CN109863275B - 无胶无尘复合地板材料产品 - Google Patents
无胶无尘复合地板材料产品 Download PDFInfo
- Publication number
- CN109863275B CN109863275B CN201680088806.8A CN201680088806A CN109863275B CN 109863275 B CN109863275 B CN 109863275B CN 201680088806 A CN201680088806 A CN 201680088806A CN 109863275 B CN109863275 B CN 109863275B
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- CN
- China
- Prior art keywords
- floor
- layer
- glueless
- polyvinyl chloride
- composite flooring
- 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.)
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Links
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Images
Classifications
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Abstract
一种无胶无尘复合地板材料产品，所述无胶无尘复合地板材料产品提供基于聚氯乙烯的地板，所述基于聚氯乙烯的地板具有提供不同的硬度、耐磨性、隔音及装饰性图案品质的层，从而避免使用易受水分影响的压缩粉尘填料，其中各层熔合在一起，从而避免了使用胶或粘合剂的制造复杂性及分层风险，其中快速固化、紫外线固化的顶部涂层提供持久的高性能并缩短及简化可以片形式、本质上连续运行的方式来进行的制造，且能够快速及简单地改变所产生的可选的设计印刷及纹理，并且所述基于聚氯乙烯的地板具有可选的衬料层。
Description
技术领域
本发明提供一种高效地制造并得到持久高性能地板的基于聚氯乙烯的无胶无尘复合地板材料系统。
背景技术
现有的使用压缩粉尘作为芯材的地板（flooring）材料产品易于由于水或其他液体而被损坏并过早失效，尤其是在潮湿的环境中以及在需要频繁清洁的使用时。然而，压缩粉尘芯提供具有某些期望特性（例如隔音（sound-deadening））的地板材料。地板组合物中的压缩粉尘的消除需要新颖方式以通过使用不同的材料或不同的制造工艺来重新获得这些特性。
现有的使用胶或粘合剂来将各层结合的层压地板材料产品易于分层及过早失效，尤其是在潮湿的环境中。粘合剂的处理、施加以及设置或固化会增加制造地板的工艺的复杂性，从而使该步骤具有妨碍高效连续运行或长期制造的潜在瓶颈。
对地板材料施加精整涂层（finishing coating）是改善地板材料的外观及耐磨性的良好方式。但在地板材料含有聚氯乙烯（polyvinyl chloride，PVC）的情况下，存在在制造工艺中实现精整涂层的适当粘附性的难题及问题以及在安装之后过早分层的其他潜在问题。为了在制造时获得良好的粘附性，目前使用需要长的固化时间或复杂处理的涂层。聚氨基甲酸酯经历可能花费八小时到十小时的氧化固化。双组分环氧树脂（two-part epoxy）可能花费至少三十分钟来固化，这仍是长的时间且是妨碍连续运行制造的潜在瓶颈。此外，双组分环氧树脂在制造工艺中需要额外的混合及处理。
表面设计及纹理常常印刷在频繁地模仿木材、石材或地砖的地板材料上并压印到所述地板材料中。施加这些装饰性图案及纹理的当前方法大部分受限于通过有限大小的辊或板进行压印的短的、频繁重复的图案。在施加多于一种颜色、色彩、色调或阴影的情况下，会频繁地引起配准（registration）问题。这些限制不利于任何将生产从一种装饰性图案切换到另一种装饰性图案的能力。一旦特定装饰性图案的生产得到校准及配准，便不情愿作出改变。
