CN108086628A - 塑胶地板层状结构的成型方法 - Google Patents

塑胶地板层状结构的成型方法 Download PDF

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Publication number
CN108086628A
CN108086628A CN201611047571.6A CN201611047571A CN108086628A CN 108086628 A CN108086628 A CN 108086628A CN 201611047571 A CN201611047571 A CN 201611047571A CN 108086628 A CN108086628 A CN 108086628A
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China
Prior art keywords
layer
substrate
roll
pvc material
roller
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Pending
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CN201611047571.6A
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English (en)
Inventor
赵培东
陆钉毅
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Individual
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Individual
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Priority to CN201611047571.6A priority Critical patent/CN108086628A/zh
Priority to US15/604,689 priority patent/US20180141253A1/en
Priority to EP17179931.5A priority patent/EP3326815B8/en
Priority to PL17179931T priority patent/PL3326815T3/pl
Publication of CN108086628A publication Critical patent/CN108086628A/zh
Pending legal-status Critical Current

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Abstract

本发明提供一种塑胶地板层状结构的成型方法，利用共挤成型方式形成一基板，再于该基板上依序设置一印刷层及耐磨层，组成一塑胶地板。该基板以共挤方式一体成型不同软硬度的第一基板层、第二基板层及第三基板层，且该些基板层在共挤成型时呈上下重叠粘合为一体；该基板在共挤成型后，与该印刷层及耐磨层利用一卷送设备分别输送至一辊压单元，利用该辊压单元将该基板、印刷层及耐磨层利用辊压方式粘合固定为一体，使塑胶地板的具有多种不同软硬度的层状结构，同时制造更具效率且环保。

Description

塑胶地板层状结构的成型方法
技术领域
本发明涉及一种塑胶地板，特别针对塑胶地板层状结构的成型方法与组成结构加以改良。
背景技术
按，利用塑胶材料制成地板，以取代天然木材，减少对自然资料的破坏，是现今塑胶地板产品开发的趋势。而由背景技术可知，现有塑胶地板的组成，都是最底下的基板表面再贴覆一印刷膜和耐磨膜，而一般基板为PVC材质，若要在底层加一软性材质时，大都是利用工业胶水粘贴，不仅作业效率低，且没有环保概念，同时，现有利用粘合方式将不同软、硬材质的基板材结合，其粘合的稳固性及品质无法有效掌控，也无法将不同软、硬材料的基板材作多种的组合变化，而有加以改善的必要。
