CN110219434A - 一种高耐磨的tpu石塑地板及其制备方法 - Google Patents

一种高耐磨的tpu石塑地板及其制备方法 Download PDF

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CN110219434A
CN110219434A CN201910433904.6A CN201910433904A CN110219434A CN 110219434 A CN110219434 A CN 110219434A CN 201910433904 A CN201910433904 A CN 201910433904A CN 110219434 A CN110219434 A CN 110219434A
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林生雄
何超金
姚兴南
吴星星
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FUJIAN SIJIA INDUSTRIAL MATERIAL Co Ltd
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Abstract

本发明涉及地板技术领域，具体涉及一种高耐磨的TPU石塑地板及其制备方法，所述高耐磨的TPU石塑地板从上到下包括：UV涂层、纯TPU耐磨层、彩膜、PVC透明层、PVC中层和PVC底层；所述制备方法包括：(1)将下述原料从上到下依次进行铺膜：盖板、帆布、压纹板、OPP膜、穿孔的PP膜、纯TPU耐磨层、彩膜、PVC透明层、PVC中层、PVC底层、OPP高温膜、底纹板、帆布和底板；(2)将步骤(1)得到的膜结构进行层压得到高耐磨的TPU石塑地板。本发明的有益效果在于：制备方法中使用压延工艺生产纯TPU薄膜，提高了效率；所得石塑地板耐磨性能大大提高，耐低温性能更佳。

