-slip flooring material according to the present invention is completely produced.

[0068] Thereafter, preferably, the flooring material is cut to a proper size and used according to necessary uses and placing manners.

[0069] The sound insulation and non-slip flooring material produced according to the present invention as described above is placed in an apartment house and KSF 2863-1 (Rating of floor impact sound insulation for impact source in buildings and of building elements) is applied to the apartment house, so that it is recognized that the apartment house satisfies the conditions of the light-weight floor impact sound of 58 dB and the heavy-weight floor impact sound of 50 dB.

[0070] Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

[0071] As the sound insulation and non-slip flooring material and the method of producing the same according to the present invention is used, the non-slip function, a cushion feel, a shock absorption function, floor serviceability, warming, insulation, a soundproof effect, and a dustproof effect of the flooring material can be obtained.