CN100478168C - 均质无定形大理石地板及其制造方法 - Google Patents
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Abstract
本发明公开了一种制备均质无定形大理石地板的方法。该方法包括以下步骤:捏和合成树脂复合物和具有不同色彩的斑点色彩碎片,并初步滚压捏和的复合物以制备初级滚压板;在将该初级滚压板切割成预定尺寸并旋转该板的同时,层压该初级滚压板;通过低温压延对该层压板进行二次滚压以制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板;通过面对面压制挤压两片半成品均质无定形大理石地板;以及在水平方向上将压制的半成品均质无定形大理石地板切割成两片,然后砂磨并抛光该切割片。所制备的新型大理石地板具有与常规地板显著不同的外观。
Description
技术领域
本发明涉及一种具有合成均质无定形大理石的地板及其制备方法,且更具体地涉及一种具有新颖外观的由合成均质无定形大理石地板制造的地板,及其制造方法。
背景技术
复合合成大理石地板具有极佳的耐久度和令人赏心悦目的外观,并且主要以以下方式制备:两种或三种不同类型的斑点彩色碎片与合成的复合物混合并对混合物进行热轧,或者将预定量的斑点彩色碎片喷在预先制备的合成板上并对该板进行热轧。
此后,在初步滚压后,旋转和层压基板并进行二次滚压,从而形成无定形大理石纹理,并砂磨和抛光。这种方法是已知的(韩国专利第249569号),并且可以去除大理石的式样,但对于复合地板的制备是受限的。
而且,在通过常规均压法制备的常规乙烯基地板中,大理石纹理具有有限的变化。
发明内容
因此,本发明是考虑到以上问题而进行的,本发明的一个目的是提供一种新型的均质无定形大理石地板以及该地板的制备方法,该地板是通过应用之前仅在旋转和层压基板的同时通过压延制备复合乙烯基地板和具有无定形大理石纹理的无定形大理石地板的外观中使用的低温处理,和通过应用在制备常规均质大理石地板的常规压制中的面对面压制过程而制备的。
根据本发明的技术方案,通过提供制备均质无定形大理石地板的方法可以实现上述和其它目的,该方法包括以下步骤:捏和合成树脂复合物和具有不同色彩的斑点色彩碎片并初步滚压捏和的复合物以制备初级滚压板;将所述初级滚压板切割成预定尺寸,旋转该板,然后层压该板;在60~100℃温度下通过低温压延对该层压板进行二次滚压以制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板;通过面对面压制挤压两片半成品均质无定形大理石地板;和在水平方向上将压制的半成品均质无定形大理石地板切割成两片,然后砂磨并抛光该切割板。
优选地,用于切割后旋转初级滚压板的旋转装置使用真空抽吸旋转装置,和通过用于连续层压薄板为阶梯形的阶梯式连续层压进行层压。
根据本发明,由于将旋转装置安装于生产线,从而在旋转薄板的同时将薄板切割为预定尺寸并层压该薄板为阶梯形,因而可以连续作业并可以实施高压滚压。
通过向合成树脂复合物中加入作为低温加工助剂的取代的聚乙二醇醚、和脂肪醇偏酯及脂肪酸酯的混合物中的至少一种,并保持温度比常规加工温度低10~20℃,从而获得用于层压基板的真空抽吸式旋转装置的真空抽吸。
由于当初次滚压后的基板的表面温度高于140℃时,基板较软且颤动,因此在旋转装置中无法进行真空抽吸。由于当基板表面温度太低时可能产生裂缝,因此真空抽吸也不能进行。本发明向合成树脂复合物中加入低温加工助剂,从而保持基板的表面温度比常规基板的表面温度低10~20℃、并且易于加工操作。
