CN110670839B - 具有木材纹理的发泡地板 - Google Patents
具有木材纹理的发泡地板 Download PDFInfo
- Publication number
- CN110670839B CN110670839B CN201911016758.3A CN201911016758A CN110670839B CN 110670839 B CN110670839 B CN 110670839B CN 201911016758 A CN201911016758 A CN 201911016758A CN 110670839 B CN110670839 B CN 110670839B
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- CN
- China
- Prior art keywords
- exposed
- wood
- foamed
- surface layer
- layer
- 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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Abstract
本发明涉及一种具有木材纹理的发泡地板。属于共挤发泡板技术领域。它包括发泡基体和硬质表层,硬质表层包括(a)和(b),(a)由第一颜色树脂形成的第一外露面、连接底材和基层;(b)由第二颜色树脂形成的第二外露面和连接底材。第一外露面由多个外露单元组成,第二外露面由多个下陷单元组成。多个外露单元与多个下陷单元交错排列。相邻外露单元和下陷单元之间设置有连接单元,连接单元由连接底材和连接表材构成。本发明以树脂为材料,基于两个表层,并通过立体(纹的深浅)、色差和明暗等多个层面的表现手法,实现了木材纹理的逼真效果。并且还可以通过对立体、色差和明暗的调节,来实现各种各样的木材纹理。
Description
技术领域
本发明涉及一种发泡地板,尤其是具有木材纹理的发泡地板。属于共挤发泡板技术领域。
背景技术
传统仿木地板一般都是复合地板。由密度板基材、木纹装饰纸、耐磨层以及底部的平衡层组成。但由于密度板基材易发霉腐烂,还有火灾隐患,本领域亟需一种具有防霉阻燃功能的地板。在这种情况下,PVC发泡地板成为了一种选择。但PVC发泡地板本身形状和外观不符合人们使用传统要求,导致其附加值低,难以大面积市场使用。
公开号为CN102294812A的中国发明专利申请,公开了一种聚苯乙烯仿木型材,它在一定程度上解决了塑料地板本身的外观缺陷问题。它是把表层材料和芯层材料分别投入到辅助挤出机和主要挤出机,共挤到一个模具,使表层材料包覆在芯层材料上。表层材料为高抗冲聚苯乙烯并含有和高抗冲聚苯乙烯相容性好但流动性和分散性不同的流纹色母,芯层材料为聚苯乙烯微发泡板。共挤出的型材表面进行产生立体效果或其他效果的压花处理。该法采用不同基材颜色的色母粒,分别做成基色色母粒和流纹色母粒,基色色母粒流动性较好,在加工过程中分散于基苯乙烯材料形成底色;流纹色母熔融指数较低,分散性较差,在加工过程中不能均匀分散,随着材料的挤出形成木纹或其他花纹。基色和流纹在相邻之处容易发生互融和串色的问题,上述共挤地板的仿木纹理与木材纹理差别较大,一般用户能够轻易地将上述地板和实木地板在外观上区分开。
发明内容
本发明要解决上述问题,提供了一种具有与木材纹理相同外观的发泡共挤地板。
本发明解决上述问题的技术方案如下:
具有木材纹理的发泡地板,包括由树脂形成且具有块状结构的发泡基体和与发泡基体一体连接并覆盖在它的至少一个面上的硬质表层,所述硬质表层包括由与发泡基体一个面大体平行的第一颜色树脂形成的第一外露面,以及由第二颜色树脂形成的第二外露面;所述第二外露面到发泡基体被覆盖之表面的距离较第一外露面小;并且,第一外露面由多个大体处于同一平面的外露单元组成,第二外露面由多个下陷单元组成,所述多个外露单元与多个下陷单元交错排列;所述硬质表层还包括处于相邻外露单元和下陷单元之间的连接单元,所述连接单元包括由第一颜色树脂形成并与第一外露面一体连接的连接底材以及覆盖在连接底材上的由第二颜色树脂形成并与第二外露面一体连接连接表材;并且,所述的硬质表层还包括由第一颜色树脂形成的与连接底材一体连接并被所述第二外露面覆盖的基层;所述第一颜色树脂与第二颜色树脂的颜色不同。
本发明上述技术方案中,硬质表层不仅起到对发泡基体的保护及约束作用,而且硬质表层的第一外露面和第二外露面的间隔排列形成木纹。由于第一外露面和第二外露面彼此独立又一体连接,并且它们具有不同的颜色,再结合它们具有不同的深浅度,可表现出立体的效果,在光线下还能表现出不同的明暗层次,因此由第一外露面和第二外露面共同表现的木纹具有逼真的效果。基于此形成的木材纹理,在表现手段上具有多个层次,如颜色、立体和明暗,并且在不同表现层面互不影响,同一表现层次的不同表现对象上也互不影响,不仅木材纹理效果逼真,还可以通过对多个层次的调节,表现出各种各样的木材纹理,更好地适应市场的需求。第一外露面和第二外露面彼此独立是因为它们之间是有分层的;一体连接是因为它们的层间连接不是通过诸如胶粘等形式来实现的。
作为上述技术方案的优选,所述地板的发泡基体为PVC发泡材质,硬质表层为ASA非发泡材质。
作为上述技术方案的优选,所述第一外露面的厚度不小于0.1mm,第二外露面的厚度不小于0.05mm。
作为上述技术方案的优选,所述木材纹理的发泡地板的密度为0.6~1.0g/cm3,表面硬度为洛氏硬度60~90。
作为上述技术方案的优选,所述地板的发泡基体由主挤出机供料,由第一颜色树脂形成的第一外露面、连接底材和基层由一台辅挤出机供料,由第二颜色树脂形成的第二外露面和连接表材由另一台辅挤出机供料。
本发明的再一个目的是提供上述木材纹理的发泡地板的一种制备方法。
该法包括以下步骤:
a、将构成发泡基体的原料及其添加剂加入到主挤出机中,原料及其添加剂在主挤出机中熔融塑化,进入模具的主流道中,并从主流道的模唇挤出,进入模具的发泡腔内发泡,进而形成发泡基体;
b、将构成第一颜色树脂的原料及其添加剂加入到第一辅挤出机,将构成第二颜色树脂的原料及其添加剂加入到第二辅挤出机,物料分别在第一辅挤出机中和第二辅挤出机中熔融塑化,分别进入模具的第一辅流道和第二辅流道中,通过第一辅流道和第二辅流道的横向扩散,熔融态的物料分别从第一辅流道的一字口和第二辅流道的一字口流出,使熔融态的物料将发泡基体分层包覆,并从模具的模口共挤挤出,形成地板前体结构;地板前体结构具有发泡基体、第一表层和第二表层,第二表层设置在第一表层和发泡基体之间;
c、地板前体结构经过冷却成型;
d、对冷却成型后的地板前体结构进行表面加热,至少使其第一表层变软;
e、通过压纹辊的压印处理,使得第一表层的部分区域压入到第二表层表面以下,使第一表层和第二表层共同表现出木材纹理的前态;
f、打磨处理,使未被压入到第二表层表面以下的第一表层被磨损,被磨损的区域相应的部位呈现出第二表层;使得木材纹理的前态转变成木材纹理。
作为上述技术方案的优选,步骤d中,表面加热时,控制第一表层的温度在250℃以内。
作为上述技术方案的优选,步骤d中,表面加热时,采用隧道式烘箱进行加热,烘箱内温度控制在150~250℃,时间控制在3~20s。
作为上述技术方案的优选,步骤e中,压纹辊的压花处理时,压纹辊为冷辊。
作为上述技术方案的优选,步骤f中,打磨处理时,采用砂光机处理。
