Flooring material and manufacturing method therefor

Abstract

The present invention relates to a flooring material and a manufacturing method therefor, the flooring material comprising a base layer and a surface treatment layer, wherein the surface treatment layer has a surface structure including 21-100 wrinkles per unit area (0.1 mm x 0.1 mm), has a surface gloss of 4 or less under a 60° gloss condition; and has a surface gloss of 30 or less under an 85° gloss condition.

Description

Flooring and its manufacturing method

[0001] This application claims the benefit of Korean Patent Application No. 10-2023-0195928, filed with the Korean Intellectual Property Office on December 29, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a flooring material with little change in gloss.

[0003] Typically, flooring blocks dust and cold air from cement floors, providing a hygienic space. Furthermore, it can be printed with beautiful patterns in a variety of colors, creating a cozy interior atmosphere to suit the customer's taste. However, these conventional flooring materials suffer from the problem of contaminants making it difficult for users to easily erase them, rendering them unable to fulfill their essential functions.

[0004] To overcome these problems, a surface treatment layer is formed on the top layer of the flooring material to provide scratch resistance as well as contamination resistance.

[0005] However, in this case, there is a problem that the safety of pedestrians is significantly reduced because the non-slip property is reduced due to the surface treatment layer, making the flooring surface smooth. In addition, in the case of conventional flooring, the lower the gloss, the lower the stain resistance, which significantly reduces the functions such as cleaning, so there is a limitation that it is difficult to provide a natural gloss like natural materials while maintaining high stain resistance. Specifically, when the existing stain-resistant flooring is stained with oil-based magic and other contaminants, the gloss can be erased above a certain level of 60° Gloss-Meter, but below that, it cannot exhibit stain resistance, and there is a problem that the stain resistance rapidly decreases due to the wear of the silicone contained in the ultraviolet-curing surface treatment agent that treats the surface of the flooring. In addition, conventional ultraviolet curing surface treatment agents contain silica as a matting agent in an amount of about 10 wt% based on the total weight to reduce the gloss of the treated flooring, but silica is porous and has a very low apparent specific gravity, so as the content increases, fine dust, moisture, grease, etc. are easily absorbed, and the contamination resistance decreases rapidly, and marks such as sweat marks from hands and feet remain on the surface of the surface-treated flooring, causing the appearance to become cloudy, like fog.

[0006] Therefore, there is an urgent need to develop a flooring material that can achieve low gloss while excluding or using very small amounts of matting agents including inorganic particles, and that can improve stain resistance so that contaminants do not easily adhere to the flooring surface.

[0007] The present invention seeks to provide an ultra-matte flooring material with minimal gloss change.

[0008] The present invention comprises a substrate layer and a surface treatment layer,

[0009] The above surface treatment layer is,

[0010] It has a surface structure including 21 to 100 wrinkles per unit area (0.1 mm × 0.1 mm),

[0011] The surface gloss is 4 or less under the condition of Gloss 60°,

[0012] A flooring material is provided having a surface gloss of 30 or less under a gloss condition of 85°.

[0013] Another embodiment of the present invention comprises a first light irradiation step of irradiating light with a wavelength of 100 nm to 450 nm in the air to an acrylic resin composition applied on a substrate layer to harden the surface of the composition;

[0014] A second light irradiation step of inducing wrinkles on the surface of the surface-cured composition by irradiating light with a wavelength of less than 300 nm under nitrogen gas (N2) conditions, and

[0015] A third light irradiation step of forming a surface treatment layer by irradiating light with a wavelength of 100 nm to 450 nm to a composition having wrinkles induced on the surface,

[0016] The above surface treatment layer is,

[0017] It has a surface structure including 21 to 100 wrinkles per unit area (0.1 mm × 0.1 mm),

[0018] The surface gloss is 4 or less under the Gloss 60° condition,

[0019] A method for manufacturing a flooring material having a surface gloss of 30 or less under a gloss condition of 85° is provided.

[0020] The flooring material of one embodiment of the present invention has excellent contamination resistance and non-slip properties.

[0021] Another embodiment of the flooring material of the present invention can achieve a significantly lower surface gloss at 60° Gloss-Meter and 85° Gloss-Meter.

[0022] Another embodiment of the flooring material of the present invention can form dense wrinkles regardless of the structure of the embossed grooves and floor, and can realize an ultra-matte surface gloss.

[0023] Figure 1 is a scanning electron microscope (SEM) image of the surface of a sample manufactured in Example 1.

[0024] Figure 2 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 1.

[0025] Figure 3 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 2.

[0026] Figure 4 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 3.

[0027] Figure 5 is a scanning electron microscope image of the surface of a sample manufactured in Example 2.

[0028] Figure 6 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 4.

[0029] Figure 7 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 5.

[0030] Figure 8 is a scanning electron microscope image of the surface of a sample manufactured in Comparative Example 6.

[0031] Figure 9 is a structural diagram showing an example of a photocuring device used in manufacturing a surface treatment layer according to the present invention.

[0032] <Explanation of symbols>

[0033] 100: Light curing device

[0034] 110: Light irradiation room

[0035] 111: First light irradiator (UV irradiator)

[0036] 112: Second light irradiator (UV irradiator)

[0037] 113: Third light irradiator (UV irradiator)

[0038] 120: Investigated light

[0039] 130: Conveyor belt

[0040] 140: Gas barrier

[0041] Psalm 150

[0042] The present invention is described in detail below.

[0043] The present invention can have various modifications and various embodiments, and specific embodiments are illustrated in the drawings and described in detail in the detailed description.

[0044] However, this is not intended to limit the present invention to a specific embodiment, but should be understood to include all modifications, equivalents, or substitutes included in the spirit and technical scope of the present invention.

[0045] In the present invention, it should be understood that terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0046]

[0047] The present invention relates to an ultra-matte flooring material with minimal gloss change and a method for manufacturing the same.

[0048] Conventional flooring has a problem: once its surface becomes contaminated with contaminants, it's difficult for users to easily erase them, rendering the flooring unable to fulfill its primary function. To overcome this problem, a surface treatment layer is applied to the top layer of the flooring, making it both scratch-resistant and stain-resistant.

[0049] However, in this case, there is a problem that the safety of pedestrians is significantly reduced because the non-slip property is reduced due to the surface treatment layer, making the flooring surface smooth. In addition, in the case of conventional flooring, the lower the gloss, the lower the stain resistance, which significantly reduces the functions such as cleaning, so there is a limitation that it is difficult to provide a natural gloss like natural materials while maintaining high stain resistance. Specifically, when the existing stain resistance-provided flooring is stained by oil-based magic and other contaminants, it cannot exhibit stain resistance below a certain level of 60° Gloss-Meter, and there is a problem that the stain resistance rapidly decreases due to the wear of the silicone contained in the ultraviolet-curing surface treatment agent that treats the surface of the flooring. In addition, conventional ultraviolet curing surface treatment agents contain silica as a matting agent in an amount of about 10 wt% based on the total weight to reduce the gloss of the treated flooring, but since the silica is porous and has a very low apparent specific gravity, as the content increases, fine dust, moisture, grease, etc. are easily absorbed, so that the contamination resistance rapidly decreases, and marks such as sweat marks from hands and feet remain on the surface of the surface-treated flooring, causing the appearance to become cloudy, like fog.

[0050] When a matte surface treatment layer is produced using a general curing method by adding a matting agent, it can be confirmed that the gloss changes due to particle shedding upon friction, as shown in Fig. 7.

[0051] When implementing a super-matte finish with surface wrinkles through 2-step curing, there is a problem that the wrinkle shapes of the valleys and peaks of the emboss change, resulting in differences in surface gloss and physical properties, as shown in Fig. 6. In addition, in this case, particle shedding upon friction is small, but it was confirmed that the difference in gloss between the peaks and valleys of the emboss is large, resulting in a large change in gloss even upon friction.

[0052] On the other hand, Fig. 5, which implemented an ultra-matte finish with surface wrinkles by 3-Step hardening, shows that there is little difference in the gloss between the deep embossing and the floor, and that there is no particle loss upon friction and little change in gloss.

[0053]

[0054] Hereinafter, the present invention will be described in more detail.

[0055] In one embodiment, the present invention provides a flooring material having a surface treatment layer formed from an acrylic resin composition on a substrate layer.

