CA2856385C - A composite floor and manufacturing method thereof - Google Patents

A composite floor and manufacturing method thereof Download PDF

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Publication number
CA2856385C
CA2856385C CA2856385A CA2856385A CA2856385C CA 2856385 C CA2856385 C CA 2856385C CA 2856385 A CA2856385 A CA 2856385A CA 2856385 A CA2856385 A CA 2856385A CA 2856385 C CA2856385 C CA 2856385C
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Prior art keywords
parts
weight
bamboo
layer
composite floor
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CA2856385A
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French (fr)
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CA2856385A1 (en
Inventor
Jiangang Song
Yongxing CHEN
Jun Xu
Weiqiang Fu
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Zhejiang Yongyu Home Furnishings Co Ltd
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Zhejiang Yongyu Bamboo Joint-Stock Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/12—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/14—Layered products comprising a layer of synthetic resin next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
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    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
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    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
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    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
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    • B32B9/048—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of particles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/041—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material
    • E04F15/042—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0016—Abrading
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/025—Particulate layer
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B32B2264/065—Lignocellulosic particles, e.g. jute, sisal, hemp, flax, bamboo
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
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    • B32B2471/00—Floor coverings

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)

Abstract

Composite flooring and a manufacturing method thereof are disclosed. The composite floor includes, at least, a bamboo-plate surface layer and an organic layer.
The manufacturing method includes the steps of: uniformly mixing 60-120m organic powder and silane coupling agent accounting for 1.1-1.3% of the organic powder by weight at a temperature of 100-130°C, then cooling to 5-45°C;
uniformly mixing 100 parts of polyvinyl chloride, 30-50 parts of calcium carbonate, 5-7 parts of sterilizer, 10-16 parts of foam regulator, 0.8-1.6 parts of foaming agent, 2-4 parts of chlorinated polyethylene, 3-5 parts of lubricant, 1-3 parts of plasticizer, 0.2-0.6 part of anti-aging agent and 30-50 parts of modified bamboo powder or wood powder by weight at a temperature of 110-130°C for 20-30min; extrusion molding and post-processing; and, finally, hot pressing or gluing the two layers and/or a bottom layer and cold pressing those layers to generate the composite floor.

Description

A COMPOSITE FLOOR AND MANUFACTURING METHOD THEREOF
TECHNICAL FIELD
[0001] The present invention relates to a floor and a manufacturing method thereof, in particular a composite floor and a manufacturing method thereof.
BACKGROUND OF THE INVENTION
[0002] As the global economy develops, numerous forests are being chopped down, leading to the deterioration of the environment. The environment in which human beings live has seen destruction like never before. Ecological environmental protection has become the common pursuit of human beings in the new century.
The use of bamboo or wood flooring obviously wastes a large amount of natural wood resources. In addition, a lot of adhesives containing formaldehyde are used during preparation, and the formaldehyde remains in the room even after a long period time.
Therefore, composite floor has become gradually more accepted. However, composite floor that is purely made from artificial materials is usually of poor quality and is inconvenient to use.
[0003] Bamboo plastic floor that imitates solid wood preserves its beautiful bamboo textures and the features of heat insulation, isolation, waterproofing, mothproofing, fire retardancy, and resistance to acids, bases and decay, and also has the following features that wood does not have: (1) Rich colors, varieties of textures: Wood plastic products that imitate solid wood are computer-designed, can generate the color and textures of natural wood, have brighter luster, more solid textures, and dynamic and vivid patterns, and fully satisfy people's demands for variety and individualization. (2) Leading the trend of "green products, green customization": No adhesives are used over the course of the entire manufacturing process for creating bamboo plastic floor that imitates solid wood, and so harmful substances such as formaldehyde are not present. Customers can thus use those products at ease. (3) Superior product performance: Bamboo plastic floor that imitates solid wood is used for outdoor decorations and does not easily deform, arch, crack, shrink and decay. (4) High product utilization rate: Bamboo plastic floor that imitates solid wood has no inherent defects like natural wood, such as wormholes, knots, and color changes. It is a decorative material having almost no defects. This material has textures and luster in a certain regular manner, and is good-looking and durable. (5) High product recycling rate: bamboo plastic floor that imitates solid wood can be repeatedly recycled a number of times due to its ability to biodegrade. In conclusion, bamboo plastic products that imitate solid wood are optimal substitutes for natural wood resources that have gradually been diminished.
