Elastic flooring material having improved durability and weatherability

Abstract

The present invention relates to an eco-friendly elastic flooring material for athletic tracks used in sports fields, etc., which is environmentally friendly due to the use of natural components as well as having excellent durability and weather resistance. The present invention is formed into a multi-layered mat in which an upper layer and a lower layer are bonded together to form an integrated structure, wherein the upper layer is composed of a mixture of 10 to 30 weight% olefin resin, 30 to 50 weight% thermoplastic elastic resin, 10 to 30 weight% mineral filler, 1 to 10 weight% natural organic filler, 10 to 30 weight% mineral oil, 1 to 10 weight% additive, and 0.1 to 1 weight% foaming agent, and the lower layer is composed of 5 to 20 weight% olefin resin, 10 to 30 weight% thermoplastic elastic resin, 10 to 20 weight% mineral filler, 30 to 60 weight% EPDM powder, and 10 to 30 weight% mineral oil. The composition is formed by mixing 1 to 5 weight percent of additives and 0.1 to 1 weight percent of foaming agent, and the natural organic filler is characterized by being composed of 300 to 400 weight percent of jojoba powder mixed with 100 weight percent of lignin.

Description

Technology Field

[0001] The present invention relates to an eco-friendly elastic flooring material for athletic tracks used in sports fields, etc., which is environmentally friendly due to the use of natural components as well as having excellent durability and weather resistance. Background Technology

[0003] Generally, walking paths, sports fields, pedestrian walkways, and children's playgrounds have a base layer formed by paving the ground with concrete, asphalt, etc., and an elastic flooring material is installed on top of the base layer to absorb shock by providing a certain amount of cushioning.

[0004] Elastic flooring materials can be made with various colors and patterns for aesthetic purposes and are manufactured using rubber material of a predetermined thickness to have a certain degree of elasticity. At this time, to impart elasticity to the floor elastic material, elastic chips such as urethane or EPDM (ethylene propylene diene monomer) chips, or waste tire chips are mixed into a binder.

[0005] Elastic flooring materials require characteristics such as anti-slip properties, elasticity, and ease of installation. To effectively control these properties, they are composed of an upper sheet and a lower sheet, and are designed to exhibit their respective characteristics.

[0006] For mass production, the material is extruded into a sheet using a continuous extruder and then manufactured into an integrated mat through a heating and pressing process.

[0007] As a conventional technology for manufacturing elastic flooring, Registered Patent Publication No. 10-1113245 describes manufacturing an elastic flooring by manufacturing an upper sheet and a lower sheet and fusing them together. The upper sheet is manufactured by extruding a mixture of thermoplastic elastomer, unvulcanized EPDM rubber, polyolefin, mineral oil, calcium carbonate, and a foaming agent, respectively, and the lower sheet is manufactured with a composition in which vulcanized rubber powder is further added to the components of the upper sheet.

[0008] The aforementioned patent describes a manufacturing process in which polyolefin is added to the basic composition of elastic flooring—thermoplastic elastomer and EPDM rubber—to impart moldability, weather resistance, and heat resistance, and calcium carbonate is added for durability, such as reinforcing physical strength; however, this poses environmental problems due to increased carbon emissions resulting from the use of large amounts of synthetic materials and the release of large quantities of harmful substances.

[0009] In addition, while the addition of polyolefin and calcium carbonate provides moldability and strength reinforcement effects, the excessive addition of calcium carbonate may reduce the inherent properties of elastic flooring, such as shock absorption and elastic recovery. Furthermore, quality issues may arise, including reduced weather resistance due to efflorescence or surface cracking, and decreased durability caused by weakened bonding strength as the binder is absorbed into the calcium carbonate, preventing particles from adhering firmly to one another.

[0010] Meanwhile, elastic flooring installed in outdoor sports facilities undergoes continuous aging depending on the external environment, which can be interpreted as the continuous detachment of synthetic resin along with the deterioration of physical properties such as the shock absorption rate of the elastic flooring.

