U.S. patent application number 14/368901 was filed with the patent office on 2014-12-18 for flooring material using poly lactic acid resin and construction methods of the same.
The applicant listed for this patent is LG HAUSYS, LTD.. Invention is credited to Hae Seung Ko, Jun Hyuk Kwon, Sang Sun Park.
Application Number | 20140370225 14/368901 |
Document ID | / |
Family ID | 48745256 |
Filed Date | 2014-12-18 |
United States Patent
Application |
20140370225 |
Kind Code |
A1 |
Ko; Hae Seung ; et
al. |
December 18, 2014 |
FLOORING MATERIAL USING POLY LACTIC ACID RESIN AND CONSTRUCTION
METHODS OF THE SAME
Abstract
Disclosed is a flooring material in which edge portions of a
base layer and a surface layer of the flooring material are formed
to be rounded when press forming the base layer and the surface
layer, thereby providing its fine appearance, and which can provide
construction joints between tiles through a dry construction method
using an adhesive. The flooring material formed of a PLA resin,
which is constructed on floor, includes a resin tile having a base
layer and a surface layer which is stacked on the base layer and
which consists of a dimensionally stabilizing layer, a balance
layer, a printed layer, a transparent layer and a protective layer,
the base layer and the surface layer being formed of the PLA resin
and each four edge portion thereof being formed into a curved
surface; and a construction joint which is formed at a gap formed
between the tiles, wherein an adhesive is applied on the floor
before the tile is attached, and the tiles are arranged to be
spaced apart from each other with a desired gap therebetween, and
the construction joint is formed at the gap.
Inventors: |
Ko; Hae Seung; (Cheongju-si,
KR) ; Kwon; Jun Hyuk; (Gunpo-si, KR) ; Park;
Sang Sun; (Cheongju-si, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LG HAUSYS, LTD. |
Seoul |
|
KR |
|
|
Family ID: |
48745256 |
Appl. No.: |
14/368901 |
Filed: |
December 28, 2012 |
PCT Filed: |
December 28, 2012 |
PCT NO: |
PCT/KR2012/011729 |
371 Date: |
June 26, 2014 |
Current U.S.
Class: |
428/46 |
Current CPC
Class: |
E04F 15/0215 20130101;
Y10T 428/162 20150115; E04F 15/105 20130101; E04F 15/02016
20130101; E04F 15/107 20130101 |
Class at
Publication: |
428/46 |
International
Class: |
E04F 15/10 20060101
E04F015/10; E04F 15/02 20060101 E04F015/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 6, 2012 |
KR |
10-2012-0001831 |
Claims
1. A flooring material formed of a PLA resin, which is constructed
on floor, comprising: a resin tile having a base layer and a
surface layer which is stacked on the base layer and which consists
of a dimensionally stabilizing layer, a balance layer, a printed
layer, a transparent layer and a protective layer, the base layer
and the surface layer being formed of the PLA resin and each four
edge portion thereof being formed into a curved surface; and a
construction joint which is formed at a gap formed between the
tiles, wherein an adhesive is applied on the floor before the tile
is attached, and the tiles are arranged to be spaced apart from
each other with a desired gap therebetween, and the construction
joint is formed at the gap.
2. The flooring material according to claim 1, wherein the
construction joint is formed at the gap formed between the tiles,
such that the four edge portions of each tile is formed into the
curved surface, and the construction joint is formed up to an upper
side surfaces of the surface layer.
3. The flooring material according to claim 1, wherein the
construction joint is formed of white cement or epoxy resin.
4. The flooring material according to claim 1, wherein one or more
of the base layer forming the resin tile, a bottom layer pressed on
a lower surface of the base layer, and the surface layer stacked on
the base layer and consisting of the dimensionally stabilizing
layer, the balance layer, the transparent layer and the protective
layer are formed of the PLA resin.
5. The flooring material according to claim 1, wherein the PLA
resin contains one or more of a non-phthalate plasticizer, an
acrylic copolymer for reinforcing melt strength, a lubricant, a
chain extender, a hydrolysis stabilizer.