[0004] The Chinese patent CN102304244B(2012-9-12) details a bamboo plastic plate for indoor decoration, wherein PE, PP, PS or ABS plastics serving as main materials are mixed and stirred with tourmaline mine powder, bamboo carbon charcoal, bamboo fiber, adhesive, lubricant and coupling agent in a stirrer, then cast and molded into bamboo plastic plates. However, this bamboo plastic plate is a single-layer structure that has a single function, poor quality, poor elasticity underfoot, and its resistance to deformation needs improvement.
BRIEF SUMMARY OF THE INVENTION
[0005] One objective of the present invention is to provide firmly constructed and deformation-resistant composite floor that is formed by combining a bamboo-plate surface layer with an organic layer.
[0006] The objective of the present invention is to provide a manufacturing method for the firmly constructed and deformation-resistant composite floor.
[0007] The present invention provides the following technical solution to fulfill the first technical objective:
[0008] The composite floor includes, at least, a bamboo-plate surface layer and an organic layer.
[0009] The organic layer of the present invention is made from local waste powder such as bamboo powder or wood powder through modification. It is environmentally-friendly and economical, and does not deform because of environmental humidity or moisture. The composite floor formed by combining the organic layer and the bamboo-plate surface layer is an effective substitute for antiseptic and solid bamboo and wood, and has higher strength and elasticity and more comfortable feel underfoot than the antiseptic and solid bamboo and wood.
The composite floor is damp-proof, fireproof, and resistant to decay, deformation and warping, is firmly constructed, and is of high quality.
[0010] Preferably, a soft wood or fireproof plate bottom player is arranged below the organic layer; the soft wood layer is a sawdust laminated layer or a soft wood EVA
foaming material layer; the bamboo-plate surface layer is 1-3mm thick and has a moisture rate of 5-15%; and the organic layer is 4-10mm thick.
[0011] The organic layer with a certain thickness is used as the core layer combined with the bamboo-plate surface layer having a specific thickness and moisture rate and the bottom layer to form the composite floor. The arrangement of the soft wood layer further increases the good elasticity underfoot. The composite floor is an effective substitute for antiseptic and solid bamboo and wood, and has higher strength and elasticity and is more comfortable underfoot than antiseptic and solid bamboo and wood. The composite floor is damp-proof, fireproof, and resistant to decay, deformation and warping, is firmly constructed, and is of high quality
[0012] Preferably, the organic layer is a bamboo plastic layer. The bamboo plastic layer comprises the following components by weight:
100 parts of polyvinyl chloride, 30-50 parts of silane coupling agent modified bamboo powder, 30-50 parts of calcium carbonate, 5-7 parts of sterilizer, 10-16 parts of foam regulator, 0.8-1.6 parts of foaming agent, 2-4 parts of chlorinated polyethylene, 3-5 parts of lubricant, 1-3 parts of plasticizer, and 0.2-0.6 part of anti-aging agent.
[0013] The present invention is based on local circumstances. The local excessive waste bamboo powder is collected and modified in a specific component ratio to obtain the organic layer with high strength, good elasticity underfoot and high resistance to deformation.
[0014] Preferably, the stabilizer is calcium stearate; the foaming agent is azodicarbonamide; the plasticizer is dimethyl phthalate, diethyl phthalate or di-n-octyl phthalate.
[0015] The bamboo plastic layer made by mixing this type of additive and the silane coupling agent modified bamboo powder is of high strength, has a good feeling of elasticity underfoot, and has a resistance to deformation.
[0016] More preferably, the foam regulator is an acrylic foam regulator; the lubricant is a fatty acid type mixer; and the anti-aging agent is a quinine type radical scavenger.
[0017] Preferably, an adhesive layer is arranged between the bamboo-plate surface layer and the organic layer; and the surface of the bamboo-plate surface layer is provided with a bamboo plastic layer having a seal coat.
[0018] The bamboo-plate surface layer with the seal coat has vivid textures and high plumpness, and does not exchange water with the surrounding environment. In addition, the bamboo plastic layer itself does not absorb moisture, so the entire floor is isolated from the moisture in the surrounding environment and is not affected by the environmental humidity. Therefore, the composite floor with high resistance to deformation and a good feeling of elasticity underfoot is obtained.
[0019] Preferably, the adhesive layer is a polyurethane glue layer.
