CN106499152A - Pvc复合地板 - Google Patents
Pvc复合地板 Download PDFInfo
- Publication number
- CN106499152A CN106499152A CN201610920219.2A CN201610920219A CN106499152A CN 106499152 A CN106499152 A CN 106499152A CN 201610920219 A CN201610920219 A CN 201610920219A CN 106499152 A CN106499152 A CN 106499152A
- Authority
- CN
- China
- Prior art keywords
- pvc
- composite floor
- floor boards
- decorative panel
- base
- 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
- 239000002131 composite material Substances 0.000 title claims abstract description 37
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims abstract description 23
- 239000004814 polyurethane Substances 0.000 claims description 32
- 239000000123 paper Substances 0.000 claims description 30
- 239000003292 glue Substances 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 20
- 229920002635 polyurethane Polymers 0.000 claims description 20
- 239000004831 Hot glue Substances 0.000 claims description 18
- 229920005989 resin Polymers 0.000 claims description 18
- 239000011347 resin Substances 0.000 claims description 18
- 238000007731 hot pressing Methods 0.000 claims description 17
- 238000006757 chemical reactions by type Methods 0.000 claims description 14
- 239000011230 binding agent Substances 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- 239000007943 implant Substances 0.000 claims description 7
- 239000002655 kraft paper Substances 0.000 claims description 7
- 238000005470 impregnation Methods 0.000 claims description 6
- 239000000314 lubricant Substances 0.000 claims description 6
- 239000003381 stabilizer Substances 0.000 claims description 6
- 239000004088 foaming agent Substances 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 5
- 229920000877 Melamine resin Polymers 0.000 claims description 4
- 230000015572 biosynthetic process Effects 0.000 claims description 4
- 238000005187 foaming Methods 0.000 claims description 4
- 210000001161 mammalian embryo Anatomy 0.000 claims description 4
- 239000004640 Melamine resin Substances 0.000 claims description 3
- 229920002522 Wood fibre Polymers 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- 239000002025 wood fiber Substances 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims 1