[0011] To prevent this, UV stabilizers and antioxidants are added. These stabilizers have a small molecular weight and tend to migrate to the surface of the elastic flooring. Once migrated to the surface, the stabilizers are washed away during rain, causing a burden on the environment. When the stabilizers are washed away, the aging of the elastic flooring proceeds faster than before, and microplastics are continuously generated on the aging surface, causing problems for the environment as well as safety.

[0012] As such, synthetic UV stabilizers have a problem in that they lack the ability to provide stability over a long period.

[0013] Recently, there has been a trend across society toward a low-carbon transition to reduce carbon emissions, and there is a need for research on technologies utilizing eco-friendly materials such as recycling and natural plant components. Prior art literature

[0015] Registered Patent Publication No. 10-1113245 (Jan. 31, 2012. Elastic flooring material having anti-slip function) Registered Patent Publication No. 10-1932142 (Dec. 18, 2018. Sheet-type elastic paving material and method for manufacturing the same) The problem to be solved

[0016] The present invention was devised to solve the aforementioned problems and aims to provide an eco-friendly elastic flooring for athletic tracks by reducing the amount of mineral filler, an inorganic compound added during the manufacturing of conventional elastic flooring, while adding natural components such as lignin and jojoba to enhance thermal stability and processability, and by reducing the amount of synthetic resin used to manufacture an eco-friendly elastic flooring that reduces carbon emissions and the emission of harmful substances.

[0017] Furthermore, the present invention provides an eco-friendly elastic flooring material for athletic tracks that can increase durability and weather resistance by preventing UV-induced aging through the addition of lignin, which functions as a natural binder, and extends the lifespan by maintaining elasticity for a long period and improving durability through the addition of jojoba powder, which acts as a natural plasticizer to prevent hardening of the rubber component. means of solving the problem

[0019] The means of the present invention for solving the above problem comprises forming a multilayer structured mat in which an upper layer and a lower layer are bonded together to form an integrated structure, wherein the upper layer is composed by mixing 10 to 30 weight% of an olefin resin, 30 to 50 weight% of a thermoplastic elastic resin, 10 to 30 weight% of a mineral filler, 1 to 10 weight% of a natural organic filler, 10 to 30 weight% of a mineral oil, 1 to 10 weight% of an additive, and 0.1 to 1 weight% of a foaming agent, and the lower layer is composed by mixing 5 to 20 weight% of an olefin resin, 10 to 30 weight% of a thermoplastic elastic resin, 10 to 20 weight% of a mineral filler, 30 to 60 weight% of EPDM powder, 10 to 30 weight% of a mineral oil, 1 to 5 weight% of an additive, and 0.1 to 1 weight% of a foaming agent. The natural organic filler is characterized by being composed of 300 to 400 parts by weight of jojoba powder mixed with 100 parts by weight of lignin.

[0020] Here, one or more types selected from SBS block copolymer (styrene-butadiene-styrene block copolymer), SEBS block copolymer (styrene-ethylene-butadiene-styrene block copolymer), and olefin block copolymer are added to the thermoplastic elastic resin.

[0021] In addition, the mineral filler added to the upper layer is one or more selected from silica, calcium carbonate, talc, mica, and bentonite, and the mineral filler added to the lower layer is preferably heavy carbon.

[0022] delete Effects of the invention

[0024] According to the present invention composed of the above, by significantly reducing the amount of mineral filler, which is an inorganic compound, and adding natural ingredients such as lignin and jojoba powder, it is possible to manufacture an eco-friendly elastic flooring material that reduces harmful substances, such as carbon emissions.

