Tile structure with excellent acid and chemical resistance, and manufacturing method thereof
Patent Information
- Application Number
- KR1020250015195
- Authority / Receiving Office
- KR · KR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-02-06
- Publication Date
- 2026-08-14
Smart Images
Figure PAT00008_ABST
Abstract
Description
Technology Field
[0001] The present invention relates to a tile structure with excellent acid and chemical resistance and a method for manufacturing the same. More specifically, the invention relates to a tile structure with excellent acid and chemical resistance and a method for manufacturing the same, which has excellent acid and chemical resistance, durability, and scratch resistance, while also improving the adhesion of the tiles by preventing slipping when laminated on a floor surface, preventing shrinkage and expansion of the tiles, and preventing the tiles from easily peeling off and reducing marketability. Background Technology
[0002] Various architectural finishing materials are used to finish and decorate the interior and exterior walls and floors of buildings. Previously, the installation of these materials was burdensome due to the complexity of the process and high costs, as it required specialized personnel, tools, and adhesives.
[0003] To resolve these inconveniences, DIY (do it yourself) products that consumers can install themselves have emerged; among these, there is a particularly increasing demand for decorative tile-type finishing materials that come in various colors, patterns, or textures and are easy to install.
[0004] For example, Korean Published Patent Application No. 10-2018-0092044 describes a decorative adhesive block comprising a release liner, an adhesive layer, a foam layer, a PE film layer, and a printed layer having a PVC film formed on its surface, as a finishing material for enhancing the aesthetic appeal of an interior wall surface; and Korean Published Patent Application No. 10-2018-0107950 discloses an adhesive wall finishing material comprising a release liner, an adhesive surface, a foam sheet, a PVC-based compressed plastic panel, and a deco sheet, wherein the compressed plastic panel and the deco sheet are laminated using an adhesive member. As such, adhesive tiles generally have a structure comprising a release film, an adhesive layer, a foam sheet, and a deco sheet, and each sheet is laminated through an adhesive member.
[0005] Polymer resins, specifically polyvinyl chloride (PVC), are primarily used as the main material for these adhesive tiles. While PVC resin has the advantages of being inexpensive and having excellent chemical resistance, its low processability necessitates the use of phthalate-based plasticizers during the manufacturing process. However, the use of these phthalate-based plasticizers is regulated due to the problems associated with endocrine disruptors and the generation of harmful substances, such as dioxins, upon incineration.
[0006] As a technology to solve these problems, Korean Published Patent Application No. 10-2018-0027222 discloses an eco-friendly plasticizer manufactured using citric acid and alcohol, and an interior sheet comprising a PVC foam layer formed using the same.
[0007] However, the supply and stability of these alternative plasticizers have not been secured.
[0008] Furthermore, when producing multi-layered tiles using PVC, curling occurs due to the low heat resistance of PVC. In particular, when the components used for each layer of the tile are produced in different production lots, various temperature stresses occur during shipping or storage after production, leading to significant errors caused by the production lot. Consequently, the product defect rate increases, and the tiles fall off because the adhesive fails to adhere properly to the surface when attached to walls or floors.
[0009] In addition, due to the heat-sensitive nature of PVC, a separate adhesive must be used when joining each component. Therefore, not only is an overlay process required to apply and dry the adhesive to form an adhesive layer and then press it onto another component, but shrinkage also occurs during the curing process of the adhesive, and environmental pollution is caused by the use of the adhesive.
[0010] Accordingly, there is a need to develop an eco-friendly tile-type architectural finishing material that can be manufactured through a simple process, while possessing excellent physical properties such as acid and chemical resistance and exhibiting minimal deformation due to temperature changes. Prior art literature
[0011] Korean Registered Patent No. 10-1116835 (Registered February 8, 2012) Korean Registered Patent No. 10-2232816 (Registered March 22, 2021) Korean Registered Patent No. 10-2342013 (Registered December 17, 2021) The problem to be solved
[0012] The problem that the present invention aims to solve is to provide a tile structure with excellent acid and chemical resistance and a method for manufacturing the same, which has excellent acid and chemical resistance, durability, and scratch resistance, while also improving the adhesion of tiles by preventing slipping when laminated on a floor surface, preventing shrinkage and expansion of tiles, and preventing the tiles from easily peeling off and reducing marketability.
[0013] The various problems that the present invention aims to solve are not limited to those mentioned above, and other unmentioned problems will be clearly understood by those skilled in the art from the description below. means of solving the problem
[0014] In one embodiment of the technical concept of the present invention, a tile structure with excellent acid and chemical resistance is disclosed.
[0015] The above tile structure with excellent acid and chemical resistance comprises a primer layer formed on a floor surface, an epoxy novolak layer formed on the primer layer, an epoxy layer formed on the epoxy novolak layer, and a tile layer formed on the epoxy layer, wherein the epoxy novolak layer is formed by applying an epoxy novolak composition on the primer layer, and the epoxy novolak composition comprises epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives.
[0016] The above epoxy novolak composition may be included in a weight ratio of 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives.
[0017] The epoxy layer is formed by applying an epoxy composition onto the epoxy novolak layer, wherein the epoxy composition may include bisphenol F type epoxy resin, titanium dioxide (TiO2), iron(II) oxide (FeO), dodecyl phenol, and epichlorohydrin-modified phenol-formaldehyde resin.
[0018] The above epoxy composition may be included in a weight ratio of 60 to 90 parts by weight of bisphenol F-type epoxy resin, 0.1 to 2 parts by weight of titanium dioxide (TiO2), 0.1 to 2 parts by weight of iron(II) oxide (FeO), 0.1 to 2 parts by weight of dodecyl phenol, and 0.01 to 0.1 parts by weight of epichlorohydrin-modified phenol-formaldehyde resin.
[0019] Tile bricks may be used for the above tile layer.
[0020] The primer layer is formed by applying a primer composition to the bottom surface, wherein the primer composition may include a polyurethane resin, a polysiloxane, a polybutylene adipate terephthalate resin (PBAT), an ethylene-vinyl acetate copolymer (EVA), biochar, a rust inhibitor, calcium carbonate, acrylonitrile-butadiene rubber (NBR), a plasticizer, a UV stabilizer, cyclohexanediamine, and 1,3-bis(aminomethyl)benzene.
[0021] The primer composition comprises 300 to 400 parts by weight of polyurethane resin, 10 to 30 parts by weight of polysiloxane, 80 to 120 parts by weight of polybutylene adipate terephthalate (PBAT) resin, 30 to 70 parts by weight of ethylene-vinyl acetate copolymer (EVA), 1 to 10 parts by weight of biochar, 1 to 10 parts by weight of rust inhibitor, 5 to 15 parts by weight of calcium carbonate, 10 to 20 parts by weight of acrylonitrile-butadiene rubber (NBR), 1 to 5 parts by weight of plasticizer, 10 to 20 parts by weight of UV stabilizer, 20 to 40 parts by weight of cyclohexanediamine, and 1,3-bis(aminomethyl)benzene may be included in a weight ratio of 30 to 50 parts by weight.
