CN110774706A - 含增强片材的面板的制造方法，和地板 - Google Patents

含增强片材的面板的制造方法，和地板 Download PDF

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CN110774706A
CN110774706A CN201910920467.0A CN201910920467A CN110774706A CN 110774706 A CN110774706 A CN 110774706A CN 201910920467 A CN201910920467 A CN 201910920467A CN 110774706 A CN110774706 A CN 110774706A
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layer
thermoplastic material
sheet
reinforcement sheet
reinforcing sheet
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K·范维拉森若德
F·G·L·博叙
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Flooring Industries Ltd SARL
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IVC NV
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Abstract

一种含增强片材(6)的面板的制造方法，该方法包括下述步骤：提供热塑性材料的第一层(3)，提供增强片材(6)，层铺增强片材(6)和第一层(3)到彼此上，将热塑性材料的第二层(11)在背对第一层(3)的侧面处施加到增强片材(6)的顶部上，至少部分熔融第一层(3)和第二层(11)的热塑性材料，将至少部分熔融的第一层(3)，至少部分熔融的第二层(11)和增强片材(6)彼此粘附，以便形成面板，其中在至少部分熔融第一层(3)的热塑性材料之后，但在施加热塑性材料的第二层(11)到增强片材(6)上之前，将增强片材(6)和第一层(3)通过在一起挤压彼此粘附。

Description

含增强片材的面板的制造方法，和地板
本申请是申请日为2015年11月19日、申请号为201580062840.3、发明名称为“含增强片材的面板的制造方法，和地板”的发明专利申请的分案申请。
本发明涉及含增强片材的面板，例如地板的制造方法，该方法包括下述步骤：提供热塑性材料的第一层，提供增强片材，将增强片材和第一层铺设在彼此上，将热塑性材料的第二层施加到增强片材的背对第一层的那面上，至少部分熔融第一层和第二层的热塑性材料，和将至少部分熔融的第一层、至少部分熔融的第二层和增强片材彼此粘附，以便形成面板。
这一方法在含增强片材的塑料地板产品领域中是已知的。
专利申请US-A-2007/0166516描述了一种通过压延和层压技术，生产(主要是塑料的)模块化地板产品的典型方法。根据这一方法，通过压延，生产若干连续片材或箔成型层，之后使用连续层压法将这些层层压在一起。在这一层压工艺中，连续添加数层，其中始于一层或多层基底层，其中包括平衡片材，和在其上添加印刷层，接着透明层。这在一个单一的生产工艺中采用一系列的层压夹辊进行，其中在每一层压卷的最前面(upfront)，从膜卷中解缠绕新的一层，预热并在事先层压的层上挤压。
还描述了在该产品中添加玻璃纤维基网状物。这一玻璃纤维网状物可以是非织造织物，网格，或稀松织物(非织造织物和网格的组合)且得到优良的产品尺寸稳定性。