发明内容
本发明的主要目的，提供一种塑胶地板层状结构的成型方法，其令塑胶地板具有软硬材质交错叠合的层状结构，且其层状结构的成型方法以自动化快速、简便且环保的方式达成，以增进塑胶地板层状结构的稳定性与使用效果。
缘于达成上述的发明目的，本发明提供一种塑胶地板层状结构的成型方法，其特征在于：该塑胶地板至少包含一基板、印刷层及耐磨层，其中：
该基板以共挤方式一体成型多层结构，至少具有不同软硬度的第一基板层及第二基板层，且所有基板层在共挤成型时，呈上下重叠粘合为一体；
该印刷层形成于该基板上缘，其表面印刷有预设的图案或纹路；
该耐磨层形成于该印刷层上；
该基板在共挤成型后，与该印刷层及耐磨层利用一卷送设备分别输送至一辊压单元，利用该辊压单元将该基板、印刷层及耐磨层辊压粘合固定为一体，使塑胶地板的具有多种不同软硬度的层状结构。
所述的塑胶地板层状结构的成型方法，其中：该基板为二层结构，其位于下层的第一基板层为PVC材料添加可塑剂，而呈现软质特性，而位于上层的第二基板层为不含可塑剂的PVC材料，呈现硬质特性。
所述的塑胶地板层状结构的成型方法，其中：该基板为三层结构，其位于最下层的第一基板层为PVC材料不含可塑剂，呈现硬质特性，中间的第二基板层为PVC材料添加发泡剂，呈现弹性特性，而最上层的第三基板层为不含可塑剂的PVC材料，呈现硬质特性，使地板尺寸保持稳定。
所述的塑胶地板层状结构的成型方法，其中：该基板为三层结构，其位于最下层的第一基板层为PVC材料含可塑剂，呈现软质特性，中间的第二基板层为PVC材料添加发泡剂，呈现有弹性特性，而最上层的第三基板层为不含可塑剂的PVC材料，呈现有硬质特性，以增进脚踏触感。
所述的塑胶地板层状结构的成型方法，其中：该基板为三层结构，其位于最下层的第一基板层为PVC材料含可塑剂，呈现软质特性，中间的第二基板层为PVC材料不添加发泡剂，不添加可塑剂，呈现有刚性特性，而最上层的第三基板层为可塑剂的PVC材料，呈现有弹性特质。
所述的塑胶地板层状结构的成型方法，其中：该基板为三层结构，其位于最下层的第一基板层为PVC材料添加可塑剂，呈现软质特性，中间的第二基板层为PVC材料以气体添加产生发泡体，不含任何发泡剂，呈现有弹性特性，而最上层的第三基板层为含可塑剂的PVC材料，呈现软质特性，使整体地板尺寸稳定且具有弹性。
所述的塑胶地板层状结构的成型方法，其中：该基板底部设一底材，该底材为PVC薄膜，并依客户需求设计有花纹，达到止滑、减少噪音效果。
所述的塑胶地板层状结构的成型方法，其中：该卷送设备包括一耐磨层放卷机构、印刷层放卷机构、耐磨层贴合机构、印刷层贴合机构及导引机构，该耐磨层利用该耐磨层放卷机构搭配耐磨层贴合机构输卷送至该辊压单元，而该印刷层利用该印刷层放卷机构配合印刷层贴合机构及导引机构卷送至该辊压单元。
所述的塑胶地板层状结构的成型方法，其中：该辊压单元为一四辊压延机，其构成包含一机架以及由下往上依序设于该机架上的第一输送辊、第二输送辊、镜面辊及花纹辊，该基板经由该第一输送辊、第二输送辊之间导入该辊压单元，再顺着该第二输送辊向上通过该镜面辊与花纹辊之间，同时该印刷层及耐磨层在该基板通过该镜面辊与花纹辊间之前，利用该卷送设备的输送，令该印刷层叠设于该基板之上，而该耐磨层则叠设于该印刷层之上，进而当该上下相叠的基板、耐磨层与印刷层通该镜面辊与花纹辊之间时，能够被该辊压单元辊压粘合为一体。
所述的塑胶地板层状结构的成型方法，其中：该辊压单元为一五辊压延机，其构成包含一机架以及沿水平方向设于该机架上的第一输送辊、第二输送辊、一镜面辊、二花纹辊以及若干导辊及压辊，该基板挤出型后输送至该二输送辊之间，再经由第三导辊导入该镜面辊的辊压行程，而该印刷层经由第四导辊及第三压辊导入该镜面辊的辊压行程，该耐磨层则经由第五导辊及第四压辊导入该镜面辊的辊压行程，令该基板、印刷层及耐磨层于该镜面辊的辊压行程中上下相叠粘合，之后再经由第六导辊导入该二花纹辊的辊压行程，令该基板、印刷层及耐磨层被该辊压单元辊压粘合为一体。