[0056] The flooring material according to the present invention is an indoor flooring material used in homes, offices, etc., and the surface treatment layer is a cured layer of an acrylic resin composition and is located as the uppermost layer of the flooring material. Here, the acrylic resin composition comprises an acrylate oligomer and a monomer, and optionally contains a matting agent together with the above components to secure the elongation of the surface treatment layer.

[0057] The flooring material of the present invention can improve the elasticity of the surface, as well as the contamination resistance, water contact angle, and non-slip properties, by introducing a fine wrinkle structure into the surface structure of the surface treatment layer.

[0058] Here, the term "wrinkled surface" means that the resin layer includes wrinkles on at least one surface thereof, and that the resin layer has a three-dimensional surface irregularity due to the wrinkles. For example, the surface has irregularities including large and small ridges, valleys, and wrinkles formed therefrom and recognizable as having a predetermined shape. Each of the ridges, valleys, and wrinkles may have a regular or irregular shape. Such a wrinkled surface may also be referred to as a surface having a micro-folding structure.

[0059] When observing the surface of the resin layer where wrinkles are formed in the normal direction of the resin layer, ridges, valleys, wrinkles, and unevenness formed from them are observed over the entire area of ​​the surface, for example, during the curing process described below.

[0060] The above wrinkles can be observed in a form including a line shape (e.g., a straight line, a curved line) having directionality. As an example, the wrinkles formed on the surface by repeating straight and curved shapes can impart a curvature like a mountain range shape to the surface of the resin layer. The surface irregularity structure formed by the wrinkles having a line shape as described above is clearly distinguished from the so-called point-wise irregularity shape formed by a method using particles in a composition for forming the resin layer or a method using an emulsion dispersion.

[0061] In addition, the surface treatment layer may include wrinkles that can be recognized with a predetermined size and shape. For example, the wrinkles may have a width on the order of nm (less than about 1 ㎛) to ㎛ and a linear (straight or curved) shape that extends for several micrometers (㎛) or more. The width and / or height of the wrinkles and the length along which the wrinkles extend can be confirmed from an image (e.g., SEM) of the surface on which the wrinkles are formed, as in the attached drawings. In addition, the length in the extension direction may be greater than the width. Specifically, the ends of the wrinkles extending in a straight or curved shape may be incorporated into the resin layer at a slope with a gradually decreasing height. In some cases, the ends of any wrinkles having the above size and shape may become the starting point of another wrinkle or a connection point with another wrinkle. In addition, when observing the cross-sectional curve near the wrinkle in the vertical direction with respect to the extension direction of the wrinkle, the width of the wrinkle can be mixed into the resin layer with a slope in which the height gradually decreases in both directions starting from the point or part (e.g., ridge) that forms the height of the wrinkle. On the other hand, when a ridge and an adjacent valley form the wrinkle or a part thereof, the area of ​​the shape that is recognized, including the valley, can be regarded as the width of the wrinkle.

[0062] As an example, the width of the wrinkles may be 50 ㎛ or less. Specifically, the width of the wrinkles may have an upper limit of 45 ㎛ or less, 40 ㎛ or less, 35 ㎛ or less, 30 ㎛ or less, 25 ㎛ or less, 20 ㎛ or less, 19 ㎛ or less, 18 ㎛ or less, 17 ㎛ or less, 16 ㎛ or less, 15 ㎛ or less, 14 ㎛ or less, 13 ㎛ or less, 12 ㎛ or less, or 11 ㎛ or less, and may have a lower limit of 1 ㎛ or more, 2 ㎛ or more, 3 ㎛ or more, or 4 ㎛ or more. When the above range is satisfied, the surface formed by the wrinkles may be advantageous in exhibiting contamination resistance and matte characteristics.

[0063] In addition, the length of the wrinkles may have an upper limit of 200 ㎛ or less, 100 ㎛ or less, 50 ㎛ or less, 40 ㎛ or less, 30 ㎛ or less, 20 ㎛ or less, 15 ㎛ or less, 11 ㎛ or less, or 10 ㎛ or less, and a lower limit of 1 ㎛ or more, 2 ㎛ or more, 3 ㎛ or more, 4 ㎛ or more, 5 ㎛ or more, 10 ㎛ or more, 20 ㎛ or more, 30 ㎛ or more, 40 ㎛ or more, 50 ㎛ or more, 60 ㎛ or more, 70 ㎛ or more, 80 ㎛ or more, or 90 ㎛ or more. When the above range is satisfied, the surface formed by the wrinkles may be advantageous in exhibiting contamination resistance and matte characteristics.

[0064] The above wrinkles may have a predetermined height for most of their extending length. For example, the wrinkles may have a height of 2 μm or less, 1.5 μm or less, 1.0 μm or less, or 0.1 to 0.9 μm. Specifically, when the cross-sectional curve of the wrinkles is observed in a direction perpendicular to the extending direction of the wrinkles, a point or portion (e.g., a ridge) forming the height of the wrinkles and a point or portion (e.g., a valley) of the resin layer where the width of the wrinkles is mixed may have a "height difference" of 2 μm or less. The present invention can prevent contamination from remaining between the wrinkles and reducing contamination resistance due to thick wrinkles by controlling the height of the wrinkles within the above range.

[0065] Meanwhile, the above "most of the length over which the height is observed" means a length that is 70% or more, 75% or more, 80% or more, 85% or more, 90% or more, or 95% or more of the length over which the wrinkles continuously extend along their shape. When the height difference in the direction of extension of the wrinkles gradually decreases and the height is significantly lowered, a shape in which the end of the wrinkle is mixed into the resin layer may be observed, or a shape in which a contact point with another wrinkle having a different size or shape from the wrinkle may be observed. In the latter case, a more complex wrinkle structure may form unevenness on the surface.

[0066] The wrinkles may be observed over the entire area of ​​the surface, and may form surface wrinkles or unevenness while showing a regular or irregular distribution. For example, the wrinkles on the surface may form surface unevenness by having a shape in which multiple wrinkles branch in different directions from one specific point. Specifically, the wrinkles on the surface may have a shape similar to "Y" or "〈". In this case, wrinkles having a shape similar to "Y" or "〈" may be densely arranged to form surface unevenness.

[0067] The present invention can increase the frequency of finer wrinkles by forming wrinkles having the above-described shape and / or size in a surface treatment layer, thereby reducing gloss even without using a matting agent or using a small amount of matting agent in the surface treatment layer, preventing contaminants from remaining between the wrinkles and contaminating the surface, and improving wax affinity of the surface.

[0068] As an example, the flooring material may include 21 to 100 wrinkles per unit area (0.1 mm × 0.1 mm) of the surface treatment layer surface. Specifically, the surface treatment layer surface of the flooring material may have 21 to 90, 25 to 90, 30 to 85, 30 to 80, 35 to 80, or 40 to 80 wrinkles per unit area (0.1 mm × 0.1 mm).

[0069] As an example, in the surface treatment layer, the distance between one wrinkle and its adjacent wrinkle may be 1 μm to 15 μm. Specifically, the distance between adjacent peaks of the wrinkles may be 1 μm to 15 μm. Additionally, the distance between adjacent valleys of the wrinkles may also be 1 μm to 15 μm.

[0070] The surface treatment layer of the above flooring material has embossing formed in addition to wrinkles. It is preferable that the elongation of the surface treatment layer be secured so that cracks do not occur due to the formation of embossing. Specifically, when tensioned at 120°C until cracks occur, the elongation of the surface treatment layer may be 1% or more and 20% or less. Specifically, the elongation of the surface treatment layer may be 10% or more and 20% or less, or 11% or more and 19% or less.

[0071]

[0072] As an example, the flooring material according to the present invention may have excellent contamination resistance by having a surface treatment layer having a hydrophobic surface and a dense wrinkle shape as the outermost layer. For example, the surface treatment layer may have hydrophobicity implemented on the surface, and when measuring the average static water contact angle indicating the affinity for water, it may be 80° to 120°, and specifically, 80° to 115°, 80° to 110°, 80° to 105°, 80° to 100°, 85° to 100°, 85° to 105°, 85° to 110°, 85° to 115°, 85° to 120°, 90° to 120°, 90° to 110°, 90° to 100°, 90° to 98°, 90° to 95°, 90° to 93°, 93° to 100°, 95° to 100°, 95° to 98°, It can be 90° to 92° or 88° to 94°.

