CN105061941A - 一种地板制造方法 - Google Patents
一种地板制造方法 Download PDFInfo
- Publication number
- CN105061941A CN105061941A CN201510478277.XA CN201510478277A CN105061941A CN 105061941 A CN105061941 A CN 105061941A CN 201510478277 A CN201510478277 A CN 201510478277A CN 105061941 A CN105061941 A CN 105061941A
- Authority
- CN
- China
- Prior art keywords
- pvc
- parts
- layer
- foaming
- pvc foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title abstract description 21
- 238000005187 foaming Methods 0.000 claims abstract description 50
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- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 24
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- NKWPZUCBCARRDP-UHFFFAOYSA-L calcium bicarbonate Chemical compound [Ca+2].OC([O-])=O.OC([O-])=O NKWPZUCBCARRDP-UHFFFAOYSA-L 0.000 description 1
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- LELOWRISYMNNSU-UHFFFAOYSA-N hydrogen cyanide Chemical compound N#C LELOWRISYMNNSU-UHFFFAOYSA-N 0.000 description 1
- 239000003317 industrial substance Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000002932 luster Substances 0.000 description 1
- QWDJLDTYWNBUKE-UHFFFAOYSA-L magnesium bicarbonate Chemical compound [Mg+2].OC([O-])=O.OC([O-])=O QWDJLDTYWNBUKE-UHFFFAOYSA-L 0.000 description 1
- 235000014824 magnesium bicarbonate Nutrition 0.000 description 1
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- 238000001149 thermolysis Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
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Abstract
本发明公开一种地板制造方法,通过在PVC发泡层表面上添加包括PVC耐磨层和PVC彩膜层的PVC层而得到,其中PVC发泡层采用以下步骤制取的PVC发泡板:将PVC复合材料的物料混合搅拌均匀,该PVC复合材料以重量份计,包括PVC40~60份、轻质碳酸钙40~60份、无机/有机复合发泡剂0.8~1.2份、发泡调节剂3~5份、增韧剂2~4份、润滑剂0.8~1.2份以及稳定剂1.5~2.5份;将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料;将发泡PVC挤出料入模定型并冷却,以得到PVC发泡型材;对出料后的PVC发泡型材进行切割,最终得到PVC发泡板成品。由此制得的PVC地板结构强度高,发泡性能好,具有较为满意的静音效果。
