CN111226013A - Pvc板和制造方法 - Google Patents

Pvc板和制造方法 Download PDF

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Publication number
CN111226013A
CN111226013A CN201780091935.7A CN201780091935A CN111226013A CN 111226013 A CN111226013 A CN 111226013A CN 201780091935 A CN201780091935 A CN 201780091935A CN 111226013 A CN111226013 A CN 111226013A
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China
Prior art keywords
layer
pvc
parts
panel
component
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CN201780091935.7A
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English (en)
Inventor
程全山
薛根祥
袁俊
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Taizhou Huali New Material Co Ltd
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Taizhou Huali New Material Co Ltd
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Abstract

提供了一种新的PVC板和制造方法。该板包括可压缩层以提供走起来舒适的地板以及易于清洁的聚氨酯表面。该制造方法简化了制造过程，并改善了制造时间和效率。

Description

PVC板和制造方法
发明领域
本发明属于作为建筑材料的工程板的技术领域，更具体地涉及一种新型的PVC板和制造方法。
发明背景
聚氯乙烯(PVC)是众所周知的合成聚合物。PVC具有许多使其成为期望的建筑材料的品质。例如，它可以制造成刚性的或具有一定范围的柔韧性，它耐潮和耐霉，防水且易清洗，并且非常耐用。刚性PVC通常用于管道、门和窗以及其他应用中的结构中，在这些应用中，其替代木材、金属和其他刚性材料。在现有技术中，通过在制造过程中向PVC组分的混合物添加增塑剂使PVC柔韧。最广泛使用的增塑剂是邻苯二甲酸酯(最近的研究已确定邻苯二甲酸酯是有毒的)。以其柔韧性形式，PVC用于电缆绝缘、人造革、标志及其他可代替橡胶、皮革和其他非刚性材料的应用中。PVC还耐冲击、耐老化、耐破裂、耐翘曲和耐变色。
由于其期望的特性，PVC具有许多商业用途。例如，PVC片材用作地板材料、内部镶板和外部侧板。作为地板材料，PVC行走起来舒适，并且可具有即使在潮湿时也防滑的非常耐用的表面层。它可以制备为具有丰富多样的颜色、设计和其他材料的模拟。例如，可得到外观类似于地毯、石材、木材和瓷砖的PVC地板，包括可以压花以增强模拟真实感的表面。可以供选择地使表面平坦，使其具有粗糙的、无光泽的或有光泽的饰面。PVC片材还可以制造成具有一个或多个可见的设计层，以达到各种效果，使用从哑光(muted)到亮光(brilliant)的几乎任何色相、饱和度和色调的非常广泛的调色板。可以形成和/或加工相邻的对比区域以具有非常精确地控制的形状和颜色。