本发明提供了一种制备均质无定形大理石地板的方法,包括以下步骤:捏和具有不同色彩的斑点色彩碎片和复合物并初步滚压捏合的复合物以制备薄板,所述的复合物在100重量份的聚氯乙烯中,包含200~350重量份作为填充剂的碳酸钙,20~40重量份增塑剂、3~10重量份的环氧树脂,2~10重量份的基于钡-锌的稳定剂,2~10重量份的低温加工助剂,以及多种颜料;在将该板切割成预定尺寸的板并旋转该初级滚压板的同时,层压该初级滚压板;在60~100℃的压延辊温度下,在层压步骤中通过使用低温压延进行二次滚压以制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板;通过面对面压制挤压两片半成品均质无定形大理石地板;和在水平方向上将压制的半成品均质无定形大理石地板切割成两片,然后砂磨并抛光这两片。
用于本发明中的低温加工助剂为选自取代的聚乙二醇醚、脂肪醇偏酯和脂肪酸酯的混合物中的至少一种,且优选为其组合物。
可用于本发明中的合成树脂包括聚氯乙烯(PVC),但本发明并不仅限于此,并且任何能被滚压的热塑性树脂都可以用作本发明中的合成树脂。
本发明涉及一种均质无定形大理石地板的制备方法,且该制备方法通常包括两个步骤。第一个是制备半成品无定形大理石地板的步骤,和第二个是面对面压制、砂磨及抛光的步骤。
在半成品无定形大理石薄板步骤中,多色的斑点彩色碎片与复合物捏和、并初步滚压捏和的复合物为薄板。旋转并层压薄板,且通过低温压延二次滚压层压的薄板以制备具有波纹纹理和粗糙表面的半成品无定形大理石薄板。尽管该方法在现有技术中已被用于制备复合乙烯基地板,本发明拓展了该方法从而包含波纹纹理和粗糙表面。
而且,本发明具有通过常规均压制备的常规乙烯基地板所没有的无定形大理石外观,并且除了压制外,本发明还结合了面对面压制的新工艺,从而制备了新型均质合成大理石地板。
在KS(韩国标准)M3802中定义了复合乙烯基地板和均质乙烯基地板的不同,在该标准中规定含有30%或更多助剂的乙烯基地板为均质乙烯基地板,而含有30%或更少助剂的乙烯基地板为复合乙烯基地板。
特别是,基于低于140℃下通过用真空旋转装置提起基板而能够层压基板的低温处理,应用于本发明的低温压延处理保持用于向具有特定厚度的均一层压薄板实施高温压制和低温压延的辊的低温,即,60~100℃。
本发明涉及一种通过压延制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板,和对半成品均质无定形大理石地板进行面对面压制,和通过实施分割、砂磨及抛光的新型完美的均质无定形大理石地板的制备。通过高温滚压和压延形成波纹纹理和粗糙表面,且具体而言,波纹纹理和粗糙表面为当通过高温滚压和低温压延处理波纹纹理和热基板时产生的裂纹(粗糙表面)。在低温处理中使用的低温加工助剂使处理比常规工艺易于在较低的温度下进行,确切的说,能够用真空抽吸实现基板的层压。
进行本发明是为了获得波纹纹理以形成独特的外观,并且为了形成波形纹理,通过低温压延得到粗糙的表面。换句话说,由于在进行低温压延时产生粗糙表面,为了克服粗糙表面,进行面对面压制和砂磨及抛光,从而使表面光滑并使波纹纹理形成柔和的大理石纹理。
根据本发明的优选实施方案,作为通过高温压制和低温压延制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板,和对半成品均质无定形大理石地板进行面对面压制和砂磨及抛光的结果,可以确定的是能够得到不同于常规均质无定形大理石地板外观的柔和的大理石纹理。
如上所述,本发明对均质乙烯基地板应用低温处理和仅用于复合乙烯基地板的助剂以及无定形大理石地板制备工艺,并且通过应用无定形大理石外观和新的压制工艺而使均质乙烯基地板具有不同于由常规压制制备的常规均质大理石地板的不同外观和高质量。
附图说明
本发明的上述及其他目的、特点和其它优势将由下面结合附图的详细描述而被更清楚的理解,其中:
图1为表示根据本发明制造半成品地板的方法的示意图;
图2为表示根据本发明面对面处理的示意图;
图3为表示根据本发明将通过压制制备的半成品地板分割为两片的分割处理的示意图;
图4为根据本发明优选实施方案的均质无定形地板的照片;和
图5为根据本发明另一优选实施方案的均质无定形地板的照片。
具体实施方式
下面,将参考附图详细描述本发明。
根据本发明,通过压延、面对面压制和砂磨制备了完美的均质无定形大理石地板。
