CN112793278A - 一种耐刮耐磨石塑复合地板 - Google Patents

一种耐刮耐磨石塑复合地板 Download PDF

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CN112793278A
CN112793278A CN202011568286.5A CN202011568286A CN112793278A CN 112793278 A CN112793278 A CN 112793278A CN 202011568286 A CN202011568286 A CN 202011568286A CN 112793278 A CN112793278 A CN 112793278A
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stone
resistant
parts
paper
energy absorption
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CN112793278B (zh
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吕磊
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Longsen Technology Co ltd Of Suzhou Industrial Park
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Longsen Technology Co ltd Of Suzhou Industrial Park
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Abstract

本发明属于地板制造技术领域，涉及一种复合地板，更具体的涉及一种耐刮耐磨石塑复合地板；其技术要点如下：从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B，其制备方法具体包括如下操作步骤：S1.准备石塑基材；S2.制备柔性中间层；S3.准备浸胶纸；S4.将材料从上向下摆布：浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板和吸能层B；摆布完成后连同花纹板一起进入多层压机，进行热压、保压冷却、卸压和取料。本发明的提供的耐刮耐磨石塑复合地板，具有耐磨、耐刮擦的优点，且生产简单及施工方便，具有应用价值。

Description

一种耐刮耐磨石塑复合地板
技术领域
本发明属于地板制造技术领域，涉及一种复合地板，更具体的涉及一种耐刮耐磨石塑复合地板。
背景技术
PVC地板目前发展成熟，PVC地板是当今世界上非常流行的一种新型轻体地面装饰材料，也称为“轻体地材”，是一种在欧美及亚洲的日韩广受欢迎的产品，风靡国外，从80年代初开始进入中国市场，至今在国内的大中城市已经得到普遍的认可，使用非常广泛，比如家庭、医院、学校、办公楼、工厂、公共场所、超市、商业等各种场所。但也存在一些问题，比如几乎所有的PVC地板都使用了PVC耐磨层，且在耐磨层上面做UV淋膜处理来起到调节光亮度和保护的作用，但这样不可避免在长期使用过程中会受环境变化特别是受高温条件下产生VOC等有害物质，影响人们的身体健康。并且使用PVC耐磨层的即便使用UV淋膜处理，但其耐刮效果很差，极易产生划痕。同样的强化地板虽然比实木地板便宜耐磨，但是不环保，强化复合用的是密度板做基板，密度板是用木粉加胶压制而成，不透气，脚感差，不耐水，不防潮，且甲醛释放量高。石塑基材表面压制常规三聚氰胺耐磨层由于材料张力不同，加温或长期使用时，板型容易出现翘曲变形。整个地面材料会出现“起拱”等不良现象，无法正常使用。三聚氰胺耐磨纸和无机板组合，由于无机板刚性较强，遇温度不易变形，能很好的解决板材翘曲问题，但材料不易加工和回收利用，生产工艺较为复杂，不良率较高，不利于生产，且综合成本较高。
有鉴于上述现有石塑基材复合地板存在的缺陷，本发明人基于从事此类材料多年丰富经验及专业知识，配合理论分析，加以研究创新，开发一种耐刮耐磨石塑复合地板，具有耐磨、耐刮擦的优点，且提高了浸胶纸的耐温性能，防止石塑板材直接压贴发生翘曲和板面“起拱”现象的发生。
发明内容
本发明的目的是提供一种耐刮耐磨石塑复合地板，具有耐磨、耐刮擦的优点，且提高了浸胶纸的可延展等性能，防止浸胶纸与石塑基材直接压贴发生翘曲和板面“起拱”现象的发生，且生产简单及施工方便，具有应用价值。
本发明的上述技术目的是通过以下技术方案得以实现的：
本发明提供的一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B，其制备方法具体包括如下操作步骤：
S1.准备石塑基材，采用双螺杆挤出机生产厚度为3～8mm的石塑基材板；
S2.制备柔性中间层；
S3.准备浸胶纸；
S4.将材料从上向下摆布：浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板和吸能层B；摆布完成后连同花纹板一起进入多层压机，进行热压、保压冷却、卸压和取料。
作为上述技术方案的优选，具体包括如下操作步骤：
S1.准备石塑基材，采用双螺杆挤出机生产厚度为3～8mm的石塑基材；
S2.制备柔性中间层；
S3.准备浸胶纸；
S4.将材料从上向下摆布：浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B和PVC透明片；摆布完成后连同花纹板一起进入多层压机，进行热压、保压冷却、卸压和取料。
作为上述技术方案的优选，步骤S4中，热压的压力为5～10Mpa，温度为135～150℃，时间为30～50分钟；保压冷却的压力为8～12Mpa，时间为10～30分钟，冷却至10～40℃。
进一步的，本发明提供的石塑基材板中PVC粉与钙粉的质量比为1:2.5～1:3.5。此种配方下获得的石塑基材板，其静曲强度＞20Mpa，弹性模量＞4000Mpa，且80℃下6小时烘箱测试尺寸变化率＜0.1％。
进一步的，按照重量份数计算，本发明提供的浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90～100份，聚乙二醇10～15份和水性聚氨酯乳液5～10份。三聚氰胺溶液在浸胶前通过聚乙二醇和水性聚氨酯乳液进行改性，使该浸胶纸热压贴合后，完全固化状态仍保持柔韧性，达到弯折包覆半径1.5mm，90°直角边，使包覆过程不发生断裂，解决了现有浸胶纸在完全固化时，浸胶纸硬脆，拉力过大，使得整个石塑基材在70℃烘烤时不变形翘曲，并与浸胶纸原纸中的三氧化二铝颗粒发生协同作用，提高浸胶纸固化后的耐磨和耐刮擦性能。