由于所有这些特性，PVC板优于其他常见的结构材料，特别是内墙镶板和地板材料，并且可以充分发挥设计师的创造力。它可以满足几乎任何装饰的独特需求。另外，PVC可以制成吸音的，将环境噪音降低多达20分贝；并且可以制成减轻诸如高跟鞋行走撞击事件产生的噪音。这使得PVC特别适合于安静的环境如医院、图书馆、演讲厅、剧院等。
此外，PVC易于处理。作为木材的替代品，它可以通过钻孔、锯、钉、刨、胶合和其他加工像木材一样被处理；并且它提供类似的性能如钉固持力。由PVC制成的产品还通常至少如由其他材料制成的那些产品一样容易安装。它坚固、轻巧，并且可以使用用于粘合PVC的粘合剂容易地组装具有匹配连接的部件，并且在相对短的时间内，粘合就如PVC主体一样强。
然而，现有技术中的PVC制造是复杂的。它需要大量的加工步骤，所有这些步骤都必须严格控制并按设定的顺序执行。例如，制造PVC板一般地涉及在单独的步骤中将PVC粉、增塑剂、稳定剂、润滑剂、填料和其他原料混合在一起。在每个步骤中，必须将材料完全并均匀地混合以产生一致的(consistent)混合物。在制造PVC材料之后，将其成型为成品通常需要首先制作PVC片材。这也需要许多有序的步骤，包括将半成品轧制成部件片材，在一个或多个单独的过程中将这些片材结合在一起，形成具有许多层的成品片材，并将分层的片材加工成成品。如果这些层没有牢固地固定至彼此，则它们可能分离、起泡、开裂，或者质量比期望的质量更差。
现有的PVC制造方法一般包括用于混合、稳定、密封、固化、回火、涂覆、层压和更多的单独步骤。通常必须按一定顺序添加组合和混合构成原料如PVC粉、增塑剂、稳定剂、润滑剂、填料及其它。具有有不同特性的层的产品要求每个层彼此单独地混合。可以将每个这样的层研磨成中间阶段，这是通过将PVC轧制成片材，然后必须按一定顺序将这些片材组合，并且经常通过一个或多个加热步骤将它们熔合在一起，形成组合片材。然后，如果需要的话，通常将组合的片材切割成形状并且模制成型。PVC可以在紫外线下固化，并且可以通过多个加热、拉伸和冷却步骤回火。在一些应用中，PVC也必须被层压。进一步的步骤可包括在一个或多个层上形成设计或图案，使一个或多个表面纹理化，等等。因此，PVC制造过程非常复杂。
发明概述
一种新的PVC板和制造方法。该板包含一种无毒的柔性PVC冲击改性剂而非增塑剂，以提供具有优良性能特征的弹性地板。该制造方法简化了制造过程，并改善了制造时间和效率。
附图简述
从以下结合附图的描述，本发明的具体特征和优点以及其他目的将显而易见，其中：
图1是根据本发明的示例性工程板的第一实施方案的侧视图。
图2A-2B是根据本发明的制造图1的板的方法的流程图。
图3是根据本发明的示例性工程板的第二实施方案的侧视图。
图4A-4B是根据本发明的制造图3的板的方法的流程图。
图5A是用于测量包括被制造成行走起来舒适的层的地板材料的回弹能力的过程的流程图。
图5B是示出图5A的过程的结果的表。
发明详述
公开并描述了一种新的PVC板和制造方法。在第一示例性实施方案中，PVC板是具有三个层的复合材料。如图1中所示，从上到下的层是1A耐冲击的透明PVC耐磨层；2A通过透明耐磨层可见的PVC膜层，该层显示一种或多种颜色、形状、图案和/或其他材料的模拟；3A包含柔性PVC冲击改性剂的PVC底层或基础层。耐磨层可以具有各种饰面，包括光滑的、无光泽的、纹理的或压花的饰面。所述基础层可以是PVC的实心层或泡沫层，并且还可以设置有底部表面处理如压花，例如，以支持使用粘合剂的容易安装。