Description

一种高耐磨的TPU石塑地板及其制备方法
技术领域
本发明涉及地板技术领域，具体涉及一种高耐磨的TPU石塑地板及其制备方法。
背景技术
石塑地板因具有防水、耐磨、使用寿命长等特点而深受广大消费者喜爱，一般由PVC(聚氯乙烯)底材层、PVC中间层、装饰层、耐磨PVC层、UV油漆涂装层依次接合而成。由此得到的石塑地板强度不高，产品性能不稳定，表面耐磨性表现一般。
TPU薄膜是一种功能性薄膜，具有其他塑胶材料无法比拟的强度高、韧性好、耐寒、耐油、耐老化、耐气候、环保无毒、可分解等特性；同时具有高防水透湿性、防风、防寒、抗菌、保暖、抗紫外线及能量释放等许多优异功能，广泛应用于各种领域。但现有的TPU薄膜高温加工性较差，在高温下时，TPU薄膜易发粘，为了避免TPU薄膜的高温发粘问题往往需要加入大量的滑剂，这样又会导致TPU薄膜制品中的滑剂易析出，TPU薄膜制品的撕裂强度较差。
如何利用TPU薄膜的特性，将其应用到石塑地板中去，以最合适的配比寻求最适宜的其他共同复合的材料，以解决现有石塑地板存在的问题值得研究。
发明内容
本发明所要解决的技术问题是：本发明的目的在于提供一种性能稳定，耐低温的高耐磨的TPU石塑地板及其制备方法。
为了解决上述技术问题，本发明采用的技术方案为：提供一种高耐磨的TPU石塑地板的制备方法，所述高耐磨的TPU石塑地板从上到下包括：UV涂层、纯TPU耐磨层、彩膜、PVC透明层、PVC中层和PVC底层；所述纯TPU耐磨层由TPU颗粒进行压延工艺生产得到；所述高耐磨的TPU石塑地板的制备方法包括：
(1)将下述原料从上到下依次进行铺膜：盖板、帆布、压纹板、OPP膜、穿孔的PP膜、纯TPU耐磨层、彩膜、PVC透明层、PVC中层、PVC底层、OPP高温膜、底纹板、帆布和底板；
(2)将步骤(1)得到的膜结构进行层压得到高耐磨的TPU石塑地板。
本发明的有益效果在于：(1)本发明中的纯TPU耐磨层为压延工艺生产的纯TPU薄膜，代替了现有挤出工艺生产的TPU薄膜，大大提高生产效率；
(2)本发明的层压成型需要进行特殊处理，为解决TPU薄膜表面气泡、发粘异常，在TPU薄膜表面垫穿孔的PP薄膜，在压纹板边缘磨边处理；为改善剥离强度在彩膜下面多加一层PVC透明层；
(3)本发明采用纯TPU耐磨层，TPU不含增塑剂，比PVC更加环保，且耐磨性能大大提高，大概是PVC耐磨层的5-10倍，耐低温性能更佳，可以耐寒-40℃。
具体实施方式
为详细说明本发明的技术内容、所实现目的及效果，以下结合实施方式予以说明。
本发明提供一种高耐磨的TPU石塑地板的制备方法，所述高耐磨的TPU石塑地板从上到下包括：UV涂层、纯TPU耐磨层、彩膜、PVC透明层、PVC中层和PVC底层；所述纯TPU耐磨层由TPU颗粒进行压延工艺生产得到；所述高耐磨的TPU石塑地板的制备方法包括：
(1)将下述原料从上到下依次进行铺膜：盖板、帆布、压纹板、OPP膜、穿孔的PP膜、纯TPU耐磨层、彩膜、PVC透明层、PVC中层、PVC底层、OPP高温膜、底纹板、帆布和底板；
(2)将步骤(1)得到的膜结构进行层压得到高耐磨的TPU石塑地板。
优先的，上述的高耐磨的TPU石塑地板的制备方法中，所述层压的温度为120-150℃，压力8-15kgf/cm2，时间为30-45min。
优先的，上述的高耐磨的TPU石塑地板的制备方法中，所述PVC透明层由以下重量份的原料制备而成：PVC树脂100份，增塑剂26-38份，大豆油ESO 2-5份，钙锌复合稳定剂1.5-3.5份，ACR加工助剂0.5-2份。
优先的，上述的高耐磨的TPU石塑地板的制备方法中，所述PVC中层由以下重量份的原料制备而成：PVC树脂100份，增塑剂28-45份，钙锌复合稳定剂1-3份，碳酸钙300-500份，颜料：0.5-1.5份，松香0.3-1.0份，增韧剂CPE0.5-2.0份。
优先的，上述的高耐磨的TPU石塑地板的制备方法中，所述PVC底层由以下重量份的原料制备而成：
PVC树脂100份，增塑剂25-35份，钙锌复合稳定剂1-3份，碳酸钙100-190份，颜料0.8-2.0份。
优先的，上述的高耐磨的TPU石塑地板的制备方法中，所述穿孔的PP膜的孔径大小1-3mm，数量为200-500个/m2。
本发明的有益效果在于：(1)本发明中的纯TPU耐磨层为压延工艺生产的纯TPU薄膜，代替了现有挤出工艺生产的TPU薄膜，大大提高效率；
使用纯TPU薄膜使本发明TPU石塑地板更耐磨、耐低温、更加环保、因弹性好，脚感舒适度更好。
行业内生产TPU薄膜大部分是挤出流延工艺，相对压延工艺而言，滑剂的添加量更小，透明度更高，但生产速度慢一般在4-10m/min。采用压延工艺生产的TPU薄膜透明度可以满足地板使用需求，加工方便，生产速度可以达到20-30m/min。
(2)本发明的层压成型需要进行特殊处理，为解决TPU薄膜表面气泡、发粘异常，表面垫PP薄膜并穿孔(因TPU地板加工温度、压力比普通的高10-20％，表面PP薄膜对TPU的包覆性强，产生的气体无法及时排出而易引起气泡，通过穿孔的方式改进)，在压纹板边缘磨边处理；
为改善剥离在彩膜下面多加一层PVC透明层(如果不加PVC透明层，变成直接和PVC中层结合，中层料的填充剂碳酸钙含量很高，和彩膜的结合牢度就变差，因表层TPU弹性好，所以彩膜下面加一层填充剂含量尽可能低的PVC层增加贴合牢度，这里选用了PVC透明层)；
(3)本发明采用纯TPU耐磨层，TPU不含增塑剂，比PVC更加环保，且耐磨性能大大提高，大概是PVC耐磨层的5-10倍，耐低温性能更佳，可以耐寒-40℃。
实施例一
一种高耐磨的TPU石塑地板，从上到下结构：UV涂层+纯TPU耐磨层+彩膜+PVC透明层+PVC中层+PVC底层；
纯TPU耐磨层为以下压延生产工艺生产得到：
(1)原料配方：TPU颗粒，聚醚或聚酯型，硬度75-95A，透明级。
(2)工艺流程：称取一定量的TPU颗粒(100％)，在密炼机塑化，时间4-6min，料成团后卸料，到1#、2#轧轮机进一步塑化，轧轮机温度130-160℃，经过滤挤出送到四辊，挤出机温度140-160℃，通过调节四辊间距得到相应所需的厚度，四辊温度在160-190℃，再经过引离、压花、冷却、收卷得到所需的纯TPU耐磨层。
PVC透明层为以下压延生产工艺生产得到：
(1)配方(以重量份计)：PVC树脂(聚合度1000-1300)：100，增塑剂DOTP/DPHP：26-38，大豆油ESO：2-5，钙锌复合稳定剂：1.5-3.5，ACR加工助剂：0.5-2，颜料：0-0.5。
(2)工艺流程：计量配料→高速混合→密炼机混炼→开炼机塑化→挤出机过滤→压延→引离→压花→冷却定型→卷取；工艺参数为：高速混合时间为：250～350S；混炼时间：3-5min，开炼机辊筒温度120～150℃；挤出机温度130～160℃；四辊温度：160-200℃；引离温度：150～170℃。
PVC中层为以下压延生产工艺得到：
(1)PVC中层配方：PVC树脂(聚合度800-1300)：100，增塑剂DOTP/DPHP：28-45，钙锌复合稳定剂：1-3，石粉(重质碳酸钙)：300-500，颜料：0.5-1.5，松香：0.3-1.0，增韧剂CPE或ACR加工助剂：0.5-2.0。
(2)工艺流程：计量配料→高速混合→密炼机混炼→开炼机塑化→压延→引离→冷却→裁切；工艺参数为：高速混合时间为：250～400S；密炼时间：3-5min，开炼机辊筒温度100～150℃；四辊温度：160-190℃；引离温度：150～170℃。
PVC底层为以下压延生产工艺得到：
(1)PVC底层配方：PVC树脂(聚合度800-1300)：100，增塑剂DOTP/DPHP：25-35，钙锌复合稳定剂：1-3，石粉(重质碳酸钙)：100-190，颜料：0.8-2.0。
(2)工艺流程：计量配料→高速混合→密炼机混炼→开炼机塑化→压延→引离→冷却→裁切；工艺参数为：高速混合时间为：250～400S；密炼时间：3-5min，开炼机辊筒温度100～150℃；四辊温度：160-190℃；引离温度：150～170℃。
上述的高耐磨的TPU石塑地板的制备方法包括：
(1)备料：根据生产订单，领取相应所需的原料：彩膜、纯TPU耐磨层、彩膜、PVC透明层、PVC中层、PVC底层、OPP膜、PP膜、帆布、模板等。
(2)对PP膜进行打孔处理，孔径大小1-3mm，个数200-500个/m2。
(3)铺膜，一块完整的地板从上到下铺膜结构为：盖板+帆布+压纹板(钢板)+OPP膜+穿孔的PP膜+纯TPU耐磨层+彩膜+PVC透明层+PVC中层+PVC底层+OPP高温膜+底纹板+帆布+底板。
(4)对上述铺膜结构进行层压：根据产品厚度、压纹及每模数量的不同，设定不同的压力、时间和温度。一般温度为120-150℃，压力8-15kgf/cm2，时间：30-45min。
(5)层压后的大块地板经过UV淋膜→回火→冲切→削边、倒角→最终得到地板成品。具体包括：TPU耐磨层首先辊涂底层UV漆，质量控制在6-15g/m2，经过紫外灯管固化后，再辊涂面层UV漆，质量控制在6-15g/m2，经过紫外固化后，进入热水进行回火处理。
上述高耐磨的TPU石塑地板的制备方法的有益效果：(1)表面耐磨层是压延工艺生产的纯TPU薄膜，代替挤出流延工艺生产的TPU薄膜，大大提高效率；
(2)层压成型需要进行特殊处理，为解结表面气泡、发粘异常，表面垫PP薄膜并穿孔，在压纹板边缘磨边处理；为改善剥离在彩膜下面多加一层PVC透明层；
(3)采用纯TPU耐磨层的优势，TPU不含增塑剂，比PVC更加环保，且耐磨性能大大提高，大概是PVC的5-10倍，耐低温性能更佳，可以达到-40℃。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所作的等同变换，或直接或间接运用在相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (7)