- 238000003825 pressing Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 10
- 238000005299 abrasion Methods 0.000 abstract description 4
- 230000006835 compression Effects 0.000 abstract description 2
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- 238000012360 testing method Methods 0.000 description 32
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- 239000000853 adhesive Substances 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 10
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- 239000012943 hotmelt Substances 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 239000002904 solvent Substances 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 238000004026 adhesive bonding Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000003086 colorant Substances 0.000 description 3
- 238000009408 flooring Methods 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 2
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- 230000007613 environmental effect Effects 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 2
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- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- FYEHYMARPSSOBO-UHFFFAOYSA-N Aurin Chemical compound C1=CC(O)=CC=C1C(C=1C=CC(O)=CC=1)=C1C=CC(=O)C=C1 FYEHYMARPSSOBO-UHFFFAOYSA-N 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- 241001060848 Carapidae Species 0.000 description 1
- 241000233855 Orchidaceae Species 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- -1 acrylic ester Chemical class 0.000 description 1
- 239000002671 adjuvant Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 230000003373 anti-fouling effect Effects 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000012752 auxiliary agent Substances 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
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- 239000000084 colloidal system Substances 0.000 description 1
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- 238000005034 decoration Methods 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000003303 reheating Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 230000003678 scratch resistant effect Effects 0.000 description 1