在基础层是实心的情况下，其包含按重量计100份聚氯乙烯(PVC)树脂、4-20份PVC弹性体冲击改性剂、0-400份碳酸钙、6-8份钙/锌复合稳定剂和1.0-2.0份润滑剂。
在基础层是泡沫的情况下，其包含按重量计100份PVC树脂、4-20份PVC弹性体冲击改性剂、0-300份碳酸钙、6-8份钙/锌复合稳定剂、0.2-1.0份发泡剂、4-8份发泡调节剂和1.0-2.0份润滑剂。
另外，公开和描述了用于制造PVC的多层复合片材的新方法。在示例性实施方案中，该方法制造具有永久熔合在一起的三个层的复合片材。这三个层包括底部PVC基础层，根据上述配方之一，其可以是实心层或泡沫层。PVC呈现层(presentation layer)与基础层相邻形成并永久熔合至基础层，提供一种或多种颜色、形状、设计和/或其他材料如木材、瓷砖等的视觉模拟。第三个层是耐冲击的透明PVC耐磨层，透过该耐冲击的透明PVC耐磨层显示层(display layer)是可见的。它邻近显示层形成并且永久地熔合至显示层。在实施方案中，耐磨层可设置有期望的饰面，该饰面可以是光滑的、无光泽的、粗糙的、有纹理的、开槽的或压花的饰面，以模拟由与之熔合的显示层视觉模拟的材料的表面。
图2A-2B是示出形成复合PVC板的方法的示例性实施方案的流程图。如所示，该方法开始于接收原料200，将由原料制造PVC板。检查原料202，和如果检查不合格，则将其拒收204。如果原料来料检查合格，则称量上述至少一个配方中指定的重量份206，并置于混合器中用于混合208。优选地，在混合器中混合期间，将材料加热至它们可以流动的温度以促进形成均匀的混合物，然后冷却直至粘性且可延展。在一个实施方案中，将PVC混合物加热至100-130℃，优选加热至110-120℃。然后将混合物冷却至降低的温度，同时继续搅拌，直到混合物呈粘性可延展状态。在一个实施方案中，将加热的混合物冷却至30-50℃，优选冷却至35-45℃，更优选冷却至约40℃。接下来，将用于PVC基础层的冷却的延展性材料挤出成平的均匀片材210，优选地挤出到相对于挤出机移动的表面上。可以使用双螺杆挤出机，优选保持在150℃至180℃的温度。
还对PVC膜层212和对透明PVC耐磨层214执行类似的过程(未示出)。协调所有三个层的加工，以便在同一制造过程期间对它们进行单独加工。然后，将三个可延展层成型在一起216，这将这些层永久性地熔合在一起，成为薄的复合层状材料片材。供选择地，可延展产品可以被成型为期望的轮廓。然后将片材进一步冷却218。然后将复合片材切割成板坯220。通过将2A的底部的带圆圈的“A”与图2B的顶部的带圆圈的“A”匹配，图2A并入图2B。
现在参考图2B，在切割之后，检查复合材料的板坯222。例如，可以检查它们以查验材料在物理性质方面的均匀性，物理性质如，例如，厚度、顶层的透明性、膜层的外观、柔韧性和/或由基础层提供的可压缩性。如果板坯检查不合格，则可以将其报废224，并回收226。例如，可以将物料切碎或制成颗粒，并用作后续制造的产品的部件，该后续制造的产品可以按重量使用原料的混合物，这些原料弥补报废的材料。可以在一个或多个后续制造阶段之后再次检查该材料，可以将那些检查不合格的材料类似地报废224和回收226。
在一个实施方案中，检查合格的板坯设置有紫外(UV)涂层228，可以将该涂层例如喷涂到板坯上，并在UV光下固化。然后可以再次检查涂覆的板坯230。如前所述，可以将检查不合格的材料报废224并回收226。然后，可以将检查合格的涂覆的板坯切割成将组成成品的块232，然后再次检查234。检查不合格的材料可以如前所述被报废224和回收226。
