CN111691637A - 具有隔音功能的地板覆盖物的多层结构 - Google Patents
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Abstract
本发明涉及一种用于生产地板或墙壁覆盖物的多层结构(1),所述结构包括至少一个由交联的聚烯烃泡沫制成的背衬层(2),赋予所述结构隔音性能,所述背衬层(2)具有旨在粘合到地板或墙壁的下表面,以及粘合到由塑料、油毡或橡胶制成的上层(3)的上表面。根据本发明,所述背衬层(2)的至少一个表面具有大于或等于40mN/m的表面张力。
Description
技术领域
本发明涉及地板或墙壁覆盖物的技术领域,更具体地说,涉及一种用于生产具有隔音性能的地板或墙壁覆盖物的多层结构。
本发明所提供的结构涉及地板覆盖物,所述地板覆盖物被铺设粘合并且具有面板、厚板或平板的形式,并且包括由塑料材料、油毡或橡胶制成的至少一层。
本发明还涉及一种用于制造这种多层结构的方法。
现有技术
用于生产具有隔音性能的地板或墙壁覆盖物的多层结构的生产在现有技术中是已知的。
事实上,声音污染已经成为一个对社会非常重要的问题。地板覆盖物市场中的许多利益相关者提供了多层结构,该多层结构包括集成在该多层结构中的背衬层和隔音层或其他应用,例如卷筒的形式。特别地,背衬层是由交联的聚乙烯泡沫制成,在声音衰减和耐压痕性之间提供了非常令人满意的关系。
这种类型的多层结构,例如以厚板或平板的形式,大部分粘合在地板上的。
也即是说,这种类型的结构的主要问题在于难以将它们粘合起来。这是因为很难将聚乙烯泡沫粘合到由PVC(聚氯乙烯)制成的背衬层上,而且也很难粘合到混凝土或纤维水泥板上,也很难粘合到由PVC制成的地板覆盖物的覆盖层上。
综上所述,现有技术的多层结构一般包括:
-耐磨层,对光透明且可选地由PVC制成;
-装饰膜;
-由PVC制成的至少一层中间层,可选地增塑并填充矿物填料;
-由交联聚乙烯泡沫制成的隔音背衬层,粘合到中间层的背面,并旨在粘合到地板上。
然而,如上所述,由PVC制成的中间层与聚乙烯泡沫层之间的粘合,或所述泡沫层的下表面与混凝土或纤维水泥板,或与作为PVC制成的现有地板覆盖物的覆盖层的粘合,都是比较困难的。
这是因为常规的丙烯酸粘合剂不能有效地将聚乙烯泡沫粘合到PVC或混凝土或纤维水泥上。
因此,用丙烯酸类粘合剂不足以抵抗粘合到由PVC制成的中间层或混凝土上的背衬层的剥离试验。
为了解决该问题,已知采用多层结构,所述多层结构使用由双面薄膜支撑的可剥离的粘合剂或粘性材料,以便将由聚乙烯泡沫制成的背衬层粘合到由PVC制成的中间层以及可选地粘合到混凝土、纤维水泥或用作覆盖层的PVC地板覆盖物。
除丙烯酸类粘合剂以外的其他粘合剂,例如聚氨酯基粘合剂,可以实现良好的抗分层性,但价格更高,并且铺设方法对于地板安装人员而言更为复杂。特别地,这种类型的粘合剂的性能,即粘合剂的打开时间、粘性等,与通常使用的丙烯酸类粘合剂的性能太不同,因而是不可取的。
发明内容
因此,本发明的目的之一是克服上述缺点,提出了一种用于生产地板或墙壁覆盖物的多层结构,所述多层结构具有由交联的聚烯烃泡沫制成的隔音背衬层,其中,用丙烯酸粘合剂粘合到由聚氯乙烯制成的上层或作为地板覆盖物的覆盖层(所述覆盖层表面由聚氯乙烯制成)是最佳的,特别是为了经受住目前的剥离试验。
本发明的另一个目的是提供一种具有良好的耐压痕性值的多层结构。
为此,开发了用于生产地板或墙壁覆盖物的多层结构,所述多层结构包括至少一个由交联的聚烯烃泡沫制成的背衬层,例如交联的聚乙烯,使所述多层结构具有隔音性能,所述背衬层具有旨在粘合到地板或墙壁上的下表面,和粘合到包括至少一个耐磨层的上层的上表面。优选地,上层由塑料材料制成,优选为热塑性材料、油毡或橡胶。更优选地,所述上层由聚氯乙烯制成。
