CN103228439A - 改进的用于地板覆盖物的背衬层 - Google Patents

改进的用于地板覆盖物的背衬层 Download PDF

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CN103228439A
CN103228439A CN2011800545987A CN201180054598A CN103228439A CN 103228439 A CN103228439 A CN 103228439A CN 2011800545987 A CN2011800545987 A CN 2011800545987A CN 201180054598 A CN201180054598 A CN 201180054598A CN 103228439 A CN103228439 A CN 103228439A
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盖里·威尔森
史蒂文·劳伦斯
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Abstract

本发明涉及用于弹性地板覆盖物的背衬膜，包括：（a）第一层和（b）第二层，其中所述第一层包含量为10重量%至80重量%的第一填料，所述第二层包含量为至80重量%的第二填料，其中所述第一填料为片状填料。

Description

改进的用于地板覆盖物的背衬层
技术领域
本发明涉及弹性地板覆盖物和制备该地板覆盖物的方法。本发明特别涉及用于弹性地板覆盖物的背衬层和制备该背衬层的方法。
背景技术
弹性地板覆盖物（包括例如乙烯基板和乙烯基片）是众所周知的。例如，在文献：Encyclopaedia of Polymer Science and Engineering，Wiley-Interscience，第7卷（1987），第233-247页的标题为“FlooringMaterials”的文章中有所描述。
如上述文章中所描述的那样，这种地板覆盖物为复合材料。最上面的膜（通常被称为耐磨层）被配置成用来提供良好的抗磨性和耐磨性。该复合材料的最下面的膜通常被称为背衬膜，并且可以包括一层或多层背衬层。印刷图案膜通常介于耐磨层和第一背衬层之间。
背衬层通常为高度填充的热塑性材料。复合材料中的所有层的组成必须平衡，从而确保地板覆盖物具有合适的性能，如绝缘性和吸声性，特别是要避免卷曲的倾向。还必须考虑到经济因素。
在弹性地板覆盖物的制造中，通常采用诸如压延、挤压和刷涂法等技术制造膜（包括背衬层）。
如同所有以用户为导向的领域那样，在弹性地板覆盖物的领域中，一直存在持续的动力促使以更低的价格提供高品质的产品。制造商可以通过与供应商协商以及仔细考察生产工艺来尽可能地降低成本，但是也可以改为生产能够降低产品自身成本的产品。
在弹性地板覆盖物的领域中，增加产品的一种或多种膜中的填料的水平能够大大降低制备该产品的成本。然而，增加填料水平所带来的问题也是必须考虑的，例如高填料水平可导致最终产品卷曲，并且能影响膜和最终产品的尺寸稳定性。由于高填料水平可导致加工问题，因此在膜的实际制造过程中也可能存在问题，无论是压延、挤压还是刷涂法都是如此。
在使用增塑溶胶法制造地板覆盖物的领域中，较为简单的做法是，在印刷图案膜和高度填充的背衬膜之间插入纤维稀松布（fibrousscrim）。稀松布使得能够使用高度填充的、因此更加廉价的背衬膜，而不会对最终产品的卷曲和尺寸稳定性有任何不利的影响。
然而，在压延、挤压或刷涂法中使用稀松布会增加额外的步骤以及生产产品的成本，而在该特定的制造方法中只提供了较少的优点。因此，仍然存在对既能够降低成本又能够避免弹性地板覆盖物（特别是通过压延、挤压或刷涂法制备的弹性地板覆盖物）卷曲的方法的需求。
发明内容
因此，本发明提供了一种用于弹性地板覆盖物中的背衬膜，所述弹性地板覆盖物至少包括耐磨层和背衬膜，所述背衬膜包括（a）第一层和（b）第二层，其中所述第一层包含量为10重量%至80重量%的第一填料，所述第二层包含量为10重量%至80重量%的第二填料，其中所述第一填料为片状填料，并且在使用时，所述第一层被布置为比所述第二层更靠近所述弹性地板覆盖物的所述耐磨层。
在一个实施方案中，所述第一填料为片状填料，所述第二填料为非片状填料。
合适的片状填料包括但不限于高岭土、滑石、云母和石墨。
合适的非片状填料包括但不限于碳酸钙（例如白垩粉和石灰岩）、白云石、氢氧化镁、ATH、碳酸镁、硫酸钙、SiO2、长石和玻璃珠。
所述背衬膜的所述第一层可以是被布置为最靠近所述耐磨层的层。可供选择的是，在使用时，所述背衬膜的所述第一层可以被布置为通过印刷图案膜与所述地板覆盖物的所述耐磨层分开。
