CN109421286B - 塑胶发泡地板的制造设备 - Google Patents

塑胶发泡地板的制造设备 Download PDF

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CN109421286B
CN109421286B CN201710780384.7A CN201710780384A CN109421286B CN 109421286 B CN109421286 B CN 109421286B CN 201710780384 A CN201710780384 A CN 201710780384A CN 109421286 B CN109421286 B CN 109421286B
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layer
roller
wear
substrate layer
substrate
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CN109421286A (zh
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陆钉毅
赵培东
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Lu Dingyi
Wuxi Boyu Plastic Machinery Co ltd
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Priority to CN201710780384.7A priority Critical patent/CN109421286B/zh
Priority to US15/871,154 priority patent/US10870266B2/en
Priority to EP18160049.5A priority patent/EP3450165A1/en
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    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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Abstract

本发明提供一种塑胶发泡地板的制造设备，是将塑胶地板的基板层利用一挤出单元发泡挤出成型后，再利用一定厚单元冷却定厚，进而令该基板层、印刷层及耐磨层通过一辊压成型设备辊压粘合为一体，如此能使塑胶地板具有发泡成型的软质特性，且该基板层与印刷层、耐磨层通过辊压热熔粘合，不须通过胶水粘合固定，具有环保特性，并能增进生产效率。