[0020] Preferably, the glue consists of the following raw materials by weight:
[0021] 70-95 parts of polyurethane, 25-35 parts of phthalic anhydride, 10-12 parts of triethylene glycol, 15-18 pats of glutaric acid, 8-10 parts of butanctriol, 5-7 parts of zinc oxide, 3-5 parts of magnesium oxide, 15-25 parts of chloroprene rubber, 2-3 parts of softening oil; 15-20 parts of dimethyl carbonate, 20-30 parts of ethylbenzene and 1-3 parts of fire retardant; the fire retardant consist of the following components by weight part: 20-50 parts of ammonium oligomericphosphate, 10-25 parts of ammonium phosphate, 6-12 parts of ammonium pyrophosphate, 5-20 parts of ammonium sulfate, 5-10 parts of boric acid and 10-25 parts of water.
[0022] The glue of the present invention has the advantages of high initial adhesion and fastness; the fire retardant of the present invention has high fire retardancy and can carry out synergistic interaction with other ingredients in the glue to increase the initial adhesion of the glue.
[0023] The present invention provides the following technical solution to fulfill the second technical objective:
A manufacturing method for the compound floor, comprising:
A. preparing the bamboo-plate surface layer: sanding the bamboo plate surface smooth to form the bamboo plate surface layer;
B. preparing the organic layer by the following steps:
(1) modification: stirring and uniformly mixing organic powder with a particle size of 60-120m and silane coupling agent which accounts for L1-1.3% of the organic powder by weight at a temperature of 100-130 C, then cooling to 5-45 C to obtain modified organic powder;
(2) materials mixing by weight ratio: stirring and mixing 100 parts of polyvinyl chloride, 30-50 parts of calcium carbonate, 5-7 parts of sterilizer, 10-16 parts of foam regulator, 0.8-1.6 parts of foaming agent, 2-4 parts of chlorinated polyethylene, 3-5 parts of lubricant, 1-3 parts of plasticizer, 0.2-0.6 part of anti-aging agent and 30-50 parts of silane coupling agent modified organic powder at a temperature of 110-130 C for 20-30min to obtain a mixed material, wherein the stirring speed is 600-1,000r/min;
(3) extrusion molding: feeding the mixed material into the barrel of a main conical double-screw extruder, and starting the extruder to extrude and mold an organic material with a density of 600-1,200kg/cm3;
(4) post processing: water cooling, drawing and cutting the molded organic material to obtain the organic plate substrate;
C. combination: hot pressing or gluing the bamboo-plate surface layer and the organic layer and then cold pressing the layers to generated the composite floor.
[0024] The modified organic powder has high processability, can effectively react with the additive and foam to generate the organic layer with a high degree of strength and certain elasticity.
[0025] The present invention is based on the local circumstances. The local excessive waste bamboo powder is collected and modified in a specific component ratio to obtain the organic layer with a high degree of strength, good elasticity underfoot and a high resistance to deformation. The composite floor is of high quality and is firmly constructed.
[0026] Preferably, the organic layer is a bamboo plastic layer, and the organic powder is bamboo powder; in step (1), the bamboo powder with a particle size of 60-120m and the silane coupling agent which accounts for 1.1-1.3% of the bamboo powder by weight are uniformly mixed and stirred at a speed of 1,000-1,300r/min for 5-8 min at temperature of 100-130 C, then kept at this temperature for 2-4min, next cooled to 5-45 C to obtain the modified bamboo powder.
[0027] The modified bamboo powder has high processability and can effectively react with the additive and foam to generate the bamboo plastic layer with a high degree of strength and certain elasticity.
[0028] Preferably, in step (2), mixing in a ratio refers to stirring and mixing 10-16 parts of foam regulator, 0.8-1.6 parts of foaming agent, 3-5 parts of lubricant, 1-3 parts of plasticizer, 0.2-0.6 part of anti-aging agent and the modified bamboo powder obtained in step (1) for 15-20min in a stirring mixer, then adding 100 parts of polyvinyl chloride, 30-50 parts of calcium carbonate, 5-7 parts of sterilizer and 2-4 parts of chlorinated polyethylene into the stirring mixer, next continuously stirring and mixing at a speed of 600-1,000r/min for 5-10min to obtain the mixed material.
[0029] Different feeding sequences and material mixing ratios are employed in the present invention, which can prevent migration of the polyvinyl chloride, chlorinated polyethylene and sterilizer, allows for the formation of a quality mixed material and is good for the subsequent extrusion molding process.