[0022] In addition, another embodiment of the technical concept of the present invention discloses a method for manufacturing a tile structure having excellent acid and chemical resistance.
[0023] The above method for manufacturing a tile structure with excellent acid and chemical resistance comprises: a primer layer forming step (S100) of forming a primer layer by applying a primer composition to a floor surface; an epoxy novolak layer forming step (S200) of forming an epoxy novolak layer by applying an epoxy novolak composition on the primer layer; an epoxy layer forming step (S300) of forming an epoxy layer by applying an epoxy composition on the epoxy novolak layer; and a tile layer forming step (S400) of forming a tile layer on the epoxy layer, wherein in the epoxy novolak layer forming step (S200), the epoxy novolak composition comprises epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives.
[0024] In the step of forming the epoxy novolak layer (S200), the epoxy novolak composition may be included in a weight ratio of 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives.
[0025] In the above epoxy layer formation step (S300), the epoxy composition may include bisphenol F type epoxy resin, titanium dioxide (TiO2), iron(II) oxide (FeO), dodecyl phenol, and epichlorohydrin-modified phenol-formaldehyde resin.
[0026] In the above epoxy layer forming step (S300), the epoxy composition may be included in a weight ratio of 60 to 90 parts by weight of bisphenol F type epoxy resin, 0.1 to 2 parts by weight of titanium dioxide (TiO2), 0.1 to 2 parts by weight of iron(II) oxide (FeO), 0.1 to 2 parts by weight of dodecyl phenol, and 0.01 to 0.1 parts by weight of epichlorohydrin-modified phenolformaldehyde resin.
[0027] In the primer layer formation step (S100) above, the primer composition comprises 300 to 400 parts by weight of polyurethane resin, 10 to 30 parts by weight of polysiloxane, 80 to 120 parts by weight of polybutylene adipate terephthalate resin (PBAT), 30 to 70 parts by weight of ethylene-vinyl acetate copolymer (EVA), 1 to 10 parts by weight of biochar, 10 to 30 parts by weight of rust inhibitor, 5 to 15 parts by weight of calcium carbonate, 10 to 20 parts by weight of acrylonitrile-butadiene rubber (NBR), 1 to 5 parts by weight of plasticizer, 10 to 20 parts by weight of UV stabilizer, and 20 to 20 parts by weight of cyclohexanediamine It may be included in a weight ratio of 40 parts by weight and 30 to 50 parts by weight of 1,3-bis(aminomethyl)benzene.
[0028] Specific details of other embodiments are included in the detailed description. Effects of the invention
[0029] A tile structure with excellent acid and chemical resistance according to various embodiments of the technical concept of the present invention has excellent acid and chemical resistance, durability, and scratch resistance, while also improving the adhesion of tiles by preventing slipping when laminated on a floor surface, preventing shrinkage and expansion of tiles, and preventing the tiles from easily peeling off and reducing marketability.
[0030] It will be fully understood that embodiments of the technical concept of the present invention may provide various effects not specifically mentioned. Brief explanation of the drawing
[0031] FIG. 1 is a cross-sectional view schematically illustrating a cross-section of a tile structure with excellent acid and chemical resistance according to one embodiment of the technical concept of the present invention. FIG. 2 is a flowchart illustrating a method for manufacturing a tile structure with excellent acid and chemical resistance according to another embodiment of the technical concept of the present invention. Figure 3 is a photograph showing the state after dropping 98% sulfuric acid onto an epoxy novolak layer prepared according to an example. Figures 4a and 4b are test reports showing the stain resistance results of an epoxy novolak layer prepared according to the example. Specific details for implementing the invention
[0032] The advantages and features of the present invention, and the methods for achieving them, will become clear by referring to the embodiments described in detail below. However, the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments introduced herein are provided to ensure that the disclosed content is thorough and complete, and to ensure that the spirit of the present invention is sufficiently conveyed to those skilled in the art.
[0033] The terms used in this application are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise.
[0034] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the present invention pertains. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in this application.
[0036] Hereinafter, a preferred embodiment of a tile structure with excellent acid and chemical resistance according to one embodiment of the technical concept of the present invention will be described in detail with reference to the attached drawings.
[0038] FIG. 1 is a cross-sectional view schematically illustrating a cross-section of a tile structure with excellent acid and chemical resistance according to one embodiment of the technical concept of the present invention.
[0040] Referring to FIG. 1, a tile structure (10) with excellent acid and chemical resistance according to one embodiment of the technical concept of the present invention comprises a primer layer (200) formed on a floor surface (100), an epoxy novolak layer (300) formed on the primer layer (200), an epoxy layer (400) formed on the epoxy novolak layer (300), and a tile layer (500) formed on the epoxy layer (400).
[0042] The above floor surface (100) is a place where tiles are installed, for example, flooring of a building or civil engineering structure, a rooftop, a retaining wall or ceiling of an underground structure, or an interior such as a toilet, bathroom, veranda, or a chemical tank, piping, pipe, steel pipe, various reinforcing bars or concrete structures, a ship, a chemical plant, an oil refinery, a power plant, a water treatment facility, etc. Specifically, the above floor surface (100) may be a floor surface (100) of a building or civil engineering structure.
[0043] Additionally, the floor surface (100) may be prepared for use. The preparation of the floor surface (100) includes cleaning the surface of the floor surface (100) of a structure on which tiles are installed, for example, a building or civil engineering structure, and removing concrete ash, laitance, oil, and other foreign substances attached to or remaining on the surface of the floor surface (100) of the building or civil engineering structure. Furthermore, if there is moisture, it may be completely dried, uneven parts may be ground down with a grinder and smoothed, or cracks may be filled with a suitable material.
[0045] The primer layer (200) can be formed by applying a primer composition to the floor surface (100) and then drying it. The primer layer (200) can prevent the tile from easily lifting or peeling off by improving the adhesion between the epoxy novolak layer (300) formed on top and the floor surface (100).
[0046] The above primer composition can penetrate from the surface of the floor surface (100) into the interior and harden into a coating film with a network structure to form a primer layer (200). The primer layer (200) can strengthen the surface of the floor surface (100) and fundamentally block moisture (H2O) or various gases that cause corrosion (e.g., O2, CO2, NOx, SOx, etc.) from entering the interior of the floor surface (100).
[0047] For example, the primer composition comprises a polyurethane resin, a polysiloxane, a polybutylene adipate terephthalate resin (PBAT), an ethylene-vinyl acetate copolymer (EVA), biochar, a rust inhibitor, calcium carbonate, acrylonitrile-butadiene rubber (NBR), a plasticizer, a UV stabilizer, cyclohexanediamine, and 1,3-bis(aminomethyl)benzene.
[0048] Specifically, the primer composition comprises 300 to 400 parts by weight of polyurethane resin, 10 to 30 parts by weight of polysiloxane, 80 to 120 parts by weight of polybutylene adipate terephthalate (PBAT) resin, 30 to 70 parts by weight of ethylene-vinyl acetate copolymer (EVA), 1 to 10 parts by weight of biochar, 1 to 10 parts by weight of rust inhibitor, 5 to 15 parts by weight of calcium carbonate, 10 to 20 parts by weight of acrylonitrile-butadiene rubber (NBR), 1 to 5 parts by weight of plasticizer, 10 to 20 parts by weight of UV stabilizer, 20 to 40 parts by weight of cyclohexanediamine, and 1,3-bis(aminomethyl)benzene may be included in a weight ratio of 30 to 50 parts by weight.