在地板材料的制造商必须解决这些问题的情况下，价格可能将会升高或利润将会下降。如果问题无法解决，则地板材料将可能过早地失效。因此需要无胶且无尘但仍具有期望品质的地板材料。目前也需要更高效、更经济、装饰性图案更加多样化、更快且生产更耐久及高性能地板材料的制造方法。
2011年2月10日由戴维C.刘（David C. Liu）针对“具有垫料的地板及地砖（Floorand Tile with Padding）”公布的美国专利公开第2011/0030300号公开了具有贴合到地板板材（floor board）的底侧的垫的柔性地板板材。所述垫局部地覆盖地板板材的底侧并延伸超过地板板材。所述垫的底侧覆盖有可再粘胶层（restickable glue layer），且地板板材在一端上具有阳锁定件（male lock）且在另一端上具有阴锁定件（female lock）。地板板材通过将第一地板板材的阴锁定件下压到第二地板板材的阳锁定件上而与相邻的地板板材啮合。未被垫覆盖的第一地板板材的底侧被放置成接触第二地板板材的延伸超过第二地板板材的垫。由于对硬木地板的需要而开发出刘氏地板（Liu flooring）且不存在胶粘（glue-down）安装及浮动安装两方面的问题。硬木地板意味着易于安装且无需脏乱的胶、不会分层、没有中空区域且不会被水快速地破坏。
美国专利公开第2009/0223162号是由豪A.陈等人（Hao A. Chen et al.）在2009年9月10日公布，其公开了“用于表面覆盖的连接系统（Connecting System for SurfaceCoverings）”。所述专利公开提供了条板，所述条板具有沿着条板的宽度延伸的相对的第一端及第二端、沿着条板的长度延伸的相对的第一纵向侧及第二纵向侧以及相对的顶表面及底表面。条板可在第一端处具有榫舌边缘（tongue edge）且在第二端处具有沟槽边缘（groove edge）。榫舌边缘可以可拆卸地锁定到相邻的相同条板的沟槽边缘中。还提供具有连接在一起的多个条板的表面覆盖系统。具体来说，地板条板的优选实施例包括（1）顶表面；（2）底表面；（3）第一纵向侧；（4）第二纵向侧，与第一纵向侧相对；（5）第一端，沿着地板条板的宽度延伸且包括榫舌边缘；以及（6）第二端，与第一端相对，沿着地板条板的宽度延伸，且包括沟槽边缘。榫舌边缘包括：垂直远侧表面，实质上垂直于顶表面及底表面；顶部平坦倾斜表面，从垂直远侧表面朝向顶表面延伸离开；垂直唇缘，从顶表面向下延伸；通道，实质上设置在顶部平坦倾斜表面与顶表面之间，所述通道包括通道底部及通道背部，所述通道背部从通道底部朝向垂直唇缘延伸离开；尖峰轨道（pinnacle rail），连接顶部平坦倾斜表面与通道，其中所述通道底部在尖峰轨道下方垂直延伸，且所述通道背部在侧向上比垂直唇缘从垂直远侧表面延伸得更远；底部平坦倾斜表面，从垂直远侧表面朝向底表面延伸离开；以及垂直肩部，从底部平坦倾斜表面向底表面延伸。
美国专利第6,558,795号针对“可剥离涂布系统（Strippable Coating System）”在2003年5月6日授予凯斯E.奥尔森（Keith E. Olson）等人。在奥尔森等人的专利中，辐射可固化涂层含有对经固化涂层赋予较大可剥离性的试剂。试剂可包含在涂层中或者包含在一个或多个随后施加的维护涂层中。可固化涂层可为水生的，由无机颗粒构成，且赋予较大可剥离性的试剂可增强辐射可固化维护涂层与经固化涂层的粘附性。试剂还可包括减少经固化涂层的分子量的链转移剂（chain transfer agent），且在优选实施例中可含有醇、酯、醛或其混合物。
在2004年5月4日授予理查德C.麦克奎恩（Richard C. MacQueen）等人的美国专利第6,730,388号涉及“具有宏观纹理的涂层及其制作工艺（Coating Having MacroscopicTexture and Process for Making Same）”。在麦克奎恩涂层的一个实施例中，经涂布的衬底包括衬底、位于所述衬底的至少一部分上的经辐射固化的涂层或经热固化的涂层，其中所述涂层包含固有的宏观纹理。在另一实施例中，所述发明提供包含辐射可固化树脂及起始剂或热可固化树脂及热起始剂的预先固化的涂布混合物，其中所述辐射可固化树脂或热可固化树脂及相应起始剂形成能够在将所述混合物施加在衬底上时形成宏观纹理的预先固化的涂布混合物。