本发明采用分层共挤法,在发泡层上共挤上两层的表面,并通过压纹辊在这个两层的表面压出木材纹理的前态;压纹辊处理后,地板表面形成深浅不同的区域,部分区域的第一表层被压印到第二表层以下;第一表层可被打磨去除,而第一表层被压印到第二表层表面以下部分无法被去除,因此留下第二表层和部分的第一表层,由此共同形成了木材纹理,该木材纹理具有逼真效果。
综上所述,本发明具有以下有益效果:
本发明具有木材纹理的发泡地板,以树脂为材料,基于两个表层,并通过立体(纹的深浅)、色差和明暗等多个层面的表现手法,实现了木材纹理的逼真效果。并且还可以通过对立体、色差和明暗的调节,来实现各种各样的木材纹理。
附图说明
图1是本发明地板前体结构的示意图;
图2是本发明共挤地板的示意图;
图3是图2的局部放大图;
图4是本发明模具的结构示意图;
图5是图4中A板的主视图;
图6是图4中B板的主视图;
图7是图4中C板的主视图;
图中,1-第一表层模块,2-第二表层模块,3-主流道模块;4-挡流板,5-模具出口;10-第一表层流延腔,20-第二表层流延腔;21-第二表层入料板,22-第二表层形成板;100-第一表层流道,200-第二表层流道;101-第一表层模块的物料入料口;201-第二表层模块的物料入料口;202-第二表层入料板的物料出料口;203-第二表层形成板的物料入料口;1000-发泡基体,2000-硬质表层,2001-第一外露面,2002-第二外露面,2003-基层,2010-连接底材,2020-连接表材;2001’-第一表层,2002’-第二表层。
具体实施方式
以下结合附图对本发明进行进一步的说明。
本具体实施方式仅仅是对本发明的解释,并不是对本发明的限制,本领域技术人员在阅读了本发明的说明书之后所做的任何改变只要在权利要求书的范围内,都将受到专利法的保护。
如图2所示,一种木质纹理的发泡地板,包括发泡基体1000和硬质表层2000。硬质表层2000是一种立体的凹凸结构,凸面为第一外露面2001,凹面为第二外露面2002。第一外露面2001,由第一颜色树脂形成,与发泡基体1000的一个面大体平行。第二外露面2002,由第二颜色树脂形成。第一颜色树脂和第二颜色树脂形成一定的色差。
第一外露面2001由多个大体处于同一平面的外露单元组成,第二外露面2002由多个下陷单元组成。多个外露单元与多个下陷单元交错排列。
如图3所示,相邻外露单元和下陷单元之间具有连接单元,它是硬质表层2000的一部分。连接单元包括一体连接的连接底材2010和连接表材2020。连接底材2010由第一颜色树脂形成并与第一外露面一体连接;连接表材2020覆盖在连接底材2010上,由第二颜色树脂形成。
硬质表层2000还包括基层2003,基层2003由第一颜色树脂形成,与连接底材2010一体连接,并被第二外露面2002所覆盖。
本实施例的木材纹理的发泡地板,发泡基体1000的材质为PVC微发泡材质,硬质表层2000的材质为ASA。第一外露面2001的厚度为0.2mm,第二外露面2002的厚度为0.08mm。密度为0.72g/cm3,表面硬度为洛氏硬度为72。
上述木材纹理的发泡地板的制造方法,包括以下步骤:
a、将构成发泡基体1000的原料及其添加剂经过高速混料机混匀后加入到主挤出机中,原料及其添加剂在主挤出机中熔融塑化,进入模具的主流道中,并从主流道的模唇挤出,进入模具的发泡腔内发泡,进而形成发泡基体1000;
b、将构成第一颜色树脂的原料及其添加剂,和,构成第二颜色树脂的原料及其添加剂,分别经过高速混料机混匀后,分别加入到第一辅挤出机和第二辅挤出机中,物料分别在第一辅挤出机中和第二辅挤出机中熔融塑化,分别进入模具的第一表层流道和第二表层流道中,通过第一表层流道和第二表层流道的横向扩散,熔融态的物料分别从第一表层流道的一字口和第二表层流道的一字口流出,分别进入第一表层流延腔和第二表层流延腔内,使熔融态的物料将发泡基体1000分层包覆,并从模具的模口共挤挤出,挤出后在定型模内空冷定型,出定型模后形成地板前体结构;如图1所示,地板前体结构具有发泡层1000、第一表层2001’和第二表层2002’;