与现有技术相比较，本发明具有的有益效果是：该基板以共挤方式一体成型多层结构，可具有不同软硬度的第一基板层、第二基板层及第三基板层，该些基板层都以PVC为主原料，分别依需求添加或不添加可塑剂或发泡剂等副原料，例如其位于最下层的第一基板层可为PVC材料不含可塑剂，呈现软质特性，中间的第二基板层可为PVC材料添加发泡剂，呈现弹性特性，而最上层的第三基板层可为不含可塑剂的PVC材料，呈现硬质特性，使地板尺寸保持稳定。其次该印刷层形成于该基板上，而该耐磨层形成于该印刷层上。该基板、印刷层及耐磨层的成型方法，该基板在共挤成型后，与该印刷层及耐磨层利用一卷送设备分别输送至一辊压单元，利用该辊压单元将该基板、印刷层及耐磨层辊压粘合固定为一体，使塑胶地板的具有多种不同软硬度的层状结构，同时自动化制造更具效率且环保。
有关本发明所采用的技术、手段及其功效，兹举一较佳实施例并配合图式详细说明于后，相信本发明上述的目的、构造及特征，当可由的得一深入而具体的了解。
附图说明
图1是本发明卷送设备及四辊式辊压单元的组合平面图。
图2是本发明五辊式的辊压单元组合平面图。
图3是本发明挤出机的挤出示意图。
图4是本发明第一种基板层状结构平面图。
图5是本发明第二种基板层状结构平面图。
图6是本发明第三种基板层状结构平面图。
图7是本发明第四种基板层状结构平面图。
图8是本发明第五种基板层状结构平面图。
图9是本发明第六种基板层状结构平面图。
图10是本发明塑胶地板搭配PVC底材的实施例图。
附图标记说明：塑胶地板10；基板11；第一基板层111；第二基板层112；第三基板层113；第四基板层114；第三基板层115；底材116；印刷层12；耐磨层13；挤出机20；挤料头21、22、23；分配器24；卷送设备30；耐磨层放卷机构31；印刷层放卷机构32；耐磨层贴合机构33；印刷层贴合机构34；导引机构35；辊压单元40；机架41；第一输送辊42A；第二输送辊42B；镜面辊43；花纹辊44；第一压辊45；第二压辊46；第一导辊47；第二导辊48；第三导辊51；第四导辊52；第五导辊53；第六导辊54；第三压辊55；第四压辊56。
具体实施方式
请参阅图1-图10所示，本发明塑胶地板层状结构的成型方法，包含一塑胶地板10，该塑胶地板10具有不同软硬材质的层状结构，利用一挤出机20、卷送设备30及辊压单元40以自动化方式制造成型，其中：
该塑胶地板10的构成包括一基板11、印刷层12及耐磨层13；该基板11通过该挤出机20以共挤方式一体成型具有多层结构的膜材，可由不同软硬度的基板层111、112、113所组成，且该些基板层111、112、113在共挤成型时上下重叠粘合为一体。如下所述，该基板11的层状结构于挤出时，可组合的软硬变化结构包括：
如图4所示，该基板11可为二层结构，其位于下层的第一基板层111可为PVC材料添加可塑剂，而呈现软质特性，而位于上层的第二基板层112可为不含可塑剂的PVC材料，呈现硬质特性。
或者，如图5所示，该基板11可为三层结构，其位于最下层的第一基板层111可为PVC材料不含可塑剂，呈现硬质特性，中间的第二基板层112可为PVC材料添加发泡剂，呈现弹性特性，而最上层的第三基板层113可为不含可塑剂的PVC材料，呈现硬质特性，使地板尺寸保持稳定。
或者，如图6所示，该基板11可为三层结构，其位于最下层的第一基板层111可为PVC材料含可塑剂，呈现软质特性，中间的第二基板层112可为PVC材料添加发泡剂，呈现有弹性特性，而最上层的第三基板层113可为不含可塑剂的PVC材料，呈现有硬质特性，以增进脚踏触感。
或者，如图7所示，该基板11可为三层结构，其位于最下层的第一基板层111可为PVC材料含可塑剂，呈现软质特性，中间的第二基板层112可为PVC材料不添加发泡剂，不添加可塑剂，呈现有刚性特性，而最上层的第三基板层113为含可塑剂的PVC材料，呈现有软质特性。
或者，如图8所示，该基板11可为三层结构，其位于最下层的第一基板层111可为PVC材料添加可塑剂，呈现软质特性，中间的第二基板层112可为PVC材料以气体添加产生发泡体，不含任何发泡剂，呈现有弹性特性，而最上层的第三基板层113可为含可塑剂的PVC材料，呈现软质特性，使整体地板尺寸稳定且具有弹性。