在另一实施例中，麦克奎恩专利提供了包含辐射可固化树脂或热可固化树脂、起始剂及纹理产生颗粒的预先固化的涂布混合物，所述纹理产生颗粒具有有效大小以在将所述混合物施加在衬底上时提供宏观纹理。在另一实施例中，所述发明提供经涂布衬底，所述经涂布衬底包括衬底及位于所述衬底的至少一部分上的经辐射固化的涂层或经热固化的涂层，其中所述涂层包含固有的宏观纹理。另外，所述专利提供了在衬底上制作涂层的工艺，所述工艺包括以下步骤：将包含辐射可固化树脂及起始剂或热可固化树脂及热起始剂的预先固化的涂布混合物分布在衬底的至少一部分之上以形成具有宏观纹理的预先固化的涂层，以及相应地对预先固化的涂层进行辐射固化或热固化以形成具有宏观纹理的经辐射固化的涂层或经热固化的涂层。
杨P.（Yang P.）的在2015年12月30日公布的中国专利公开第204920130号涉及“瓷质木料板砖（Porcelain Timber Apron Brick）”。杨的公开的实用新型公开了包括陶瓷砖层、木材板层及防水层的瓷质木料板砖。木材板层及防水层分别固定在陶瓷砖层的两侧上，以使木材板层位于陶瓷砖层的上表面上。在杨式地砖（Yang tile）中，木材板层与防水层组合起来的厚度小于陶瓷砖层的厚度。配备有木材板层会防止砖表面温度过低并在使用期间提高舒适性。防水层有效地防止浸在地面上的水进入陶瓷砖层及木材板层，从而实现地砖的防水性能。
中国专利公开第201972361号是由梁Y.（Liang Y.）关于“木材与陶瓷复合地板砖（Wood and Ceramic Composite Floor Tile）”在2011年9月14日公开。梁的公开的实用新型公开了包括芯材、面板及底板的木材与陶瓷复合地板砖，其中所述芯材布置在面板与地板之间。芯材分别通过粘合层与面板及底板连接，且是一种或多种陶瓷砖。还提供框架条，且所述框架条布置在芯材的外围处。所述砖试图解决陶瓷砖的以下问题：现有木材与陶瓷复合地板砖易于被损坏且以高制造成本为特征。所公开的砖提供很难被损坏、易于加工、便于安装且具有高的不可变形性特征的复合地板砖，因而会有效地降低砖的成本。
2012年5月1日授予戴维C.刘（David C. Liu）的美国专利第8,166,718号涉及“在水平方向上工程设计的硬木地板及安装方法（Horizontally Engineered Hardwood Floorand Method of Installation）”。地板板材包括被放置多个条的顶部装饰性层。所述多个条被布置成具有一些为X轴取向且一些为Y轴取向。所述多个条还具有使木地板板材能够如地砖那样安装的特性。具体来说，刘的专利涉及具有长度的高性能工程设计的木地板板材，其包括：（1）顶部木材层，具有沿着地板板材的长度排开的木纹，所述顶部木材层具有顶表面及底表面；（2）多个支撑条，贴合在顶部木材层之下，所述多个支撑条中的第一子组在第一方向上取向，且所述多个支撑条中的第二子组在第二方向上取向，所述多个支撑条中的第一子组与所述多个支撑条中的第二子组物理地分离且不接触第二子组，其中所述顶部木材层实质上覆盖支撑条的第一子组及第二子组；以及（3）粘合层，放置在顶部木材层与所述多个支撑条之间。粘合层覆盖顶部木材层的底表面。另外，所述多个支撑条中的第一支撑条具有锁定唇缘，且所述多个中的第二支撑条具有凹进的狭槽，且高性能工程设计木地板板材的第一支撑条的锁定唇缘能够耦合到地板板材的第二支撑条的凹进的狭槽。
国际专利公开第WO 2005/116362A1号是由德朗涛（Delong Tao）在2005年12月8日公开，其公开了“陶瓷木材层压地板（A Ceramic Wood Laminated Floor）”。涛的公开的地板是由陶瓷砖所制成的基底层以及木材或竹子所制成的表面层组成。在表面层与基底层之间，设置有结合涂层。基底层的下面配备有弹性垫。
发明内容
本发明提供基于聚氯乙烯的地板的无胶无尘复合地板材料系统，所述基于聚氯乙烯的地板具有提供不同的硬度、耐磨性、隔音及装饰性图案品质的层，其中各层在不使用胶或粘合剂的条件下熔合在一起，具有可选的紫外线固化的顶部涂层、可改变的设计印刷及纹理，并且所述基于聚氯乙烯的地板根据需要具有衬料层，所述衬料层可以片形式、本质上连续运行的方式来制造，且能够快速及简单地改变所产生的可选的设计印刷及纹理，从而得到持久性高性能地板产品。