c、地板前体结构经过水冷却成型;
d、对水冷却成型后的地板前体结构进行表面加热,使其第一表层2001’和第二表层2002’变软;具体地,通过隧道式加热烘箱,烘箱温度控制在200℃,通过隧道式烘箱的时间为10s,使第一表层2001’加热到90℃左右,使其软化,适于被压印出纹理;
e、通过压纹辊的压印处理,使得第一表层2001’的部分区域压入到第二表层2002’表面以下,使第一表层2001’和第二表层2002’共同表现出木材纹理的前态;
f、打磨处理,使未被压入到第二表层2002’表面以下的第一表层2001’被磨损,被磨损的区域相应的部位上呈现出第二表层2002’;使得木材纹理的前态转变成木材纹理。
由于实施例上述技术方案中,构成发泡基材1000的原料及其添加剂和构成硬质表层2000的原料及其添加剂均属于现有技术,故不再进行详细描述。
如图4所示,一种用于制造上述发泡地板的模具,包括主流道模块3、第二表层模块2和第一表层模块1,共由A-H八块流道板组成。
其中,D-H板设有模具芯层的主流道300,用于仿木纹理的发泡共挤地板的芯层发泡层的成型。
同时参照图7,C板除了设有模具芯层的主流道300外,还设有第二表层模块的物料入料口201和第二表层入料板的物料出料口202。这两个口子之间通过流道连通。
同时参照图6,B板除了设有模具芯层的主流道300外,还设有第二表层形成板的物料入料口203和第二表层流道200,第二表层流道200和主流道300之间形成第二表层流延腔20。第二表层流延腔20两侧端部还设置有挡流板4。第二表层流道200与第二表层流延腔20通过一字口连通;如此设置,可使得第二表层的熔料以半包覆地形式包覆在芯层板上,形成第一中间体。
C板也就是第二表层入料板21,B板也就是第二表层形成板22;第二表层入料板的物料出料口202与第二表层形成板的物料入料口203相接;所述第二表层流延腔20设置在第二表层形成板22上,第二表层模块的物料入料口201设置在整个模具的侧部。
B板和C板共同构成了第二表层模块2。
同时参照图5,A板除了设有模具芯层的主流道300外,还设有第一表层模块的物料入料口101和第一表层流道100,第一表层流道100和主流道300之间形成第一表层流延腔10。第一表层流延腔10两侧端部还设置有挡流板4。第一表层流道100与第一表层流延腔10通过一字口连通;如此设置,可使得第一表层的熔料以半包覆地形式包覆在第一中间体上,形成具有木材纹理的发泡地板的前体结构。
本实施例中,第一表层模块1单独地由一个流道板组成,也就是A板。第一表层模块的物料入料口101和模具出口5都设置在A板上,同时第一表层模块的物料入料口101设置在模具上部。
为了使第一表层和第二表层不串色,第一表层流延腔10的出料口和第二表层流延腔20的出料口在模具出板方向上的间距为不小于0.1mm。
具有木材纹理的发泡地板的前体结构经后续处理,可得到具有木材纹理的发泡地板。后期处理是基于两个表层实现的,公开号为CN102294812A的中国发明专利申请它只有一个表层,故在表现手法上比较单调。而基于两个表层的地板,可以通过对两个表层分别处理,如两个表层用不同的颜色、对上面的表层进行压纹、压纹后去除部分的表层使地板表面出现两种层次的表面,从立体(压纹深度)、色差、明暗等角度去表现,从而实现纹理逼真的效果。
Claims (9)