进一步的，按照重量份数计算，本发明提供的吸能层A包括如下组分：PVC粉90～100份，铋硼酸盐3～5份，BOVC 3～5份，EBS 0.5～1份和石蜡0.5～1份。铋硼酸盐体系中存在Bi-O-Bi结构，并含有Bi2O3玻璃体系，结构稳定，加入到吸能层A材料中，参与PVC和石蜡的交联，并通过Bi-O-Bi结构的撑起的无机骨架提高吸能层A的耐热性和抗老化性能以及缓冲过程中的稳定性。
进一步的，按照重量份数计算，本发明提供的吸能层B包括如下组分：PVC粉90～100份，铋硼酸盐3～5份，苯并噁嗪树脂3～5份，EBS 0.5～1份和石蜡0.5～1份。苯并噁嗪树脂具有良好的耐热性能，加入到吸能层B中，提高了吸能层B在缓冲过程中的韧性和塑化性能。
进一步的，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。三元系列的骨架结构中含有[BiO6]和[BO3]，通过其结构的稳定性和微晶玻璃的特殊性能对吸能层A和吸能层B的热膨胀系数进行改善，进而通过不同的基材的热膨胀系数选择不同含量的铋硼酸盐，根据铋硼酸盐的含量调整吸能层的热膨胀系数，保证了热压过程中，复合地板不发生“起拱”或翘曲的现象。
进一步的，本发明提供的吸能层B的下层还覆盖PVC透明片，PVC透明片的厚度为0.05～0.5mm。
进一步的，柔性中间层是厚度为0.1～0.3mm的PVC材质透明膜，通过凹版印刷机对柔性中间层材料进行底涂和面涂两道涂布而成。
进一步的，底涂是涂布聚氨酯树脂材料，涂布量是10～15g/m2；所述面涂是涂布丙烯酸乳液，涂布量为10～15g/m2；其中所述丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂。底涂的目是改变中间层表面的极性，增强后续面涂和中间层的附着力以及后期的高温烘烤，耐水煮性能。面涂的目的是提高柔性中间层和浸胶纸之间的贴合性。
综上所述，本发明具有以下有益效果：
本发明的提供的一种耐刮耐磨石塑复合地板，具有将石塑基材和三聚氰胺浸胶纸利用现有的多层压机，热压成地板或墙板，在兼顾现有石塑材料防火、防水、环保等优良性能基础上，解决了现有表面UV涂层所无法解决的耐刮、耐磨问题。同时通过吸能层A和吸能层B材料的改性，得到热膨胀系数更加合适的缓冲层，从而避免热压过程中翘曲和起拱现象的发生。本发明提供的复合地板所涉及的材料都可用做回料，边角料及不良品进入磨粉机，磨粉后可作为回料添加至挤出原料中使用，完全解决了无机板无法直接回收利用的问题，降低了成本，减少了污染。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效，对依据本发明提出的一种耐刮耐磨石塑复合地板，其具体实施方式、特征及其功效，详细说明如后。
实施例1：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B；石塑基材板中PVC粉与钙粉的质量比为1:2.5～1:3.5。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为3.5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:3，所挤出的基材性能满足以下条件：静曲强度>20Mpa,弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：浸胶前，三聚氰胺溶液需要进行改性处理，原纸的克重选择35g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃。
实施例2：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B；石塑基材板中PVC粉与钙粉的质量比为1:3.5。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:3.5，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺100份，聚乙二醇15份和水性聚氨酯乳液10份，原纸的克重选择48g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃。
实施例3：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B；石塑基材板中PVC粉与钙粉的质量比为1:2.5。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为3.5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:2.5，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90份，聚乙二醇15份和水性聚氨酯乳液5份，原纸的克重选择30g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃，按照重量份数计算，吸能层A包括如下组分：PVC粉100份，铋硼酸盐5份，BOVC 5份，EBS 1份和石蜡1份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
实施例4：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B和花纹板；石塑基材板中PVC粉与钙粉的质量比为1:2.8。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为3.5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:2.8，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90份，聚乙二醇15份和水性聚氨酯乳液10份，原纸的克重选择28g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力12Mpa，时间10～30分钟，冷却至10～40℃；按照重量份数计算，吸能层B包括如下组分：PVC粉100份，铋硼酸盐5份，苯并噁嗪树脂5份，EBS 1份和石蜡1份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
