CN110219434B - 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 PDFInfo
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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
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 (3)
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;
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CPE 0.5-2.0份;
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;
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;
所述层压的温度为120-150℃,压力8-15kgf/cm2,时间为30-45min。
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,所述穿孔的PP膜的孔径大小1-3mm。
3.一种权利要求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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