Description

塑胶发泡地板的制造设备
技术领域
本发明涉及一种以塑胶地板，特别是针对以发泡方式成型基板层的塑胶地板的制造设备及成型方法。
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，塑胶地板的基板部份，有发泡或非发泡的材质结构，发泡后的基板较软且具弹性，但发泡的基板必须以胶水方能和印刷层粘合固定，因此不仅生产效率及品质较差，且胶水的使用也不具环保性，而有加以改善的必要。
有鉴于此，本发明设计人乃针对前述现有技术的问题深入探讨，并凭借多年从事相关产业的研发与制造经验，积极寻求解决的道，经过长期努力的研究与发展，终于成功的开发出本发明塑胶发泡地板的基板制造设备及其成型方法，以改善现有产品的问题。
发明内容
本发明的主要目的，提供一种塑胶发泡地板的基板及其制造设备与成型方法，其令塑胶地板的基板以发泡方式成型，并能利用热熔粘合方式与印刷层、耐磨层粘合固定，据以增进塑胶地板的成型效率及品质，并能符合环保特性。
缘于达成上述的发明目的，本发明提供：
一种塑胶发泡地板的基板制造设备，其特征在于，其构成包含：
一挤出单元，一端设有一挤出口，用以将塑料发泡成型后，经由该挤出口向外挤出成型一发泡的基板层；
一定厚单元，设于对应该挤出口的外侧，该定厚单元具有一置入口，内侧通道可供该基板层通过，并具有一冷却组件，用以将该基板层降温，以确保其板厚；
一辊压成型设备，包括一印刷层卷送机、耐磨层卷送机以及一辊压机，该印刷层卷送机能够将一印刷层输送至该辊压机，该耐磨层卷送机用以将一耐磨层输送至该辊压机，该辊压机设于相邻该定厚单元一侧，至少具有一预贴辊及压合辊，该预贴辊用以将该基板层、印刷层及耐磨层作辊压前的预贴，并通过一加热单元对该基板层、印刷层及耐磨层进行加热，再利用该压合辊将该基板层、印刷层及耐磨层辊压粘合固定。
所述的塑胶发泡地板的基板制造设备，其中：该挤出单元为一挤出机，用以挤出单层的基板层，或者为由两个以上的挤出机所构成，而以共挤方式型成多层且不同软硬度的基板层。
所述的塑胶发泡地板的基板制造设备，其中：该定厚单元由若干二二相对的滚轴构成，相邻的滚轴被马达带动转动，且各该滚轴内设一冷却管路，可供冷却水流循环流动，以构成该冷却组件。
所述的塑胶发泡地板的基板制造设备，其中：该基板层的塑料发泡为物理或化学发泡，且其发泡倍率能够视耐磨层厚度进行调配。
所述的塑胶发泡地板的基板制造设备，其中：该加热单元由若干循环管路组成，该若干循环管路分别设于该预贴辊及压合辊内，利用该若干循环管路配合外部装置循环热油进行加热；或者，该加热单元设于对应该预贴辊外围适当处，由一罩体内设一电热器而构成，该电热器通电后能产生高温。
一种塑胶发泡地板的基板成型方法，其特征在于，其步骤包含：
A．发泡成型一基板层，利用一挤出单元将塑料发泡后，向外挤出成型一基板层；
B．基板层冷却定厚，令该基板层输送通过一定厚单元，用以将该基板层定厚，并进行冷却降温；
C．基板层预贴，将该基板层输送至一辊压机，与印刷层及耐磨层进行预贴；
D．印刷层预贴，利用一印刷层卷送机将印刷层卷送至该辊压机进行预贴；
E．耐磨层预贴，利用一耐磨层卷送机将耐磨层卷送至该辊压机进行预贴；
F．预贴加热，利用一加热单元于该基板层、印刷层及耐磨层进行预贴时进行加热软化；
G．辊压粘合，利用该辊压机将软化后的基板层、印刷层及耐磨层辊压成型，使其粘合为一体，而可作为塑胶发泡地板的成品。
所述的塑胶发泡地板的基板成型方法，其中：该挤出单元为一挤出机，用以挤出单层的基板层，或者由二以上的挤出机所构成，而以共挤方式型成多层且不同软硬度的基板层。
所述的塑胶发泡地板的基板成型方法，其中：该定厚单元由若干二二相对的滚轴构成，相邻的滚轴被马达带动转动，且各该滚轴内设一冷却管路，可供冷却水流循环流动，以构成该冷却组件。
所述的塑胶发泡地板的基板成型方法，其中：该辊压机为四辊或五辊结构，具有一输送辊、预贴辊及压合辊，该输送辊用以卷送该基板层并作第二次定厚，而该预贴辊用以将该基板层、印刷层及耐磨层作辊压前的预贴，再利用该压合辊将该基板层、印刷层及耐磨层辊压粘合固定，又该加热单元由若干循环管路组成，该若干循环管路分别设于该输送辊、预贴辊及压合辊内，利用该若干循环管路配合外部装置循环热油进行加热。
一种塑胶发泡地板的基板，其特征在于，其构成包含：
一基板层，该基板层以塑料发泡成型；
一印刷层，热压粘合于该基板层上；
一耐磨层，热压粘合于该印刷层上。
所述的塑胶发泡地板的基板，其中：该基板层为单层发泡结构，或至少二层结构，且其中一层为发泡，另一层非发泡结构。
如此，利用塑胶地板的基板层发泡成型后，再利用该辊压机与印刷层、耐磨层热压粘合固定，达到不须通过胶水粘合便可制成具发泡基板的塑胶地板，不仅能增进塑胶地板的生产效率及品质，更使其符合环保特性。
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，当可由之得一深入而具体的了解。
附图说明
图1是本发明搭配四辊式辊压机的制造设备组合平面图。
图2是本发明搭配五辊式辊压机的制造设备组合平面图。
图3是本发明基板层单层发泡的组合剖面图。
图4是本发明基板层双层结构的组合剖面图。
图5是本发明单层基板层搭配底垫层的组合剖面图。
附图标记说明：基板层11、11’；第一基板层111；第二基板层112；印刷层12；耐磨层13；底垫层14；挤出单元20；挤出口21；定厚单元30；滚轴31；置入口311；冷却组件32；冷却管路321；辊压成型设备40；印刷层卷送机41；耐磨层卷送机42；底垫层放卷机43；辊压机50；输送辊51；预贴辊52；压合辊53；导辊54、55、56；该加热单元60；循环管路61；电热器62；罩体63。
具体实施方式
请参阅图1～图5所示，本发明塑胶发泡地板的基板制造设备及其成型方法，其系令塑胶地板的基板层11以发泡方式成型，再利用热压方式令该基板层11与印刷层12、耐磨层13粘合固定为一体；其制造设备包含：
一挤出单元20，一端设有一挤出口21，用以将塑料发泡成型后，经由该挤出口21向外挤出成型一发泡的基板层11；其发泡该基板层11的塑料可为PVC或PE，可通过物理化学发泡，且其发泡倍率可视耐磨层13厚度进行调配。又该挤出单元20可为一挤出机，用以挤出单层的基板层11，也可由二以上的挤出机所构成，而以共挤方式型成多层且不同软硬度的基板层11’。
一定厚单元30，设于对应该挤出口21的外侧，可由若干上下二二相对的滚轴31构成，该些上方及下方相邻的滚轴31可被马达图中未显示带动转动，并通过上下相对设置而于外侧区隔出一置入口311，内侧则区隔成可供该基板层11通过的通道，并于该些滚轴31内设一冷却组件32，用以将该基板层11降温，以确保其板厚。该冷却组件32由分别设于各该滚轴31内的冷却管路321组成，可供冷却水流循环流动。
一辊压成型设备40，包括一印刷层卷送机41、耐磨层卷送机42，以及一辊压机50，该印刷层卷送机41是将该印刷层12输送至该辊压机50，该耐磨层卷送机42用以将耐磨层13输送至该辊压机50。该辊压机50设于相邻该定厚单元30一侧，可为直立式四辊结构或水平式五辊结构，其具有一输送辊51、预贴辊52、压合辊53，以及若干设于该预贴辊52外侧的导辊54、55、56，该输送辊51用以卷送该基板层11并作第二次定厚，而该预贴辊52系通过该些导辊54、55、56的辅助，将该基板层11、印刷层12及耐磨层13作辊压前的预贴，且并利用一加热单元60加热后，再通过该压合辊53将该基板层11、印刷层12及耐磨层13辊压粘合固定。
承上述，该加热单元60可由若干循环管路61组成，该辊压机50若是直立式四辊结构时如图1所示，该些循环管路61分别设于该输送辊51、预贴辊52及压合辊53内，利用该些循环管路61配合外部装置图中未显示循环热油进行加热。其次，如图2所示，该辊压机50若是五辊结构时，该预贴辊52设于该辊压机50之机架中间适当处，这些导辊54、55、56设于该机架对应该预贴辊52上方外侧适当处,该循环管路61可设于该预贴辊52内，同时也可于对应该预贴辊52外围适当处设一电热器62，该电热器62系置于一罩体63，通电后能产生高温。
利用上述的机器设备，本发明的制造成型步骤如下：
A．发泡成型基板层11，利用该挤出单元20将塑料发泡后，向外挤出成型一基板层11。
B．基板层11冷却定厚，令该基板层11输送通过该定厚单元30，用以将该基板层11定厚，并通过该冷却组件32进行冷却降温。
C．基板层11预贴，将该基板层11输送至该辊压机50的预贴辊52与印刷层12及耐磨层13进行预贴。
D．印刷层12预贴，利用该印刷层卷送机41将印刷层12卷送至该辊压机50的预贴辊52进行预贴。
E．耐磨层13预贴，利用耐磨层卷送机42将耐磨层13卷送至该辊压机50的预贴辊52进行预贴。
F．预贴加热，利用加热单元60于该基板层11、印刷层12及耐磨层13进行预贴时进行加热，使其材料结构软化。
G．辊压粘合，利用该辊压机50的压合辊53将软化后的基板层11、印刷层12及耐磨层13辊压成型，使其粘合为一体，而可作为塑胶发泡地板的成品。
请参阅图3所示，本发明该基板层11、印刷层12与耐磨层13粘合为一体时，该基板层11可为单层的发泡结构，或者如图4所示，该基板层11可为二层结构，其位于下层的第一基板层111可为PVC材料添加可塑剂及碳酸钙等填充物，而呈现软质特性，而位于上层的第二基板层112可为添加发泡剂产生的发泡体，呈现硬质特性。
另外，如图5，本发明步骤C．基板层11预贴时，该基板层11输送至该辊压机50的预贴辊52时，可于该基板层11底面设一底垫层14，该底垫层14可利用一底垫层放卷机43卷送底垫层14至该预贴辊组52，用以增加塑胶地板使用的舒适度。
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，在不脱离权利要求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 (5)