根据本发明,所述背衬层的至少一个表面具有大于或等于40mN/m的表面张力,这与现有技术不同,在现有技术中,表面张力约为35mN/m。
聚烯烃泡沫例如通过辐照交联的事实使得产生结构化学键成为可能。这使得改善耐温性以及机械抗压强度,或防潮性成为可能。特别地,交联的聚乙烯泡沫使得能够在机械抗压强度,特别是能够承受地板覆盖物经受的交通压力,与地板覆盖物的声学性能之间获得良好的折中。
背衬层的一个表面的表面张力大于或等于40mN/m的事实使得改善粘结成为可能,特别是使用聚氨酯基粘合剂,例如众所周知的“热熔”型,所诉粘合剂以PSA(压力敏感型粘合剂)的缩写而闻名,但最重要的是使用丙烯酸类粘合剂。
有利地,为了优化背衬层的下表面与混凝土或纤维水泥板,或者作为由PVC制成的地板覆盖物的覆盖层的粘合,所述下表面的表面张力大于或等于40mN/m。
有利地,为了优化背衬层的上表面与由PVC制成的上层的粘合,所述上表面的表面张力大于或等于40mN/m。
根据一个具体的实施例,并且为了获得所需的表面张力,通过氟化对所述背衬层的上表面和/或下表面进行了表面处理。换句话说,这意味着背衬层的上表面以及可选地下表面的表面,例如从所述处理过的表面开始的前10纳米的厚度,包含氟原子,例如其含量大于1.3%,优选地大于5%。大于3%的氟含量可以实现大于约0.6daN/cm的分层值。大于5%的氟含量可以实现大于约0.8daN/cm的分层值。测量分层的方法由标准NF EN ISO24345定义。
在氟化表面的处理过程中,由于所述背衬层的所述被处理表面的表面上的氟气的反应性,导致氢原子被氟原子取代,从而优化了粘合剂的粘附性。
为了改善隔音性能并保持良好的耐压痕性,所述背衬层的厚度在0.5-2mm之间,优选地等于1mm。
同样地,为了改善隔音和耐压痕性能,所述背衬层的密度在70-120kg/m3之间,或甚至在80-120kg/m3,优选地等于95kg/m3。
从这个概念出发,多层结构可能有几种配置。
所述多层结构包括耐磨层,可选地由聚氯乙烯制成。所述背衬层可以直接粘合到所述耐磨层。
根据另一实施例,所述耐磨层对可见光是透明的并且连接至装饰膜。
根据又一个实施方案,所述多层结构包括一个或多个由聚氯乙烯制成的中间层,所述中间层的一侧与所述耐磨层连接,所述耐摩层整合或不整合装饰膜,而在另一侧粘合至所述背衬层。
根据一个具体的实施例,所述中间层由聚氯乙烯制成,可选地被增塑,并且可选地包含矿物填料。
所述上层和/或所述耐磨层和/或所述中间层一般由塑料材料制成,优选热塑性材料、油毡或橡胶。
特别地,可以根据生产所述上层和/或所述耐磨层和/或所述中间层所需的机械性能而使用的材料,特别是聚烯烃、热塑性共聚酯、热塑性聚酰胺、聚氯乙烯(PVC)、聚乙烯醇缩丁醛(PVB)、聚乳酸(PLA)、聚对苯二甲酸乙二酯(PET)、聚甲基丙烯酸甲酯(PMMA)、聚丙烯(PP)、聚乙二醇(PETG)、热塑性聚氨酯(TPU)、聚(乙烯-乙酸乙烯酯)(EVA)、聚(乙烯-丙烯酸甲酯)(EMA)、聚(乙烯-丙烯酸丁酯)(EBA)、聚(乙烯-丙烯酸乙酯)(EEA),单独或混合使用。
本发明还涉及一种用于制造地板或墙壁覆盖物的多层结构的制造方法,所述结构包括由交联的聚烯烃泡沫(例如交联的聚乙烯)制成的背衬层,使所述多层结构具有隔音性能。所述背衬层具有旨在粘合到地板或墙壁上的下表面,以及旨在粘合到由聚氯乙烯制成的上层的上表面。
根据本发明,所述方法包括在将所述背衬层的上表面粘合至上层之前,对所述上表面进行处理,将其表面张力增加至大于或等于40mN/m的水平。