[0073] In addition, the flooring material according to the present invention has improved surface contamination resistance, and the contamination level can be 4 or higher when subjected to a scratch test using an oil-based magic marker as a contaminant according to KS M 3802. Specifically, when the flooring material according to the present invention is contaminated with an oil-based magic marker, and after 30 seconds, the oil-based magic marker is wiped off with a Kimwipe, and the degree of surface damage of the flooring material is visually checked, the contamination level of the flooring material can range from 4 (contaminant residual area based on the initial contamination area: 5% or more and less than 20%) to 5 (contaminant residual area based on the initial contamination area: less than 5%), and specifically, can be 5.

[0074] As another example, the flooring material according to the present invention can realize significantly low gloss even if the surface treatment layer contains a very small amount of a matting agent, or in some cases, does not contain a matting agent, by inducing scattering of light incident on the surface through a dense wrinkle shape formed on the surface of the surface treatment layer. Specifically, the flooring material may have a surface gloss of 4 or less when measured in terms of 60° gloss (gloss 60° condition) using a gloss meter, and more specifically, the upper limit may be 3.5 or less, 3 or less, 2.5 or less, or 2.3 or less, and the lower limit may be 0.1 or more, 0.5 or more, 1 or more, 1.1 or more, or 2 or more. For example, the average surface gloss of the flooring material may be 0.1 to 4, 0.1 to 3.5, 0.1 to 3, 0.1 to 2.8, 0.1 to 2.4, 0.5 to 1.8, 3.2 to 4, 0.1 to 0.4, 0.5 to 4, 0.5 to 3, 1 to 2.5, 1 to 2.2, 1.7 to 2.9, 0.8 to 1.9, 1.3 to 2.2, 1.2 to 1.7, 1.8 to 2.2, or 1.3 to 2.4.

[0075] As another example, the flooring material according to the present invention can achieve significantly low gloss even if it includes a very small amount of a matting agent in the surface treatment layer, or in some cases, no matting agent, by inducing scattering of light incident on the surface through the dense wrinkle shape formed on the surface of the surface treatment layer. Specifically, the flooring material may have a surface gloss of 30 or less when measured at 85° gloss (85° gloss condition) using a gloss meter, and more specifically, the upper limit may be 29 or less, 28 or less, 27 or less, 26 or less, 25 or less, 24 or less, 23 or less, 22 or less, 21 or less, 20 or less, 19 or less, 18 or less, 17 or less, 16 or less, 15 or less, 14 or less, 13 or less, 12 or less, 11 or less, or 10 or less, and the lower limit may be 0.1 or more, 0.5 or more, 1 or more, or 1.1 or more, or 2 or more.

[0076] As an example, the flooring material according to the present invention is characterized by a small change in gloss after friction.

[0077] After 100 friction tests with a load of 90 kg according to KS K ISO 4918 standard, the change in surface gloss at 60° condition may be 2 or less based on the value before the friction test, and more specifically, the upper limit may be 1.9 or less, 1.8 or less, 1.7 or less, 1.6 or less, 1.5 or less, 1.4 or less, 1.3 or less, 1.2 or less, 1.1 or less, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, 0.6 or less, or 0.5 or less, and the lower limit may be 0.1 or more or 0.2 or more.

[0078] After 1,000 friction tests with a load of 90 kg according to KS K ISO 4918 standard, the change in surface gloss at 60° condition may be 2 or less based on the value before the friction test, and more specifically, the upper limit may be 1.9 or less, 1.8 or less, 1.7 or less, 1.6 or less, 1.5 or less, 1.4 or less, 1.3 or less, 1.2 or less, 1.1 or less, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, or 0.6 or less, and the lower limit may be 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more.

[0079] After 3,000 friction tests with a 90 kg load according to KS K ISO 4918 standard, the change in surface gloss at 60° condition may be 2 or less based on the value before the friction test, and more specifically, the upper limit may be 1.9 or less, 1.8 or less, 1.7 or less, 1.6 or less, 1.5 or less, 1.4 or less, 1.3 or less, 1.2 or less, 1.1 or less, 1 or less, 0.9 or less, or 0.8 or less, and the lower limit may be 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more.

[0080] In addition, after 1,000 friction tests using a crocodile meter, the change in surface gloss at a gloss 60° condition may be 2 or less based on the value before the friction test, and more specifically, the upper limit may be 1.9 or less, 1.8 or less, 1.7 or less, 1.6 or less, 1.5 or less, 1.4 or less, 1.3 or less, 1.2 or less, 1.1 or less, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, 0.6 or less, 0.5 or less, 0.4 or less, 0.3 or less, 0.2 or less, or 0.1 or less, and the lower limit may be 0 or more, more than 0, or 0.1 or more.

[0081] As another example, after 100 friction tests with a load of 90 kg according to KS K ISO 4918 standard, the change in surface gloss at 85° condition may be 2 or less based on the value before the friction test, and more specifically, the upper limit may be 1.9 or less, 1.8 or less, 1.7 or less, 1.6 or less, 1.5 or less, 1.4 or less, 1.3 or less, 1.2 or less, 1.1 or less, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, 0.6 or less, or 0.5 or less, and the lower limit may be 0.1 or more or 0.2 or more.

[0082] After 1,000 friction tests with a load of 90 kg according to KS K ISO 4918 standard, the change in surface gloss at 85° Gloss may be 4 or less based on the value before the friction test, and more specifically, the upper limit may be 3.9 or less, 3.8 or less, 3.7 or less, 3.6 or less, 3.5 or less, 3.4 or less, 3.3 or less, 3.2 or less, 3.1 or less, 3 or less, or 2.9 or less, and the lower limit may be 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more.

[0083] After 3,000 friction tests with a 90 kg load according to KS K ISO 4918 standard, the change in surface gloss at 85° Gloss may be 4 or less based on the value before the friction test, and more specifically, the upper limit may be 3.9 or less, 3.8 or less, 3.7 or less, 3.6 or less, 3.5 or less, or 3.4 or less, and the lower limit may be 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more.

[0084]

[0085] In addition, after 1,000 friction tests using a crocodile meter, the change in surface gloss at 85° compared to before the friction test may be 2 or less.

[0086]

[0087] The surface treatment layer may have an average thickness in an appropriate range that does not affect durability. For example, the surface treatment layer may have an average thickness of 5 μm to 30 μm so as not to be torn or lost due to external stimuli, and more specifically, may be 5 μm to 30 μm, 5 μm to 15 μm, 10 μm to 20 μm, 10 μm to 30 μm, 20 μm to 30 μm, 8 μm to 17 μm, 11 μm to 20 μm, or 12 μm to 18 μm. The average thickness of the surface treatment layer mentioned in the present invention may mean the average thickness of the surface treatment layer excluding the height of dense wrinkles, and in some cases, may mean a thickness including the average thickness of the surface treatment layer excluding the height of dense wrinkles and half the value of the average maximum height of dense wrinkles.

[0088] Meanwhile, the flooring material according to the present invention may further include a separate layer in addition to the substrate layer and the surface treatment layer, and may further include, for example, one or more of a foam layer, a printing layer, and a dimensional stabilization layer.

[0089] A flooring material according to one embodiment of the present invention may further include at least one of a printing layer and a dimensionally stable layer between the substrate layer and the surface treatment layer.

[0090] A flooring material according to another embodiment of the present invention may further include a foam layer. In this case, the foam layer may be provided on the opposite side of the surface of the substrate layer on which the surface treatment layer is provided, and specifically, the flooring material may be formed by sequentially laminating a foam layer, a substrate layer, and a surface treatment layer. Here, at least one of a printing layer and a dimensionally stable layer may be further included, and for example, the flooring material may have a structure in which a foam layer, a printing layer, a substrate layer, and a surface treatment layer are sequentially laminated, or a structure in which a foam layer, a dimensionally stable layer, a printing layer, a substrate layer, and a surface treatment layer are sequentially laminated.

[0091] Here, the substrate layer, the printing layer, and the dimensionally stable layer are formed by photocuring or thermally curing each composition including at least one selected from the group consisting of, for example, a binder resin, an initiator, a curing agent, other additives, and combinations thereof, or can be formed as a film or sheet using an extrusion method, a calendaring method, or the like. In addition, each of the above compositions can appropriately adjust the types and contents of the components included therein according to the properties and functions of each layer, and is not particularly limited. Specifically, the flooring material can be formed by applying a predetermined composition to one surface of a layer and then photocuring or thermally curing it, or can be formed by forming each layer as a film or sheet and then using a plywood process known in the art, but is not limited thereto. In addition, the binder resin can include a synthetic resin, a bio-resin, or all of these, and can include, for example, a polyvinyl chloride (PVC)-based resin, a polyurethane-based resin, a polylactic acid-based resin, a polyolefin resin, or the like.

