CN109605770A - 一种软木石塑地板的生产工艺 - Google Patents
一种软木石塑地板的生产工艺 Download PDFInfo
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Abstract
本发明提供一种软木石塑地板的生产工艺,该工艺包括如下步骤:步骤1)、石塑板的制备:混料‑挤塑‑压延贴面;步骤2)、UV、回火处理:步骤3)粘贴软木层;通过软木与石塑地板的结合,不但可以辅助提高石塑地板的厚实感,使地板具有一定弹性,踩起来更舒适,脚感更好,还可以通过软木的吸音、隔音功能,赋予石塑地板的静音作用。
Description
技术领域
本发明属于地板领域,具体涉及一种石塑地板,尤其涉及一种软木石塑地板的生产工艺。
背景技术
石塑地板是基于高科技开发出的新型环保型地板,其主成分是70%~80%的石粉加20%~30%的聚氯乙烯,SPC地板是由挤出机结合T型模具挤出PVC的基材,经四辊压延机组分别把PVC耐磨层、PVC彩膜和PVC底膜,一次性压贴复合而成的产品。
石塑地板是100%不含甲醛和重金属的环保地板,无毒无味,不怕水、不怕火、不怕潮,具有出色的稳定性和耐用性。普通实木复合地板或强化木地板,都存在一定的甲醛问题,不耐水泡,尺寸变化后还会出现响声。与实木复合地板相比,石塑地板的优势是价格低廉、防水防火、不易变形、耐磨;与强化地板相比,石塑地板的优势是,甲醛含量低,阻燃、防水;与大理石、瓷砖相比,石塑地板的优势是安装简单、可重复使用、在原有地面上可以直接铺装而不压缩空间。石塑地板既解决了木质地板受潮变形霉烂的问题,解决了装修材料的甲醛等污染问题,又解决了大理石、瓷砖易碎、笨重、难铺装的问题。石塑地板由于其耐磨、环保、经济、易于拼装打理等优点,适用于机场、酒店、商场、写字楼、医院,学校等公共场所领域。
然而石塑地板密度大、重量重,地板脚感硬,整体厚度偏薄,对于习惯了木质地板和瓷砖的室内家装市场的消费者,还需要对石塑地板的功能性进一步提升。
发明内容
为了解决以上问题,本发明提供一种软木石塑地板,软木是以优质天然软木为原料,经过粉碎、热压而成板材,再通过机械设备加工而成。通过软木与石塑地板的结合,不但可以辅助提高石塑地板的厚实感,使地板具有一定弹性,踩起来更舒适,脚感更好,还可以通过软木的吸音、隔音功能,赋予石塑地板的静音作用。
为了实现上述发明目的,本发明提供一种软木石塑地板的生产工艺,该工艺包括如下步骤:
步骤1)、石塑板的制备:
混料:将制作石塑板的配料投入混料机,将高速混合机热混温度控制在125~130℃,去除原材料中的水分,随后进入冷混,冷混温度控制在35~55℃;
挤塑:通过冷却混合均匀的材料加入双螺杆挤出机,进行加热挤出,物料进入螺杆料筒后通过加温碾压进行塑化,温度设定由刚进入料筒的190~210℃后逐渐递减到料筒末端的165~195℃;物料塑化完成后,强压挤出,推向片材模具成型,片材模具温度在185~205℃之间;
压延贴面:成型的片材进入四辊压延机,由一辊、二辊进行辊压,确保其厚度均匀且达标,随后进入牵引机进行冷却,经剪板机进行长度、宽度定尺后堆垛养生;
步骤2)、UV、回火处理:
将步骤1)获得的养生好的整块片材放入传送带,经粉尘清除机、热风干燥机除尘升温后,由涂布机在片材表面均匀地涂上一层水性UV底漆,之后进入UV干燥机进行固化;然后再涂布一层水性UV面漆,经加热流平机、UV干燥机进行烘烤,涂料充分固化之后,将地板进行快速冷却后,常温常态养生;
步骤3)粘贴软木层:
将步骤2)获得板材放入自动上料机,经除尘系统将板面进行涂胶之前的除尘处理,经除尘毛刷去除板面灰尘后进行涂胶,通过单面涂胶机在石塑地板底面均匀涂布一层热熔胶,经热风加热隧道加热,以辊压的方式,将成卷的软木经复合压贴机粘贴于石塑地板背面,后经软木裁断机,将多余的软木去除。
进一步优选地,步骤3)中,所述的热熔胶为PUR热熔胶,通过自动供胶系统、模温机将胶液输送到涂布辊并保证胶液温度在110~140℃之间进行涂布作业。
更进一步优选地,所述的步骤1)的压延贴面工序中,成型的片材进入四辊压延机,由一辊、二辊进行辊压后,利用片材自身的温度与辊筒加热将彩膜层和耐磨层假性贴合,并送往三辊、四辊压纹,随后进入牵引机进行冷却,经剪板机进行长度、宽度定尺后堆垛养生;
再进一步地,所述的配料按重量百分比计算包括如下组份:聚氯乙烯(PVC)100份,重质碳酸钙300份,钙锌稳定剂8份,PE蜡0.8~1份,内润滑剂0.8~1份,抗冲改性剂5~8份,色素炭黑0.2~0.3份,回料50~80份
基于以上的生产工艺,本发明获得了一种软木石塑地板,该软木石塑地板从上到下依次包括水性UV漆层、耐磨层、彩膜层、石塑基材层、软木层组成。
石塑基材层通过挤压成型,具有零甲醛、防蛀、防腐蚀、防水、不变形等特点;
彩膜层位于基材层的上表面,主要起装饰作用;
耐磨层位于彩膜层上表面,主要起到耐磨作用;
水性UV漆层位于耐磨层上表面,主要起到防污、易于打理的目的,同时地板坯料通过加热、UV回火处理后,尺寸更稳定。水性UV漆主要起到防污、易于打理、耐磨的目的,相比油性漆,只以清水作为稀释剂,不含苯、甲苯、二甲苯、甲醛、游离TDI、重金属等有毒有害物质,可最大限度地减少对自然环境污染和对人体健康的危害。由于不含有害物质,不会向空气中挥发,因此也不会有易黄变等缺陷,更持久如新。软木层位于基材层下表面,提高软木石塑地板的弹性,解决了石塑地板脚感偏硬的问题,同时软木层多孔结构,该软木石塑地板还具有一定的吸音、静音作用。该软木石塑地板具有环保、阻燃、耐磨、消音、导热等一系列优势。
另外,在本发明提供的生产工艺中,软木和石塑地板基材的粘贴选用PUR热熔胶,即单组份反应型聚氨酯热熔胶。其特点是,热熔胶在发生物理固化后,会和环境中的水分继续作用,发生化学交联反应。交联反应后生成具有高内聚力的高分子聚合物,一旦固化,具有很好的防水性,耐化学腐蚀性和极高的耐候性。
软木可以提高软木石塑地板的弹性,增加行走的舒适度,解决了石塑地板脚感偏硬的问题;同时软木层由于其特殊的结构,还具有一定的吸音、静音作用,显著降低地板对楼下和室内的噪音干扰。由于软木的使用,使软木石塑地板的保温性能更好,当室温达到一定温度后,室内恒温持续的时间较长,适用于暖气和各种地暖房间的使用。
附图说明
图1为本发明提供的软木石塑地板的剖面示意图。
具体实施方式
实施例1一种软木石塑地板的生产工艺
步骤1)、石塑板的制备:
混料:将原材料按配方比例投入混料机,其它加工助剂需单独计量混配后一起投入投料站并通过真空上料机吸进料罐,随后将原材料和助剂在高速混合机热混温度控制在125~130℃,作用是各种材料混合均匀,将加工助剂融化,排除原材料中的水分,随后进入冷混,给物料降温,防止结块和变色,冷混温度控制在35~55℃;
其中,上述所述的配方在本实施例为聚氯乙烯(PVC)100份,重质碳酸钙300份,钙锌稳定剂8份,PE蜡0.8~1份,内润滑剂0.8~1份,抗冲改性剂5~8份,色素炭黑0.2~0.3份,回料50~80份。其配方环保,不含重金属、邻苯二甲酸酯、甲醇等有害物质,且具有其出色的尺寸稳定性和耐用性。