使非片状填料位于所述第二层中并且使片状填料位于所述第一层中是有利的，特别是在如下情况中更是如此，所述情况为：在使用时，所述第一层为背衬膜的、位于最靠近地板覆盖物的耐磨层的层。非片状填料通常价格低廉。当使用片状填料，特别是在第一层中使用时（在所述第一层被布置为靠近所述耐磨层的情况下），能够克服背衬膜的所有层中的填料如果为非片状所引起的潜在的卷曲问题。之前，由于当背衬膜的所有层中为非片状填料时会发生卷曲，因此除了位于最靠近耐磨层的层以外，其它层中的填料水平必须保持在最低值，并且必然要小于最靠近耐磨层的层中的填料水平，而这会增加成本。
片状填料的加入提供了与上下层（例如耐磨层和填充有非片状填料的背衬层）相比热运动降低的层。该层与其它两层之间的热运动/稳定性的差别提供了“平摊”式产品。
第一填料的存在量可以为15重量%至75重量%，20重量%至70重量%，25重量%至65重量%，30重量%至60重量%，35重量%至55重量%，40重量%至50重量%，42重量%至48重量%（例如45重量%）。
第二填料的存在量可以为15重量%至75重量%，20重量%至70重量%，25重量%至65重量%，30重量%至70重量%，35重量%至65重量%，40重量%至65重量%（例如45重量%），55重量%至65重量%（例如60重量%）。
第一填料的存在量可以为所述第一层的15重量%至75重量%，20重量%至70重量%，25重量%至65重量%，30重量%至60重量%，35重量%至55重量%，40重量%至50重量%，42重量%至48重量%（例如45重量%）。
第二填料的存在量可以为所述第二层的15重量%至75重量%，20重量%至70重量%，25重量%至65重量%，30重量%至70重量%，35重量%至65重量%，40重量%至65重量%（例如45重量%），55重量%至65重量%（例如60重量%）。
所述第一层和所述第二层可以独立地包含任意合适的塑料组合物，如合适的热塑性聚合物组合物、乙烯基聚合物、乙烯甲基丙烯酸酯（EMA）、乙烯乙酸乙烯酯（EVA）、或任意其它烯烃类聚合物，例如聚氨酯（PU）或丙烯腈丁二烯苯乙烯（ABS）。
所述第一层和所述第二层各自所用的聚合物组合物可以相同或不同。
所述第一层还可以包含一种或多种非片状填料。所述非片状填料中的一种或多种可以为粒状或球状。所述一种或多种非片状填料的总量可以占所述第一层的1重量%至10重量%，例如3重量%至8重量%。
就相对于背衬膜中所讨论的层的重量而计算的重量百分比来说，所述第一层中的与任意附加填料组合的片状填料的量可以与所述第二层中的第二填料的量相似或相同。
就相对于背衬膜中所讨论的层的重量而计算的重量百分比来说，所述第一层中的与任意附加填料组合的片状填料的量可以低于所述第二层中的第二填料的量。
所述第一层和所述第二层可以包含任意其它合适的材料。所述第一层和所述第二层可以额外地包含合适量的润滑剂、抗氧化剂、稳定剂和增塑剂。
在本发明的背衬膜中，第一背衬膜的厚度可以为200微米至500微米，更优选地为250微米至450微米，300微米至400微米，最优选地为320微米至340微米，例如330微米。
在本发明的背衬膜中，第二背衬膜的厚度可以为1280微米至1580微米，更优选地为1320微米至1520微米，1380微米至1480微米，最优选地为1430微米至1470微米，例如1450微米。
可以使用常规的共挤压、压延和刷涂的设备和方法来制造本发明所要求保护的背衬膜。
本发明还提供了一种复合叠层弹性地板覆盖物，其特征在于，其包括至少一种本发明的背衬膜。
本发明还提供了一种地板砖，其特征在于，其包括至少一种本发明的背衬膜。
附图说明
以下将参照附图对本发明进行描述，其中：
图la和lb为具有本发明的背衬膜的地板砖或地板覆盖物的一部分的横截面，其分别示出了分开的膜和层，以及层叠形式的膜和层。
具体实施方式
图la和lb示出了地板砖或地板覆盖物的一部分1，其具有耐磨层2、位于耐磨层2下方的以印刷图案膜3的形式存在的装饰层。印刷图案膜3的下方布置有本发明的背衬膜4。背衬膜4包括：第一层4a，其直接位于印刷图案层下方，因此形成表层；以及第二层4b，其位于所述第一层的下方，因此形成地板覆盖物的最底层。
实施例
具有如图1和1a所示的组成、并且包括本发明的背衬膜的地板砖或地板覆盖物的一部分可以具有如下组成（重量%）和厚度：
耐磨层-厚度为521微米。耐磨层包含76%的PVC、22%的增塑剂、以及2%的UV和热稳定剂。
印刷图案膜-厚度为75微米。
第一背衬层-厚度为330微米。第一背衬层包含42%的PVC、12%的增塑剂、1%的稳定剂（热稳定剂）和45%的片状填料（如粘土）。
第二背衬层-厚度为1450微米。第二背衬层包含42%的PVC、12%的增塑剂、1%的稳定剂（热稳定剂）和45%的非片状填料（如白垩粉）。