[0050] The above polyurethane resin may be a known soft polyurethane resin, and for example, the soft polyurethane resin may be manufactured by including an isocyanate composition, a polyol composition, and a crosslinking agent.
[0051] In addition, the crosslinking agent satisfies the following [Chemical Formula 1], and the soft polyurethane composition has an NCO index of the isocyanate composition relative to the polyol composition of 1.4 to 1.6, and may contain 1.5 to 2.0 parts by weight of the crosslinking agent based on 100 parts by weight of the total content of the polyol composition.
[0052] [Chemical Formula 1]
[0053] R1-(CH2)m-NH-(CH2)n-R2
[0054] R1 and R2 are each independently an amine group or a hydroxyl group, and m and n are each independently natural numbers from 5 to 8.
[0055] In addition, the isocyanate composition may include one or more selected from methylene diphenyl diisocyanate (MDI) or toluene diisocyanate (TDI), and the polyol composition may include one or more selected from the group consisting of polyether polyol, polyester polyol, and copolymer polyol.
[0057] The above polysiloxane provides excellent water repellency, thereby providing excellent water repellency and water repellency durability effects on the surface of the primer layer (200) formed by the primer composition.
[0058] The above polysiloxane can be represented as shown in [Chemical Formula 2] below.
[0059] [Chemical Formula 2]
[0060]
[0061] In the above [Chemical Formula 2], R 4 Each is independently a hydrogen atom, a substituted or unsubstituted C1 to C10 alkyl group, a substituted or unsubstituted C6 to C30 aromatic organic group, an acrylate organic group, an epoxy organic group, or a combination thereof, X is a hydrogen atom, a hydrogen sulfide group, a substituted or unsubstituted C1 to C10 alkyl group, an acrylate organic group, an epoxy organic group, or a combination thereof, and n is an integer of 1 or more such that the weight-average molecular weight (Mw) of the polysiloxane is 1,000 g / mol to 100,000 g / mol.
[0062] For example, the polysiloxane can be used by mixing dimethylpolysiloxane and organopolysiloxane, and the polysiloxane can be used by mixing dimethylpolysiloxane and organopolysiloxane in a weight ratio of 4:6 to 6:4.
[0064] The above polybutylene adipate terephthalate (PBAT) resin is a biodegradable bioplastic and is an eco-friendly material that decomposes 100% within 6 months in the soil. The above PBAT resin can be obtained by condensing 1,4-butanediol, adipic acid, and terephthalic acid according to a generally known method.
[0065] For such PBAT resins, one may use one synthesized directly by this general method, or one may obtain and use a commercially available resin, such as ECOPLEX (BASF) or PBG7070 (Samsung Fine Chemicals).
[0066] In addition, the above PBAT resin may have a weight-average molecular weight of 150,000 to 400,000. As the above PBAT resin has this range of molecular weight, the compatibility and processability between the above PBAT resin and other materials such as polysiloxane and polyurethane resin may be better, and improved physical properties may be exhibited depending on the relatively high molecular weight.
[0068] The above ethylene-vinyl acetate copolymer (EVA) is a polymer obtained by copolymerizing ethylene and vinyl acetate monomers, and refers to a polymer resin commonly called EVA. When the content of vinyl acetate monomers is low, it has excellent physical properties such as impact resistance and stress cracking resistance like ordinary low-density polyethylene, and when the content of vinyl acetate is high, it has improved adhesive properties, so it can be used as a raw material for adhesives or hot melts.
[0069] The above ethylene-vinyl acetate copolymer (EVA) is a copolymer resin of ethylene and vinyl acetate that has excellent characteristics such as transparency, flexibility, and low-temperature brittleness, and is also a very environmentally friendly resin. For example, it is preferable to use an ethylene-vinyl acetate copolymer with a melt index of 400, a vinyl acetate content of 28%, and a glass transition temperature of -28.6℃.
[0071] The above biochar is a compound word of biomass (Bio) and charcoal, referring to charcoal produced through a carbonization process using biomass. This biochar is formed through thermal decomposition at 400 to 1,000°C in a state with almost no oxygen. This biochar neutralizes the soil and prevents carbon dioxide emissions by storing carbon in the soil through thermal decomposition without oxygen.
[0072] The above biochar may be biochar prepared by the following method.
[0073] To manufacture the above biochar, first, bottom ash can be prepared.
[0074] The above bottom ash refers to ash generated in an incinerator and filtered by a dry scrubber and a filter dust collector. The above bottom ash refers to non-combustible components and some combustible components that were not burned, such as wood pellets, that fell into a residue hopper placed under the grate inside the incinerator.
[0075] Next, the above flooring material can be dried.
[0076] The moisture remaining in the flooring material can be removed by drying the flooring material. For example, the flooring material can be dried by storing it at a temperature of 40 to 60°C for 1 to 5 days so that the moisture content of the flooring material becomes 1 to 5 weight%.
[0077] By drying the above-mentioned dried flooring material so that its moisture content is in the range of 1 to 5 weight percent, the flooring material can be uniformly mixed with additives or binders in a subsequent step and the bonding strength can be enhanced.
[0078] Next, a mixture can be prepared by mixing additives into the dried flooring material.
[0079] By preparing a mixture by mixing additives with the above-mentioned dried flooring material, the bonding strength of the biochar formed by the flooring material can be improved and the porosity can also be enhanced. For example, the additives may include black clay, red clay, white clay, and fly ash.
[0080] Specifically, the mixture may be prepared by mixing 80 to 120 parts by weight of additives with respect to 100 parts by weight of the total content of the dried flooring material, and the additives may be included in a weight ratio of 10 to 20 parts by weight of black clay, 1 to 10 parts by weight of red clay, 1 to 10 parts by weight of white clay, and 5 to 15 parts by weight of fly ash.
[0081] The above black clay is an aggregate of hydrated alumina silicate minerals, and the clay has a fine particle size so that it can float when dissolved in water, and has the property of exhibiting plasticity when water is added. In addition, the above black clay has the characteristic of hardening and exhibiting rigidity when dried, and hardening when fired at high temperatures. As clay minerals of the above black clay, there are various types including kaolinite-based minerals such as kaolinite, dipite, and halloysite; montmorillonite-based minerals such as montmorillonite, bentonite, and acid clay; mica-based minerals such as illite and glaugreen; as well as chlorite-based minerals and allophane.
[0082] The above red clay is a natural soil in a reddish state composed of silica containing hydrated and anhydrous iron oxides. It contains large amounts of substances such as SiO2, Al2O3, Fe2O3, Na2O, CaO, TiO2, and MgO, and possesses physicochemical properties similar to red clay, allowing it to exert beneficial effects on the human body just like red clay. Among the components of the above red clay, quartz, feldspar, mica, and calcite undergo oxidation along with iron, resulting in various colors. This red clay possesses various eco-friendly properties, including decomposition power, self-purification power, far-infrared rays emitted from the red clay, antibacterial, insecticidal, air purification, and deodorization effects.