图1为表示根据本发明制造半成品地板的方法的示意图。该方法主要包括:原料混合步骤、均匀加热及压制混合原料的捏和步骤、均匀混合原料的混合步骤、以及形成无定形大理石纹理的压延步骤。
更具体而言,为了制备合成均质无定形地板,首先将聚氯乙烯(PVC)复合物和多颜色的斑点彩色碎片捏和并初次滚压捏和的复合物以制备基板;切割并旋转基板以层压;和通过低温压延处理对层压薄板进行第二次滚压;从而制备了具有波纹纹理和粗糙表面的半成品地板。
在100重量份的PVC(聚合度为800~1000)中,基板1的组成包括:200~350重量份作为填充剂的碳酸钙,20~40重量份作为增塑剂的邻苯二甲酸二辛酯(DOP)、3~10重量份的环氧树脂,2~10重量份的基于Ba-Zn的稳定剂,2~10重量份的低温加工助剂,和多种颜料。
通常,术语“均质”是指包含等于或大于30%的除碳酸钙之外的组分。由韩国标准(KS)定义的“粘合剂”包含乙烯基树脂、增塑剂、稳定剂等,粘合剂的组成满足“均质”的定义。
将颜料混入PVC中并滚压混合的薄板,并用破碎机将滚压板破碎为0.5mm~20mm,从而制备斑点彩色碎片2,并且通过改变增塑剂的含量不同于基板中的含量而使用具有不同硬度的碎片。
根据本发明的均质无定形大理石地板的制备方法将详细描述如下。
首先,混合和分散预定量的液体和粉末原料,在120℃~150℃下班伯里混炼机3(Banbury mixer)中捏和分散的原料。用混合辊4在100℃~130℃下将捏和的原料制备为饼状基板1。
通过接合压延机(joining calendar)5将基板1和具有不同颜色的斑点碎片2制成厚度小于3.0mm的薄板,于炉17中、在200~250℃下粉碎并加热该薄板,通过初级压延机8在110~150℃下将加热的薄板1压制成厚度为1.0mm~5.0mm的薄板,通过切割机9切割该薄板,在真空态吸附该切割薄板,并采用90度旋转装置10将其旋转90度,并且按预设的间隔层压12以具有阶梯形状。这里,“按预设的间隔层压”是指在保持预设间隔13的同时进行层压。斑点碎片2可以在初次压延中单独注入。
切割机9用于将初次滚压的基板1切割成预定长度,并且被构造为通过使用光学传感器检测切割薄板1的长度从而以预定长度切割基板。
旋转装置10为真空90度旋转装置,并且包括中空的四方形罩和附于罩的下侧的大量硅帽11,从而当薄板1到达需要位置时,在2~20kg/cm2的负压下用真空帽11吸附初次滚压基板1。在沿轨道旋转的同时,被吸附的基板1被层压12,然后被输送到第二压延机14。
同时,通过捏和和滚压混合的PVC和斑点彩色碎片2制备初级滚压基板1,并且使该基板在长度方向上具有大理石纹理。
进一步,优选在90度旋转后保持100mm~500mm的层压间隔。大理石纹理根据层压层的层压间隔和数量而变化,换句话说,如果层压层的间隔和数量较小,则不能得到需要的无定形大理石,因为当初次形成的大理石在旋转90度后进行二次滚压时,在宽度方向上轻微偏移的大理石出现在已有定向大理石中。
层压基板的数量取决于薄板1的厚度和层压间隔13,且优选层压2~10层薄板。
层压薄板在60~100℃的低温下经第二压延机14进行压延,从而制备具有波形纹理和粗糙表面的半成品大理石地板。这时,在长度方向上形成的大理石旋转90度并变为自然的无定形大理石,并且基板1和斑点彩色碎片2自然地彼此结合。二次滚压薄板的厚度保持在2.5~4.5mm。
图2是表示根据本发明通过以面对面接触方式压制的结合的半成品地板的示意图。二次滚压薄板被切割为1m×1m的薄板,并且薄板被插入模具以彼此相对并在150℃~200℃下压制。
图3为表示根据本发明在面对面压制中将半成品地板分割为两片的分割处理的示意图。面对面半成品地板被切割为3~5mm宽度的薄片,且通过砂磨该薄片制备具有2~3mm宽度的均质无定形大理石地板。