1.具有木材纹理的发泡地板,包括由树脂形成且具有块状结构的发泡基体(1000)和与发泡基体一体连接并覆盖在它的至少一个面上的硬质表层(2000),所述硬质表层(2000)包括由与发泡基体一个面平行的第一颜色树脂形成的第一外露面(2001),以及由第二颜色树脂形成的第二外露面(2002);所述第二外露面(2002)到发泡基体被覆盖之表面的距离较第一外露面(2001)小;并且,第一外露面(2001)由多个处于同一平面的外露单元组成,第二外露面(2002)由多个下陷单元组成,所述多个外露单元与多个下陷单元交错排列;所述硬质表层还包括处于相邻外露单元和下陷单元之间的连接单元,所述连接单元包括由第一颜色树脂形成并与第一外露面一体连接的连接底材(2010)以及覆盖在连接底材上的由第二颜色树脂形成并与第二外露面一体连接的连接表材(2020);并且,所述的硬质表层还包括由第一颜色树脂形成的与连接底材一体连接并被所述第二外露面覆盖的基层(2003);所述第一颜色树脂与第二颜色树脂的颜色不同。
2.根据权利要求1所述的具有木材纹理的发泡地板,其特征在于:所述地板的发泡基体(1000)为PVC发泡材质,硬质表层(2000)为ASA非发泡材质。
3.根据权利要求1所述的具有木材纹理的发泡地板,其特征在于:所述第一外露面(2001)的厚度不小于0.1mm,第二外露面(2002)的厚度不小于0.05mm。
4.根据权利要求1所述的具有木材纹理的发泡地板,其特征在于:所述地板的发泡基体(1000)由主挤出机供料,由第一颜色树脂形成的第一外露面(2001)、连接底材(2010)和基层(2003)由一台辅挤出机供料,由第二颜色树脂形成的第二外露面(2002)和连接表材(2020)由另一台辅挤出机供料。
5.权利要求1~4任一项所述的具有木材纹理的发泡地板,包括以下步骤:
a、将构成发泡基体的原料及其添加剂加入到主挤出机中,原料及其添加剂在主挤出机中熔融塑化,进入模具的主流道中,并从主流道的模唇挤出,进入模具的发泡腔内发泡,进而形成发泡基体(1000);
b、将构成第一颜色树脂的原料及其添加剂加入到第一辅挤出机,将构成第二颜色树脂的原料及其添加剂加入到第二辅挤出机,物料分别在第一辅挤出机中和第二辅挤出机中熔融塑化,分别进入模具的第一辅流道和第二辅流道中,通过第一辅流道和第二辅流道的横向扩散,熔融态的物料分别从第一辅流道的一字口和第二辅流道的一字口流出,使熔融态的物料将发泡基体(1000)分层包覆,并从模具的模口共挤挤出,形成地板前体结构;地板前体结构具有发泡基体(1000)、第一表层(2001’)和第二表层(2002’),第二表层设置在第一表层和发泡基体之间;
c、地板前体结构经过冷却成型;
d、对冷却成型后的地板前体结构进行表面加热,至少使其第一表层(2001’)变软;
e、通过压纹辊的压印处理,使得第一表层(2001’)的部分区域压入到第二表层(2002’)表面以下,使第一表层和第二表层共同表现出木材纹理的前态;
f、打磨处理,使未被压入到第二表层(2002’)表面以下的第一表层(2001’)被磨损,被磨损的区域相应的部位呈现出第二表层(2002’);使得木纹理的前态转变成木材纹理。
6.根据权利要求5所述的具有木材纹理的发泡地板的制备方法,其特征在于:步骤d中,表面加热时,控制第一表层(2001’)的温度在250℃以内。
7.根据权利要求6所述的具有木材纹理的发泡地板的制备方法,其特征在于:步骤d中,表面加热时,采用隧道式烘箱进行加热,烘箱内温度控制在150~250℃,时间控制在3~20s。
8.根据权利要求6所述的具有木材纹理的发泡地板的制备方法,其特征在于:步骤e中,压纹辊的压花处理时,压纹辊为冷辊。
9.根据权利要求6所述的具有木材纹理的发泡地板的制备方法,其特征在于:步骤f中,打磨处理时,采用砂光机处理。
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