6. A construction method of a flooring material formed of a PLA
resin, comprising: making construction floor even and removing
foreign substances; applying an adhesive on the construction floor;
attaching tiles consisting of a bottom layer, a base layer, a
dimensionally stabilizing layer, a balance layer, a printed layer,
a transparent layer and protective layer which are formed of the
PLA resin and stacked in turn, such that the tiles are arranged to
be spaced apart from each other with a gap therebetween; and
forming a construction joint at the gap between the tiles.
7. The construction method according to claim 6, wherein the tile
of which four edge portions are respectively formed into a curved
surface are attached to the adhesive.
8. The construction method according to claim 7, wherein the tile
is pressed by a molding die in which each edge portion formed by an
upper plate and a side plate, and the edge portions are
respectively formed into a curved surface.
9. The construction method according to claim 6, wherein the
construction joint formed between the tiles is formed up to the
protective layer which is the uppermost layer of the tile.
10. A flooring material formed of a PLA resin, which is constructed
on floor, comprising: a resin tile having a base layer, and a
printed layer and a transparent layer which are stacked in turn on
the base layer, one or more of the base layer, the printed layer
and transparent layer being formed of the PLA resin and each four
edge portion thereof being formed into a curved surface; and a
construction joint which is formed at a gap formed between the
tiles, wherein an adhesive is applied on the floor before the tile
is attached, and the tiles are arranged to be spaced apart from
each other with a desired gap therebetween, and the construction
joint is formed at the gap.
11. The flooring material according to claim 10, wherein a
protective layer is stacked on the transparent layer.
12. The flooring material according to claim 10, wherein a
dimensionally stabilizing layer and a balance layer are stacked
between the base layer and the printed layer.
13. The flooring material according to claim 10, wherein a bottom
layer is provided at a lower surface of the base layer.
14. The flooring material according to claim 2, wherein the PLA
resin contains one or more of a non-phthalate plasticizer, an
acrylic copolymer for reinforcing melt strength, a lubricant, a
chain extender, a hydrolysis stabilizer.
Description
TECHNICAL FIELD
[0001] The present invention relates to a flooring material using a
natural resin, and more particularly to a flooring material in
which edge portions of a base layer and a surface layer of the
flooring material are formed to be rounded when press forming the
base layer and the surface layer, thereby providing its fine
appearance, and which can provide construction joints between tiles
through a dry construction method using an adhesive.
[0002] The present invention relates to a flooring material formed
of a PLA (Poly Lactic Acid) resin, which can provide
environment-friendly base layer and surface layer stacked on the
base layer, thereby being recyclable and rapidly decomposed upon
the discarding thereof.
[0003] Further, the present invention relates to a construction
method of the flooring material using the PLA resin, in which the
adhesive is applied to the bottom portion of the tile, and the
tiles are spaced apart from each other in a desired distance,
thereby forming the construction joints between the tiles.
BACKGROUND ART
[0004] Generally, a tile is a plate type product which coats a
surface of the floor, wall or the like, and it can be classified
into an interior tile, an exterior tile, a mosaic tile, a acid
resistant tile, a floor tile, a salt pond tile and the like
according to its applications, and can be formed of a porcelain
material, a stony material, a semi-porcelain material, an earthen
ware material, a clay material and a synthetic resin according to
its materials, and can be installed in a wet or dry construction
method.
[0005] The dry construction method uses an adhesive. Herein, after
the planarizing and cleaning processes of the floor or wall, the
adhesive is applied thereon and then the tiles are attached
thereon. The tile formed of the synthetic resin but not the ceramic
material is mainly used.
[0006] Further, in a conventional resin tile used in the dry
construction method, a base layer thereof is formed by rolling a
polyvinyl chloride compound with a calender, and a printing hidden
layer is formed by rolling a soft or hard polyvinyl chloride
compound containing calcium carbonate as a filler, and an printed
ink layer is formed on the printing hidden layer using transfer
paper which is formed by directly performing a gravure printing
process on the printing hidden layer.