Description
本发明为申请人于2014年03月21日提出的专利申请号为“201410106959.3”、名称为“PVC复合材料、发泡板及生产方法、设备和地板”的中国发明专利申请的分案申请,其全部内容结合于本申请之中。
技术领域
本发明涉及PVC板材,尤其涉及一种PVC复合材料、发泡板及生产方法、设备和地板。
背景技术
PVC发泡板又称为雪弗板和安迪板,其主要化学成分是聚氯乙烯(PolyvinylChloridePolymer),生产时将PVC与发泡剂等混合物料进行高温发泡,之后由挤塑机挤出熔体后送入模具成型并冷却,定型后被切割成所需板材。现有PVC发泡板的材料配方存在一定的缺陷,例如:(1)使用单一发泡剂,发泡效果不够充分、均匀,不能很好地实现静音效果;(2)辅料成分不够合理,导致板材的强度、硬度、韧性不够,影响板材使用寿命;(3)PVC在光、热等条件下容易分解,产品性能不够稳定;(4)工件表面容易划伤,外观效果不够理想;等等。这些因素大大地影响了板材的质量,因此有必要研发一种新的PVC复合材料,以便有效地改善相应产品的品质。
发明内容
针对现有技术存在的缺陷,本发明的目的在于提供一种PVC复合材料、发泡板及生产方法、设备和地板,可以有效地提高PVC板材产品的质量。
为解决以上技术问题,本发明提供一种地板制造方法,通过在PVC发泡层表面上添加包括PVC耐磨层和PVC彩膜层的PVC层而得到,其中PVC发泡层采用以下步骤制取的PVC发泡板:
将PVC复合材料的物料混合搅拌均匀,该PVC复合材料以重量份计,包括PVC40~60份、轻质碳酸钙40~60份、无机/有机复合发泡剂0.8~1.2份、发泡调节剂3~5份、增韧剂2~4份、润滑剂0.8~1.2份以及稳定剂1.5~2.5份;
将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料;
将发泡PVC挤出料入模定型并冷却,以得到PVC发泡型材;
对出料后的PVC发泡型材进行切割,最终得到PVC发泡板成品。
较优地,所述将PVC复合材料的物料混合搅拌均匀步骤中包括两次混料:以1000~1200转/分的速度进行高速搅拌,以促进各原料成分混合均匀;之后,以500~600转/分的速度进行低速搅拌,并在进一步混合的同时实现降温。
较优地,所述将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料的步骤在挤塑机中进行,以使得物料熔融塑化为粘流态。
较优地,挤塑机中的加热发泡温度为160℃~190℃。
较优地,所述将发泡PVC挤出料入模定型并冷却,以得到PVC发泡型材的步骤包括:将发泡PVC挤出料送入预设形状和规格的模具中进行定型及定厚,冷却后获得PVC发泡板初胚;将PVC发泡板初胚进行升温定型,之后再次冷却而获得满足相应产品性能的PVC发泡型材。
较优地,PVC发泡板初胚冷却温度为20℃~40℃;PVC发泡板初胚升温定型的温度85℃~120℃,升温定型的时间为2.5min~3min;PVC发泡型材冷却温度为20℃~40℃。
较优地,所述PVC发泡型材在80℃、6h检测条件下的收缩比为0.25%~1.0%。
较优地,PVC层以粘合方式附着在PVC发泡层表面。
较优地,PVC耐磨层和PVC彩膜层热压,PVC彩膜层和PVC发泡层粘合。
较优地,增设PVC基片层,其中:PVC耐磨层、PVC彩膜层及PVC基片层热压,PVC基片层和PVC发泡层粘合。
