CN106836719A - 石化木防水复合地板 - Google Patents
石化木防水复合地板 Download PDFInfo
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- CN106836719A CN106836719A CN201710227393.3A CN201710227393A CN106836719A CN 106836719 A CN106836719 A CN 106836719A CN 201710227393 A CN201710227393 A CN 201710227393A CN 106836719 A CN106836719 A CN 106836719A
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Abstract
一种石化木防水复合地板，包括基材层、粘贴在基材层两侧的面层，其技术要点是：所述基材层与面层之间通过PUR胶或聚氨酯胶粘贴，基材层为矿物质塑合基材层，矿物质塑合基材层为中空或实心结构；一个面层为实木表板层，实木表板层由实木皮或软木皮制成，实木表板层上涂敷有木蜡油；另一个面层为弹性缓冲层，弹性缓冲层上开有排水道，弹性缓冲层由栎树皮软木或橡胶或塑料或橡塑复合材料制成，弹性缓冲层上涂敷木蜡油；实木表板层厚度为0.3~5mm，弹性缓冲层厚度为0.3~8mm，弹性缓冲层边缘小于基材2~20mm；其具有制备工艺简单、制备成本低、使用寿命长等优点。
Description
技术领域
本发明涉及一种地板的制造领域，具体地说是一种防水并带有水道的石化木防水复合地板，其主要适用于浴室、卧室、会议室、图书馆、录音棚等场所的地面铺装材料。
背景技术
众所周知，一直以来浴室里的地面和墙面铺装材料大采用瓷砖、大理石等同质通透材料。用石木面料做浴室地面铺装材料试人们梦寐以求的。其天然的木纹给人回归自然的感觉，具有弹性舒适的脚感给人以和谐、惬意与放松。但是由于实木怕水泡、不防水确是的不争事实，是人们渴盼难以实现的一种奢求。
为解决上述问题，曾设计出如申请公开号为CN104870178A的发明专利申请公开的一种复合防水地板，该技术方案包括：(a)耐磨层，所述耐磨层粘接至防水芯的顶表面；(b)第一防水粘合剂层，所述第一防水粘合剂层使所述耐磨层与所述防水芯的顶表面结合；(c)防水芯，所述防水芯包括压制的屑和塑料的复合物；(d)所述板具有带有侧向延伸入所述防水芯的槽的第一边缘，以及带有从所述防水芯侧向突起的第二相对边缘，其中所述槽和突起具有定形成形成喀哒锁定边缘紧固系统的轮廓。但是其制备工艺复杂，制备成本高不利于市场推广。
发明内容
本发明的目的是提供一种石化木复合防水地板，从根本上解决了上述问题，其具有制备工艺简单、制备成本低、使用寿命长等优点。
为实现上述目的，本发明提供了如下技术方案：该石化木防水复合地板，包括基材层、粘贴在基材层两侧的面层，其技术要点是：所述基材层与面层之间通过PUR胶或聚氨酯胶粘贴，基材层为矿物质塑合基材层，矿物质塑合基材层为中空或实心结构；一个面层为实木表板层，实木表板层由实木皮或软木皮制成，实木表板层上涂敷有木蜡油；另一个面层为弹性缓冲层，弹性缓冲层上开有排水道，弹性缓冲层由栎树皮软木或橡胶或塑料或橡塑复合材料制成，弹性缓冲层上涂敷木蜡油；实木表板层厚度为0.3~5mm，弹性缓冲层厚度为0.3~8mm，弹性缓冲层边缘小于基材2~20mm；