[0083] The above kaolin is a white clay composed primarily of kaolinite and halloysite. The silica component of the kaolin acts as the framework for the brick, while the alumina component provides refractory properties that extend the firing range. Furthermore, it exhibits excellent resistance to chemical reactions, abrasion, and thermal shock.
[0084] The above fly ash refers to ash (coal ash) collected from the flue gas of a boiler burning pulverized coal using a dust collector, and the fly ash can be included in the mixture to improve coagulation properties.
[0085] The above fly ash is produced when coal is finely ground in a thermal power plant and injected into a furnace at high speed along with hot air; at a temperature range of 1300 to 1700°C, which is above the melting point, most of the minerals contained in the coal are instantly combusted in a suspended state, and after combustion, they can be collected by a dust collector.
[0086] Next, the above mixture can be heated and calcined.
[0087] The above firing can be performed by heating the mixture in a kiln, for example, a tunnel kiln or a discontinuous kiln, and the kiln can maintain an internal temperature of 380 to 420°C, and after introducing the mixture into the kiln, the mixture can be fired in an oxidizing or reducing (neutral) atmosphere for 5 to 7 hours while gradually increasing the temperature to 900 to 1100°C.
[0088] The mixture can be introduced after the internal temperature of the kiln is initially maintained at 380 to 420°C. By maintaining the internal temperature of the kiln under such temperature conditions, the explosion and damage of the mixture caused by the initial rapid heating can be prevented.
[0089] In addition, after adding the above mixture, the temperature is gradually increased to 900 to 1100°C and calcined in an oxidizing or reducing (neutral) atmosphere for 5 to 7 hours. If calcined below the above temperature and time conditions, problems may arise such as a decrease in water absorption and difficulty in producing biochar with the desired compressive strength. If calcined above the above temperature and time conditions, the improvement in the physical properties of the biochar is minimal, while the cost of high-temperature treatment increases, which may lead to a problem of rising production costs.
[0090] Next, the above-mentioned calcined mixture can be cooled to produce biochar.
[0091] The above biochar can be produced by removing the calcined mixture from the kiln and cooling it at a temperature of 40 to 60°C.
[0093] The above rust inhibitor can prevent the physical properties of the tile including the primer layer (200) from deteriorating due to moisture and optimize the corrosion prevention effect, and the rust inhibitor includes zinc, aluminum, dicyclohexyl ammonium carbamate, cellulose, trimethoxyvinylsilane, and arabic gum.
[0094] In addition, the above rust inhibitor may be included in a weight ratio of 30 to 40 parts by weight of zinc, 10 to 20 parts by weight of aluminum, 5 to 15 parts by weight of dicyclohexyl ammonium carbamate, 1 to 10 parts by weight of cellulose, 1 to 5 parts by weight of trimethoxyvinylsilane, and 5 to 15 parts by weight of arabic gum.
[0095] The above zinc and aluminum are included in the rust inhibitor and perform a corrosion prevention role, and can exhibit excellent rust prevention performance.
[0096] The above dicyclohexyl ammonium carbamate can be used as a rust-preventing material, sodium carboxymethyl cellulose can be used as the cellulose, and the above trimethoxyvinylsilane can be used as an inorganic binder.
[0098] The above calcium carbonate is used as an inorganic filler and can play a role in increasing initial adhesion by raising apparent viscosity, improving workability and adhesion by reducing shrinkage and expansion during curing, and enhancing the heat resistance and durability of the adhesive.
[0099] The above calcium carbonate has the chemical formula CaCO3 and is the most abundant salt found in nature. It exists in various forms, including marble, calcite, argillaceous minerals, limestone, chalk, iceberg minerals, seashells, eggshells, and coral. The calcium carbonate is generally a colorless crystal or a white solid with a specific gravity of 2.93. It can decompose at 825°C and, when heated, produces carbon dioxide (CO2) and yields quicklime (CaCO3 → CaO + CO2↑).
[0100] The above calcium carbonate is inexpensive and has a low specific gravity, so it can be widely used in industrial fields. The above calcium carbonate can be used as a main raw material for cement, a raw material for calcium oxide, and a neutralizing agent for building materials, etc. It is used in white pigments and water-based paints, and precipitated calcium carbonate is used in pigments, paints, toothpaste, etc., and can also be incorporated as a reinforcing agent into rubber.
[0102] The acrylonitrile-butadiene rubber (NBR) mentioned above is the only rubber that can be mixed with polyurethane resin, and is produced based on the copolymerization of acrylonitrile (AN, Acrylonitrile) and 1,3-butadiene (BD, 1,3-Butadiene), and its main feature is the excellent oil resistance provided by acrylonitrile (AN, Acrylonitrile).
[0103] Furthermore, the acrylonitrile butadiene rubber mentioned above has excellent physical properties such as oil resistance, aging resistance, wear resistance, and gas permeability, and has good processability, so it is widely used in the development of various industrial component materials in the machinery industry, such as automobiles.
[0104] The acrylonitrile-butadiene rubber described above can, in principle, be distinguished into so-called cold polymerization and hot polymerization. Cold polymerization generally takes place at a temperature of 5 to 15°C and, in contrast to hot polymerization which is generally performed at 30 to 40°C, forms a smaller number of chain branches. For example, the acrylonitrile-butadiene rubber is available from numerous manufacturers such as Nitriflex, Zeon, LG Chemicals, and Lanxess.
[0105] The above acrylonitrile-butadiene rubber (NBR) can be used with a plasticizer to provide high friction not only in a dry sheet state but also in a wet sheet state caused by moisture, etc., prevent the ejection of the plasticizer, and improve bonding properties.
[0107] The above-mentioned plasticizer acts as a rubber softener to improve elongation and elasticity, and is an essential additive that, when added to intermediate compositions, lowers melt viscosity and glass transition temperature (Tg) to improve processability and impart various physical properties and functions to the final product, such as flexibility and cold resistance.
[0108] For example, one or more selected from the group consisting of epoxy-based plasticizers, benzoate-based plasticizers, citrate-based plasticizers, phosphate-based plasticizers, and adipate-based plasticizers may be used as the plasticizers, and preferably, an epoxy-based plasticizer that is a stabilizer with excellent heat resistance, cold resistance, processability, etc. may be provided.
[0109] The above-mentioned epoxy plasticizer may include epoxidized octyl stearate, epoxidized fatty acid ester, etc., but is not limited thereto.
[0110] The above benzoate-based plasticizers may include, but are not limited to, 2-(2-(2-phenylcarbonyloxyethoxy)ethoxy)ethyl benzoate, glyceryl tribenzoate, trimethylolpropane tribenzoate, isononyl benzoate, 1-methyl-2-(2-phenylcarbonyloxypropoxy)ethyl benzoate, 2,2,4-trimethyl-1,3-pentanediol dibenzoate, n-hexyl benzoate, or trimethylolpropane tribenzoate.