[0030] Preferably, in step (3), the main extruder for extrusion and molding has a temperature of 130-170 C, a rotation speed of 40-50r/min and an extrusion speed of 600mm/min; the melt pressure of the extruder is 3-8Mpa; the rotation speed of the feeding machine is 4-6r/min; and the temperature of the machine head is 160-170 C.
[0031] The inventor found that the bamboo plastic plate substrates made from the bamboo plastic materials extruded and molded by the main extruder and the feeding machine which are matched in parameters have a high degree of strength, good elasticity underfoot and a high resistance to deformation.
[0032] Preferably, the bottom surface of the bamboo-plate surface layer is sanded with a sanding belt to form a smooth surface and then cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 5-60 C under a pressure of 1-3MPa/cm2.
[0033] The bamboo-plate surface layer and the bamboo plastic layer laminated at this temperature under this pressure arc firmly constructed and have high resistance to deformation. The glue is polyurethane type cold pressing glue. The bamboo plastic substrate does not release formaldehyde; the bamboo plate paint is sealed and releases little formaldehyde; the formaldehyde emission of the bamboo-bamboo plastic floor reaches level Eo.
[0034] Preferably, the bamboo-plate surface layer acts as a surface layer, the organic layer acts as a core layer and the EVA, soft wood or fireproof plate layer acts as the bottom layer, and the three are hot pressed or glued and then cold pressed to generate the composite floor.
[0035] Preferably, the manufacturing method also comprises manufacturing a seal coat on the surface of the bamboo-plate surface layer by steps of: coloring the surface of the bamboo-plate surface layer first, then heating the floor to 30-38 C, next spraying a primer to the colored surface of the bamboo-plate surface layer, and finally applying varnish on the primer surface after the primer has dried.
[0036] The bamboo-plate surface layer with the seal coat has vivid textures and high plumpness, and does not exchange water with the surrounding environment. In addition, the bamboo plastic layer itself does not absorb moisture, so the entire floor is isolated from the moisture in the surrounding environment and is not affected by the environmental humidity.
[0037] In conclusion, the bamboo plastic composite floor of the present invention has the following beneficial effects:
1. Resistance to humidity, fire and decay;
2. Resistance to bending and wrapping and firm adhesion.

DETAILED DESCRIPTION OF THE INVENTION
[0038] Embodiment 1
[0039] The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.
[0040] Manufacturing method of the bamboo plastic layer:
[0041] (1) modification: bamboo powder with a particle size of 60-120 m and silane coupling agent which accounts for 1.1% of the organic powder by weight are uniformly mixed and stirred at a temperature of 100 C, then cooled to 5 C to obtain modified bamboo powder
[0042] (2) material mixing in a weight ratio: 100 parts of polyvinyl chloride, parts of calcium carbonate, 5 parts of sterilizer, 10 parts of foam regulator, 0.8 part of foaming agent, 2 parts of chlorinated polyethylene, 3 parts of lubricant, 1 part of plasticizer, 0.2 part of anti-aging agent and 30-50 parts of silane coupling agent modified organic powder are mixed and stirred at a speed of 600r/min for 20 min at a temperature of 110 C to obtain a mixed material, wherein the sterilizer is calcium stearate; the foaming agent is azodicarbonamide; the plasticizer is dimethyl phthalate, diethyl phthalate or di-n-octyl phthalate; the foam regulator is an acrylic foam regulator; the lubricant is a fatty acid type mixer; and the anti-aging agent is a quinine type radical scavenger.
[0043] (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 600-800 kg/cm3, wherein the main extruder for extrusion and molding has a temperature of 130 C, a rotation speed of 40r/min and an extrusion speed of 600mm/min; the melt pressure of the extruder is 3Mpa; the rotation speed of the feeding machine is 4r/min; and the temperature of the machine head is 160 C;
[0044] (4) post processing: the molded bamboo plastic material water cooled, drawn and cut to obtain the bamboo plastic plate substrate.
[0045] Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120-150m sanding belt to be smooth.
