CN111395686A - Stone-plastic floor and preparation method thereof - Google Patents

Stone-plastic floor and preparation method thereof Download PDF

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Publication number
CN111395686A
CN111395686A CN202010215005.1A CN202010215005A CN111395686A CN 111395686 A CN111395686 A CN 111395686A CN 202010215005 A CN202010215005 A CN 202010215005A CN 111395686 A CN111395686 A CN 111395686A
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China
Prior art keywords
dry
layer
stone
parts
semi
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CN202010215005.1A
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Chinese (zh)
Inventor
赖毅强
陈宏�
杨松伟
苏清发
尤钰锋
陈庆华
王建春
曹长林
罗永晋
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LONJING ENVIRONMENT TECHNOLOGY CO LTD
Fujian Normal University
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LONJING ENVIRONMENT TECHNOLOGY CO LTD
Fujian Normal University
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Priority to CN202010215005.1A priority Critical patent/CN111395686A/en
Publication of CN111395686A publication Critical patent/CN111395686A/en
Pending legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/08—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing halogen
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Floor Finish (AREA)

Abstract

The invention provides a stone-plastic floor, comprising: an SPC base layer; the color film layer is attached to the SPC base layer; the wear-resistant layer is attached to the color film layer; a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash. Compared with the prior art, the stone-plastic floor provided by the invention adopts the cheap dry method/semi-dry method desulfurized ash as a novel filler to replace the heavy calcium carbonate as the filler, and is matched with the modifier with a specific content of components, so that the density and warpage of the stone-plastic floor can be effectively reduced at lower cost on the basis of ensuring the stability of mechanical properties, the transportation cost of products is effectively reduced, and the stability of the products is improved; meanwhile, the cheap dry method/semi-dry method desulfurized fly ash is selected, so that the production cost is greatly reduced, the comprehensive application of industrial solid wastes is realized, the exploitation amount of limestone mines is reduced, and the method has better social benefit, economic benefit and environmental benefit.

Description

Stone-plastic floor and preparation method thereof
Technical Field
The invention relates to the technical field of PVC (polyvinyl chloride) floors, in particular to a stone-plastic floor and a preparation method thereof.
Background
In recent years, the demand of the PVC flooring industry is increasing, the ratio is increasing from 3% in 2014 to 7% in 2018, wherein the stone plastic flooring, which is the most important product, is rapidly developed. After the stone-plastic floor is formally developed and appeared in 2017, the stone-plastic floor is rapidly accepted by the market due to the advantages of convenience in installation, multiple colors and varieties, no formaldehyde and the like, and a large number of stone-plastic floors are exported to Europe and AmericaThe market is in active promotion and high-speed development stage at home and abroad in China. According to statistics, the industry of the Chinese stone-plastic floor is rapidly developed in 2017, the speed is rapidly increased by 30% every year, and the yield of the Chinese stone-plastic floor in 2018 is nearly 3.5 hundred million m2Over 70% of export is European and American, the export amount is nearly 35 hundred million dollars, and the heavy calcium is consumed about 220 million tons. Domestic large-scale developers such as constant-large, Pigui garden, Wanke and other merchants are gradually using the stone plastic floor to replace the laminate wood floor and the multilayer wood floor as the floor material of the hardcover house, and the future application prospect is huge.
Important problems faced by stone-plastic flooring are high shipping costs and high warpage during use, often approaching 1 mm. Stone-plastic flooring is almost always delivered to the european and american sector by the form of sea containers loaded with strict gross weight regulations. Because the heavy calcium is added into the stone-plastic floor (the heavy calcium powder particles are compact, and the bulk density can reach 1.2g/cm3) The proportion can reach 78 percent at most, so the density is larger and is close to 2.2kg/cm3The volume utilization rate of the existing container is less than 50 percent, and the transportation cost is higher; and the mechanical property of the stone plastic floor is influenced by adding a foaming agent, reducing the addition amount of heavy calcium and the like. In addition, the existing stone plastic floor mainly adopts lock catch splicing, is not adhered by glue, has high requirement on dimensional stability, directly influences the ground paving effect by warping caused by the size change of the floor at high temperature and low temperature (certain internal stress in the floor can not be completely eliminated after the existing production process is rolled by a plurality of wheels), and causes the floor to be raised and deformed due to overhigh warping, and the splicing seam is enlarged to cause the floor to be loosened.