1.一种高耐磨的TPU石塑地板的制备方法，其特征在于，所述高耐磨的TPU石塑地板从上到下包括：UV涂层、纯TPU耐磨层、彩膜、PVC透明层、PVC中层和PVC底层；所述纯TPU耐磨层由TPU颗粒进行压延工艺生产得到；
所述高耐磨的TPU石塑地板的制备方法包括：
(1)将下述原料从上到下依次进行铺膜：盖板、帆布、压纹板、OPP膜、穿孔的PP膜、纯TPU耐磨层、彩膜、PVC透明层、PVC中层、PVC底层、OPP高温膜、底纹板、帆布和底板；
(2)将步骤(1)得到的膜结构进行层压得到高耐磨的TPU石塑地板。
2.根据权利要求1所述的高耐磨的TPU石塑地板的制备方法，其特征在于，所述层压的温度为120-150℃，压力8-15kgf/cm2，时间为30-45min。
3.根据权利要求1所述的高耐磨的TPU石塑地板的制备方法，其特征在于，所述PVC透明层由以下重量份的原料制备而成：PVC树脂100份，增塑剂26-38份，大豆油ESO2-5份，钙锌复合稳定剂1.5-3.5份，ACR加工助剂0.5-2份。
4.根据权利要求1所述的高耐磨的TPU石塑地板的制备方法，其特征在于，所述PVC中层由以下重量份的原料制备而成：PVC树脂100份，增塑剂28-45份，钙锌复合稳定剂1-3份，碳酸钙300-500份，颜料：0.5-1.5份，松香0.3-1.0份，增韧剂CPE0.5-2.0份。
5.根据权利要求1所述的高耐磨的TPU石塑地板的制备方法，其特征在于，所述PVC底层由以下重量份的原料制备而成：
PVC树脂10份，增塑剂25-35份，钙锌复合稳定剂1-3份，碳酸钙100-190份，颜料0.8-2.0份。
6.根据权利要求1所述的高耐磨的TPU石塑地板的制备方法，其特征在于，所述穿孔的PP膜的孔径大小1-3mm。
7.一种权利要求1所述的高耐磨的TPU石塑地板的制备方法制备的高耐磨的TPU石塑地板。
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