本发明避免使用压缩粉尘填料，所述压缩粉尘填料易受水分损坏，例如肿胀及失效。本发明避免使用胶或粘合剂，所述胶或粘合剂易于过早分层失效且会增加制造的成本及复杂性。以新颖方式提供压缩粉尘填料以及胶或粘合剂的期望品质。
附图说明
现在将参照附图，其中相同的部分将由相同的编号标示，且在附图中：
图1是本发明的无胶无尘复合地板材料系统的实施例的示意性剖面图。
图2是本发明的无胶无尘复合地板材料系统的实施例的示意性分解图。
图3是本发明的无胶无尘复合地板材料系统的实施例的示意性分解图。
图4是模仿水磨石的本发明的无胶无尘复合地板材料系统的另一实施例的示意性剖面图。
图5是模仿大理石的本发明的无胶无尘复合地板材料系统的另一实施例的示意性剖面图。
图6是具有单一挤出基底层的本发明的无胶无尘复合地板材料系统的实施例的示意性剖面图。
图7是具有双重挤出基底层的本发明的无胶无尘复合地板材料系统的实施例的示意性剖面图。
图8是生产本发明的无胶无尘复合地板材料系统的方法的流程图表示。
具体实施方式
大体参照所有附图，附图中示出无胶无尘复合地板系统100及生产方法200的实施例。
参照图1及图2，无胶无尘复合地板系统100包括不同材料的三个层20、30、40以及可选的衬料层10，所述三个层20、30、40在不使用单独的胶或粘合剂的条件下坚牢地彼此结合。可选的衬料层10可为例如软木或橡胶等天然材料或者例如开孔塑料泡沫或闭孔塑料泡沫等合成材料。乙烯乙酸乙烯酯（ethylene vinyl acetate，EVA）是合适的材料。无胶无尘复合地板系统100为所使用的任何类型的可选的衬料层10提供防水覆盖，从而使得能够对衬料使用水敏材料（water-sensitive material）。可选的衬料层10可被省略，或者可在制造期间贴附到已完成的地板，或者可被制作成可用作单独封装的物品。根据任何特定衬料材料耐受以下公开的热熔叠加工艺的能力而定，衬料可在制造工艺之前或之后贴附到无胶无尘复合地板系统100的其余部分。
无胶无尘复合地板系统100提供地板基底层20，地板基底层20是通过根据图8所示以及以下更详细公开的无胶无尘复合地板系统方法200对聚氯乙烯树脂及其他材料的掺合混合物进行熔合、挤出及模制成型来形成。根据需要，聚氯乙烯树脂及其他材料的两种或更多种不同的混合物可被共挤出到同一模具中，所述模具将会生产具有不同的子层或阶层（strata）的熔合地板基底层20，所述子层或阶层为例如所示第一基底挤出物21及第二基底挤出物22。聚氯乙烯树脂掺合物可通过使用不同的材料及填料或者不同比例的材料及填料来调整，以在熔合及挤出时具有不同的性质。如果一种聚氯乙烯树脂掺合物产生期望的硬度及稳定性，但在隔音或其他海绵质品质方面存在缺陷，则可施加不同的聚氯乙烯树脂掺合物或不同的挤出技术作为共挤出，以提供否则缺失的品质。在优选的共挤出实施例中，形成较坚硬的较硬阶层以实现强度，且形成致密泡沫式的较松软阶层以实现缓冲及吸声作用。
能够通过调整一种或多种聚氯乙烯树脂掺合物以及一种或多种挤出方法来调整地板基底层20的特性且因此调整总体已完成的地板的特性不再需要使用压缩粉尘，所述压缩粉尘易受水分侵害且另外在一些气候条件下以及对于一些使用来说存在问题。举例来说，根据对硬度的同时需要，在地板基底层20中（或者在所述整个层中或在所述层内的阶层中）一致地形成受控量的致密泡沫可复制压缩粉尘芯的期望品质但不会复制粉尘的缺点。
构成合适的地板基底层20的材料的混合体的优选实施例是（1）聚氯乙烯：50公斤；（2）800-1000筛目（mesh）碳酸钙（calcium carbonate，Caco3）：75公斤到100公斤；（3）热稳定剂：钙-锌（Ca/Zn）：3.8公斤到5.0公斤；（4）氯化聚乙烯弹性体（Chlorinatedpolyethylene elastomer，CPE）：2.5公斤到4.0公斤；（5）改性剂（Modifier）丙烯酸聚合物（Acrylic acid，ACR）：3.0公斤到4.0公斤；（6）高密度聚环氧乙烷OA6：0.2公斤到0.3公斤；（7）内部润滑剂（Internal lubricant）G60：0.4公斤到0.6公斤；以及（8）高熔点聚合物PE-蜡（PE-wax）：0.5公斤到0.7公斤。该混合物适用于单一挤出基底层或共挤出层。构成合适的共挤出层的材料的混合体的另一优选实施例是聚氯乙烯：50公斤；800-1000筛目碳酸钙：25公斤到50公斤；热稳定剂：钙-锌：3.0公斤到4.0公斤；氯化聚乙烯弹性体：2.0公斤到4.0公斤；改性剂丙烯酸聚合物：2.0公斤到3.5公斤；高密度聚环氧乙烷OA6：0.1公斤到0.2公斤；内部润滑剂G60：0.2公斤到0.4公斤；高熔点聚合物PE-蜡：0.15公斤到0.35公斤；环氧化大豆油（Epoxidized soybean oil）DOBS：1.0公斤到2.0公斤。