Meanwhile, the heavy calcium which is the most consumed in the stone-plastic floor industry comes from nonrenewable limestone and is obtained by crushing and grinding. Due to the uneven distribution of resources in China, limestone resources in stone plastic floor production areas are scarce, the nation has a strong governing on mining, the examination and approval procedures of limestone mining rights are stricter, the price of coarse whiting is continuously increased, and the production cost of the stone plastic floor is continuously increased.
Disclosure of Invention
In view of the above, the invention aims to provide a stone-plastic floor and a preparation method thereof, the stone-plastic floor provided by the invention adopts dry method/semi-dry method desulfurized fly ash as a novel filler, on the basis of ensuring stable mechanical properties, the density and warpage of the stone-plastic floor can be effectively reduced, meanwhile, the cost of raw materials can be greatly reduced, and the stone-plastic floor has better social benefits, economic benefits and environmental benefits.
The invention provides a stone-plastic floor, comprising:
an SPC base layer;
the color film layer is attached to the SPC base layer;
the wear-resistant layer is attached to the color film layer;
a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
Preferably, the PVC base material layer filled with the dry/semi-dry desulfurized fly ash is prepared from the following raw materials:
100 to 120 parts by weight of PVC resin powder;
300-400 parts of dry/semi-dry desulfurized fly ash;
0-30 parts of desulfurization ash modifier;
28-48 parts of processing aid.
Preferably, the particle size D of the dry/semi-dry desulfurized fly ash90<100 μm, water content<2.0％。
Preferably, the desulfurization ash modifier comprises a first modifier and a second modifier; the first modifier is selected from one or more of polyethylene wax, oxidized polyethylene wax and low molecular weight polypropylene; the second modifier is selected from one or more of fatty acid salt, fatty acid amine and fatty acid ester.
Preferably, the processing aid comprises the following components:
6-12 parts by weight of calcium stearate;
6 to 12 parts by weight of chlorinated polyethylene;
6 to 9 parts by weight of acrylate;
8-10 parts by weight of stearic acid;
2-5 parts of polyethylene wax.
Preferably, the preparation method of the PVC substrate layer filled with the dry/semi-dry desulfurized fly ash specifically comprises the following steps:
a) after the dry desulfurization ash is modified by a desulfurization ash modifier, sequentially adding PVC resin powder and a processing aid for mixing to obtain an SPC base layer mixture;
b) heating and blending the SPC base layer mixture obtained in the step a) by a double-screw extruder, extruding, and forming to obtain the PVC base layer filled with the dry/semi-dry desulfurization ash.
Preferably, the mixing mode in the step a) is high-speed stirring; the high-speed stirring speed is 1000rpm to 20000rpm, and the auxiliary heating temperature is 60 ℃ to 100 ℃.
Preferably, the temperature for heating and blending in the step b) is 180-220 ℃; the extrusion discharging speed is 2.5 m/min-3.5 m/min.
The invention also provides a preparation method of the stone-plastic floor, which comprises the following steps:
sequentially placing a color film layer and a wear-resistant layer on the SPC base layer for hot lamination, and forming a UV layer on the wear-resistant layer through UV coating treatment to obtain the stone-plastic floor; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
Preferably, the temperature of the thermal bonding is 90-120 ℃.
The invention provides a stone-plastic floor, comprising: an SPC base layer; the color film layer is attached to the SPC base layer; the wear-resistant layer is attached to the color film layer; a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash. Compared with the prior art, the stone-plastic floor provided by the invention adopts the cheap dry method/semi-dry method desulfurized ash as a novel filler to replace the heavy calcium carbonate as the filler, and is matched with the modifier with a specific content of components, so that the density and warpage of the stone-plastic floor can be effectively reduced at lower cost on the basis of ensuring the stability of mechanical properties, the transportation cost of products is effectively reduced, and the stability of the products is improved; meanwhile, the cheap dry method/semi-dry method desulfurized fly ash is selected, so that the production cost is greatly reduced, the comprehensive application of industrial solid wastes is realized, the exploitation amount of limestone mines is reduced, and the method has better social benefit, economic benefit and environmental benefit.
In addition, the preparation method provided by the invention is simple in process, easy to control and suitable for large-scale industrial production.
Drawings
FIG. 1 is a schematic structural view of a stone-plastic floor provided by the present invention;
fig. 2 is a schematic structural diagram of a stone-plastic floor provided in embodiment 1 of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments of the present invention, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention provides a stone-plastic floor, comprising:
an SPC base layer;
the color film layer is attached to the SPC base layer;
the wear-resistant layer is attached to the color film layer;
a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
Referring to fig. 1, fig. 1 is a schematic structural diagram of a stone-plastic floor provided by the present invention; wherein, 1 is the SPC basic unit, 2 is various rete, 3 is the wearing layer, and 4 is the UV layer.