可在层压生产线中添加玻璃纤维，其中将它粘附到事先压延的层上，之后在这一复合物(complex)顶部上添加另一压延层，之后可添加进一步的层。可以以未处理形式添加玻璃纤维网状物，但也可以在离线步骤中用涂层预热，以便确保更好的连接。在备选的离线步骤中，可在压延生产线上浸渍玻璃纤维网状物，其中在一个步骤中，由熔融热塑性材料生产压延层，在层压夹辊中在其上立即添加玻璃纤维网状物。然后可在层压生产线上，结合这一中间复合物与其他必须的层。
在已知的生产步骤中的关键工艺步骤是在高线速度下充分地浸渍玻璃纤维网状物。在这些连续工艺中，在玻璃纤维网状物和塑料层在其内层压和/或浸渍的夹辊处的接触时间如此短，以致于存在没有适当地浸渍的风险，从而导致在进一步的转化步骤过程中或者在产品的使用过程中，在最终产品内，层从玻璃纤维网状物中脱层。克服这一问题的一种方式是用涂层预浸渍纤维。然而，这会增加最终产品的成本，要求额外的离线操作，且也可改变产品的最终性能，例如弯曲劲度。
在专利申请WO 2013/179261Al中描述了生产模块化地板产品的另一方法。根据这一方法，在构成双层压带机一部分的环带上铺展开热塑性材料的粒子，在这一铺展开的层上施加玻璃纤维层，和在玻璃纤维层的顶部上铺展开另一热塑性材料的粒子层，其中在后续步骤中，包括玻璃纤维层在内的这两层在双层压带机内压缩。该皮带还确保热塑性材料熔融，这是通过下部和上部皮带提供的热能和浸渍玻璃纤维层导致的，以便获得玻璃纤维增强的连续塑料厚板，典型地将其完工成地板面板。
此外，在这一方法中，玻璃纤维得到良好的最终产品尺寸稳定性。
玻璃纤维的关键浸渍工艺问题被部分克服，因为塑料材料和玻璃纤维的接触时间较长，结果可确保浸渍。然而，这一体系的缺点是，玻璃纤维可能的损坏。由于玻璃纤维包埋在两层颗粒层之间，并在双层压带机内压缩，因此，单独的粒子可使纤维局部变形或者甚至使之穿孔。在熔融和压机内的压力之间需要寻找仔细的平衡。鉴于此，双层皮带工艺在产品厚度、玻璃纤维类型，配方，或类似方面并不总是灵活地进行快速的转换。部分克服变形问题或者使玻璃纤维穿孔问题的一种方式是，使用典型地在造粒挤出机内制造的非常微细的粒子(微粒)。这些微粒料的生产也是困难的，因为当降低粒料直径时，产量减少，从而导致较高的挤出机投资。当压力太高时，有更大的材料燃烧几率。
本发明目的是提供一种制造含增强片材的面板的方法，该方法包括不具有以上描述的缺点。
该目的通过本发明的方法来实现，该方法的特征在于，在至少部分熔融第一层的热塑性材料之后，但在施加热塑性材料的第二层到增强片材上之前，将增强片材和第一层通过一起挤压彼此粘附。
这意味着在挤压步骤过程中，因例如第一层内单独的颗粒使增强片材变形的风险最小化，这是因为还不存在第二层。特别地，若存在第二层并使它至少部分熔融导致软化，则在挤压过程中因第一层内的尚未充分软化的粒子导致增强片材可能变形和/或损坏。在本发明的方法中，在施加第二层之前，一起挤压增强片材和第一层，这意味着增强片材可由硬质的压机元件，例如压板或压带直接支持，这会最小化增强片材变形和/或损坏的风险。
可进一步处理所得产品，获得厚度范围典型地为1.5-6.5mm，和优选为2mm至5mm的地板产品。
位于最终产品背面的第一层和典型地位于产品中间的增强片材的范围最后为1-2.5mm。为了避免所得产品向上卷曲，增强片材也可位于另一高度位置，而不是在最终产品的中间内。例如，可定位其位置，使得该产品向上自然弯曲到有限的程度，但由于其自重，它将平躺在地面上。按照这一方式，确保了没有消费者不希望的直立的边缘。当增强片材位于更高位置时，第一层的厚度在挤压之后典型地可以是1.25至3.5mm。
注意到第一层和第二层通过各自的熔融热塑性材料的粘附性能固定到增强片材上。
在实际的实施方案中，以铺展开和随后至少部分熔融的粒子形式提供热塑性材料的第一层，和/或以铺展开和随后至少部分熔融的粒子形式提供热塑性材料的第二层。
在具体的实施方案中，以铺展开和随后至少部分熔融的的粒子形式提供热塑性材料的第一层，和以片材或膜形式提供热塑性材料的第二层。可挤压例如独立地来自粒子的片材或膜，且在将其施加到增强片材上之前，仍然可能至少部分熔融。
一旦使第一层和第二层彼此紧密地接触，则它们粘附到增强片材上。将第一层和增强层彼此挤压，但在下一步中，可在没有压力下，或者在比挤压第一层和增强层到彼此上所施加的压力低的压力下，使第二层与增强层紧密地接触。
