INLAID TYPE FLOOR SHEET HAVING POLYVINYL CHLORIDE CHIP AND THE METHOD OF MANUFACTURING THEREOF

Abstract

Disclosed is a inlaid type floor sheet having polyvinyl chloride chip and a method of manufacturing thereof. The in-laid 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

TECHNICAL FIELD

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.

BACKGROUND ART

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 1.25 mm, 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.

DISCLOSURE OF INVENTION

Technical Problem

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.

Solution to Problem

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 1×1 mm.

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.

Advantageous Effects of Invention

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.

BRIEF DESCRIPTION OF DRAWINGS

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

BEST MODE FOR CARRYING OUT THE INVENTION

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 2.0 mm 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 25 mesh, more detailedly a grid of 1×1 mm.

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 25 mesh, 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 30 cm×30 cm is put in a dry oven of about 80° C. 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 25 cm×25 cm 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.

INDUSTRIAL APPLICABILITY

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

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; anda 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 1×1 mm.

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.