在一个实施方案中，检查合格的块可以例如通过机械加工块的一个或多个边缘和/或表面进行饰面。然后，可以再次检查成品块238。检查不合格的材料可以如前所述被报废224和回收226。检查合格的成品块构成成品。可以将这些包装240，并再次检查242。检查不合格的材料可以如前所述被报废224和回收226。最后，可以将最终检查合格的包装的成品块储存在仓库中244，或者以其他方式准备运输。
总之，以上描述了一个实施方案，其中PVC地板材料在单个生产线中用仅三个层就被简单和有效地制造。将三个层中的每个层的PVC材料彼此分开地混合、加热和冷却。然后，在各层均处于热粘性状态下时，将它们在单个加工步骤中在单独的挤出机上一层压一层地挤出。挤出机可以是双螺杆挤出机，其维持在恒定的高温下以维持每个层的延展状态，从而使其熔合至相邻的层。
在一个实施方案中，将这些层挤出到单个生产路径的移动表面上，例如挤出到转鼓上。可以将基础层挤出并进料入第一组热辊中，将其压平成薄片。当第二呈现层沿着生产路径移动时，其可以被挤出到仍然延展的基础层上或其附近。由于当两个片材在相遇时它们的热延展态，所以它们永久地熔合在一起，形成两层复合片材。在一个实施方案中，另一组辊可进一步压平并熔合两层复合片材。最后，耐磨层材料可以被挤出到呈现层上或呈现层附近。同样，由于当耐磨层和呈现层在相遇时它们的热延展状态，所以两个片材永久地熔合在一起，形成三层复合片材。在一个实施方案中，可以通过从三个不同方向以相同的速度，例如，从左、从右和从正上方，进给三个层而在单个步骤中连接三个层。然后可以将三个挤出的片材轧在一起并熔合。在另一个实施方案中，不同的辊组可以将三个层中的每个层引入生产路径。例如，可以首先挤出基础层，然后可以将呈现层挤出至基础层的顶部，形成两层复合材料。可以将两层复合材料进料入一组辊中，以将它们压平并熔合在一起。或者，可将耐磨层挤出到呈现层上，形成三层复合片材，耐磨层在顶部。然后可以使三层复合材料通过另一组辊以将这些层压平并熔合在一起。在任何一种情况下，所有三个层都因此在单个生产路径中被压平并永久地彼此熔合。
在实施方案中，加热PVC材料的三种混合物包括分别将每种混合物加热至100-130℃，优选至110-120℃。然后将这些混合物冷却至降低的温度，同时继续搅拌，直到它们处于粘性可延展状态。在一个实施方案中，将每种搅拌混合物冷却至30-50℃，优选至35-45℃，更优选至约40℃。在此温度下，每种材料都增稠成粘性可延展状态。然后将该可延展材料进料到双螺杆挤出机中，然后如上所述进料到辊中。
在实施方案中，可以如上所述地形成复合片材或面板，但是具有另外的加工步骤。这样的步骤可以在材料移动通过生产线时仍在单个生产过程中执行。这样的加工步骤可以包括，例如，在一个实施方案中，在生产线中的任何适当点处，通过一个或多个另外的加热-冷却步骤和/或牵拉和拉伸步骤回火复合材料。还可以将复合材料切割、成型、压制、造型、刨平、抛光和/或以其他方式机械加工，以形成任何期望的轮廓或其他期望的实心或空心形状。还可以在一个或多个附加的工艺步骤中为该产品提供任何期望的表面模拟或饰面。例如，可以将直线蚀刻到表面中，和/或可以对表面进行加工以提供光滑、无光泽或粗糙的饰面、纹理、压花、波纹化等。因此，可以制造几乎无限数量的成品。
尽管上文已经描述了具有三个不同层的复合片材，但是成品的形式不必是片材，并且其不必具有三个层。相反，通过在制造过程中包括所需的步骤，可以将任意数量的层形成为任意数量的形状。然而，如上所述，一个当前优选的实施方案制造了具有适合用作地板材料的三个层的平PVC面板。
在前面的PVC混合物描述中，要强调的是，无毒的冲击改性剂而非增塑剂用于提供震动吸收。这可导致提供更好的环境性能的更弹性的地板。通过上述方法，在冷却和成型复合PVC面板之后，可以将其切割以形成大的墙面板或地板面板。