- 230000001568 sexual effect Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000012745 toughening agent Substances 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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- E—FIXED CONSTRUCTIONS
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- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
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Abstract
本发明涉及一种PVC复合地板,其包括PVC基材和表面热压有三氧化二铝的装饰板。本发明还涉及制造所述PVC复合地板的方法,包括将PVC基材和表面热压有三氧化二铝的装饰板通过热熔胶粘合在一起。本发明的PVC复合地板的耐磨性优异,具有显著提高的耐压痕性,并且其受压稳定性也特别好。
Description
技术领域
本发明涉及地板领域,更具体涉及表面热压有三氧化二铝的复合PVC地板。
背景技术
PVC地板是指采用聚氯乙烯材料生产的地板,是当今世界上非常流行的一种新型轻体地面装饰材料,也称为“轻体地材”,在欧美及亚洲的日韩广受欢迎的产品,从80年代初开始进入中国市场,至今在国内的大中城市已经得到普遍的认可,使用非常广泛,比如家庭、医院、学校、办公楼、工厂、公共场所、超市、商业等各种场所。但PVC地板的耐磨转数低,容易产生划痕,不容易清洁。另外,现有PVC地板表面的纹路是采用不同色彩的粒料,根据料流速度差异的原理制得的纹路图案,因此纹路比较单一,不够逼真。
木质地板主要分为实木地板和强化木地板两类。由于实木地板稳定性差,价格高,难保养,且木材稀有,因此更广泛使用的是强化木地板。强化木地板的基材是中密度或高密度纤维板以及刨花板,尺寸稳定性好,面层为含耐磨材料的浸渍装饰纸,保证了面层的耐磨性能、耐灼烧性、耐划痕性和耐污染性能好。但强化地板的最主要问题是甲醛含量高,被称为“毒地板”。并且这两种木质地板都不防水,不防火。
于是,理想的是,找到更好的地板来代替目前的PVC地板,其既具有PVC地板的优点,又具有强化地板表面的耐磨性能和美观。
发明内容
本发明在一个方面提供了一种PVC复合地板,其包括:
-PVC基材;和
-表面热压有三氧化二铝的装饰板。
并且优选所述PVC基材和表面热压有三氧化二铝的装饰板之间由湿气固化反应型聚氨酯热熔胶粘合。
本发明在另一方面提供了一种制备PVC复合地板的方法,其包括以下步骤:
1)将以重量份计的以下组分在混料设备中搅拌均匀,温度控制在100-110℃,搅拌时间为3-8分钟,然后进入冷混锅中继续搅拌,将物料降温至35-40℃,时间控制在5-10分钟的范围内:
树脂:100
填充物:10-350
稳定剂:8-20
润滑剂:8-20。
然后物料投入挤出机中挤出,得到PVC基材,其中,挤出机机筒温度为140℃至210℃之间,呈由高到低再至高温阶段的马鞍型设置;
2)将一张或多张牛皮纸,浸胶组胚,经过喷胶冷压成型,形成基纸,
然后将装饰纸放入三聚氰胺树脂胶粘剂中浸泡,干燥后铺装在基纸上,经140-160℃的高温,以每平方厘米90-110千克左右的压力持续施压1-1.5小时,从而形成装饰板;
随后,将三氧化二铝耐磨纸在170-230℃的温度、2000-2600吨的压力下热压在装饰板表面,从而形成热压有三氧化二铝的装饰板;
3)将步骤1)制备的PVC基材和步骤2)制备的热压有三氧化二铝的装饰板通过粘合剂对二者进行粘合,从而得到PVC复合地板。
由于本发明的PVC复合地板既有实木地板木纹纹理,又有强化地板的耐刮耐磨性,同时具有防水、防火、耐腐蚀、耐磨、保暖、节能环保的功能,因此其综合性价比特别高。
并且本发明的PVC复合地板通过一种新的工艺制备,相比于传统工艺,具有省时且节约成本的优点。
具体实施方式
除非另外定义,本文所使用的所有技术和科学术语具有本发明所属领域普通技术人员通常所理解的相同含义。在相抵触的情况下,以本说明书中的定义为准。
除非另外说明,所有的百分数、份数、比例等都以重量计。
当给出数值或数值范围、优选范围或一系列下限优选值和上限优选值时,应理解其具体公开了由任何较小的范围限值或优选值和任何较大的范围限值或优选值的任何一对数值所形成的所有范围,而无论范围是否分别被公开。除非另有说明,在本文描述数值范围之处,所述范围意图包括范围端值和范围内的所有整数和分数。
当术语“约”或“左右”用于描述数值或范围的端值时,所公开的内容应理解为包括该具体数值或所涉及的端值。