基材层由以下重量份配比的原料制成：
聚氯乙烯10~100份；钙锌复合稳定剂或稀土复合稳定剂1~10份；硬脂酸0.1~5份；氯化聚乙烯 0.5~12份；
丙烯酸酯类共聚物 0.5~8份；聚乙烯蜡 0.1~5份；粒度1~100nm的重质碳酸钙 0.03~10份；粒度3~45μm的重质碳酸钙或轻质碳酸钙 10~75 份；石蜡0.1~5份；聚氯乙烯废料0~50份。
所述基材层制备原料还包括秸秆粉或木粉3~40份。
所述基材层制备原料还包括增塑剂3316A 0.001~5份、发泡剂MS-206 0.1~10份、发泡剂MS-107 1~20份、发泡剂总质量的1.5~20倍的发泡调节剂 K400。
本发明还提供了一种石化木防水复合地板的制备方法，其技术要点是，包括以下步骤：
步骤1）基材层原料的预处理：向混料机中投入聚氯乙烯、复合稳定剂混合加热到50~80℃，然后投入硬脂酸、氯化聚乙烯、丙烯酸酯类共聚物、聚乙烯蜡和纳米级重质碳酸钙继续升温至90~100℃，然后投入粒度3~45μm的重质碳酸钙或轻质碳酸钙、石蜡和聚氯乙烯废料充分搅拌混合10~20min后升温至120~130℃去除物料中的水分，继续搅拌10min~30min至含水量为4~9wt%，然后将混合干燥后的物料转入冷却锅，自然冷却至30~50℃；
步骤2）基材层的制备：将步骤1）所得准备好的物料投入挤出机挤出，牵引机牵引通过模具成型；通过真空定型台使产品定型；通过切断机按设计长度定尺切断，即得基材毛坯；
步骤3）面层的制备：对基材毛坯外表面砂光定厚，按设计尺寸裁切0.3mm~5.0mm的实木皮备用，按设计尺寸裁切0.3~8.0mm的软木皮备用，软木皮的外边缘小于基材层2~20mm；用PUR胶或聚氨酯胶在基材一面粘贴实木皮，在另一面粘贴软木皮；通过地板机锁扣或平扣的槽、榫加工，即得地板半成品；
步骤4）面层的表面处理：用砂光机把地板半成品表面的实木皮抛光，在抛光后的实木皮表面涂敷木蜡油，自然干燥20min~30min后檫掉表面多余的木蜡油，继续自然干燥，重复涂油干燥两至三遍，待完全干燥后即得成品。
所述步骤1）中，基材层制备原料还包括秸秆粉或木粉3~40份。
所述步骤1）中，基材层制备原料还包括增塑剂3316A 0.001~5份、发泡剂MS-2060.1~10份、发泡剂MS-107 1~20份、发泡剂总质量的1.5~20倍的发泡调节剂 K400。
本发明的有益效果：以矿物质粉（重质碳酸钙）、PVC、可回收塑料为制备基材的主要原料，制备了具有高刚性的惰性基材（芯），其不会吸收湿气并且不会扩张或收缩，避免传统地板由于水浸而产生的“鼓包”现象。无需使用偶联剂（偶联剂有低毒），应用纳米级的重质碳酸钙（比表面积大）的表面效应改善填充的重质碳酸钙、秸秆粉（木粉）与PVC的聚合力，替代偶联剂的作用。
填充重质碳酸钙起到增加产品强度，避免热胀冷缩的形变量，尺寸稳定，同时降低制备成本，同时添加一定量的钙锌复合稳定剂或稀土复合稳定剂，在整个配方原料中均匀分散，由于存在相同的金属离子，可提高木屑、塑料以及重质碳酸钙的亲和性。而填充的秸秆粉或木粉能增加产品韧性减轻产品重量。而采用中空结构，则可进一步降低重量和制备成本。