[0092] In one embodiment of the present invention, the substrate layer is a layer located at the lowest part of the flooring material and supports the upper surface treatment layer, printing layer, dimension stabilization layer, etc. In addition, the average thickness of the substrate layer may be 0.5 to 10T, and more specifically, may be 0.5 to 8T, 0.5 to 6T, 0.5 to 4T, 4 to 10T, 6 to 10T, 8 to 10T, 3 to 6T, 4 to 7T, 7 to 9T, 2 to 3T or 0.5 to 1.5T. At this time, the unit 'T' means mm. In addition, the composition of the above-mentioned base layer is not particularly limited, but may include polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), nitrile-butadiene rubber (NBR), polyvinylether (PVE), ethylene vinylacetate (EVA), polyurethane (PU), etc.

[0093] In addition, the substrate layer may be a transparent or translucent polyvinyl chloride (PVC) layer having a thickness of about 0.05 mm to about 2.0 mm, and by having a thickness within the above range, the pattern or design of the printed layer laminated thereon can be sufficiently protected as described below without excessively increasing the total thickness of the flooring material.

[0094] Another embodiment of the present invention may be a flooring material such as tiles. In this case, the substrate layer may be a ceramic layer. The ceramic layer comprises ceramic and is manufactured from a composition comprising ceramic. This ceramic layer is manufactured by agglomerating non-metallic inorganic particles, forming a shape, and firing the resulting material at a high temperature. In this case, the composition may further comprise a binder resin, an organic solvent, and other additives in addition to the non-metallic inorganic particles.

[0095] In addition, the printing layer may include a white layer forming a base and a transfer layer implementing a pattern, and may be formed by imparting a pattern in various ways, such as transfer printing, gravure printing, screen printing, offset printing, rotary printing, or flexographic printing. At this time, the printing layer may have an average thickness of about 1 μm to about 10 μm.

[0096] In addition, the dimensionally stable layer may be formed from a composite material in which glass fibers are impregnated into a binder resin. The dimensionally stable layer formed in this manner can reduce dimensional deformation even under high temperature and high humidity conditions, thereby realizing excellent dimensional stability, while maintaining a high level of adhesion with other layers laminated on top and bottom, thereby realizing excellent durability. In this case, the average thickness of the dimensionally stable layer may be about 0.1 mm to about 2.0 mm.

[0097] Furthermore, the foam layer is a layer located at the lowest part of the flooring material, and supports the upper surface treatment layer, substrate layer, printing layer, dimensional stabilization layer, etc., while including pores of a certain size and having the function of absorbing shock and noise from the upper or lower parts. At this time, the average size of the pores may be 100 to 900 ㎛, and specifically, 100 to 800 ㎛, 100 to 700 ㎛, 100 to 600 ㎛, 100 to 500 ㎛, 200 to 900 ㎛, 300 to 900 ㎛, 400 to 900 ㎛, 500 to 900 ㎛, 600 to 900 ㎛, 200 to 800 ㎛, 500 to 800 ㎛, 600 to 700 ㎛, 200 to 400 ㎛, or 750 to 900 ㎛. In addition, the average thickness of the foam layer may be 0.5 to 10T, and more specifically, 0.5 to 8T, 0.5 to 6T, 0.5 to 4T, 4 to 10 T, 6 to 10 T, 8 to 10T, 3 to 6T, 4 to 7T, 7 to 9T, 2 to 3T, 0.5 to 1.5T. In addition, the components of the foam layer are not particularly limited, but may include polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), nitrile-butadiene rubber (NBR), polyvinylether (PVE), ethylene vinylacetate (EVA), polyurethane (PU), etc.

[0098] In addition, the method of applying the composition on the substrate can be performed by a method known in the art, and can be performed using, for example, Mayer, D-bar, rubber roll, G / V roll, air knife, slot die, microgravure, etc.

[0099] The three-step curing method for curing the above surface treatment layer is:

[0100] A first light irradiation step of curing the surface of an acrylic resin composition applied on a substrate layer by irradiating light with a wavelength of 100 nm to 450 nm in the air;

[0101] A second light irradiation step of inducing wrinkles on the surface of the surface-cured composition by irradiating light with a wavelength of less than 300 nm under nitrogen gas (N2) conditions, and

[0102] It may include a third light irradiation step of forming a surface treatment layer by irradiating light having a wavelength of 100 nm to 450 nm to a composition having wrinkles induced on the surface.

[0103] The method for manufacturing a flooring material according to the present invention has a step of curing an acrylic resin composition by irradiating it with short wavelength light of a specific range under different conditions in three stages. Here, the short wavelength is an expression that is distinct from the long wavelength and means a wavelength with strong energy and a short wavelength length, and refers to UV, X-ray, etc., which have a wavelength shorter than blue light among visible light, and uses light with a wavelength of 400 nm or less, or further, 100 nm to 450 nm. This is a different expression from the narrow wavelength and the broad wavelength, which are expressions that are distinguished by the range of the emission spectrum emitted by a light source to be described later.

[0104]

[0105] Specifically, the first light irradiation step is the first step of irradiating light to an acrylic resin composition applied to a substrate, applying ultraviolet (UV) energy to harden the surface of the acrylic resin composition. At this time, the surface hardening provides a level of fixing strength that prevents the applied composition from flowing away without hardening the entire application, which would allow wrinkles to form in a step described below.

[0106] The first light irradiation step is a step of applying ultraviolet (UV) energy to the surface treatment layer to cure it, and can be performed by irradiating light having a wavelength of 100 to 450 nm, specifically, a wavelength of 100 nm to less than 200 nm, 100 nm to 190 nm, 100 nm to less than 180 nm, 200 to 400 nm, 250 to 380 nm, 280 to 380 nm, 250 to 350 nm, or 280 to 320 nm, under air conditions. At this time, the surface temperature of the composition and / or the surface treatment layer can be 20 to 90°C, specifically, 20 to 80°C or 30 to 70°C.

[0107] The light source used in the first light irradiation step is selected to emit light with a broad wavelength, emitting all or part of the light within the range of 100 to 450 nm. Using a light source with such a broad wavelength facilitates surface hardening control. For example, mercury, gallium, or metal halide lamps with a broad emission spectrum within the range of 100 to 450 nm can be used.

[0108] On the other hand, when the first light irradiation step is performed using a light source with a narrow wavelength in the long wavelength (365 nm to 405 nm) range of UV, such as an LED, the shape of the wrinkles may be formed in a sharp shape, such as a pointed shape, so that contaminants are better fixed to the surface treatment layer, which may reduce contamination resistance.

[0109] In the first light irradiation step, the light irradiation amount may be 1 mJ / cm2 to 800 mJ / cm2, specifically 1 mJ / cm2 to 700 mJ / cm2¸ 1 mJ / cm2 to 600 mJ / cm2, 1 mJ / cm2 to 500 mJ / cm2, 1 mJ / cm 2 150 mJ / cm 2, 1 mJ / ㎠ to 90 mJ / ㎠, 90 mJ / ㎠ to 400 mJ / ㎠, 90 mJ / ㎠ to 300 mJ / ㎠, 90 mJ / ㎠ to 200 mJ / ㎠ or 95 mJ / ㎠ to 105 mJ / ㎠.

[0110] When using the same light source, the farther the distance of the light source from the composition and / or surface treatment layer, the less light there is, and the closer the distance of the light source from the composition and / or surface treatment layer, the more light there is. Therefore, in order to control the amount of light irradiated to the composition and / or surface treatment layer, it is necessary to consider not only the light amount of the light source itself, but also the change in light amount depending on the distance.

[0111] As another example, in the first light irradiation step, the distance between the composition and / or surface treatment layer and the light source may be 0.5 to 100 mm, and specifically, may be 0.5 to 80 mm, 0.5 to 60 mm, 0.5 to 40 mm, 5 to 80 mm, 5 to 60 mm, 5 to 40 mm, 10 to 70 mm, 10 to 50 mm, 10 to 30 mm, 20 to 80 mm, 20 to 60 mm, 20 to 50 mm, 20 to 30 mm, 25 to 75 mm, 50 to 80 mm, 40 to 60 mm or 45 to 55 mm. If the distance between the surface treatment layer and the light source is satisfied, the surface may be properly cured without over-curing, thereby reducing the gloss of the surface, and if it is not satisfied, the surface may be over-cured, thereby increasing the gloss.