In the invention, the SPC base layer is a PVC base layer filled with dry/semi-dry desulfurized fly ash. The thickness of the SPC base layer is preferably 1mm to 10mm, and more preferably 3mm to 6 mm.
In the invention, the PVC base material layer filled with the dry/semi-dry desulfurized ash is preferably prepared from the following raw materials:
100 to 120 parts by weight of PVC resin powder;
300-400 parts of dry/semi-dry desulfurized fly ash;
0-30 parts of desulfurization ash modifier;
28-48 parts of processing aid;
more preferably:
100 parts by weight of PVC resin powder;
300-350 parts of dry/semi-dry desulfurized fly ash;
6-11 parts of a desulfurized fly ash modifier;
41-45 parts of processing aid.
The PVC resin powder of the present invention is not particularly limited in its source, and commercially available products known to those skilled in the art may be used.
In the invention, the dry/semi-dry desulphurization ash is a calcium-based powdery mixture rich in calcium sulfite, which is generated by dry/semi-dry desulphurization processes such as a Circulating Fluidized Bed (CFB), an NID (non-fluidized bed) or an SDA (SDA) (formed by reaction under a severely disturbed bed layer of the circulating fluidized bed), and is a dry, fine-particle-size and loose general industrial solid waste powder material, and the main components of the dry/semi-dry desulphurization ash are calcium-based substances such as calcium sulfite, calcium sulfate, calcium carbonate and calcium hydroxide; preferably dry desulphurised ash. In the present invention, the particle size D of the dry/semi-dry desulfurized fly ash90Preference is given to<100 μm, water content is preferably<2.0％。
The invention adopts cheap dry method/semi-dry method desulfurized ash as a novel filler to replace heavy calcium carbonate as the filler; firstly, the desulfurized fly ash contains calcium carbonate which has similar physicochemical properties with heavy calcium carbonate, and calcium sulfite has good compatibility with high molecular substances such as PVC and the like, has stable chemical properties, is suitable for being applied to calcium plastic plates as inorganic filler, and calcium hydroxide can be used as filler in PVC products to improve the thermal stability of a matrix, thereby reducing the warpage of the plate; secondly, the bulk density is less than that of heavy calcium due to loose particle structure of the desulfurized fly ash (the bulk density of the desulfurized fly ash by the dry method/semi-dry method is 0.7 g/cm)3～0.8g/cm3) After being treated by the modifier, the desulfurized fly ash can wrap and seal partial holes to form closed holes, so that the oil absorption value of the desulfurized fly ash is reduced, the processing fluidity of the desulfurized fly ash by a dry method/semi-dry method is equivalent to that of heavy calcium carbonate, and the final density of the stone plastic floor is ensuredLess than heavy calcium filled stone-plastic flooring; therefore, the treated dry/semi-dry desulfurized ash can replace heavy calcium carbonate for the stone plastic floor, and the density and the warping of the stone plastic floor are effectively reduced. Meanwhile, as the national 'winning blue sky guard war' is continuously promoted to the deep depth, the devices adopting the dry method/semi-dry method desulfurization system are close to thousands, the yield of the dry method/semi-dry method desulfurization ash is close to 6000 million tons/year, and the requirements of the stone-plastic floor can be completely met; after the heavy calcium is replaced in a large scale, the mining amount of limestone mines can be obviously reduced, and the damage of mining to the environment is reduced.
In the present invention, the desulfurization ash modifier preferably includes a first modifier and a second modifier; wherein, the first modifier is preferably selected from one or more of polyethylene wax, oxidized polyethylene wax and low molecular weight polypropylene, and is more preferably polyethylene wax or oxidized polyethylene wax; the second modifier is preferably selected from one or more of fatty acid salts, fatty acid amines and fatty acid esters, more preferably from one or both of fatty acid amines and fatty acid esters. The source of the desulfurization ash modifier is not particularly limited in the present invention, and the desulfurization ash modifier is prepared by combining commercially available products of the above-mentioned fatty acid salt, fatty acid amine, fatty acid ester, polyethylene wax, oxidized polyethylene wax and low molecular weight polypropylene, which are well known to those skilled in the art. According to the invention, the dry-process/semi-dry-process desulfurized ash is preferably modified by the first modifier, and then the dry-process/semi-dry-process desulfurized ash is modified by the second modifier, so that the modification effect of the dry-process/semi-dry-process desulfurized ash is favorably improved.