生产无胶无尘地板材料系统的方法提供：在合适的大容器中对用于地板基底层20的材料进行混合，直到材料彻底混合。然后，在同一大容器中或在不同的容器中，熔合步骤提供：在继续对材料进行混合的同时对材料的混合物进行加热。所述方法的优选实施例是在接近但不超过每分钟1600转（RPM）的高速下搅拌的同时将混合物加热到115℃到130℃。在熔合完成之后，使熔合的聚氯乙烯材料稍微冷却。聚氯乙烯材料在挤出工艺中必定会被重新加热，因此如果立即将批量的熔合混合物发送到挤出机，则熔合混合物需要冷却到足以安全且高效地从布满粉尘的混合及熔合区域输送到挤出及模制区域的较清洁的环境。该种输送或递送可使用所属领域中已知的大管道来进行。可使水或另一冷却剂在用于熔合的容器周围的护套中循环以从熔合的聚氯乙烯混合物带走热量，注意不能使冷却速度过快，这可能会影响地板基底层20的塑料性质。
混合步骤、熔合步骤及冷却步骤本质上是分批工艺。然而，通过仔细地调整及控制工艺，或者通过设置多于一条生产线并使其操作错开，可生产本质上连续供应的熔合的聚氯乙烯材料，且熔合的聚氯乙烯材料可被供应到后续操作。
将熔合的聚氯乙烯混合物输送到螺杆挤出机以挤出到升温及升压的挤出模具。优选实施例是使用80毫米（mm）直径的螺杆在不超过每分钟40转的速度、20毫帕（mpa）到35毫帕的挤出压力及160℃到186℃的温度下挤出。可将多于一种混合物共挤出到同一挤出模具以用于形成不同的阶层，如上所公开。该种挤出及模制成型工艺得到一片地板基底层20。所述片可能非常长或者本质上是连续的。如果工艺的混合-熔合-冷却-递送步骤经适当协调以将连续供应的熔合的聚氯乙烯材料提供到螺杆挤出机，则挤出机可供应本质上连续的一片地板基底层20以用于本质上连续的一片地板表面层30的热熔叠加。
地板表面层30包括熔合到承磨表面子层（wearing face sublayer）32的装饰性表面子层31。装饰性表面子层31可由聚氯乙烯装饰性膜形成，且通常将为不透明的并具有充当旨在施加的任何装饰性图案33（例如木材、石材或地砖的仿制品或其他装饰性图案）的底色或背景色的颜色。承磨表面子层32可由通常为透明或大部分为透明的高分子耐磨性聚氯乙烯聚合物膜形成，因而可以看到装饰性表面子层31。在无胶无尘复合地板系统100的大部分实施例中，在装饰性表面子层31与承磨表面子层32熔合之前，将装饰性图案33施加到装饰性表面子层31。装饰性图案33可能是模仿例如木材、石材或地砖等传统地板材料。简略地参照图3，其示意性地示出地板表面层30可能具有模仿大理石、水磨石或木材的装饰性图案，不同的装饰性图案33可与无胶无尘复合地板系统100一起使用。所述图案可使用印刷辊或使用数字图像印刷装置来施加。数字印刷的优点是可生产无精确性重复或非常长的重复周期的图像，这与辊印刷时固有的重复形成对比。数字印刷的另一优点是可适当地施加或甚至掺合几种不同的颜色、阴影或色调，这在地板制造环境中利用辊印刷是非常难处理的或不可能的。
形成装饰性表面子层31的聚氯乙烯装饰性膜可以大卷来供应。这种聚氯乙烯装饰性膜的强度及磨损特性不会显著影响已完成的地板的强度及磨损特性，这是因为其他元素会提供这种强度及磨损特性。根据实际情况，聚氯乙烯装饰性膜应足够强以避免在地板制造工艺期间撕裂。
对承磨表面子层32使用高分子耐磨性聚氯乙烯聚合物膜对已完成的地板提供大部分的期望的耐磨性，地板涂层40提供其余的耐磨性。这种膜也可以大卷供应。
可使用大卷聚氯乙烯膜或通过具有高效的再装方法来生产本质上连续的一片地板表面层30。