[0007] And after a pattern protective layer for protecting the ink
layer and an inside layer is formed by rolling a soft or semi-hard
polyvinyl chloride compound, the inside layer, the base layer, the
printing hidden layer and the pattern protective layer are stacked
and then pressed by a laminating roll or a press.
[0008] However, in the above-mentioned tile construction method,
since the wet construction method needs curing time, the
construction period is extended and also the wet construction
method needs a skilled person. Further, in case of the dry
construction method, the construction period is short and the
construction is simple, but since the tiles are installed without
any gap therebetween, it is impossible to provide various
expressions. Even though the tiles are installed with a gap
therebetween like in the wet construction method, the external
appearance is deteriorated due to the exposure of the printed layer
and the base layer.
[0009] Further, in the conventional resin tile, since the base
layer and the surface layer are formed of the polyvinyl chloride
compound, it may be harmful to the human body. Further, since the
edge portion of the tile has a square shape, the protective layer
may be peeled off and thus the printed layer may be damaged as time
passes.
DISCLOSURE OF INVENTION
Technical Problem
[0010] An object of the present invention is to provide a flooring
material which can form the construction joints between the tiles
even though being installed by the dry construction method, and of
which the base layer and the surface layer are formed of the PLA
resin material which is environment-friendly and harmless to the
human body.
[0011] Another object of the present invention is to provide a
flooring material and a construction method thereof, in which edge
portions of each tile are formed to be rounded so that the boundary
of the surface layer is not exposed to the outside, thereby
providing the fine appearance, and also in which the tiles are
spaced apart from each other with a desired gap therebetween and
the construction joints are formed at the gap.
[0012] Yet another object of the present invention is to provide a
flooring material and a construction method thereof, in which the
edge portions of each tile are formed to be rounded, thereby
preventing the damage of the edge portion and also preventing the
protective layer from being peeled off by many pedestrians.
Solution to Problem
[0013] To achieve the object of the present invention, the present
invention provides a flooring material formed of a PLA resin, which
is constructed on floor, including a resin tile having a base layer
and a surface layer which is stacked on the base layer and which
consists of a dimensionally stabilizing layer, a balance layer, a
printed layer, a transparent layer and a protective layer, the base
layer and the surface layer being formed of the PLA resin and each
four edge portion thereof being formed into a curved surface; and a
construction joint which is formed at a gap formed between the
tiles, wherein an adhesive is applied on the floor before the tile
is attached, and the tiles are arranged to be spaced apart from
each other with a desired gap therebetween, and the construction
joint is formed at the gap.
[0014] Further, the present invention provides a construction
method of a flooring material formed of a PLA resin,
comprising:
[0015] making construction floor even and removing foreign
substances;
[0016] applying an adhesive on the construction floor;
[0017] attaching tiles consisting of a bottom layer, a base layer,
a dimensionally stabilizing layer, a balance layer, a printed
layer, a transparent layer and protective layer which are formed of
the PLA resin and stacked in turn, such that the tiles are arranged
to be spaced apart from each other with a gap therebetween; and
[0018] forming a construction joint at the gap between the
tiles.
Advantageous Effects of Invention
[0019] According to the present invention, the flooring material is
formed of the PLA resin material which is environment-friendly and
harmless to the human body, it is possible to prevent environmental
pollution.
[0020] Further, since each of the edge portion of the tile is
formed to be rounded, it is possible to provide the fine appearance
and also to prevent the protective layer from being peeled off by
many pedestrians.
[0021] Further, since each of the edge portion of the tile forming
the flooring material is formed to be rounded, it is possible to
prevent the boundary of the surface layer from being exposed to the
outside after the construction and thus to prevent the peeling of
the protective layer because pedestrians could not step on the
boundary of the surface layer, and it is also possible that tiles
are spaced apart from each other with a desired gap.
[0022] Furthermore, since the construction joints which could be
formed in only the wet construction method can be formed even in
the dry construction method, it is possible to prevent the tiles
from being separated by the contraction and expansion of the tile,
it is possible to provide the various expressions, and it is also
possible to simply construct the tiles.