或者，如图9所示，该基板11可为五层结构，其位于最下层的第一基板层111可为PVC材料添加可塑剂，呈现软质特性，位于下方第二层的第二基板层112可为PVC材料添加发泡剂，呈现有弹性特性，而位于下方第三层的第三基板层113为不添加发泡剂及可塑剂的PVC材料，呈现有硬质特性；再者从下方起算第四层的第四基板层114可为PVC材料添加发泡剂，呈现有弹性特性，而最上层的第五基板层115则为不添加发泡剂及可塑剂的PVC材料，呈现有硬质特性，使塑胶地板10的整体更具有硬中透软的使用特点。
综合上述实施例，如图10所示，该基板底11部可设一底材116，该底材可为PVC薄膜，并可依客户需求设计不同花纹，达到止滑，减少噪音效果。
该印刷层12表面印刷有预设图案或纹路的薄膜，设于该基板11上缘面。
该耐磨层13是透明薄膜，设于该印刷层12上，具有耐磨抗刮的特性。
该挤出机20是一般的塑料挤出机器，依照该基板11所需的层状结构，具有若干对应层数的挤料头21、22、23，针对不同配方材料的基板层进行挤出作业。原则上一个挤料头可产生一种配方的基板层，二个挤料头利用分配器24分配，可使基板11作三种层状结构的排列，而三个挤料头利用分配器24分配，则可作五种层状结构的排列组合
该卷送设备30设于该辊压单元40上方及外侧周围，包括一用于卷绕耐磨层13的耐磨层放卷机构31、一可卷绕印刷层12的印刷层放卷机构32、一用于压抵耐磨层13的耐磨层贴合机构33、一用于压抵印刷层12的印刷层贴合机构34及引导该印刷层12的导引机构35。该耐磨层13利用该耐磨层放卷机构32搭配耐磨层贴合机构34输卷送至该辊压单元40，而该印刷层12利用该印刷层放卷机构32配合印刷层贴合机构34及导引机构35卷送至该辊压单元40。
该辊压单元40可为一四辊压延机，其构成是一机架41由下往上分别设置第一、第二输送辊42A、42B、一镜面辊43及花纹辊44，用以将经由该挤出机20成型后输送的基板11，以及由该卷送设备30输送的印刷层12及耐磨层13辊压粘合为一体。辊压成型时，该基板11经由该二输送辊42A、42B之间导入该辊压单元40，再顺着该第二输送辊42B向上通过该镜面辊43与花纹辊44之间；同时该印刷层12及耐磨层13在该基板11通过该镜面辊43与花纹辊44间之前，利用该卷送设备30的输送，令该印刷层12叠设于该基板11之上，而该耐磨层13则叠设于该印刷层12之上，进而当该上下相叠的基板11、印刷层12与耐磨层13通该镜面辊43与花纹辊44之间时，可被该辊压单元40辊压粘合为一体。
承上述，为使印刷层12及耐磨层13的卷送稳定，是在该印刷层12自起始位置输送至镜面辊43与花纹辊44压合处之间设一第一压辊45及第二压辊46，以及于该耐磨层13自起始位置输送至镜面辊43与花纹辊44压合处之间设一第一导辊47与第二导辊48。
另外，如图2所示，该辊压单元40可为一五辊压延机，其构成包含一机架41，以及沿水平方向设于该机架41上的第一、第二输送辊42A、42B、一镜面辊43、二花纹辊44，以及若干导辊51、52、53、54及压辊55、56，该基板11经由挤出机20挤出型后，输送至该二输送辊42A、42B之间，再经由第三导辊51导入该镜面辊43的辊压行程，而该印刷层12经由第四导辊52及第三压辊55导入该镜面辊43的辊压行程，该耐磨层13则经由第五导辊53及第四压辊56导入该镜面辊43的辊压行程，令该基板11、印刷层12及耐磨层43于该镜面辊43的辊压行程中上下相叠粘合，之后再经由第六导辊54导入该二花纹辊44的辊压行程，令该基板11、印刷层12及耐磨层13被该辊压单元40辊压粘合为一体。
凭借上述的制程方法而成型的塑胶地板10，不仅能具有软硬及弹性等层状结构，而能提供更舒适且品质稳定的使用效果，同时成型时以自动化设备完成，并不须以传统胶水粘合各个结构层，因此生产效率佳，且更符合环保概念。
综上所述，本发明在同类产品中实有其极佳的进步实用性，同时遍查国内外关于此类结构的技术资料、文献中也未发现有相同的构造存在在先，是以本发明实已具备专利要件，爰依法提出申请。
以上说明对本发明而言只是说明性的，而非限制性的，本领域普通技术人员理解，在不脱离本申请所限定的精神和范围的情况下，可作出许多修改、变化或等效，但都将落入本发明的保护范围之内。

Claims (10)

1.一种塑胶地板层状结构的成型方法，其特征在于：该塑胶地板至少包含一基板、印刷层及耐磨层，其中：