[0111] Acetyl tributyl citrate or tributyl citrate may be used as the above-mentioned citrate-based plasticizer, but is not limited thereto.
[0112] Tricresyl phosphate or tributyl phosphate may be used as the above-mentioned phosphate-based plasticizer, but is not limited thereto.
[0113] The above adipate-based plasticizers may include bis(2-ethylhexyl)adipate, dimethyl adipate, monomethyl adipate, or dioctyl adipate diisononyl adipectite, but are not limited thereto.
[0115] The above UV stabilizer blocks the penetration of ultraviolet rays in sunlight, thereby delaying the oxidation of the tile containing the primer layer (200) due to the chemical action and bleaching action of ultraviolet rays for a certain period, and thus extends the function and lifespan of the tile.
[0116] For example, the above UV stabilizer may include at least one selected from benzotriazole-based and hindered amine-based light stabilizers (HALS). In particular, the above HALS is a representative substance of radical scavengers that capture radicals and is mainly effective in preventing gloss loss and yellowing.
[0117] Examples of the above UV stabilizers include benzotriazole-based UV stabilizers such as Ciba’s Tinuvin 234 and Tinuvin 360.
[0119] The above cyclohexanediamine can be represented by the following [Chemical Formula 3] or [Chemical Formula 4], and the cyclohexanediamine represented by the following [Chemical Formula 3] or [Chemical Formula 4] is desirable because it has high mechanical properties and has the effect of improving tensile strength, tear strength, and film hardness.
[0120] [Chemical Formula 3]
[0121]
[0122] In the above [Chemical Formula 3], R 5 to R 8 are identical or different from one another and are each independently a substituted or unsubstituted alkyl group having 1 to 20 carbon atoms, or a substituted or unsubstituted alkoxy group having 1 to 20 carbon atoms, preferably a substituted or unsubstituted alkyl group having 1 to 10 carbon atoms, or a substituted or unsubstituted alkoxy group having 1 to 10 carbon atoms. More preferably, R 5 to R 8Each is independently a linear or branched alkyl group having 1 to 4 carbon atoms. Most preferably, R 5 to R 8 Each is independently selected from methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, or t-butyl groups, and R 5 to R 8 It is particularly desirable that all of them are methyl groups.
[0124] [Chemical Formula 4]
[0125]
[0126] In the above [Chemical Formula 4], R 9 to R 12 are identical or different from one another and are each independently a substituted or unsubstituted alkyl group having 1 to 20 carbon atoms, or a substituted or unsubstituted alkoxy group having 1 to 20 carbon atoms, preferably a substituted or unsubstituted alkyl group having 1 to 10 carbon atoms, or a substituted or unsubstituted alkoxy group having 1 to 10 carbon atoms. More preferably R 9 to R 12 Each is independently a linear or branched alkyl group having 1 to 4 carbon atoms. Most preferably, R 9 to R 12 Each is independently selected from methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, or t-butyl groups, and R 9 to R 12 It is particularly desirable that all of them are methyl groups.
[0128] The above 1,3-bis(aminomethyl)benzene can be used as a curing agent to control the curing speed of the adhesive, and the above 1,3-bis(aminomethyl)benzene can have a fast curing speed and prevent whitening phenomena.
[0129] In addition, the 1,3-bis(aminomethyl)benzene (1,3-bis(Aminomethyl)Benzene) can exhibit excellent adhesion without dissolution and without causing damage to the bottom surface (100), and can prevent lifting and peeling phenomena.
[0131] The above epoxy novolak layer (300) is formed on the above primer layer (200), and the epoxy novolak layer (300) is manufactured from an epoxy novolak resin with excellent acid resistance, thereby improving the acid and chemical resistance of the tile.
[0132] The epoxy novolak layer (300) can be formed by applying an epoxy novolak composition onto the primer layer (200) and then drying it. For example, the epoxy novolak composition comprises epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives.
[0133] Specifically, the epoxy novolak composition may be included in a weight ratio of 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives.
[0135] The above epoxy novolak resin may be a phenolic resin, and the phenolic resin may be manufactured by including the steps of: (1) reacting phenol with formaldehyde; (2) vacuum dehydrating the reaction product; and (3) adding a phenol-oil compound to the vacuum dehydrated reaction product to cure it.
[0136] The above phenolic resin can be broadly divided into two general categories, namely novolak and resol, and the above novolak resin is generally characterized by having insufficient formaldehyde, with the ratio of formaldehyde to phenol group being less than 1.
[0137] The above resol resin is generally characterized by being rich in formaldehyde, and the ratio of formaldehyde resin to phenol group is greater than 1.
[0138] The above novolak and resol may both incorporate various phenolic compounds, either alone or in combination, including but not limited to phenol, resorcinol, bisphenol, floglucinol, cresol, alkyl phenol, phenyl ether, tannin, and lignin. Similarly, other aldehydes, including but not limited to acetaldehyde, propionaldehyde, cyclohexanedicarboxaldehyde, benzaldehyde, furfural, and other aryl or heterocyclic aldehydes, may substitute all or part of formaldehyde.
[0139] The above novolak resin can generally be cured (crosslinked, cured) through the use of formaldehyde, formaldehyde-donating curing agent compounds, or formaldehyde equivalent compounds. Hexa-methylenetetramine (hexa) and paraformaldehyde can often be used to cure novolak resins.
[0140] In addition to the source of formaldehyde, the presence of heating and a catalyst may generally be used to increase the speed and degree of curing, said catalyst may include an inorganic base including calcium hydroxide, sodium hydroxide, potassium hydroxide, calcium oxide, magnesium oxide, or a combination thereof; a Lewis acid including zinc chloride, zinc acetate, or a combination thereof; or an amine including triethylamine.
[0141] In the step of reacting the phenol and formaldehyde in (1) above, the molar ratio of the formaldehyde to the phenol may be 0.5 to 1.0, and more specifically, it is preferably 0.5 to 0.8. At this time, if the molar ratio of the formaldehyde to the phenol is less than 0.5, there is a problem of weak strength, and if it exceeds 1.0, there is a problem of poor compatibility.
[0142] At this time, the formaldehyde may include paraformaldehyde, and when reacting phenol with paraformaldehyde, the molar ratio of paraformaldehyde to phenol is preferably 1.5 to 2.5.
[0143] The step of reacting phenol and formaldehyde (1) above is preferably carried out for 1 to 2 hours at a temperature range of 100 to 120°C. When the step of reacting phenol and formaldehyde (1) above is carried out within the above range, there is an advantage in that the problem of environmental pollution can be minimized by minimizing unreacted material.
[0144] The step of reacting (1) phenol with formaldehyde is carried out in the presence of a catalyst, and the catalyst may include NaOH, Ba(OH)2, Ca(OH)2, Mg(OH)2, KOH, or a combination thereof.
[0145] In the step of reacting (1) phenol and formaldehyde, a curing agent may be added during the reaction, and the curing agent may be an acid curing agent and may include oxalic acid, hydrogen chloride, phosphoric acid, salicylic acid, sulfuric acid, benzenesulfonic acid, toluenesulfonic acid, xylenesulfonic acid, or a combination thereof.