尽管在随后与地板基底层20熔合之前，承磨表面子层32可熔合到装饰性表面子层31作为制造工艺中的单独的步骤，然而无胶无尘复合地板系统方法200的优选实施例提供一次将承磨表面子层32、装饰性表面子层31及地板基底层20同时熔合。这种熔合通过以下方式来实现：热熔叠加，使子层与层以适当的次序接触彼此且同时加热并对堆叠施加压缩以在不使用胶或粘合剂的条件下将各层熔合在一起，且因此本质上消除了已完成的地板分层或其他失败的潜在问题。热熔叠加可通过将承磨表面子层32、装饰性表面子层31及地板基底层20馈送到一组经加热的辊来进行。在承磨表面子层32及装饰性表面子层31以本质上相等宽度的聚氯乙烯聚合物膜的大卷来供应且地板基底层20被形成为与膜的卷具有本质上相同宽度的片或者被形成为允许并排地同时加工多个片的所述宽度的分区的情况下，热熔叠加可以连续或接近连续运行的方式来执行。
根据需要，可对熔合的基底层及表面层的地板表面层30施加纹理化、浮凸的或凹陷的表面图案。这种纹理可为对印刷的装饰性图案33进行补充的模仿装饰性纹理，或者可为旨在改善已完成的地板的牵引力、光反射或其他品质的纹理。纹理化、浮凸的或凹陷的表面图案可与热熔叠加压缩阶段同时或紧接其后施加到熔合的基底层及表面层的地板表面层30，同时地板表面层30仍被局部地熔融且为柔韧的。与地板表面层30进行接触的一个或多个热熔辊可被配置成使纹理浮凸，但这种布置将需要小的纹理重复周期或大的辊。浮凸可由一个或多个辊、板或其他装置（例如耙式工具（rake））紧接热熔叠加压缩之后压印到现在熔合的基底层及表面层的地板表面层30中来执行，同时部分总成仍是柔韧的。根据纹理的量及属性，可使用坚硬线材的圆柱作为用于凹陷的辊，可使用打孔的圆柱作为用于浮凸的辊，或者可使用可能允许耙齿移动以产生变化的耙式布置。
热熔叠加在不使用胶或粘合剂的条件下将地板表面层30及地板基底层20熔合在一起。表面及基底子总成是通过在非常高的温度下进行热熔叠加及根据需要进行纹理化来形成。然后对表面及基底子总成进行调理。这一调理步骤使表面及基底子总成能够相当缓慢及均匀地冷却到周围环境温度，而不会骤冷或其他突然冷却，以防止在片中产生应力。由于表面及基底子总成是几乎整个表面区域的薄片，因此冷却不需要过量的时间，且调理可通过对输送带提供足够的额外长度以使得能够实现冷却而在连续运行的基础上进行。根据需要，可执行额外的调理程序，例如电晕放电或燃烧以制备用于施加地板涂层40的聚氯乙烯表面。可选的衬料10可在该点处或在已执行热熔叠加及可选的纹理化之后的随后的点处添加到子总成。
本质上连续的一片表面及基底子总成可通过热熔叠加步骤来生产，只要存在连续供应的基底层及表面层片即可。
在表面及基底子总成已在调理步骤中冷却之后，然后将子总成涂布在具有塑料树脂的顶部或地板表面层30侧上，所述塑料树脂可在紫外（UV）光下固化，从而形成地板涂层40。适用于施加到聚氯乙烯上的紫外线固化底漆及顶部涂层在所属领域中是已知的。一般来说，紫外线固化底漆及顶部涂层将是透亮的、无色的及透明的，以使得能够通过其显示出装饰性图案33。一般来说，无色的涂层可比有色的涂层更快地且使用更少的曝光来固化。紫外线固化顶部涂层是可用的，其提供有光泽的表面处理或无光泽的表面处理，且具有例如抗刮性等期望的性质。根据需要，砂质颗粒材料（例如氧化铝）可添加到紫外线固化塑料树脂且并入地板涂层40中，以提供额外的牵引力及额外的耐磨性。在优选实施例中，紫外线底漆及紫外线顶部涂层是使用一系列辊以长期运行或连续运行的方式来施加。
应存在施加紫外线固化底漆及至少一次施加紫外线固化顶部涂层，但多于一次地施加紫外线固化顶部涂层将可能改善已完成的地板的外观及耐久性。固化通过曝光到来自例如汞（Hg）灯或镓（Ga）灯的紫外光来进行。紫外线固化进行地非常快，仅在几秒的时间内，且可在工件在一排紫外光之下通过的输送带上行进的时间内实现。相比之下，聚氨基甲酸酯的氧化固化可能花费八小时到十小时，且双组分环氧树脂的固化可能花费至少三十分钟或大于三十分钟。
在无胶无尘复合地板系统方法200的地板涂层40中使用紫外线固化塑料树脂消除了制造工艺中的潜在瓶颈，从而使得能够生产本质上连续的一片完全组装的、熔合的、装饰的、经涂布及经固化的地板材料。熔合的基底及表面子总成的涂布及紫外线固化得到复合地板材料的已完成的大片总成，其包括地板基底层20、地板表面层30及地板涂层40以及可选的衬料层10。这种已完成的大片总成旨在被分成可在安装期间易于处理的期望大小及构型的片段，例如可在安装期间易于处理的地砖或条板或者大卷的片。
无胶无尘复合地板系统方法200中的最终步骤是其中大片已完成的地板材料被切割成期望的大小并形成有适当的凹口、沟槽、突片或其他安装相关组件的轮廓加工，然后进行检查，然后对已完成的、铣出轮廓的地板材料进行包装以用于运输及销售。