[0025] In addition, due to the addition of lignin and jojoba components, the surface layer (upper layer) is resistant to ultraviolet rays and slows down aging, as well as possessing flexibility, allowing elasticity to be consistently maintained without discoloration or changes in physical properties over a long period, thereby enabling the manufacture of an elastic flooring with improved durability and weather resistance. Furthermore, it has the effect of making maintenance easier by reducing maintenance costs. Brief explanation of the drawing

[0027] FIG. 1 is a cross-sectional view of an embodiment illustrating the structure of an eco-friendly elastic flooring material according to the present invention. Specific details for implementing the invention

[0028] Hereinafter, an eco-friendly elastic flooring material for athletic tracks with improved durability and weather resistance according to a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0029] As shown in FIG. 1, the eco-friendly elastic flooring for a running track with improved durability and weather resistance according to the present invention is formed into an integrated multilayer structure mat by being formed into an upper layer (10) and a lower layer (20), respectively, and then bonded together through fusion.

[0030] The upper layer is the part whose surface is exposed to the outside when constructed for an athletics track. It is designed to provide anti-slip functions as well as shock absorption and resilience. Since continuous aging occurs due to environmental conditions such as climate and usage conditions such as friction with users, leading to a deterioration of physical properties like shock absorption and the detachment of synthetic resin, it is molded to possess weather resistance and durability.

[0031] Furthermore, the lower layer, which is not exposed to the outside during construction, is molded to possess basic durability and weather resistance while assisting in enhancing the shock absorption and repulsion of the upper layer. Additionally, since the lower layer is in direct contact with the floor surface, it is molded to be harder than the upper layer and possess high elasticity to increase repulsion.

[0032] Accordingly, the upper layer is formulated with natural ingredients such as lignin and jojoba powder to enhance thermal stability and slow down the aging rate, thereby increasing weather resistance and durability, while reducing the use of petroleum-based raw materials to lower carbon emissions and prevent the release of harmful substances; meanwhile, the lower layer is formulated with EPDM powder to provide additional elasticity, which enhances the shock absorption and resilience of the upper layer while ensuring rigid molding to prevent breakage.

[0033] In the present invention, the upper layer is composed of a mixture of an olefin resin, a thermoplastic elastic resin, a mineral filler, mineral oil, an additive, and a foaming agent, to which lignin and jojoba powder are additionally added as natural organic fillers.

[0034] Specifically, the composition is formed by mixing 10 to 30 weight% of an olefin resin, 30 to 50 weight% of a thermoplastic elastic resin, 10 to 30 weight% of a mineral filler, 1 to 10 weight% of a natural organic filler, 10 to 30 weight% of a mineral oil, 1 to 10 weight% of an additive, and 0.1 to 1 weight% of a foaming agent.

[0035] Olefin resins are components for imparting weather resistance and heat resistance, and are not significantly limited in type as long as they are commonly used or known. Considering commercial availability and moldability into sheet form, one or more types selected from polyethylene or polypropylene may be used.

[0036] The above thermoplastic elastic resin is a rubber for imparting elasticity, and considering that it is commercially available and has moldability into a sheet form, adhesion, and shock absorption properties, one or more types selected from commonly used SBS block copolymer (styrene-butadiene-styrene block copolymer), SEBS block copolymer (styrene-ethylene-butadiene-styrene block copolymer), and olefin block copolymer may be added.

[0037] The mineral filler may consist of one or more of calcium carbonate, talc, silica, mica, and bentonite, and is added to increase the weight, reinforcement, and elasticity of the upper layer. It is preferable to use a mixture of silica and calcium carbonate to make the upper layer soft and increase its elasticity.

[0038] At this time, the mineral filler is added in an amount of 10 to 30 weight percent, which is less than the amount added to conventional elastic flooring materials.

[0039] In the present invention, the amount of commonly used mineral filler is reduced, and a natural organic filler is added as an eco-friendly material. The lignin and jojoba powder added as natural organic fillers are composed of 300 to 400 parts by weight of jojoba powder mixed with 100 parts by weight of lignin.