供选择的实施方案、配方和制造方法包括以下。在另一个示例性实施方案中，PVC板是具有五个层的复合材料。如图3中所示，从上到下的层是1B-聚氨酯(PU)涂层；2B-耐冲击的透明PVC耐磨层；3B-通过透明耐磨层可见的PVC膜层，其显示一种或多种颜色、形状、图案和/或其他材料的模拟；4B-缓冲的弹性舒适层；和5B-包含柔性PVC冲击改性剂的PVC底层或基础层。
层2B、3B和5B可以分别与先前描述的层1A、2A和3A相同或相似。如前所述，耐磨层可以设置有各种饰面，包括光滑的、无光泽的、有纹理的或压花的饰面。所述基础层可以是PVC的实心层或泡沫层，并且还可以设置有底表面处理如压花，例如，以支持使用粘合剂的容易安装。另外，添加柔软层4B以改善脚舒适度并降低噪音；并且添加聚氨酯(PU)涂层1B以防止表面污垢。PU坚固，易于清洁，且几乎不需要维护或不需要维护。在形成耐磨层2B之后，可以将PU以液体或气溶胶的形式直接施加到耐磨层2B上。供选择地，如下所述，PU层可以独立地形成为单独的层，然后包括在该方法中。
聚氨酯(PU)层1B是在紫外光下固化的地板涂层，形成耐磨损且易清洁的层。柔软层4B是聚氯乙烯的弹性体层或改性的环境增塑剂复合材料，具体质量份如下：100份PVC树脂、弹性体或增塑剂20-60份、钙锌复合稳定剂2-6份、碳酸钙0-500份。
在示例性实施方案中，制造方法制造具有永久熔合在一起的五个层的复合片材。每个层单独地形成，并选择和组装这些层以提供具有期望性质的PVC板。在该示例性实施方案中，五个层包括底部PVC基础层，其可以是根据前述配方之一的实心层或泡沫层。可以单独地形成柔软层并且将其放置为与基础层相邻以用于舒适和噪声抑制。可以将PVC呈现层单独制作并放置成与柔软层相邻，以提供一种或多种颜色、形状、设计和/或其他材料如木材、瓷砖等的视觉模拟。下一层可以是耐冲击的透明PVC耐磨层，通过该PVC耐磨层显示层可见。并且，PU层或顶部涂层可以直接施加到耐磨层的上表面，或者可以独立地形成为板坯并与耐磨层相邻地组装。在实施方案中，耐磨层可以设置有期望的饰面，该饰面可以是光滑的、无光泽的、粗糙的、有纹理的、开槽的或压花的饰面，以模拟由与之熔合的显示层视觉模拟的材料的表面。
本发明的示例性新制造方法包括：获得针对其特定物理特性选择的多个板坯层，以选择的顺序组装所述层，以及热压组装的层以将它们熔合在一起作为复合板。包括相同或不同的部件层的多个复合板可以以相同或不同的顺序组装。包括选择部件层的复合板可通过非熔合涂层或层彼此分开，以在单个热压步骤中形成多个复合板。形成的复合板可具有以相同或不同顺序组装的相同或不同的部件层。在当前优选的实施方案中，可以使各自具有不同配方和物理特性的多个部件层可供选择并包含在复合板中。所述部件层可以包括例如用于抵抗表面污垢和易于维护的PU层；遮光板；任何数量的相同或不同厚度的PVC板，以给复合板提供基材；任何数量的相同或不同厚度的柔软材料板，以给复合板提供弹性质量，用于舒适和/或噪音抑制；作为复合显示层的任何数量的具有任何期望颜色、图案、图像、透明度等的膜层；任何期望厚度的PVC透明耐磨层，以及可能具有压花外表面的表面板。将所述板以任何期望的顺序组装并一起放置在热压机中，在选择的压力和温度下经受熔合步骤，持续选择的时间，并且然后在不同的选择压力和温度下经受冷却步骤，持续选择的时间。例如，熔合步骤压力为4-8MPa，温度为130-160℃，持续30-50分钟，以及随后的冷却步骤压力为8-12MPa，持续25-40分钟。可以将多个第一熔合和冷却步骤应用于组装的选择部件层以形成复合部件层，然后可以将复合部件层包含在另外的组件中以形成另外的部件层或成品复合板。