[0146] The step of vacuum dehydrating the above (2) reaction product is preferably carried out at a temperature of 100 to 200°C for 100 to 150 seconds (sec). When the vacuum dehydration process is performed within the above range, the molecular weight of the material containing condensed water and foreign substances is controlled along with the dehydration process, thereby allowing it to have good physical properties.
[0147] The step of adding a phenol-oil compound to the vacuum-dehydrated reactant (3) and curing it may have a weight ratio of the phenol-oil compound to the reactant of 0.1 to 0.5. If the weight ratio of the phenol-oil compound to the reactant is less than 0.1, there is a problem with stability due to the formation of macromolecules, and if it exceeds 0.5, there is a problem with not being able to utilize the advantages of the compound's properties.
[0148] At this time, it is preferable that the weight ratio of oil in the phenol-oil compound is 0.8 to 0.9, and when the oil content in the phenol-oil compound is carried out within the above range, an active chemical reaction can occur during curing.
[0149] Here, the oil in the phenol-oil compound may, for example, include a fatty acid having a conjugated double bond. If the oil is an oil having a conjugated double bond, the step of adding the phenol-oil compound to the vacuum dehydrated reactant described above (3) and curing it is preferably carried out at a temperature of 100 to 200°C for 80 to 100 seconds.
[0150] Meanwhile, as another example, the oil in the above phenol-oil compound may include tung oil, drying oil, or a combination thereof. If the oil is the tung oil, drying oil, or a combination thereof, the step of adding the phenol-oil compound to the above vacuum dehydrated reactant (3) and curing it is preferably carried out at a temperature of 100 to 200°C for 60 to 100 seconds.
[0152] The titanium dioxide mentioned above acts as a photocatalyst, and the photocatalyst refers to a substance that accepts light and promotes a chemical reaction. This photocatalyst mainly generates electrons and holes when light energy greater than the band gap energy is irradiated, and hydroxyl radicals (-OH) are generated by the generated holes, and it refers to a substance that causes a so-called 'photooxidation reaction' that decomposes gaseous or liquid organic matter adsorbed on its surface through the strong oxidizing power of the hydroxyl radicals.
[0153] The titanium dioxide mentioned above exhibits catalytic activity by absorbing light energy, and through the strong oxidizing power generated at this time, it oxidizes and decomposes harmful substances emitted from human sweat, waste products, and secretions. Utilizing these properties, titanium dioxide is primarily used in the purification of organically polluted water to decompose bacteria, microorganisms, and organic substances.
[0155] The above glass fiber is made by melting and processing glass with silicate as the main component into a fiber shape, and is also called glass fiber or glass wool.
[0156] These glass fibers not only possess excellent heat resistance, corrosion resistance, moisture resistance, thermal insulation, and sound absorption properties, but also have the characteristic that tensile strength and flexibility increase as the diameter of the glass fibers decreases; therefore, they are widely used in a wide variety of industrial fields, such as raw materials for reinforced plastics, electrical insulation materials, battery separators, sound-absorbing (soundproofing) materials, thermal insulation materials, decorative fabrics, and filters.
[0158] The above epichlorohydrin modified phenol formaldehyde resin serves to enhance adhesion and improve strength.
[0159] The above epichlorohydrin modified phenol formaldehyde resin can be combined with epoxy novolak resin to form a coating film with excellent impact resistance and chemical resistance. The above epichlorohydrin modified phenol formaldehyde resin has the advantages of being non-flammable, having good weather resistance, having high mechanical strength and relatively elasticity, good thermal and electrical insulation, water resistance, and excellent chemical resistance.
[0161] The above carbon black can be used as a black coloring pigment to impart color and opacity to the epoxy novolak layer (300), and the carbon black has excellent coloring power and blackness, so it can have excellent color and opacity.
[0162] The above carbon black is intended to improve workability by reducing the flowability of the epoxy novolak composition, while simultaneously increasing thermal and mechanical stability; any conventional carbon black in the industry having this purpose may be used.
[0164] The above additives may be included to enhance the physical properties of the epoxy novolak composition, for example, one or more selected from the group consisting of fillers, leveling agents, and wetting agents may be used.
[0165] The above filler may be included to improve the impact resistance and strength of the coating film. For example, one or more selected from the group consisting of calcium carbonate, talc, aluminum oxide, aluminum hydroxide, magnesium carbonate, silica, and kaolinite may be used as the filler.
[0166] The above leveling agent can improve fluidity by lowering the surface tension of the coating film. For example, one or more selected from polyacrylate or polyethylene oxide acetate may be used as the leveling agent.
[0167] The above wetting agent may be included to increase diffusion power by reducing the surface tension of the primer layer (200) and the tile, for example, one or more selected from the group consisting of monoglycerides, polyglycerol fatty acid esters, sorbitan fatty acid esters, polyethylene glycol, and ethoxylates may be used as the wetting agent.
[0169] The above epoxy layer (400) is formed on the epoxy novolak layer (300), thereby strengthening the adhesion between the epoxy novolak layer (300) and the tile layer (500) and preventing the tile layer (500) from being easily separated or peeled off.
[0170] The epoxy layer (400) can be formed by applying an epoxy composition onto the epoxy novolak layer (300) and then drying it. For example, the epoxy composition includes bisphenol F type epoxy resin, titanium dioxide (TiO2), iron(II) oxide (FeO), dodecyl phenol, and epichlorohydrin-modified phenol-formaldehyde resin.
[0171] Specifically, the epoxy composition may be included in a weight ratio of 60 to 90 parts by weight of bisphenol F-type epoxy resin, 0.1 to 2 parts by weight of titanium dioxide (TiO2), 0.1 to 2 parts by weight of iron(II) oxide (FeO), 0.1 to 2 parts by weight of dodecyl phenol, and 0.01 to 0.1 parts by weight of epichlorohydrin-modified phenol-formaldehyde resin.
[0173] The above-mentioned bisphenol F-type epoxy resin is a resin in which H is present instead of CH3 in the molecules of bisphenol A-type epoxy resin, and compared to bisphenol A-type, it has low viscosity, excellent plasticity, and high reactivity. As high filler content is sought to improve heat resistance and mechanical properties in electrical and electronic materials, low-viscosity epoxy resins are being introduced, and bisphenol F-type epoxy resin is widely known as such low-viscosity epoxy resin.
[0174] The above bisphenol F type epoxy resin may be used having an epoxy equivalent of 160 to 180 (g / eq), a viscosity of 2,500 to 4,500 (cps, at 25℃), and a molecular weight (Mw) of 500 to 1,500, and the above bisphenol F type epoxy resin may be a bisphenol F type epoxy resin having the structure of [Chemical Formula 5] below.
[0175] [Chemical Formula 5]
[0176]
[0177] In the above [Chemical Formula 5], n is a positive number in the range of 1 to 10, and for example, the above bisphenol F type epoxy resin is YDF-720 (product name) of Kookdo Chemical Co., Ltd. or SEF-170 of Shin-A T&C Co., Ltd.