[0046] Preparation of the polyurethane glue: the following components are mixed by weight: 70 parts of polyurethane, 25 parts of phthalic anhydride, 10 parts of triethylene glycol, 15 pats of glutaric acid, 8 parts of butanetriol, 5 parts of zinc oxide, 3 parts of magnesium oxide, 15 parts of chloroprene rubber, 2 parts of softening oil;
15 parts of dimethyl carbonate, 20 parts of ethylbenzene and 3 parts of fire retardant;
the fire retardant consist of the following components by weight: 20 parts of ammonium oligomericphosphate, 10 parts of ammonium phosphate, 6 parts of ammonium pyrophosphate, 5 parts of ammonium sulfate, 10 parts of boric acid and 25 parts of water.
[0047] Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using the polyurethane glue at a temperature of 5 C under a pressure of 1MPa/cm2. Finally, manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 30 C, next a primer is sprayed to the colored surface of the bamboo-plate surface layer; and finally, a varnish is applied onto the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 2mm thick and has a moisture rating of 10%, and the bamboo plastic layer is 7mm thick.
[0048] Embodiment 2
[0049] The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.
[0050] Manufacturing method of the bamboo plastic layer:
[0051] (1) modification: the bamboo powder with a particle size of 60-120 m and silane coupling agent which accounts for 1.3% of the organic powder by weight are uniformly mixed and stirred at a temperature of 130 C, then cooled to 45 C to obtain modified bamboo powder;
[0052] (2) material mixing in a weight ratio:100 parts of polyvinyl chloride, 50 parts of calcium carbonate, 7 parts of sterilizer, 16 parts of foam regulator, 1.6 parts of foaming agent, 4 parts of chlorinated polyethylene, 5 parts of lubricant, 3 parts of plasticizer, 0.6 part of anti-aging agent and 30-50 parts of silane coupling agent modified organic powder are mixed and stirred at a temperature of 130 C for 30min to obtain a mixed material, wherein the stirring speed is 1,000r/min;
[0053] (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 1,200kg/cm3, wherein the main extruder for extrusion and molding has a temperature of 170 C, a rotation speed of 50r/min and an extrusion speed of 600mm/min; the melt pressure of the extruder is 8Mpa; the rotation speed of the feeding machine is 6r/min; and the temperature of the machine head is 170 C;
[0054] (4) post processing: the molded organic material is water cooled, drawn and cut to obtain the organic plate substrate.
[0055] Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120-150m sanding belt to be smooth.
[0056] Preparation of the polyurethane glue: the following components are mixed by weight: 80 parts of polyurethane, 35 parts of phthalic anhydride, 12 parts of triethylene glycol, 18 pats of glutaric acid, 10 parts of butanetriol, 7 parts of zinc oxide, 5 parts of magnesium oxide, 25 parts of chloroprene rubber, 3 parts of softening oil; 20 parts of dimethyl carbonate, 30 parts of ethylbenzene and 1 part of fire retardant; the fire retardant consist of the following components by weight: 50 parts of ammonium oligomericphosphate, 25 parts of ammonium phosphate, 12 parts of ammonium pyrophosphate, 20 parts of ammonium sulfate, 5 parts of boric acid and parts of water.
[0057] Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 60 C under a pressure of 3MPa/cm2. Finally, manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 38 C, next a primer is sprayed to the colored surface of the bamboo-plate surface layer; and finally, a varnish is applied onto the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 1mm thick and has a moisture rate of 5%, and the bamboo plastic layer is 4mm thick.
[0058] Embodiment 3
[0059] The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.
[0060] Manufacturing method of the bamboo plastic layer:
[0061] (1) modification: the bamboo powder with a particle size of 60-120 m and silane coupling agent which accounts for 1.2% of the organic powder by weight are uniformly mixed and stirred at a temperature of 120 C, then cooled to 25 C to obtain modified bamboo powder;
[0062] (2) material mixing in a weight ratio:100 parts of polyvinyl chloride, 40 parts of calcium carbonate, 6 parts of sterilizer, 12 parts of foam regulator, 1.2 parts of foaming agent, 3 parts of chlorinated polyethylene, 4 parts of lubricant, 2 parts of plasticizer,0.4 part of anti-aging agent and 30-50 parts of silane coupling agent modified organic powder are mixed and stirred at a temperature of 120 C for 26min to obtain a mixed material, wherein the stirring speed is 800r/min;
[0063] (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 800-1,000kg/cm3, wherein the main extruder for extrusion and molding has a temperature of 150 C, a rotation speed of 45r/min and an extrusion speed of 800mm/min; the melt pressure of the extruder is 5Mpa; the rotation speed of the feeding machine is 5r/min; and the temperature of the machine head is 165 C;
[0064] (4) post processing: the molded organic material is water cooled, drawn and cut to obtain the organic plate substrate.