采用不可逆的环保胶（如PUR胶或双组份聚氨酯胶YX4137或YX4238）粘贴0.3~5mm实木皮，环保胶性质稳定，不怕长时间水浸。在石化木防水复合地板的基材的下面粘贴0.3~8mm软木皮或其它不怕水泡的具有弹性的材料。弹性缓冲层采用片装的木屑结构，材质内部留有空隙，外部通过木蜡油密封，空隙中的空气可用于导热、隔音与减震，富于弹性，地板上有人踩踏时可起到缓冲作用，避免形变量过大导致地板变形。缓冲层外缘相对于基材层采用缩边结构，总缩边距为2~20mm，在铺设完成后，地板地面形成矩阵式的排水通道。实木表板层经过多次涂敷或浸泡木蜡油，木蜡油浸透木板的微孔结构，在表面形成防水的耐磨层，不仅耐潮，还能提供足够的静摩擦系数。还可将排水道与水平面之间设置一定夹角，使其中的积水在重力作用下向单一方向流动，进而排向指定的总排水通道，避免由于长时间积水发生的细菌滋生。
制备方法中，先投入聚氯乙烯和复合稳定剂加热到50~80℃混合搅拌10~20min，使复合稳定剂均匀分散在主成分聚氯乙烯中。然后依次投入硬脂酸、氯化聚乙烯、丙烯酸酯类共聚物、聚乙烯蜡等加工助剂，然后投入纳米级重质碳酸钙继续升温至90~100℃，使得纳米级重质碳酸钙均匀分散在物料中，并进行预反应，最后投入重质碳酸钙、石蜡和聚氯乙烯废料充分搅拌混合10~20min，使得最后加入的组分包裹在前组分的外部，后升温至120~130℃去除物料中的水分杂质继续搅拌10min~30min至含水量为4~9wt%，以提高各组分之间亲和度。采用逐步升温与投料的方法，将材料逐步进行预反应，避免其他副反应的产生，同时由于各组分的含水量不同，分批分温度范围加入，有利于控制整体的水分。
综上所述，本发明石化木防水复合地板的基材层、弹性缓冲层和实木表板层均采用疏水（惰性）材料制备，可在潮湿和干燥反复变换的环境下（例如浴室）使用而不发生变形，有效拓展了地板的使用范围，克服了现有地板不耐潮的弊端，即使长期处于水浸环境下仍能保证尺寸稳定不变形，同时兼备实木地板的良好导热性，在地热采暖时导热好利于节能。
附图说明
图1为本发明其中一块地板的等轴侧视结构示意图；
图2为图1的俯视结构示意图；
图3为图2的剖视结构示意图。
附图标记说明：1弹性缓冲层、2基材层、3中空结构、4实木表板层、5排水道、6榫卯结构、7缩边结构。
具体实施方式
以下结合图1~3，通过具体实施例详细说明本发明的内容。
实施例1
该石化木防水复合地板，包括基材层2、粘贴在基材层两侧的面层，相邻地板之间通过榫卯结构6拼接。基材层与面层之间通过PUR胶或聚氨酯胶粘贴，基材层为矿物质塑合基材层（密度为0.7~2.2g/cm3），矿物质塑合基材层为纵向贯通的中空结构3或实心结构，中空结构为贯通基材层的水道3。一个面层为实木表板层4，板面大小与基材层相接面相等，实木表板层由实木皮或软木皮制成，实木表板层上涂敷有木蜡油。另一个面层为弹性缓冲层1，弹性缓冲层上开有位于基材层上的排水道5，排水道位于弹性缓冲层与基材层之间，并且弹性缓冲层覆盖在排水道上，仅将排水道端部露出。弹性缓冲层由栎树皮软木、橡胶、塑料或橡塑复合材料制成，弹性缓冲层上涂敷可起到防水作用的木蜡油。实木表板层厚度为0.3~5mm，弹性缓冲层厚度为0.3~8mm，弹性缓冲层采用缩边结构，该边缘可采用单侧缩边（本实施例采用该方式），也可两侧缩边，总缩边量为2~20mm。