[0040] With the addition of the above mineral filler, it is possible to manufacture an elastic flooring material that is not only heat-resistant but also harder and less deformed. However, in the past, when a large amount of mineral filler was added, the physical properties of the elastic flooring material were actually degraded, leading to problems such as reduced elasticity and resilience. Additionally, the material could not stretch flexibly and became stiff, increasing the likelihood of it tearing or breaking easily even with a small impact. Furthermore, weather resistance could be reduced due to efflorescence, and durability issues could arise as the binder is absorbed into the mineral filler, causing the components to not adhere firmly to each other and easily separate.

[0041] In contrast, the present invention reduces the content of mineral filler while adding natural organic filler, thereby solving the problems associated with the addition of a large amount of mineral filler, while also allowing for the expected effects of adding natural organic filler.

[0042] Lignin, added as a natural organic filler, is a complex, amorphous natural polymer that accounts for 20 to 35 weight percent of wood. It is a material with very high thermal stability and acts as a natural UV stabilizer. In addition, lignin acts as a natural adhesive and support, increasing the compatibility between synthetic rubber components (olefin resins, thermoplastic elastic resins) and mineral fillers, thereby improving durability and increasing the modulus of elasticity.

[0043] In addition, lignin is a natural antioxidant that inhibits the growth of mold and bacteria even in humid external environments, prevents changes in the internal properties of the upper layer, thereby improving overall structural durability and delaying aging to extend the lifespan.

[0044] Jojoba seed powder is a byproduct remaining after extracting oil from jojoba seeds; it consists of protein and fiber and is characterized by high thermal stability.

[0045] Jojoba seed powder is rich in natural antioxidants, which inhibits oxidation that causes elastic flooring to harden or crack due to ultraviolet rays and oxygen. It also inhibits the growth of mold and bacteria even in environments prone to exposure to moisture. Additionally, due to trace amounts of natural wax, it acts as a lubricant, improving processability and providing flexibility, thereby helping to maintain elasticity for a long period without hardening.

[0046] In addition, jojoba seed powder enables the production of eco-friendly products, such as reduced carbon emissions, by reducing the amount of petroleum-based compounds along with lignin.

[0047] In this way, jojoba seed powder acts as a natural protective agent for elastic flooring, simultaneously preventing the top layer from hardening (flexibility), preventing oxidation (durability), and inhibiting harmful bacteria (hygiene). In particular, when used together with lignin, it provides improved durability of the top layer and anti-aging effects.

[0048] Lignin and jojoba seed powder are added in a ratio of 1:3 to 4. This is because adding too much lignin can cause the upper layer to harden and reduce elasticity. As relatively more jojoba seed powder is added, it acts as an excellent plasticizer as well as providing antibacterial properties and flexibility to the upper layer, thereby extending the lifespan and reducing maintenance costs.

[0049] In addition, as previously mentioned, natural organic fillers should be added in an amount of no more than 10% by weight, and if added in excess, serious problems may occur.

[0050] When lignin is added in excess, problems may arise such as reduced dispersibility where the lignin does not mix properly and clumps together, causing the upper layer to partially break down, and yellowing may occur as absorbed ultraviolet rays decompose on their own.

[0051] In addition, if jojoba seed powder is added in excess, the adhesive strength may be reduced due to the excessive oil content, and although it softens the upper layer, the tensile strength drops sharply, causing it to collapse or tear easily when stepped on by a user, and the surface is slippery, posing a risk of safety accidents.

[0052] Since such problems may occur, natural organic filler should be added in an amount of no more than 10% by weight, and since adding less than 1% by weight results in insufficient practical effect, it should be added in an amount of 1% or more by weight.

[0053] The above mineral oil is an oil commonly used to ensure a uniform mixture and improve processability when processing a mixture of various components.

[0054] Additives include pigments for imparting color (color masterbatch (M / B)) and desiccant for controlling moisture.

[0055] Since the lower layer is manufactured in the form of a sheet separately from the upper layer and must be firmly bonded to the upper layer, the basic compositional material is similar, but instead of adding the natural organic filler added to the upper layer, EPDM powder is added to support the upper layer and provide continuous elasticity.