[0112] In this specification, the first light irradiation step can be performed in an oxygen atmosphere, an air atmosphere, or a nitrogen atmosphere.

[0113] As an example, the first light irradiation step may be performed by irradiating the composition and / or the surface treatment layer with light having a wavelength of 100 to 450 nm in air conditions at a light dose of 1 to 800 mJ / cm2 for a very short time of 1 to 2 seconds, and the distance between the composition and / or the surface treatment layer and the light source may be 0.5 to 60 mm.

[0114] The second light irradiation step is a step of increasing the scattering rate of light incident on the surface by shrinking the surface of the acrylic resin composition and / or its cured product to which the excimer generated by the irradiated light is applied, thereby forming wrinkles. The present invention can increase the scattering rate of light by shrinking the surface of the acrylic resin composition and / or its cured product into the above-described dense wrinkle form using the excimer, thereby reducing the gloss of the surface treatment layer even without using a very small amount of a matting agent or, in some cases, without using one.

[0115] In addition, the second light irradiation step can be performed in a nitrogen (N2) atmosphere containing a small amount of oxygen (O2) using light having a wavelength of less than 300 nm, specifically 100 to 200 nm or 150 to 195 nm, having high energy. Specifically, the concentration of oxygen (O2) contained in nitrogen (N2) in the second light irradiation step may be 10 to 30,000 ppm, specifically 10 to 20,000 ppm, 10 to 5,000 ppm, 1,000 to 2,000 ppm, 2,000 to 3,000 ppm, 3,000 to 4,000 ppm, 4,000 to 5,000 ppm, 10 to 2,000 ppm, 10 to 1,000 ppm, 10 to 500 ppm, 100 to 300 ppm, 10 to 200 ppm, 50 to 150 ppm, 80 to 120 ppm, 4,000 to 6,000 ppm, 4,500 to 5,500 ppm or 4,800 to 5,200 ppm. In addition, in the second light irradiation step, the distance between the acrylic resin composition and the light source may be 50 to 150 mm, and specifically, 5 to 80 mm, 5 to 60 mm, 5 to 40 mm, 10 to 70 mm, 10 to 50 mm, 10 to 30 mm, 20 to 80 mm, 20 to 60 mm, 20 to 50 mm, 20 to 30 mm, 25 to 75 mm, 50 to 80 mm, 40 to 60 mm, or 45 to 55 mm.

[0116] In addition, in the second light irradiation step, the light irradiation amount may be 25 mJ / cm2 to 75 mJ / cm2, and specifically, 25 mJ / cm2 to 70 mJ / cm2, 25 mJ / cm2 to 50 mJ / cm2, 50 mJ / cm2 to 75 mJ / cm2, 40 mJ / cm2 to 60 mJ / cm2, 25 mJ / cm2 to 45 mJ / cm2, 35 mJ / cm2 to 45 mJ / cm2, or 38 mJ / cm2 to 43 mJ / cm2.

[0117] As an example, the second light irradiation step may be performed by irradiating the composition with light having a wavelength of 172±5 nm under nitrogen (N2) conditions containing 1000 ppm of oxygen (O2) at a light dose of 45 to 55 mJ / cm2 (i.e., light irradiance) for a very short time of 1 to 2 seconds to cure the acrylic resin composition. At this time, the distance between the composition and / or the surface treatment layer and the light source may be 100±1 mm.

[0118] The present invention can easily control the average diameter, height and / or frequency of dense wrinkles formed on the surface of the surface treatment layer by controlling the gas conditions, the distance between the composition and the light source and / or the light irradiation amount within the above ranges when performing the second light irradiation step. In one embodiment of the present invention, when the base layer is a film or sheet and is a flooring material that is a sheet product, controlling the gas conditions, the distance between the composition and the light source and / or the light irradiation amount within the above ranges when performing the second light irradiation step can prevent the curing density of the surface treatment layer from excessively increasing and easily breaking at low temperatures.

[0119] In addition, the third light irradiation step is a step of performing curing by additionally irradiating the activated composition and / or surface treatment layer with ultraviolet (UV) light, and may use light having a wavelength of 100 to 450 nm, specifically, 100 nm to less than 200 nm, 100 nm to 190 nm, 100 nm to less than 180 nm, 200 to 400 nm, 250 to 380 nm, 280 to 380 nm, 250 to 350 nm, or 280 to 320 nm.

[0120] In this specification, the third light irradiation step may be performed in an oxygen atmosphere, an air atmosphere, or an inert atmosphere. Here, the air atmosphere refers to a natural air state without artificial treatment, with an oxygen concentration of approximately 21%, and the oxygen atmosphere refers to an artificial air state with a higher oxygen concentration than the air atmosphere.

[0121] The gas used to create the inert atmosphere may be, for example, He, Ne, Ar, and / or N2. Here, the inert atmosphere may be a nitrogen atmosphere. A nitrogen atmosphere refers to an artificial atmosphere having a higher nitrogen concentration than an air atmosphere, which is 78% nitrogen. When the third light irradiation step is performed in a nitrogen atmosphere, it can be performed in a nitrogen (N2) atmosphere containing a small amount of oxygen (O2). Here, the concentration of oxygen (O2) contained in the nitrogen (N2) can be 10 to 30,000 ppm, and specifically, 10 to 5,000 ppm, 1,000 to 2,000 ppm, 2,000 to 3,000 ppm, 3,000 to 4,000 ppm, 4,000 to 5,000 ppm, 100 to 1,000 ppm, 100 to 500 ppm, 100 to 200 ppm, 10 to 2,000 ppm, 10 to 1,000 ppm, 10 to 500 ppm, 100 to 300 ppm, 10 to 200 ppm, It can be 50 to 150 ppm, 80 to 120 ppm, 15,000 to 25,000 ppm, 17,000 to 23,000 ppm, 19,000 to 21,000 ppm, or 19,500 to 20,500 ppm. The present invention can not only improve the curing rate of the composition and / or the surface treatment layer by controlling the concentration of oxygen (O2) within the above range in the third light irradiation step in which curing is performed, but can also induce the effect of cleaning the surface of the surface treatment layer through conversion of oxygen molecules (O2) to ozone (O3).

[0122] As an example, the third light irradiation step may be performed by irradiating the composition and / or the surface treatment layer with light having a wavelength of 100 to 450 nm at a light dose of 100 to 3,000 mJ / cm2, and at this time, the distance between the composition and / or the surface treatment layer and the light source may be 100±1 mm.

[0123] The light irradiated in the present invention can be irradiated according to a known method capable of irradiating light of a required wavelength at each stage. For example, light having a wide wavelength range in the UV region of 400 nm or less can be irradiated using a mercury, gallium, or metal halide lamp, etc. In this case, mercury is a light source with a maximum emission wavelength (λmax) of the late 200 nm, gallium is a light source with a maximum emission wavelength (λmax) of 350 nm to 450 nm, and metal halide is a light source with a maximum emission wavelength (λmax) of 300 nm to 399 nm.

[0124] In addition, in the present invention, the time for which light is irradiated can be a very short time of 1 to 2 seconds, and this light irradiation time can be controlled by the speed at which the composition moves during the light irradiation, for example, the moving speed of the composition coated on the substrate. For example, the moving speed of the composition and / or the substrate coated with the composition can be 1 to 50 m / min, and specifically, 5 to 40 m / min, 10 to 40 m / min, 20 to 40 m / min, 30 to 40 m / min, 15 to 25 m / min, 5 to 15 m / min, 15 to 20 m / min, 35 to 40 m / min, or 18 to 22 m / min.

[0125] The present invention can exhibit a high curing rate even if an initiator is included in a small amount within the above range by using short wavelength light of a specific range in stages under different conditions during curing of the composition.

[0126]

[0127] Meanwhile, the acrylic resin composition may include an acrylic oligomer and an acrylic monomer.

[0128] The above acrylic oligomer refers to an oligomer obtained using a monomer containing an acrylic group, and the monomer may be at least one (meth)acrylate selected from the group consisting of methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, pentyl (meth)acrylate, hexyl (meth)acrylate, heptyl (meth)acrylate, octyl (meth)acrylate, and benzyl acrylate. For example, the acrylic oligomer may include a methyl acrylate oligomer, a (meth)acrylate oligomer, a methyl (meth)acrylate oligomer, an ethyl acrylate oligomer, a benzyl acrylate oligomer, a benzyl (meth)acrylate oligomer, etc., which are polymerized by polymerizing methyl acrylate, (meth)acrylate, ethyl acrylate, benzyl acrylate, or a mixture thereof.