同样地,根据具体实施例,特别地,当所述多层结构粘合到现有的PVC地板覆盖物、混凝土或纤维水泥时,在粘合之前,所述背衬层的下表面进行了表面处理,将其表面张力增加到大于或等于40mN/m的水平。
根据具体的实施例,所述处理包括通过氟化的表面处理,例如氧氟化或全氟化处理,或者由电晕处理组成。
附图说明
通过以下参考附图作为非限制性示例提供的描述,其他特征和优点将变得更加清楚,其中:
图1是本发明所提供的多层结构的第一实施例的示意性截面图;
图2是与图1类似的示意图,示出了本发明的第二实施例;
图3是与图1类似的示意图,示出了本发明的第三实施例。
具体实施方式
参考图1至图3,本发明涉及一种用于生产具有隔音性能的地板或墙壁覆盖物的多层结构(1)。
为此,以已知的方式,所述多层结构(1)包括至少一个由交联聚烯烃泡沫制成的背衬层(2),赋予所述结构隔音性能,所述背衬层包括旨在粘合到地板或墙壁上的下表面。
所述背衬层(2)由交联的聚烯烃泡沫制成,例如特别地由交联的聚乙烯泡沫制成,所述背衬层(2)的厚度优选为0.5mm至2mm,例如1mm,密度在70kg/m3至120kg/m3之间,或甚至在80kg/m3至120kg/m3之间,例如等于95kg/m3。
综上所述,与由塑料材料、油毡或橡胶制成的耐磨层(4)组成的上层(3)相关的所述背衬层(2)使所述多层结构(1)具有良好的隔音性能和和耐压痕性。
所述上层(3)的厚度优选地在1-6mm之间。更优选地,所述上层(3)的厚度在1-3mm之间,以便具有良好的耐磨性,同时限制了制造所述多层结构(1)的成本。
所述背衬层(2)的上表面以已知的方式粘合到由聚氯乙烯制成的所述上层(3)上。
根据本发明,为了便于粘合操作,以使用丙烯酸类粘合剂为例,特别地,为了确保对电流剥离试验的最佳抵抗性,所述背衬层(2)的上表面的表面张力大于或等于40mN/m。表面张力根据标准ISO 8296-2003定义的。
同样,为了便于粘合所述背衬层(2)的下表面的,特别是当其粘合到混凝土或纤维水泥上时,所述背衬层(2)的下表面也具有大于或等于40mN/m的表面张力。
为了获得所述表面张力值,有几种解决方案是可能的。
根据第一实施例,在所述背衬层(2)的上表面(可选地在下表面)上进行表面处理,从而将它们的表面张力增加到大于或等于40mN/m的水平。
例如,所述表面处理可以包括通过氟化作用的表面处理,如氧氟化作用或全氟化作用。
在最终的所述多层结构(1)上可以看到用所述氟化作用进行所述表面处理的过程,因为所述背衬层(2)的厚度,例如被处理面的前10纳米的厚度包含氟原子,例如,其含量大于3%,优选地大于5%。
在氟化过程中,氟气在交联聚烯烃泡沫(或更具体地说是交联聚乙烯泡沫)表面的反应性导致氢原子被氟原子取代,从而提高了粘合剂的粘附性,特别是丙烯酸类粘合剂的粘附性。
为了验证处理过的表面上的氟含量,例如通过X射线光电子能谱法分析所述表面。
分析条件如下:
NOVA KRATOS设备上的XPS
分析条件:来源:单色AlKα;带电荷补偿;一般光谱为150瓦,高分辨率光谱为225瓦;分析面积:300μm x 700μm;检测角度:法线(θ=0°)。正常检测中分析的深度小于10nm。
在这些所述条件下,分析使得可以在处理过的表面的前10纳米中检测到8.2%的氟原子含量。
所述8.2%的氟含量使得所述背衬层(2)的处理过的表面可以具有大于40mN/m的表面张力,特别是52mN/m的表面张力。根据ISO 8296-2003标准定义了测量表面张力的方法。
为了检查所述背衬层(2)的粘附性,对进行了氟化处理且表面张力为52mN/m的所述背衬层(2)的上表面和下表面进行了测试。