典型的热塑性粒子由挠性或半硬质的聚氯乙烯(PVC)制造，但也可以是硬质PVC。其他可能的聚合物是聚烯烃，如聚丙烯，聚氨酯，橡胶基胶料，弹性体或聚合物如弹性体和聚丙烯的混合物，或者木塑复合材料(它是包括木粉或颗粒和聚合物的混合物)。
热塑性材料的第一层可以由含至少35％无机填料的半硬质PVC制造。
发明人已经证明，对于以上所述的整个厚度范围来说，更具体地还对于相对薄的1mm层来说，可能的是使用粒子直径为3.2mm的标准粒子尺寸。当使用3.2mm的这一标准粒子直径时，通过调节颗粒的长度到0.5mm，产生短的圆柱体形状，得到具有非常窄厚度公差的挤压层的均匀地挤压表面的最好结果。短的圆柱体形状对粒子的生产没有产生限制。它仅仅需要在挤出机头处比较快速的切割速度，在所述挤出机头内，熔体挤出通过穿孔板。3.2mm的典型尺寸在热塑性材料工业中是标准的，且在没有产生高反压情况下，允许在高产率下运行挤出工艺。高的反压容易产生剪切敏感材料，例如PVC的燃烧，鉴于此，需要降低产量，从而导致较高的生产或者投资成本。
优选地，以连续工艺进行该方法，从而导致之后可切割成任何所需尺寸面板的连续片材。然后可采用联接面板到彼此上的连接机构，提供面板，以便形成覆盖层。例如，可提供具有舌头和沟槽的面板边缘。
可借助双层压带机，一起挤压增强片材和第一层。这在第一层上产生增强片材的均匀的力分布。
特别地，发明人已发现，通过施加增强片材到铺展开的第一层的顶部上，上部皮带保护增强片材防止变形或者通过粒子穿孔，而与所使用的压力无关。因此，甚至在高压下，和甚至当粒子没有达到它完全变为热塑性状态的温度下以便它可成型时，增强片材仍然保持完整。
已经表明，铺展开一层和挤压这一层与由双层皮带工艺支撑的增强片材的这一特殊工艺的优点是，能采用3.2mm的标准粒子直径运行，且不需要较小的颗粒或者微颗粒。
粒子可具有圆柱体直径范围为2.5-3.5mm和圆柱体高度范围为0.2-2.0mm的圆柱体形状。优选约0.5mm的高度。
可在第一层和第二层上施加额外的层，例如在第一层上施加衬里层，和在第二层上施加印刷装饰层，可能地覆盖有保护层。这通过层压或涂布工艺来实现。
可包括额外的步骤，例如压花层压复合物的顶侧和底侧，在顶侧上施加UV清漆，和以厚板形式切割这一材料以供进一步转变成最终的模块化地板元件。
可借助压延，在增强片材上挤压在增强片材上的至少部分熔融的热塑性材料的第二层。这是一个相对简单的工艺。
压延工艺的特别的优点是，压延的第二层调平了所得产品的厚度。常常需要调平，因为双层压带机的机械公差限制为0.1mm。通过喷砂挤压表面进行典型的现有技术的调平操作。对于这一喷砂操作来说，需要冷却基底。然而，这是复杂的，要求额外的空间，投资和能量成本，因为从压机出来的产品需要冷却到它可在其下喷砂的温度。然而，这是非所需的，因为当需要施加装饰层和/或保护层时，它需要再次加热。
可通过压延装置进行压延工艺，所述压延装置包括大于两个压延辊，例如2至5个压延辊。
采用压延机在以上所述的挤压粒子和增强片材的复合物上施加的第二热塑性层典型地是挠性或者半硬质的聚氯乙烯(PVC)，但也可以是硬质PVC。其他可能的聚合物是聚烯烃，例如聚丙烯，聚氨酯，橡胶基胶料，弹性体或者聚合物如弹性体和聚丙烯的混合物，或木塑复合材料(它是包括木粉或颗粒和聚合物的混合物)。
第二层和第二层中的热塑性材料可以相同，或者可以基于相同的聚合物，但具有不同的制法(recipe)，或者可以基于不同的热塑性材料。
增强片材可包括玻璃纤维箔，优选其重量为25-70g/m2。
发明人已发现，可在这一方法中使用各种玻璃纤维，且具有良好的结果。一般地，较高重量的纤维导致较低的渗透率，因此更加困难的浸渍和工艺稳定性，但较好的尺寸稳定性。在现有技术的层压或挤压方法中，施加大部分这一范围的玻璃纤维导致差的浸渍结果和/或在薄与厚的产品之间难以进行产品转换。采用本文描述的方法，可使用25至70g/m2的玻璃纤维，并具有非常好的结果。