BRIEF DESCRIPTION OF DRAWINGS
[0023] The above and other objects, features and advantages of the
present invention will become apparent from the following
description of preferred embodiments given in conjunction with the
accompany drawings, in which:
[0024] FIG. 1 is a perspective view of a flooring material formed
of a PLA resin according to the present invention.
[0025] FIG. 2 is an exploded cross-sectional view of a resin tile
which is applied to the present invention.
[0026] FIG. 3 is a side view of the resin tile which is applied to
the present invention.
[0027] FIG. 4 is a side view of a molding die for molding the resin
tile according to the present invention.
[0028] FIG. 5 is a side view showing an example of a molding device
for molding the resin tile which is applied to the present
invention.
[0029] FIG. 6 is a cross-sectional view showing a construction
process of the resin tile according to the present invention.
[0030] FIG. 7 is an expanded view of a main part of the present
invention.
DETAILED DESCRIPTION OF MAIN ELEMENTS
[0031] 10: tile 12: base layer [0032] 14: bottom layer 20:
construction joint [0033] 30: surface layer 31: dimensionaly
stabilizing layer [0034] 32: balance layer 33: printed layer [0035]
34: transparent layer 35: protective layer
BEST MODE FOR CARRYING OUT THE INVENTION
[0036] Hereinafter, the embodiments of the present invention will
be described in detail with reference to accompanying drawings.
[0037] Firstly, FIG. 1 is a perspective view of a flooring material
formed of a PLA resin according to the present invention, FIG. 2 is
an exploded cross-sectional view of a resin tile which is applied
to the present invention, and FIG. 3 is a side view of the resin
tile which is applied to the present invention.
[0038] Further, FIG. 4 is a side view of a molding die for molding
the resin tile according to the present invention, FIG. 5 is a side
view showing an example of a molding device for molding the resin
tile which is applied to the present invention, FIG. 6 is a
cross-sectional view showing a construction process of the resin
tile according to the present invention, and FIG. 7 is an expanded
view of a main part of the present invention.
[0039] In the drawings, a flooring material 1 formed of a natural
resin includes a tile 10 which is formed of a PLA resin, and a
construction joint 20 which is formed between the tiles 10 after
adhering construction of the tiles 10.
[0040] The construction joint 20 can be formed of white cement, an
epoxy resin or other filler. The while cement is mixed with water
when being used, and the epoxy resin is applied directly or
indirectly using a gun.
[0041] The resin tile 10 basically consists of a base layer 12, a
bottom layer 14 which is pressed to a lower surface of the base
layer 12, and a surface layer 30 which is stacked on the base layer
12. The surface layer 30 includes a dimensionally stabilizing layer
31, a balance layer 32, a printed layer 33, a transparent layer 34
and a protective layer 35.
[0042] The base layer 12 is formed with a PLA (Poly Lactic Acid)
resin using a press or roll pressing method.
[0043] The dimensionally stabilizing layer 31 of the surface layer
30 functions to reinforce the resin tile 10 and also to prevent a
dimensional change thereof. The dimensionally stabilizing layer 31
is formed with the PLA resin. If necessary, glass fiber or
non-woven fabric may be used as the dimensionally stabilizing layer
31. Further, the dimensionally stabilizing layer 31 also functions
to prevent cracks generated upon using of the resin tile 10.
[0044] The bottom layer 14 formed on the lower surface of the base
layer 12 and the balance layer 32 formed on the dimensionally
stabilizing layer 31, which are formed of the PLA resin, function
to maintain the balance of the bottom of the tile 10, i.e., the
base layer 12, to reinforce the reality and provide surface
properties, and also to prevent bending of the tile.
[0045] The printed layer 33 is provided with various patterns and
designs which may be intaglioed or embossed using various colors.
Recently, customized patterns or designs which are selected by a
customer are printed thereon.