所述测试包括以下方面的测量:拉下所述背衬层(2)一侧粘合到增塑PVC的上层(3)并填充矿物填料,所述背衬层(2)的另一侧粘合到纤维水泥地板上,与在相同条件下粘合但未经氟化处理的背衬层(2)相比,即表面张力约为35mN/m。
所述多层结构(1)在纤维水泥载体上的组装进行剥离试验,得到包含未处理的背衬层(2)的结构的平均受力值为0.1daN/cm。
试验采用包括背衬层(2)的多层结构(1)进行,所述背衬层的上表面和下表面均经过处理,得出的平均受力值为1.3daN/cm。
因此,似乎包括根据本发明处理的背衬层(2)的多层结构(1)具有良好的粘附性,并指出现行标准所要求的拉拔力的最小值必须为0.6daN/cm。
因此,本发明使得特别是借助于常规的丙烯酸粘合剂,可以容易地将所述背衬层(2)粘合到PVC的上层(3)上,同时保证最佳的粘合,并且还可以容易地铺设多层结构(1)的组件,因为可以在混凝土或纤维水泥板上粘合,而无需改变地板安装人员通常使用的工艺或产品。
为了获得大于或等于40mN/m的表面张力,另一种解决方案在于对所述背衬层的上表面以及可选地,下表面进行电晕处理。电晕处理包括朝被处理表面发射高频放电。这使得可以实现表面的非常高的氧化水平并且改变其润湿性,以促进粘合剂的粘附性,特别是丙烯酸类粘合剂的粘附性。
然而,电晕处理的效果往往在几周内趋于降低。因此,更优选使用电晕处理将所述背衬层(2)的上表面粘合至上层(3)。
基于所需的应用,可以想到所述多层结构(1)多个实施例。
例如,参考图1,所述上层(3)可以特别地由单耐磨层(4)组成,所述单耐磨层由聚氯乙烯制成,可选地被增塑并且可选地填充有矿物填料。
根据一个实施例,特别是如图2所示,所述上层(3)可以由连接到中间层(5)的耐磨层(4)组成,所述上层本身由PVC制成,可选地被增塑,可选地填充有矿物填料。
根据另一个实施例,特别是如图3所示,所述上层(3)由耐磨层(4)组成,所述耐磨层连接至装饰膜(6)和中间层(5),所述上层本身由聚氯乙烯制成,可选地被增塑,可选地用矿物填料填充。根据该实施例,所述耐磨层(4)的厚度优选地在0.3mm至1mm之间。这使得可以根据大多数应用所需的对交通压力的耐受性来适配耐磨层,同时限制了所述多层结构(1)的制造成本。
本发明在于以下事实:旨在与PVC接触的所述背衬层(2)的上表面具有大于或等于40mN/m的表面张力,如果所述背衬层(2)旨在与混凝土或纤维水泥或任何其他具有中等粘合力的丙烯酸类粘合剂材料粘合,则所述背衬层(2)的下表面也具有大于或等于40mN/m的表面张力。
综上所述,本发明确实提供了一种用于生产具有隔音性能的地板覆盖物的多层结构(1),同时使得交联聚烯烃泡沫的丙烯酸类粘合剂与PVC、混凝土或纤维水泥的粘合优化成为可能,同时可以承受电流剥离试验并具有良好的耐压痕性。
Claims (14)
1.一种用于生产地板或墙壁覆盖物的多层结构(1),所述结构包括至少一个由交联聚烯烃泡沫制成的背衬层(2),赋予所述结构隔音性能,所述背衬层(2)具有旨在粘合到地板或墙壁的下表面,以及粘合到由塑料材料、油毡或橡胶制成的上层(3)的上表面,其特征在于,所述背衬层(2)的至少一个表面具有大于或等于40mN/m的表面张力。
2.根据权利要求1所述的结构,其特征在于,所述背衬层(2)的下表面具有大于或等于40mN/m的表面张力。
3.根据前述权利要求中的一项所述的结构,其特征在于,所述背衬层(2)的上表面具有大于或等于40mN/m的表面张力。
4.根根据前述权利要求中的一项所述的结构,其特征在于,所述上表面和/或所述下表面通过氟化进行了表面处理。
5.根据权利要求1所述的结构,其特征在于,所述背衬层(2)的厚度在0.5mm至2mm之间,并且优选地等于1mm。