[0065] Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120-150m sanding belt to be smooth.
[0066] Preparation of the polyurethane glue: the following components are mixed by weight part: 95 parts of polyurethane, 29 parts of phthalic anhydride, 11 parts of triethylene glycol, 16 pats of glutaric acid, 9 parts of butanetriol, 6 parts of zinc oxide, 4 parts of magnesium oxide, 21 parts of chloroprene rubber, 2.5 parts of softening oil;
18 parts of dimethyl carbonate, 26 parts of ethylbenzene and 2 parts of fire retardant;
the fire retardant consist of the following components by weight: 30 parts of ammonium oligomericphosphate, 18 parts of ammonium phosphate, 9 parts of ammonium pyrophosphate, 15 parts of ammonium sulfate, 8 parts of boric acid and 18 parts of water.
[0067] Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using the polyurethane glue at a temperature of 30 C under a pressure of 2MPa/cm2. Finally, the manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 35 C, next a primer is sprayed to the colored surface of the bamboo-plate surface layer;
and finally, a varnish is applied to on the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 3mm thick and has a moisture rating of 15%, and the bamboo plastic layer is lOmm thick.
[0068] Embodiment 4
[0069]
[0070] Similar to embodiment 1, different in that the composite floor is a wood plastic composite floor
[0071] Embodiment 5
[0072] Similar to embodiment 2, different in that the composite floor is a wood plastic composite floor
[0073] Embodiment 6
[0074] Similar to embodiment 1, different in that the composite floor is a wood plastic composite floor
[0075] Embodiment 7
[0076] Similar to embodiment 1, different in that: in step (1), the organic powder with a particle size of 60-120m and the silane coupling agent which accounts for 1.1%
of the organic powder by weight are uniformly mixed and stirred at a speed of 1,000r/min for 5min at temperature of 100 C, then kept at this temperature for 2min, .
next cooled to 5 C to obtain the modified organic powder.
[0077] In step (2), materials mixing comprises stirring and mixing the foam regulator, the foaming agent, the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 110 C for 15min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for 5min to obtain the mixed material, wherein the stirring speed is 600r/min.
[0078] In order to manufacture the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the fireproof plate layer serving as the bottom layer are glued and cold pressed to form the composite floor.
[0079] Embodiment 8
[0080] Similar to embodiment 2, different in that: in step (1), the organic powder with a particle size of 60-120m and the silane coupling agent which accounts for 1.3%
of the organic powder by weight are uniformly mixed and stirred at a speed of 1,300r/min for 8min at temperature of 130 C, then kept at this temperature for 4min, next cooled to 45 C to obtain the modified organic powder.
[0081] In step (2), material mixing comprises stirring and mixing the foam regulator, the foaming agent, 3-5 parts of the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 130 C for 20min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for 10min to obtain the mixed material, wherein the stirring speed is 1,000r/min.
[0082] When manufacturing the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the EVA bottom layer are hot pressed to form the composite floor.
[0083] Embodiment 9
[0084] Similar to embodiment 3, different in that: in step (1), the organic powder with a particle size of 60-120m and the silane coupling agent which accounts for 1.2%
of the organic powder by weight are uniformly mixed and stirred at a speed of 1,200r/min for 6min at temperature of 120 C, then kept at this temperature for 3min, next cooled to 35 C to obtain the modified organic powder.
[0085] In step (2), material mixing comprises stirring and mixing the foam regulator, the foaming agent, 3-5 parts of the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 110-130 C for 18min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for Smin to obtain the mixed material, wherein the stirring speed is 800r/min.
[0086] When manufacturing the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the sawdust soft wood bottom layer are glued and cold pressed into the composite floor.
[0087] Comparative Embodiment 1 100881 Similar to embodiment 1, different in that the bamboo powder is not modified by the silane coupling agent, and the bamboo plastic layer does not include calcium carbonate and chlorinated polyethylene.
[0089] Comparative Embodiment 2 [0090] Similar to embodiment 2, different in that the bamboo powder is not modified by the silane coupling agent. To manufacture the composite floor, the bottom surface of the bamboo surface layer is sanded with the sanding belt to be smooth and then cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 70 C under a pressure of 4MPa/cm2.