该基板以共挤方式一体成型多层结构，至少具有不同软硬度的第一基板层及第二基板层，且所有基板层在共挤成型时，呈上下重叠粘合为一体；
该印刷层形成于该基板上缘，其表面印刷有预设的图案或纹路；
该耐磨层形成于该印刷层上；
该基板在共挤成型后，与该印刷层及耐磨层利用一卷送设备分别输送至一辊压单元，利用该辊压单元将该基板、印刷层及耐磨层辊压粘合固定为一体，使塑胶地板的具有多种不同软硬度的层状结构。
2.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板为二层结构，其位于下层的第一基板层为PVC材料添加可塑剂，而呈现软质特性，而位于上层的第二基板层为不含可塑剂的PVC材料，呈现硬质特性。
3.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板为三层结构，其位于最下层的第一基板层为PVC材料不含可塑剂，呈现硬质特性，中间的第二基板层为PVC材料添加发泡剂，呈现弹性特性，而最上层的第三基板层为不含可塑剂的PVC材料，呈现硬质特性，使地板尺寸保持稳定。
4.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板为三层结构，其位于最下层的第一基板层为PVC材料含可塑剂，呈现软质特性，中间的第二基板层为PVC材料添加发泡剂，呈现有弹性特性，而最上层的第三基板层为不含可塑剂的PVC材料，呈现有硬质特性，以增进脚踏触感。
5.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板为三层结构，其位于最下层的第一基板层为PVC材料含可塑剂，呈现软质特性，中间的第二基板层为PVC材料不添加发泡剂，不添加可塑剂，呈现有刚性特性，而最上层的第三基板层为可塑剂的PVC材料，呈现有弹性特质。
6.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板为三层结构，其位于最下层的第一基板层为PVC材料添加可塑剂，呈现软质特性，中间的第二基板层为PVC材料以气体添加产生发泡体，不含任何发泡剂，呈现有弹性特性，而最上层的第三基板层为含可塑剂的PVC材料，呈现软质特性，使整体地板尺寸稳定且具有弹性。
7.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该基板底部设一底材，该底材为PVC薄膜，并依客户需求设计有花纹，达到止滑、减少噪音效果。
8.根据权利要求1所述的塑胶地板层状结构的成型方法，其特征在于：该卷送设备包括一耐磨层放卷机构、印刷层放卷机构、耐磨层贴合机构、印刷层贴合机构及导引机构，该耐磨层利用该耐磨层放卷机构搭配耐磨层贴合机构输卷送至该辊压单元，而该印刷层利用该印刷层放卷机构配合印刷层贴合机构及导引机构卷送至该辊压单元。
9.根据权利要求1或5所述的塑胶地板层状结构的成型方法，其特征在于：该辊压单元为一四辊压延机，其构成包含一机架以及由下往上依序设于该机架上的第一输送辊、第二输送辊、镜面辊及花纹辊，该基板经由该第一输送辊、第二输送辊之间导入该辊压单元，再顺着该第二输送辊向上通过该镜面辊与花纹辊之间，同时该印刷层及耐磨层在该基板通过该镜面辊与花纹辊间之前，利用该卷送设备的输送，令该印刷层叠设于该基板之上，而该耐磨层则叠设于该印刷层之上，进而当该上下相叠的基板、耐磨层与印刷层通该镜面辊与花纹辊之间时，能够被该辊压单元辊压粘合为一体。
10.根据权利要求1或5所述的塑胶地板层状结构的成型方法，其特征在于：该辊压单元为一五辊压延机，其构成包含一机架以及沿水平方向设于该机架上的第一输送辊、第二输送辊、一镜面辊、二花纹辊以及若干导辊及压辊，该基板挤出型后输送至该二输送辊之间，再经由第三导辊导入该镜面辊的辊压行程，而该印刷层经由第四导辊及第三压辊导入该镜面辊的辊压行程，该耐磨层则经由第五导辊及第四压辊导入该镜面辊的辊压行程，令该基板、印刷层及耐磨层于该镜面辊的辊压行程中上下相叠粘合，之后再经由第六导辊导入该二花纹辊的辊压行程，令该基板、印刷层及耐磨层被该辊压单元辊压粘合为一体。
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