其中，基材层由以下重量份配比的原料制成：SG-5型聚氯乙烯（PVC）25.0kg、钙锌复合稳定剂8.0kg、硬脂酸3.0kg、增韧增塑剂氯化聚乙烯（CPE）1.0kg、丙烯酸酯类共聚物（ACR）2.2kg、聚乙烯蜡（PE蜡）3.0kg、粒度5~90nm重质碳酸钙5.0kg、粒度15~30μm重质碳酸钙70.5kg、半精炼石蜡3.0kg。
其中，聚氯乙烯的选择根据《悬浮法通用型聚氯乙烯树脂国家标准GB/T 5761-2006》制备的SG-4型或SG-5型或SG-7型或SG-8型PVC，不同型号的PVC主要是聚合度不同。SG-4型聚合度1200，主要用于膜、软管和人造革；SG-5型聚合度1000，主要用于型材、管材生产；SG-7型聚合度800，SG-8型聚合度700，聚合度较低，更易于加工，多用于生产片材和注塑管件。在通常制备时采用SG-4型或SG-5型，在制备微发泡基材时采用SG-7型或SG-8型。
以生产910×95×15mm浴室地板实施例，具体包括以下步骤：
步骤1）基材层原料的预处理： 向JZRL500/1000热冷混合机中依次投入SG-5型聚氯乙烯25.0kg、钙锌复合稳定剂8.0kg混合加热到50~80℃混合搅拌10~20min，投入硬脂酸3.0kg、氯化聚乙烯1.0kg、丙烯酸酯类共聚物2.2kg、聚乙烯蜡3.0kg和5~90nm重质碳酸钙5.0kg，继续升温至90~100℃，投入粒度15~30μm（约合600目）重质碳酸钙70.5kg、半精炼石蜡3.0kg和回收料充分搅拌混合后升温至120~130℃，搅拌10min~30min，将混合干燥后的物料转入冷却锅自然冷却至30~50℃；得到含水量4~9wt%（水分由于搅拌过程中的蒸发而减少）的基材物料；
步骤2）基材层的制备：将冷却好的基材物料投入65/132挤出机挤出，牵引机牵引通过模具成型；通过真空定型台使产品定型使基材定型基材宽100±2mm，厚10.2±0.4mm；通过切断机按915mm±3mm切断，即得定长定宽的基材毛坯；
步骤3）面层的制备：对基材毛坯上表面和下表面砂光定厚得到10mm±0.1mm的基材，按设计尺寸裁切2.0mm的菠萝格实木皮，按设计尺寸裁切长930mm×宽105mm×厚3mm的软木皮，软木皮的外边缘小于基材层2~20mm，起到排水作用；在涂胶机上用不可逆的PUR胶或双组份环保聚氨酯胶或单组份专用水性胶在基材一面粘贴菠萝格实木皮，在另一面粘贴裁切好的软木皮；用裁板锯裁切多余的木皮边，通过地板机锁扣或平扣的槽、榫加工，即得地板半成品。当浴室地板要做“人”字形铺装时平扣的槽榫加工为左槽右榫和右槽左榫。
步骤4）面层的表面处理：用砂光机把地板半成品表面的实木皮（实木皮和软木皮）抛光；上辊涂生产线辊涂切瑞西牌高硬质木蜡油或手工檫涂木蜡油或在木蜡油中浸泡，自然干燥20min~30min后檫掉表面多余的木蜡油，自然干燥或干燥箱干燥后抛光，重复两至三遍；完全干燥后进行成品检验、包装。
实施例2
为提高板材隔热、保温、隔音功能（主要作为墙板时），在实施例1的基础上通过在基材原料中加入发泡剂MS-206 5.0kg、发泡剂MS-107 10.0kg、发泡调节剂K400 75.0kg，可制得与原板材性状基本相同，但密度更小的微发泡基材。
实施例3
当作为墙板使用时，为提高材质的吸湿性，同时降低板材的平均密度，还可在实施例1或2的基础上使用秸秆粉或木粉3.0~40.0kg替代等量的粒度15~30μm重质碳酸钙。
Claims (6)