[0091] According to the evaluation standard GB/T18103-2003, the standard value of static bending intensity is more than or equal to 300MPa; the elasticity modulus is more than or equal to 4,000MPa; the formaldehyde emission Eo is less than or equal to 0.5Mg/L.

[0092] Embodiments and comparative embodiment detection results of the present invention are as follows:
Static Elasticity Formaldehyde Item bending modulus emission Soaked in water intensity MPa Mg/L
Soaked for 85 days, no Embodiment 1 50 8640 0.2 expansion, no deformation Soaked for 85 days, no Embodiment 2 54 8750 0.2 expansion, no deformation Soaked for 85 days, no Embodiment 3 58 8910 0.2 expansion, no deformation Soaked for 95 days, no Embodiment 4 52 8440 0.1 expansion, no deformation 0.1 Soaked for 95 days, no Embodiment 5 51 8370 expansion, no deformation 0.1 Soaked for 95 days, no Embodiment 6 53 8438 expansion, no deformation 0.1 Soaked for 95 days, no Embodiment 7 62 8960 expansion, no deformation 0.1 Soaked for 95 days, no Embodiment 8 64 8980 expansion, no deformation 0.1 Soaked for 95 days, no Embodiment 9 66 9018 expansion, no deformation Comparative Soaked for 60 days, no 36 7000 0.3 Embodiment 1 expansion, no deformation Comparative Soaked for 65 days, no 38 7400 0.3 Embodiment 2 expansion, no deformation [0093] From the above table it can be seen that the bamboo-organic floor, in particular the bamboo-bamboo plastic and/or soft wood or fireproof button layer composite floor has formaldehyde emission of reaching level E0, almost negligible, and has high static bending intensity and elasticity modulus. This means that the composite floor of the present invention is firmly constructed, resistant to bending, wrapping and deformation, damp-proof and antiseptic.
[0094] The specific embodiments are merely used to explain the present invention, and shall not be regarded as expressing the limits of the present invention.
Those skilled in this field can make modifications without a creative step after reading this specification. All modifications which fall within the protective scope of claims of the present invention are protected by the Patent Law.

Claims (9)

WHAT IS CLAIMED IS:
1. A composite floor comprising:
a. a bamboo-board surface layer which is 1-3mm thick and has a moisture rating of 5-15%;
b. an organic layer which is 4-10mm thick and is a bamboo plastic layer; and c. a fireproof bottom layer arranged below the organic layer being a soft wood layer, a sawdust laminated layer or a soft wood EVA foaming material layer;
wherein the organic layer comprises the following components:
100 parts by weight of polyvinyl chloride, 30-50 parts by weight of silane coupling agent modified bamboo powder, 30-50 parts by weight of calcium carbonate, 5-7 parts by weight of calcium stearate sterilizer, 10-16 parts by weight of foam regulator, 0.8-1.6 parts by weight of azodicarbonamide foaming agent, 2-4 parts by weight of chlorinated polyethylene, 3-5 parts by weight of lubricant, 1-3 parts by weight of plasticizer being dimethyl phthalate, diethyl phthalate or di-n-octyl phthalate, and 0.2-0.6 part of anti-aging agent;
wherein the composite floor is manufactured in a method comprising the steps of:
a. a sanding step comprising sanding a bamboo board surface until the surface is smooth to form the bamboo board surface layer;
b. a preparation step comprising preparation of the organic layer in the following steps:
i. a powder modification step comprising uniformly mixing and stirring bamboo powder with a particle size of 60-120 mesh and silane coupling agent which accounts for 1.1-1.3% of the bamboo powder by weight at a temperature of 100-130V, then cooling to 5-45V to obtain modified bamboo powder;
ii. a material mixing step comprising mixing and stirring in a weight part ratio 100 parts by weight of polyvinyl chloride, 30-50 parts by weight of calcium carbonate, 5-7 parts by weight of sterilizer, 10-16 parts by weight of foam regulator, 0.8-1.6 parts by weight of foaming agent, 2-4 parts by weight of chlorinated polyethylene, 3-5 parts by weight of lubricant, 1-3 parts by weight of plasticizer, 0.2-0.6 part of anti-aging agent and 30-50 parts by weight of silane coupling agent modified bamboo powder at a speed of 600-1,000r/min for 20-30 min at a temperature of 110-130°C to obtain a mixed material;
iii. an extrusion step comprising feeding the mixed material into the barrel of a main conical double-screw extruder, and starting the extruder to extrude and mold an organic material with a density of 600-1,200kg/cm3; and iv. a board finishing step comprising water cooling, drawing and cutting the molded organic material to obtain the organic board substrate; and c. a bonding step comprising hot pressing or gluing the bamboo-board surface layer, the organic layer and the fireproof bottom layer and then cold pressing the layers to generate the composite floor.