可获得高的生产速度，以及在1.5至5mm的总产品厚度之间快速和急剧的产品转换。
有利的是当在挤压增强片材和第一层到彼此上的步骤过程中，通过第一层的热塑性材料，在其至少80％的厚度上浸渍增强片材。这可通过在挤压步骤过程中选择至少合适的压力和温度来控制。另外，在压机内的停留时间可影响浸渍速率。
本发明还涉及根据本文中前面描述的方法制造的地板面板。可以预见到用于备选用途的其他面板，例如用于内部或外部用途，用于墙壁覆盖层，或天花板覆盖层等的面板。
下文参考作为实例显示本发明实施方案的示意图，解释本发明。
图1是实施制造本发明面板的方法的实施方案的装置的示意性侧视图。
图1示出了连续加工网状物的一部分装置1并阐述了本发明含增强片材的面板的制造方法的实施方案的一些步骤。装置1包括颗粒供应2，它被改编为供应颗粒的第一层或基层3到支持下部传送带4上。下部传送带4是环带。粒子在下部传送带4上均匀地铺展开。该粒子由热塑性材料，例如挠性PVC制造。
下部传送带4具有比第二上部环形传送带5大的长度，所述第二上部环形传送带5位于颗粒供应2下游的一定距离处，且沿着一部分下部传送带4行进。在下部传送带4的上端部处，在图1中在下部传送带4处用箭头表示的从左到右以相同制造方向运转这两个传送带4,5。
在粒子的基层3的顶部上供应增强片材6。增强片材6可以是玻璃纤维箔或者具有增强性能的任何备选的箔。通过从供应卷7中解缠绕，供应增强片材6。随后，在下部和上部传送带4，5之间沿着加热装置8传输增强片材6和粒子的基层3，以便熔融粒子的基层3，然后通过压机单元9一起挤压。熔融速率可使得粒子完全转化成糊状物质，但也可预见到粒子部分熔融。增强片材6和基层3在压力下，通过熔融热塑性材料的粘附性能连接到彼此上。随后，含增强片材6的基层3沿着冷却单元10传输。有利的是增强片材6通过挤压单元9的硬质挤压元件直接支持，这是因为在增强片材6和硬质压机元件之间的柔软层将因没有完全熔融的第一层3中的粒子而增加增强片材6变形或损坏的风险。它提供了在基材3中采用相对大粒子的几率。
在下一步中，在增强片材6的顶部上提供第二层或者顶层11。顶层11由与基层3相同的热塑性材料制造，但在备选的实施方案中，它可以不同。顶层11中的热塑性材料熔融并通过夹辊挤压成片材，然后通过压延辊12，一起挤压仍然至少部分熔融的片材11和含增强片材6的基层3，从而导致具有光滑上表面的网状物。
在压延辊12下游的位置处，可排列切割装置(未示出)，以切割所得连续网状物成单独的面板，然后收集所述面板以供进一步加工。
在备选的实施方案(未阐述)中，在第一步中，增强片材可置于下部压板或挤压部件的顶部上，之后在增强片材上铺展开热塑性粒子，形成第一层。该粒子可以在铺展开之前或之后至少部分熔融。随后，将上部压板或挤压部件置于第一层顶部上，并且下部和上部压板或挤压部件可挤压第一层和增强片材到彼此上。所得中间产品可以倒转，并可在增强片材的顶部上，在背对第一层的其侧面处，施加热塑性材料的第二层，例如至少部分熔融的片材。在将至少部分熔融的片材置于增强片材顶部上的情况下，它可借助压延固定到其上。同样可能的是所得中间产品没有倒转，和当增强片材在第一层下面延伸时，在增强片材上施加第二层。
根据前面内容，清楚的是本发明提供含增强片材的面板的改进的制造方法。
在一些实施方案中，本发明涉及以下项目：
1.含增强片材(6)的面板的制造方法，该方法包括下述步骤：
提供热塑性材料的第一层(3)，
提供增强片材(6)，
将增强片材(6)和第一层(3)铺到彼此上，
将热塑性材料的第二层(11)施加到增强片材(6)的背靠第一层(3)的那面上，
至少部分熔融第一层(3)和第二层(11)的热塑性材料，
将至少部分熔融的第一层(3)、至少部分熔融的第二层(11)和增强片材(6)彼此粘附，以便形成面板，
其特征在于，在至少部分熔融第一层(3)的热塑性材料之后、但在施加热塑性材料的第二层(11)到增强片材(6)上之前，将增强片材(6)和第一层(3)通过在一起挤压彼此粘附。