采用“一”和“一个/种”的用法描述本发明的要素和组分。这只是出于便利和为了给出本发明的一般情况。除非另有明显表示,应将该说明理解为包括一个/种或至少一个/种。
本发明中所用PVC基材是指将聚氯乙烯树脂作为主要原料,加入填料、增塑剂、稳定剂、着色剂等辅料,经压延、挤出或挤压工艺生产而成的板材。
在本发明的一个优选实施方案中,PVC基材包含以下组分(以重量份计):
PVC树脂:100
填充物:10-350
稳定剂:8-20
润滑剂:8-20
在本发明中苏勇PVC树脂可以选用5型、7型和8型PVC树脂或它们的组合。根据中国对PVC树脂的型号规定,5型PVC树脂是指K值为68-66、聚合度为1100-1000;7型PVC树脂是指K值为62-60、聚合度850-750;8型PVC树脂是指K值为59-55、聚合度为750-650。
填充物可以选用PVC地板领域常用的填充物,例如选自硬质碳酸钙、轻质碳酸钙、活化碳酸钙、高岭土、滑石粉、蒙脱土等的一种或多种。
稳定剂和润滑剂可以选用PVC地板领域常用的成分,例如硬脂酸盐、氧化聚乙烯蜡等。
在一个优选的实施方案中,PVC基材优选还包含以下组分(以重量份计):
发泡剂:0.1-10
发泡调节剂:0.3-30
这里的发泡剂和发泡调节剂可以选用PVC地板领域常用的成分,例如市售的偶氮二甲酰胺发泡剂等。
在再一个优选的实施方案中,PVC基材优选还包含以下组分(以重量份计):
木纤维:0.5-5。
在本发明的PVC基材中,还可根据不同的使用要求,加入不同的助剂以改善产品的适应性。例如加入抗冲改良剂改善抗冲击效果,加入增韧剂以改善PVC制品在低温下的韧性,加入抗氧化剂以改善耐候性等。
在一个优选实施方案中,所述装饰板包括基纸和装饰纸。
所述基纸是通过以下过程得到的。将一张或多张牛皮纸,浸胶组胚,确保胶量均匀,并控制其厚度,经过喷胶冷压成型,形成基纸。在这个过程中采用牛皮纸而非实木面皮来制备基纸,因为实木面皮的成本更高,而且其浸润性比牛皮纸低而不适合经受浸胶。
所述装饰板是通过以下过程得到的,将带有不同颜色或纹理的装饰纸放入三聚氰胺树脂胶粘剂中浸泡,然后干燥到一定固化程度,将其铺装在基纸上,经150℃左右的高温,以每平方厘米100千克左右的压力持续均衡施压一个小时左右,从而形成装饰板。
随后,为了提高装饰板的耐磨性,将三氧化二铝耐磨纸在170-230℃的温度、2000-2600吨的压力下热压在装饰板表面,所热压的三氧化二铝的克重量越高,其赋予装饰纸的耐磨性越强。
最后,用常规工艺对所得到的热压有三氧化二铝的装饰板进行修边和磨砂等操作。
本申请的发明人注意到,只有将三氧化二铝通过上述过程热压在装饰板上,才能在保持三氧化二铝耐磨性的同时,使得三氧化二铝完全游离,从而使得三氧化二铝耐磨层透明,清楚地显现其下面的装饰纸的纹理和色彩。如果只是简单地将三氧化二铝通过粘合剂粘合到装饰纸上,那么所形成的装饰板表面上三氧化二铝不能游离,使得表面不透明,从而无法清楚地显示地板需要的纹理和色彩。
将已经准备好的PVC基材和热压有三氧化二铝的装饰板通过粘合剂进行粘合。优选通过由湿气固化的热熔胶粘合对二者进行粘合,这里的湿气固化是指当与空气接触时,该热熔胶与空气中的水分发生反应变成固体。
本发明中的所用的湿气固化的热熔胶优选为湿气固化反应型聚氨酯热熔胶,可以由市售购得。湿气固化反应型聚氨酯热熔胶的增粘效果好于其它树脂粘合剂,特别是针对纸类、布类、木材类基材,更是如此。
在强化地板领域传统使用的粘合剂通常是冷胶,即粘合前不需加热的粘合剂,主要包括单组分或双组分冷胶,例如聚氨酯粘合剂和丙烯酸酯类粘合剂。冷胶在胶水固化之前需要一直用压力机将工件压住。而且双组分冷胶在将主剂与固化剂这两组分混合之后就会发生固化反应,有效使用时间短,容易造成浪费,不适合自动化生产。并且在基材与装饰板经冷胶粘合后,还需要施加每平方厘米15兆帕的压力,经过120分钟左右的时间固化,增加了生产时间和生产成本。
另外,在传统强化地板领域使用粘合剂例如丙烯酸酯类粘合剂进行粘合时,在用压力机将工件压住一定时间后,还需要加热以使粘合剂完全固化,这样才能使最终的地板具有所需强度。但是对于PVC地板来讲,由于PVC本身的特性,在超过70℃的温度下,PVC基材会软化变形。因此使用丙烯酸酯类粘合剂等传统粘合剂,将面临升高加热温度以保持粘结强度和减低加热温度以保持PVC基材性能的两难抉择。
本申请发明人为了克服使用传统粘合剂的上述缺点,经过一系列科学实验,选择了湿气固化反应型聚氨酯热熔胶作为粘合剂。
湿气固化反应型聚氨酯热熔胶不含有水和溶剂,固含量100%,是一种高性能环保型胶粘剂,其在地板的制备过程中,相比于丙烯酸酯类传统树脂型粘合剂,具有无需加压,也无需加压后高温固化的过程。并且兼有普通热熔胶粘剂无溶剂、初粘性高、装配时定位迅速等特性。其施胶温度又低于普通热熔胶粘剂,在兼具热熔胶快速粘接性能的同时,会与空气中水分反应,最终形成高强度、高弹性、防水、耐温的聚氨酯树脂。
另外聚氨酯热熔胶具有耐水浸泡、并抗大多数溶剂、油的侵蚀的特性。反应型聚氨酯热熔胶的涂胶温度低,从而可以有效防止由于高温造成的基材变形的问题。