In the invention, the first modifier is preferably used in an amount of 0 to 15 parts by weight, more preferably 2 to 5 parts by weight; the second modifier is preferably used in an amount of 0 to 15 parts by weight, more preferably 4 to 6 parts by weight.
In the present invention, the processing aid preferably comprises the following components:
6-12 parts by weight of calcium stearate;
6 to 12 parts by weight of chlorinated polyethylene;
6 to 9 parts by weight of acrylate;
8-10 parts by weight of stearic acid;
2-5 parts of polyethylene wax;
more preferably:
10 parts by weight of calcium stearate;
12 parts by weight of chlorinated polyethylene;
6 parts of acrylic ester;
10-12 parts by weight of stearic acid;
3-5 parts of polyethylene wax.
The source of the processing aid is not particularly limited in the present invention, and is prepared by combining commercially available products of calcium stearate, Chlorinated Polyethylene (CPE), Acrylate (ACR), stearic acid, and polyethylene wax (PE wax) which are well known to those skilled in the art.
In the invention, the preparation method of the PVC substrate layer filled with the dry/semi-dry desulfurized fly ash is preferably as follows:
a) after the dry desulfurization ash is modified by a desulfurization ash modifier, sequentially adding PVC resin powder and a processing aid for mixing to obtain an SPC base layer mixture;
b) heating and blending the SPC base layer mixture obtained in the step a) by a double-screw extruder, extruding, and forming to obtain the PVC base layer filled with the dry/semi-dry desulfurization ash.
According to the invention, firstly, the dry-process desulfurized fly ash is modified by the desulfurized fly ash modifier, and then the PVC resin powder and the processing aid are sequentially added for mixing, so as to obtain the SPC base layer mixture. In the invention, the modification process specifically comprises the following steps:
adding the dry method/semi-dry method desulfurized ash into a high-speed mixer for stirring, wherein the rotating speed of the high-speed mixer is set to be 1000-20000 rpm, the auxiliary heating temperature is 60-100 ℃, and the stirring time is 4-6 min; and then adding a first modifier and the dry desulfurization ash, blending for 4-6 min, then adding a second modifier, and continuing blending for 5-7 min to finish the modification process.
In the present invention, the mixing is preferably performed by high-speed stirring; this is achieved using a high speed stirrer well known to those skilled in the art. In the present invention, the rotation speed of the high speed stirring is preferably 1000rpm to 20000rpm, more preferably 1200rpm to 10000 rpm; the auxiliary heating temperature of the high-speed stirring is preferably 60-100 ℃, and more preferably 80-90 ℃.
In the present invention, the mixing process preferably includes:
adding PVC resin powder into the modified dry/semi-dry desulfurization ash, blending for 6-15 min, adding a processing aid, and continuously mixing for 3-10 min to obtain an SPC base layer mixture;
more preferably:
and adding PVC resin powder into the modified dry/semi-dry desulfurization ash, blending for 8min, adding the processing aid, and continuously mixing for 5min to obtain an SPC base layer mixture.
After the SPC base layer mixture is obtained, the method preferably further comprises the step of cooling the SPC base layer mixture to 45-55 ℃ and then placing the mixture into a storage bin for storage.
After the SPC base layer mixture is obtained, the obtained SPC base layer mixture is heated and blended by a double-screw extruder and then extruded, and the PVC base layer filled with the dry-process/semi-dry-process desulfurized ash is obtained after molding.
In the invention, the SPC base layer mixture is fed into a double-screw extruder through a screw feeder, and is heated and blended by a screw, and then the mixture is extruded from the tail end of the double-screw extruder; the heating and blending temperature is preferably 180-220 ℃, and more preferably 185-212 ℃; the extrusion discharge speed is preferably 2.5m/min to 3.5m/min, and more preferably 3m/min to 3.3 m/min.