[0129] The weight average molecular weight of the acrylic oligomer may be 100 to 50,000, and more specifically, 500 to 30,000; 1,000 to 10,000; 5,000 to 10,000; 6,000 to 8,000; 1,000 to 5,000 or 1,500 to 2,500. The present invention can further improve the durability of the cured layer by adjusting the weight average molecular weight of the acrylic oligomer within the above range. At this time, the unit of molecular weight may be expressed as g / mol, but may be omitted.

[0130] The above multifunctional acrylic monomer is a compound containing a straight-chain or branched-chain alkyl group having 1 to 7 carbon atoms and an acrylic group, and can be classified as monofunctional or multifunctional depending on the number of acrylic groups contained in the compound. For example, if there are two or more acrylic groups in the compound, it can be classified as multifunctional, and the multifunctional acrylic monomer used in the present invention can include at least one of a difunctional monomer, a trifunctional monomer, a tetrafunctional monomer, and a hexafunctional monomer.

[0131] As an example, the multifunctional acrylic monomer may include at least one selected from the group consisting of 1,6-hexanediol diacrylate, tetraethylene glycol diacrylate, tripropylene glycol diacrylate, triethylene glycol diacrylate, dipropylene glycol diacrylate, pentaerythritol triacrylate, trimethylolpropanethoxytriacrylate, and hexamethyldiamine diacrylate.

[0132] The above acrylic monomer includes a bifunctional first acrylate monomer, and may further include 30 to 50 parts by weight of a multifunctional second acrylate monomer per 100 parts by weight of the bifunctional first acrylate monomer.

[0133] The above acrylic oligomer may include 30 to 140 parts by weight of a multifunctional first acrylate oligomer based on 100 parts by weight of a bifunctional first acrylate monomer.

[0134] The above acrylic oligomer may include 30 to 50 parts by weight of a monofunctional second acrylate oligomer per 100 parts by weight of a bifunctional first acrylate monomer.

[0135] The above acrylic resin composition may be used without or in a small amount of a matting agent. Specifically, the matting agent has a particle shape and can impart a matte effect to the film by increasing the light scattering rate at the film surface. However, the use of a matting agent brings about the problem of increased stain resistance, as described above. However, since the cured layer of the present application has the surface properties described above, it can effectively implement matte properties. Therefore, the film of the present application can implement sufficient matte properties without using a matting agent, which is used to implement a matte effect in the prior art.

[0136] In addition, even if a matting agent is used, the amount of matting agent used to implement a matte characteristic in the prior art may not be used. That is, according to the present application, the amount of matting agent used can be significantly reduced. For example, the matting agent can be used in an amount of 1 to 10 parts by weight based on 100 parts by weight of the difunctional first acrylate monomer. Specifically, the acrylic resin composition may include a matting agent component in an amount of 9 parts by weight or less, specifically 8 parts by weight or less, 7 parts by weight or less, 6 parts by weight or less, 5 parts by weight or less, 4 parts by weight or less, 3 parts by weight or less, or 2 parts by weight or less, based on 100 parts by weight of the difunctional first acrylate monomer. Accordingly, the film of the present application has an advantage of being able to prevent problems such as reduced contamination resistance due to the use of a matting agent.

[0137] The above acrylic resin composition may further include a silicone additive. This silicone additive is not silica, but an organic compound containing Si. The silicone additive may be a low-molecular silicone additive having a molecular weight of approximately 100 g / mol, or a high-molecular-weight amphiphilic silicone additive. In this case, the high-molecular-weight amphiphilic silicone additive may have a molecular weight of 30,000 g / mol to 90,000 g / mol.

[0138] Additionally, the silicone additive may be used in a small amount. Specifically, the silicone additive may be used in an amount of 0.01 to 5 parts by weight, and more specifically, 0.1 to 4 parts by weight, 0.1 to 3 parts by weight, 0.1 to 2 parts by weight, 0.5 to 1.5 parts by weight, 0.1 to 1.1 parts by weight, or 0.7 to 1.3 parts by weight, based on 100 parts by weight of the bifunctional first acrylate monomer.

[0139] When using a silicone additive, there is a problem that the surface tension of the acrylic resin composition is lowered, thereby reducing the wax affinity of the surface treatment layer. However, the present invention introduces a fine wrinkle structure on the surface of the surface treatment layer and simultaneously controls the content of the silicone additive within the above range, thereby appropriately lowering the surface tension of the acrylic resin composition, thereby improving the contamination resistance of the surface treatment layer formed using the acrylic resin composition while minimizing the reduction in wax affinity. In addition, it is possible to prevent a significant reduction in the curing rate due to an excessive amount of silicone additive.

[0140] The above composition may further include an initiator (C). The type of initiator is not particularly limited, as long as it is an initiator that can be used in the curing process described below, and known commercially available products may also be used.

[0141] The content of the initiator is not particularly limited. For example, the composition may contain 20 parts by weight or less of the initiator. Specifically, the content of the initiator may be 15 parts by weight or less, 10 parts by weight or less, 5 parts by weight or less, 4 parts by weight or less, 3 parts by weight or less, 2 parts by weight or less, or 1 part by weight or less. And, the lower limit of the content may be, for example, 0.1 parts by weight or more, 1 part by weight or more, 2 parts by weight or more, 3 parts by weight or more, 4 parts by weight or more, or 5 parts by weight or more. As described below, in the present application, since stepwise curing is performed when curing the cured layer, the curing efficiency is excellent even when a small amount of the initiator is used.

[0142] The composition may further include a dispersant, and the type of the dispersant is not particularly limited, and known commercially available products may also be used. The content of the dispersant is not particularly limited. For example, the composition may include 5 parts by weight or less of the dispersant with respect to 100 parts by weight of the bifunctional first acrylate monomer. Specifically, the content of the dispersant may be 4 parts by weight or less, 3 parts by weight or less, 2 parts by weight or less, or 1 part by weight or less. In addition, the lower limit of the content may be, for example, 0.01 parts by weight or more, 0.05 parts by weight or more, 0.1 parts by weight or more, 0.2 parts by weight or more, 0.5 parts by weight or more, or 1 part by weight or more.

[0143]

[0144] The method for manufacturing the above flooring material may further include an embossing step of contacting an embossing roll having a protruding pattern on the surface of the surface treatment layer of the laminate to form an embossing pattern corresponding to the protruding pattern of the embossing roll on the surface treatment layer.

[0145] The above embossing can be formed as a negative through a process of pressing a surface treatment layer by passing it between a single rotating embossing roller or a pair of embossing rollers. More specifically, the pair of embossing rollers maintain a predetermined gap so that the upper surface of the surface layer pressed in one direction is not crushed and the embossing can be formed with a constant pressing force.

[0146] The outer surface of the embossing roller is provided with a protruding pattern of a predetermined shape for forming an embossing by pressing one side of the surface treatment layer. Here, in the case of providing a pair of embossing rollers, the protrusions may be formed on the roller provided on the upper side.

[0147] The embossing roller receives power from a motor (not shown) installed on one side and rotates at a constant speed to repeatedly form an embossing pattern consisting of a wood grain pattern or one of various patterns along the longitudinal direction of the upper surface of the surface treatment layer applied on one side.

[0148] The height of the protruding pattern of the above embossing roll may be 50 μm or more and 500 μm or less. Correspondingly, the height of the formed embossing pattern, i.e., the depth of the embossing, is also determined by the height of the protruding pattern of the above embossing roll, and the height of the embossing pattern may be 50 μm or more and 500 μm or less.

[0149] Hereinafter, the present invention will be described in more detail through examples. However, the following examples are intended only to illustrate the present invention and are not intended to limit the present invention.

[0150] [Example]

[0151] Manufacturing Examples 1 to 4. Manufacturing of acrylic resin composition

[0152] A solvent-free type acrylic resin composition was prepared by mixing a first acrylic monomer (bifunctional monomer), a second acrylic monomer (polyfunctional monomer), a first acrylic oligomer (polyfunctional oligomer), a second acrylic oligomer (monofunctional oligomer), colloidal silica (average diameter: 5 to 10 μm) as a filler, and a dispersant together with Irgacure 754 as an initiator, as shown in Table 1 below.