由于聚氨酯热熔胶组成是100%的固体成分,所以没有任何有机挥发成分(VOC),并且不需要任何烘干装置。这样就避免了溶剂性产品所带来的环境问题,和烘干溶剂性产品及水基产品所需要的能源问题。因为不含任何溶剂,固化过程中及固化后不会释放出任何有害的成份,完全满足人们对家居的环保要求。本发明使用湿气固化反应型聚氨酯热熔胶,在完成涂胶后,会与空气或基材中的水分反应最终成聚氨酯,再加热不会再熔化。因此,既减少了使用丙烯酸酯粘合剂的耗时问题,又因为不需要加压而节约成本。
根据本发明,可以使用市售的湿气固化反应型聚氨酯热熔胶,在本发明的实施例中优选使用台湾南宝树脂集团生产的南宝树脂K-AA20湿气固化反应型聚氨酯热熔胶。
在本发明的一个实施方案中,首先对湿气固化反应型热熔胶加温,使其熔化,在PVC基材的表面上涂覆熔化的湿气固化反应型热熔胶,然后将装饰板覆盖到热熔胶表面上,即得到最终产品-本发明的PVC复合地板。应注意到,在粘合过程中,不需要使用压力机将工件压住一定时间,也不需要在基材和装饰板粘合后进一步加热。
现在,将参考如下实施例以非限制性的方式对本发明进行进一步的说明。
实施例
制备本发明的PVC复合地板,并与现有技术PVC地板进行性能比较。所用材料:
地板1:根据本发明的PVC复合地板,其中使用湿气固化反应型热熔胶作为粘合剂;
地板2:根据本发明的PVC复合地板,其中使用冷胶作为粘合剂;
地板3:现有技术PVC地板,其是通过压延或挤出或挤压工艺生产的产品,它的表面耐磨层为PVC材质。
冷胶:东莞兰宝化工新材料有限公司生产的兰宝聚氨酯胶,其是一种双组分胶
湿气固化反应型热熔胶:台湾南宝树脂集团生产的南宝树脂K-AA208
本发明地板的制备过程
制备地板1本发明的PVC复合地板
1).首先分别按照以下配方(以重量份计)制备PVC基材。
配方 | |
PVC树脂 | 100 |
填充物(1:1:1的硬质碳酸钙、轻质碳酸钙、活化碳酸钙) | 180 |
稳定剂(硬脂酸盐) | 14 |
润滑剂(氧化聚乙烯蜡) | 14 |
发泡剂(偶氮二甲酰胺) | 5 |
发泡调节剂 | 15 |
木纤维 | 3 |
将以上配方的材料在混料设备中充分搅拌均匀,温度控制在105℃左右,树脂含量越高,温度要求越低。搅拌时间为3-8分钟,视产品的成分含量来设定时间。然后进入冷混锅中继续搅拌,目的是将物料降温至35-40℃,保证产品的颜色一致和生产稳定,时间控制在5-10分钟。
然后物料投入挤出机中,从而得到PVC基材。其中,挤出机机筒温度由高到低再至高温阶段,呈马鞍型设置,140度至210℃之间,树脂含量越高所需温度越低,温度越低,速度越快。
2).制备热压有三氧化二铝的装饰纸
将一张或多张牛皮纸,浸胶组胚,确保胶量均匀,并控制其厚度,经过喷胶冷压成型,形成基纸。
在准备好基纸后,将带有不同颜色或纹理的装饰纸放入三聚氰胺树脂胶粘剂中浸泡,然后干燥到一定固化程度,将其铺装在基纸上,经150℃左右的高温下,以每平方厘米100千克左右的压力持续均衡施压一个小时左右,从而形成装饰板。
随后,将三氧化二铝耐磨纸在170-230℃的温度、2000-2600吨的压力下热压在装饰板表面,所热压的三氧化二铝的克重量越高,其赋予装饰板的耐磨性越强
最后,用常规工艺对所得到的热压有三氧化二铝的装饰板进行修边和磨砂等操作。
3).将所制备的三种PVC基材和热压有三氧化二铝的装饰纸通过湿气固化反应型聚氨酯热熔胶对二者进行粘合,从而得到本发明的PVC复合地板。
具体而言,本发明湿气固化反应型聚氨酯热熔胶采用以下方式进行压盘式粘贴:加热部件为一铝合金加热盘,使用时加热盘从上向下压入胶桶内,加热盘位于热熔胶上方,当加热盘加热时,温度在110-130℃之间,仅有最上面一层胶与加热盘接触,使之达到熔点而熔化,胶桶下部分此时不加热,生产时需要多少,熔化多少,避免热熔胶长时间加热而老化变质。热熔胶熔化时与空气隔离:加热盘与胶桶内壁之间有O型圈密封,使得熔化的液体胶不会与空气接触,保证了湿气固化反应型聚氨酯热熔胶的使用条件要求。压盘采用铝合金精铸,CNC精密加工,加热盘外表面经杜邦特氟龙深层渗透烧结处理,具有涂层强度高不易脱落等优点。其上热熔胶极易清除,可有效防止热熔胶炭化,减少输胶系统堵塞。
熔化的湿气固化反应型聚氨酯热熔胶在涂胶机的连续运转下,均匀的涂布在PVC基材的表层,与装饰板快速贴合,不需要额外的压力即可粘牢,瞬间固化。
制备地板2:与上述制备地板1的过程相同,区别仅在于步骤3)中以冷胶代替湿气固化反应型热熔胶。
实施例1
测试地板1的表面耐磨性
取1片上述制备的本发明的PVC复合地板(地板1),根据EN660-2:1999+A1:2003ANDEN 649:2011,对其进行耐磨性测试。其中每个磨耗轮负荷为(1±0.01)千克,落砂速率为(21±3)克/分钟。
测试结果:每100转的磨耗值在0.1克以下,6000转时耐磨层没有明显的损坏,
实施例2
测试地板1的抗压痕性
根据EN ISO 24343-1:2012,将测试样品置于平面上,将环形加载重物放于测试样品上。在2S内缓慢的施加总共500N的力在样品表面上。150分钟后移出施加力,再经过150分钟后使用适当的仪器测量样品的最终厚度,精确至0.01mm。
测试结果:经过上述测试过程后,测得本发明PVC复合地板的厚度减小0.01mm。