与现有技术相比,本发明优化了PVC复合材料的物料成分及配比,可以改善板材的质量,主要表现在以下方面:(1)使用了适量的无机/有机复合发泡剂及发泡调节剂,可保证发泡效果充分、均匀,这有利于较好地实现静音效果;(2)合理配置轻质碳酸钙、增韧剂,有利于提高板材的强度、硬度及韧性;(3)优化了稳定剂的用量,防止PVC在不利条件下分解;(4)添加合适的润滑剂,保持工艺过程中工件具有较好的流动性,防止工件表面被划伤,有利于改善产品外观;通过这些措施,本发明就可以有效地改善产品性能,有助于获得较好的市场占有率。在此基础上,本发明通过配套改进工艺、设备,有助于保证有关材料、产品具有较好的品质。
附图说明
通过阅读下文优选实施方式的详细描述,各种其他的优点和益处对于本领域普通技术人员将变得清楚明了。附图仅用于示出优选实施方式的目的,而并不认为是对本发明的限制。而且在整个附图中,用相同的参考符号来表示相同的部件。在附图中:
图1为本发明PVC发泡板生产方法一实施例的流程图;
图2为本发明PVC发泡板生产设备一实施例的系统图;
图3为本发明地板一实施例的结构示意图。
具体实施方式
在下面的描述中阐述了很多具体细节以便于充分理解本发明。但是本发明能够以很多不同于在此描述的其它方式来实施,本领域技术人员可以在不违背本发明内涵的情况下做类似推广,因此本发明不受下面公开的具体实施例的限制。
本发明实施例中的PVC复合材料的物料由PVC40~60份、轻质碳酸钙40~60份、复合发泡剂0.8~1.2份(其中无机发泡机与有机发泡剂重量之比约为1/2~1)、发泡调节剂3~5份、增韧剂2~4份、润滑剂0.8~1.2份以及稳定剂1~2份等组份构成(均以重量份计);此外,根据需要也可添加少量增白剂(一般小于1.5份)、植物纤维(一般为3~5份)等。这些组份的特性及作用如下所述:
PVC(Polyvinylchloridepolymer,聚氯乙烯)作为热塑性主树脂,为一种无定形结构的白色粉末(或为Φ8mm以下的颗粒)。PVC无固定熔点,在80~85℃开始软化,在130℃变为高弹态,在160~180℃开始转变为粘流态,因此可容易通过加热而塑化成型。
轻质碳酸钙(LightCalciumCarbonate)是一种常见的化工原料,其采用化学方法制得。轻质碳酸钙的沉降体积为2.4~2.8ml/g,远大于通过机械方法制得的重质碳酸钙沉降体积(1.1~1.9ml/g)。在本发明实施例的PVC复合材料中,这些轻质碳酸钙起填充作用,可以有效地提高材料硬度、稳定性。
复合发泡剂,其作用是促进原料在加热过程中形成气泡,由此形成多孔状成品,以最终达到降音/消噪的目的。本实施例中的复合发泡剂可选用市场上的一些现有产品,也可由无机发泡剂和有机发泡剂组成。在一种具体的复合调节剂中,无机发泡剂(如碳酸氢钙、碳酸氢镁、碳酸氢钠等)与有机发泡剂(如偶氮化合物、磺酰肼类化合物、亚硝基化合物等)之比约为1/2~1。更为具体的实例是,作为活化剂的有机发泡剂AC(偶氮二甲酰胺)为0.6±0.1重量份,作为吸热型无机发泡剂的碳酸氢钠为0.8±0.1重量份,这就一方面改善了AC分解的突发性,另一方面也更易于制备出满足要求的成型发泡剂。使用这种改良的复合发泡剂,有助于提高发泡效率,也有助于保证发泡更为细腻、均匀。
发泡调节剂是丙烯酸酯类加工助剂,它为韧性树脂,在本发明物料中的主要作用为:促进PVC塑化;提高PVC熔体强度,防止气泡合并或破裂;保证熔体具有良好的流动性,提高制品表面光泽度。在本发明实施例中,发泡调节剂可为530系列发泡调节剂(ZD530、LS530、BZ530、PA530等,具体可参见JINHASS等公司的产品介绍),其能够显著地提高PVC熔体的压力和扭矩,从而有效增加PVC熔体的内聚力和均质性,使所得到的PVC制品更为致密。
增韧剂(toughener)为增加复合材料层柔韧性的物质,其作为塑化加工助剂,其主要作用在于提高产品韧性及抗冲击性能。本实施例中,增韧剂可以是CPE(氯化聚乙烯),也可以是ACR(聚丙烯酸酯类)等。
润滑剂作为内润滑剂,起到的主要作用是润滑复合材料的接触面,使其具有较好的流动性,由此防止工件被划伤。此处的润滑剂可由硬脂酸和PE蜡组成,其中两种成分可以按照接近等量(0.8~1:0.8~1)的比例配置。该润滑剂还可以加速PVC熔融,提高熔体强度及均匀性,减少熔体破裂和渗出,且对PVC机械性能无明显不良影响。