在本发明中,通过面对面压制和砂磨,粗糙表面光滑且波纹纹理柔和,所以无定形大理石地板看上去像真实的大理石。根据本发明的均质无定形大理石地板具有与通过均匀压制和砂磨制备的常规地板相同的耐久性和耐污性,有划痕或污点的均质无定形大理石地板可以通过轻易地除去划痕和污点从而使其恢复原貌,且安装后均质无定形大理石地板之间没有缝隙。
图4和5为根据本发明完成的均质无定形地板的照片。常规大理石地板通过压制薄片或碎片制备并且具有非定向大理石纹理或非定式大理石纹理的大理石纹理。但是,由于常规大理石地板经常使用相同的纹理,常规大理石地板变得单调和陈旧,相反,由于根据本发明的均质无定形大理石地板具有不同于常规大理石地板的柔和的大理石纹理,所以根据本发明的均质无定形大理石地板是新颖和别致的。
实施例
为了制造根据本发明的均质无定形大理石地板,混合和分散预定量的各液体和粉末原料。在120℃~150℃下于班伯里混炼机3中由螺杆捏和均匀分散的原料,并且用混合辊4在100℃~130℃下将捏和的原料制备为饼状基板1。
通过使用接合压延机5将基板1和具有不同颜色的斑点碎片2制成厚度小于3.0mm的薄板。
通过接合压延机5将基板1和具有不同颜色的斑点碎片2制成厚度小于3.0mm的薄板,该薄板于炉17中、在200~250℃下被破碎并加热,通过初级压延机8在110~150℃下将加热的薄板1制成厚度为1.0~5.0mm的薄板,该薄板被切割为预定厚度,并用旋转装置10的吸取帽11将其旋转90度,并且层压12,和2~10层按预定间隔13层压的薄板在60~100℃下通过二次压延机14,从而通过低温压延制备了具有波纹纹理和粗糙表面厚度为2.5~4.5mm的薄板。
二次滚压板被切割为1m×1m的薄板以制备半成品大理石地板,在面对面压制中半成品大理石地板被放置在模具中并在150~200℃下压制(见图2),结合的薄板被分割为两片从而制备具有3~5mm厚度的半成品大理石地板(见图3),然后通过砂磨薄片制备具有2~3mm厚度的均质无定形大理石地板。
尽管出于说明的目的,已经公开了本发明的优选实施方案,但本领域技术人员可以理解,在不偏离所附权利要求公开的本发明的范围和实质内的各种修改、添加和替代都是可以的。
Claims (4)
1、一种制造均质无定形大理石地板的方法,所述均质为包含等于或大于30%的除碳酸钙之外的组分,该方法包括以下步骤:
捏和合成树脂复合物和具有不同色彩的斑点色彩碎片,并初步滚压捏和的复合物以制备初级滚压板;
将所述初级滚压板切割成预定尺寸,旋转该板,然后层压该板;
在60~100℃的温度下通过压延对该层压板进行二次滚压,以制造具有波纹纹理和粗糙表面的半成品均质无定形大理石地板;
通过面对面压制挤压两片半成品均质无定形大理石地板;和
在水平方向上将压制的半成品均质无定形大理石地板切割成两片,然后砂磨并抛光该切割片。
2、根据权利要求1的方法,其特征在于,用真空抽吸旋转装置旋转初级滚压板,和通过阶梯式连续层压将初级滚压板连续层压为阶梯形。
3、根据权利要求1的方法,其特征在于,向合成树脂复合物中加入至少一种以下物质以保持处理温度比常规处理温度低10~20℃:
取代的聚乙二醇醚;和
脂肪醇偏酯与脂肪酸酯的混合物。
4、一种制备均质无定形大理石地板的方法,所述均质为包含等于或大于30%的除碳酸钙之外的组分,该方法包括以下步骤:
捏和合成树脂复合物和具有不同色彩的斑点色彩碎片并初步滚压捏和的复合物以制备初级滚压板,所述的合成树脂复合物在100重量份的聚氯乙烯中,包含200~350重量份的碳酸钙,20~40重量份的增塑剂、3~10重量份的环氧树脂,2~10重量份的基于钡-锌的稳定剂,2~10重量份的低温加工助剂,以及多种颜料;
将所述初级滚压板切割成预定尺寸,旋转该板,然后层压该板;
在60~100℃的温度下通过压延对该层压板进行二次滚压,以制备具有波纹纹理和粗糙表面的半成品均质无定形大理石地板;
通过面对面压制挤压两片半成品均质无定形大理石地板;和
在水平方向上将压制的半成品均质无定形大理石地板切割成两片,然后砂磨并抛光该切割片。
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