In the invention, the molding mode is preferably to enter a four-roll calender for molding through a mold; in addition, in the forming process, the color film layer and the wear-resistant layer can be further placed in a four-roller calender for simultaneous hot lamination, so that the assembling and forming of the SPC base layer, the color film layer and the wear-resistant layer are realized; and the three rollers and the four rollers are used for film sticking and embossing, so that the color film layer and the wear-resistant layer are simultaneously thermally laminated with the SPC base layer, and the embossed plate is obtained. In the invention, the temperature of the first roller is preferably 135-160 ℃, more preferably 155 ℃, and the temperature of the second roller is preferably 135-160 ℃, more preferably 135 ℃; the temperature of the three rollers is preferably 90-120 ℃, and more preferably 120 ℃; the temperature of the four rollers is preferably 90-120 ℃, and more preferably 100 ℃; the roller speed is preferably 1.3rpm to 1.9rpm, more preferably 1.5 rpm.
In the invention, the color film layer is attached to the SPC base layer; the source of the color film layer is not particularly limited in the present invention, and commercially available PVC color film layers well known to those skilled in the art can be used. In the present invention, the thickness of the color film layer is preferably 0.05mm to 0.1mm, and more preferably 0.06mm to 0.08 mm.
In the invention, the wear-resistant layer is attached to the color film layer; the source of the wear-resistant layer is not particularly limited in the invention, and a commercially available PVC wear-resistant layer well known to those skilled in the art can be used. In the present invention, the thickness of the wear-resistant layer is preferably 0.1mm to 1mm, and more preferably 0.2mm to 0.8 mm.
In the invention, the UV layer is compounded on the wear-resistant layer and is used for protecting a color film from fading forever. In the present invention, the UV layer is preferably formed by a UV coating process.
In the present invention, an optional additional layer is preferably disposed on one side of the SPC base layer of the stone-plastic flooring; either a Cork layer, an EVA layer or an IXPE layer known to those skilled in the art may be used.
The stone-plastic floor provided by the invention adopts the cheap dry method/semi-dry method desulfurized ash as a novel filler to replace heavy calcium carbonate as the filler, and is matched with the modifier with a specific content of components, so that the density and warpage of the stone-plastic floor can be effectively reduced at lower cost on the basis of ensuring the stability of mechanical properties, the transportation cost of products is further effectively reduced, and the stability of the products is improved; meanwhile, the cheap dry method/semi-dry method desulfurized fly ash is selected, so that the production cost is greatly reduced, the comprehensive application of industrial solid wastes is realized, the exploitation amount of limestone mines is reduced, and the method has better social benefit, economic benefit and environmental benefit.
The invention also provides a preparation method of the stone-plastic floor, which comprises the following steps:
sequentially placing a color film layer and a wear-resistant layer on the SPC base layer for hot lamination, and forming a UV layer on the wear-resistant layer through UV coating treatment to obtain the stone-plastic floor; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
In the present invention, the thermal bonding apparatus is preferably a four-roll calender; one roller and two rollers of the four-roller calender are used for sizing and fixing the thickness to obtain an SPC (SPC) base layer with determined thickness and shape, and the three rollers and the four rollers are used for film pasting and embossing to enable the color film layer and the wear-resistant layer to be simultaneously thermally laminated with the SPC base layer to obtain the embossed plate. In the invention, the temperature of the first roller is preferably 135-160 ℃, more preferably 155 ℃, and the temperature of the second roller is preferably 135-160 ℃, more preferably 135 ℃; the temperature of the three rollers is preferably 90-120 ℃, and more preferably 120 ℃; the temperature of the four rollers is preferably 90-120 ℃, and more preferably 100 ℃; the roller speed is preferably 1.3rpm to 1.9rpm, more preferably 1.5 rpm.
After obtaining the embossed plate, the present invention preferably further comprises:
and cutting the obtained embossed plate into plates with certain size requirements through a traction machine according to requirements. In the present invention, the speed of the traction machine is preferably 2.5m/min to 4m/min, more preferably 3.2m/min to 3.5 m/min.
And then, preferably, the plate is cooled to room temperature in air, and then UV coating treatment is carried out to form a UV layer on the wear-resistant layer, so that the stone-plastic floor is obtained. In the present invention, the UV coating treatment apparatus is preferably a UV coater. In the present invention, the process of the UV coating treatment is preferably as follows:
putting the plate on a UV film coating machine, coating gloss oil, and drying to form a UV layer; the conveying speed of the UV film coating machine is preferably 10 m/min-25 m/min, and more preferably 20 m/min.
Finally, the present invention preferably further comprises:
and (3) conveying the board with the UV layer formed on the surface to a grooving machine, and performing transverse and longitudinal grooving according to the product size requirement to obtain the stone plastic floor.
The preparation method provided by the invention is simple in process, easy to control and suitable for large-scale industrial production.