稳定剂的主要用途是使物质减慢反应,保持化学平衡,降低表面张力,防止光、热分解或氧化分解等。在本发明中,稳定剂的主要作用是抑制PVC的分解,保证产品质量。在本发明的实施例中,稳定剂可选用金属皂类稳定剂,具体可为硬脂酸钙和硬脂酸锌按接近等量(0.8~1:0.8~1)的比例制配而成。
增白剂又称光学增白剂、荧光增白剂,是一种可选配的原料,其主要作用是使产品具有较好的外观。本实施例中可以选用钛白粉(titaniumoxide),主要成分为二氧化钛(TiO2),可以改善产品性能,相比其它增白剂可降低材料的使用成本。
其它辅剂,可以添加3~5份秸秆粉、木粉或竹粉等植物纤维类辅料或它们的混合料,一方面可以提高发泡效果,改善产品密度、弹性和韧性,另一方面也有助于降低材料的综合成本。
以上实施例优化了PVC复合材料的物料成分及配比,主要为:(1)合理选择无机/有机复合发泡剂及发泡调节剂,可以保证发泡效果充分、均匀,有利于较好地实现静音效果;(2)合理配置轻质碳酸钙、增韧剂,以便提高板材的强度、硬度及韧性;(3)优化稳定剂的用量,防止PVC在不利条件下分解,保持产品稳定性;(4)添加合适的润滑剂,使工件在工艺过程中具有较好的流动性,防止工件表面被划伤,产品外观较好。通过采取这些措施,由本发明PVC复合材料得到的板材,可以有效改善产品质量,最终有助于获得较好的市场占有率。
按照以上物料的功能特性要求,本发明所述的PVC复合材料可选用不同的配方组合,来满足不同产品的要求,表1示出多种不同的PVC符合材料配方组合。
表1:本发明PVC复合材料配方组合
表1中的PVC复合材料组份具有以下特点:PVC、轻质碳酸钙为主料,其中PVC的含量一般大于轻质碳酸钙的含量;复合发泡剂、发泡调节剂、增韧剂、润滑剂、稳定剂为辅料,它们的总量相当于主料的10%~15%;增白剂为选配组份,一般在对材料有颜色要求的时候选用;植物纤维未列出,可视情根据产品要求加入。
上述配方组合均能实现防水、静音的效果,以下进一步列举具体实施例进行描述。
实施例1
按重量份计算,该PVC复合材料的组分为:PVC50份;轻质碳酸钙50份;复合发泡剂1份(碳酸氢钠0.4份+AC0.6份);发泡调节剂ZD5304份;增韧剂CPE3份;润滑剂1份(硬脂酸0.5份+PE蜡0.5份);稳定剂2份(硬脂酸钙1份+硬脂酸锌1份);增白剂1份;未添加植物纤维类辅料。该实施例的组分按照中位值配置,可获得较为中性(相对于其它实施例)的优良产品。
实施例2
按重量份计算,该PVC复合材料的组分为:PVC50份;轻质碳酸钙50份;复合发泡剂1份(碳酸氢钠0.4份+AC0.6份);发泡调节剂ZD5304份;增韧剂ACR3份;润滑剂1份(硬脂酸0.5份+PE蜡0.5份);稳定剂2份(硬脂酸钙1份+硬脂酸锌1份);未添加增白剂;未添加植物纤维类辅料。该实施例中未添加增白剂,可适用于地板芯板、基板等场合。
实施例3
按重量份计算,该PVC复合材料的组分为:PVC54份;轻质碳酸钙46份;复合发泡剂1.1份(碳酸氢钠0.4份+AC0.7份);发泡调节剂ZD5304.5份;增韧剂ACR3.3份;润滑剂1.1份(硬脂酸0.5份+PE蜡0.6份);稳定剂2.1份(硬脂酸钙1份+硬脂酸锌1.1份);未添加增白剂;未添加植物纤维类辅料。该实施例PVC组分明显大于轻质碳酸钙,韧性较好,强度比前述实施例略高。
实施例4
按重量份计算,该PVC复合材料的组分为:PVC49份;轻质碳酸钙51份;复合发泡剂1份(碳酸氢钠0.4份+AC0.6份);发泡调节剂ZD5304份;增韧剂ACR3.1份;润滑剂1份(硬脂酸0.5份+PE蜡0.5份);稳定剂2份(硬脂酸钙1份+硬脂酸锌1份);未添加增白剂;未添加植物纤维类辅料。该实施例采用了适量的ZD530发泡调节剂,发泡效果较为满意,静音效果较好。
实施例5
按重量份计算,该PVC复合材料的组分为:PVC58份;轻质碳酸钙42份;复合发泡剂1.2份(碳酸氢钠0.5份+AC0.7份);发泡调节剂ZD5304.8份;增韧剂CPE3.8份;润滑剂1.2份(硬脂酸0.6份+PE蜡0.6份);稳定剂2.5份(硬脂酸钙1.2份+硬脂酸锌1.3份);钛白粉0.9份;未添加植物纤维类辅料。该实施例PVC比例较大,韧性十分优良。