参照图8，无尘无胶复合地板系统生产方法200的流程图表示，通过混合、熔合、冷却、递送、挤出、模制成型及调理-冷却由聚氯乙烯及其他原材料形成地板基底层20，从而得到可能本质上是连续的以片形式供应的地板基底层20。通过提供聚氯乙烯修饰膜、根据需要在其上印刷装饰性图案33、然后添加聚氯乙烯耐磨性膜来单独地以及可能同时地形成地板表面层30，从而得到也可能是本质上连续的以片形式供应的地板表面层30。然后使地板基底层20的片及地板表面层30的片以适当的取向靠近并在不使用胶或粘合剂的条件下通过热熔叠加、根据需要然后进行纹理而熔合在一起，从而得到也可能是本质上连续的以片形式供应的基底及表面子总成。然后调理步骤使热熔基底及表面子总成能够冷却并根据需要提供其他调理程序。然后施加紫外线固化塑料树脂涂层作为底漆层及至少一个顶部涂层。在每次施加紫外线固化塑料树脂之后，通过曝光到紫外光使经涂布的地板材料片经受紫外线固化，从而进行非常快的固化。调理工艺、涂布工艺及紫外线固化工艺可在本质上连续的以片形式供应的基底及表面子总成上执行，且得到也能是本质上连续的以片形式供应的已完成的、熔合的、经涂布及经固化的地板材料。然后在轮廓加工步骤中将已完成的地板片切割成一定大小且所述已完成的地板片形成有任何凹口、沟槽或突片以用于安装目的。最终步骤是对铣出轮廓的地板材料件进行检查及包装。
无胶无尘复合地板系统方法200能够基于连续运行的组装线输送带来制造地板。其还能够将生产从一种颜色或设计图案变为另一种颜色或设计图案。其得到不含粉尘且不含胶的地板材料产品，但拥有与粉尘及胶相关联的期望品质，所述期望的品质是通过其他新颖方式来实现。
在不背离本发明的精神的条件下，可在本发明中作出诸多改变及修改。因此，本发明的保护范围由所附的权利要求范围限定。
Claims (17)
1.一种无胶无尘复合地板材料产品，具有标称顶部及底部方向，所述无胶无尘复合地板材料包括：
(i)防水地板基底层，包括聚氯乙烯树脂混合物，所述聚氯乙烯树脂混合物不含压缩纤维质材料及胶并具有适于在使用时在所述地板基底层中提供期望品质的相容材料，所述混合物是通过混合、熔合、冷却、递送、挤出及模制成型而形成的，
其中所述聚氯乙烯树脂混合物包括：
第一基底子层，包括：
(a)50公斤聚氯乙烯；
(b)75公斤到100公斤800-1000筛目碳酸钙；
(c)3.8公斤到5.0公斤钙-锌热稳定剂；
(d)2.5公斤到4.0公斤氯化聚乙烯弹性体；
(e)3.0公斤到4.0公斤丙烯酸聚合物改性剂；
(f)0.2公斤到0.3公斤高密度聚环氧乙烷OA6；
(g)0.4公斤到0.6公斤内部润滑剂G60；以及
(h)0.5公斤到0.7公斤高熔点聚合物PE-蜡；以及
第二基底子层，包括：
(a)50公斤聚氯乙烯；
(b)25公斤到50公斤800-1000筛目碳酸钙；
(c)3.0公斤到4.0公斤钙-锌热稳定剂；
(d)2.0公斤到4.0公斤氯化聚乙烯弹性体；
(e)2.0公斤到3.5公斤丙烯酸聚合物改性剂；
(f)0.1公斤到0.2公斤高密度聚环氧乙烷OA6；
(g)0.2公斤到0.4公斤内部润滑剂G60；
(h)0.15公斤到0.35公斤高熔点聚合物PE-蜡；以及
(i)1.0公斤到2.0公斤环氧化大豆油DOBS；
(ii)防水地板表面层，包括固定于所述地板基底层的顶部的装饰性表面子层及固定于所述装饰性表面子层的顶部的承磨表面子层，所述装饰性表面子层包括聚氯乙烯装饰性聚合物膜且所述承磨表面子层包括聚氯乙烯耐磨性膜；
其中所述地板表面层是通过热熔叠加到所述地板基底层的顶表面来熔合，并形成单一的基底及表面子总成；以及
(iii)防水地板涂层，包括紫外线可固化塑料树脂并固定于所述承磨表面子层的顶部，所述地板涂层是通过以至少一种紫外线可固化塑料树脂对所述基底及表面子总成的顶表面进行涂布且随后通过曝光到紫外光固化而形成的；
其中所述基底及表面子总成及所述地板涂层是熔合在一起的并形成防水的已完成的大片总成；
其中所述已完成的大片总成的轮廓加工成期望的大小及形状，从而得到多个地板区段；且
其中随后对所述地板区段进行检查及封装。
2.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板基底层包括：第一基底挤出子层及第二基底共挤出子层，所述第二基底共挤出子层熔合于所述第一基底子层的顶部，所述第一基底子层及第二基底子层是模制成型的。