1.一种石化木防水复合地板，包括基材层、粘贴在基材层两侧的面层，其特征在于：所述基材层与面层之间通过PUR胶或聚氨酯胶粘贴，基材层为矿物质塑合基材层，矿物质塑合基材层为中空或实心结构；一个面层为实木表板层，实木表板层由实木皮或软木皮制成，实木表板层上涂敷有木蜡油；另一个面层为弹性缓冲层，弹性缓冲层上开有排水道，弹性缓冲层由栎树皮软木或橡胶或塑料或橡塑复合材料制成，弹性缓冲层上涂敷木蜡油；实木表板层厚度为0.3~5mm，弹性缓冲层厚度为0.3~8mm，弹性缓冲层边缘小于基材2~20mm；
基材层由以下重量份配比的原料制成：
聚氯乙烯10~100份；钙锌复合稳定剂或稀土复合稳定剂1~10份；硬脂酸0.1~5份；氯化聚乙烯 0.5~12份；丙烯酸酯类共聚物 0.5~8份；聚乙烯蜡 0.1~5份；粒度1~100nm的重质碳酸钙 0.03~10份；粒度3~45μm的重质碳酸钙或轻质碳酸钙 10~75份；石蜡0.1~5份；聚氯乙烯废料0~50份。
2.根据权利要求1所述的石化木防水复合地板，其特征在于：所述基材层制备原料还包括秸秆粉或木粉3~40份。
3.根据权利要求1或2所述的石化木防水复合地板，其特征在于：所述基材层制备原料还包括增塑剂3316A 0.001~5份、发泡剂MS-206 0.1~10份、发泡剂MS-107 1~20份、发泡剂总质量的1.5~20倍的发泡调节剂 K400。
4.一种权利要求1所述石化木防水复合地板的制备方法，其特征在于，包括以下步骤：
步骤1）基材层原料的预处理：向混料机中投入聚氯乙烯、复合稳定剂混合加热到50~80℃混合搅拌10~20min，然后投入硬脂酸、氯化聚乙烯、丙烯酸酯类共聚物、聚乙烯蜡和纳米级重质碳酸钙继续升温至90~100℃，然后投入粒度3~45μm的重质碳酸钙或轻质碳酸钙、石蜡和聚氯乙烯废料充分搅拌混合10~20min后升温至120~130℃去除物料中的水分，继续搅拌10min~30min至含水量为4~9wt%，然后将混合干燥后的物料转入冷却锅，自然冷却至30~50℃；
步骤2）基材层的制备：将步骤1）所得准备好的物料投入挤出机挤出，牵引机牵引通过模具成型；通过真空定型台使产品定型；通过切断机按设计长度定尺切断，即得基材毛坯；
步骤3）面层的制备：对基材毛坯外表面砂光定厚，按设计尺寸裁切0.3mm~5.0mm的实木皮备用，按设计尺寸裁切0.3~8.0mm的软木皮备用，软木皮的外边缘小于基材层2~20mm；用PUR胶或聚氨酯胶在基材一面粘贴实木皮，在另一面粘贴软木皮；通过地板机锁扣或平扣的槽、榫加工，即得地板半成品；
步骤4）面层的表面处理：用砂光机把地板半成品表面的实木皮抛光，在抛光后的实木皮表面涂敷木蜡油，自然干燥20min~30min后檫掉表面多余的木蜡油，继续自然干燥，重复涂油干燥两至三遍，待完全干燥后即得成品。
5.根据权利要求4所述的石化木防水符合地板的制备方法，其特征在于：所述步骤1）中，基材层制备原料还包括秸秆粉或木粉3~40份。
6.根据权利要求4或5所述的石化木防水符合地板的制备方法，其特征在于：所述步骤1）中，基材层制备原料还包括增塑剂3316A 0.001~5份、发泡剂MS-206 0.1~10份、发泡剂MS-107 1~20份、发泡剂总质量的1.5~20倍的发泡调节剂 K400。
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