挤塑:通过冷却混合均匀的材料加入双螺杆挤出机,进行加热挤出,物料进入螺杆料筒后通过加温碾压进行塑化,在此过程中温控是关键环节,温度设定由刚进入料筒的190~210℃后逐渐递减到料筒末端的165~195℃。物料塑化完成后,经强大背压挤出,推向片材模具成型,片材模具温度在185~205℃之间。
压延贴面:成型的片材进入四辊压延机,由一辊、二辊进行辊压,确保其厚度均匀且达标,随后,利片材自身的温度与辊筒加热将彩膜和耐磨层假性贴合,并送往三辊、四辊压纹,随后进入牵引机进行冷却,经剪板机进行长度、宽度定尺后堆垛养生。
步骤2)、UV、回火处理:
将养生好的整块片材放入传送带,经粉尘清除机、热风干燥机除尘升温后,由涂布机在片材表面均匀地涂上一层水性UV底漆,之后进入UV干燥机进行固化。然后再涂布一层水性UV面漆,经加热流平机、UV干燥机进行烘烤,涂料充分固化之后,将地板进行快速冷却,最后放入常温常态下养生。
在这个过程中水性UV漆会辊涂两次,采用一底一面工艺,UV漆的目的是满足防污、易于打理的需求;同时,通过面漆的调节,可以控制地板表面光泽度达到客户的要求。通过流水线上的加热和冷却的回火处理,对石塑地板的收缩和翘曲进行工艺上的加强。
实验数据表明:经过回火处理的石塑地板收缩率:≤1‰;没有经过回火处理的石塑地板收缩率≤2.5‰。
步骤3)、粘贴软木层
自动上料机,除尘系统,涂胶机,加热隧道,软木卷材输送机,复合压贴机,裁断修边系统,码垛输板系统组成。
将石塑板放入自动上料机,经除尘系统将板面进行涂胶之前的除尘处理(用加湿喷雾加毛刷辊,抗静电、便于粉尘的收集),经除尘毛刷去除板面灰尘后进行涂胶,地板通过单面涂胶机在地板底面均匀涂布一层PUR热熔胶,经热风加热隧道加热,以辊压的方式,将成卷的软木经复合压贴机粘贴于石塑地板背面,后经软木裁断机,长度、宽度修边裁切装置等将多余的软木去除。
通过加热隧道对涂胶地板进行加热,可以使胶水更加均匀,同时保持板面胶水适宜的温、湿度,延长胶黏剂开放时间,便于增强后期的黏合效果。涂胶机包括熔胶机、自动供胶系统,模温机等,PUR热熔胶一般为白色至淡黄色固体,经熔胶机在140℃左右将其熔为液体,通过自动供胶系统、模温机将胶液输送到涂布辊并保证胶液温度在110~140℃之间进行涂布作业。同时,控制车间温度23-25℃,相对湿度65%左右。
步骤4)、分切、开槽:
将整张大板经多片锯裁切成地板规格需要的尺寸,并进行养生处理。养生后将分切好的地板进行开榫槽。
根据本实施例提供的软木石塑地板生产工艺得到的石塑地板结构如图1所示,石塑基材层是由聚氯乙烯树脂、石粉及各种加工助剂通过混料、挤出而得。厚度在3.0~4.5mm之间。其配方环保,不含重金属、邻苯二甲酸酯、甲醇等有害物质,且具有其出色的尺寸稳定性和耐用性。
彩膜层厚度为0.07mm,耐磨层厚度为0.1~0.7mm,彩膜层和耐磨层都是一层PVC膜,具有高抗光性和耐火性。彩膜层通过机器印刷而得,色泽自然、色彩华丽、图案丰富多样、式样典雅。耐磨层位于彩膜层上表面,耐磨层的厚度,决定了地板的耐磨转数。
水性UV漆位于耐磨层的上表面,漆膜厚度在0.02~0.1mm之间,主要起到防污、易于打理、耐磨的目的,相比油性漆,只以清水作为稀释剂,不含苯、甲苯、二甲苯、甲醛、游离TDI、重金属等有毒有害物质,可最大限度地减少对自然环境污染和对人体健康的危害。由于不含有害物质,不会向空气中挥发,因此也不会有易黄变等缺陷,更持久如新。
同时,在水性UV涂饰过程中,地板坯料通过热风干燥机、UV干燥机升温,然后进行快速冷却的回火处理,回火处理后,尺寸更稳定。实验数据表明:经过回火处理的石塑地板收缩率:≤1‰;没有经过回火处理的石塑地板收缩率≤2.5‰。