[0179] The titanium dioxide mentioned above acts as a photocatalyst, and the photocatalyst refers to a substance that accepts light and promotes a chemical reaction. This photocatalyst mainly generates electrons and holes when light energy greater than the band gap energy is irradiated, and hydroxyl radicals (-OH) are generated by the generated holes, and it refers to a substance that causes a so-called 'photooxidation reaction' that decomposes gaseous or liquid organic matter adsorbed on its surface through the strong oxidizing power of the hydroxyl radicals.
[0180] The titanium dioxide mentioned above exhibits catalytic activity by absorbing light energy, and through the strong oxidizing power generated at this time, it oxidizes and decomposes harmful substances emitted from human sweat, waste products, and secretions. Utilizing these properties, titanium dioxide is primarily used in the purification of organically polluted water to decompose bacteria, microorganisms, and organic substances.
[0182] The above iron(II) oxide (FeO) is a substance formed by the combination of oxygen and iron, and it may be a naturally occurring substance. It is widely used as a pigment because it has almost no impact on the environment and the human body, and also produces strong colors.
[0184] The above dodecyl phenol acts as a plasticizer and can control the curing speed.
[0185] The above dodecyl phenol may be included in a weight ratio of 0.1 to 2 parts by weight of the total content of the epoxy composition. If the above dodecyl phenol is included in an amount less than 0.1 parts by weight, the impact resistance of the epoxy layer (400) may decrease, and if it is included in an amount exceeding 2 parts by weight, the hardness of the coating film decreases and a phenomenon of the coating film surface lifting occurs after drying, and a phenomenon of cloudiness may occur in the coating film.
[0187] The above epichlorohydrin modified phenol formaldehyde resin serves to enhance adhesion and improve strength.
[0188] The above epichlorohydrin modified phenol formaldehyde resin can be combined with epoxy novolak resin to form a coating film with excellent impact resistance and chemical resistance. The above epichlorohydrin modified phenol formaldehyde resin has the advantages of being non-flammable, having good weather resistance, having high mechanical strength and relatively elasticity, good thermal and electrical insulation, water resistance, and excellent chemical resistance.
[0190] The above tile layer (500) is formed on the epoxy layer (400), and the tile layer (400) may use known tiles. Generally, a tile is a flat, fired product made for surface decoration, such as floors and walls. Depending on its function and material, tiles are used in various ways, such as interior tiles, exterior tiles, mosaic tiles, acid-resistant tiles, floor tiles, salt field tiles, and quarry tiles. Tiles are widely used in kitchens, restrooms, bathrooms, washrooms, etc. because they are easy to install.
[0191] That is, the above tile is a flat, fired clay product made to cover the surface of a building, such as a floor or wall. The tile possesses various properties and is relatively easy to install. Furthermore, it rarely cracks or discolors after installation and is particularly durable, making it the best material for covering and protecting the surface of a structure. For example, tile bricks can be used as the tile.
[0192] The above tile brick is processed into a rectangular block shape, similar to general masonry bricks. Recently, tile bricks are being used not only for interior decoration but also as exterior materials. Examples of the above tile brick may include those made by molding raw materials such as clay and weathered granite soil and then firing them, but are not limited thereto.
[0193] As the composition of the tile including the tile brick in the present invention is a known technology, a detailed description thereof will be omitted for the convenience of explanation and to clarify the technical concept of the present invention.
[0195] Hereinafter, a method for manufacturing a tile structure with excellent acid and chemical resistance according to another embodiment of the technical concept of the present invention will be described in more detail with reference to the attached drawings.
[0197] FIG. 2 is a flowchart illustrating a method for manufacturing a tile structure with excellent acid and chemical resistance according to another embodiment of the technical concept of the present invention.
[0199] Referring to FIG. 2, a method for manufacturing a tile structure (10) with excellent acid and chemical resistance according to another embodiment of the technical concept of the present invention includes a primer layer forming step (S100), an epoxy novolak layer forming step (S200), an epoxy layer forming step (S300), and a tile layer forming step (S400).
[0201] 1. Primer layer formation step (S100)
[0202] The above primer layer formation step (S100) is a step of forming a primer layer (200) by applying a primer composition to a bottom surface (100).
[0203] In the above primer layer formation step (S100), the floor surface (100) is a place where tiles are installed, for example, flooring of a building or civil engineering structure, a rooftop, a retaining wall or ceiling of an underground structure, an interior such as a toilet, bathroom, veranda, etc., or a surface or floor surface of a chemical tank, piping, pipe, steel pipe, various reinforcing bars or concrete structures, a ship, a chemical plant, an oil refinery, a power plant, a water treatment facility, etc. Specifically, the floor surface may be a floor surface of a building or civil engineering structure.
[0204] For example, in the primer layer formation step (S100), the primer composition comprises a polyurethane resin, a polysiloxane, a polybutylene adipate terephthalate resin (PBAT), an ethylene-vinyl acetate copolymer (EVA), biochar, a rust inhibitor, calcium carbonate, acrylonitrile-butadiene rubber (NBR), a plasticizer, a UV stabilizer, cyclohexanediamine, and 1,3-bis(aminomethyl)benzene.
[0205] Specifically, the primer composition comprises 300 to 400 parts by weight of polyurethane resin, 10 to 30 parts by weight of polysiloxane, 80 to 120 parts by weight of polybutylene adipate terephthalate (PBAT) resin, 30 to 70 parts by weight of ethylene-vinyl acetate copolymer (EVA), 1 to 10 parts by weight of biochar, 10 to 30 parts by weight of rust inhibitor, 5 to 15 parts by weight of calcium carbonate, 10 to 20 parts by weight of acrylonitrile-butadiene rubber (NBR), 1 to 5 parts by weight of plasticizer, 10 to 20 parts by weight of UV stabilizer, 20 to 40 parts by weight of cyclohexanediamine, and 1,3-bis(aminomethyl)benzene may be included in a weight ratio of 30 to 50 parts by weight.
[0207] 2. Epoxy novolak layer formation step (S200)
[0208] The above epoxy novolak layer formation step (S200) is a step of forming an epoxy novolak layer (300) by applying an epoxy novolak composition on the primer layer (200).
[0209] For example, in the epoxy novolak layer forming step (S200), the epoxy novolak composition comprises epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives.
[0210] Specifically, the epoxy novolak composition may be included in a weight ratio of 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives.
[0212] 3. Epoxy layer formation step (S300)
[0213] The above epoxy layer formation step (S300) is a step of forming an epoxy layer (400) by applying an epoxy composition onto the epoxy novolak layer (300).
[0214] For example, in the epoxy layer forming step (S300), the epoxy composition comprises bisphenol F type epoxy resin, titanium dioxide (TiO2), iron(II) oxide (FeO), dodecyl phenol, and epichlorohydrin-modified phenol-formaldehyde resin.
[0215] Specifically, the epoxy composition may be included in a weight ratio of 60 to 90 parts by weight of bisphenol F-type epoxy resin, 0.1 to 2 parts by weight of titanium dioxide (TiO2), 0.1 to 2 parts by weight of iron(II) oxide (FeO), 0.1 to 2 parts by weight of dodecyl phenol, and 0.01 to 0.1 parts by weight of epichlorohydrin-modified phenol-formaldehyde resin.