2.项目1的方法，其中热塑性材料的第一层(3)以铺展开和随后至少部分熔融的粒子形式提供，和/或其中热塑性材料的第二层(9)以铺展开和随后至少部分熔融的粒子形式提供。
3.项目1的方法，其中热塑性材料的第一层(3)以铺展开和随后至少部分熔融的粒子形式提供，和其中以片材或膜形式提供热塑性材料的第二层(11)。
4.项目3的方法，其中在将片材或膜(11)施加到增强片材(6)上之前，独立地挤压它且至少部分熔融。
5.前述任何一项项目的方法，其中以连续工艺形式进行该方法。
6.项目5的方法，其中借助双层压带机，一起挤压增强片材(6)和第一层(3)。
7.项目5或6的方法，其中借助压延，将在增强片材(6)上的至少部分熔融的热塑性材料的第二层(11)挤压到增强片材(6)上。
8.前述任何一项项目的方法，其中增强片材(6)包括玻璃纤维箔，优选其重量为25-70g/m2。
9.前述任何一项项目的方法，其中第一层(3)和第二层(11)的热塑性材料相同。
10.前述任何一项项目的方法，其中将增强片材(6)置于第一层(3)的顶部上，之后一起挤压它们。
11.前述任何一项项目的方法，其中将第二层(11)施加于增强片材(6)的顶部上，之后一起粘附第二层(11)和增强片材(6)。
12.前述任何一项项目的方法，其中热塑性材料的第一层由含至少35％无机填料的半硬质PVC制造。
13.前述任何一项项目的方法，其中以圆柱体直径范围为2.5-3.5mm和圆柱体高度范围为0.2-2.0mm，优选约0.5mm的圆柱体形状的颗粒形式提供热塑性材料的第一层(3)。
14.前述任何一项项目的方法，其中至少选择在挤压步骤过程中的压力和第一层(3)的热塑性材料的熔融速率，使得增强片材(6)被第一层(3)的热塑性材料浸渍至少其厚度的80％。
15.项目7的方法，其中使用含两个以上压延辊的压延装置。
并没有将本发明限制到附图所示和本文前面描述的实施方案上，所述实施方案可在权利要求及其技术等价方案的范围内以不同方式变化。例如，第一层可以在熔融条件下施加在下部传送带上而不是首先铺展开，然后熔融粒子。此外，可在增强片材和第一层层铺到彼此上之前，进行第一层粒子的加热。

Claims (11)

1.一种含增强片材的面板的制造方法，该方法包括下述步骤：
提供颗粒形式的热塑性材料的第一层，
提供增强片材，
将增强片材和第一层铺到彼此上，
在第一压力下在至少部分熔融热塑性材料的第一层之后,通过双层压带机将增强片材和第一层挤压在一起，使增强片材和第一层彼此粘附,增强片材由此直接啮合压机元件；
在使增强片材和第一层彼此粘附之后，
提供片材或膜形式的热塑性材料的第二层；
将第二层直接施加到增强片材的背对第一层的那面上；和
通过压延将第二层挤压到增强片材上，包括：
至少部分熔融第一层和第二层的热塑性材料；和
在比第一压力低的第二压力下，将至少部分熔融的第一层、至少部分熔融的第二层和增强片材彼此粘附，以便形成面板；和
在第二层上施加印刷装饰层和覆盖印刷装饰层的保护层。
2.权利要求1的方法，其中在将第二层施加到增强片材上之前，独立地挤压且至少部分熔融第二层。
3.权利要求1的方法，其中以连续工艺形式进行该方法。
4.权利要求1的方法，其中增强片材包括玻璃纤维箔，优选其重量为25-70g/m2。
5.权利要求1的方法，其中第一层和第二层的热塑性材料相同。
6.权利要求1的方法，其中将增强片材置于第一层的顶部上，之后将它们挤压在一起。
7.权利要求1的方法，其中热塑性材料的第一层由含至少35％无机填料的半硬质PVC制造。
8.权利要求1的方法，其中以圆柱体直径范围为2.5-3.5mm和圆柱体高度范围为0.2-2.0mm的圆柱体形状的颗粒形式提供热塑性材料的第一层。
9.权利要求1的方法，其中至少选择在挤压步骤过程中的压力和第一层的热塑性材料的熔融速率，使得增强片材被第一层的热塑性材料浸渍其厚度的至少80％。
10.权利要求1的方法，其中使用含大于两个压延辊的压延装置。
11.权利要求8的方法，其中圆柱体高度为约0.5mm。
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