[0046] The transparent layer 34 formed of the PLA resin is to
protect the printed layer 33, and wax is used as the protective
layer 35.
[0047] Meanwhile, the PLA resin used in the present invention,
which is a thermoplastic polyester resin of lactide or lactic acid,
can be manufactured by polymerzing lactic acid prepared by
fermenting starch extracted from corn or potatoes. Further, since
the PLA resin can be recycled repeatedly, it is possible to solve
the problems occurred by the exhaustion of resources, and emission
of environmental pollutants is smaller than in other resins, e.g.,
polyvinyl chloride, and also it can be decomposed rapidly upon the
discarding thereof.
[0048] The PLA resin can be classified into a crystalline PLA
(c-PLA) resin and an amorphous PLA (a-PLA) resin. In case of the
crystalline PLA resin, the bleeding that a plasticizer is flowed
out onto a sheet surface may occur, and thus the amorphous PLA
resin is used in the present invention.
[0049] When using the amorphous PLA resin, it is preferable to use
100% amorphous PLA resin. If necessary, a mixture of the
crystalline PLA resin and the amorphous PLA resin may be used.
[0050] In the molding process, a non-phthalate plasticizer or an
acrylic copolymer for reinforcing melt strength may be contained in
the PLA resin.
[0051] A pair of or multiple pressing rolls or presses are used in
the molding process. In the present invention, a molding device
shown in FIGS. 4 and 5, which will be described later, may be
used.
[0052] When forming the base layer 12, the bottom layer 14, the
dimensionally stabilizing layer 31, the balance layer 32 and the
transparent layer 34, one or more of a lubricant, a chain extender,
a hydrolysis stabilizer or the like may be further added to the PLA
resin.
[0053] That is, it is preferable in the base layer 12 that 5 to 100
parts by weight of the non-phthalate plasticizer is used with
respect to 100 parts by weight of the PLA resin, 1 to 20 parts by
weight of the acrylic copolymer is used with respect to 100 parts
by weight of the PLA resin, and 0.01 to 10 parts by weight of the
lubricant is used with respect to 100 parts by weight of the PLA
resin.
[0054] Moreover, it is preferable that 0.01 to 10 parts by weight
of the chain extender which functions to increase molecular weight
and thus to improve tensile strength and heat-resisting property is
used with respect to 100 parts by weight of the PLA resin, and 1 to
10 parts by weight of the hydrolysis stabilizer is used with
respect to 100 parts by weight of the PLA resin.
[0055] In the dimensionally stabilizing layer 31, the balance layer
32 and the transparent layer 34, it is preferable that 5 to 60
parts by weight of the non-phthalate plasticizer is used with
respect to 100 parts by weight of the PLA resin, 1 to 20 parts by
weight of the acrylic copolymer is used with respect to 100 parts
by weight of the PLA resin, and 0.01 to 10 parts by weight of the
lubricant is used with respect to 100 parts by weight of the PLA
resin.
[0056] And it is also preferable that 0.01 to 10 parts by weight of
the chain extender and hydrolysis stabilizer are respectively used
with respect to 100 parts by weight of the PLA resin.
[0057] Meanwhile, thermosetting or UV curable paint is used as the
protective layer 35.
[0058] Preferably, the base layer 12 is formed to have a thickness
of 1 to 3 mm, and the dimensionally stabilizing layer 31, the
printed layer 33, the transparent layer 34 and the protective layer
35 are respectively formed to have a thickness of 0.01 to 1 mm, and
the balance layer 32 and the bottom layer 14 have a thickness of
0.01 to 2 mm, respectively.
[0059] In the resin tile 10 of the flooring material 1 formed of a
natural resin according to the present invention, the base layer
22, the dimensionally stabilizing layer 31, the balance layer 32,
the printed layer 33, the transparent layer 34 and the protective
layer 35 are continuously or independently formed by the pressing
roll or press and then laminated by a molding device.
[0060] As shown in FIG. 4, a molding die 100 for pressing and
laminating each layer is formed into a square container having an
upper wall 120 and a side wall 140, and an edge portion in which
the upper and side walls 120 and 140 are contacted with each other
is formed to be rounded.