实施例5：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B；石塑基材板中PVC粉与钙粉的质量比为1:2.8。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为3.5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:2.8，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺100份，聚乙二醇15份和水性聚氨酯乳液10份，原纸的克重选择25g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃；按照重量份数计算，吸能层A包括如下组分：PVC粉90～100份，铋硼酸盐5份，BOVC 4份，EBS 0.8份和石蜡0.5份；吸能层B包括如下组分：PVC粉100份，铋硼酸盐5份，苯并噁嗪树脂5份，EBS 0.8份和石蜡0.6份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
实施例6：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B、PVC透明片；石塑基材板中PVC粉与钙粉的质量比为1:2.6。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为5mm，基材配方中PVC粉与钙粉的混合的质量比例为1:2.6，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90份，聚乙二醇10份和水性聚氨酯乳液10份，原纸的克重选择48g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B+0.3mmPVC透明片，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃。
实施例7：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B、PVC透明片；石塑基材板中PVC粉与钙粉的质量比为1:2.5。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为4mm，基材配方中PVC粉与钙粉的混合的质量比例为1:2.5，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺100份，聚乙二醇15份和水性聚氨酯乳液10份，原纸的克重选择45g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B+0.3mmPVC透明片，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃；按照重量份数计算，吸能层A包括如下组分：PVC粉100份，铋硼酸盐5份，BOVC 5份，EBS 1份和石蜡1份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
实施例8：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B、PVC透明片；石塑基材板中PVC粉与钙粉的质量比为1:3.4。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为4mm，基材配方中PVC粉与钙粉的混合的质量比例为1:3.4，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90份，聚乙二醇15份和水性聚氨酯乳液10份，原纸的克重选择36g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B+0.3mmPVC透明片，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃；按照重量份数计算，吸能层B包括如下组分：PVC粉100份，铋硼酸盐5份，苯并噁嗪树脂5份，EBS 0.5份和石蜡1份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
实施例9：一种耐刮耐磨石塑复合地板，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B、PVC透明片；石塑基材板中PVC粉与钙粉的质量比为1:3.3。
其制备方法，包括如下操作步骤：
S1基材的制备：通过双螺杆挤出机生产石塑基材板，石塑基材板厚度为4mm，基材配方中PVC粉与钙粉的混合的质量比例为1:3.3，所挤出的基材性能满足以下条件：静曲强度>20Mpa，弹性模量>4000Mpa，基材80℃6小时烘箱测试尺寸变化率<0.1％；使用螺杆挤出机，按照石塑地板正常生产工艺制备石塑基材；
S2.柔性中间层的制备：选择0.1～0.3mm的PVC材质透明膜，通过凹版印刷机在此柔性中间层材料表面进行两道涂布：底涂和面涂；第一道底涂，涂布聚氨酯树脂材料，涂布量为10～15g/m2；第二道面涂，底涂涂布后通过印刷机烘道，使其完全干燥，再进行面涂；面涂为丙烯酸乳液，且丙烯酸乳液中配质量分数为1～2％的硅烷偶联剂，涂布量为10～15g/m2；
S3.浸胶纸准备：按照重量份数计算，浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，三聚氰胺混合液包括如下组分：三聚氰胺90～100份，聚乙二醇10～15份和水性聚氨酯乳液5～10份，原纸的克重选择33g/m2；
S4.热压成型，将材料从上向下摆布：浸胶纸+柔性中间层+PVC彩膜纸+吸能层A+石塑基材板+吸能层B+0.3mmPVC透明片，摆布完成后连同花纹板一起浸入多层压机，进行热压、保压冷却、卸压、取料，完成压贴生产过程。
其中，热压工艺：该热压成型工艺分热压和保压冷却两个过程；热压：压力5～10Mpa，温度135～150℃，时间30～50分钟；冷却：压力8～12Mpa，时间10～30分钟，冷却至10～40℃；按照重量份数计算，吸能层A包括如下组分：PVC粉100份，铋硼酸盐3份，BOVC 3份，EBS 1份和石蜡1份；吸能层B包括如下组分：PVC粉90份，铋硼酸盐5份，苯并噁嗪树脂3份，EBS 1份和石蜡1份，铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
对实施例1～9的复合地板的各项性能进行检测，结果如下表：
Figure BDA0002861653540000161
Figure BDA0002861653540000171
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例展示如上，但并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容做出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (10)