实施例6
按重量份计算,该PVC复合材料的组分为:PVC52份;轻质碳酸钙48份;复合发泡剂1份(碳酸氢钠0.5份+AC0.5份);发泡调节剂ZD5304份;增韧剂ACR3份;润滑剂1份(硬脂酸0.5份+PE蜡0.5份);稳定剂2份(硬脂酸钙1份+硬脂酸锌1份);钛白粉1.2份;未添加植物纤维类辅料。该实施例添加了较多的增白剂,外观色泽较好。
实施例7
按重量份计算,该PVC复合材料的组分为:PVC51份;轻质碳酸钙49份;复合发泡剂1份(碳酸氢钠0.4份+AC0.6份);发泡调节剂ZD5304.2份;增韧剂CPE3.2份;润滑剂1份(硬脂酸0.5份+PE蜡0.5份);稳定剂2份(硬脂酸钙1份+硬脂酸锌1份);钛白粉1份;木粉4份。该实施例添加了木粉,增加了产品强度与韧性。
实施例8
按重量份计算,该PVC复合材料的组分为:PVC58份;轻质碳酸钙42份;复合发泡剂1.2份(碳酸氢钠0.5份+AC0.7份);发泡调节剂BZ5304份;增韧剂ACR3.8份;润滑剂1.1份(硬脂酸0.5份+PE蜡0.6份);稳定剂2.4份(硬脂酸钙1.2份+硬脂酸锌1.2份);钛白粉1.1份;竹粉5份。该实施例PVC组份较多,添加竹粉后的产品韧性、延展性提高。
实施例9
按重量份计算,该PVC复合材料的组分为:PVC56份;轻质碳酸钙44份;复合发泡剂1.1份(碳酸氢钠0.5份+AC0.6份);发泡调节剂PA5304.6份;增韧剂ACR3.8份;润滑剂1.1份(硬脂酸0.5份+PE蜡0.6份);稳定剂2.4份(硬脂酸钙1.2份+硬脂酸锌1.2份);钛白粉1.1份;秸秆粉4份。该实施例PVC组份较多,其中添加秸秆粉后的产品韧性、延展性得到较大改善。
实施例10
按重量份计算,该PVC复合材料的组分为:PVC57份;轻质碳酸钙43份;复合发泡剂1.1份(碳酸氢钠0.5份+AC0.6份);发泡调节剂LS5304.6份;增韧剂ACR3.8份;润滑剂1.1份(硬脂酸0.5份+PE蜡0.6份);稳定剂2.4份(硬脂酸钙1.2份+硬脂酸锌1.2份);钛白粉1.1份;竹份、木粉混合料4份。该实施例在PVC中混入竹份、木粉混合料,在保证产品韧性、强度的基础上同时降低了成本。
以上对本发明的PVC复合材料的物料进行了说明,这种复合材料有助于提高板材质量。在此基础上,本发明配套改进有关生产工艺、设备,由此得到的板材及最终产品具有较好的品质,以下进一步说明。
本发明的PVC发泡板通过前文所述的PVC复合材料发泡成型制得,以下对PVC发泡板的具体工艺(本发明有时称生产方法,其含义相同)过程进行简要描述。为了更好地理解本发明的技术原理及工作过程,以下结合附图及具体实施例来进一步对本发明进行详细描述。
参见图1,表示本发明PVC发泡板生产方法的实施例的流程图,主要包括S110~S140等步骤,具体描述如下:
S110、搅拌混料步骤,将PVC复合材料的物料(组份如前文所述)混合搅拌均匀。具体可采用高、低速两次混料:初次混料以1000~1200转/分的速度进行高速搅拌,促进各原料成分混合均匀;再次混料以500~600转/分的速度进行低速搅拌,在进一步混合的同时实现降温。两次混料后得到的产品,密度及稳定性大大提高。
S120、挤塑出料步骤,将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料。这个步骤一般可在挤塑机中进行,其加热发泡温度为160℃~190℃,由此使得物料熔融塑化为粘流态,因而可以在外力作用下顺利地挤出,最终连续地送入模具中定型。
S130、定型冷却步骤,将发泡PVC挤出料入模定型并冷却,以便得到PVC发泡型材。在这步骤中具体采用了两次定型冷却工序,具体是在现有工艺的基础上增加了二次定型即升温定型及冷却步骤,由此有效避免因上游工序收缩比变化带来的裂缝、拱起等质量缺陷。
在这步骤S130中,两次定型冷却工序具体如下所述:
第一次定型冷却工序(步骤S131),将发泡PVC挤出料送入预设形状和规格的模具中进行定型及定厚,冷却后获得PVC发泡板初胚(冷却温度为20℃~40℃),冷却后的PVC发泡板初胚可以进行一定程度的拉伸,由此可在牵引设备的牵引下,送至下一工序进行二次定型处理,以减小收缩比。
第二次定型冷却工序(步骤S132),实际上包括升温定型及冷却两个工序(它们可以分开在不同装置中进行,也可依序在同一装置中进行),具体过程是将PVC发泡板初胚进行升温定型(初胚升温定型的温度85℃~120℃,升温定型的时间为2.5min~3min),之后再次冷却而获得满足相应产品性能的PVC发泡型材(冷却温度为20℃~40℃),冷却后的PVC发泡型材牵引至切割工序就可制得成品。
这样经过步骤S131、S132两次定型冷却之后制得的PVC发泡型材变形小,其在80℃、6h检测条件下的收缩比为0.25%~1.0%,由此可以大大地改善产品质量。
可以理解的是,图1所示本发明的各工序可采用多种方式来实现上述工艺参数要求的升温或降温。一种组合方式是:PVC物料加热发泡的方式、PVC发泡板初胚升温定型的方式为水加热、油加热或电阻介质加热;PVC发泡板初胚冷却的方式、PVC发泡型材冷却的方式为风冷、水冷或自然冷却。当然,此工艺也可采取其它的加热、冷却组合方式,在此不再赘述。
值得指出的是,图1所述的工艺流程中一次定型(降温定型,即入模定型及冷却步骤)、二次定型(升温定型,即升温定型及冷却步骤)分别在各自的定型台上进行,它们互不干涉。可以理解的是,该工艺流程中也可以不使用定型台;或者,仅仅是在入模定型及升温定型时使用定型台,而两次冷却时均不使用定型台。特别地,本工艺流程可以两次牵引的方式来连续输送相应物料或工件,其中:第一牵引设在降温定型工位后,第二牵引设在出料工位前,且第一次牵引(PVC发泡板初胚的牵引)速度略小于第二次牵引PVC发泡型材的牵引速度(两者速度差大致与收缩比0.25%~1.0%相当)。这样,经过这两次牵引就可以克服长距离及确定性状态物料的变形缺陷,从而改善产品质量。
在该实施例的PVC发泡板生产工艺中,对由一次牵引拉伸的板材进行二次定型,通过利用先热后冷两步操作来减小板材在一次牵引后的变形;之后,经过二次定型工序得到的板材重新进行第二次牵引,由此制得的板材变形小,收缩比和拱形弯曲率都明显降低,从而有助于提高产品质量。
根据图1所述的PVC发泡板的生产方法,可以相应地构设PVC发泡板的成套生产设备,以下进行详细的描述。顺便指出的是,本实施例所述生产设备中如有描述不尽之处,请参见前文工艺部分的描述内容;同样地,前述工艺部分中如涉及到有关设备,也可引见以下描述内容。
参见图2,其为本发明PVC发泡板的生产设备一实施例的系统图,该图中箭头表示工件(物料)到输送方向。该实施例中的PVC发泡板的生产设备由搅拌混料装置210、挤塑出料装置220、定型冷却装置230及成品制作装置240等部分组成,它们依工件输送顺序设置,其中:
搅拌混料装置210,作用是将PVC复合材料的物料混合搅拌均匀。具体可采用前述方法所揭示的高、低速两次混料,以便使产品的密度及稳定性提高。
挤塑出料装置220,具体可选用挤塑机,其将添加有发泡剂的PVC物料进行加热发泡,之后挤出粘流态的发泡PVC挤出料。
定型冷却装置230,用于将发泡PVC挤出料入模定型并冷却以得到PVC发泡型材。如图2所示,定型冷却装置230具体包括入模定型及冷却装置231、第一牵引机232、升温定型及冷却装置233及第二牵引机234等部分组成,其中:入模定型及冷却装置231(可以为整体或分立结构),将发泡PVC挤出料送入预设形状和规格的模具中进行定型及定厚,冷却后获得PVC发泡板初胚;第一牵引机232,将冷却后的PVC发泡板初胚进行一定程度的拉伸,送至下一工序进行二次定型;升温定型及冷却装置233也可以为整体或分立结构,它将PVC发泡板初胚进行升温定型,之后再次冷却而获得满足相应产品性能的PVC发泡型材;第二牵引机234,将冷却后的PVC发泡型材牵引至切割工序进行处理。