[0056] Specifically, the lower layer is composed of a mixture of 5 to 20 weight% olefin resin, 10 to 30 weight% thermoplastic elastic resin, 10 to 20 weight% mineral filler, 30 to 60 weight% EPDM powder, 10 to 30 weight% mineral oil, 1 to 5 weight% additives, and 0.1 to 1 weight% foaming agent.

[0057] The maximum content of olefin resin added to the lower layer is lower than that added to the upper layer. This is because, unlike the upper layer which is exposed to the outside, the lower layer is located on the inside and is not exposed to the outside, resulting in low or no damage caused by environmental factors such as weather or user friction.

[0058] The thermoplastic elastic resin is mixed with the same components as those mixed into the upper layer.

[0059] In this case, it is desirable that the mineral filler added to the lower layer be composed of heavy carbon, so that it provides stability and imparts harder characteristics unlike the components added to the upper layer, thereby effectively supporting the upper layer.

[0060] In other words, the medium-sized carbon has excellent stability, which suppresses the shrinkage and expansion of the elastic flooring due to temperature changes, thereby preventing lifting or gaps after installation. It also optimizes elongation and tensile strength, and helps prevent tearing or deformation while maintaining shock absorption performance.

[0061] As such, the mineral filler mixed into the upper layer contains components that aid in flexibility and elasticity, whereas the mineral filler mixed into the lower layer contains components that aid in stability as well as relatively harder rigidity and cost-effectiveness compared to the upper layer.

[0062] EPDM powder is mixed into the lower layer; this is added to impart elasticity, effectively supporting the upper layer while further enhancing its shock absorption and repulsion capabilities.

[0063] In other words, in the present invention, the upper layer is formed to have shock absorption, repulsion retention, and anti-slip properties, and the lower layer is formed to facilitate installation on the floor surface and to further enhance the repulsion of the upper layer.

[0065] As the main characteristic of the present invention lies in the composition of the upper layer exposed to the outside, the changes in the physical properties of the upper layer due to the addition of natural organic fillers are examined below through examples.

[0066] < Upper layer manufacturing >

[0067] In the examples and comparative examples, the addition ratio of the compositional components of the upper layer was stated in parts by weight based on the thermoplastic elastic resin, as errors may occur if stated in weight percent.

[0068] [Example 1]

[0069] As an upper layer composition, 20 parts by weight of olefin resin, 30 parts by weight of mineral filler, 30 parts by weight of mineral oil, 1 part by weight of additive, 0.1 parts by weight of foaming agent, and 5 parts by weight of natural organic filler were added and mixed to 100 parts by weight of thermoplastic elastic resin to prepare an extrusion composition, and the upper layer was formed into a sheet with a thickness of 3 mm by extrusion and foaming using an extruder.

[0070] [Example 2]

[0071] An extrusion composition was prepared by adding 7 parts by weight of natural organic filler as the upper layer composition, while the remaining amounts were composed in the same way as in Example 1, and the upper layer was formed into a 3 mm thick sheet by extrusion and foaming using an extruder.

[0072] [Comparative Example]

[0073] As an upper layer composition, an extrusion composition was prepared by composing it in the same way as in Example 1 without adding natural organic filler, and the upper layer was formed into a 3 mm thick sheet by extruding and foaming it using an extruder.

[0075] In Examples 1 and 2 above, the ratio of lignin and jojoba powder added as natural organic fillers was divided into 1:3, 1:1, and 3:1, respectively, and no separate UV stabilizer was added.

[0077] Upper Layer Material Properties Test >

[0078] For the physical property test of the upper layer, test specimens of the upper layer were prepared with the composition ratios of Examples 1 and 2 and Comparative Example, and the elongation (%) and impact strength (kgf.cm / ㎠) were measured. Additionally, the elongation and impact strength of the same specimens were measured after 30 days in an oven at 70°C.