The invention provides a stone-plastic floor, comprising: an SPC base layer; the color film layer is attached to the SPC base layer; the wear-resistant layer is attached to the color film layer; a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash. Compared with the prior art, the stone-plastic floor provided by the invention adopts the cheap dry method/semi-dry method desulfurized ash as a novel filler to replace the heavy calcium carbonate as the filler, and is matched with the modifier with a specific content of components, so that the density and warpage of the stone-plastic floor can be effectively reduced at lower cost on the basis of ensuring the stability of mechanical properties, the transportation cost of products is effectively reduced, and the stability of the products is improved; meanwhile, the cheap dry method/semi-dry method desulfurized fly ash is selected, so that the production cost is greatly reduced, the comprehensive application of industrial solid wastes is realized, the exploitation amount of limestone mines is reduced, and the method has better social benefit, economic benefit and environmental benefit.
In addition, the preparation method provided by the invention is simple in process, easy to control and suitable for large-scale industrial production.
To further illustrate the present invention, the following examples are provided for illustration. The dry desulfurized fly ash used in the following examples of the invention was obtained from the sintering machine of a certain Steel works of Fujian province, having a particle size D90<100 μm, water content<2.0 percent, and the main components are as follows: 48.57 wt% of calcium sulfite, 13.54 wt% of calcium hydroxide and 25.66 wt% of calcium carbonate; the PVC resin powder is SG-5 type PVC resin powder sold in the market; the used color film layer is a commercial PVC color film layer; the wear-resistant layer is a commercially available PVC wear-resistant layer.
Example 1
(1) Adding 300 parts by weight of dry desulfurization ash into a high-speed mixer for stirring, wherein the rotating speed of the high-speed mixer is 2000rpm, the auxiliary heating temperature is 85 ℃, and the stirring time is 5 min; then adding 2 parts by weight of polyethylene wax and the dry-process desulfurized ash, blending for 5min, then adding 4 parts by weight of fatty acid ester, blending for 6min, then adding 100 parts by weight of PVC resin powder, blending for 8min, and finally adding 41 parts by weight of processing aid (composed of 10 parts by weight of calcium stearate, 12 parts by weight of chlorinated polyethylene, 6 parts by weight of acrylate, 10 parts by weight of stearic acid and 3 parts by weight of polyethylene wax), and continuing mixing for 5min to obtain an SPC base layer mixture; cooling to 50 deg.C, and storing in a storage bin.
(2) Feeding the SPC base layer mixture obtained in the step (1) to a double-screw extruder through a screw feeder, heating and blending the mixture, and then extruding the mixture, wherein the maximum temperature of the double-screw extruder is 210 ℃, and the discharging speed is 3 m/min; then, the extruded materials enter a four-roll calender through a die for assembly forming, the temperature of the die is 195 ℃, the rotating speed of the rolls is 1.5rpm, one roll and two rolls of the four-roll calender are used for sizing and thickness fixing to obtain an SPC (selective catalytic cracking) base layer with determined thickness and shape, wherein the temperature of the one roll is 155 ℃, and the temperature of the two rolls is 135 ℃; and (3) sticking a film and embossing by using three rollers and four rollers of a four-roller calender, and simultaneously thermally sticking the color film layer and the wear-resistant layer with the SPC base layer to obtain the embossed plate, wherein the temperature of the three rollers is 120 ℃, and the temperature of the four rollers is 100 ℃.
(3) Passing the embossed plate obtained in the step (2) through a traction machine, wherein the speed of the traction machine is 3.2m/min, and cutting the plate into plates with certain size requirements according to requirements; after air cooling to room temperature, placing the plate on a UV film coating machine, coating gloss oil, and drying to form a UV layer, wherein the conveying speed of the UV film coating machine is 20 m/min; and finally, conveying the plate with the UV layer formed on the surface to a grooving machine, and performing transverse and longitudinal grooving according to the product size requirement to obtain the stone plastic floor.
The structure schematic diagram of the stone plastic floor provided by the embodiment 1 of the invention is shown in fig. 2, wherein the thickness of the SPC base layer is 3.2 mm-5.5 mm, the thickness of the color film layer is 0.07mm, the thickness of the wear-resistant layer is 0.3 mm-0.7 mm, and the UV layer protects the color film from fading forever; while the optional additional layer may be Cork, EVA or IXPE, not represented in the preparation method of example 1.
The stone plastic floor prepared by the preparation method provided by the embodiment 1 of the invention is made into a corresponding test standard shape for various performance tests, and the results are shown in table 1.