2. The composite floor of Claim 1 further comprising an adhesive layer arranged between the bamboo-board surface layer and the organic layer; and wherein the surface of the bamboo-board surface layer is provided with a bamboo plastic layer having a seal coat.
3. The composite floor of Claim 2 wherein the adhesive layer is a polyurethane glue layer.
4. The composite floor of Claim 3 wherein the glue comprises the following raw materials:
70-95 parts by weight of polyurethane, 25-35 parts by weight of phthalic anhydride, 10-12 parts by weight of triethylene glycol, 15-18 parts by weight of glutaric acid, 8-10 parts by weight of butanetriol, 5-7 parts by weight of zinc oxide, 3-5 parts by weight of magnesium oxide, 15-25 parts by weight of chloroprene rubber, 2-3 parts by weight of softening oil;
15-20 parts by weight of dimethyl carbonate, 20-30 parts by weight of ethylbenzene, and 1-3 parts by weight of fire retardant; and and wherein the fire retardant comprises the following components:
20-50 parts by weight of ammonium oligomericphosphate, 10-25 parts by weight of ammonium phosphate, 6-12 parts by weight of ammonium pyrophosphate, 5-20 parts by weight of ammonium sulfate, 5-10 parts by weight of boric acid and 10-25 parts by weight of water.
5. The composite floor of Claim 1 whcrein the bamboo powder with a particle size of 60-120m and the silane coupling agent which accounts for 1.1-1.3% of the bamboo powder by weight are uniformly mixed and stirred at a speed of 1,000-1,300r/min for 5-8 min at temperature of 100-130°C, then kept at this temperature for 2-4min, next cooled to 5-45°C to obtain the modified bamboo powder.
6. The composite floor of Claim I wherein the material mixing step comprises:
a. stirring and mixing 10-16 parts by weight of foam regulator, 0.8-1.6 parts by weight of foaming agent, 3-5 parts by weight of lubricant, 1-3 parts by weight of plasticizer, 0.2-0.6 part of anti-aging agent and the modified bamboo power obtained in the powder modification step for 15-20min in a stirring mixer; and b. adding 100 parts by weight of polyvinyl chloride, 30-50 parts by weight of calcium carbonate, 5-7 parts by weight of sterilizer and 2-4 parts by weight of chlorinated polyethylene into the stirring mixer, and continuously stirring and mixing at a speed of 600-1,000r/min for 5-10min to obtain the mixed material.
7. The composite floor of Claim 1 wherein the extruder used in the extrusion step has a temperature of 130-170°C, a rotation speed of 40-50r/min and an extrusion speed of 600mm/min; the melt pressure of the extruder is 3-8Mpa; the rotation speed of the feeding machine is 4-6r/min; and the temperature of the machine head is 160-170°C.
8. The composite floor of any one of Claims 1 to 7, wherein the bottom surface of the bamboo-board surface layer is sanded with a sanding belt to be a smooth surface and then cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 5-60°C under a pressure of 1-3MPa/cm2.
9. The composite floor of Claim 1, wherein the method of production further includes a final sealing step comprising manufacturing the seal coat on the surface of the bamboo-board surface layer by steps of:
a. coloring the surface of the bamboo-board surface layer;
b. heating the floor to 30-38°C;
c. spraying a primer to the colored surface of the bamboo-board surface layer;
and d. applying varnish on the primer surface after the primer has dried.
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CN108948566A (en) * 2018-04-25 2018-12-07 曾冬梅 A kind of PVC antibacterial flame-retardant floor and preparation method
CN113211924B (en) * 2020-11-27 2023-05-09 天津科技大学 Thermal insulation packaging bag for cooling and preventing dewing of quick-frozen food
CN113276497A (en) * 2021-01-18 2021-08-20 安徽昊森新材料科技有限公司 Heat dissipation type wood-plastic floor and preparation method thereof
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CN114670519B (en) * 2022-04-19 2023-03-24 安徽科居新材料科技有限公司 Antibacterial PVC (polyvinyl chloride) wood-plastic multilayer composite material and preparation method thereof
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