[0079] At this time, the natural organic filler added to Examples 1 and 2 was added by adjusting the ratio of lignin to jojoba powder, and then each test specimen was prepared and its physical properties measured.

[0080] In the physical property test, the value of the comparative example without added natural organic filler was set to a reference value of 100, so that it could be intuitively verified through the relative comparison between the comparative example and the example.

[0082]

[0083] As shown in [Table 1], the results of measuring the physical properties of the upper layer showed that the specimen with lignin and jojoba powder added in a 1:3 ratio had higher overall elongation and impact strength than the specimen with other ratios.

[0084] In addition, Example 1, with 5 parts by weight of lignin and jojoba added, showed a higher elongation rate compared to Example 2, with 7 parts by weight added, while the impact strength was lower. This suggests that as the amount of lignin added increased, the impact strength increased slightly while the elongation rate decreased slightly.

[0086]

[0087] [Table 2] shows the elongation and impact strength of the upper layer test specimens after 30 days in an oven at 70°C.

[0088] It was found that the test specimen with lignin and jojoba powder added in a 1:3 ratio showed almost no change in elongation and impact strength compared to the test specimen with lignin and jojoba powder added in a 1:1 or 3:1 ratio, and also that Example 1 with 5 parts by weight of lignin and jojoba powder and Example 2 with 7 parts by weight of lignin and jojoba powder showed no significant change.

[0089] Therefore, it is judged that if the upper layer is prepared by mixing and adding lignin and jojoba powder in a ratio of 1:3, it can be used for a long time without changes in physical properties, making maintenance and management easy.

[0090] Meanwhile, in the case of the comparative example, both the elongation and impact strength were found to have decreased significantly compared to the test values ​​in [Table 1] measured after production. This implies that the physical properties of the upper layer exposed to the outside are continuously decreasing, and it is judged that this decrease will affect the track record over time.

[0091] Furthermore, from the perspective of chemical changes in elastic flooring, it can be observed that as time passes, aging phenomena persist and microplastics detach, leading to increased maintenance costs as well as various environmental issues resulting from the generation of hazardous substances. Explanation of the symbols

[0093] 10: Upper layer 20: Lower layer

Claims

Claim 1 A multilayer structure mat is formed by bonding an upper layer and a lower layer to form an integrated structure, wherein the upper layer is composed of a mixture of 10 to 30 wt% olefin resin, 30 to 50 wt% thermoplastic elastic resin, 10 to 30 wt% mineral filler, 1 to 10 wt% natural organic filler, 10 to 30 wt% mineral oil, 1 to 10 wt% additive, and 0.1 to 1 wt% foaming agent, and the lower layer is composed of a mixture of 5 to 20 wt% olefin resin, 10 to 30 wt% thermoplastic elastic resin, 10 to 20 wt% mineral filler, 30 to 60 wt% EPDM powder, 10 to 30 wt% mineral oil, 1 to 5 wt% additive, and 0.1 to 1 wt% foaming agent, and the natural organic filler is lignin An eco-friendly elastic flooring material for athletic tracks with improved durability and weather resistance, characterized by being composed of 300 to 400 parts by weight of jojoba powder mixed per 100 parts by weight. Claim 2 An eco-friendly elastic flooring material for running tracks with improved durability and weather resistance according to claim 1, characterized in that the thermoplastic elastic resin is one or more selected from SBS block copolymer (styrene-butadiene-styrene block copolymer), SEBS block copolymer (styrene-ethylene-butadiene-styrene block copolymer), and olefin block copolymer. Claim 3 An eco-friendly elastic flooring material for athletic tracks with improved durability and weather resistance, characterized in that, in claim 1, the mineral filler added to the upper layer is one or more selected from silica, calcium carbonate, talc, mica, and bentonite, and the mineral filler added to the lower layer is heavy carbon. Claim 4 delete

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