Example 2
(1) Adding 330 parts by weight of dry desulfurization ash into a high-speed mixer for stirring, wherein the rotating speed of the high-speed mixer is 2000rpm, the auxiliary heating temperature is 85 ℃, and the stirring time is 5 min; then adding 6 parts by weight of oxidized polyethylene wax and the dry desulfurization ash, blending for 5min, then adding 3 parts by weight of fatty acid ester and 2 parts by weight of fatty acid amine, continuing to mix for 5min, then adding 100 parts by weight of PVC resin powder, blending for 8min, and finally adding 45 parts by weight of processing aid (comprising 10 parts by weight of calcium stearate, 12 parts by weight of chlorinated polyethylene, 6 parts by weight of acrylate, 12 parts by weight of stearic acid and 5 parts by weight of polyethylene wax), continuing to mix for 5min to obtain an SPC base layer mixture; cooling to 50 deg.C, and storing in a storage bin.
(2) Feeding the SPC base layer mixture obtained in the step (1) to a double-screw extruder through a screw feeder, heating and blending the mixture, and then extruding the mixture, wherein the maximum temperature of the double-screw extruder is 212 ℃, and the discharging speed is 3.3 m/min; then, the extruded materials enter a four-roll calender through a die to be assembled and molded, wherein the temperature of the die is 196 ℃, the rotating speed of the rolls is 1.6rpm, one roll and two rolls of the four-roll calender are used for sizing and thickness fixing to obtain an SPC (selective catalytic cracking) base layer with determined thickness and shape, the temperature of the one roll is 155 ℃, and the temperature of the two rolls is 135 ℃; and (3) sticking a film and embossing by using three rollers and four rollers of a four-roller calender, and simultaneously thermally sticking the color film layer and the wear-resistant layer with the SPC base layer to obtain the embossed plate, wherein the temperature of the three rollers is 120 ℃, and the temperature of the four rollers is 100 ℃.
(3) Passing the embossed plate obtained in the step (2) through a traction machine, wherein the speed of the traction machine is 3.5m/min, and cutting the plate into plates with certain size requirements according to requirements; after air cooling to room temperature, placing the plate on a UV film coating machine, coating gloss oil, and drying to form a UV layer, wherein the conveying speed of the UV film coating machine is 20 m/min; and finally, conveying the plate with the UV layer formed on the surface to a grooving machine, and performing transverse and longitudinal grooving according to the product size requirement to obtain the stone plastic floor.
Comparative example 1
The stone-plastic floor was prepared by the preparation method provided in example 1, with the difference that step (1): adding 300 parts by weight of dry desulfurization ash into a high-speed mixer for stirring, wherein the rotating speed of the high-speed mixer is 2000rpm, the auxiliary heating temperature is 85 ℃, and the stirring time is 5 min; then adding 100 parts by weight of PVC resin powder and the dry desulfurization ash, blending for 8min, finally adding 41 parts by weight of processing aid (composed of 10 parts by weight of calcium stearate, 12 parts by weight of chlorinated polyethylene, 6 parts by weight of acrylate, 10 parts by weight of stearic acid and 3 parts by weight of polyethylene wax), and continuously mixing for 5min to obtain an SPC base layer mixture; cooling to 50 deg.C, and storing in a storage bin.
Comparative example 2
The stone-plastic floor was prepared by the preparation method provided in example 1, with the difference that step (1): 300 parts by weight of 325-mesh coarse whiting is added into a high-speed mixer for stirring, the rotating speed of the high-speed mixer is set to be 2000rpm, the auxiliary heating temperature is 85 ℃, and the stirring time is 5 min; then adding 100 parts by weight of PVC resin powder and the heavy calcium, blending for 8min, finally adding 41 parts by weight of processing aid (composed of 10 parts by weight of calcium stearate, 12 parts by weight of chlorinated polyethylene, 6 parts by weight of acrylate, 10 parts by weight of stearic acid and 3 parts by weight of polyethylene wax), and continuously mixing for 5min to obtain an SPC base layer mixture; cooling to 50 deg.C, and storing in a storage bin.