成品制作装置240,具体可采用习知的切割机械,以便对出料后的PVC发泡型材进行切割,最终得到PVC发泡板成品。
本实施例中设置了第一牵引机232、第二牵引机234,其中第一牵引机232的牵引机速度略小于第二牵引机234的牵引速度,两者的具体设置位置为:第一牵引机232设置在入模定型及冷却装置231与升温定型及冷却装置233之间的工位上,以牵引PVC发泡板初胚;第二牵引机234设置在升温定型装置233及成品制作装置240之间的工位上,以牵引PVC发泡型材。可以理解的是,此处的第一牵引机232、第二牵引机234的也可设置在其它合适工位;当然,它们也可以其它类型的输送机(如摩擦输送机等)代替,在此不再赘述。在该实施例中,通过采用二次定型的方式来降低芯板生产过程中的收缩比和拱形弯曲率,由此可以提高PVC发泡板的产品质量。可以理解的是,为了较好地保证产品产量,本发明应当根据产品的需要合理调整工艺参数及设备选型,以下为一较优应用实例。
在该PVC发泡板生产设备的实施例中:降温定型和升温定型分别在各自的定型台上进行(根据工艺要求也可以不使用定型台,或仅部分使用定型台),其中加温可以通过水、油或电阻介质等方式加热,降温通过冷却水或自然冷却等方式降温。一种较优的工艺参数如下:(1)挤塑出料:将PVC物料送入挤塑机加热发泡挤出,加温发泡的温度控制在180℃;(2)入模定型:将挤出料送入模具定型定厚;(3)降温定型:将出模的挤出料第一次降温定型,降温定型的温度为30℃;(4)一次牵引,降温定型后的挤出料经过第一牵引机牵引送出;(5)升温定型:将降温定型过的基础料再次升温并定型,为90℃,用时3分钟;(6)牵引出料:将升温定型后的挤出料降温到30℃后,通过第二牵引机牵引出料。
这种设备选型及工艺参数,可以有效地降低芯板生产过程中的收缩比和拱形弯曲率,从而有助于提高PVC发泡板的产品质量。相对于现有技术在牵引降温定型的物料时,会改变尚在热态的挤出物料形状(包括厚度和高度),由此容易造成以后工序出现较高的收缩比变化率的问题,本实施例在物料降温定型后进行再次升温和降温定型,使得通过二次定型制成的芯板能有效地避免收缩比变化带来的裂缝、拱起等问题。
上述PVC发泡板可以较好地用于地板,以下为一种具有防水、静音效果的地板实例。
参见图3,表示本发明地板的结构示意图。该地板包括作为基板的PVC发泡层(板)310,该PVC发泡层310厚约4~5mm,四周边缘部分设置有端头卡扣311和侧边卡扣312(卡扣组合方式有多种,例如使地板的前端卡扣朝上、后端卡扣方向朝下、左侧卡扣朝下、右侧卡扣朝上),以便于快速地将相邻地板组件无缝连接。该PVC发泡层310由前述PVC复合材料发泡成型制得,具有较好的静音效果,同时具有较好的强度、硬度及韧性,产品的品质及寿命大大提高。为实现防水、耐磨等性能,PVC发泡层310的上面设置有PVC层320,其自上而下由PVC耐磨层(膜)321、PVC彩膜层322及PVC基片层323热压而成,其中:PVC彩膜层322厚约0.1mm,上面印制有地板花纹,以提高地板美观性;PVC耐磨层321厚约0.3-0.5mm,覆盖在PVC彩膜层322上,可防止彩膜层322被划伤,同时也起到防水效果;PVC基片层323厚约1.2~2mm,它与PVC彩膜层322、PVC耐磨层321热压后,再与PVC发泡层310粘合,该PVC基片层323可以添加碳酸钙或其它类似物,以提高强度与硬度,来达到提高地板品质的目的。由于使用了上述的PVC复合材料,该地板可以有效地改善产品性能,这有助于获得较好的市场占有率。
顺便指出的是,在制作地板时也可以考虑去除上述实施例中的PVC基片层323,此时PVC彩膜层322与PVC发泡层310粘合。一般而言,在未使用PVC基片层323时,可稍微增加PVC发泡层310的厚度。关于该地板不同层之间的粘合及热压工艺,可参照习知的现有技术,在此不再赘述。
本发明虽然以较佳实施例公开如上,但其并不是用来限定本发明,任何本领域技术人员在不脱离本发明的精神和范围内,都可以做出可能的变动和修改,因此本发明的保护范围应当以本发明权利要求所界定的范围为准。
Claims (10)