在一个实施方案中，部件复合层可以由PVC基材层、柔软层、模拟图案PVC膜和PVC透明耐磨层形成，以形成4层复合结构。然后可以将该结构与PU涂层层压，并进一步加工以形成5层复合板。或者，该制造方法可以包括热压步骤，其中将透明耐磨层添加到具有压花表面的表面板和一个或多个呈现膜，以模仿期望的材料。
在一个实施方案中，可以通过将原料进料到混合器中，将其加热并搅拌以形成PVC热混合物而形成PVC层的制造方法的方法。然后可将PVC混合物冷却至一定温度并在PVC双螺杆挤出机中挤出。如前所述，可以通过三辊热轧成型、冷却和成型而形成复合部件层。然后可以将复合部件层切割成期望尺寸的部件板。在一个实施方案中，该制造方法可包括在搅拌和加热至110-120℃的同时在混合器中混合PVC原料，在搅拌的同时将热混合物冷却至40℃，然后在双螺杆挤出机中挤出冷却的PVC混合物。
在一个实施方案中，可以通过将成品复合板切割成期望尺寸的板形成PVC壁板。在一个实施方案中，可以通过将成品复合板切割成板并将板边缘机械加工成适合作为开槽地板的形状而形成PVC地板。
图4A-4B是示出形成复合PVC板如图3的PVC板的另一示例性方法的流程图。如所示，该方法开始于接收原料400，将由该原料制作成品PVC板的至少一个层。一旦收到就对原料进行检查402，并且如果检查不合格则将其拒收404。如果原料来料检查合格，则称量至少前述配方之一中指定的重量份数406，并将其置于用于混合的混合器中408。优选地，在混合器中混合期间，将材料加热至它们可以流动以促进形成均匀混合物的温度，然后冷却直至粘性且可延展。在一个实施方案中，可将PVC混合物加热至100-130℃，并且优选加热至110-120℃。然后可以在继续搅拌的同时将混合物冷却至降低的温度，直到混合物处于粘性可延展状态。在一个实施方案中，可以将加热的混合物冷却至30-50℃，并且优选冷却至35-45℃，以及更优选冷却至约40℃。接下来，将用于PVC底层的冷却的可延展材料挤出成平的均匀片材410，优选地挤出到相对于挤出机移动的表面上。可以使用双螺杆挤出机，优选保持在150℃至180℃的温度下。
然后可以通过成型412、冷却414并切割成板坯416形成部件板(例如，对应于图3中的层5B)。尽管在图中示出了三辊成型，但是可以使用其他成型结构如两辊成型。可以对板坯进行检查418，并且可以将不合格的那些板坯报废420，并回收422，因为它们也可以处于随后的检查中。可以通过热压430将检查合格的板坯与一个或多个其他预形成的板坯层如耐磨层424(对应于层2B)、可见膜层426(对应于层3B)和/或柔软层428(对应于层4B)组合在一起。这些层可以在包括类似于步骤400-422的步骤的过程中独立地形成。部件层的形成无需协调，除非形成复合板坯的部件必须可用于组装。在热压步骤期间，将组装的层永久地熔合在一起，成为复合层状材料板坯。
通过将4A的底部的带圆圈的“B”与图4B的顶部的带圆圈的“B”匹配，图4A与图4B合并。检查在步骤430中形成的复合板坯432，并且可以将不合格的那些复合板坯报废并回收。在该实施方案中，检查合格的那些复合板坯设置有紫外(UV)涂层434(对应于图3的层1B)。该涂层可以是通过施加紫外光固化的一个层或两个层，或者是将保护成品免受紫外光影响如变色的涂层，变色可能是当成品板在使用时长时间暴露于太阳光的结果。再次检查经UV涂覆的板坯436。将检查合格的那些板坯切割成适合于所制造的成品的块438，并且对这些块进行检查440。可以使检查合格的那些块经受造型步骤442，以赋予它们一个或多个具有期望轮廓的边缘。可以将边缘中的一个或多个弄方正(square off)并使其平滑。供选择地，可以赋予一个或多个边缘轮廓，该轮廓可以在组装期间与组装时相邻块的边缘的轮廓互锁。