[0153] Manufacturing Example 1 Manufacturing Example 2 Manufacturing Example 3 1st acrylic monomer (bifunctional) 35g 35g 35g 2nd acrylic monomer (polyfunctional) 15g 15g 15g 1st acrylic oligomer (polyfunctional) 35g 35g 35g 2nd acrylic oligomer (monofunctional) 15g 15g 15g Colloidal silica 3g 15g 3g Dispersant 1g 1g 1g Irgacure 754 4g 4g Silicone additive 1g 1g 0g

[0154] Example 1

[0155] The acrylic resin composition manufactured in Manufacturing Example 1 was applied to a substrate on which a polyvinyl chloride (PVC)-based floor tile and a transparent polyvinyl chloride (PVC) film, each measuring 20 cm in width × 30 cm in length, were laminated, and a light curing device having a structure as shown in Fig. 9 was fixed, and then, while moving the substrate at a moving speed of 20±1 m / min under the conditions shown in Tables 2 and 3 below, light irradiation was performed stepwise to manufacture a flooring specimen. At this time, the average thickness of the surface treatment layer was 15±1 ㎛. In Table 3 below, the light source used for the first and third light irradiations is a mercury lamp having an emission spectrum in the range of 200 to 450 nm.

[0156] Example 1 Acrylic composition type Composition of manufacturing example 1 Curing conditions Curing conditions 1

[0157] Curing conditions 1. 1st light irradiation wavelength range 200~450 nm. Irradiation dose 100±5 mJ / ㎠. Distance from light source 50±1 mm. Gas conditions Air conditions 2. 2nd light irradiation wavelength range 172±5 mm. Irradiation dose 50±5 mJ / ㎠. Distance from light source 100±1 mm. Gas conditions N2 conditions (O2 1,000 ppm) 3. 3rd light irradiation wavelength range 200~450 nm. Irradiation dose 700±10 mJ / ㎠. Distance from light source 100±1 mm. Gas conditions N2 conditions

[0158] Comparative Examples 1 to 3

[0159] A flooring sample was manufactured in the same manner as in Example 1, except that the composition was cured under the conditions shown in Tables 4 and 5 below. At this time, the average thickness of the surface treatment layer was 15±1 ㎛.

[0160] Comparative Example 1 Comparative Example 2 Comparative Example 3 Acrylic composition type Composition of Manufacturing Example 1 Composition of Manufacturing Example 2 Curing condition Curing condition 2 Curing condition 3

[0161] Curing Condition 2 Curing Condition 3 First light irradiation wavelength range Less than 300 nm 100-450 nm Irradiation dose 40±2 mJ / ㎠ 700±10 mJ / ㎠ Distance from light source 50±1 mm 100±1 mm Gas condition N2 condition (O2 1,000 ppm) Air condition Second light irradiation wavelength range 100-450 nm - Irradiation dose 700±10 mJ / ㎠ Distance from light source 100±1 mm Gas condition Air condition

[0162] Experimental Example 1

[0163] The specimens manufactured in Examples 1 and 2 and Comparative Examples 1 to 4 were tested for gloss, stain resistance (cleaning), stain resistance (KS), and scratch resistance. The specific measurement methods are as follows, and the measured results are shown in Table 6 below.

[0164] a) Surface gloss evaluation

[0165] The glossiness of the specimens of the examples and comparative examples was measured at 60° and 85° using a gloss meter (gloss 60° and 85° conditions).

[0166] b) Evaluation of contamination resistance (cleanliness)

[0167] The test was conducted according to KS M 3802, but using a magic marker and a board marker as contaminant materials, a square measuring approximately 10 cm × 10 cm was drawn on the surface, and after 30 seconds or more, the drawn square was rubbed off with Kimwipes, and the area that remained without being erased (e.g., traces or smudges) based on the initial contaminated area was visually checked, and the results were classified according to the following criteria:

[0168] - Grade 1: The remaining area is 90% or more of the initial contaminated area.

[0169] - Grade 2: The remaining area is 60% or more but less than 90% of the initial contaminated area.

[0170] - Grade 3: The remaining area is 20% or more but less than 60% of the initial contaminated area.

[0171] - Grade 4: The remaining area is 5% or more but less than 20% of the initial contaminated area.

[0172] - Grade 5: The remaining area is less than 5% of the initial contaminated area.

[0173] D) Evaluation of contamination resistance (KS)

[0174] The test was conducted according to KS M 3802, and 10 types of contaminants were used on the top of the floor specimens, including soybean oil, lubricating oil, 95% ethanol, cement paste, 10% ammonia solution, milk, 5% acetic acid, 5% hydrochloric acid, kerosene, and soy sauce, and evaluated. After wiping the floor specimens with a dry cloth, 2 mL of the contaminant was dropped. After confirming that it spread in a circular shape, it was covered with a watch glass and left to stand for 24 hours. After that, it was washed with water containing a neutral detergent, and then washed again with ethanol. The surface of the specimen was wiped clean with a dry gauze and left to stand for 1 hour. After visually checking the color, gloss change, and swelling of the area where the contaminant was dropped, the results were classified according to the following criteria:

[0175] - PASS: No change in color, gloss, or swelling in the area where the contaminant was dropped.

[0176] - NG: There is a change in color, gloss, and swelling in the area where the contaminant was dropped. (Indicate changes in color, gloss, and swelling)

[0177] a) Scratch resistance evaluation

[0178] The surface of the coating layer was evaluated for scratch resistance (Micro Scratch Resistance) according to EN16094 B standard, and micro scratch resistance was evaluated according to EN 16094:2012 B procedure. Specifically, the surface of the laminated film was rubbed 160 times with a medium-fine hand pad (Scotch Brite SB7440). Afterwards, the rubbed surface was visually inspected for scratches and the presence of scratch-induced patterns, and a grade was assigned according to the following criteria:

[0179] B1 Grade: No scratches whatsoever,

[0180] B2 Grade: Less than 10 light scratches found,

[0181] B3 Grade: 10 to 30 light scratches confirmed,

[0182] Grade B4: Numerous narrow and fine scratches are confirmed, and Lissajous figures are partially confirmed due to the scratches.

[0183] Grade B5: Numerous narrow and fine scratches are confirmed, and Lissajous figures are confirmed to be mixed in due to the scratches.

[0184] Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 Glossiness (60°) 3±15±210±16±1 Glossiness (85°) 10±15±223±120±1 Stain resistance (magic) Grade 4~5 Grade 4 Grade 3 Grade 3 Stain resistance (marker) Grade 5 Grade 5 Grade 5 Grade 5 Stain resistance (KS) PASS PASS PASS PASS Scratch resistance B1~B2 B1~B2 B2 B3

[0185] Experimental Example 2

[0186] In order to confirm the surface structure of the surface treatment layer, which is the outermost layer of the flooring material according to the present invention, a scanning electron microscope (SEM) analysis was performed on the flooring material samples manufactured in Example 1 and Comparative Examples 1 to 3, and the results are shown in Figs. 1 to 4. As shown in Fig. 1, the wrinkle structure of Example 1 had a width of 3 to 11 μm and a length of about 5 to 20 μm. In addition, the wrinkles were formed very uniformly, with 21 to 100 wrinkles formed per unit area (0.1 x 0.1 mm). The distance between adjacent peaks of the wrinkles was 1 to 15 μm, and the distance between adjacent valleys of the wrinkles was also 1 to 15 μm.

[0187] As shown in Fig. 2, the wrinkle structure of Comparative Example 1 had a width of 10 to 50 μm and a length of about 10 to 50 μm. In addition, the wrinkles were formed unevenly depending on the embossing depth, with 5 to 20 wrinkles formed per unit area (0.1 x 0.1 mm). The distance between adjacent peaks of the wrinkles was 1 to 15 μm, and the distance between adjacent valleys of the wrinkles was also 1 to 15 μm.

[0188] As shown in Figures 3 and 4, Comparative Examples 2 and 3 had matting agents exposed on the surface without forming wrinkles.

[0189] Experimental Example 3

[0190] In order to test the friction fastness of the surface treatment layer, which is the outermost layer of the flooring material according to the present invention, the flooring material specimens manufactured in Example 1 and Comparative Examples 1 to 3 were subjected to 1,000 friction tests using a croakmeter device as shown in Table 7 below. The results of the evaluations of the gloss, stain resistance (magic, marker), and stain resistance (KS) of the specimens are shown in Table 8.