3.根据权利要求1所述的无胶无尘复合地板材料产品，还包括(iv)衬料层。
4.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述聚氯乙烯装饰性聚合物膜还包括有色的膜。
5.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述聚氯乙烯装饰性聚合物膜还包括施加的装饰性图案。
6.根据权利要求1所述的无胶无尘复合地板材料产品，还包括在所述基底及表面子总成上浮凸的纹理化表面。
7.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述聚氯乙烯耐磨性膜是透明的。
8.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板涂层是透明的。
9.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板涂层还包括砂质颗粒材料。
10.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板涂层还包括氧化铝。
11.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板涂层还包括：紫外线可固化的底漆及至少一种紫外线可固化的顶部涂层。
12.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述紫外线可固化塑料树脂是通过曝光到汞灯而固化的。
13.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述紫外线可固化塑料树脂是通过曝光到镓灯而固化的。
14.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板基底层是在接近但不超过每分钟1600转的高速下搅拌的同时将所述混合物加热到115℃到130℃而形成的。
15.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板表面层与所述地板基底层的所述热熔叠加是使所述地板基底层与所述地板表面层通过至少一组经加热的辊而熔合的。
16.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述地板基底层的所述挤出还包括：使用80毫米直径的螺杆在不超过每分钟40转的速度、20毫帕到35毫帕的挤出压力及160℃到186℃的温度下进行挤出。
17.根据权利要求1所述的无胶无尘复合地板材料产品，其中所述聚氯乙烯耐磨性膜及所述聚氯乙烯装饰性聚合物膜是以大卷来供应。
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| EP3475498A1 (en) | 2019-05-01 |
| CN109863275A (zh) | 2019-06-07 |
| AU2016412932A1 (en) | 2019-02-07 |
| US20170370111A1 (en) | 2017-12-28 |
| CA3029194C (en) | 2023-10-10 |
| CA3029194A1 (en) | 2018-01-04 |
| EP3475498A4 (en) | 2020-03-04 |
| US10220599B2 (en) | 2019-03-05 |
| KR20190043131A (ko) | 2019-04-25 |
| WO2018004724A1 (en) | 2018-01-04 |
| AU2016412932B2 (en) | 2023-01-19 |
| JP6928012B2 (ja) | 2021-09-01 |
| JP2019522745A (ja) | 2019-08-15 |
| MX2019000142A (es) | 2019-09-04 |
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