软木层位于基材层下表面,厚度在1~3mm之间,可以提高软木石塑地板的弹性,增加行走的舒适度,解决了石塑地板脚感偏硬的问题;同时软木层由于其特殊的结构,还具有一定的吸音、静音作用,显著降低地板对楼下和室内的噪音干扰。由于软木的使用,使软木石塑地板的保温性能更好,当室温达到一定温度后,室内恒温持续的时间较长,适用于暖气和各种地暖房间的使用。
由于软木的多孔性及石塑表面非常光洁,且软木石塑地板要保证很好的防水性,软木和石塑地板基材的粘贴选用PUR热熔胶,即单组份反应型聚氨酯热熔胶。其特点是,热熔胶在发生物理固化后,会和环境中的水分继续作用,发生化学交联反应。交联反应后生成具有高内聚力的高分子聚合物,一旦固化,具有很好的防水性,耐化学腐蚀性和极高的耐候性。
Claims (4)
1.一种软木石塑地板的生产工艺,其特征在于:该工艺包括如下步骤:
步骤1)、石塑板的制备:
混料:将制作石塑板的配料投入混料机,将高速混合机热混温度控制在125~130℃,去除原材料中的水分,随后进入冷混,冷混温度控制在35~55℃;
挤塑:通过冷却混合均匀的材料加入双螺杆挤出机,进行加热挤出,物料进入螺杆料筒后通过加温碾压进行塑化,温度设定由刚进入料筒的190~210℃后逐渐递减到料筒末端的165~195℃;物料塑化完成后,强压挤出,推向片材模具成型,片材模具温度在185~205℃之间;
压延贴面:成型的片材进入四辊压延机,由一辊、二辊进行辊压,确保其厚度均匀且达标,随后进入牵引机进行冷却,经剪板机进行长度、宽度定尺后堆垛养生;
步骤2)、UV、回火处理:
将步骤1)获得的养生好的整块片材放入传送带,经粉尘清除机、热风干燥机除尘升温后,由涂布机在片材表面均匀地涂上一层水性UV底漆,之后进入UV干燥机进行固化;然后再涂布一层水性UV面漆,经加热流平机、UV干燥机进行烘烤,涂料充分固化之后,将地板进行快速冷却后,常温常态养生;
步骤3)、粘贴软木层:
将步骤2)获得板材放入自动上料机,经除尘系统将板面进行涂胶之前的除尘处理,经除尘毛刷去除板面灰尘后进行涂胶,通过单面涂胶机在石塑地板底面均匀涂布一层热熔胶,经热风加热隧道加热,以辊压的方式,将成卷的软木经复合压贴机粘贴于石塑地板背面,后经软木裁断机,将多余的软木去除。
2.根据权利要求1所述的软木石塑地板的生产工艺,其特征在于:步骤3)中,所述的热熔胶为PUR热熔胶,通过自动供胶系统、模温机将胶液输送到涂布辊并保证胶液温度在110~140℃之间进行涂布作业。
3.根据权利要求1所述的软木石塑地板的生产工艺,其特征在于:所述的步骤1)的压延贴面工序中,成型的片材进入四辊压延机,由一辊、二辊进行辊压后,利用片材自身的温度与辊筒加热将彩膜层和耐磨层假性贴合,并送往三辊、四辊压纹,随后进入牵引机进行冷却,经剪板机进行长度、宽度定尺后堆垛养生。
4.根据权利要求1所述的软木石塑地板的生产工艺,其特征在于:所述的配料按重量百分比计算包括如下组份:聚氯乙烯(PVC)100份,重质碳酸钙300份,钙锌稳定剂8份,PE蜡0.8~1份,内润滑剂0.8~1份,抗冲改性剂5~8份,色素炭黑0.2~0.3份,回料50~80份。
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CN113002095A (zh) * | 2021-03-10 | 2021-06-22 | 潘国益 | 一种pvc材质的aba结构地板及生产工艺 |
CN113246565A (zh) * | 2021-05-08 | 2021-08-13 | 福建思嘉新材料科技有限公司 | 一种新型底贴布pvc弹性地板及其加工方法和装置 |
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