1.一种耐刮耐磨石塑复合地板，其特征在于，从上到下依次包括，浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板、吸能层B，其制备方法具体包括如下操作步骤：
S1. 准备石塑基材，采用双螺杆挤出机生产厚度为3~8mm的石塑基材板；
S2. 制备柔性中间层；
S3. 准备浸胶纸；
S4. 将材料从上向下摆布：浸胶纸、柔性中间层、PVC彩膜纸、吸能层A、石塑基材板和吸能层B；摆布完成后连同花纹板一起进入多层压机，进行热压、保压冷却、卸压和取料。
2.根据权利要求1所述的一种耐刮耐磨石塑复合地板，其特征在于，所述步骤S4中，热压的压力为5~10Mpa，温度为135~150℃，时间为30~50分钟；所述保压冷却的压力为8~12Mpa，时间为10~30分钟，冷却至10~40℃。
3.根据权利要求1所述一种耐刮耐磨石塑复合地板，其特征在于，所述石塑基材板中PVC粉与钙粉的质量比为1:2.5~1:3.5；按照重量份数计算，所述吸能层A包括如下组分：PVC粉90~100份，铋硼酸盐3~5份，BOVC 3~5份，EBS 0.5~1份和石蜡0.5~1份。
4.根据权利要求1所述一种耐刮耐磨石塑复合地板，其特征在于，按照重量份数计算，所述浸胶纸为浸渍在三聚氰胺混合液中的三聚氰胺浸渍纸，所述三聚氰胺混合液包括如下组分：三聚氰胺90~100份，聚乙二醇10~15份和水性聚氨酯乳液5~10份。
5.根据权利要求1所述的一种耐刮耐磨石塑复合地板，其特征在于，按照重量份数计算，所述的吸能层A包括如下组分：PVC粉90~100份，铋硼酸盐3~5份，BOVC 3~5份，EBS 0.5~1份和石蜡0.5~1份。
6. 根据权利要求1所述的一种耐刮耐磨石塑复合地板，其特征在于，按照重量份数计算，所述吸能层B包括如下组分：PVC粉90~100份，铋硼酸盐3~5份，苯并噁嗪树脂3~5份，EBS0.5~1份和石蜡0.5~1份。
7.根据权利要求6所述的一种耐刮耐磨石塑复合地板，其特征在于，所述铋硼酸盐是BiO3-B2O3-SiO2三元系列，其制备方法为高分子凝胶法。
8.根据权利要求1所述的一种耐刮耐磨石塑复合地板，其特征在于，所述吸能层B的下层还覆盖PVC透明片，所述PVC透明片的厚度为0.05~0.5mm。
9.根据权利要求1所述的一种耐刮耐磨石塑复合地板，其特征在于，所述柔性中间层是厚度为0.1~0.3mm的PVC材质透明膜，通过凹版印刷机对所述柔性中间层材料进行底涂和面涂两道涂布而成。
10.根据权利要求9所述的一种耐刮耐磨石塑复合地板，其特征在于，所述底涂是涂布聚氨酯树脂材料，涂布量是10~15g/m2；所述面涂是涂布丙烯酸乳液，涂布量为10~15g/m2；其中所述丙烯酸乳液中含有质量分数为1~2%的硅烷偶联剂。
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CN107060261A (zh) * 2017-06-05 2017-08-18 浙江巨美家科技有限公司 一种硬质多层复合pvc地板
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CN115949197A (zh) * 2021-10-07 2023-04-11 财纳福诺木业(中国)有限公司 装饰性镶板和镶板的制造方法

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