[0061] This is to form a curved surface 40 at each of the four edge
portions of the tile 10 when the tile 10 is completed.
[0062] The curved surface 40 of the tile 40 is one of the features
of the present invention, which provides fine appearance of the
tile 10 and also allows a construction joint 20 to be formed. In
other words, each end of the surface layer 30 of the tile 10 is
located at the side portion of the tile 10, and thus the boundary
of the surface layer 30 is not exposed to the outside after
construction, thereby providing the fine appearance. Therefore, the
tiles 10 can be constructed to be spaced apart from each other with
a desired gap, and the construction joint 20 is formed at the gap,
thereby preventing the tile 10 from being separated and also
allowing the whole appearance of a flooring material 1 to be
expressed variously.
[0063] FIG. 5 is a schematic view of a device for operating the
molding die 100. The tile 10 is put on a transfer table 220, and
the molding die 100 is fixed to a lifting part 240 so as to be
lifted up and down, thereby press-molding the tile. The lifting
part 240 may be a cylinder or other mechanical devices.
[0064] Of course, the molding device of FIG. 5 is an example, and
other type molding devices and dies having different driving means
may be used in the molding of the tile. Even in this case, each of
the edge portions of the tile 10 has to be formed into the curved
surface.
[0065] Hereinafter, the construction process of the present
invention will be described.
[0066] First of all, in the present invention, the tile 10 is
manufactured using the PLA resin.
[0067] The bottom layer 14, the base layer 12, the dimensionally
stabilizing layer 31, the balance layer 32, the printed layer 33,
the transparent layer 34 and the protective layer 35 are formed
through the press rolling or pressing and then pressed and
laminated through the molding device or other molding devices.
[0068] Herein, the four edge portions of the tile 10 are formed to
be rounded, i.e., have the curved surface 40, and thus the boundary
of the surface layer 30 stacked on the base layer 12 is not exposed
to the outside, and also it is prevented that the boundary of the
surface layer 30 is damaged by many pedestrians. Therefore, it is
possible to prevent damage of the printed layer, the transparent
layer and the protective layer.
[0069] In the construction of the flooring material, i.e., the tile
10, firstly, the floor on which the tile 10 is installed is made
even and foreign substances are removed.
[0070] After removing the foreign substances, an adhesive is
applied to the floor, and then the tiles 10 are attached thereon.
Herein, the tiles 10 are arranged to be spaced apart from each
other with a desired gap, and the constructions joints are formed
at the gap.
[0071] Of course, if necessary, the tiles 10 may be attached
without the gap.
[0072] White cement or epoxy resin is used in the forming of the
construction joints. Further, the edge portions are formed into the
curved surfaces 40, and the construction joints are formed up to
the upper end of the surface layer 30 of which the boundary is
located at the side surface of the tile 10, i.e., the boundary of
the protective layer 30, thereby preventing the peeling of the
surface layer 30 and the separation of the tiles 10.
INDUSTRIAL APPLICABILITY
[0073] The flooring material is formed of the PLA resin material
which is environment-friendly and harmless to the human body, it is
possible to prevent environmental pollution.
[0074] Further, since each of the edge portion of the tile is
formed to be rounded, it is possible to provide the fine appearance
and also to prevent the protective layer from being peeled off by
many pedestrians.
[0075] Further, since each of the edge portion of the tile forming
the flooring material is formed to be rounded, it is possible to
prevent the boundary of the surface layer from being exposed to the
outside after the construction and thus to prevent the peeling of
the protective layer because pedestrians could not step on the
boundary of the surface layer, and it is also possible that tiles
are spaced apart from each other with a desired gap.
[0076] Furthermore, since the construction joints which could be
formed in only the wet construction method can be formed even in
the dry construction method, it is possible to prevent the tiles
from being separated by the contraction and expansion of the tile,
it is possible to provide the various expressions, and it is also
possible to simply construct the tiles.
[0077] 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.
* * * * *