Claims (16)

1.一种用于弹性地板覆盖物的背衬膜，所述弹性地板覆盖物至少包括耐磨层和背衬膜，所述背衬膜包括（a）第一层和（b）第二层，其中所述第一层包含量为10重量%至80重量%的第一填料，所述第二层包含量为10重量%至80重量%的第二填料，其中所述第一填料为片状填料，并且在使用时，所述第一层被布置为比所述第二层更靠近所述弹性地板覆盖物的所述耐磨层。
2.根据权利要求1所述的背衬膜，其中所述第一填料为片状填料，所述第二填料为非片状填料。
3.根据权利要求1或2所述的背衬膜，其中所述片状填料包括高岭土、滑石、云母或石墨。
4.根据权利要求2所述的背衬膜，其中所述非片状填料包括碳酸钙、白云石、氢氧化镁、ATH、碳酸镁、硫酸钙、SiO2、长石或玻璃珠。
5.根据前述权利要求中任意一项所述的背衬膜，其中所述第一填料以占所述第一层的25重量%至65重量%的量存在。
6.根据前述权利要求中任意一项所述的背衬膜，其中所述第二填料以占所述第二层的20重量%至70重量%的量存在。
7.根据前述权利要求中任意一项所述的背衬膜，其中所述第一层和所述第二层独立地包含合适的热塑性聚合物组合物、乙烯基聚合物、乙烯甲基丙烯酸酯（EMA）、乙烯乙酸乙烯酯（EVA）、或任意其它烯烃类聚合物，如聚氨酯（PU）或丙烯腈丁二烯苯乙烯（ABS）。
8.根据前述权利要求中任意一项所述的背衬膜，其中所述第一背衬膜的厚度为200微米至500微米。
9.根据前述权利要求中任意一项所述的背衬膜，其中所述第二背衬膜的厚度为1280微米至1580微米。
10.一种复合叠层弹性地板覆盖物，包括至少一种根据权利要求1至9中任意一项所述的背衬膜。
11.一种地板砖，包括至少一种本发明的背衬膜。
12.根据权利要求10所述的复合叠层或根据权利要求11所述的地板砖，其包括耐磨层，其中所述背衬膜的所述第一层是被布置为最靠近所述耐磨层的层。
13.根据权利要求10所述的复合叠层或根据权利要求11所述的地板砖，其包括耐磨层，其中在使用时，所述背衬膜的所述第一层被布置为通过印刷图案膜与所述地板覆盖物的所述耐磨层分开。
14.一种实质上如本文所述或者如参照附图所述的用于弹性地板覆盖物的背衬膜。
15.一种实质上如本文所述或者如参照附图所述的复合叠层弹性地板覆盖物。
16.一种实质上如本文所述或者如参照附图所述的地板砖。
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