造型的块再次被检查444，包装446，并在被存储450或递送之前进行最后一次检查448。
可以选择和组装部件板坯，以提供具有期望的物理性质的成品。例如，通过选择必需的层，可以将成品形成为具有期望的厚度、外观、柔韧性和/或可压缩性。
总之，上述实施方案提供了一种可在单个生产线中简单和有效地制造的具有任何期望数量的层的基于PVC的产品，这些层提供这些层的物理特性的任何期望的组合。在实施方案中，复合板坯或块可以如上所述形成，但是具有另外的加工步骤。这样的步骤可以在材料移动通过生产线时仍在单个生产过程中执行。这样的加工步骤可以包括例如在生产线的任何适当点处通过一个或多个另外的加热-冷却步骤和/或牵拉和拉伸步骤对复合材料进行回火。还可以将复合材料切割、成型、压制、造型、刨平、抛光和/或以其他方式处理，以形成任何期望的轮廓或其他期望的实心或中空形状。该产品还可以设置有任何期望的表面模拟或饰面。
尽管已经描述了具有某些不同层的复合片材，但成品的形式不必是平片材、板坯或块。并且，它不需要有仅三个、四个或五个层。而是，通过在制造过程中包括所需的步骤，可以将任意数量的层形成为任意数量的形状。然而，前述当前优选的实施方案制造具有五个层的平PVC板，其适合用作低维护、消音的地板材料，如所述的那样，其行走起来特别舒适。
图5A示出了在2016年8月执行的新的测试方法，以证明和量化包括如前所述的柔软舒适层的地板材料的回弹特性，并将结果与具有相似结构但没有舒适层的地板的回弹特性进行比较。因此，测试的材料包括有和无舒适层的地板材料样品。测试了每种类型地板的三个样品，并对这两种类型的地板材料的三个测试的结果进行了平均。
测得样品为约8mm x 8mm，并且标称厚度均为5mm。在测试期间，测量了样品的厚度，精确到0.01mm以内。通过测量样品的初始厚度500，指定为t0，开始对每个样品执行测试程序。然后将90KG的负载设置在样品的顶部510，以模仿站立在由该材料制成的地板上的人对该材料的影响。在五秒时间段内将负载完全放在样品上，并且在整个负载静止在样品上的两秒内启动计时器。10分钟后，移除负载520，并测量样品的厚度530，指定为t1。然后样品被无负载放置60分钟，540，并再次测量其厚度550，指定为t2。然后计算反弹百分比560，为100x(t2-t1)/t0。对两种类型的地板的三个样品的结果取平均值。
图5B是示出测量值的表。发现有舒适层的地板材料回弹6.00％；而没有舒适层的地板回弹仅2.20％。因此，有舒适层的地板应近似具有薄绒毛的地毯的感觉，这比坚硬的硬质地板舒适得多，同时保持与坚硬的地板一样容易清洁和维护。
本文公开的结构的许多改变将呈现在本领域技术人员眼前。本公开内容涉及仅用于说明目的描述的本发明的实施方案。所描述的实施方案不应被解释为限制本发明，除非在本公开内容中明确这样指出了这种限制。不背离本发明的精神的修改旨在包括在所附权利要求书所限定的本发明的范围内。

Claims (20)

1.一种板，其包括：
包含柔性冲击改性剂且不包含任何有毒的增塑剂的PVC基材层；
永久地连接到所述基材层的可压缩PVC舒适层；
永久地连接到所述舒适层的作为呈现层的膜；
永久地连接到舒适层的透明耐磨层；和
聚氨酯(PU)顶层。
2.权利要求1所述的板，其中，所述基材层是由PVC混合物形成的实心层，所述PVC混合物包含按重量计：
100份聚氯乙烯树脂，
4-20份聚氯乙烯弹性体冲击改性剂，
200-300份碳酸钙，
6-8份钙/锌稳定化合物，和