Table 1 shows performance test results of stone plastic floors prepared by the preparation methods provided in examples 1-2 and comparative examples 1-2
Figure BDA0002424103570000121
As can be seen from table 1, in the preparation method provided in embodiments 1 to 2 of the present invention, the cheap dry desulfurized fly ash is used as a novel filler to replace the heavy calcium carbonate as the filler, and the modifier with a specific content of components is used, so that the density and warpage of the stone plastic floor can be effectively reduced at a lower cost on the basis of ensuring the stable mechanical properties, thereby effectively reducing the transportation cost of the product and improving the stability of the product; meanwhile, the cheap dry-process desulfurized fly ash is selected, so that the production cost is greatly reduced, the comprehensive application of industrial solid waste is realized, the exploitation amount of limestone mines is reduced, and the good social benefit, economic benefit and environmental benefit are achieved.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (10)

1. A stone-plastic flooring comprising:
an SPC base layer;
the color film layer is attached to the SPC base layer;
the wear-resistant layer is attached to the color film layer;
a UV layer compounded on the wear-resistant layer; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
2. The stone-plastic floor as claimed in claim 1, wherein the PVC substrate layer filled with the dry/semi-dry desulfurized fly ash is prepared from raw materials comprising:
100 to 120 parts by weight of PVC resin powder;
300-400 parts of dry/semi-dry desulfurized fly ash;
0-30 parts of desulfurization ash modifier;
28-48 parts of processing aid.
3. The stone-plastic floor as claimed in claim 2, wherein the dry/semi-dry desulfurized fly ash has a particle size D90<100 μm, water content<2.0％。
4. The stone-plastic flooring of claim 2, wherein the desulfurized ash modifier comprises a first modifier and a second modifier; the first modifier is selected from one or more of polyethylene wax, oxidized polyethylene wax and low molecular weight polypropylene; the second modifier is selected from one or more of fatty acid salt, fatty acid amine and fatty acid ester.
5. The stone-plastic floor as claimed in claim 2, wherein the processing aid comprises the following components:
6-12 parts by weight of calcium stearate;
6 to 12 parts by weight of chlorinated polyethylene;
6 to 9 parts by weight of acrylate;
8-10 parts by weight of stearic acid;
2-5 parts of polyethylene wax.
6. The stone-plastic floor as claimed in claim 2, wherein the preparation method of the PVC substrate layer filled with the dry/semi-dry desulfurized fly ash specifically comprises:
a) after the dry desulfurization ash is modified by a desulfurization ash modifier, sequentially adding PVC resin powder and a processing aid for mixing to obtain an SPC base layer mixture;
b) heating and blending the SPC base layer mixture obtained in the step a) by a double-screw extruder, extruding, and forming to obtain the PVC base layer filled with the dry/semi-dry desulfurization ash.
7. The stone-plastic floor as claimed in claim 6, wherein the mixing in step a) is by high speed stirring; the high-speed stirring speed is 1000rpm to 20000rpm, and the auxiliary heating temperature is 60 ℃ to 100 ℃.
8. The stone-plastic floor as claimed in claim 6, wherein the temperature of the heating blending in step b) is 180 ℃ to 220 ℃; the extrusion discharging speed is 2.5 m/min-3.5 m/min.
9. A preparation method of a stone-plastic floor comprises the following steps:
sequentially placing a color film layer and a wear-resistant layer on the SPC base layer for hot lamination, and forming a UV layer on the wear-resistant layer through UV coating treatment to obtain the stone-plastic floor; the SPC base layer is a PVC base material layer filled with dry-process/semi-dry-process desulfurized fly ash.
10. The method according to claim 9, wherein the temperature of the thermal bonding is 90 ℃ to 120 ℃.
CN202010215005.1A 2020-03-24 2020-03-24 Stone-plastic floor and preparation method thereof Pending CN111395686A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114656689A (en) * 2020-12-23 2022-06-24 福建龙净脱硫脱硝工程有限公司 Modified desulfurized fly ash, PVC building template and preparation method thereof
CN115028877A (en) * 2022-05-23 2022-09-09 安徽工业大学 Solid waste based stone crystal floor base material and preparation method thereof
CN116178854A (en) * 2022-11-22 2023-05-30 日昌升建筑新材料设计研究院有限公司 Environment-friendly stone plastic floor base material and preparation method thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114656689A (en) * 2020-12-23 2022-06-24 福建龙净脱硫脱硝工程有限公司 Modified desulfurized fly ash, PVC building template and preparation method thereof
CN115028877A (en) * 2022-05-23 2022-09-09 安徽工业大学 Solid waste based stone crystal floor base material and preparation method thereof
CN116178854A (en) * 2022-11-22 2023-05-30 日昌升建筑新材料设计研究院有限公司 Environment-friendly stone plastic floor base material and preparation method thereof

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