[0191] Sample Example 2 Comparative Example 4 Comparative Example 5 Comparative Example 6 Evaluation target specimen Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 Evaluation conditions Croke meter friction fastness evaluation

[0192] Example 2 Comparative Example 4 Comparative Example 5 Comparative Example 6 Glossiness (60°) 3±15±29±26±2 Glossiness (85°) 11±15±220±218±2 Stain resistance (magic) Grade 4~5 Grade 4 Grade 2 Grade 2 Stain resistance (marker) Grade 5 Grade 5 Grade 3 Grade 3 Stain resistance (KS) PASS PASS NGNG Scratch resistance B1~B2 B1~B2 B3 B4

[0193] Experimental Example 4

[0194] The surface of the flooring specimen evaluated in the above Experimental Example 3 was analyzed using a scanning electron microscope (SEM), and the results are shown in Figs. 5 to 9. Fig. 1, which realized an ultra-matte finish with surface wrinkles by 3-Step curing, shows that there is little difference in the gloss of the deep embossing and the floor, and as shown in Fig. 5, there was no particle shedding upon friction, little change in gloss, and no surface change after friction fastness evaluation (scratch resistance B1~B2 -> B1~B2).

[0195] In the case of implementing an ultra-matte finish with surface wrinkles through 2-step curing as in Comparative Example 1, there is a problem that the wrinkle shapes of the valleys and peaks of the emboss are different, resulting in differences in surface gloss and physical properties, as shown in Fig. 6. In Comparative Example 4, when evaluating friction fastness, particle shedding was small and scratch resistance was the same as before friction, but the difference in gloss between the valleys and peaks of the emboss was large, confirming that the difference in gloss between them increased when rubbed.

[0196] When a matte surface treatment layer was manufactured using a 1-step general curing method by adding a matting agent as in Comparative Example 2 or 3, it was confirmed that the gloss changed due to particle shedding upon friction, as shown in Fig. 7. Comparative Example 2 had a surface treatment layer formed with a composition (the composition of Preparation Example 1) containing less colloidal silica, which is a matting agent, and as in Comparative Example 5, it was confirmed that a small amount of matting agent shedding occurred after the friction fastness evaluation and that the scratch resistance decreased from B2 to B3. Comparative Example 3 had a surface treatment layer formed with a composition (the composition of Preparation Example 2) containing more matting agent, and as in Comparative Example 6, it was confirmed that the matting agent and the coating layer shedding occurred after the friction fastness evaluation and that the scratch resistance decreased from B3 to B4.

[0197] Experimental Example 5

[0198] To conduct a repeated walking test on the surface treatment layer, which is the outermost layer of the flooring material according to the present invention, the flooring material specimens manufactured in Example 1 and Comparative Examples 1 to 3 were subjected to a caster chair repeated walking test. The caster chair repeated walking test was simulated with reference to the KS K ISO 4918 standard (applied with a load of 90 kg). The results of the gloss evaluation of the specimens are shown in Table 9.

[0199] Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 Gloss change (60°, 100 times) 0.2 0.3 0.4 2.2 Gloss change (60°, 1000 times) 0.6 1.0 1.6 3.5 Gloss change (60°, 3000 times) 0.8 2.2 3.0 4.3 Gloss change (85°, 100 times) 1.3 1.7 4.1 4.6 Gloss change (85°, 1000 times) 2.9 3.5 6.0 8.0 Gloss change (85°, 3000 times) 3.4 4.5 7.4 10.9

[0200] Experimental Example 6

[0201] The acrylic resin compositions manufactured in Manufacturing Examples 1, 3, and 4 were each applied on a substrate on which a polyvinyl chloride (PVC)-based floor tile and a transparent polyvinyl chloride (PVC) film, each measuring 20 cm in width × 30 cm in length, were laminated, and a light curing device having a structure as shown in Fig. 9 was fixed, and then light irradiation was performed stepwise while moving the substrate at a moving speed of 20±1 m / min under the conditions as shown in Table 10 below, thereby manufacturing a flooring specimen. At this time, the average thickness of the surface treatment layer was 15±1 ㎛.

[0202] Example 3 Example 4 Comparative Example 9 Comparative Example 10 Acrylic Composition Type Composition of Preparation Example 1 Composition of Preparation Example 3 Composition of Preparation Example 1 Composition of Preparation Example 3 Curing Conditions Curing Conditions 1 Curing Conditions 3

[0203] In order to evaluate the gloss, stain resistance (cleanness), and stain resistance (KS) of the flooring material according to the present invention, the surface gloss and stain resistance were measured for the specimens manufactured in Example 3 and Comparative Examples 7 to 11 in the same manner as in Experimental Example 1, and the measured results are shown in Table 11 below.

[0204] Example 3 Example 4 Comparative Example 8 Comparative Example 9 Glossiness (60°) 3±13±111±212±2 Glossiness (85°) 10±112±124±225±2 Stain resistance (magic) Grade 4~5 Grade 3 Grade 3 Grade 1 Stain resistance (marker) Grade 5 Grade 5 Grade 3 Stain resistance (KS) PASSPASSPASSNG

[0205] Example 1, to which 3-Step curing was applied, achieved an ultra-matte gloss (simultaneously satisfying the range of glossiness of 60° below 4 and glossiness of 85° below 30), and it was confirmed that the contamination resistance was good through Example 3 by adding a silicone additive. When applying the curing condition 3, which is a general curing, it was confirmed through Comparative Examples 9 to 11 that an ultra-matte gloss could not be achieved even with the same composition, and the contamination resistance tended to decrease compared to when applying the curing condition 1, which is a 3-Step curing, regardless of whether or not the silicone additive was included.

Claims

1. Contains a substrate layer and a surface treatment layer, The above surface treatment layer is, It has a surface structure including 21 to 100 wrinkles per unit area (0.1 mm × 0.1 mm), The surface gloss is 4 or less under the gloss 60° condition, Flooring having a surface gloss of 30 or less under 85° gloss conditions.

2. In claim 1, the surface treatment layer comprises: A flooring material, after a friction test of 3,000 times with a load of 90 kg according to the KS K ISO 4918 standard, the change in surface gloss at 60° is 2 or less compared to before the friction test.

3. In claim 1, the surface treatment layer, A flooring material, which has a change in surface gloss of 4 or less at a gloss condition of 85° compared to before the friction test after a friction test of 3,000 times with a load of 90 kg according to the KS K ISO 4918 standard.

4. A flooring material according to claim 1, wherein the width of the wrinkles of the surface treatment layer is 3 ㎛ to 11 ㎛, and the length is 1 ㎛ to 30 ㎛.

5. A flooring material according to claim 1, wherein the distance between one wrinkle and an adjacent wrinkle in the surface treatment layer is 1 ㎛ to 15 ㎛.

6. A flooring material according to claim 1, wherein the average thickness of the surface treatment layer is 5 ㎛ to 30 ㎛.

7. A first light irradiation step of curing the surface of the composition by irradiating light with a wavelength of 100 nm to 450 nm in the air to the acrylic resin composition applied on the substrate layer. A second light irradiation step of inducing wrinkles on the surface of the surface-cured composition by irradiating light with a wavelength of less than 300 nm under nitrogen gas (N2) conditions, and A third light irradiation step of forming a surface treatment layer by irradiating light of a wavelength of 100 nm to 450 nm to a composition having wrinkles induced on the surface, The above surface treatment layer is, It has a surface structure including 21 to 100 wrinkles per unit area (0.1 mm × 0.1 mm), The surface gloss is 4 or less under the Gloss 60° condition, A method for manufacturing a flooring material having a surface gloss of 30 or less under a gloss condition of 85°.

8. In claim 7, the light irradiation dose of the first light irradiation step is 1 mJ / cm 2 Within 150 mJ / cm 2 A method for manufacturing a flooring material.

9. In claim 7, the acrylic resin composition, For 100 parts by weight of the bifunctional first acrylate monomer, 30 to 50 parts by weight of a multifunctional second acrylate monomer 30 to 140 parts by weight of a multifunctional first acrylate oligomer 1 to 10 parts by weight of a quencher, and A method for manufacturing a flooring material comprising 0.01 to 5 parts by weight of a silicone additive.

10. In claim 9, the acrylic resin composition, For 100 parts by weight of the above bifunctional first acrylate monomer, 0.01 to 5 parts by weight of dispersant, 30 to 50 parts by weight of a monofunctional second acrylate oligomer and A method for manufacturing a flooring material further comprising at least one of 5 to 20 parts by weight of an initiator.

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