1.一种地板制造方法,其特征在于,通过在PVC发泡层表面上添加包括PVC耐磨层和PVC彩膜层的PVC层而得到,其中PVC发泡层采用以下步骤制取的PVC发泡板:
将PVC复合材料的物料混合搅拌均匀,该PVC复合材料以重量份计,包括PVC40~60份、轻质碳酸钙40~60份、无机/有机复合发泡剂0.8~1.2份、发泡调节剂3~5份、增韧剂2~4份、润滑剂0.8~1.2份以及稳定剂1.5~2.5份;
将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料;
将发泡PVC挤出料入模定型并冷却,以得到PVC发泡型材;
对出料后的PVC发泡型材进行切割,最终得到PVC发泡板成品。
2.如权利要求1所述的地板制造方法,其特征在于,所述将PVC复合材料的物料混合搅拌均匀步骤中包括两次混料:以1000~1200转/分的速度进行高速搅拌,以促进各原料成分混合均匀;之后,以500~600转/分的速度进行低速搅拌,并在进一步混合的同时实现降温。
3.如权利要求1所述的地板制造方法,其特征在于,所述将混合均匀的PVC复合材料的物料加热发泡,之后挤出粘流态的发泡PVC挤出料的步骤在挤塑机中进行,以使得物料熔融塑化为粘流态。
4.如权利要求3所述的地板制造方法,其特征在于,挤塑机中的加热发泡温度为160℃~190℃。
5.如权利要求1所述的地板制造方法,其特征在于,所述将发泡PVC挤出料入模定型并冷却,以得到PVC发泡型材的步骤包括:将发泡PVC挤出料送入预设形状和规格的模具中进行定型及定厚,冷却后获得PVC发泡板初胚;将PVC发泡板初胚进行升温定型,之后再次冷却而获得满足相应产品性能的PVC发泡型材。
6.如权利要求5所述的地板制造方法,其特征在于,PVC发泡板初胚冷却温度为20℃~40℃;PVC发泡板初胚升温定型的温度85℃~120℃,升温定型的时间为2.5min~3min;PVC发泡型材冷却温度为20℃~40℃。
7.如权利要求6所述的地板制造方法,其特征在于,所述PVC发泡型材在80℃、6h检测条件下的收缩比为0.25%~1.0%。
8.如权利要求1~7任一项所述的地板制造方法,其特征在于,PVC层以粘合方式附着在PVC发泡层表面。
9.如权利要求8所述的地板制造方法,其特征在于,PVC耐磨层和PVC彩膜层热压,PVC彩膜层和PVC发泡层粘合。
10.如权利要求8所述的地板制造方法,其特征在于,增设PVC基片层,其中:PVC耐磨层、PVC彩膜层及PVC基片层热压,PVC基片层和PVC发泡层粘合。
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US20150267025A1 (en) | 2015-09-24 |
AU2015234011A1 (en) | 2015-11-12 |
EP2998353B1 (en) | 2017-05-17 |
CA2910369A1 (en) | 2015-09-24 |
CN105064658B (zh) | 2017-08-25 |
CN105061941B (zh) | 2017-09-12 |
CN103865208A (zh) | 2014-06-18 |
AU2015234011B2 (en) | 2016-06-30 |
CN105064658A (zh) | 2015-11-18 |
PT2998353T (pt) | 2017-08-07 |
EP2998353A1 (en) | 2016-03-23 |
US9527975B2 (en) | 2016-12-27 |
ES2635068T3 (es) | 2017-10-02 |
CN103865208B (zh) | 2015-08-26 |
CA2910369C (en) | 2017-09-26 |
WO2015139541A1 (zh) | 2015-09-24 |
EP2998353A4 (en) | 2016-04-13 |
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