6.根据权利要求1所述的结构,其特征在于,所述背衬层(2)的密度在70kg/m3至120kg/m3之间,优选地等于95kg/m3。
7.根据权利要求1所述的结构,其特征在于,所述上层(3)由聚氯乙烯制成。
8.根据权利要求1所述的结构,其特征在于,所述结构包括对可见光透明并连接至装饰膜(6)的耐磨层(4)。
9.根据权利要求7和8中任一项所述的结构,其特征在于,所述结构包括由聚氯乙烯制成的中间层(5),所述中间层粘合到背衬层(2)上。
10.根据权利要求9所述的结构,其特征在于,由聚氯乙烯制成的所述中间层(5)是增塑的并且包括矿物填料。
11.一种用于生产地板或墙壁覆盖物的多层结构(1)的制造方法,所述多层结构(1)包括由交联聚烯烃泡沫制成的的背衬层(2),赋予所述结构隔音性能,所述背衬层(2)具有旨在粘合到地板或墙壁上的下表面和粘合到由聚氯乙烯制成的上层(3)的上表面,其特征在于,在背衬层(2)的上表面粘合至所述上层(3)之前,对所述上表面进行表面处理,所述表面处理将其表面张力增加至大于或等于40mN/m的水平。
12.根据权利要求11所述的方法,其特征在于,所述背衬层(2)的下表面也经过表面处理,所述表面处理将其表面张力增加至大于或等于40mN/m的水平。
13.根据权利要求11所述的方法,其特征在于,所述表面处理包括通过氟化的表面处理。
14.根据权利要求11所述的方法,其特征在于,所述表面处理包括电晕处理。
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CA2192946C (en) * | 1994-06-17 | 2006-08-01 | Pieter Andries Blatt Carstens | Method for the production of composites |
US20160185025A1 (en) * | 2014-12-30 | 2016-06-30 | Toray Plastics (America), Inc. | Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same |
CN107405845A (zh) * | 2014-12-30 | 2017-11-28 | 东丽塑料美国股份有限公司 | 来自循环的聚烯烃材料的共挤出的交联的多层聚烯烃泡沫结构体及其制造方法 |
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CA2192946C (en) * | 1994-06-17 | 2006-08-01 | Pieter Andries Blatt Carstens | Method for the production of composites |
US20160185025A1 (en) * | 2014-12-30 | 2016-06-30 | Toray Plastics (America), Inc. | Coextruded, crosslinked multilayer polyolefin foam structures and methods of making the same |
CN107405845A (zh) * | 2014-12-30 | 2017-11-28 | 东丽塑料美国股份有限公司 | 来自循环的聚烯烃材料的共挤出的交联的多层聚烯烃泡沫结构体及其制造方法 |
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