[0217] 4. Tile layer formation step (S400)
[0218] The above tile layer forming step (S400) is a step of forming a tile layer (500) on the epoxy layer (400).
[0219] In the above tile layer forming step (S400), the tile can be used in various ways depending on its function and material, such as interior tiles, exterior tiles, mosaic tiles, acid-resistant tiles, floor tiles, salt field tiles, quarry tiles, etc., and preferably, tile bricks can be used as the tile.
[0221] Hereinafter, with reference to the attached drawings, an embodiment of a tile structure with excellent acid and chemical resistance according to one embodiment of the technical concept of the present invention will be described in more detail.
[0223] < Examples >
[0224] A tile structure was manufactured comprising a primer layer formed on a bottom surface, an epoxy novolak layer formed on the primer layer, an epoxy layer formed on the epoxy novolak layer, and a tile layer formed on the epoxy layer.
[0225] At this time, the primer layer was formed by applying a primer composition to the bottom surface, wherein the primer composition comprises 350 parts by weight of polyurethane resin, 20 parts by weight of polysiloxane, 100 parts by weight of polybutylene adipate terephthalate (PBAT), 50 parts by weight of ethylene-vinyl acetate copolymer (EVA), 5 parts by weight of biochar, 5 parts by weight of rust inhibitor, 10 parts by weight of calcium carbonate, 15 parts by weight of acrylonitrile-butadiene rubber (NBR), 3 parts by weight of plasticizer, 15 parts by weight of UV stabilizer, 30 parts by weight of cyclohexanediamine, and 40 parts by weight of 1,3-bis(aminomethyl)benzene. It was manufactured by mixing.
[0226] In addition, the epoxy novolak layer was formed by applying an epoxy novolak composition onto a primer layer, and the epoxy novolak composition was prepared by mixing 45 parts by weight of epoxy novolak resin, 20 parts by weight of titanium dioxide (TiO2), 18 parts by weight of glass fiber, 0.5 parts by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.3 parts by weight of carbon black, and 2 parts by weight of additives.
[0227] As the above additives, a filler, a leveling agent, and a wetting agent were mixed in a weight ratio of 1:1:1 and used.
[0228] In addition, the epoxy layer was formed by applying an epoxy composition onto the epoxy novolak layer, and the epoxy composition was prepared by mixing 75 parts by weight of bisphenol F type epoxy resin, 1 part by weight of titanium dioxide (TiO2), 1 part by weight of iron(II) oxide (FeO), 1 part by weight of dodecyl phenol, and 0.05 parts by weight of epichlorohydrin-modified phenol-formaldehyde resin.
[0230] 1. Acid resistance test
[0231] After dropping 98% sulfuric acid onto the epoxy novolak layer prepared according to the above example, an acid resistance test was performed.
[0233] Figure 3 is a photograph showing the state after dropping 98% sulfuric acid onto an epoxy novolak layer prepared according to an example.
[0235] Referring to Fig. 3, it can be confirmed that after dropping 98% sulfuric acid onto an epoxy novolak layer prepared according to the example, there is no change in color or gloss and no surface swelling caused by sulfuric acid, which confirms that the tile structure prepared according to the example has excellent acid resistance properties.
[0237] 2. Stain resistance test
[0238] A stain resistance test was performed on the epoxy novolak layer prepared according to the above example.
[0240] Figures 4a and 4b are test reports showing the stain resistance results of an epoxy novolak layer prepared according to the example.
[0242] Referring to FIGS. 4a and 4b, it can be seen that the epoxy novolak layer prepared according to the example does not show significant changes in color, gloss, or swelling when exposed to 98% sulfuric acid, toluene, 40% sodium hydroxide solution, and 35% hydrochloric acid, thereby confirming that the tile structure prepared according to the example has excellent stain resistance properties.
[0244] Although a preferred embodiment of the present invention has been described above with reference to the attached drawings, those skilled in the art will understand that the present invention may be implemented in other specific forms without altering its technical concept or essential features. Therefore, the embodiment described above should be understood as illustrative in all respects and not restrictive. Explanation of the symbols
[0245] 10; Tile structure 100; bottom surface 200; Primer layer 300; Epoxy novolak layer 400; epoxy layer 500; Tile layer
Claims
Claim 1 A tile structure having excellent acid and chemical resistance, comprising a primer layer formed on a bottom surface, an epoxy novolak layer formed on the primer layer, an epoxy layer formed on the epoxy novolak layer, and a tile layer formed on the epoxy layer, wherein the epoxy novolak layer is formed by applying an epoxy novolak composition on the primer layer, and the epoxy novolak composition comprises an epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives. Claim 2 A tile structure with excellent acid and chemical resistance according to claim 1, characterized in that the epoxy novolak composition comprises 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives. Claim 3 A tile structure with excellent acid and chemical resistance according to claim 2, wherein the epoxy layer is formed by applying an epoxy composition onto the epoxy novolak layer, and the epoxy composition comprises bisphenol F-type epoxy resin, titanium dioxide (TiO2), iron(II) oxide (FeO), dodecyl phenol, and epichlorohydrin-modified phenol-formaldehyde resin. Claim 4 A tile structure having excellent acid and chemical resistance according to claim 3, characterized in that the epoxy composition comprises 60 to 90 parts by weight of bisphenol F-type epoxy resin, 0.1 to 2 parts by weight of titanium dioxide (TiO2), 0.1 to 2 parts by weight of iron(II) oxide (FeO), 0.1 to 2 parts by weight of dodecyl phenol, and 0.01 to 0.1 parts by weight of epichlorohydrin-modified phenol-formaldehyde resin. Claim 5 In claim 4, the tile structure having excellent acid and chemical resistance is characterized by the use of tile bricks in the tile layer. Claim 6 A method for manufacturing a tile structure with excellent acid and chemical resistance, comprising: a primer layer forming step (S100) of forming a primer layer by applying a primer composition to a floor surface; an epoxy novolak layer forming step (S200) of forming an epoxy novolak layer by applying an epoxy novolak composition on the primer layer; an epoxy layer forming step (S300) of forming an epoxy layer by applying an epoxy composition on the epoxy novolak layer; and a tile layer forming step (S400) of forming a tile layer on the epoxy layer, wherein in the epoxy novolak layer forming step (S200), the epoxy novolak composition comprises an epoxy novolak resin, titanium dioxide (TiO2), glass fiber, epichlorohydrin-modified phenolformaldehyde resin, carbon black, and additives. Claim 7 A method for manufacturing a tile structure with excellent acid and chemical resistance according to claim 6, wherein in the step of forming the epoxy novolak layer (S200), the epoxy novolak composition comprises 30 to 60 parts by weight of epoxy novolak resin, 10 to 30 parts by weight of titanium dioxide (TiO2), 10 to 25 parts by weight of glass fiber, 0.1 to 1 part by weight of epichlorohydrin-modified phenolformaldehyde resin, 0.1 to 0.5 parts by weight of carbon black, and 1 to 3 parts by weight of additives.