实施例3
测试地板1的稳定性
根据EN ISO 23999:2012,先测试样品的翘曲高度和尺寸,然后将样品放在温度为(80±2)℃的烘箱里(360±15分钟)后,然后把样品放在温度(23±2)℃、相对湿度(50±5)%的条件下至少24小时后,记录样品翘曲高度和尺寸,并计算变化量。
测试结果:本发明的PVC复合地板的尺寸变化率为3%
实施例4
测试地板1的阻燃性
根据ASTM E84-12A,测试地板1的阻燃性能。
测试结果:火焰传播指数小于FSI<10,烟雾发展指数SDI<100。
实施例5
测试地板1的粘结性能。
根据GB/T18102-2000,测试地板1的代表粘结性能的内结合强度。
测试结果:使用湿气固化反应型聚氨酯热熔胶的本发明PVC复合地板的内结合强度平均值为1.20。
实施例6
测试地板2的粘结性能
根据GB/T18102-2000,测试地板2的代表粘结性能的内结合强度。
测试结果:使用冷胶的本发明PVC复合地板的内结合强度为1.05。
实施例7
测试地板1的180度剥离强度
根据ISO 8510—2:1990,测试地板1表征粘结性能的剥离强度。
测试结果:使用湿气固化反应型聚氨酯热熔胶的本发明PVC复合地板的剥离强度为4.64kN/m-1。
实施例8
测试地板2的剥离强度
根据ISO 8510—2:1990,测试地板2表征其粘结性能的剥离强度。
测试结果:使用冷胶的本发明PVC复合地板的剥离强度为1.54kN/m-1。对比例1
测试地板3的耐磨性
取3块相同的现有技术PVC地板进行测试。
第一片样品在磨完5000转前已被磨穿,丢弃该样品。
测试其余两片样品时,每200转停下来观察,直至2000转或样品被磨穿。
测试结果:现有技术PVC地板,每100转的磨耗值在0.15克以上。
对比例2
测试地板3的抗压痕性
重复实施例2的测试过程,只是以现有技术PVC地板为样品。
测试结果:现有的PVC地板的厚度减小0.1mm。
对比例3
测试地板3的稳定性
重复实施例3的测试过程,只是以现有技术PVC地板为样品。
测试结果:现有的PVC地板的尺寸变化率为15%。
通过以上实施例和对比例,可以发现本发明的PVC复合地板的耐磨性优异,具有显著提高的耐压痕性,受压稳定性特别好,并且地板的粘结强度也很高。
上面通过一些实施方式和实施例对本发明进行了具体的描述,但是这些实施方式和实施例不是对本发明的范围的限制,本领域技术人员应该明白的是,在本申请公开内容的基础上可以对PVC复合地板做出很多改变,这些改变都包括在本发明的精神范围内。
Claims (10)
1.一种PVC复合地板,其包括:
-PVC基材;和
-表面热压有三氧化二铝的装饰板。
2.权利要求1的PVC复合地板,其中所述PVC基材和表面热压有三氧化二铝的装饰板之间由湿气固化反应型聚氨酯热熔胶粘合。
3.权利要求1的PVC复合地板,其中所述PVC基材包含以重量份计的以下组分:
树脂:100
填充物:10-350
稳定剂:8-20
润滑剂:8-20。
4.权利要求3的PVC复合地板,其中所述PVC基材还包含以重量份计的以下组分:
发泡剂:0.1-10
发泡调节剂:0.3-30。
5.权利要求4的PVC复合地板,其中所述PVC基材以重量份计的以下组分:
木纤维:0.5-5。
6.权利要求1-5之一的复合地板,其中所述装饰板包括基纸和装饰纸,所述基纸由一层或多层浸胶牛皮纸经过喷胶冷压而形成。
7.权利要求1-6之一的PVC复合地板,其中所述表面热压有三氧化二铝的装饰板是通过以下过程制备的:在170-230℃的温度和100-2600吨的压力下将三氧化二铝热压在装饰板表面上。
8.权利要求1-7之一的PVC复合地板,其根据EN 660-2:1999+A1:2003AND EN 649:2011测量的耐磨转数为至少6000转。
9.制备PVC复合地板的方法,其包括以下步骤:
1)将以重量份计的以下组分在混料设备中搅拌均匀,温度控制在100-110度,搅拌时间为3-8分钟,然后进入冷混锅中继续搅拌,将物料降温至35-40度,时间控制在5-10分钟:
树脂:100
填充物:10-350
稳定剂:8-20
润滑剂:8-20
然后物料投入挤出机中挤出,得到PVC基材,其中,挤出机机筒温度为140度至210度之间,呈由高到低再至高温阶段的马鞍型设置;
2)将一张或多张牛皮纸,浸胶组胚,经过喷胶冷压成型,形成基纸,
然后将装饰纸放入三聚氰胺树脂胶粘剂中浸泡,干燥后铺装在基纸上,经140-160℃的高温,以每平方厘米90-110千克左右的压力持续施压1-1.5小时,从而形成装饰板;
随后,将三氧化二铝耐磨纸在170-230℃的温度、2000-2600吨的压力下热压在装饰板表面,从而形成热压有三氧化二铝的装饰板;以及
3)将步骤1)制备的PVC基材和步骤2)制备的热压有三氧化二铝的装饰板通过粘合剂对二者进行粘合,从而得到PVC复合地板。
10.权利要求9的制备PVC复合地板的方法,其中步骤3)中所用的粘合剂是湿气固化反应型聚氨酯热熔胶。
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