1.0-2.0份润滑剂。
3.权利要求1所述的板，其中，所述基材层是由PVC混合物形成的泡沫，所述PVC混合物包含按重量计：
100份聚氯乙烯树脂，
4-20份聚氯乙烯弹性体冲击改性剂，
150-300份碳酸钙，
6-8份钙/锌稳定化合物，
0.2-1.0份发泡剂，
4-8份发泡调节剂，和
1.0-2.0份润滑剂。
4.权利要求1所述的板，其中，所述舒适层包含按重量计：
100份PVC树脂或增塑剂；
20-60份PVC弹性体；
2-6份钙锌复合稳定剂；和
1-500份碳酸钙。
5.权利要求1所述的板，其中，所述PU层独立于其它层作为单独的层形成。
6.权利要求1所述的板，其中，所述PU层通过在另一层的顶表面上喷涂液体PU形成。
7.权利要求1所述的板，其中，所述板的至少一个表面被压花。
8.权利要求1所述的板，其中：
所述呈现层模拟非PVC的建筑材料的外观，并且
在施加PU层之前，对耐磨层的顶表面压花，其纹理模拟由呈现层模拟的建筑材料的纹理。
9.一种制造不包含增塑剂的板的方法，其包括：
形成多层复合材料，其包括：
形成包含柔性冲击改性剂且不包含任何有毒增塑剂的PVC基材层；
形成永久地连接至基材层的可压缩PVC舒适层；
形成永久地连接至舒适层的作为呈现层的膜；
形成永久地连接至舒适层的透明耐磨层；和
形成聚氨酯(PU)顶层；和
加工所述多层复合材料以形成所述板。
10.权利要求9所述的方法，其中，所述基材层、舒适层和呈现层以及所述耐磨层中的至少一个独立地且与其它层分开地形成为部件层，所述方法还包括对于每个不同的部件层：
根据该层的预定配方，将预定重量的原料置于混合器中；
混合并加热混合物，直至其均匀混合和可延展；
挤出均匀的延展混合物；
将挤出的混合物成型为平片材；
冷却所述平片材；和
将冷却的片材切割成部件板坯。
11.权利要求10所述的方法，还包括：
基于每个板坯的预定物理特性，选择多个用于包含在成品板中的部件板坯；
以预定的顺序和排列，组装和对准选择的部件板坯以形成部件板坯组件；和
热压组件以将其部件板坯熔合成复合板坯。
12.权利要求11所述的方法，还包括：
形成多个部件板坯组件；
堆叠多个组件；和
在单个热压步骤中对组件的堆叠进行热压以形成多个复合板坯。
13.权利要求12所述的方法，其中，通过非熔合材料的层或涂层将所述堆叠中的每个组件与相邻的组件分开。
14.权利要求12所述的方法，其中，使用以相同顺序组装的相同类型的复合板坯形成所述堆叠的所有组件。
15.权利要求12所述的方法，其中，所述堆叠中的至少一个组件包含至少一个与所述堆叠中的至少一个其他组件的部件板坯不同的部件板坯。
16.权利要求9所述的方法，其中，所述呈现层包括具有沿第一方向对准的第一可见设计的第一片材，和具有第二可见设计的至少一个第二片材，所述第二可见设计通过所述第一片材至少部分可见。
17.权利要求9所述的方法，还包括：
使用紫外(UV)光固化多层复合材料。
18.权利要求9所述的方法，还包括：
将多层复合材料切割成多个块。
19.权利要求18所述的方法，还包括对所述多个块中的至少一些块的边缘的至少一部分进行造型。
20.权利要求19所述的方法，其中，所述块中的至少一个的造型边缘被配置为适配所述块中的另一个的造型边缘，以助于将块安装作为安装的表面的部分。
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US20200047471A1 (en) 2020-02-13
AU2017412552A1 (en) 2019-11-21
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