1.一种塑胶发泡地板的基板制造设备，其特征在于，其构成包含：
一挤出单元，一端设有一挤出口，用以将塑料发泡成型后，经由该挤出口向外挤出成型一发泡的基板层；
一定厚单元，设于对应该挤出口的外侧，该定厚单元具有一置入口，内侧通道可供该基板层通过，并具有一冷却组件，用以将该基板层降温，以确保其板厚；
一辊压成型设备，包括一印刷层卷送机、耐磨层卷送机以及一辊压机，该印刷层卷送机能够将一印刷层输送至该辊压机，该耐磨层卷送机用以将一耐磨层输送至该辊压机，该辊压机设于相邻该定厚单元一侧，为水平式五辊结构，其是一机架上设一输送辊、预贴辊、压合辊、若干导辊，以及一加热单元，该预贴辊设于该机架中间适当处，该输送辊及压合辊分别设于该预贴辊相对的二侧，该加热单元设于该预贴辊内,由若干循环管路组成，该若干循环管路可配合外部装置循环热油进行加热,而该若干导辊设于该机架对应该预贴辊上方外侧适当处，又该输送辊与该定厚单元直线相对，用以将该基板层作第二次定厚，而该预贴辊是用以将来自输送辊的基板层，以及通过该若干导辊导引的印刷层与耐磨层作辊压前的预贴，令该基板层、印刷层及耐磨层依序相叠，并通过加热单元对该基板层、印刷层及耐磨层进行加热，再利用该压合辊将该基板层、印刷层及耐磨层辊压粘合固定。
2.根据权利要求1所述的塑胶发泡地板的基板制造设备，其特征在于：该挤出单元为一挤出机，用以挤出单层的基板层，或者为由两个以上的挤出机所构成，而以共挤方式型成多层且不同软硬度的基板层。
3.根据权利要求1所述的塑胶发泡地板的基板制造设备，其特征在于：该定厚单元由若干二二相对的滚轴构成，相邻的滚轴被马达带动转动，且各该滚轴内设一冷却管路，可供冷却水流循环流动，以构成该冷却组件。
4.根据权利要求1所述的塑胶发泡地板的基板制造设备，其特征在于：该基板层的塑料发泡为物理或化学发泡，且其发泡倍率能够视耐磨层厚度进行调配。
5.根据权利要求1所述的塑胶发泡地板的基板制造设备，其特征在于：该加热单元设于对应该预贴辊外围适当处，由一罩体内设一电热器而构成，该电热器通电后能产生高温。
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